Ball and seat valve assembly and downhole pump utilizing the valve assembly

Abstract

Disclosed is a work for oilwell plunger pumping under a packer system used to increase the wear life of API ball and seat valves and of ball and seat valves seat utilizing a piston actuator mechanism to unseat the ball from the seat, which during operation, create turbulent flow within the housing to increase force to move piston actuator like rifle bullet or weighted blow dart in dynamic high velocity high impact in stages to overcome hydraulic head and surface tension between ball and seat. Also disclosed umbrella shaped disks on the piston actuator for increased force to be used in both insert and tubing type down hole plunger oil well pumps. The labyrinth of fluid passages that are rectangular channels not holes help keep ball off its seat for complete down stroke and keep solids in suspension to prevent plugging of API ball in API valve cage. Part of the art is based on “Hydraulic Jump” theory by Leonardo Di Vinci in 1500's where thin film at the surface, greatly increases force due to physical changes to fluid at high speeds hitting objects.

Claims

1. This tool is for installation inside a pump barrel in a downhole sucker rod plunger Pump (for both tubing and insert) attached to a travel valve cage with a actuator moveably mounted in it's own housing for purpose of moving the ball off it's seat in the downstroke comprising: (a) a hollow tubular member with threads on top to screw on to a plunger valve cage that is to hold the ball and the seat in place having an interior wall defining an internal cross-sectional area. (b) the tubular member, having a seating passage with a seating cross-sectional area and flow passages in the circumference of the tublar member. (c) the ball positioned above the tubular member and above the valve seat in the plunger valve cage with screwed connection. (d) a piston actuator with umbrella disks mounted within the tubular member below the valve seat comprising an actuator for engaging the ball through the passage while the ball is seated on the seat and comprising a sealing member with a sealing area for sealing the tubular member below the valve seat across the entire internal cross-sectional area of the tubular member; and wherein the ball and valve seat is closed by the ball being seated on the valve seat, and opened by an increase in pressure from below unseating the ball from the valve seat. e) the piston actuator with a plurality of umbrella discs with flow areas on circumference to add force to move the ball off the seat and keep open entire downstroke and the piston actuator tip is beveled in 2 directions to act like screw adding force to open ball from the seat working like a pry bar to move the ball off the seat. f) the piston actuator tip that holds the ball off the seat for complete down stroke of pump plunger with a bottom stop and a top stop. g) the piston actuator moving in staged movement from one flow area to the next flow area in the flow passage areas in the circumference of the tubular member. h) the piston actuator that hits the ball at high velocity to impact and open the ball from the seat and allows fluid flow to tubing above.

2. A valve assembly of claim 1 for plunger pumps in oil and gas wells further comprising: (a) the hollow tubular member of claim 1 having an interior wall defining an internal cross-sectional area with guides to keep the piston actuator from claim 1 straight and balance forces for striking the ball from the seat. (b) the piston actuator has valve seat mounted above the tubular member, having a seating passage with a seating cross-sectional area. (c) the ball positioned above the tubular member and above the valve seat is protected from damage by particulate matter by flushing flow on each stroke. (d) the piston actuator with a top stop and a bottom stop moveably mounted within the tubular member below the valve seat comprising an actuator that is heat treated for wear while engaging the ball through the passage while the ball is seated on the seat and comprising the valve seat across the entire internal cross-sectional area of the tubular member and supported by the tubular member walls for control of the horizontal forces when striking the ball. (e) a plurality of turbulent flow disks positioned within the tubular member below the ball and valve seat and below the sealing member substantially spanning the cross-sectional area with the flow disk defining fluid passages providing fluid communication between the internal cross-sectional area above the flow disk and the internal cross-sectional area below the flow disk; wherein the ball and valve seat is closed by the ball being seated on the valve seat, and opened by an increase in pressure from below that creates force from high velocity fluid hitting the umbrella disks below the upper flow disc unseating the ball from the valve seat. (f) the piston actuator with the plurality of turbulent flow disks positioned within the tubular member below the ball and the valve seat with flow disc areas defining fluid passages around outer diameter of the discs and the piston actuator providing fluid communication between the internal cross-sectional area above the flow disks and the internal cross sectional area below the flow disks. g) an actuator guide treated for wear and friction defining an actuator passage for receiving the piston actuator positioned within the tubular member below the valve seat and positioned such the actuator is within the hollow tubular member.

3. The valve assembly of claim 2 to greatly comprising: (a) at least one turbulent flow disk is umbrella shaped with rectangular flow areas arranged on edges for open flow through assembly to tubing above pump. (b) at least one turbulent flow disk further comprises at least one flow vane to aid in the production of turbulent flow to keep particulate matter flowing up to the tubing above. (c) a screwed connection to the ball and seat valve assembly in plunger cage mounted above for use with fluids containing particulate matter. (d) the hollow tubular member having an interior wall defining an internal cross-sectional area. (e) the valve seat mounted above the tubular member, having a sealing passage with a sealing cross-sectional area held in place by the tubular threaded connection. (f) the ball positioned above the tubular member and above the valve seat is kept clean due to the opening by each stroke of the plunger. (g) the piston actuator moveably mounted within the tubular member below the valve seat comprising an actuator for engaging the ball through the passage while the ball is seated on the seat and comprising a sealing member with a sealing area for sealing the tubular member below the valve seat across the entire internal cross-sectional area of the tubular member moving the ball. (h) at least one turbulent flow disk positioned within the tubular member below the ball and the valve seat utilizing Leonardo Divinci's hydraulic jump theory. (i) a system positioned within the tubular member for keeping particulate matter in suspension. (j). a main body positioned within the tubular member above the ball and the seat valve substantially spanning the tubular member cross-sectional area with the main boded defining fluid passages providing fluid communication between the internal cross-sectional area above the main body and below the main body, (k) threads on bottom of the tubular member for attachment of retrieval tool to retrieve standing valve in a tubing pump. (l) the piston actuator with flow channel for tip that breaks surface tension between ball and seat of travel ball. (m) with Consistent flow through to open the travel valve to all passages to the tubing above (n) the piston actuator tip beveled in 2 directions acts as screw to increase force to open travel valve treated for impact to the ball. (o) the piston actuator tip that keeps the ball off the seat for duration of the down stroke of the plunger. (p) the piston actuator tip that stops horizontal spin of the ball to reduce wear of the ball and the seat. (q) a valve system that contains at least 2 stages for the piston actuator movement and flow to tubing above.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] FIGS. 1A, and 1B are cross-sectional views of reciprocating fluid pump 5 of the present invention showing piston 41 in a lower and in an upper position, respectively. Also showing umbrella shaped discs. FIG. 1B also shows location of cross sections 3-3, 11-11, 12-12

[0030] FIG. 2 is an enlarged view of tubular assembly 5 illustrating piston actuator 241 and flow areas around disc and flow areas around umbrella shaped discs. Cross section 11-11, and 12-12 locations are also shown. Grove 246 at top of 241 is also shown

[0031] FIG. 3 A is enlarged oblique view of piston actuator showing disc from bottom showing flow areas 81.

[0032] FIG. 3 B is enlarged oblique view of piston actuator showing disc from top showing flow areas 81

[0033] FIG. 4 is view of top of piston actuator tip 241A showing slopes 243 and 245 and grove 246

[0034] FIG. 5 is enlarged side view of piston actuator tip 241A showing tip showing slopes 243 and 245 and grove 246

[0035] FIG. 6 is a horizontal cross-sectional view of flow areas and stops around top piston actuator housing 69 taken along line 11-11 of FIG. 1B

[0036] FIG. 7 is a vertical cross-sectional view showing seat, piston actuator tip 241A, barrel, and flow area of piston actuator housing taken along line 12-12 of FIG. 1B

[0037] FIG. 8 is a horizontal cross-sectional view of a second embodiment showing tubing pump piston actuator with bottom threads to attach standing valve puller where pump barrel is actually the bottom section of the tubing string. This also shows opening of bottom valve 32 opening to allow flow to umbrella discs through flow area 62 and upper valve 38 in staged fashion.

[0038] FIG. 9 is a horizontal view showing flow areas 62w and actuator guides 64 taken along line 3-3 of FIG. 1B.

[0039] FIG. 10 is FIG. 1B showing fluid flow tracking through passages in down stroke of plunger.

[0040] FIG. 11 is enlarged view of umbrella flow areas 81 on piston shaft 41.

DETAILED DESCRIPTION OF THE INVENTION

[0041] Referring now to the figures the present invention will be shown and described in detail. Fluid is defined as gas, water, oil or mixture thereof.

[0042] FIGS. 1A and 1B are cross-sectional views of reciprocating fluid pump 10 of the present invention showing piston 40 in a lower and in an upper position, respectively.

[0043] In general, sucker rod 322 connects to and actuates pump pull rod 12. Sucker rod 322 is actuated from the surface by any of the well known means, usually a “rocking horse” type pump jack unit . . . .

[0044] Threaded connection 25 joins traveling valve cage 21 with tubular housing 27, which extends downwardly to lower housing 29 by threaded connector 31. Housing 29 in turn extends downwardly and connects to housing 33 through threaded connector 35. It is to be understood that housings 27, 29 and 33 form hollow tubular housing assembly 5 which is adapted for attachment to the traveling valve 70.

[0045] At the bottom of barrel 23 is positioned conventional standing valve 58, including conventional seat 57 and ball 56.

[0046] Piston 40 is positioned within tubular assembly 5 within pump 10 as shown, and includes actuator 241 having engaging end 241A, lower sealing member 36, upper sealing member 38, piston body 42, umbrella shaped discs 80 are attached to piston body 40. Flow area 81 is on circumference of umbrella shaped discs 80.

[0047] The vertical motion of piston 40 in housing assembly 5 within pump 10 is restricted at its uppermost point by the engagement of upper stops 55 of housing 27 and shoulders 32 of upper sealing member 38 as shown in FIG. 1B, and at its lowermost point by engagement of lower stops 54 of housing 33 with bottom shoulder 36A of lower sealing member 36 as shown in FIG. 1A.

[0048] Fluid flow around lower sealing member 36 through channels 62 in housing 29 occurs once bottom shoulder 36A clears lower end 62A of channels 62 in staged fashion.

[0049] Generally, channels 62 are not continuously connected around the perimeter of housing 29, but rather are spaced by guides formed in the walls of housing 29. It is to be understood that any number of channels 62 may be utilize, as long as at least one channel 62 is provided. Thus, when bottom shoulder 36A is above lower channel end 62A, lower sealing member 36 is positioned in lower housing 29 by the guides formed in the walls of housing 29.

[0050] Fluid flow around sealing member 36 is prevented when bottom shoulder member 36A is positioned below lower channel member 62A. Sealing member 36 will form a seal with lower housing 29 such that pressure can be held by sealing member 36. Additional optional sealing can be provided by utilizing a sealing seat against which sealing member 36 will abut. In the embodiment shown in FIG. 1A, lower stop 54 is additionally a seal seat for sealing member 36. Thus, sealing is provided by sealing member 36 circumferentially abutting housing 29, and by the bottom of sealing member 36 abutting lower stop or seat 54.

[0051] Lower sealing member 36 includes sealing area 71 which may be any shape suitable to seal the internal cross-section of housing 29 below channel end 62A. In the embodiment shown, sealing area 71 is a concave shape, although any suitable shape may be utilized.

[0052] It is to be understood that in the event of fluid leakage past or failure of traveling valve 70, sealing member 36 may be designed suitable to provide backup sealing.

[0053] Fluid flow around upper sealing member 38 through channels 67 in housing 27 occurs once bottom shoulder 38A clears lower end 67A of channels 67. Generally, channels 67 are not continuously connected around the perimeter of housing 27, but rather are spaced by guides formed in the walls of housing 27. It is to be understood that any number of channels 67 may be utilized, as long as at least one channel 67 is provided. Thus, when bottom shoulder 38A is above lower channel end 67A, lower sealing member 38 is positioned in housing 27 by the guides formed in the walls of housing 27.

[0054] With piston 40 at its uppermost point, with upper stops 55 of housing 27 arid shoulders 32 of upper sealing member 38 in engagement, fluid flow will still occur around sealing member 38. Flow area 79 extends downwardly along the side of sealing member 38 to form a liquid passage with channel 67. Even when shoulder 32 is abutted against stop 55 this flow area 79 is in liquid communication with channel 67, and thus allows for passage of fluid from channel 67 and past sealing member 38 through flow area 79.

[0055] Fluid flow around sealing member 38 is prevented when bottom shoulder member 38A is positioned below lower channel member 67A. Sealing member 38 will form a seal with housing 27 such that pressure can be held by sealing member 38.

[0056] Sealing member 38 includes sealing area 74 which may be any shape suitable to seal the internal cross-section of housing 27 below channel end 67A. In the embodiment shown, sealing area 74 is a concave shape, although any suitable shape may be utilized.

[0057] The embodiment of the present invention is illustrated with two sealing members 36 and 38. It is to be understood that at the very least, one sealing member must be utilized, with additional sealing members being optional. However, one problem that must be addressed is the orientation of the piston 40. While one sealing member could be modified to keep piston 40 in its proper vertical alignment, it is preferred to utilize either a second sealing member, or a rod guide to keep piston 40 aligned properly.

[0058] It is important that the sealing area of the sealing member that holds pressure against standing valve 58, which in the embodiment shown is sealing area 71 of member 36 initially, and subsequently sealing area 74 of member 38, have a sealing area that is greater than the cross-sectional area of valve seat passage 78B. Preferably, the sealing area of sealing member 36 and/or 38 will be at least 1.1 times greater than the cross-sectional area of valve seat passage 78B, more preferably at least 2 times greater, even more preferably at least 5 times greater, even still more preferably at least 6 times greater, even yet more preferably at least 9 times greater, and most preferably at least 12 times greater. Also umbrella shaped discs to provide additional force for actuator to keep valve open through complete down stroke

[0059] Operation of pump 10 is as follows. In the upstroke, sucker rod 322 driven by a surface pumping unit moves plunger 18, traveling cage 21 and tubular assembly 5 upward. This motion closes traveling valve 70, forces piston 40 into its downward position with shoulder 36A abutted against stop 54, and opens standing valve 58 and pulls liquid into conical area 61 of pump 10f. Umbrella shaped flow disks create turbulence in the pump to keep sand and other particles, in suspension moving into tubing above thereby keeping the solids away from the wear parts of pump 10 such as piston 40, actuator 241, ball 75 and seat 78.

[0060] On the down stroke, plunger 18, traveling cage 21 and tubular assembly 5 are driven downward thereby closing standing valve 58 and compressing the fluid drawn into area 61 between lower sealing member 36 and the now closed standing valve 58, see FIG. 1A. With the continuing downstroke, this pressure builds and acts upon sealing surface 71 of piston 40, ultimately driving it upward in staged movement. Once shoulder 36A clears channel bottom 62A liquid flow bypasses sealing member 36 by passing through channel 62. With piston 40 in this intermediate position, pressure is now being held by sealing member 38. With the continuing down stroke, this pressure builds and acts upon sealing surface 74 of piston 40, ultimately driving it upward. Once shoulder 38A clears channel bottom 67A, liquid flow goes around sealing member 38 through channels 67, and on through traveling valve 70. Piston 40 is ultimately driven to its upmost position with shoulder 32 of member 38 abutting stop 55. Adding to this movement with flow around outer edge slots are the umbrella shaped discs. At this point, fluid will continue to bypass sealing members 36 and 38 through channels 62 and 67, respectively, and on through traveling valve 70.

[0061] Although actuator 241 is shown in the figures to strike traveling valve ball 75 asymmetrically with respect to its vertical axis, it is understood that actuator 241 may be configured to strike seated traveling valve ball 75 near its vertical center axis as it is in its seated position. Preferably, actuator 241 strikes ball 75 such as to allow it to pivot on seat 78 at pivot point 78P. More specifically, actuator 241 will strike traveling valve ball 75 asymmetrically with respect to its vertical center axis as it is in its seated position. The asymmetrical striking of traveling valve ball 75 could be achieved by angling member 241 or by offsetting member 241 from the vertical center line of pump 10.

[0062] While not wishing to be limited to theory, the inventor believes that this asymmetrical striking will create a moment that will allow the ball 75 to pivot on its seat 78 at point 78P shown in FIG. 2. The inventor believes that this pivoting or prying action provides a mechanical advantage over merely forcing ball 75 in the vertical direction that will help to overcome the liquid column pressure acting downwardly on ball 75. The edge of 241 is beveled in two directions allowing actuator work like a screw for additional force to open ball. A vertical channel in tip aids in breaking surface tension between ball and seat.

[0063] While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled the art to which this invention pertains.