Ball and Plug Dropping Head with Bypass Flow Channels
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Solution Overview
Problem
Current cementing operations in oil and gas well exploration and production face challenges in efficiently and reliably dropping plugs or balls into well tubing, particularly in ensuring fluid flow around valving members when they are closed, and supporting large plugs or balls during the process.
Innovation Solution
A ball and plug dropping head with a housing having an inlet connected to a top drive, a main flow channel, and multiple valving members that can move between open and closed positions, allowing fluid to bypass the valving members when closed, and supporting plugs or balls with sliding sleeves, enabling passage of plugs up to 6.5 inches in diameter and withstanding high pressures and torques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If valving members are used to control fluid flow in cementing operations, then fluid flow control is improved, but fluid cannot pass through the valving members when they are in closed position
Solution Approach 1:
The flow channel is segmented into multiple paths: a main flow channel that passes through the valving member and a bypass flow channel that goes around it. This segmentation allows the system to control flow through the valve while providing an alternative path that maintains continuous fluid flow even when the valve is closed.
Solution Approach 2:
A bypass flow channel acts as an intermediary path that mediates between the need for valve control and the need for continuous fluid flow. When the valving member closes the main channel, the bypass channel provides an alternative route, ensuring that cementing operations can continue without interruption.
2Ease of operation
If conventional plug dropping heads are used, then basic plug dropping function is achieved, but they cannot reliably support large diameter plugs or balls during cementing operations
Solution Approach 1:
The invention transitions from a single flow channel design to a multi-dimensional flow path system with both main and bypass channels. This dimensional change in the flow path architecture enables the system to handle larger diameter plugs by providing alternative flow routes that accommodate the increased size and weight of the plugs being dropped.
Solution Approach 2:
The system incorporates movable valving members that can dynamically switch between open and closed positions, allowing the flow distribution to adapt based on operational needs. This dynamic capability enables reliable support and controlled dropping of large diameter plugs by adjusting flow paths in real-time during cementing operations.
3Reliability
If high pressure and torque withstanding capability is increased, then reliability under harsh conditions is improved, but device complexity increases
Solution Approach 1:
The valving members serve multiple functions: they control fluid flow in the main channel, support large diameter plugs during dropping operations, and can be positioned to open or close flow paths. This multi-functionality allows the same component to address multiple requirements (pressure resistance, plug support, flow control) without proportionally increasing device complexity.
Solution Approach 2:
The invention merges the flow control function and plug support function into a single integrated system with valving members that perform both roles. By combining these functions in one component rather than using separate mechanisms, the system achieves high pressure and torque reliability while minimizing the increase in structural complexity.
Data Source
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AI summary
An improved method and apparatus for dropping a ball, plug or dart during oil and gas well operations (e.g., cementing operations) employs a specially configured valving member with curved and flat portions that alternatively direct fluid flow through a bore or opening in the valving member via an inner channel or around the periphery of the valving member in an outer channel. In one embodiment, the ball(s), dart(s) or plug(s) are contained in a sliding sleeve that shifts position responsive to valve rotation.