Pilot and Stopper Ball Valve for Wellbore Drilling
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Solution Overview
Problem
Conventional check valves in the oil and gas industry face reliability issues due to wear and corrosion from abrasive fluid flows, particularly in high vibration environments, leading to valve failure and potential well control problems.
Innovation Solution
A valve system featuring a ball with an internal pilot that allows one-way fluid flow without direct contact with the seat, utilizing a pusher rod and seal design that rotates to control fluid flow, preventing wear and corrosion, and an isolation rod or accumulator to manage pressure and maintain the open position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional check valves are used in abrasive fluid flows, then fluid flow control is achieved, but wear and corrosion occur leading to valve failure
Solution Approach 1:
The patent introduces a pilot valve as an intermediary component that mediates between the abrasive fluid flow and the main valve seat. The pilot valve is positioned to allow fluid flow to pass through it rather than directly impacting the main valve seat, thereby protecting the seat from wear and corrosion while still enabling flow control functionality
Solution Approach 2:
The valve system is segmented into multiple functional components: a main valve body, a pilot valve, and a valve seat. This segmentation allows the pilot valve to handle the abrasive fluid flow separately from the main valve seat, reducing direct exposure and wear on critical sealing surfaces
2Reliability
If check valves are placed in high vibration environments, then fluid flow control is maintained, but misalignment between sealing member and valve seat occurs
Solution Approach 1:
The patent employs a spherical ball valve design where the ball rotates within the valve body. The spherical geometry provides inherent alignment tolerance, allowing the ball to self-align with the valve seat even under high vibration conditions, maintaining sealing effectiveness without precise mechanical alignment
3Ease of operation
If pilots are exposed to direct fluid flow, then fluid flow control is achieved, but corrosion of seat and valve occurs
Solution Approach 1:
The pilot valve serves as a protective intermediary that is specifically designed to be in the path of abrasive fluid flow. By positioning the pilot valve to intercept the flow, the system protects the main valve seat and sealing surfaces from direct exposure to corrosive and abrasive fluids, extending component life while maintaining 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
The solution enhances the reliability of fluid control in wellbore operations by reducing wear and corrosion, ensuring consistent fluid flow and preventing well control issues, even in abrasive and high-pressure conditions.
Implementation Method 1
Rotation of the bore of the ball away from the internal diameter of the pusher rod prevents fluid flow through the ball, while rotation of the bore of the ball in alignment to the internal diameter of the pusher rod permits one-way fluid flow
Implementation Method 2
The seat prevents fluid flow between the ball and the tubular body
Implementation Method 3
an isolation rod or accumulator to manage pressure and maintain the open position
Data Source
AI summary
An apparatus, system, and method of use that enables control of fluid flow in a wellbore drill string with a pilot. The apparatus comprises a pusher rod with a bore for fluid flow contacting a rotatable ball with an internal bore comprising at least one pilot, wherein the seat between the pusher rod and the interior of the tubular prevents fluid flow. Pressure changes on the pusher rod rotate the bore of the ball in and out of contact with the bore of the pusher rod, to enable or prevent fluid flow, respectively. A method of use opens the ball by exerting pressure and/or force on the pusher rod to enable fluid through the ball by aligning the internal bores. Fluid flow is stopped by pressure exerted on the bottom of the ball causing the ball to rotate whereby the internal bore of the pusher rod is connected to the exterior surface of the ball. An accumulator can control the operations of the valve by selectively exerting pressure and/or fluid flow on the pusher rod.