Flow Control Screen Valve Assembly for Reverse Flow Management
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Solution Overview
Problem
Current flow control screens in subterranean wells require separate work strings or permanent check valves for pressure operation during completion, and lack the ability to selectively allow reverse flow, which complicates sand control and tool setting processes.
Innovation Solution
A flow control screen with a valve assembly featuring a piston body and valve plug that shifts from a first to a second operating position upon reaching a predetermined internal differential pressure, allowing reverse flow when an external differential pressure is applied, enabling pressure operation during completion and selective reverse flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flow control screen incorporates permanent check valves to prevent reverse flow, then reverse flow control is improved, but device complexity increases and sand control capability is compromised
Solution Approach 1:
The valve plug automatically responds to differential pressure changes without external control. When differential pressure across the screen exceeds a threshold, the valve plug shifts position to block reverse flow through the flow control section, eliminating the need for external check valves or work strings
Solution Approach 2:
The reverse flow control function is integrated directly into the flow control screen structure. The valve plug is positioned within the flow control section and works in conjunction with the screen's differential pressure mechanism, combining sand control and reverse flow prevention in a single device
2Adaptability or versatility
If separate work strings are used to pressure up the completion string for tool setting, then tool setting capability is improved, but device complexity and operational difficulty increase
Solution Approach 1:
The flow control screen serves multiple functions: sand control through the screen structure, flow rate control through the flow control section, reverse flow prevention through the valve plug, and tool setting capability by allowing pressure buildup during installation. This eliminates the need for separate work strings or specialized tools
3Manufacturing precision
If flow restrictors are individually adjusted to control production rate, then flow control precision is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The valve plug position changes in response to differential pressure parameters. When the differential pressure across the screen reaches a predetermined threshold, the valve plug shifts from its initial position to block reverse flow, providing automatic control without manual adjustment
Solution Approach 2:
The system automatically regulates flow based on differential pressure conditions. The valve plug responds to pressure differentials across the screen, eliminating the need for individual adjustment of flow restrictors while maintaining precise flow control
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 control of formation fluid inflow and reverse flow, simplifying the completion process by eliminating the need for separate work strings and permanent check valves, while maintaining pressure integrity during installation and operation.
Implementation Method 1
an internal differential pressure seats the valve plug on the internal seat and causes the piston body to shift from the first operating position to the second operating position
Implementation Method 2
an external differential pressure causes the valve plug to be expelled through the collet assembly, thereby no longer preventing reverse flow
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A flow control screen having a fluid flow path between a perforated section of a base pipe and a filter medium positioned around a blank pipe section of the base pipe. A valve assembly, including a piston body and a valve plug, is disposed within the fluid flow path. The piston body has an internal seat and a collet assembly that is radially outwardly constrained in a first operating position of the piston body to retain the valve plug therein and radially outwardly unconstrained in a second operating position of the piston body. Reverse flow is initially prevented as an internal differential pressure seats the valve plug on the internal seat and causes the piston body to shift to the second operating position upon reaching a predetermined threshold. Thereafter, an external differential pressure causes the valve plug to be expelled through the collet assembly, thereby no longer preventing reverse flow.