Submersible Pump Safety Valve Using Differential Pressure Shutoff
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Solution Overview
Problem
Existing safety valves in the oil industry are complex, unreliable, and cannot be used independently or in slim wells due to design flaws and the need for a hydraulic line from a main valve, limiting their functionality and reliability.
Innovation Solution
A simplified safety valve design for an electrical submersible pumping system with a composite housing, a movable tubular element, and a spring-loaded plunger mechanism that aligns openings to control fluid flow based on differential pressure, allowing for automatic shut-off and uninterrupted supply in slim wells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex design with multiple ball valves and springs is used, then the valve can shut off the wellbore during workover procedures, but the design complexity increases and reliability decreases
Solution Approach 1:
The patent removes unnecessary components (ball valves and springs) from the valve design, retaining only the essential elements needed for shut-off functionality. This extraction of non-essential parts simplifies the design while maintaining reliability.
Solution Approach 2:
The valve design enables automatic operation through differential pressure control, eliminating the need for complex external control mechanisms. The valve serves itself by using the pressure differential to automatically open or close, reducing mechanical complexity.
2Adaptability or versatility
If a traditional safety valve design is used, then the valve can control fluid flow, but it cannot be used independently without a hydraulic line from a main valve
Solution Approach 1:
The valve uses the natural differential pressure between the wellbore and pump inlet to control its own operation, eliminating dependence on external hydraulic lines. The valve autonomously responds to pressure changes without requiring additional control infrastructure.
Solution Approach 2:
The valve can function independently in various well configurations without requiring connection to a main valve's hydraulic system. This universal design allows the valve to be deployed in multiple scenarios including slim wells and standalone applications.
3Adaptability or versatility
If a conventional valve design is used, then the valve can shut off fluid flow, but it cannot be used in slim wells due to size constraints
Solution Approach 1:
The valve is divided into modular components including a compact body, separate control mechanism, and segmented internal parts. This segmentation allows for a more space-efficient design that can fit within the constrained dimensions of slim wellbores.
Solution Approach 2:
The valve design optimizes its dimensional profile by redistributing components along different axes, creating a more compact form factor. The control mechanism and flow paths are arranged to minimize the valve's overall footprint while maintaining functionality.
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 operational reliability by ensuring continuous well fluid supply when the electric motor is running and automatic shut-off when it's not, while being adaptable for use in wells of various diameters, including slim wells.
Implementation Method 1
The valve is controlled by differential pressure on both sides
Implementation Method 2
a spring-loaded tubular plunger having a ring piston on an upper outer surface of the tubular plunger
Data Source
AI summary
Various implementations include a safety valve for mounting in a landing nipple in a wellbore. The safety valve includes a composite housing having a central passage, a shutoff element and a control mechanism. The shutoff element includes a collet and a movable mandrel having stops located in the upper part. When the shutoff element moves axially, the stops extend through the composite housing to interact with a landing nipple stop surface. The control mechanism includes a spring-loaded tubular plunger having a ring piston on its upper outer surface and longitudinal openings in its lower part, the openings being configured to align with openings in the composite housing. The movable mandrel is connected to the safety valve head at the mandrel top and rests against the plunger at the mandrel bottom. The movable mandrel has grooves and shoulders on its outer surface, which allow for taking one of the fixed positions.