Rotating Valve Member Downhole Seal Integrity
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Solution Overview
Problem
Existing downhole tools face challenges in accurately locating and isolating plugs in wellbores under fluid pressure, with conventional seals compromising integrity when exposed to wellbore fluids, and requiring complex pressure equalization during plug retrieval.
Innovation Solution
A downhole apparatus with a rotating valve member and metal-to-metal seal arrangement, connected to a gearbox and motor assembly, allowing for open configuration running without compromising seal integrity, and controlled actuation using sensors and pressure measurements for pressure equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional seals are exposed to wellbore fluids in an open configuration, then fluid flow is allowed through the ports, but seal integrity is compromised
Solution Approach 1:
The sealing element is extracted from the flow path during normal operation. The valve member rotates to position the sealing element away from the ports, allowing fluid flow without exposing the seal to wellbore fluids. The seal is only exposed to fluids when actively engaged in the closed position against the valve seat.
Solution Approach 2:
The system transitions from a static seal arrangement to a dynamic one where the valve member rotates between open and closed positions. This dynamic positioning allows the sealing element to be removed from the fluid exposure zone during running operations while maintaining sealing capability when closed.
2Reliability
If plugs are run against fluid pressure in the wellbore, then isolation is achieved, but locating and positioning the plug becomes difficult
Solution Approach 1:
The system incorporates sensors that detect pressure differentials and provide feedback about the plug's position and sealing status. This allows real-time monitoring of plug location and confirmation that the isolation barrier is effectively positioned and sealed.
3Ease of operation
If pressure equalization is required during plug retrieval, then safe removal is enabled, but time delays are extended
Solution Approach 1:
The pressure equalization process uses periodic opening and closing of the valve member to gradually balance pressures on both sides of the plug. This controlled cyclic action allows pressure equalization to occur more efficiently than passive waiting, reducing the overall time required for safe retrieval.
4Reliability
If conventional plugs are run in closed position, then seal integrity is maintained, but fluid flow is blocked during running operations
Solution Approach 1:
The valve member enables dynamic switching between open and closed states. During running operations, the valve remains open to allow fluid flow and facilitate plug positioning. When isolation is required, the valve closes to maintain seal integrity and block fluid flow.
Solution Approach 2:
The system is designed to be run in the open configuration preliminarily, allowing easy positioning and deployment. The sealing function is activated only when needed, rather than being permanently closed during the entire running operation.
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
Enables safe and efficient running and retrieval of plugs with high-integrity sealing, reducing seal damage and eliminating the need for lengthy time delays, while allowing for repeated opening and closing without compromising performance.
Implementation Method 1
a motor assembly to rotate the valve member between the open and closed positions
Implementation Method 2
a gearbox and motor assembly
Data Source
AI summary
A downhole apparatus (10) adapted to be run on a workstring in a well bore. The apparatus has a body (12) including ports (42) and a valve (26) which is rotatable to open and close the ports to selectively allow fluid flow through the body between regions of a well bore above and below the apparatus. The valve is rotated via a gearbox (28) and motor (30) in the apparatus. A sealing arrangement between the valve and body is also described. A method of running the apparatus in a well bore and monitoring pressure above the apparatus in order to control opening and closing of the valve under predetermined conditions is presented.