Pump-Through Fluid Loss Control Device with Dual One-Way Valves
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Solution Overview
Problem
Existing pump-through fluid loss control devices face challenges in deep water applications due to the need for high-pressure sealing against hydrostatic and tubing pressures, while also requiring controlled fluid leakage for lubrication and priming, which complicates design and material selection.
Innovation Solution
A pump-through fluid loss control device with two one-way valves, where the first valve opens in response to upward differential pressure for production and closes when pressure is reduced, and the second valve opens in response to downward differential pressure for fluid flow downward, allowing controlled leakage and priming of the pump.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single valve is used for both production and pump-through with biasing spring assemblies, then the valve can provide lower differential pressure opening for production and higher differential pressure opening for pump-through, but the design becomes more complex and requires hard materials like tungsten carbide with exacting tolerances to adequately seal and provide a closely defined small cross-sectional differential area
Solution Approach 1:
The patent divides the single valve system into two separate one-way valves: a first one-way valve for production flow control and a second one-way valve for pump-through flow control. Each valve is independently configured with its own biasing mechanism and sealing arrangements, simplifying the design of each individual valve while maintaining the dual-function capability of the overall assembly.
Solution Approach 2:
The patent extracts the pump-through valve function from the production valve design. By separating the two functions into distinct valves, each valve can be optimized for its specific purpose without the compromises required by a combined design, eliminating the need for hard materials like tungsten carbide and exacting tolerances in both valve seats.
2Reliability
If the standing valve is designed to seal against high hydrostatic pressure (e.g., 8,000 feet of production fluid or 3500 psi differential pressure), then the valve can prevent backflow effectively, but it becomes more difficult to design and manufacture with the required sealing performance and small cross-sectional differential area
Solution Approach 1:
The patent segments the high-pressure sealing function into two separate valves, each handling specific pressure differentials. The first valve handles production flow at controlled differentials, while the second valve handles pump-through flow. This segmentation allows each valve to be manufactured with more relaxed tolerances and simpler sealing arrangements while collectively maintaining the required backflow prevention capability against high hydrostatic pressures.
3Ease of operation
If the valve is designed to open at relatively low differential upward pressure (3600-4000 psi) for production, then production flow is enabled, but the same valve must also open at relatively high pump-down pressure for leakage, requiring complex biasing mechanisms and movable valve seats
Solution Approach 1:
The patent segments the dual-pressure opening function into two separate one-way valves with different opening pressure characteristics. The first one-way valve is configured to open at the lower differential pressure required for production, while the second one-way valve is configured to open at the higher differential pressure required for pump-through. This eliminates the need for complex movable valve seats and variable biasing mechanisms required in single-valve designs.
Solution Approach 2:
The patent extracts the high-pressure pump-through opening function from the low-pressure production valve. By using separate valves, each can be optimized for its specific operating pressure range with simple, reliable sealing surfaces and biasing mechanisms, eliminating the mechanical complexity of a single valve attempting to handle both pressure ranges.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device effectively prevents backflow and ensures proper lubrication and priming of the pump, maintaining high-pressure sealing and reducing the risk of pump damage, while allowing controlled fluid flow for maintenance and operations.
Implementation Method 1
The first one-way valve is openable in response to a first, selected differential pressure acting upward across the first one-way valve
Implementation Method 2
The second one-way valve is opened in response to a second, selected differential pressure acting downward across the valve
Data Source
AI summary
Presented are apparatus and methods for pump-through fluid loss control. In one embodiment, the fluid loss control device is positioned in a wellbore having a first and a second one-way valve therein. The first one-way valve is openable in response to a first, selected differential pressure acting upward across the first one-way valve. For example, fluid pumped from an ESP from below the device acts to open the first one-way valve. Fluid is flowed upward through the device through the first one-way valve while the second one-way valve is closed. The first one-way valve is closed by reducing the first differential pressure across the first one-way valve, for example, by turning off the ESP. The second one-way valve is opened in response to a second, selected differential pressure acting downward across the valve. Fluid is flowed downward through the second one-way valve while the first one-way valve is closed.