Downhole Flow System With Pressure Module Valve
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current downhole injection systems face challenges in handling variable flow rates while maintaining effective reverse flow protection and long-term operation in arduous conditions, as existing check valves are prone to erosion, wear, and oscillation issues, especially at higher flow rates.
Innovation Solution
A flow system that utilizes a pressure module to create a differential pressure, actuating a valve actuator to open and close a non-return valve, ensuring reliable operation across a wide range of flow rates and minimizing oscillations, with the valve actuator biased to maintain a fully open position to reduce pressure losses and protect valve components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ball or poppet check valves are used for lower flow regimes, then reverse flow protection is effective, but erosion and wear of sealing components occur at higher flow rates
Solution Approach 1:
The invention extracts the valve body from the direct flow path by positioning it upstream of the pressure module. The flow path is routed through the pressure module and downstream, bypassing the valve body. This extraction eliminates the harmful interaction between high-velocity fluid and the valve sealing components, preventing erosion and wear while maintaining effective reverse flow protection.
2Reliability
If valve body is biased towards closed position, then reverse flow protection is ensured, but pressure losses increase and valve oscillation occurs
Solution Approach 1:
The invention inverts the conventional valve operation by biasing the valve body towards the open position rather than the closed position. The valve remains fully open during normal forward flow, eliminating pressure losses and oscillation. Reverse flow protection is achieved not by closing the valve, but by the pressure module establishing differential pressure that prevents reverse flow while the valve remains open.
3Productivity
If valve is opened by inlet pressure, then forward flow is permitted, but valve oscillation occurs at variable flow rates
Solution Approach 1:
The invention introduces a pressure module as an intermediary between the inlet and the valve actuator. The pressure module converts variable inlet pressure into a stable differential pressure that consistently actuates the valve actuator to maintain the valve in a fully open position. This intermediary stabilizes valve operation across variable flow rates, eliminating oscillation while maintaining forward flow capability.
4Productivity
If check valve components are exposed to high flow rates, then flow capacity is maintained, but wear and erosion compromise sealing capability
Solution Approach 1:
The invention extracts the valve body and its sealing components from the high-velocity flow path. The flow path is routed through the pressure module and downstream, completely bypassing the valve assembly. This extraction allows the valve to maintain sealing capability by preventing direct exposure to erosive flow, while the system maintains full flow capacity through the alternative path.
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 manages flow rates from ultra-small to high rates, ensuring reliable operation and minimizing wear and pressure losses, thus providing a long-lasting and efficient solution for downhole injection applications.
Implementation Method 1
a pressure module provided within the system flow path to establish a differential pressure between upstream and downstream sides thereof during flow from the system inlet to the system outlet
Implementation Method 2
a valve actuator in pressure communication with the system flow path on upstream and downstream sides of the pressure module to be driven by a differential pressure established by the pressure module
Data Source
AI summary
A flow system comprises a system flow path extending from a system inlet to a system outlet. A pressure module is provided within the system flow path to establish a differential pressure between upstream and downstream sides thereof during flow from the system inlet to the system outlet The system also comprises a valve provided within the system flow path, and a valve actuator in pressure communication with the system flow path on upstream and downstream sides of the pressure module. The valve actuator is driven by a differential pressure established by the pressure module to move between a first position in which the valve is closed, and a second position in which the valve is opened.