Hydraulic Toe Valve Sleeve Actuation and Cement Blockage Prevention
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Solution Overview
Problem
Existing toe valves in oil and gas well fracturing operations often face issues with cement hardening in apertures, which can block fluid flow and require increased pressure to actuate, potentially exceeding the liner's pressure rating, leading to operational inefficiencies and potential damage.
Innovation Solution
The design of novel toe valves featuring a hydraulically mounted sleeve with a passage that is in fluid communication with the bore, allowing the sleeve to move from a closed to an open position in response to fluid pressure, and incorporating a pressure release device such as a rupture disc to ensure reliable actuation without cement interference, along with features like radial clearance and threaded connections for enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cement is pumped through the toe valve during cementing operations, then the liner is successfully cemented in place, but cement hardens in the aperture and blocks fluid flow, requiring increased pressure to actuate the valve
Solution Approach 1:
The invention extracts the aperture from the main valve body and relocates it to a separate drift collar component. This separation allows the aperture to be positioned in a location less susceptible to cement hardening, while the main valve body retains its sealing and actuation functions. The drift collar with the aperture is designed to minimize cement accumulation, thereby maintaining reliable fluid flow and valve actuation at normal pressures without the need for excessive pressure buildup.
Solution Approach 2:
The invention introduces a drift collar as an intermediary component between the main valve body and the aperture. This drift collar serves as a mediator that protects the aperture from direct cement exposure while still allowing necessary fluid communication. The drift collar's design includes features that prevent cement hardening in the aperture area, thus maintaining reliable fluid flow paths without requiring increased actuation pressure.
2Ease of operation
If cement hardens in the aperture, then fluid flow is blocked, but increased pressure is required to actuate the valve, potentially exceeding the liner's pressure rating
Solution Approach 1:
By extracting the aperture from the main valve body and placing it in a separate drift collar, the invention eliminates the problem of cement hardening blocking the aperture. This separation ensures that the aperture remains clear for fluid flow, allowing the valve to be actuated easily at normal pressures without risking liner damage from excessive pressure requirements.
Solution Approach 2:
The drift collar is designed with features that preliminarily prevent cement hardening in the aperture area before cementing operations complete. This preliminary protection ensures that the aperture remains open and functional, allowing for easy valve actuation without the need for excessive pressure that could damage the liner.
3Reliability
If the sleeve is hydraulically mounted with a passage for fluid communication, then the sleeve can move reliably from closed to open position, but the passage may be blocked by hardened cement
Solution Approach 1:
The invention segments the valve into distinct components: the main valve body, the drift collar containing the aperture, and the sleeve assembly. This segmentation allows the passage to be positioned in the drift collar away from cementing zones, reducing the risk of cement blockage. The segmented design maintains reliable sleeve actuation while managing complexity through modular construction, where each segment performs a specific function and can be optimized independently.
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 novel toe valves ensure reliable and efficient initiation of fracturing operations by preventing cement interference with the pressure release mechanism, allowing for consistent actuation at rated pressures, reducing the risk of liner damage and improving fluid flow control during fracturing.
Implementation Method 1
the aperture is normally closed by a pressure device, such as a rupture disc. As pressure increases within the bore, the disc will rupture and fluid will flow into the chamber
Implementation Method 2
The sleeve is mounted for hydraulic displacement in the radial space between the housing and the inner ends of the subs. The sleeve is moveable in response to fluid pressure from the bore through the passage
Data Source
AI summary
A valve has a valve body which includes a sub. A bore extends through the valve body and the sub. The valve also comprises a port and a sleeve. The sleeve is mounted for hydraulic displacement. There is a passage through the sleeve which is in fluid communication with the bore. The sleeve is moveable in response to fluid pressure from the bore through the passage. The sleeve is moveable from a closed position, in which it restricts flow out of the bore through the port, to an open position, in which it allows flow out of the bore through the port.