Pressure-Actuated Recirculation Valve Mandrel Shift
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Solution Overview
Problem
Existing hydrocarbon well testing technologies lack an effective mechanism for automatically closing off flow and enabling reverse circulation in response to annulus pressure, which is crucial for efficient drilling and testing operations.
Innovation Solution
A closure and circulation valve with a tubular housing and a reverse circulation port, featuring a variable volume actuation chamber that shifts the valve mandrel in response to increasing annulus pressure, utilizing a rupture disc to open the actuation chamber and shear pins to facilitate upward movement of the mandrel, thereby actuating the closure and recirculation valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closure valve is used to close off flow in response to annulus pressure, then flow control is improved, but the complexity of the valve mechanism increases
Solution Approach 1:
The valve mechanism is designed to automatically respond to annulus pressure changes without external control. The mandrel assembly self-actuates through pressure differential forces, rupture disc failure, and shear pin breaking to close the closure valve and open recirculation ports when needed, eliminating the need for external actuation systems
Solution Approach 2:
The valve mechanism is divided into functionally independent components: the mandrel assembly for flow control, the rupture disc for pressure sensing, the shear pins for mechanical linkage, and the recirculation ports for alternative flow paths. This segmentation allows each component to perform its specific function while simplifying the overall system design
2Speed
If the valve mandrel shifts upward abruptly at high pressure, then rapid valve operation is achieved, but damage to the valve structure occurs
Solution Approach 1:
A cushioning element is positioned between the mandrel assembly and the valve structure to absorb and distribute the abrupt upward force generated during high-pressure operation. This pre-positioned cushioning prevents direct impact damage to the valve structure while allowing the mandrel to shift rapidly when needed
Solution Approach 2:
The cushioning element changes the mechanical parameters of the system by providing a compliant interface that transforms the abrupt high-force impulse into a more gradual force distribution over time and space, reducing peak stresses on the valve structure during rapid mandrel movement
3Reliability
If redundant seals are provided in the actuation chamber, then sealing reliability is improved, but the device complexity increases
Solution Approach 1:
The redundant seals are designed to automatically engage and disengage based on pressure differential conditions. The seals self-adjust their positioning and sealing action in response to annulus pressure changes, eliminating the need for external actuation or complex control mechanisms
Solution Approach 2:
The seal system is designed with redundant seals that can be temporarily displaced or compromised during high-pressure operation but are capable of self-repairing or being replaced by the redundant seal, ensuring continuous sealing function without requiring complex monitoring or replacement mechanisms
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 enables reliable automatic closure of the valve and opening of recirculation ports in response to pressure changes, allowing for efficient fluid circulation and testing while preventing damage from high pressure shifts, thus enhancing the operational safety and efficiency of hydrocarbon well testing.
Implementation Method 1
The rupture disc is designed to rupture and open the port to flow in response to pressure in the annulus
Implementation Method 2
The actuation chamber is formed between the valve mandrel and interior of the tool and, when sufficient pressure is applied to the annulus, causes the valve mandrel to shift closing the closure valve and opening the recirculation valve
Implementation Method 3
Shear pins prevent the valve mandrel from shifting upward. The pins shear when the desired pressure is present in the annulus, thus allowing the valve mandrel to shift upward and operate the valves
Data Source
AI summary
According to one embodiment, a recirculation safety valve is disclosed. The valve has a tubular body with mandrel that is axially shifted in response to annulus pressure. Shifting of the mandrel can either close a safety valve or close a safety valve and open a recirculation port. The valve has an annular actuation chamber that relieves that pressure to prevent inadvertent shifting of the mandrel.