Rotating Spherical Sealing Element for ESP Blanking Tool
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Solution Overview
Problem
Existing differential pressure-operated blanking completion tools for ESPs in oil wells face issues with flapper deterioration, leading to loss of sealing capabilities and requiring costly interventions for tool removal when sealing fails, causing production delays.
Innovation Solution
An automatic blanking completion tool with a rotatable spherical sealing element that provides a fresh sealing surface each time it contacts an outlet, eliminating wear-related issues and ensuring continuous operation without the need for frequent interventions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a flapper valve is used in a differential pressure-operated blanking completion tool, then the tool can automatically seal the ESP or bypass tubing based on pressure differential, but the flapper deteriorates with use and loses sealing capabilities, requiring tool removal and causing production delays
Solution Approach 1:
The patent replaces the traditional flat flapper valve with a spherical sealing element that rotates on a pivot. The spherical geometry allows the sealing surface to continuously present a fresh, unworn area with each rotation, eliminating the progressive wear that plagues flat flapper valves. The sphere contacts the sealing seat at a point or small area, concentrating the sealing function while allowing the rest of the spherical surface to remain intact for future sealing cycles.
Solution Approach 2:
The invention introduces rotational movement to the sealing element, transforming it from a static or reciprocating component into a dynamically rotating one. This rotation is driven by the pressure differential itself, which causes the sphere to pivot from one sealing position to another. The dynamic rotation ensures that the sealing surface is constantly renewed, preventing the wear accumulation that leads to sealing failure in traditional designs.
2Productivity
If a blanking plug is used to prevent fluid recirculation, then the pump can operate, but the plug must be run-in on wireline or coiled tubing and pulled when the pump is switched on, which is time consuming and expensive
Solution Approach 1:
The patent designs a system where the blanking function is automatically performed by the pressure differential generated during normal pump operation. The sphere rotates automatically when pressure builds up in the sealed line, opening the seal without requiring external intervention. This self-actuating mechanism eliminates the need for wireline or coiled tubing operations to install or remove blanking plugs, saving significant time and cost while maintaining pump productivity.
Solution Approach 2:
The invention extracts the blanking function from a separate intervention operation and integrates it into the normal pump operation sequence. By using the pressure differential generated during pumping to automatically actuate the sealing element, the system removes the need for separate wireline or coiled tubing interventions, effectively taking out the time-consuming intervention step while preserving the essential blanking function.
3Ease of operation
If a flapper valve is used for automatic blanking, then no intervention is required during operation, but the entire completion tool must be removed from the well when the flapper deteriorates, causing significant delays and substantial costs
Solution Approach 1:
The spherical sealing element provides a continuously renewable sealing surface through rotation, dramatically extending the operational life of the blanking mechanism. Unlike a flat flapper that wears at the same contact point until failure, the sphere presents a fresh surface with each rotation, allowing the tool to remain in the well for much longer periods without requiring removal. This resolves the contradiction by maintaining ease of automatic operation while eliminating the time loss associated with frequent tool removals.
Solution Approach 2:
The patent employs a spherical surface that is excessive in terms of the sealing area available - only a small portion of the sphere contacts the sealing seat at any given time. This excess sealing surface area ensures that even after extensive operation, there is always an unworn portion of the sphere available for sealing, preventing the premature failure that would necessitate tool removal. The partial use of the spherical surface maximizes the component's service life.
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 tool effectively prevents fluid recirculation and maintains production by offering a self-centering, self-seating sealing mechanism that rotates freely, reducing wear and extending the tool's operational life, thus minimizing downtime and costs.
Implementation Method 1
a sealing element mounted on the support member and rotatable with respect to the support member, the element including a substantially spherical surface; and wherein the support member is pivoted between the outlets to bring the sealing element into contact with either outlet
Implementation Method 2
This tool operates on the differential pressure between the bypass tubing and the ESP. A hinged flapper is mounted in the Y-Block at the point where the two limbs meet. The flapper is biased towards an open position
Data Source
AI summary
A differential pressure-operated blanking completion tool for use at a Y-Block with an electrical submergible pump (ESP) in oil or other wells. The tool has a body having an inlet and first and second outlets, the outlets being arranged in parallel and opposite the inlet; a support member located between the outlets; a sealing element mounted on the support member and rotatable with respect to the support member, the element including a substantially spherical surface; and wherein the support member is pivoted between the outlets to bring a fresh sealing surface into contact with either outlet and thereby selectively seal the respective outlet and prevent fluid flow therethrough.