Gas lift valve assemblies and methods of assembling same

1. A gas lift valve assembly comprising:

a housing defining an inlet port and an outlet port, said housing comprising:

an outer casing; and

an inner casing having a radial outer surface and a radial inner surface at least partially defining a main flow passage providing fluid communication between the inlet port and the outlet port; and

a check valve comprising:

a sealing mechanism disposed around said radial outer surface of the inner casing; and

a valve member comprising an outwardly extending sealing segment, said valve member moveable between an open position, in which said sealing segment is spaced from said sealing mechanism and said outer casing such that fluid flow is facilitated between said sealing segment and said outer casing, and a closed position in which said sealing segment sealingly engages said sealing mechanism, wherein said valve member further comprises a valve stem and a hollow cup-shaped portion extending from said valve stem, said sealing segment extending outward from said cup-shaped portion.

2. The gas lift valve assembly in accordance with claim 1 , wherein said sealing mechanism comprises a high pressure sealing element and a low pressure sealing element, said valve member configured to sealingly engage said low pressure sealing element at a first pressure differential across said valve member, and to sealingly engage said high pressure sealing element at a second pressure differential across said valve member greater than the first pressure differential.

3. The gas lift valve assembly in accordance with claim 2 , wherein said high pressure sealing element comprises a portion of said radial outer surface.

4. The gas lift valve assembly in accordance with claim 2 , wherein said inner casing defines a groove extending radially inward from said radial outer surface, said low pressure sealing element disposed within the groove.

5. The gas lift valve assembly in accordance with claim 1 , further comprising an injection control valve coupled in serial fluid communication with and upstream from said check valve, said injection control valve configured to regulate fluid flow between the inlet port and the main flow passage.

6. The gas lift valve assembly in accordance with claim 5 , wherein the main flow passage has an upstream end and a downstream end, said housing further comprising a venturi nozzle disposed at the upstream end of the main flow passage, said venturi nozzle defining a valve seat of said injection control valve.

7. The gas lift valve assembly in accordance with claim 1 , wherein said inner casing defines a plurality of flow guiding ports at a downstream end of the main flow passage, each of the flow guiding ports configured to direct fluid flow from the main flow passage away from said sealing mechanism.

8. The gas lift valve assembly in accordance with claim 1 , wherein said housing further comprises a lower housing portion defining a longitudinally extending recess positioned radially inward from the outlet port, the recess configured to receive said valve member therein when said valve member is in the open position.

9. The gas lift valve assembly in accordance with claim 8 , wherein said check valve further comprises a biasing member configured to bias said valve member towards the closed position, said biasing member disposed within the recess.

10. The gas lift valve assembly in accordance with claim 1 , wherein said inner casing comprises a valve guide member configured to engage said cup-shaped portion to facilitate maintaining alignment of said valve member.

11. A method of assembling a gas lift valve assembly, said method comprising:

providing a housing defining an inlet port and an outlet port, the housing including an outer casing and an inner casing, the inner casing having a radial outer surface and a radial inner surface at least partially defining a main flow passage providing fluid communication between the inlet port and the outlet port;

providing a sealing mechanism around the radial outer surface of the inner casing; and

coupling a valve member including an outwardly extending sealing segment to the housing such that the valve member is moveable between an open position, in which the sealing segment is spaced from the sealing mechanism and the outer casing such that fluid flow is facilitated between the sealing segment and the outer casing, and a closed position in which the sealing segment sealingly engages the sealing mechanism, wherein said valve member further comprises a valve stem and a hollow cup-shaped portion extending from said valve stem, said sealing segment extending outward from said cup-shaped portion.

12. The method in accordance with claim 11 , wherein providing a sealing mechanism comprises providing a low pressure sealing element and a high pressure sealing element, the low pressure sealing element configured to sealingly engage the valve member at a first pressure differential across the valve member, and the high pressure sealing element configured to sealingly engage the valve member at a second pressure differential across the valve member greater than the first pressure differential.

13. The method in accordance with claim 11 , further comprising coupling an injection control valve in fluid communication between the inlet port and the main flow passage to regulate fluid flow between the inlet port and the main flow passage.

14. The method in accordance with claim 11 , wherein the housing further includes a lower housing portion defining a longitudinally extending recess positioned radially inward from the outlet port, wherein coupling the valve member further comprises coupling the valve member to the housing such that the valve member is received within the recess when the valve member is in the open position.

15. A gas lift system comprising:

a production tubing defining a central passageway;

a well casing defining an annulus between said production tubing and said well casing; and

a gas lift valve assembly coupled in fluid communication between the annulus and the central passageway, said gas lift valve assembly comprising:

a housing defining an inlet port and an outlet port, said housing comprising:

an outer casing; and

an inner casing having a radial outer surface and a radial inner surface at least partially defining a main flow passage providing fluid communication between the inlet port and the outlet port; and

a check valve comprising:

a sealing mechanism disposed around the radial outer surface of the inner casing; and

a valve member comprising an outwardly extending sealing segment, said valve member moveable between an open position, in which said sealing segment is spaced from said sealing mechanism and said outer casing such that fluid flow is facilitated between said sealing segment and said outer casing, and a closed position in which said sealing segment sealingly engages said sealing mechanism, wherein said valve member further comprises a valve stem and a hollow cup-shaped portion extending from said valve stem, said sealing segment extending outward from said cup-shaped portion.

16. The gas lift system in accordance with claim 15 , wherein said sealing mechanism comprises a high pressure sealing element and a low pressure sealing element, said valve member configured to sealingly engage said low pressure sealing element at a first pressure differential across said valve member, and to sealingly engage said high pressure sealing element at a second pressure differential across said valve member greater than the first pressure differential.

17. The gas lift system in accordance with claim 16 , wherein said inner casing defines a groove extending radially inward from said radial outer surface, said low pressure sealing element disposed within the groove.

18. The gas lift system in accordance with claim 15 , wherein said gas lift assembly further comprises an injection control valve coupled in serial fluid communication with and upstream from said check valve, said injection control valve configured to regulate fluid flow between the inlet port and the main flow passage.

19. The gas lift system in accordance with claim 15 , wherein said inner casing defines a plurality of flow guiding ports at a downstream end of the main flow passage, each of the flow guiding ports configured to direct fluid flow from the main flow passage away from said sealing mechanism.