Back Pressure Valve Plug for Wellhead Maintenance
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Solution Overview
Problem
The existing back-pressure valves (BPVs) require specialized tools like lubricators for pressure management during maintenance, which are often unavailable on-site and require skilled operators, leading to inefficiencies in well maintenance and testing processes.
Innovation Solution
A plug tool that can selectively plug a BPV without contacting its poppet, allowing for pressure sealing and well control during maintenance, enabling BPV testing and fluid pumping without a two-way check valve or lubricator, and can be removed while the BPV is still installed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-way check valve is used to test the BOP, then the BOP can be tested in both directions, but the valve cannot be removed without a specialized lubricator tool
Solution Approach 1:
The invention divides the system into two separate components: the existing BPV remains in place for pressure sealing, while a removable plug tool is inserted into the BPV to enable BOP testing. This segmentation allows the BPV to stay installed without requiring removal tools, while the plug tool provides the additional functionality needed for bidirectional testing.
Solution Approach 2:
The plug tool is designed to be inserted into and nest within the BPV body. The plug tool contains a smaller check valve that nests within the BPV's flow path, allowing the plug tool to control flow direction while the BPV maintains its pressure sealing function. This nested configuration enables both functions in a compact arrangement.
2Ease of repair
If a lubricator is used to remove the BPV, then the BPV can be removed and reinstalled, but the process requires specialized tools and experienced operators
Solution Approach 1:
The invention extracts the testing functionality from the BPV itself and places it in a separate, removable plug tool. This allows the BPV to remain permanently installed in the tubing hanger without needing to be removed for testing purposes. The plug tool can be independently inserted and removed without affecting the BPV's position or requiring specialized removal tools.
Solution Approach 2:
The plug tool serves multiple functions: it acts as a flow control mechanism for BOP testing, provides a sealing interface within the BPV, and can be easily installed and removed without specialized tools. This multi-functionality eliminates the need for complex lubricator equipment while achieving the same operational goals.
3Reliability
If the BPV is removed to install a two-way check valve, then bidirectional testing is enabled, but well pressure must be killed and downtime increases
Solution Approach 1:
The plug tool is pre-configured with a check valve mechanism that enables bidirectional testing functionality before being inserted into the BPV. This preliminary preparation allows the tool to be quickly deployed without requiring well pressure to be killed or the BPV to be removed, thereby minimizing well downtime while achieving the testing objective.
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
Facilitates efficient BPV testing and maintenance by allowing pressure sealing and fluid pumping without specialized tools, reducing downtime and operational costs by enabling testing from above and normalizing well pressure.
Implementation Method 1
A spring is positioned in the bore and biased against the poppet
Implementation Method 2
The seal prevents fluid leakage between the plug body and the bore
Data Source
AI summary
A plug tool is presented to selectively plug a back pressure valve (BPV) in a tubing hanger associated with a wellhead of a well. The plug tool and the BPV can seal bottom hole pressure from the well during removal of the Christmas tree, and can retain control of the well while the Christmas tree is removed. The plug tool and the BPV allow a blowout preventer (BOP) to nipple-up and be tested without removing the BPV and without replacing the BPV with a two-way check valve. The plug tool has lower threads to engage internal threads of the BPV, and upper threads to be engaged by a retrieval tool. The plug tool has a seal to seal with the BPV above the internal threads and below a notch.