Pressure-Actuated Flapper Valve Assembly for Self-Filling Production Tubing
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Solution Overview
Problem
The existing production tubing systems require significant time and equipment for installation and testing, and often necessitate well intervention operations, which are costly and inefficient.
Innovation Solution
A valve assembly with a flapper element biased to a closed position that opens when differential fluid pressure exceeds a predetermined threshold, allowing for self-filling and reducing the need for well intervention, integrated with a production tubing sub that includes a flapper aligning body, spring device, and securing mechanism to facilitate efficient installation and testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional production tubing systems are installed and tested using traditional methods, then the system can be properly installed and tested, but the installation time is excessive and requires significant equipment
Solution Approach 1:
The flapper valve is pre-configured in a biased closed position within the production tubing sub before installation. This preliminary configuration allows the system to be self-contained and ready for automatic operation, eliminating the need for time-consuming post-installation adjustments and well intervention operations.
Solution Approach 2:
The flapper valve assembly automatically opens when differential fluid pressure exceeds the predetermined threshold, enabling self-filling of the production tubing system without requiring external equipment or well intervention operations. The system serves itself by using the incoming fluid pressure to actuate the valve.
2Device complexity
If traditional valve mechanisms are used, then the system requires complex equipment and multiple well intervention operations, but simpler mechanisms would not provide reliable fluid control
Solution Approach 1:
The invention extracts the complex control system from the valve mechanism and replaces it with a simple flapper valve that responds automatically to differential fluid pressure. The complicated external control equipment, actuators, and well intervention tools are eliminated, while the flapper valve's automatic opening and closing provides reliable fluid control based on pressure differential.
Solution Approach 2:
The invention replaces complex mechanical control systems with a pressure-differential-based flapper valve mechanism. Instead of using motors, hydraulics, or external control equipment to operate the valve, the system uses the natural differential pressure between the annulus and production tubing to automatically actuate the flapper, simplifying the device while maintaining reliable fluid control.
3Ease of manufacture
If well intervention operations are performed to install and test the production tubing system, then proper installation and testing can be achieved, but the operations are costly and inefficient
Solution Approach 1:
The flapper valve assembly enables self-filling of the production tubing system by automatically opening when differential fluid pressure exceeds the predetermined threshold. This self-service capability eliminates the need for costly and inefficient well intervention operations, allowing the system to install and test itself using the incoming fluid pressure.
Solution Approach 2:
The invention changes the operational parameter from requiring external control and intervention to responding automatically to differential fluid pressure. By setting a predetermined pressure threshold, the system transforms the installation and testing process into an automatic operation that occurs when the pressure parameter exceeds the threshold, greatly improving operational efficiency.
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 reduces installation time, minimizes equipment requirements, and eliminates the need for well intervention operations by enabling self-filling and reliable testing of the production tubing system.
Implementation Method 1
the flapper element is configured to be brought from its closed position to its open position when a force created by the differential fluid pressure between the outside of the housing and the bore is above a predetermined threshold value
Implementation Method 2
a spring device biasing the flapper element in relation to the flapper aligning body
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a valve assembly (20) for connection to an opening (16) provided in a housing (12) of a well tool device (10). It comprises a fluid communication channel (23) providing fluid communication from an outside (o) of the housing (12) to a bore (13) provided on the inside of the housing (12). It comprises a flapper valve device (30) comprising a flapper element (32) configured to be in a closed position in which the fluid communication channel (23) is closed and an open position in which the fluid communication channel (23) is open. The flapper element (32) is biased to its closed position. It comprises a flapper element supporting device (40) for supporting the flapper element (32) when the flapper element (32) is in its open position. It comprises a securing device (50) for securing the flapper valve device (30) and the flapper element supporting device (40) to the opening (16). The securing device (50) comprises a through bore (23a) forming a first part of the fluid communication channel (23). The present invention also relates to a production tubing sub (10) for a production tubing system (1). The present invention also relates to a production tubing system (1) for an oil and/or gas well (w). The present invention also relates to a method for installing a production tubing system (1) in a well (w).