Semi-autonomous Insert Valve for Well Systems
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Solution Overview
Problem
Existing well systems face issues with subsurface safety valves malfunctioning, leading to restricted fluid flow, as they often rely on the same actuation mechanism as the insert valve, and battery-powered solutions with poppet closure mechanisms cause flow restrictions, making them unsuitable for long-term production.
Innovation Solution
A semi-autonomous insert valve with an independent actuation mechanism, including a body, closure mechanism, autonomous actuation system, and control subsystem that can wirelessly communicate signals, allowing it to operate independently of the subsurface safety valve's actuation mechanism and provide power through a battery or electrical connection, ensuring continued fluid flow even when the subsurface safety valve malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the insert valve uses the same actuation mechanism as the subsurface safety valve, then the device complexity is reduced, but the reliability deteriorates because a single control line failure prevents actuation of both valves
Solution Approach 1:
The actuation system is segmented into two independent components: the subsurface safety valve retains its original control line actuation mechanism, while the insert valve is equipped with a separate autonomous actuation mechanism. This segmentation ensures that failure of one actuation system does not prevent operation of the other valve, thereby resolving the reliability issue while maintaining reasonable device complexity through modular design.
2Ease of operation
If battery-powered insert valves with poppet closure mechanism are used, then the ease of operation is improved, but the productivity deteriorates due to large flow path restrictions
Solution Approach 1:
The poppet closure mechanism, which causes large flow restrictions, is extracted from the insert valve design. Instead, a flapper valve closure mechanism is implemented that provides full-bore flow capability with minimal restriction. The battery-powered actuation system is retained to maintain ease of operation, thus resolving the contradiction between ease of operation and productivity.
3Reliability
If pressurization above the insert valve is required to open the valve, then the reliability is improved, but the use of energy deteriorates due to continuous pressurization requirements
Solution Approach 1:
The mechanical pressurization system is replaced with an autonomous actuation mechanism that uses a motor-driven piston to directly open the valve. This eliminates the need for continuous pressurization energy input, as the motor only needs to operate briefly to actuate the closure mechanism. The reliability is maintained through the autonomous nature of the actuation system, which can operate independently without external energy supply during valve opening.
Data Source
AI summary
Certain aspects and embodiments of the present invention are directed to a semi-autonomous insert valve. The semi-autonomous insert valve includes a body, a closure mechanism coupled to the body, an autonomous actuation mechanism coupled to the body, and a control system disposed in the body. The body engages an inner wall of a subsurface safety valve and causes a subsurface safety valve closure mechanism to open, allowing fluid to flow toward the surface of the wellbore. The closure mechanism selectively allows fluid to flow toward the surface of the wellbore. The autonomous actuation mechanism actuates the closure mechanism independently from a subsurface safety valve actuation mechanism that actuates the subsurface safety valve closure mechanism. The control sub-system includes one or more transceiving devices that can wirelessly communicate signals. The control sub-system closes the closure mechanism in response to losing signal communication between the transceiving devices and a signal source.