Patent Application
20100098568
1. Field Of The Invention
This present invention is directed to drilling wellbores in the earth, to systems for pumping drilling fluid (“mud”) for such operations, to mud pumping systems and valves for them, and methods of their use.
2. Description of Related Art
The prior art discloses a wide variety of drilling systems, apparatuses, and methods including, but not limited to, the disclosures in U.S. Pat. Nos. 6,944,547; 6,918,453; 6,802,378; 6,050,348; 5,465,799; 4,995,465; 4,854,397; and 3,658,138, all incorporated fully herein for all purposes. The prior art discloses a wide variety of drilling fluid pumps (“mud pumps”) used in drilling operations and pump systems, for example, and not by way of limitation, those pumps and systems disclosed in U.S. Pat. Nos. 6,257,354; 4,295,366; 4,527,959; 5,616,009; 4,242,057; 4,676,724; 5,823,093; 5,960,700; 5,059,101; 5,253,987; in U.S. applications Ser. No. 10/833,921 filed Apr. 28, 2004 (all said U.S. references incorporated fully herein for all purposes).
A drill bit carried at an end of a drillstring is rotated to form wellbores in the earth. Certain drillstrings include tubulars which may be drill pipe made of jointed sections or a continuous coiled tubing and a drilling assembly that has a drill bit at its bottom end. The drilling assembly is attached to the bottom end of the tubing or drillstring. In certain systems, to drill a wellbore, the drill bit is rotated (e.g., by a top drive, a power swivel, a rotary table system, or by a downhole mud motor carried by the drilling assembly). Drilling fluid, also referred to as “mud,” is pumped through the wellbore under pressure from a pit or container at the surface by a pumping system at the surface.
In certain known mud pump systems, suction and discharge modules have valves therein that selectively control fluid flow through the module in an intake (suction) mode in which piston apparatus creates a vacuum drawing drilling fluid into the module and in an output mode (Discharge) in which the piston apparatus creates pressure forcing drilling fluid out of the module. In the suction mode, a suction valve opens allowing drilling fluid into the module while a discharge valve remains closed. In the discharge mode, the pressure of the drilling fluid closes the suction valve and opens the discharge valve.
Both valves, the suction valve and the discharge valve, are subjected to the erosive and damaging effects of the flow of drilling fluid. The drilling fluid contains drilled cuttings and debris which can erode valve parts (e.g. seats, stems, valve members, seals, guide bushings, insert, liners, wear plates etc.). Also, mud pumps which can pump relatively hot drilling fluid at, e.g., 500 to 2000 gallons per minute, force the erosive drilling fluid against the valve parts at high velocities which add to the fluid's damaging effects.
In many valves used in mud pump systems, a guide in the valve which is disposed across a flow path or guide fingers extending from a valve member into a valve seat guide a valve member so that valve member seats correctly and effectively against the valve seat. In many valves, the valve seat surface against which the valve member (or poppet) seats is, ideally, flat; and the surface of the valve member which sealingly abuts the flat seat surface of the valve seat is, correspondingly, and ideally, flat. A guide or guide fingers facilitates correct seating of the valve member's flat seating surface against the valve seat's flat seat surface. If either surface is not flat, or if one surface does not contact the other in a substantially parallel (flat surface to flat surface) manner, ineffective or inefficient valve operation may result.
The erosive and/or damaging effects of drilling fluid flow through a valve can damage the seating surfaces so that the ideal flat-surface-to-flat surface seating is not achieved. Also, the drilling fluid can damage a guide (e.g. ribs and a channel for receiving a stem or rod projecting from a valve member) or guide fingers so that the ideal surface seating is not achieved. In some instances, damage to a guide or to guide fingers results in a flat valve member surface contacting a flat seating surface at an angle so that effective valve closure is not possible or so that the valve is insufficiently closed for efficient operation. In some aspects, erosive drilling fluid flow renders initially-flat seating surfaces non-flat with resulting ineffective sealing and valve closure.
For these reasons in many mud pump systems, suction and discharge valves are repaired or replaced on a regular basis.
In many known mud pump valves, the valves are opened and closed by mechanically creating a vacuum or fluid pressure increase in the valve that overcomes a spring to allow a valve member to move. The movement of the valve member is not controlled, i.e., it is subject to a surge of fluid under pressure. As fluid pressure builds up to move a valve member, a corresponding amount of fluid builds up adjacent the valve. when the pressure is high enough, a relatively large charge of fluid goes through the valve at high velocity. This surge of fluid can have deleterious effects on valve parts.
The present invention discloses, in certain aspects, a drilling fluid pumping system, also known as a mud pump system, for pumping drilling fluid or mud used in wellbore operations which has pumping modules with valves that have non-flat seating surfaces. In certain aspects, such valves have a valve member or poppet that is movable with multiple degrees of freedom in any of which effective seating of the valve member against a valve seat is achieved. In particular aspects of such a valve, dual sealing is achieved by sealing of a valve member against both a valve seat and against a seal disposed in a valve seat.
In certain particular aspects of a mud pump system according to the present invention, a mud pump valve has a tapered spring biased against a valve member which enhances the free seating movement of a valve member.
The present invention discloses, in certain aspects, valves for a system for pumping a drilling fluid mixture, the drilling fluid mixture containing drilling fluid and solids, the valves having: a seat with a valve seat surface; a valve member with a member surface, part of the valve member movable to seat the member surface against the valve seat surface to prevent the flow of the drilling fluid mixture past the valve seat; a cartridge stem positioned with respect to the valve member, and a valve actuator within the cartridge stem for selectively moving the valve member. In certain aspects, the present invention discloses a system for pumping a drilling fluid mixture, the drilling fluid mixture containing drilling fluid and solids, the system having: a pump apparatus;the pumping apparatus having a body with an inlet and an outlet;a suction valve in the body for selectively controlling flow of the drilling fluid mixture in through the inlet; a discharge valve in the body for selectively controlling flow of the drilling fluid mixture out through the outlet; and a dampener within the body for inhibiting pulsations of fluid pumped from the pump apparatus In certain valves according to the present invention a valve actuator is used which is pneumatically powered without certain mechanically moving parts used in prior valves.
Accordingly, the present invention includes features and advantages which are believed to enable it to advance mud pump valve technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.
Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.
What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, other objects and purposes will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide new, useful, unique, efficient, nonobvious valves for use in drilling fluid pump systems, drilling fluid pumping systems, methods of their use, drilling systems and methods, mud pump systems for use in drilling operations;
Such pumping systems with valve(s) that have a valve member with a curved seating surface which is free to move to effectively seat against a corresponding curved surface of a valve seat;
Such valves with a tapered spring for facilitating effective seating of the valve member against the valve seat; and
Such valves with a pneumatically-powered valve actuator that is controllable.
The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, other purposes and advantages will be appreciated from the following description of certain preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form, changes, or additions of further improvements.
The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way.
It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.
Certain aspects, certain embodiments, and certain preferable features of the invention are set out herein. Any combination of aspects or features shown in any aspect or embodiment can be used except where such aspects or features are mutually exclusive.
A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or legally equivalent embodiments.
Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. Various aspects and features of embodiments of the invention are described below and some are set out in the dependent claims. Any combination of aspects and/or features described below or shown in the dependent claims can be used except where such aspects and/or features are mutually exclusive. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference. So long as they are not mutually exclusive or contradictory any aspect or feature or combination of aspects or features of any embodiment disclosed herein may be used in any other embodiment disclosed herein.
The system 500 shown in
During drilling, the drilling fluid 524 is pumped by pump(s) 521 of the mud pump system 522 into the drillstring 504 (thereby operating a downhole motor 532 if such an optional motor is used). Drilling fluid 524 flows to the drill bit 512, and then flows into the wellbore 530 through passages in the drill bit 512. Circulation of the drilling fluid 524 transports earth and/or rock cuttings, debris, etc. from the bottom of the wellbore 530 to the surface through an annulus 527 between a well wall of the wellbore 530 and the drillstring 504. Cuttings and debris are removed from the drilling fluid 524 with equipment and apparatuses not shown, and it is re-circulated from a mud pit or container 528 by the pump(s) of the mud pump system 522 back to the drillstring 506. Also, some desirable solids may be added to the drilling fluid.
A system 10 according to the present invention as shown in
An oil pump 2 pumps lubricating oil to various parts of the system. A water pump 4 pumps water to a filtration system (not shown) and a cooler (not shown). The pumps are mounted on pump mounts 8b connected to the base 8. Doors 3 and 5 (one each for each pump system 30) provide access to various internal parts of the system 10. Drilling fluid enters the system 10 through an inlet 7 and is pumped out via the modules 650 to a main outlet 9.
The modules 650 have a body 602 with a first bore 602a and a second bore 602b. A discharge valve assembly according to the present invention is in the first bore and a suction valve assembly according to the present invention is in the second bore. With a piston fluid is pumped into a chamber 652 of the module 650 via an inlet port 604 and is discharged from the module 650 into a discharge conduit 634 via an outlet port 606.
Fluid pumped from the chamber 404 can impact parts of the discharge valve 100x. Optionally, an accumulator/dampener 410, positioned within the block B, is in fluid communication with the pumping chamber 404. The accumulator/dampener 410 reduces undesirable pulsations of fluid under pressure from the pumping chamber 404. Any suitable known accumulator/dampener may be used.
The valve assembly 100 has a hollow cartridge stem 102 with an interior channel 104 within which are located a valve actuator 130 and an adapter 106. A spring support 108, connected to a flange 110 of the cartridge stem 102, has an end 112 which is encompassed by part of an expansion spring 120 an end of which abuts the spring support 108.
A poppet (or curved valve member) 114 rests on a support 116. An end 122 of the spring 120 abuts and is biased against a bottom of the support 116. A ball 118 rests on a ball support 124 which rests on the support 116. A cable 128 (i.e. a non-rigid connector) (made of any known cable material) connected to the ball 118 passes through a hole 140 in and through the support 124, through a hole 142 in the support 116, through the spring 120, through a hole 143 in the spring support 108, through a hole 144 in the adapter 106 which is and is connected to the adapter 106 connected to an actuator 130.
A washer 151 above the ball 118 abuts an underside 115 of the poppet 114. A recess 152 within the poppet 114 houses the ball 118, the washer 151 and the support 124. The poppet 114 has a tapered surface 136 for sealingly abutting a valve seat and a seal of a valve seat as described below.
The poppet 114 is movable toward and away from a valve seat 160. The valve seat 160 has a channel 162 for fluid flow therethrough. The poppet 114 selectively closes off and opens up the channel 162 to fluid flow. Part of the channel 162 is sized and configured for the poppet 114. A surface 166 of the valve seat 160 is positioned to seal against the tapered of the surface 136 of the poppet 114. Optionally, there are no guide fingers projecting from the poppet 114 (although it is within the scope of the present invention to use them); and there are no arms or ribs across the valve seat (it is unobstructed) for receiving and stabilizing a rod, stem or neck projecting from a poppet; and there is no rod, neck or stem projecting from the poppet. Thus, flow through the channel 162 is unobstructed by such parts which are present in many prior valves.
A recess 168 around the valve seat 160 holds a seal 169. Part of the surface 136 of the poppet 114 sealingly abuts the seal 169 when the valve assembly is closed, preventing fluid flow. Thus dual sealing is achieved.
The poppet 114 has a range of freedom of movement within the channel 162 of the valve seat 160. However the poppet 114 is located within and with respect to the valve seat 160, part of the outer tapered surface 136 of the poppet 114 will sealingly abut the seal 169 and the surface 136 will sealingly abut the surface 166. The poppet 114 can be aligned (or not) with the valve seat 160, but either way an effective seal is maintained with part of the surface 136 sealed against the seal 169. Movement of the poppet 114 on the ball 118 and the sizing and configuration of the various parts contribute to permissible freedom of movement of the poppet 114 without sacrificing the sealing necessary to close the valve assembly.
In one aspect, as shown in
As shown in
As shown in
It is advantageous that the poppet is part of the valve cartridge. During assembly, when the pump is assembled for the first time, it is much easier to have a preassembled valve cartridge and, without adjustments, to insert and bolt it in and have it immediately become functional. Moreover, in servicing the valve, it is much easier to extract the entire cartridge, versus bits, individual parts, and/or pieces. In certain current designs, a poppet/valve has a pseudo cartridge design in the sense that the valve has no restricting elements to keep it attached to the cartridge. In other words, the cartridge can be loosely put together prior to assembly and it can be inserted as a cartridge being secured to the body by bolts. However, if during this assembly process, or later on during servicing the valve, this cartridge is turned upside down, the valve itself can become loose and fall to the ground.
Often in such prior systems there is no element like a snap ring to secure the valve to the cartridge. It is also advantageous that the seal is part of the valve housing. It is easier to have the seat part of a block that can be preassembled to the pump and, later on, during a later step in manufacturing, to bolt on to it a subassembly like the valve cartridge.
In designs according to the present invention, seals, e.g. the seal 169, do not resonate. According to the present invention, such seals are surrounded by a support and have no extraneous or “banging” features which could be excited by a surrounding flow stream.
In certain aspects according to the present invention, poppets and seats are made of ceramics which do not rust. In certain particular aspects, an alumina based ceramic offers very high strength and good wear resistance. In other aspects, a boron carbide ceramic can be used which has excellent erosion wear resistance. Both of these two ceramics have a higher erosion resistance then steel. In certain aspects the poppets of assemblies according to the present invention are made with a steel core surrounded by a ceramic. The steel core supports the Belleville washers and can have cut threads into it. A ceramic outer skin provides erosion resistance. In certain aspects, the special profiles facilitate the flow opening and closing the valve gradually.
In certain current designs, valves have two parallel surfaces. Often these surfaces form a seal that is part of conical bodies; i.e. the seal has a conical machined surface against which is pushed a poppet. The poppet's sealing surface is also conical so that, at every instance, the seat's and poppet's sealing surfaces are parallel. During discharge, when the two bodies are separating and, thus, allowing the fluid to flow from the pumping chamber into the discharge manifold, the fluid is squeezed in between these flat surfaces. During this phase the fluid's velocity can be greatly increased as it passes from a large cross section of the pumping chamber into a small one with parallel surfaces of the valve's passage way. Moreover, because there is no controlling actuator, such a valve can open suddenly when the fluid's pressure exerts onto the valve's face a force slightly higher than that developed by the spring acting on the opposite face. As the fluid leaves at high velocity, it enters into a larger cross section that is the discharge manifold The high velocity and energy fluid acts almost like a piston in this case and pushes an adjacent block of fluid along the discharge line. This sudden move of a significant block of fluid can create a “bang” or a specifically loud noise almost like a pounding. This repeated banging/pounding can have detrimental effects on the drill line or other equipment.
In certain valve assemblies according to the present invention, the flat parallel surfaces are replaced by curved ones. Additionally, there is a controlling actuator that can open the valve before pressure in the pumping chamber reaches a value high enough to counteract the spring and, thus, to open the vale. Pressure at which the fluid leaves the pumping chamber is greatly reduced. Being formed in between two curved surfaces, the valve's passage way flow characteristics do not impart a high velocity/energy to the fluid stream. Consequently, the fluid enters and leaves the discharge manifold and line respectively in a more dispersed manner. There is no “bang” as in certain previous valves because the fluid does not flow in discrete “blocks”.
The control system CS controls the air supply 200 and, thus, controls the valve assembly 100. This is in contrast to prior valves in which fluid flow opens and closes the valve. In one aspect, the control system controls the speed with which the parts move and thereby controls the speed of opening and of closing off the valve. Using appropriate software programming of programmable media in the control system, the control system controls an electro proportional valve control (e.g. the valve 200p,
The control system has programmable media, e.g. in a computer, computers, and/or PLC(s). In one aspect, the control system is preloaded with a program that includes a defining equation and a curve fitter. The defining equation is a function of pump shaft speed. The curve fitter compares the curve generated by the defining equation with an “ideal” curve desired to drive the valve The ideal curve usually represents the valve's speed, or acceleration, or opening and/or, a different relevant parameter plotted versus time. The output from the control system drives a proportional valve, a valve that controls the actuator 130, e.g., in one aspect, supply air into a FESTO (TRADEMARK) “muscle”. Thus, the valve being actuated closely follows the preprogrammed curve/equation and the valve opens or closes at a certain velocity or acceleration, or that it opens at a certain rate over the duration of a pumping cycle. The opening or closing rate can be constant or variable. That is, the valve can start opening at a certain low rate followed by a higher rate followed by a different rate, and so on.
In one aspect, during a cycle the valve tends to follow a certain bell-shaped curve. Thus, the valve starts opening at a low rate followed at the very next instance by a slightly higher rate and in the next instance by an even higher rate and so on. All this is followed on the descending side of the curve by a lower rate followed by a slightly lower rate and so on until the valve closes. By introducing or expelling fluid into or from the pumping chamber at certain times the pump's behavior is changed or the pump's flow is measurable.
The mechanical equivalent of controlling a valve's opening rate is a cam. The cam, through its profile, controls how fast and in what relationship relative to another element, e.g. a crankshaft, the valve will open or close. In other words, it controls the valve's rate (displacement versus time). However, a cam's profile can not be changed very easily because it is cut in metal. A practical method is to introduce a hydraulically actuated push rod or cam follower in between the cam and valve. Thus, the rate can change at will within a limited range. In the control strategy according to the present invention there is no piece of hardware/cam that limits the valve's rate. Consequently, in the proposed actuation and control strategy, the desired curve can be changed on the fly as long as the controller, e.g. a computer or PLC, can accept/support it. Programmability makes this equivalent to an infinitely variable profile cam shaft and the pump's output flow and vibration can be controlled. (An undesirable consequence of output flow in certain prior systems is component failure, e.g. due to cavitation.)
With the curved mating sealing surfaces of the valve seat and poppet, any contact results in an effective seal. Pressure fluctuations generated in or by prior art valves are reduced or eliminated and valve control reduces pressure fluctuation in the discharge line during pump operation.
Systems according to the present invention provide a fail safe mode. If a valve assembly according to the present invention that is inserted fails, then, for safety reasons, the pump continues working at either reduced or normal parameters until it is safe to stop it for service. In systems according to the present invention, if the actuator fails, e.g. if the muscle fails, it breaks or bursts, the valve will operate unrestricted (e.g. as a current known design valve). Thus, the pump can continue working at almost the same parameters until it is safe to stop it.
Valve “shivering” occurs when a valve is not actuated (pushed or pulled onto its seat) with a high enough force, and flow induced forces fully or partially unseat or seat the valve in a rapid sequence. Thus, the valve can not fulfill its primary function of separating two cavities. In systems according to the present invention, the actuator working against a spring reduces or eliminates valve “shivering” because two main forces are acting upon the valve's poppet—the force generated by a compressed spring and, in opposite direction, the force developed by the FESTO (TRADEMARK) “muscle” or an equivalent actuator 132. Secondary forces that are pulling and pushing the poppet are those flow induced because of the high mainly axial forces generated by the two components, spring and actuator, any minute force variation induced by flow is counteracted by either one of the two large forces. The spring will oppose the motion if a minute variation will try pushing the poppet or to unseat it. Conversely, the actuator will oppose any pulling or seating of the poppet; and thus the poppet has a very stable attitude in flow.
A valve assembly according to the present invention with a poppet like the poppet 114a provides uniform and stable poppet positioning and movement.
In contrast, in certain prior art valve assemblies with typical plain rounded-head poppets, there are sudden ninety degree changes of fluid flow direction on both faces of the poppets. Sudden changes in the direction of fluid flow, as well as turbulence behind the poppet, can generate some flow-induced destabilizing forces. Also, with such typical plain rounded-head poppets with relatively large flat end surfaces, two areas of low pressure (vacuum or close to vacuum) are developed around sharp edges of the poppets. These areas are within and surrounded by high pressure. This pressure distribution can lead to cavitation and unstable attitude in flow. Also, discrete veins of flow can occur where these low pressure areas take place. Consequently, because of a non-uniform distribution around the body, the poppets will have a precession motion. This effect is amplified by the geometrical dimensions of the poppets. Non-uniform flow distribution results on the poppets back sides.
A pin 120f rests in a recess 120r of a support 120h. The pin 120f projects through openings in the projections 120k to secure the spring 120c to the support 120h. A cable (not shown) is wrapped around (or connected to) the pin 120f and extends down through the spring 120c. A hole 120u houses a set screw 120w to secure the base 114s to support 120h.
In certain particular aspects, two first coils 120j of the spring 120c, optionally of high elasticity material allow the poppet 114b to center itself on a seat. After seating of the poppet 114b against a seat, the coils 120j are completely compressed and in contact. The remaining coils of the spring 120c take the load and thus elastically support the poppet 114b.
The support 120h (see, e.g.,
The present invention, therefore, provides in at least some embodiments, a system for pumping a drilling fluid mixture, the drilling fluid mixture containing drilling fluid and solids, the system including: a pump apparatus; the pumping apparatus having a body with an inlet and an outlet; a suction valve in the body for selectively controlling flow of the drilling fluid mixture in through the inlet; a discharge valve in the body for selectively controlling flow of the drilling fluid mixture out through the outlet; each of the suction valve and the discharge valve having a seat with a curved valve seat surface and a valve member with a curved member surface, part of the valve member movable to seat the curved member surface against the curved valve seat surface to prevent the flow of the drilling fluid mixture past the valve seat. Such a system according to the present invention may have one or some (in any possible combination) of the following: a seal recess in the curved valve seat of each of the suction valve and the discharge valve, a seal positioned in each seal recess so that resonating of the seal is inhibited, each valve member movable to seat against a corresponding seal; wherein each valve member has a range of freedom of movement for effecting seating against an adjacent corresponding curved valve seat surface (and, in certain aspects, against a seal in the valve seat), the freedom of movement including the ability to move not just toward and away from the vavle seat but at an angle thereto; wherein each valve member has a spring urging the valve member against the curved valve seat surface; wherein the spring has a spring body with a first end and a second end, the first end in contact with the valve member, the first end tapering from the spring body; each valve having a cartridge stem positioned with respect to the valve member, and a valve actuator within the cartridge stem for selectively moving the valve member;wherein the valve actuator is interconnected with the valve member via a cable; the valve actuator includes a selectively expandable hose for moving the valve member; an air supply for supplying air to the valve actuator, and a control system for controlling the air supply to selectively open and close the valve; a ball movably mounted within each valve member, the cable connected to the ball and to the valve actuator, the valve member movable with respect to the ball; each valve member has a rounded nose and a curved tapered outer surface so that fluid flow contacting the nose and curved tapered outer surface forms stabilizing fluid cushions around the valve member; each valve member has a back surface, a portion of the fluid flow onto the nose and curved outer surface gradually changes direction on the back surface; wherein the seat has a flow channel adjacent the curved valve seat and the valve member is movable to close off flow through the flow channel and wherein the flow channel is unobstructed; and/or wherein each valve member has a spring urging the valve member against the curved valve seat surface, each spring having a top end with at least one curved spring projection, a spring mount within the valve member, the at least one spring projection movably connected to the spring mount to facilitate freedom of movement of the valve member with respect to the curved valve seat surface and/or a dampener within the body for inhibiting pulsations of fluid pumped from the pump apparatus.
The present invention provides systems for pumping a drilling fluid mixture, the drilling fluid mixture containing drilling fluid and solids, the systems having: a pump apparatus, the pumping apparatus having a body with an inlet and an outlet, a suction valve in the body for selectively controlling flow of the drilling fluid mixture in through the inlet, a discharge valve in the body for selectively controlling flow of the drilling fluid mixture out through the outlet, each of the suction valve and the discharge valve having a seat with a curved valve seat surface and a valve member with a curved member surface, part of the valve member movable to seat the curved member surface against the curved valve seat surface to prevent the flow of the drilling fluid mixture past the valve seat, a seal recess in the curved valve seat surface of each of the suction valve and the discharge valve, a seal positioned in each seal recess so that resonating of the seal is inhibited, each valve member movable to seat against a corresponding seal, each valve having a cartridge stem positioned with respect to the valve member, and a valve actuator within the cartridge stem for selectively moving the valve member.
The present invention provides a method method for pumping fluid, the method including: sucking fluid into an inlet of a pumping apparatus of a system, the system comprising a pump apparatus, the pumping apparatus having a body with an inlet and an outlet, a suction valve in the body for selectively controlling flow of the drilling fluid mixture in through the inlet, a discharge valve in the body for selectively controlling flow of the drilling fluid mixture out through the outlet, each of the suction valve and the discharge valve having a curved valve seat surface and a valve member with a curved member surface, part of the valve member movable to seat the curved member surface against the curved valve seat surface to prevent the flow of the drilling fluid mixture past the valve seat; and with the pump apparatus, pumping fluid into the inlet and then out the outlet. The present invention provides wherein such a system, in certain aspects, that has a seal recess in the curved valve seat of each of the suction valve and the discharge valve, a seal positioned in each seal recess so that resonating of the seal is inhibited, each valve member movable to seat against a corresponding seal, the method further including seating each valve member surface agains a corresponding seal; and/or wherein each valve has a cartridge stem positioned with respect to the valve member, and each valve has a valve actuator within the cartridge stem for selectively moving the valve member, the method further including actuating each of the suction valve and the discharge valve with the valve actuator.
The present invention provides a method for pumping fluid, the method including: sucking fluid into an inlet of a pumping apparatus of a system, the system having a pump apparatus, the pumping apparatus having a body with an inlet and an outlet, a suction valve in the body for selectively controlling flow of the drilling fluid mixture in through the inlet, a discharge valve in the body for selectively controlling flow of the drilling fluid mixture out through the outlet, each of the suction valve and the discharge valve having a curved valve seat surface and a valve member with a curved member surface, part of the valve member movable to seat the curved member surface against the curved valve seat surface to prevent the flow of the drilling fluid mixture past the valve seat, wherein each valve member has a range of freedom of movement for effecting seating against an adjacent corresponding curved valve seat surface; with the pump apparatus, pumping fluid into the inlet and then out the outlet; controlling fluid flow in through the inlet with the suction valve; and controlling fluid flow out the outlet with the discharge valve.
The present invention provides a method for pumping fluid, the method including: sucking fluid into an inlet of a pumping apparatus of a system, the system including a pump apparatus, the pumping apparatus having a body with an inlet and an outlet, a suction valve in the body for selectively controlling flow of the drilling fluid mixture in through the inlet, a discharge valve in the body for selectively controlling flow of the drilling fluid mixture out through the outlet, each of the suction valve and the discharge valve having a curved valve seat surface and a valve member with a curved member surface, part of the valve member movable to seat the curved member surface against the curved valve seat surface to prevent the flow of the drilling fluid mixture past the valve seat, each valve having a cartridge stem positioned with respect to the valve member, and a valve actuator within the cartridge stem for selectively moving the valve member; with the pump apparatus, pumping fluid into the inlet and then out the outlet; and with the valve actuator selectively operating the suction valve and the discharge valve.
The present invention provides a valve for a valve assembly for a pump apparatus of a system for pumping a drilling fluid mixture, the drilling fluid mixture containing drilling fluid and solids, the pumping apparatus having a body with an inlet and an outlet, the valve for disposition in one of the inlet and outlet for selectively controlling flow of the drilling fluid mixture, the valve including: a seat with a curved valve seat surface, a valve member with a curved member surface, part of the valve member movable to seat the curved member surface against the curved valve seat surface to prevent the flow of the drilling fluid mixture past the valve seat. Such a valve may have a seal recess in the curved valve seat surface, a seal positioned in the seal recess, the valve member movable to seat against the seal.
The present invention provides a valve for a system for pumping a drilling fluid mixture, the drilling fluid mixture containing drilling fluid and solids, the valve having: a seat with a valve seat surface, a valve member with a member surface, part of the valve member movable to seat the member surface against the valve seat surface to prevent the flow of the drilling fluid mixture past the valve seat, a cartridge stem positioned with respect to the valve member, and a valve actuator within the cartridge stem for selectively moving the valve member.
The present invention provides system for pumping a drilling fluid mixture, the drilling fluid mixture containing drilling fluid and solids, the system having: a pump apparatus, the pumping apparatus having a body with an inlet and an outlet, a suction valve in the body for selectively controlling flow of the drilling fluid mixture in through the inlet, a discharge valve in the body for selectively controlling flow of the drilling fluid mixture out through the outlet, and a dampener within the body for inhibiting pulsations of fluid pumped from the pump apparatus
In conclusion, therefore, it is seen that the present invention is well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention and changes are possible within the scope of this invention and it is further intended that each element or step recited herein refers to the step literally and/or to all equivalent elements or steps. This specification is intended to cover the invention as broadly as legally possible in whatever form it may be utilized. All patents and applications identified herein are incorporated fully herein for all purposes.
