Ball Valve Actuation Mechanism for Debris-Laden Environments
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Solution Overview
Problem
Isolation valves in hydrocarbon reservoirs face performance issues and failure due to increased friction from debris and foreign materials in dirty environments, requiring excessive force to operate, which can exceed equipment ratings.
Innovation Solution
The isolation valve system features a ball valve actuation mechanism that moves internal components away from the ball valve, reducing friction and force requirements by creating space for debris to flow around the valve, allowing for reliable operation in debris-laden environments with reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional ball valve actuation mechanism is used in debris-laden environments, then the valve can provide isolation function, but the friction between internal components and debris increases excessively, requiring force beyond equipment ratings to operate
Solution Approach 1:
The patent extracts and removes debris from the critical actuation path by providing a debris collection chamber that captures foreign materials before they can enter the ball valve actuation mechanism. This prevents debris from interfering with the movement of internal components, thereby maintaining reliable operation without requiring excessive actuation force.
Solution Approach 2:
The patent introduces a debris collection chamber as an intermediary component between the incoming fluid/debris and the ball valve actuation mechanism. This chamber acts as a buffer zone that traps debris particles, preventing them from directly contacting and increasing friction on the actuation components, thus reducing the force needed for operation.
2Device complexity
If internal components are positioned close to the ball valve for compact design, then device complexity is reduced, but friction from debris increases and hinders valve operation
Solution Approach 1:
The patent segments the valve assembly into distinct functional zones: a debris collection chamber separated from the ball valve actuation mechanism, and an insert that positions internal components at optimized locations. This segmentation allows debris to be captured in one zone while keeping the actuation mechanism in a cleaner zone, reducing friction without requiring complex actuation systems.
Solution Approach 2:
The patent performs preliminary action by capturing debris in the collection chamber before the debris can reach and interfere with the ball valve actuation mechanism. The insert pre-positions internal components to minimize their exposure to debris, preventing friction issues before they occur and ensuring ease of operation.
3Adaptability or versatility
If high-force actuation mechanisms are used to overcome debris friction, then the valve can operate in dirty environments, but equipment rating requirements increase and manufacturing costs rise
Solution Approach 1:
The patent converts the harmful effect of debris into a beneficial outcome by designing a debris collection chamber that captures and contains foreign materials. Instead of fighting against debris with high-force mechanisms, the system utilizes the debris collection chamber to trap particles, transforming the debris problem into a simple containment solution that reduces actuation force requirements and lowers manufacturing costs.
Solution Approach 2:
The patent employs simple, easily manufactured components such as the debris collection chamber and insert that can be produced at low cost. These components provide effective debris management without requiring expensive, high-force actuation mechanisms, making the valve economically viable for debris-laden environments.
Data Source
AI summary
An isolation valve system includes a well string having an isolation valve including a ball rotatably mounted to a pair of inserts for rotation about a fixed axis, an arm coupled to the ball at a position offset from the fixed axis, and a mandrel connected to an actuation end of the arm, the mandrel and the actuation end of the arm being disposed uphole of the ball. Via the actuation end of the arm, the mandrel forces rotation of the ball from a closed position to an open position by moving in a linear direction away from the ball, which allows flow of fluid along a through hole of the ball.