Pump-Down Float Valve with Rupture Disc for Well Control
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Solution Overview
Problem
Existing wellbore drilling and workover systems face challenges in preventing unwanted fluid flow up the drill string due to pressure changes or well control events, which current float valves do not adequately address, especially in ensuring reliable fluid flow control and efficient deployment of downhole tools.
Innovation Solution
A non-return float valve system featuring a valve assembly with a flapper and rupture disc that can be pumped down the tubular string to lock into a landing sub, allowing fluid flow in the downhole direction while preventing uphole flow, and includes a retrieval tool for safe removal, utilizing a combination of springs and locking profiles for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a float valve is installed to prevent unwanted fluid flow up the drill string, then well control and fluid flow safety are improved, but the complexity of the downhole equipment increases
Solution Approach 1:
The float valve is divided into separate functional components: a body portion with setting dogs, a flapper valve mechanism, and a rupture disc. This segmentation allows each component to perform its specific function independently while simplifying the overall assembly and installation process.
Solution Approach 2:
The rupture disc acts as an intermediary element between the setting dogs and the flapper valve. It provides a controlled failure mechanism that allows the setting dogs to engage the landing sub locking profile while simultaneously opening the flapper valve, thereby coordinating two critical actions through a single intermediate component.
2Productivity
If a pump-down mechanism is used to deploy the valve assembly down the tubular string, then deployment efficiency and installation speed are improved, but the pressure requirements and energy consumption increase
Solution Approach 1:
The setting dogs are pre-configured in a retracted position before deployment. During the pump-down process, the rupture disc is designed to fail at a predetermined pressure point, which automatically triggers the setting dogs to engage the landing sub locking profile. This preliminary configuration eliminates the need for additional activation mechanisms and reduces pumping energy requirements.
Solution Approach 2:
The system utilizes pressure as a control parameter for deployment. By designing the rupture disc to fail at a specific pressure threshold, the system converts continuous pressure application into a discrete engagement event, allowing efficient deployment without requiring excessive pumping energy.
3Reliability
If the flapper valve is designed to seal against the flapper seat for preventing uphole flow, then fluid flow control effectiveness is improved, but the risk of leakage and valve failure increases
Solution Approach 1:
The float valve incorporates a secondary containment mechanism through the rupture disc and setting dog system. If the flapper valve seal fails or leaks, the setting dogs engage the landing sub locking profile to physically isolate the valve assembly, and the rupture disc provides an additional barrier. This beforehand cushioning protects against the harmful effects of flapper seal failure.
4Reliability
If the valve assembly is designed to lock into the landing sub with setting dogs and locking profile, then positioning accuracy and valve stability are improved, but the difficulty of retrieval and maintenance increases
Solution Approach 1:
The setting dogs are designed with a dynamic engagement mechanism that allows them to flexibly engage and disengage from the landing sub locking profile. During installation, the rupture disc failure drives the setting dogs into the locked position. During retrieval, applying upward force causes the setting dogs to disengage, allowing the valve assembly to be pulled free. This dynamic design balances stable positioning with ease of retrieval.
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 controls fluid flow, allowing high-pressure downhole operation while preventing uphole flow, enabling efficient drilling and ensuring well control, with the ability to quickly latch into place and maintain position using a rupture disc mechanism, and allows for tool passage through the central bore.
Implementation Method 1
a rupture disc positioned in the valve central bore and configured to rupture in response to an application of a predetermined fluid pressure
Implementation Method 2
The flapper is biased to the closed positon by a spring
Data Source
AI summary
A well system includes a tubular string comprising a plurality of tubular segments and positioned in a wellbore drilled into a subterranean zone, and a landing sub connected to a bottom end of one of the plurality of tubular segments. The landing sub includes a landing sub central bore and a landing sub locking profile on an inner surface of the landing sub central bore. The well system also includes a valve assembly configured to be pumped down the tubular string by fluid flowing in a downhole direction through the tubular string and to land within the landing sub central bore. The valve assembly includes a main body with a valve central bore and a flapper configured to pivot between an open position and a closed position. In the closed positon the flapper seals against a flapper seat and blocks fluid from flowing in an uphole direction through the valve central bore. The valve assembly also includes a rupture disc positioned in the valve central bore and configured to rupture in response to an application of a predetermined fluid pressure and configured to block fluid from flowing through the valve central bore when in an unruptured state. The valve assembly also includes one or more valve body setting dogs positioned on an outer surface of the main body and configured to lock into the landing sub locking profile and thereby limit axial movement of the main body within the landing sub.