Two-Plane Shear Valve for Emergency Well Closure
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Solution Overview
Problem
Current blow-out preventers (BOPs) have limitations in shearing drill pipes, particularly failing to effectively cut thicker and larger diameter tool joints, leading to incomplete separation and residual metal debris that can block the well closure, especially under high pressure and stress conditions.
Innovation Solution
A safety valve assembly with a punch and counter-punch mechanism that creates two shearing planes, capable of cutting a wide range of tubular elements, including casings and drill pipes, with a hydraulic-seal closure system that avoids metal debris and requires no maintenance during the operational life of the well.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional BOPs with single-plane shearing mechanism are used, then the device complexity is reduced, but the shearing capacity is insufficient for thicker and larger diameter tool joints
Solution Approach 1:
The shearing action is divided into two separate planes: a first shearing plane created by a punch and a second shearing plane created by a counter-punch. This segmentation allows each punch to handle specific portions of the tubular element, enabling the system to shear thicker and larger diameter tool joints that would be impossible with a single-plane mechanism, while keeping each individual punch relatively simple in design
2Reliability
If conventional BOPs are used under high pressure and stress conditions, then the intervention time is reduced, but metal debris blocks the well closure
Solution Approach 1:
The harmful factor of metal debris is extracted and removed from the system by designing the two-plane shearing mechanism to produce minimal debris. The punch and counter-punch configuration ensures complete separation of the tubular element with reduced crushing, preventing metal debris from remaining entrapped and blocking the subsequent closing phase of the well
Solution Approach 2:
The two-plane shearing action performs preliminary cutting separation before the closing phase. By creating two distinct shearing planes, the tubular element is completely separated in advance, ensuring that no residual material remains to interfere with the subsequent hydraulic-seal closure operation
3Reliability
If shear rams are used to induce shear stress on tubular materials, then the closing effectiveness is improved, but the shearing is incomplete when the drill string is compressed or diverted
Solution Approach 1:
The invention transitions from a single-plane shearing approach to a two-dimensional shearing approach with punch and counter-punch creating separate shearing planes. This dimensional change allows the system to effectively shear tubular elements regardless of their orientation or stress state, whether the drill string is compressed, diverted laterally, or in a centered position, thereby improving adaptability while maintaining closing effectiveness
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 safety valve effectively shears tubular elements under critical conditions, ensuring complete closure and preventing metal debris from blocking the valve, thus enhancing well control and safety without the need for maintenance, even after ineffective BOP interventions.
Implementation Method 1
Particular BOPs called 'shear rams' can induce shear stress on the tubular materials engaged in the valve body of the BOP so as to shear them and obtain the desired results
Implementation Method 2
The intervention times of BOPs generally range from tens of seconds to minutes thanks to dedicated actuations and hydraulic controls
Data Source
AI summary
A safety valve assembly for extradition of hydrocarbons includes a valve body including a passage duct, configured to be traversed by a production and/or drilling line. The valve body includes housings for a punch and counter-punch, arranged diametrically opposite to one another with a common longitudinal axis substantially perpendicular to the longitudinal axis of the valve. The punch slides linearly in a controlled manner in the housing along the axis which intersects the longitudinal axis of the pipe, and the counter-punch slides linearly in a controlled manner in the housing along the axis which intersects the longitudinal axis of the pipe. The punch and counter-punch are configured to allow the counter-punch to slidingly receive the punch in its interior to create two different shearing planes. The counter-punch includes a hollow part to slidingly receive the section of tubular material and the punch, in the linear movement during the shearing operation.