Flapper Valve Assembly for Cable-Deployed ESP Well Safety
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Solution Overview
Problem
Existing safety systems for oil or gas wells with cable deployed electronic submersible pumps fail to effectively prevent upward flow of fluid when it is undesirable, particularly in situations where the electric cable is present in the tubing.
Innovation Solution
A safety system incorporating a barrier valve and an integral safety valve assembly with two flapper valve assemblies, one normally open and the other capable of sealing around a cable, to prevent fluid flow both during normal operations and in emergency situations, ensuring failsafe well control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional safety valve is used, then it can prevent upward fluid flow when open, but it cannot effectively seal when a cable is present in the tubing
Solution Approach 1:
The safety valve is divided into two distinct flapper valve assemblies: a first flapper valve assembly that remains open during cable deployment, and a second flapper valve assembly that seals when the cable is in place. This segmentation allows each assembly to perform its specific function without interference from the cable.
Solution Approach 2:
The system is configured so that the first flapper valve assembly opens in advance of cable deployment, allowing the cable to be inserted through the tubing. The second flapper valve assembly is positioned to automatically seal around the cable once deployment is complete, ensuring safety without requiring manual intervention.
2Reliability
If the safety valve is designed to seal tightly, then it prevents fluid flow effectively, but it blocks the passage of the electric cable through the tubing
Solution Approach 1:
The valve system is segmented into two functional zones: an upper portion with the first flapper valve assembly that remains open to accommodate cable passage, and a lower portion with the second flapper valve assembly that seals around the cable to prevent fluid flow. This spatial segmentation resolves the conflict between sealing effectiveness and cable accessibility.
Solution Approach 2:
The second flapper valve assembly acts as an intermediary mechanism that adapts to the presence of the cable. It seals around the cable in a manner that is compatible with cable deployment while still effectively preventing fluid flow, thus mediating between the conflicting requirements of tight sealing and cable passage.
3Reliability
If a single safety valve is used, then the system is simpler, but it cannot provide failsafe well control during both cable deployment and production
Solution Approach 1:
Two flapper valve assemblies are merged into a single integrated safety valve unit that functions as one cohesive component. This integration provides failsafe well control during both cable deployment and production phases without requiring separate valve systems, thereby achieving high reliability while controlling complexity through unified design.
Solution Approach 2:
The integrated safety valve assembly performs multiple functions: it allows cable deployment during installation, seals around the cable during production, and provides failsafe well control in both phases. This multi-functionality achieves comprehensive safety without proportionally increasing device complexity, as both valve assemblies are combined into a single universal unit.
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 system effectively prevents upward fluid flow, maintaining well integrity by automatically shutting the flapper valve assemblies in case of compromised fluid pressure and ensuring primary barrier functionality during both normal and emergency conditions.
Implementation Method 1
automatically shutting the flapper valve assemblies in case of compromised fluid pressure
Data Source
AI summary
A safety system for a well having a cable deployed electronic submersible pump includes a barrier valve having a control line for opening and closing the valve, a first flapper safety valve assembly, and a second flapper safety valve assembly. The second flapper safety valve allows the cable for the pump to pass through the second flapper safety valve when the valve is in a closed position. An integral flapper safety valve assembly incorporates the first and second flapper safety valves.