Flow-Activated Shut-Off Valve with Compressible Cushioning
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Solution Overview
Problem
Existing flow-activated shut-off valves in oil field tools experience instantaneous closure, leading to high pressure surges or 'water hammer' effects, which can damage components or cause conduit bursting, as they rely on high flow rates to close the valve, making reliable sealing during high circulation flow rates unreliable.
Innovation Solution
A flow-activated valve design featuring an outer body with a piston, flow restriction member, shear member, bias member, and position control member, allowing fluid flow at varying rates to control piston movement and seal the valve without sudden pressure surges, utilizing a combination of flow restriction and bias forces to gradually close the valve at near-zero flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a flow activated shut off valve is used to close the fluid passage, then the valve can be actuated by flow rate changes, but the instantaneous closure causes high pressure surge or water hammer effect that may damage tool components or conduit
Solution Approach 1:
The patent applies beforehand cushioning by introducing a compressible bubble or gas pocket between the piston and the closed position. As the piston moves toward closure, this compressible element absorbs the impact energy, preventing instantaneous closure and the resulting water hammer effect. The compressible bubble acts as a cushion that gradually decelerates the piston, eliminating the harmful pressure surge while maintaining automated flow-actuated operation.
2Productivity
If high flow rate is used to close the valve, then the valve closure is achieved, but the closure is almost instantaneous causing water hammer effect
Solution Approach 1:
The compressible bubble positioned in the piston cavity provides beforehand cushioning that transforms the rapid closure motion into a controlled, gradual deceleration. The bubble compresses as the piston approaches closure, extending the closure time and reducing the impact force, thereby eliminating water hammer effect while still achieving reliable valve closure.
Solution Approach 2:
The patent changes the physical state parameter of the fluid in the piston cavity by introducing a compressible gas phase (bubble) amidst the liquid drilling fluid. This phase change creates a compressible cushion that modifies the closure dynamics, transforming instantaneous closure into a controlled, gradual process that prevents pressure surges.
3Reliability
If a dart or ball sealing member is used, then the fluid passage can be sealed, but the passage diameter of the conduit is significantly larger than the tool passage diameter making sealing unreliable or impossible
Solution Approach 1:
Instead of trying to make the sealing member larger to match the conduit diameter, the patent inverts the approach by using a piston that seals against the smaller tool passage. The piston is sized to match the tool passage diameter, and closure is achieved by blocking the tool passage internally, eliminating the need for the sealing member to span the larger conduit diameter.
Solution Approach 2:
The patent segments the sealing function into two parts: the piston seals the tool passage internally, while the external conduit connection is handled separately by the tool housing. This segmentation allows the sealing member to be sized appropriately for the tool passage rather than requiring it to bridge the entire conduit-to-tool diameter gap.
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 reliable high circulation flow rates during tool deployment while preventing pressure surges by gradually closing the valve, ensuring safe operation and preventing conduit damage.
Implementation Method 1
a flow restriction member disposed in a piston inner cavity
Implementation Method 2
the flow rate is increased to a higher level so that backpressure develops and urges the valve into a closed position
Implementation Method 3
a bias member disposed in an inner cavity of the outer body
Implementation Method 4
a shear member disposed in the outer body
Data Source
AI summary
A flow activated valve includes an outer body and a piston disposed in an inner cavity of the outer body. The flow activated valve also includes one or more fluid passage exits in the outer body and one or more piston fluid passages in the piston. The one or more fluid passage exits and the one or more piston fluid passages allow fluid flow out of the valve. The flow activated valve also includes a flow restriction member disposed in a piston inner cavity. In addition, the flow activated valve includes a shear member disposed in the outer body, and a bias member disposed in an inner cavity of the outer body. The flow activated valve further includes a position control member disposed in the piston and a sealing member.