Downhole Valve Segmented Flow Control
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Solution Overview
Problem
Current downhole valves cannot be run into a wellbore in a closed position while allowing fluid flow through the tool string for simultaneous operations below the valve, and they lack the ability to redirect flow and close the redirected path while maintaining flow through the tool string.
Innovation Solution
A downhole valve design featuring two pistons with recesses and ports that allow fluid flow through the valve to be opened and closed by moving the pistons within a housing, enabling fluid to flow through the valve even when it is in a closed position, by using shear screws and pressure to align ports with recesses for fluid communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ball is landed on the seat to block flow, then flow through the seat is blocked and pressure builds to actuate tools, but flow through the downhole tool is blocked and operations below the seat cannot proceed
Solution Approach 1:
The valve is divided into multiple independent flow paths: a primary flow path through the seat controlled by the ball, and a secondary flow path around the ball through bypass ports. This segmentation allows the ball to block the primary path while fluid can still flow through the secondary path, maintaining operational continuity below the valve.
Solution Approach 2:
Bypass ports and annular spaces act as intermediary flow paths that allow fluid to circumvent the ball when it blocks the primary seat. This intermediary path enables continuous operation of downhole tools while the ball remains in place to control or block the primary flow path as needed.
2Reliability
If a valve is run into the wellbore in the closed position, then flow is blocked at the valve, but no fluid flow is permitted to pass below the valve for simultaneous operations
Solution Approach 1:
The valve structure segments flow into multiple independent paths: flow through the seat and flow around the ball through bypass ports. This allows the valve to be run in a closed position with the ball blocking the seat, while fluid can still pass through the bypass ports to enable operations below the valve.
Solution Approach 2:
The valve is designed with multi-functionality to serve different operational needs: it can block flow through the seat while allowing bypass flow, or allow flow through both paths simultaneously. This universal design enables the valve to be run in closed position while maintaining adaptability for simultaneous operations below the valve.
3Productivity
If the ball is removed to re-establish flow through the downhole tool, then flow is restored, but the opened secondary flow directions are not closed
Solution Approach 1:
Instead of using the ball removal to control both primary and secondary flow paths, the invention inverts the control logic: the ball controls only the primary path through the seat, while the bypass ports provide independent control of secondary flow. This allows the ball to be removed to restore primary flow while secondary flow directions can be independently managed through the bypass system.
Solution Approach 2:
The flow control is segmented into independent functions: the ball controls the primary path through the seat, while bypass ports control the secondary path. This segmentation allows independent management of each flow path, enabling the ball to be removed to restore primary flow while secondary flow directions can be separately controlled or closed as needed.
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
Enables the downhole valve to be opened and closed while maintaining fluid flow through the valve, allowing for simultaneous performance of operations below the valve and redirecting fluid flow as needed, enhancing operational flexibility in wellbore operations.
Implementation Method 1
Fluid pressure acts on the piston to move the piston downward
Implementation Method 2
The resultant build-up of pressure can actuate a downhole tool such as by causing shear screws to break
Data Source
AI summary
Downhole valves comprise a housing having a bore, a port, upper and lower recesses disposed in an inner wall surface of the bore, the upper recess disposed above the port and the lower recess disposed below the port, and upper and lower pistons disposed in the bore. The upper and lower pistons each comprise a bore with a port in communication with housing bore. During run-in, the housing port is blocked by the lower piston. Actuation of the lower piston unblocks the housing port and aligns the lower piston port with the lower recess. Actuation of the upper piston closes the housing port and aligns the upper piston port with the upper recess. Alignment of the ports of the pistons with their respective recesses permits fluid flow through the tool both when the valve is opened by the lower piston and closed by the upper piston.