Safety Valve Actuator with Visual Override Indicator
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Solution Overview
Problem
Current valve actuators lack a visual indication of the actuation mechanism and safe mode status, leading to potential misinterpretation of valve positions and interference with fail-safe mechanisms, causing operational issues and potential leakage.
Innovation Solution
A valve system incorporating a mechanical override and a safe mode indicator that provides visual signals to indicate whether the valve is operating in safe mode, which actuation mechanism is used, and if the mechanical override is interfering with the fail-safe mechanism, through a piston-based indicator system within the actuator housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mechanical override is added to provide additional opening/closing power, then the valve can be opened during wellbore completion operations, but the system loses visual indication of which actuation mechanism is being used
Solution Approach 1:
A drive sleeve is introduced as an intermediary component between the mechanical override and the valve stem. This drive sleeve includes a tapered shoulder that can contact a ball member to indicate mechanical override activation, while also transmitting force to move the valve. The intermediary component enables both mechanical override functionality and visual indication without requiring separate independent systems.
Solution Approach 2:
The indication system uses visual signals (analogous to color changes) through a ball member that can be positioned in different states. When the drive sleeve's tapered shoulder contacts the ball member, it provides visual feedback that the mechanical override is active. This visual indication mechanism allows operators to immediately recognize which actuation method is currently engaged.
2Loss of information
If the shaft extends external to the actuator to provide visual indication of valve position, then the valve position can be observed, but the indication does not communicate which actuation mechanism is being used or whether the valve is fully open/closed
Solution Approach 1:
The visual indication system is segmented into multiple independent indicators: the shaft extension for basic open/closed position, the ball member indication for mechanical override status, and the drive sleeve tapered shoulder for activation state. This segmentation allows each component to provide specific information without interfering with others, enabling precise determination of both valve position and actuation mechanism.
Solution Approach 2:
The ball member serves as an intermediary indicator between the drive sleeve's mechanical state and the operator's visual observation. When the drive sleeve's tapered shoulder contacts the ball member, it translates internal mechanical override activation into an externally visible signal, providing precise information about which actuation mechanism is active without interfering with the shaft's position indication.
3Adaptability or versatility
If the mechanical override is used to lock the valve in the open position, then the valve remains open during wellbore completion operations, but the fail-safe closed mechanism is overridden and may prevent proper closure during shutdown
Solution Approach 1:
The system performs preliminary action by providing visual indication through the ball member and drive sleeve tapered shoulder before the valve is actually locked in the open position. This early warning system alerts operators that the mechanical override is active and the fail-safe mechanism is overridden, allowing them to take preventive measures before shutdown occurs. The indication is established in advance of any potential safety issues.
Solution Approach 2:
The drive sleeve's tapered shoulder contacting the ball member creates a feedback mechanism that continuously informs operators of the mechanical override's active state. This feedback loop ensures that operators are always aware when the fail-safe mechanism has been overridden, enabling them to make informed decisions about valve operation and shutdown procedures to maintain system reliability.
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
Ensures accurate determination of valve position and actuation mode, preventing misinterpretation and ensuring the valve operates in a safe mode by providing clear visual indications, thus preventing unintended valve positions and ensuring proper closure.
Implementation Method 1
a biasing member operable to move the piston within the housing to a first position
Data Source
AI summary
Embodiments of a method of operating a safety valve and a safety valve system are provided. The valve system includes a valve, an actuator, a mechanical override, and an indicator. The actuator includes a fail-safe mechanism and the indicator is configured to indicate whether the fail-safe mechanism is operable during use of at least one of the actuator and the mechanical override. In one embodiment, a method of operating the safety valve includes actuating the valve into an open position and sending a signal to indicate that the fail-safe mechanism is operable to move the valve to the closed position, while the valve is in the open position.