Section-Balanced Electric Safety Valve for High-Flow Wellbores
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Solution Overview
Problem
Existing safety valves for wellbore operations with electric actuators face challenges in maintaining a large inner diameter while minimizing outer diameter, due to the need for larger casing diameters, which increases drilling and operational expenses, and may lead to wellhead damage and hydrocarbon leakage.
Innovation Solution
A section-balanced electric safety valve design with a pressure and temperature-compensated coiled tubing compensating subassembly, a thin protective sleeve for magnetic coupling, and compression springs parallel to the electric actuator, allowing for a reduced cross-section and increased inner diameter for higher flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the safety valve is equipped with an electric actuator and electronic components, then the valve can be remotely controlled and monitored, but the outer diameter of the valve increases
Solution Approach 1:
The electric actuator and electronic components are nested within the valve body structure, with components arranged concentrically and integrated into existing cavities. The motor assembly is positioned within the bonnet area, and electronic components are mounted on the valve body surface or within dedicated compartments, allowing the automated valve to fit within standard wellbore dimensions.
Solution Approach 2:
The design transitions from a purely radial layout to a three-dimensional arrangement where electronic components are distributed across multiple planes and depths. The actuator extends axially rather than radially, and electronic components are positioned at different elevations within the valve assembly, optimizing space utilization and reducing the outer diameter.
2Extent of automation
If the casing diameter is increased to accommodate a larger safety valve, then the valve can accommodate the electric actuator, but drilling and operational expenses increase
Solution Approach 1:
The electric actuator, electronic components, and valve mechanism are merged into a single integrated assembly. The actuator is coupled directly to the valve stem, and electronic components are positioned adjacent to or within the actuator housing, eliminating the need for separate mounting structures and reducing overall valve dimensions.
Solution Approach 2:
The valve body and bonnet structures serve multiple functions: they contain the valve mechanism, provide mounting surfaces for electronic components, and house the actuator. The bonnet acts as both a protective cover and a structural element that transmits actuator force to the valve stem, reducing the need for additional components.
3Area of stationary object
If the inner diameter of the safety valve is reduced to minimize outer diameter, then the valve fits in smaller wellbores, but the flow rate of production fluids decreases
Solution Approach 1:
The valve design features an asymmetric cross-section where the flow passage is optimized independently of the outer diameter. The internal geometry includes streamlined contours and enlarged flow channels that maximize flow capacity within the constrained external dimensions, creating a discrepancy between the compact outer shape and the spacious internal flow path.
Solution Approach 2:
The valve body utilizes thin-walled construction with optimized wall thickness distribution. The shell thickness is minimized in non-critical areas to maximize inner diameter, while maintaining structural integrity through strategic reinforcement at stress concentration points and using high-strength materials.
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 design enables a compact, efficient electric safety valve with enhanced flow capacity and reduced operational costs by maintaining a large inner diameter while minimizing the outer diameter, thus preventing wellhead damage and hydrocarbon leakage.
Implementation Method 1
the interior chamber is pressure and temperature compensated with a flow passage extending axially through the electric safety valve
Implementation Method 2
the interior chamber further comprises a dielectric fluid and the interior chamber is pressure and temperature compensated with a flow passage
Implementation Method 3
The closure member is closed by a magnetic coupling between the electric actuator and the closure member, or by compression springs, or by a combination thereof
Implementation Method 4
The closure member is closed by a magnetic coupling between the electric actuator and the closure member
Data Source
AI summary
Provided are electric safety valves and methods of use. An electric safety valve comprises an electric actuator positioned in an interior chamber of the electric safety valve; the interior chamber comprising a dielectric fluid and being pressure and temperature compensated with a flow passage extending axially through the electric safety valve. The pressure and temperature compensation is performed via a compensating subassembly in pressure communication with the interior chamber thereby providing a section-balanced electric safety valve. The electric safety valve further comprises a protective sleeve separating the interior chamber from the flow passage. The electric safety valve further comprises at least one compression spring rod coupled to a closure member capable of restricting or preventing fluid flow through the flow passage. A method includes actuating the electric actuator; the electric actuator being magnetically coupled to the closure member such that actuation of the electric actuator pivots the closure member.