Downhole Flapper Valve Pressure Relief for Rupture Prevention

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Solution Overview

Problem

Existing isolation valves in wellbores face issues with flapper rupture due to excessive pressure differentials, leading to uncontrolled pressure release.

Innovation Solution

A downhole isolation valve with a pressure relief assembly that includes a piston movably positioned in an annular space between the housing and valve body, activating to open a relief port when the pressure differential exceeds a predetermined threshold, thereby controlling the pressure release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a flapper valve is used for isolation, then the valve can be quickly opened and closed to isolate formation pressure, but the flapper may rupture when pressure differential exceeds the design limit

Engineering Contradiction:

Improvequick opening and closingVSAvoidflapper rupture risk

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The pressure relief assembly is activated in advance before the pressure differential exceeds the flapper's design limit. The piston moves preliminarily to open the relief port when pressure reaches a predetermined threshold, preventing the harmful condition of flapper rupture before it occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The pressure relief assembly acts as a cushioning mechanism that activates beforehand to protect the flapper from excessive pressure differentials. By providing a relief path in advance, it cushions the flapper against pressure spikes that would otherwise cause rupture.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If pressure relief is added to prevent flapper rupture, then flapper reliability is improved, but the device complexity increases

Engineering Contradiction:

Improveflapper protectionVSAvoidvalve assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The pressure relief assembly is nested within the existing valve body structure. The piston is positioned in an annular space between the flapper and the valve body, utilizing existing spatial relationships rather than adding completely separate external components.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The piston serves multiple functions: it acts as both a sealing element against the valve seat and a pressure-sensing element that triggers the relief mechanism. The relief port itself serves dual purposes for pressure equalization and flow control.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Prevents flapper rupture by allowing a controlled pressure release, providing early surface indication of pressure differential exceedance, and enabling well control measures to mitigate over-pressure conditions.

Implementation Method 1

a pressure relief assembly operable to open the relief port when a pressure differential across the flapper reaches an activation pressure differential

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentEP4150191B1Downhole isolation valves with pressure relief

Publication Date: 2026.01.07 WEATHERFORD TECHNOLOGY HOLDINGS LLC

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AI summary

The present disclosure generally relates to a flapper valve including a pressure relief assembly. The pressure relief assembly is operable to activate when a pressure differential across the flapper approaches or exceeds a design pressure of the flapper.