Large Bore Auto-Fill Float Assembly with Composite Flapper Valves
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Solution Overview
Problem
Conventional float assemblies have limited pressure ratings, small internal flow bores, and inadequate debris tolerance, leading to issues during cementing operations in oil and gas wells, where they can become lodged with rock or debris, and struggle with pressure loading and actuation.
Innovation Solution
A large-bore float assembly with composite, curved flapper valves and a torsion spring mechanism, actuated by a floatable ball, allowing for high-pressure operation and adjustable activation pressure and flow rate, featuring components made from high-temperature resins and carbon- or glass-reinforced materials for enhanced strength and debris tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional float assemblies use metallic components and small internal bores, then pressure rating is maintained, but debris tolerance is poor and flow rates are limited
Solution Approach 1:
The patent applies composite materials by replacing traditional metallic components with composite materials made from high-temperature resins and carbon- or glass-reinforced materials. This allows the float assembly to achieve both high debris tolerance and high flow rates while maintaining structural integrity under pressure, directly resolving the contradiction between reliability and productivity.
2Reliability
If conventional float assemblies use small internal flow bores, then device size is reduced, but debris tolerance and flow rates are limited
Solution Approach 1:
The use of composite materials enables the construction of larger internal bores without sacrificing structural strength or pressure rating. The high strength-to-weight ratio and debris resistance of composite materials allow the float assembly to accommodate larger internal bores that can tolerate debris and maintain high flow rates, resolving the contradiction between reliability and volume.
3Adaptability or versatility
If conventional float assemblies use fixed activation mechanisms, then device complexity is reduced, but adaptability to different pressure and flow rate conditions is limited
Solution Approach 1:
The patent implements dynamics by providing adjustable activation pressure and flow rate settings, allowing the float assembly to adapt to different wellbore conditions and cementing operations. This adjustability enhances versatility while the modular design keeps the added complexity manageable, resolving the contradiction between adaptability and device complexity.
4Strength
If conventional float assemblies use metallic components, then strength is maintained, but drillability is poor
Solution Approach 1:
The patent replaces metallic components with composite materials that maintain high strength and pressure rating while significantly improving drillability. Composite materials can be more easily drilled and removed during wellbore operations, resolving the contradiction between strength and ease of manufacture.
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 float assembly achieves higher auto-filling flow rates, maximum debris tolerance, and improved pressure ratings, reducing the risk of fluid surge pressure and allowing larger solids to pass through, enhancing operational safety and efficiency during cementing operations.
Implementation Method 1
Each of said flappers of the present invention have a substantially 90° range of motion, and are closed via a torsion spring.
Implementation Method 2
said float assembly comprises a floatable ball actuated ball seat member
Data Source
Figure 1
Figure 2~10
Figure 3
AI summary
An auto-fill type float collar assembly (100) has at least one curved composite flapper-style valve assembly (40). Each valve assembly includes a flapper (140) that has a substantially 90 range of motion, and is closed via a torsion spring (44). Each flapper is held in the open (or "auto-fill"), position via an external shifting mechanism (150) passing around, rather than through, each valve body. A floatable actuation ball (110) can be run with the tool, or pumped downhole, in order to selectively actuate the assembly and close the flappers.