Slant-drilled Valve Collar for High-Pressure Downhole Tools
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Solution Overview
Problem
Current two-valve controlled packers for downhole wellbores require ports to be drilled from both ends of the tubular segment, limiting the length of the valve collar and thus the pressure it can handle, due to the need for epoxy resin coupling, which restricts the design and functionality.
Innovation Solution
A method and design for a valve collar that includes a mandrel with strategically drilled blind end holes, slant shell holes, and radial holes to form valve cylinders and ports, allowing for a more compact and pressure-efficient valve system by fluidly coupling these elements within the mandrel, enabling the insertion of a valve assembly and independent operation of valve systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ports are drilled from both ends of the tubular segment to create valve cylinders, then the valve collar can be manufactured with traditional two-valve configuration, but the length of the valve collar is limited and the pressure handling capacity is reduced
Solution Approach 1:
The patent transitions from drilling ports only from end faces to drilling at angular orientations including from the lateral surface of the tubular segment. This dimensional change in drilling approach allows valve cylinders to be formed without requiring the tubular segment to be divided into short sections, thereby maintaining both manufacturability and pressure handling capacity.
2Ease of operation
If the valve collar is designed to slip over an existing tubular mandrel and coupled by epoxy resin, then the valve collar can be installed easily, but the amount of pressure the valve collar can handle is limited
Solution Approach 1:
The patent removes the epoxy resin coupling requirement by drilling valve cylinders directly into the tubular segment itself. This extraction of the intermediate coupling material eliminates the weakness in the pressure path, allowing the valve collar to handle higher pressures while maintaining ease of installation through direct integration.
3Ease of manufacture
If the valve collar length is minimized to accommodate epoxy resin coupling, then the manufacturing is simplified, but the operational efficiency and pressure handling are reduced
Solution Approach 1:
The patent merges the valve cylinder formation process directly into the tubular segment manufacturing by drilling valve cylinders into the tubular segment itself rather than requiring separate coupling components. This integration eliminates the need for epoxy resin and intermediate coupling steps, simultaneously simplifying manufacturing and improving operational efficiency by creating a unified pressure-containing structure.
Data Source
AI summary
A valve collar for use with a fluid actuated downhole tool includes a mandrel having one or more valve cylinders formed in the wall thereof, the valve cylinders formed at an angle to the mandrel. The valve cylinders may be connected to each other, to the interior of the mandrel, and to the fluid actuated downhole tool through end holes, slant shell holes, and radial holes. Each valve cylinder may include a valve assembly inserted thereinto.