Expanded Float Valve Insert for Custom Casing Threads
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Solution Overview
Problem
Conventional cement float equipment is limited in its ability to accommodate unique casing materials and threads, requiring special equipment and long lead times, and existing solutions with drillable packers are expensive and require extensive inventory.
Innovation Solution
A float valve assembly comprising an expanded sleeve, caps, and a flow tube, all made of drillable materials, which can be installed inside a tubular before deployment, allowing for customization and seamless integration with standard or customized casing threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional float equipment is designed with special casing material and threads to accommodate unique requirements, then the equipment can meet specific installation needs, but the lead time increases and inventory requirements expand
Solution Approach 1:
The float valve is divided into two separate components: a standard float valve body and a custom adapter. The adapter is tailored to match unique casing materials and threads, while the valve body remains standardized. This segmentation allows the adaptable portion (adapter) to be customized without requiring the entire float valve to be specially manufactured, thereby reducing lead time while maintaining compatibility with unique casing requirements
Solution Approach 2:
A custom adapter serves as an intermediary component between the standardized float valve body and the unique casing. This adapter translates the standard valve interface to match proprietary casing threads and materials, enabling the use of standard float valves with unique casing without requiring specialized float valve designs, thus reducing both lead time and inventory requirements
2Adaptability or versatility
If drillable packers with inserted float valves are used to accommodate different casing requirements, then versatility is improved, but the cost increases and inventory requirements expand
Solution Approach 1:
The float valve body is designed as a universal, standardized component that can be used with multiple types of casing through the use of different adapters. Rather than maintaining inventory of specialized float valves for each casing type, the system uses one standardized valve body with multiple interchangeable adapters, each designed for specific casing configurations. This reduces inventory requirements while maintaining versatility across different casing types
Solution Approach 2:
The system segments the float valve assembly into a standardized valve body and separate custom adapters. This allows the expensive, complex float valve mechanism to be standardized and shared across applications, while only the simpler, cheaper adapters need to be customized for different casing types. This segmentation significantly reduces the overall inventory burden while maintaining compatibility with different casing configurations
3Loss of time
If standard float equipment is used without customization, then lead time and inventory costs are reduced, but the equipment cannot accommodate unique casing materials and threads
Solution Approach 1:
The custom adapters are designed and prepared in advance for specific casing configurations, while the float valve body remains standardized and ready for immediate use. When a installation requires unique casing compatibility, the pre-designed adapter can be quickly attached to the standard valve body, minimizing preparation time while ensuring compatibility. This preliminary preparation of adapters allows standard float valves to be rapidly adapted to unique casing requirements without incurring full custom manufacturing lead times
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 efficient installation of float valves in various casing materials and threads without the need for specialized inventory, reducing costs and lead times, and allows for easy removal post-use by milling out the assembly.
Implementation Method 1
The expanded sleeve has first and second ends and is composed of a first drillable material. The expanded sleeve is expanded from a smaller diameter to a larger diameter inside the tubular.
Data Source
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AI summary
Disclosed is a method of incorporating a float valve assembly with a tubular, the tubular to being deployed on tubing in a well having flow. The method comprises expanding a sleeve composed of a first drillable material from a smaller diameter to a larger diameter inside the tubular; positioning a valve in an interior of the sleeve expanded inside the tubular, the valve configured to control the flow in the tubing, the valve composed of a second drillable material; and supporting the valve in the interior of the sleeve by filling an annulus between the valve and the interior of the sleeve with a third drillable material and engaging the third drillable material on one or more shoulders disposed on the sleeve. Also disclosed is a float assembly for use on tubing.