Valve System with Erodible Inset for Multi-Stage Opening
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Solution Overview
Problem
Conventional drop ball systems for operating valves in tubulars are limited to about 20 valves due to the need for distinct drop ball sizes and the pressure drop associated with opening each valve, which restricts the number of operable valves and leads to large dead zones in hydrocarbon reservoirs.
Innovation Solution
A valve system with at least two valves operable by one drop ball, featuring a closed state, an intermediate state providing an intermediate opening, and an open state with full radial opening, where the intermediate state is achieved using an inset made of standard steel that can be eroded by abrasive materials to reveal a larger opening, allowing multiple valves to be opened efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional drop ball systems are used to operate valves in tubulars, then each valve can be opened reliably, but the number of operable valves is limited to about 20 due to pressure drop and distinct drop ball size requirements
Solution Approach 1:
The valve opening process is segmented into two distinct phases: first opening to an intermediate state with restricted flow, then later opening to full flow. This segmentation allows multiple valves to be opened sequentially with one drop ball, as the intermediate state minimizes pressure drop during the opening sequence, enabling operation of 20+ valves rather than being limited to about 20 valves with conventional systems
Solution Approach 2:
The valve opening state is made dynamic and time-dependent. Valves transition from closed → intermediate (restricted) state → full open state. The intermediate state is maintained temporarily to allow subsequent valves to open before full flow begins, dynamically managing pressure drop to enable operation of multiple valves with a single drop ball
2Productivity
If multiple valves are opened simultaneously to full opening, then hydrocarbon recovery is enhanced, but pressure drop becomes too large to open subsequent valves with the same drop ball
Solution Approach 1:
Valves are preliminarily opened to an intermediate state with restricted flow before being opened to full flow. This preliminary action allows subsequent valves to open without experiencing the full pressure drop that would occur if all valves opened simultaneously to full opening, enabling the drop ball to traverse the entire tubular and open multiple valves
Solution Approach 2:
The valve opening process occurs in periodic stages: first stage opens valves to intermediate state, second stage (after drop ball passes) opens valves to full state. This periodic action manages pressure drop temporally, allowing multiple valves to be operated with one drop ball while ultimately achieving full hydrocarbon recovery
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
Enables a larger number of valves along a tubular while minimizing the need for expensive hydraulic control lines and equipment, effectively managing pressure drops to maintain hydraulic pressure for subsequent valve openings, reducing dead zones and enhancing hydrocarbon recovery.
Implementation Method 1
an intermediate state providing an intermediate opening for at least the time required to open all the remaining valves in the valve group, and an open state providing a full radial opening larger than the intermediate opening
Data Source
AI summary
A valve system for providing fluid flow through radial openings disposed along an axial length of a tubular. The tubular comprises at least one valve group containing at least two valves operable by one drop ball. An inset 302 e.g. of standard grade steel provided in a harder liner 301 in the opening provides an intermediate small opening for at least the time required to open all the remaining valves in the group. The small opening limits the pressure drop over the valve. When all valves are open, the insets 302 are eroded away by an abrasive material, e.g. a slurry used for hydraulic fracturing, and permanent full openings are created.