Patent Application
20250137363
Embodiments of the subject matter disclosed herein relate to an improved tail plug and assembly for a gas lift valve for use in oil and gas wells.
Those skilled in the art know that gas lift mandrels and valves play a crucial role in enhancing oil and gas production from wells, particularly in challenging conditions where traditional methods may fall short. These systems utilize the injection of gas to lighten the hydrostatic column of fluid in the wellbore, thereby reducing the pressure required to lift fluids to the surface. This method is especially beneficial in wells with low reservoir pressure or high fluid viscosity, where conventional pumping techniques may struggle.
At the core of gas lift systems are mandrels, which are tubular devices installed at various depths in the well. These mandrels serve as anchor points for the gas lift valves, which control the injection of gas into the produced fluids. The design of the mandrel allows for easy installation and retrieval of the valves, facilitating maintenance and adjustments without needing to pull the entire tubing string. This flexibility is a significant advantage in maximizing production efficiency and minimizing downtime.
The gas lift valves are strategically positioned within the mandrels to regulate gas flow based on the relative pressure between lift gas injected into the well and pressure and fluid levels in the well itself. When the reservoir pressure drops or when fluid levels are insufficient for natural flow, the valves can open to allow gas to enter the wellbore. This injection reduces the density of the fluid column, enabling the hydrostatic pressure to be overcome more easily. As a result, the mixture of gas and fluid can be lifted to the surface with less energy.
A key benefit of using gas lift systems is their adaptability. Operators can adjust the amount and timing of gas injection based on real-time data from the well. This ability to dynamically control production allows for optimization based on varying reservoir conditions, which can significantly improve recovery rates. In essence, gas lift systems can be tailored to fit the specific characteristics of a well, leading to enhanced production efficiency.
Another advantage of gas lift technology is its lower operational costs compared to other artificial lift methods. Unlike electric submersible pumps (ESPs) or rod pumps, gas lift systems do not require extensive electrical infrastructure or complex mechanical components. This simplicity translates to reduced maintenance costs and fewer failures, making gas lift an attractive option for operators seeking to minimize expenses while maximizing output.
Moreover, gas lift systems can be deployed in environments where other artificial lift methods may be impractical. For instance, in offshore applications or remote locations with limited access to power sources, gas lift provides a reliable alternative that can be implemented with minimal logistical challenges. This versatility enables operators to extend the productive life of their wells and make the most of available resources.
As the oil and gas industry continues to evolve, the integration of advanced monitoring and control technologies with gas lift systems offers evolving possibilities. By incorporating sensors and real-time data analytics, operators can achieve even greater precision in managing gas injection and production rates. This integration can lead to improved recovery factors and more efficient use of reservoir resources, ultimately enhancing the economic viability of oil and gas projects.
Heretofore, however, gas lift valves have suffered leaks that diminish the efficiency and operability of the valves themselves. As those skilled in the art know, the ability of a gas lift valve to maintain a predetermined (or set) pressure level is important to the efficient operation of the valve in a well. Indeed, beyond mere inefficiencies, valve failures can result in costly delays and equipment costs if the valve(s) must be replaced.
As indicated, although it is desirable and important that gas chamber 15 remain charged to its predetermined pressure level, such prior art gas lift valves can suffer from leakage of gas/pressure from chamber 15, principally on a path past gas injection valve core 20 and tail plug 25 and on to the ambient outside gas lift valve 10. This gas/pressure leakage can occur despite efforts to design gas injection valve core 20 and tail plug 25 to prevent such leakage. Reasons for the leakage can vary, including operators not properly torquing tail plug 25 in place.
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The following disclosure may be understood by reference to the description herein taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements. The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate one or more exemplary embodiments of the present invention, except where the drawings are indicated to illustrate the prior art. The present invention should not be considered limited to the following drawings. In the drawings:
Various features and advantageous details are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the description herein. Descriptions of well-known starting materials, processing techniques, components, and equipment are omitted so as not to unnecessarily obscure the invention. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the invention, are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and/or rearrangements within the spirit and/or scope of the underlying inventive concept will become apparent to those skilled in the art from this disclosure.
The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended or implied. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than that understood by skilled artisans, such special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase.
The present exemplary embodiments describe an improved tail plug and assembly for a gas lift valve. Those skilled in the art will appreciate that other embodiments are contemplated. For example,
In the embodiment of
As shown in more detail in
Applicant has discovered (among other things disclosed here and as will be appreciated by those skilled in the art by reading the present application) that using an NPT thread to connect a brass tail plug to a stainless-steel dome cap creates a better barrier against leaks of the type described above in the prior art. Aside from the enhanced leak-proof barrier provided by the NPT thread itself, this enhanced barrier appears to be particularly efficient at eliminating leaks in embodiments where the brass tail plug includes male threads and the stainless-steel dome cap includes female threads since the softer brass tail plug's male threads crush and deform into the dome cap's harder stainless-steel female threads. Applicant has discovered that the leak-proof nature of this design is not as susceptible to operators not properly torquing the tail plug into the dome cap as was the case in the prior art.
In still other/alternate embodiments, the leak path may be further enhanced against leaks by including copper crush washer 70 and/or O-ring seal 75 in the path as shown in the exemplary embodiment of
Finally,
Although the invention(s) is/are described herein with reference to specific embodiments, various modifications and changes can be made without departing from the scope of the present invention(s), as set forth in the claims below. Accordingly, the specification and Figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention(s). Any benefits, advantages, or solutions to problems that are described herein with regard to specific embodiments are not intended to be construed as a critical, required, or essential feature or element of any or all the claims.
Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The terms “coupled” or “operably coupled” are defined as connected, although not necessarily directly, and not necessarily mechanically. The terms “a” and “an” are defined as one or more unless stated otherwise. The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements but is not limited to possessing only those one or more elements. Similarly, a method or process that “comprises,” “has,” “includes” or “contains” one or more operations possesses those one or more operations but is not limited to possessing only those one or more operations.
Accordingly, the protection sought herein is as set forth in the claims below.
This application claims priority to provisional patent application Ser. No. 63/594,736 filed Oct. 31, 2023, which is fully incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63594736 | Oct 2023 | US |
