Emergency Valve Assembly Rotating Stopper Shear Mechanism
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Solution Overview
Problem
Current safety systems for preventing hydrocarbon or natural gas blow-outs from extraction wells, such as blow-out preventers (BOPs) and safety valves, are often inadequate and ineffective, especially at deep sea or ocean floor depths, as exemplified by the Deepwater Horizon disaster, highlighting the need for additional and more reliable emergency measures.
Innovation Solution
An emergency valve assembly with a rotating stopper and stopper drive, capable of shearing and blocking production or drilling lines by using an explosive charge to generate mechanical energy for rotation, ensuring irreversible closure and effective prevention of fluid outflow, even at great depths, independent of conventional BOP systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional safety systems (BOPs and safety valves) are used to prevent blow-outs, then the well is protected under normal operating conditions, but these systems prove inadequate and ineffective when emergency conditions occur or when positioned at great depths
Solution Approach 1:
The safety system is segmented into multiple independent components: the emergency valve assembly with rotating stopper, the explosive charge mechanism, and the drive system. This segmentation allows the emergency valve to function independently of conventional BOP systems, providing redundant safety without requiring a fully integrated complex system. The rotating stopper itself is segmented with shearable sections that can be divided by the explosive charge.
Solution Approach 2:
The emergency valve assembly is pre-positioned in the wellhead with the rotating stopper initially in the open position allowing fluid flow. The explosive charge is pre-installed in the drive mechanism, ready to be activated immediately upon emergency detection. This preliminary preparation ensures that no time is lost in assembling or activating the safety mechanism during a blow-out event.
2Strength
If the rotating stopper is designed to shear the production or drilling line effectively, then fluid flow is blocked, but the mechanism requires high mechanical force that is difficult to generate at deep sea depths
Solution Approach 1:
The conventional mechanical drive system that would require complex hydraulic or electric motors is replaced with a chemical energy system. An explosive charge is used to generate the high-force impulse needed to shear the production or drilling line and rotate the stopper into the closed position. This substitution of chemical energy for mechanical energy systems solves the problem of generating sufficient force at deep sea depths where mechanical systems become increasingly complex and less reliable.
Solution Approach 2:
The state of the drive mechanism changes from a steady-state mechanical system to a high-energy impulse system. The explosive charge converts chemical energy into a sudden, high-magnitude mechanical impulse that exceeds the shear strength of the production line. This parameter change in energy delivery (from continuous to impulsive) enables the system to overcome the high strength requirements without needing continuously high power availability.
3Reliability
If the emergency valve assembly is made independent of conventional BOP systems, then reliability under emergency conditions improves, but the device complexity and design constraints increase
Solution Approach 1:
The rotating stopper serves multiple functions: it acts as a flow control element when in the open position, serves as a shearable barrier when activated, and functions as a closure mechanism when rotated into the closed position. The explosive charge mechanism also serves dual purposes by both driving the rotation and providing the shearing force. This multi-functionality reduces the need for separate components, thereby reducing overall complexity while maintaining independence.
Solution Approach 2:
The emergency valve assembly is nested within the existing wellhead structure, utilizing the available space and integration points. The rotating stopper is nested within the valve body, and the explosive charge is nested within the drive mechanism. This nesting approach allows the independent emergency system to be integrated into the existing wellhead without requiring a completely separate external system, thereby reducing complexity.
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
The emergency valve assembly provides a reliable and independent safety measure to prevent blow-outs by effectively shearing and blocking fluid flow, even when conventional systems fail, ensuring safety at deep underwater depths and facilitating maintenance and operation with reduced complexity and design constraints.
Implementation Method 1
a stopper drive (56) arranged for actuating the rotating stopper (54) making it rotate so as to shear the production or drilling line passing through it
Data Source
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AI summary
The emergency valve assembly (5) for extraction wells according to the invention comprises A) an external housing (50) and B) a rotating stopper (54). The passthrough duct (52) is arranged for the passage of a production and/or drilling line arranged for containing and carrying, through at least one relative pipe (9), extraction fluids such as, for example, petroleum, oil, water, sludge, rock debris and/or earth, natural gas, or other fluids extracted from an underground reservoir. The valve (5) also comprises a stopper drive (56), arranged for actuating the rotating stopper (54) making it rotate so as to shear the production or perforation line passing through it, in particular shearing the pipe (9) and closing the pass-through duct (52). The pass-through duct (52, 520) has a minimum passage section having a diameter equal to or greater than seven inches. It provides an effective additional safety measure in the case of emergencies.