Downhole Backpressure Valve Locking Mechanism
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Solution Overview
Problem
The drilling and completion industry faces significant costs and time inefficiencies due to the labor-intensive process of removing plugs from boreholes to access resource-bearing formations, as existing methods require withdrawing and re-running drill and production strings.
Innovation Solution
A downhole tool equipped with a backpressure valve featuring a flapper valve and locking system that can be pivoted and locked open using a snap-fastener mechanism, allowing for efficient fluid flow and reducing the need for frequent string operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug is installed in the borehole to isolate a portion of the resource bearing formation, then formation isolation is achieved, but the process becomes time-consuming and costly when string operations are required for plug removal
Solution Approach 1:
The backpressure valve is segmented into modular components including a body, flapper valve, and locking system that can be independently manufactured and assembled. This modular design allows for efficient deployment and retrieval without requiring complete string operations, reducing time loss while maintaining formation isolation capability.
Solution Approach 2:
The locking system is pre-configured to automatically engage with the flapper valve upon deployment, establishing formation isolation immediately without requiring subsequent string operations. The preliminary positioning of locking elements ensures that the valve is secured in the closed position before production begins, eliminating the need for time-consuming post-deployment adjustments.
2Ease of operation
If a traditional backpressure valve is used without a locking system, then the valve can pivot freely for operation, but the valve cannot be reliably held in the open position for production
Solution Approach 1:
The valve system transitions from a static fixed-position design to a dynamic system where the flapper valve can pivot freely during operation but is selectively locked in the open position by the locking system during production. This dynamic capability allows the valve to adapt to different operational phases, providing both ease of operation and reliable position holding as needed.
Solution Approach 2:
The locking system acts as an intermediary mechanism between the flapper valve and the borehole environment. It provides the necessary force to hold the valve in the open position against pressure differential forces, while allowing the valve to pivot freely when the locking system is disengaged. This intermediary locking mechanism resolves the contradiction between free pivoting and reliable position holding.
3Reliability
If the flapper valve is held closed during milling operations, then fluid flow is prevented, but the valve must be reliably opened and locked for production mode
Solution Approach 1:
The locking system is designed to automatically engage with the flapper valve through a snap-fit mechanism that utilizes the valve's own movement and pressure differential forces. When the valve transitions from closed to open position, the locking elements automatically align and engage without requiring external actuation, thereby reducing device complexity while maintaining reliable fluid flow control during both milling and production modes.
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
This solution streamlines the process by preventing fluid flow during milling, allowing for easy transition to production mode, thereby reducing operational time and costs associated with plug removal and resource production.
Implementation Method 1
a flapper valve having a first side and an opposing second side pivotally mounted to the inner surface to selectively extend across the flowbore
Implementation Method 2
a locking system mounted to the inner surface in the flowbore and snap-fittingly engageable with the flapper valve
Data Source
AI summary
A downhole tool includes a tubular having an outer surface and an inner surface defining a flowbore having a longitudinal axis, and a backpressure valve arranged in the flowbore. The backpressure valve includes a flapper valve having a first side and an opposing second side pivotally mounted to the inner surface to selectively extend across the flowbore and a locking system mounted to the inner surface in the flowbore and snap-fittingly engageable with the flapper valve. The flapper valve is pivotable between a first position, wherein the flapper valve is free to pivot relative to the inner surface, and a second position, wherein the flapper valve is pivoted away from the flowbore and locked open by the locking system such that the first side forms part of the flowbore.