Segmented Drilling Valve for Constant Fluid Circulation

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Solution Overview

Problem

Existing drilling fluid circulation systems face challenges in maintaining continuous fluid circulation during pipe connections and disconnections, leading to pressure changes that can cause formation fractures and fluid losses, especially in high-pressure applications, and require complex and costly modifications to drilling rigs.

Innovation Solution

The development of specially designed automatic circulation valves with a smooth central bore, capable of withstanding high pressures up to 1600 bar, and operated remotely to ensure continuous fluid circulation independent of pipe connections/disconnections, rotation, and mud composition, reducing the risk of pressure shocks and allowing tool passage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If mud pumps are stopped and started during pipe connections/disconnections, then pipe makeup and breakout can be performed, but pressure changes occur that cause formation fractures and fluid losses

Engineering Contradiction:

Improvepipe connection and disconnectionVSAvoidwell security and formation integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The drill string is divided into modular sections that can be connected or disconnected independently. The circulation system is segmented into alternative flow paths, allowing one path to remain active while another is being modified, thus maintaining continuous circulation without pressure shocks.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A circulation maintenance device acts as an intermediary between the drilling circulation system and the pipe connection operations. This device provides alternative flow paths that allow circulation to continue through the intermediary device while pipe sections are being connected or disconnected elsewhere in the system.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Extent of automation

If pressure operated valves are used for circulation control, then automatic valve operation is achieved, but the required pressure to open/close valves may exceed permitted pressure limits

Engineering Contradiction:

Improveautomatic valve operationVSAvoidvalve operation pressure

Core Design Contradiction:

Extent of automationVSStress or pressure

Solution Approach 1:

The patent replaces purely pressure-operated mechanical valves with a hybrid system that includes remotely operated valve control. This allows valve operation to be controlled by external signals rather than requiring extreme pressure differentials, reducing the peak pressures needed for valve actuation while maintaining automation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If pressure operated valves with radial surfaces are used, then valve operation is enabled, but tool passage through the central bore becomes difficult or impossible

Engineering Contradiction:

Improvevalve operationVSAvoidtool passage capability

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The patent resolves the conflict between valve operation surfaces and tool passage by moving the valve actuation mechanism to a different dimensional space. Instead of requiring radial surfaces that block the central bore, the valve control is achieved through axial or external mechanisms that leave the central bore clear for tool passage while still enabling valve operation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Reliability

If complex circulation systems are used to maintain continuous flow, then well security is improved, but rig modifications become complex and costly

Engineering Contradiction:

Improvecontinuous circulation maintenanceVSAvoidrig modification complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The circulation maintenance device is designed with multi-functionality to reduce overall system complexity. It can operate in multiple modes (normal circulation, connection/disconnection mode, emergency backup) and serves multiple purposes including maintaining flow, providing alternative pathways, and enabling safe pipe operations, thereby reducing the need for separate specialized systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8590640B2Apparatus and method to maintain constant fluid circulation during drilling

Publication Date: 2013.11.26 BAKER HUGHES CO

AI summary

An apparatus for maintaining constant circulation of drilling fluid includes a valve section (5) at the top of each section of drill pipes to be connected to or removed from the drill string. The valve section (5) has a top inlet for axial circulation and a side inlet (5b) for radial circulation. Two separate valves (5c, 5d) within the valve section controls flow through the inlets. An external valve control device (4) has a circulation adapter (4b) for connecting drill fluid at operational pressure to the side inlet (5b) and separate activating adapters (4c, 4d) connecting to the couplings for opening or closing the valves (5c, 5d).