Wellbore Flow Control Valve with Preliminary Flapper Mechanism
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Solution Overview
Problem
Existing well control systems, particularly those using flapper valves, face challenges in managing reverse flow and sustaining high production rates due to substantial loading forces during closure, which can lead to valve damage and unreliable operations.
Innovation Solution
A flow control system that integrates a flow reduction mechanism with a flapper-type device, allowing for reduced loading forces by actuating prior to or in conjunction with the flow control device, thereby enabling higher production rates and preventing uncontrolled well flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flapper valve is used to control flow in one direction while blocking flow in the opposite direction, then flow control capability is provided, but the valve is subjected to substantial loading forces when closing against a moving flow stream
Solution Approach 1:
The flow control system is divided into two separate functional components: a flow reduction mechanism with flapper elements that reduce flow velocity, and a flow control device (valve) that provides bidirectional flow control. This segmentation allows the flapper elements to handle flow reduction while the main valve handles control, preventing the valve from承受ing substantial loading forces during closure
Solution Approach 2:
The flow reduction mechanism acts prior to the flow control device closure to reduce flow velocity and loading forces. By preliminarily reducing the flow using flapper elements before the main valve closes, the system prevents the valve from closing against a moving flow stream, thereby reducing substantial loading forces on the valve
2Reliability
If the valve closes against a moving flow stream to shut in production or injection flow, then flow shutdown function is achieved, but the valve reliability is compromised due to substantial loading forces
Solution Approach 1:
The system segments the flow shutdown function into two parts: flow reduction by flapper elements and flow control by the main valve. This allows the valve to achieve flow shutdown while avoiding substantial loading forces that would compromise reliability
Solution Approach 2:
The flow reduction mechanism performs preliminary action by reducing flow velocity before the main valve closes. This preliminary flow reduction ensures the valve can reliably shut in flow without being subjected to damaging loading forces from closing against a moving stream
3Ease of operation
If flapper valves are used to prevent detrimental reverse flow, then flow direction control is provided, but adjustment ability is limited to accommodate various procedures
Solution Approach 1:
The system separates the flow direction control function (performed by flapper elements in the flow reduction mechanism) from the flow control function (performed by the main valve). This segmentation allows the valve to provide adjustment ability for various procedures while the flapper elements handle reverse flow prevention
Solution Approach 2:
The flow control device serves multiple functions: it provides flow direction control through coordination with the flow reduction mechanism, offers adjustment ability for various production and injection procedures, and maintains reliability by avoiding substantial loading forces. This multi-functionality resolves the contradiction between ease of operation and adaptability
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 loading forces on the flow control device during closure, allowing for higher initial flow rates and enhanced durability, while maintaining nominal flow area unobstructed during normal conditions, thus preventing damage from rapid closures and ensuring reliable operation.
Implementation Method 1
The flow reduction mechanism actuates prior to or in conjunction with the flow control device to reduce flow and thus reduce the loading forces that would otherwise act against the flow control device upon closure
Data Source
AI summary
A technique enables control over flow in a wellbore with a flow control system. The flow control system combines a flow reduction mechanism with a flow control device, such as a valve. The flow reduction mechanism comprises a closure member which can be selectively moved between an unactuated and actuated position, allowing relatively greater flow through the flow control device in the unactuated position. The flow reduction mechanism actuates prior to or in conjunction with the flow control device to reduce flow and thus reduce the loading forces that would otherwise act against the flow control mechanism upon closure of the flow control device.