Thrust-Actuated Control Valve for ESP Sand Management
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Solution Overview
Problem
Deep-set subsurface safety valves in oil and gas wells pose operational risks due to trapped hydrocarbons and complicate well control, while shallow-set valves face challenges with sand accumulation and deployment issues in cable-deployed electric submersible pump systems.
Innovation Solution
A control valve assembly utilizing a propeller shaft, stinger, flow tube, and spring, which aligns ports for fluid communication when activated and misaligns upon deactivation, reducing sand accumulation and simplifying deployment by using a thrust force to operate the valve without surface control lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a deep-set SSSV is installed, then well control is improved, but operational risk increases due to trapped hydrocarbons
Solution Approach 1:
The patent positions the SSSV at a shallower depth than conventional deep-set valves, changing the vertical dimension of installation. This allows the valve to be set above the downhole production equipment while still providing well control, thereby reducing trapped hydrocarbon volume without sacrificing safety valve functionality
2Object-affected harmful factors
If a shallow-set SSSV is installed, then trapped hydrocarbon volume is reduced, but sand accumulation and deployment issues occur
Solution Approach 1:
The patent extracts the SSSV from the conventional deep-set position and relocates it to a shallow-set position above the downhole production equipment. This extraction removes the valve from the hydrocarbon trap zone while maintaining well control capability, thereby eliminating sand accumulation issues associated with deep-set valves
3Ease of operation
If a shallow-set SSSV is used in cable-deployed ESP systems, then deployment is simplified, but valve operation reliability decreases
Solution Approach 1:
The patent implements a self-actuating mechanism where the SSSV automatically opens and closes based on pump operation. The valve uses the pump's own hydraulic pressure to actuate the valve mechanism, eliminating the need for separate control lines and surface equipment, thereby ensuring reliable operation while maintaining deployment simplicity
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 system effectively reduces sand accumulation and simplifies operational deployment and retrieval in cable-deployed ESP systems, ensuring proper functionality and eliminating the need for separate control lines for well control.
Implementation Method 1
rotating a propeller by a fluid travelling upwards towards a surface location upon activation of a pump of the electric submersible pump assembly, thereby thrusting the propeller shaft axially downhole along a central axis
Implementation Method 2
The spring slides the propeller shaft when the pump of the electric submersible pump assembly is inactive
Data Source
AI summary
A system includes an electric submersible pump assembly and a control valve assembly. The electric submersible pump assembly transports a fluid in a casing string of a well to a surface location and includes a pump that receives the fluid through a pump intake and vents the fluid through a pump discharge when activated. The electric submersible pump assembly further includes a shaft that is fixed to the pump and extends downhole from the pump. The control valve assembly includes a propeller shaft axially movable along a central axis of the system, a propeller attached to the propeller shaft that pushes the propeller shaft downhole when the pump of the electric submersible pump assembly is active, a shaft coupler that connects the propeller shaft and the shaft of the electric submersible pump assembly, and a stinger that has a conduit for the fluid to flow from the casing string to the pump intake. The stinger includes an entrance for receiving the fluid and an exit for venting the fluid to the pump intake of the electric submersible pump assembly. In addition, the control valve assembly includes a flow tube, connected to the propeller shaft, and a spring. The flow tube includes ports which create fluid communication between the flow tube and the stinger when the ports and the entrance of the stinger are aligned. The spring slides the propeller shaft when the pump of the electric submersible pump assembly is inactive.