Valve Assembly Locking Collar for Drilling Erosion
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Solution Overview
Problem
Current continuous circulation systems in drilling operations face challenges such as complex mechanical-hydraulic designs, high maintenance costs, and susceptibility to erosion, particularly due to the use of flapper valves which do not provide robust high-pressure seals and obstruct the main bore flow path.
Innovation Solution
A valve assembly featuring a poppet check valve with a resilient biasing element and a locking collar mechanism, allowing for continuous fluid circulation without interrupting the drilling process, and a two-part design where the valve seat can be replaced independently of the valve body to address erosion and corrosion issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flapper valve is used in continuous circulation systems, then the main bore flow path is kept open, but the valve does not provide robust high-pressure seals and is susceptible to erosion
Solution Approach 1:
The valve assembly is divided into modular components including a replaceable valve seat, valve body, and poppet. This segmentation allows the valve seat to be independently replaced when eroded, without replacing the entire valve assembly, thereby addressing erosion susceptibility while maintaining sealing capability.
Solution Approach 2:
The valve seat is designed as a consumable component that can be easily replaced when eroded. By making the valve seat replaceable rather than part of a permanent assembly, the system allows for cost-effective maintenance by replacing only the worn seat rather than the entire valve, addressing both erosion and cost concerns.
2Reliability
If a complex mechanical-hydraulic design is used in continuous circulation systems, then circulation control is achieved, but maintenance costs increase and system complexity increases
Solution Approach 1:
The invention extracts the complex mechanical-hydraulic components from the continuous circulation system and replaces them with a simpler poppet valve mechanism. The valve uses a straightforward spring-loaded poppet design that opens under pressure differential, eliminating the need for complex mechanical-hydraulic control systems while maintaining circulation control functionality.
Solution Approach 2:
The complex mechanical-hydraulic control system is replaced with a pressure-driven poppet valve mechanism. The valve operates automatically based on pressure differential across the valve seat, substituting complex mechanical control with a simpler pressure-responsive mechanism that achieves the same circulation control function.
3Ease of manufacture
If the valve seat is integral with the valve body, then manufacturing is simplified, but erosion of the valve seat requires replacement of the entire valve body increasing maintenance costs
Solution Approach 1:
The valve assembly is segmented into a valve body and a separate valve seat that can be independently replaced. This segmentation complicates manufacturing slightly but dramatically improves maintainability by allowing the valve seat to be replaced without replacing the entire valve body, directly addressing the maintenance cost issue.
Solution Approach 2:
The valve seat is designed as a discardable component that can be replaced when eroded, while the valve body is recovered and reused. This approach separates the consumable part (seat) from the durable part (body), allowing cost-effective maintenance by replacing only the worn component rather than the entire assembly.
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 solution provides a robust, efficient, and cost-effective continuous circulation system that maintains fluid tightness, reduces maintenance complexity, and prevents fluid loss during drilling operations, while allowing for easy replacement of worn components to minimize downtime and costs.
Implementation Method 1
a resilient biasing element biased the valve member into engagement with the valve seat
Implementation Method 2
the valve member is movable between a closed position in which the valve member engages with a seat face of the valve seat to substantially prevent flow of fluid along the main passage, and an open position in which the valve member is spaced from the seat face
Data Source
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AI summary
An assembly comprising a rod having a longitudinal axis, a support part, a resilient biasing element, and a nut, the nut being mounted on a screw thread around the rod, the assembly further comprising a locking collar which is mounted around the rod such that the biasing element extends between the support part and the locking collar, the locking collar having a first locking formation which engages with a corresponding locking formation of the rod to substantially prevent rotation of the locking collar around the rod, the biasing element pushing the locking ring into engagement with the nut so that at least one locking formation on the nut engages with a second locking formation on the locking collar, and, as a result, the locking collar substantially prevents further rotation of the nut about the rod.