Lubricator Valve Pump-Through Fail-Safe Mechanism
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Solution Overview
Problem
Existing lubricator valves lack the ability to automatically open or restore access to a wellbore when the hydraulic control system fails, leading to potential operational disruptions during wellbore interventions.
Innovation Solution
A lubricator valve assembly with a pump-through functionality, featuring a tubular valve body, a rotatable ball element, and a dual-piston system that allows for opening the valve even when the hydraulic system fails, utilizing a pump-through piston and an optional balance piston to facilitate fluid communication across the valve at varying pressure differentials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lubricator valve is controlled by a hydraulic system, then the valve can be remotely operated to open or close, but the valve cannot be opened if the hydraulic system fails
Solution Approach 1:
The pump-through piston and balance piston are pre-positioned within the valve body, with the balance piston initially blocking the pump-through passage. When hydraulic failure occurs, fluid pressure automatically acts on the pump-through piston to rotate the ball element and open the valve, enabling recovery without requiring preliminary manual intervention or complex emergency procedures
Solution Approach 2:
The pump-through piston serves as an intermediary mechanism between the hydraulic control system and the ball element. It translates fluid pressure into mechanical rotation of the ball element, providing a backup pathway for valve operation that bypasses the failed hydraulic operator while maintaining controlled, reliable valve opening capability
2Reliability
If a pump-through mechanism is added to the lubricator valve, then the valve can be opened upon hydraulic system failure, but the device complexity increases
Solution Approach 1:
The pump-through piston, balance piston, and ball element rotation mechanism are merged into a single integrated assembly within the valve body. The balance piston doubles as both a sealing element and a blocker of the pump-through passage under normal conditions, eliminating the need for separate components and reducing overall structural complexity despite the added fail-safe functionality
Solution Approach 2:
The balance piston performs multiple functions: it seals the pump-through passage during normal operation, provides a mechanical link to the ball element for rotation, and acts as a pressure-sensitive trigger for emergency valve opening. This multi-functionality reduces the number of dedicated components needed, thereby limiting the increase in device 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
Enables reliable restoration of access to the wellbore by ensuring the valve can be opened or closed regardless of hydraulic system failures, maintaining operational integrity during interventions across a range of pressure differentials, from 300 to 12,500 psi.
Implementation Method 1
a pump-through piston having a first end connected to the operator and a second end in fluid communication with the bore above the ball element and a counter piston having an end connected to the operator and a second end in fluid communication with the bore below the ball element
Data Source
AI summary
A lubricator valve assembly adapted for connection in a pipe string for use in a well includes a tubular valve body having a bore formed longitudinally therethrough; a valve seat connected to the valve body and in communication with the bore; a valve element mounted in the bore and rotatable with respect to the valve seat between positions opening and closing the bore; an operator in connection between the valve element and a hydraulic control system, the operator moving the valve element between the open and close bore positions in response to the hydraulic control system; and a system for opening the valve element upon failure of the hydraulic system.