Drilling Flow Controller with Pivoting Valve for Borehole Pressure Management
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Solution Overview
Problem
Existing drilling systems face challenges in managing fluid flows from boreholes drilled through fluid-containing subterranean formations, particularly when drilling upwards, as they often result in safety hazards and hinder sample retrieval due to complex valve systems that do not allow passage for conventional accessories.
Innovation Solution
A flow controller system comprising an outer tube and a flow controller body that can move between open and closed configurations, allowing passage for drilling accessories while inhibiting fluid flow towards the borehole proximal end, and automatically switching configurations based on fluid flow and accessory movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a valve is used to control fluid flow in the borehole, then fluid flow can be mitigated, but the valve system becomes complex and does not allow passage of conventional sample recovering accessories
Solution Approach 1:
The flow controller is divided into multiple functional segments: a body defining a passageway, movable members (pivoting members with blocking portions) that can independently move to block or allow flow, and actuating mechanisms. This segmentation allows each component to perform a specific function while maintaining overall system simplicity and compatibility with drilling accessories.
Solution Approach 2:
The valve members are designed to be movable between different positions (open and closed configurations) rather than fixed. The pivoting members can rotate about pins to transition between blocking and non-blocking positions, allowing the system to dynamically respond to fluid pressure and operational requirements while maintaining a relatively simple structural design.
2Ease of operation
If a complex control system is used to operate the valve between open and closed configurations, then selective operation is achieved, but the system complexity increases
Solution Approach 1:
The flow controller utilizes the natural fluid pressure itself to actuate the valve members. When fluid pressure exceeds a predetermined threshold, the pressure differential automatically moves the pivoting members to the closed position, blocking fluid flow. This self-actuating mechanism eliminates the need for complex external control systems, operators, or power sources while maintaining selective operation capability.
Solution Approach 2:
The system incorporates inherent feedback through the pressure-sensitive actuation mechanism. The fluid pressure continuously monitors the flow conditions and automatically triggers the valve closure when pressure exceeds safe levels. This feedback loop provides automatic control without requiring complex external monitoring or control systems.
3Object-affected harmful factors
If the flow controller is positioned closer to the borehole distal end, then fluid flow control is improved, but access to the distal end for drilling operations becomes restricted
Solution Approach 1:
The flow controller is designed as a nested structure where the valve members, actuating mechanisms, and body are concentrically arranged within the drill string passage. This nesting allows the flow controller to occupy minimal space within the borehole while maintaining effective flow control capability, thereby preserving access to the distal end for drilling operations.
Solution Approach 2:
The flow controller utilizes the radial dimension by positioning the valve members to block flow across the cross-sectional area of the borehole when needed, rather than requiring axial space. The pivoting members extend radially to block flow when in the closed position, allowing effective flow control with minimal axial footprint and maintaining versatility for distal end access.
Data Source
AI summary
A system (10) for drilling a borehole (14) in a subterranean formation (16) containing a fluid (18), comprising: an outer tube (24) defining an outer tube distal end (26) configured for attaching a drill bit (12) thereto and a flow controller receiving section (27) spaced apart therefrom; a flow controller (28) including a flow controller body (30) defining body proximal and distal ends (32 and 34) and securable to the outer tube (24) in the flow controller receiving section (27); and a drilling accessory (36) insertable in the outer tube (24) and through the flow controller (28). The flow controller (28) is movable between open and closed configurations. In the open configuration, the flow controller (28) allows passage of the drilling accessory (36) therethrough. In the closed configuration, the flow controller (28) hinders flow of the fluid therethrough towards the borehole proximal end (20) when the flow controller (28) is located closer to the borehole proximal end (20) than the fluid (18).