Upstream Shuttle Valve for Progressive Cavity Pump
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Solution Overview
Problem
Existing downhole progressive cavity pump systems face issues with fluid level loss during power failures and gas impregnation, leading to lengthy restart times and equipment damage, and prior flow restriction solutions cause installation difficulties and flow restrictions.
Innovation Solution
A non-weighted shuttle valve is positioned upstream of the progressive cavity pump, movable by fluid force to open and close, preventing downstream flow and minimizing fluid loss, with multiple sealing areas and a centralized design for easy installation and reduced flow losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a downstream check valve is used to prevent fluid level loss, then fluid level is maintained during power failures, but installation becomes difficult and flow restrictions occur at the PC pump intake
Solution Approach 1:
The invention inverts the conventional approach by placing the check valve upstream of the PC pump instead of downstream. This upstream positioning allows the rotor to be easily installed and aligned without being blocked by a check valve, while still maintaining fluid levels during power failures. The upstream location provides easier access for installation and maintenance operations.
Solution Approach 2:
The invention extracts the check valve function from the downstream location near the pump intake and relocates it upstream. This separation removes the flow restriction problem at the pump intake while maintaining the fluid level protection function. The check valve is isolated to a specific upstream location, eliminating its negative impact on pump performance.
2Reliability
If an inertial mass-operated check valve is used to prevent backflow, then fluid level is maintained, but enlarged tubing string ID is required to overcome flow losses
Solution Approach 1:
The invention replaces the inertial mass-operated mechanism with a simpler spring-loaded check valve mechanism. Instead of relying on inertial forces from moving mass to open and close the valve, a spring provides the closing force, allowing the valve to respond to pressure changes without requiring enlarged tubing dimensions. This simplifies the tubing string configuration while maintaining backflow prevention.
3Reliability
If a weighted shuttle valve is used to prevent downstream flow, then fluid level is maintained during shutdown, but additional weight and complexity are introduced
Solution Approach 1:
The invention uses a spring as a counterweight mechanism to balance the shuttle valve. Instead of relying on the weight of the shuttle itself to close the valve, a spring provides the closing force, allowing the shuttle to be lighter and easier to actuate. The spring counteracts the opening force, enabling reliable downstream flow prevention without requiring a heavy weighted shuttle.
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 solution effectively maintains fluid levels during power outages, reduces startup time, and prevents equipment damage by ensuring no backflow and minimizing flow losses, while allowing smooth rotor insertion and operation in deviated wells.
Implementation Method 1
a non-weighted shuttle (38) positioned within said shuttle valve, said non-weighted shuttle (38) being moveable axially within said shuttle valve from a force of fluid alone
Data Source
AI summary
An artificial lift system is provided for use for pumping fluid from a downhole wellbore to surface. The system comprises a progressive cavity pump, said progressive cavity pump comprising a stator run on a tubing string and a rotor run on a rod string into the stator and a shuttle valve positioned upstream of the progressive cavity pump, wherein said shuttle valve comprises a non-weighted shuttle and wherein said non-weighted shuttle is moveable axially within said shuttle valve from force of fluid alone. An upstream shuttle valve is further provided for use upstream of a progressive cavity pump, wherein said shuttle valve comprises a non-weighted shuttle that is moveable axially within said shuttle valve from a force of fluid alone, to open and close the shuttle valve. A method is further still provided for pumping fluid from a wellbore in an artificial lifts system.