Hydraulically Overrideable Check Valve for Well Testing
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Solution Overview
Problem
Current check valves in well testing require manual mechanical override, posing risks to operational personnel and increasing operational time due to the need for manual disengagement in the 'red zone, and suffer from leakage issues at zero or low pressure.
Innovation Solution
A hydraulically overrideable check valve design that uses a piston and flapper mechanism, where hydraulic pressure controls the flapper's position, eliminating the need for manual intervention and ensuring sealing without relying on well-side pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual mechanical override function is used, then the check valve can be engaged and disengaged, but personnel must enter the red zone which increases safety risks and operational time
Solution Approach 1:
The patent replaces the manual mechanical override system with a hydraulic override system. A hydraulic piston is connected to the flapper valve mechanism, and hydraulic pressure applied through a control line actuates the piston to open or close the valve. This substitution eliminates the need for personnel to manually operate the override mechanism in the red zone, thereby removing the associated safety risks while maintaining full operational capability.
Solution Approach 2:
The patent employs a hydraulic actuation system where hydraulic fluid under pressure is transmitted through a control line to a piston. The piston converts this hydraulic pressure into mechanical motion to move the flapper valve between open and closed positions. This hydraulic mechanism allows remote operation of the override function without personnel exposure to hazardous areas, resolving the contradiction between operational ease and personnel safety.
2Ease of operation
If manual mechanical override function is used, then the check valve can be engaged and disengaged, but it requires approximately 30 minutes of operational time each time
Solution Approach 1:
The hydraulic override system replaces the time-consuming manual mechanical operation. Instead of personnel needing to physically access the valve, use tools, and manually manipulate components (which took 30 minutes), the hydraulic system allows remote actuation through a control line. The hydraulic piston responds rapidly to pressure changes, enabling quick opening and closing of the valve without manual intervention, thus dramatically reducing operational time loss.
3Device complexity
If traditional check valve design is used, then the valve structure is simple, but leakage occurs at zero or low pressure on the well side
Solution Approach 1:
The patent introduces a hydraulic piston as an intermediary mechanism between the control system and the flapper valve. The piston is connected to the flapper through a link mechanism, and it uses hydraulic pressure to actively position the flapper against the valve seat. This intermediary ensures reliable sealing even at zero or low well-side pressures, as the hydraulic force actively maintains the seal rather than relying solely on pressure differential or simple spring force.
Solution Approach 2:
The hydraulic system provides self-service sealing by using the applied hydraulic pressure to automatically position the flapper valve in the closed position and maintain the seal. The system monitors and adjusts the valve position through the hydraulic piston, ensuring continuous reliable sealing without requiring complex additional sealing mechanisms or frequent manual intervention, thus improving reliability while maintaining reasonable structural complexity.
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
Reduces operational time from 30 minutes to 3-4 minutes, minimizes leakage, and allows for safer operations by eliminating the need for personnel to enter the 'red zone, thereby reducing risks and enabling simultaneous performance of other tasks.
Implementation Method 1
an expandable chamber (11) which, when provided with hydraulic pressure, expands and thereby moves a piston (4)
Implementation Method 2
a pre-stressed spring (15) arranged behind the piston (4) and in contact with the piston (4)
Data Source
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AI summary
The present invention provides a check valve comprising a valve housing (1,2), a substantially circular flapper (3), a valve seat (16) for the flapper (3), an expandable chamber (11) in fluid contact with a connecting port (8) for hydraulics fluid, and a piston (4) having a first and a second end, the flapper comprises a first (19) and a second (18) connection point and is pivotably connected at the first connection point (19), said flapper is capable of pivoting between a closed position in close contact with the valve seat (16) and an open position which allows fluid to flow through the valve, the piston (4) is in contact with the expandable chamber (11) and a pre-stressed compressible device (15), said piston (4) pivotably connected at the first end to the flapper (3) via the second connection point (18), wherein the compressible device (15) can move the piston (4) in a direction towards the valve seat ( 16), and that hydraulics fluid can move the piston (4) in a direction away from the valve seat when sufficient hydraulics fluid is supplied through the connection port (8) to expand the chamber (11), and that the second connection point (18) is situated closer to the center of the circular part of the flapper than the first connection point (19), such that the flapper (3) comes into close contact with the valve seat (16) when the piston (4) is moved in a direction towards said valve seat and the flapper will pivot around the first connection point (19) in a direction towards the piston (4) when the piston is moved in a direction away from the valve seat (16).