Shear Seal Check Valve for Dirty Fluid Reliability
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Solution Overview
Problem
Flow control devices used in subsurface applications, such as well boreholes, face reliability issues due to debris fouling from 'dirty' fluids like formation and drilling fluids, which can cause erosion, corrosion, and clogging, leading to reduced efficiency and operational challenges.
Innovation Solution
The development of self-piloting check valves employing shear seals to enhance reliability, which reduce the likelihood of debris fouling by using stationary shear seal elements that form a fluid-tight barrier, and a 'dirty fluid pressure relief valve' design that incorporates biasing members to ensure proper fluid flow control, even in harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flow control devices are used in subsurface applications, then fluid flow control is achieved, but reliability deteriorates due to debris fouling from dirty fluids
Solution Approach 1:
The valve body is divided into separate sections with distinct functions: a first section with a first shear seal element for inlet flow control, and a second section with a second shear seal element for outlet flow control. This segmentation allows each seal element to independently handle debris fouling issues, improving overall reliability
Solution Approach 2:
Instead of using traditional seals that are susceptible to debris fouling, the invention inverts the sealing approach by using shear seal elements that are specifically designed to resist fouling from dirty fluids. The shear seal elements operate on a different principle than conventional seals, making them immune to the harmful effects of debris in subsurface fluids
2Reliability
If shear seal elements are used to prevent debris fouling, then reliability improves, but device complexity increases
Solution Approach 1:
The biasing member combines multiple functions: it biases the valve element to the closed position, maintains contact between shear seal elements and the valve element, and ensures proper sealing operation. This merging of functions reduces the number of separate components needed, thereby reducing device complexity while maintaining reliability
Solution Approach 2:
The valve element serves multiple purposes: it controls fluid flow between inlet and outlet, provides a surface for shear seal elements to seal against, and works in conjunction with the biasing member to maintain proper valve operation. This multi-functionality reduces the need for additional components, simplifying the overall device structure
3Manufacturing precision
If biasing members are incorporated to ensure proper flow control, then flow control precision improves, but device complexity increases
Solution Approach 1:
The biasing member is designed to automatically maintain the valve element in the closed position and ensure proper contact between shear seal elements without requiring external control mechanisms. The valve element self-regulates flow control through the mechanical action of the biasing member, achieving precise flow control without additional complex components
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 shear seal-based flow control devices effectively manage fluid flow, preventing clogging and maintaining reliability by using stationary shear seal elements and biasing members to ensure consistent operation, even with abrasive and viscous 'dirty' fluids, thereby enhancing the overall performance and longevity of flow control systems in subsurface applications.
Implementation Method 1
The flow control device may include a first shear seal element disposed in a first bore formed in the body and a second shear seal element disposed in a second bore formed in the body
Implementation Method 2
The valve element may include a seal and a biasing member
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
An apparatus for controlling fluid flow that includes a chamber having a first valve and a second valve; a sensor that senses a pressure parameter associated with the chamber; and a controller programmed to operate the first valve and the second valve in response to the sensed pressure parameter may be used to control for flow and to obtain data relating to a formation and/or formation fluid. The apparatus may include a manifold for using a fluid mover to convey fluid between the first location and the second location and at least one module received by the manifold.