Method and apparatus for retaining a soft seal in an integrated flapper mount, hard seat, spring housing surface controlled subsurface safety valve

Abstract

Presented is a subsurface safety valve in which the flapper mount, hard seat and spring housing have been integrated into a single assembly. To accommodate a “soft seat insert,” a special retainer soft seat ring and soft seat seal are provided. The soft seat seal fits over a conical protruding surface (hard seat) that surrounds the main bore of the safety valve on the bottom side of the spring housing. The retainer ring fits over the soft seat seal and holds it in place against the conical surface. Notches along the perimeter of an upper flanged end of the soft seat seal prevent gases, such as nitrogen, from becoming trapped behind the seal and potentially damaging it during a rapid decompression event. A gap between the upper flanged end of the soft seat seal and the lower spring housing allow the seal to move up and down the conical protruding surface as the flapper opens and closes, reducing compression of the seal and the risk of a compression set due to repeated opening and closing of the flapper.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of an exemplary embodiment of a typical subsurface safety valve with integrated flapper mount, hard seat and soft seat seal with tabbed soft seal retaining ring.

FIG. 2 is a sectional view of an exemplary embodiment of a typical subsurface safety valve with integrated flapper mount, hard seat, and soft seat seal with tabbed retaining ring.

FIG. 3 is another sectional view of an exemplary embodiment of a typical subsurface safety valve with integrated flapper mount, hard seat and soft seat seal with tabbed retaining ring.

FIG. 4 is an isometric assembled view of an exemplary embodiment of a typical subsurface safety valve with integrated flapper mount, hard seat, and soft seat seal.

FIG. 5 is an isometric exploded view of an exemplary embodiment of a typical subsurface safety valve with integrated flapper mount, hard seat and soft seat seal with tabbed soft seal retaining ring showing either roll pins or set screws to restrain further movement of the retainer ring upon assembly.

DETAILED DESCRIPTION

Referring in particular to FIG. 2, flapper 10 mounts to hinge posts 20 that protrude from the bottom of the spring housing 30 so that the flapper 10 becomes part of the spring housing 30. A conical surface area (hard seat) 40 annularly surrounding the main bore 50 of the safety valve and protruding from the bottom of the spring housing 30 creates a metal-to-metal contact surface 60 with the flapper 10 when the flapper 10 is in the closed position, as shown in the figure. A non-metal sealing ring 70, or soft seat, installs around the conical surface 40 and is retained in place on the bottom side of the spring housing 30 by a retainer ring 80. Now referring to FIGS. 3 and 5, the outer parts of the retainer ring 80 contain tabs 90 that fit into mating slots 100 milled into the bottom of the housing 30. The tabs 90 insert into the mating slots 100, and, when the retainer ring 80 is rotated, slide into grooves 110 adjacent to the mating slots 100 to prevent the retainer ring 80 from slipping off of the spring housing 30. Two roll pins or set screws 120 insert into two holes 130 on the outer, annular surface of the spring housing 30 and protrude into the groove 110 on each side of at least one tab 90 to immobilize it within the groove 110 to prevent the retainer ring 80 from inadvertently rotating back off of the housing 30. The retainer ring 80 contains slots “castellations” 140 that facilitate rotation by an installation tool (not shown) during assembly.

Referring to FIG. 2, in one embodiment, the soft seat seal 70 fits around the outer side of the conical surface 40 and has a flanged upper end 150 that contacts the bottom side of the spring housing 30 when the seal is pushed up the conical surface 40 by the closing of the flapper 10. The flanged end 150 fits inside a circular, milled slot 160 (FIG. 5) on the bottom side of the spring housing 30. By design, the milled slot 160 (FIG. 5) is larger than the flanged end 150 so that when the soft seat seal 70 installs onto the conical surface 40, the flanged end 150 of the seal 70 does not initially contact the bottom side of the housing 30 or the outer diameter surface of the circular, milled slot 160. When the flapper 10 pivots closed and pressure builds up underneath the flapper 10, the flapper 10 pushes the soft seat seal 70 up the conical surface 40. The gap 170 between the flanged end 150 of the seal 70 and the bottom side of the housing 30 allows the soft seat seal 70 to move upwards without compressing the seal. The soft seat seal 70 material stretches as it slides up the ever-increasing diameter of the conical surface 40, building up energy within the material. When the flapper 10 is opened, the energy stored in the soft seat material releases, causing the soft seat seal 70 to move back up the conical surface 40 to its original position. During opening and closing of the flapper 10, the soft seat seal 70 is not compressed because of its movement along the conical surface 40 and does not get damaged due to compression. Nor is the soft seat seal 70 at risk of a compression set due to repeated openings and closings of the flapper 10.

Referring now to FIGS. 2 and 5, the soft seat seal 10 also contains one or more notches 180 along the perimeter of the upper flanged end 150 of the seal 70. When the flapper 10 closes and the soft seat seal 70 is pushed up the conical surface 40, if the gap 170 did not exist between the bottom of the spring housing 30 and the upper flanged end 150 of the soft seat seal 70, the upper flanged end 150 would tend to buckle, thereby opening a gap where gases, such as nitrogen, may get trapped between. When the gas pressures are rapidly bled from below the closed flapper 10 the gases trapped between spring housing 30 and the upper flanged end 150 of the soft seat seal 70 would rush past the seal, deform it, and cause damage to the soft seat material. The gap 170 between the flanged end 150 of the seal 70 and the annular outer surface of the circular milled slot 160, along with the notches 180 along the perimeter of the flanged end 150 of the seal 70, provide a release path for trapped gases, thereby reducing or eliminating the damaging effect of trapped gases behind the seal.

The soft seat material may be made of any suitable elastomeric or non-elastomeric material such as Teflon®. The retaining ring is made of a metallic material that conforms with the requirements of NACE MR0175.

It will be apparent to one of skill in the art that described herein is a novel method and apparatus for sealing a subsurface valve. While the invention has been described with references to specific preferred and exemplary embodiments, it is not limited to these embodiments. The invention may be modified or varied in many ways and such modifications and variations as would be obvious to one of skill in the art are within the scope and spirit of the invention.

Claims

1. A subsurface safety valve apparatus, the apparatus comprising: a spring housing comprising first and second ends, wherein at least a portion of the second end exhibits a generally conical shape;a non-metallic sealing ring concentrically located around the generally conically-shaped portion of the second end of the spring housing;a retainer ring adapted to retain the non-metallic sealing ring around the generally conically-shaped portion of the second end of the spring housing;at least one hinge post connected to the second end of the spring housing; anda flapper connected to the at least one hinge post, the flapper operable to rotate between an open and closed position.

2. The subsurface safety valve apparatus of claim 1, wherein the non-metallic sealing ring comprises a flanged end.

3. The subsurface safety valve apparatus of claim 2, wherein the flanged end of the non-metallic sealing ring further comprises at least one notch.

4. The subsurface safety valve apparatus of claim 2, wherein the second end of the spring housing comprises at least one concentric slot capable of receiving the flanged end of the non-metallic sealing ring.

5. The subsurface safety valve apparatus of claim 1, wherein the retainer ring comprises at least one tab.

6. The subsurface safety valve apparatus of claim 5, wherein the second end of the spring housing comprises at least one groove operable to receive the at least one tab of the retainer ring.

7. The subsurface safety valve apparatus of claim 6, wherein the groove is capable of locking the retainer ring in position adjacent to the non-metallic sealing ring.

8. The subsurface safety valve apparatus of claim 1, wherein the flapper seals against the generally conically-shaped portion of the second end of the spring housing and the non-metallic sealing ring when in the closed position.

9. The subsurface safety valve apparatus of claim 1, wherein the longitudinal length of the non-metallic sealing ring is less than the longitudinal length of the generally conically-shaped portion of the second end of the spring housing.

10. The subsurface safety valve apparatus of claim 7, wherein the retainer ring is further locked in position adjacent to the non-metallic sealing ring by at least one screw extending through the at least one hinge post.

11. A subsurface safety valve apparatus, the apparatus comprising: a spring housing comprising first and second ends, wherein at least a portion of the second end exhibits a generally conical shape;a non-metallic sealing ring concentrically located around the generally conically-shaped portion of the second end of the spring housing, wherein the longitudinal length of the non-metallic sealing ring is less than the longitudinal length of the generally conically-shaped portion of the second end of the spring housing,a retainer ring adapted to retain the non-metallic sealing ring around the generally conically-shaped portion of the second end of the spring housing;a flapper connected to the second end of the spring housing, the flapper operable to rotate between an open and closed position, the flapper further operable to seal against the generally conically-shaped portion of the second end of the spring housing and the non-metallic sealing ring when the flapper is in the closed position.

12. The subsurface safety valve apparatus of claim 11, wherein the non-metallic sealing ring comprises a flanged end, the flanged end further comprising at least one notch.

13. The subsurface safety valve apparatus of claim 12, wherein the second end of the spring housing comprises at least one concentric slot capable of receiving the flanged end of the non-metallic sealing ring.

14. The subsurface safety valve apparatus of claim 11, wherein the retainer ring comprises at least one tab.

15. The subsurface safety valve apparatus of claim 14, wherein the second end of the spring housing comprises at least one groove operable to receive the at least one tab of the retainer ring thereby locking the retainer ring in position adjacent to the non-metallic sealing ring.

16. A method of sealing the central bore of production tubing against fluid flowing from a wellbore towards the surface, the method comprising: attaching a safety valve assembly to the production tubing, the safety valve assembly comprising a spring housing having a lower portion that exhibits a generally conical shape, a non-metallic sealing ring concentrically located around the generally conically-shaped portion of the spring housing, a retainer ring adapted to retain the non-metallic sealing ring around the generally conically-shaped portion of the spring housing, and a flapper connected to the lower portion of the spring housing, the flapper operable to rotate between an open and closed position;placing the safety valve assembly and the production tubing in a wellbore; andclosing the flapper such that the flapper seals against the generally conically-shaped portion of the spring housing and the non-metallic sealing ring thereby substantially preventing fluid from flowing from the wellbore towards the surface through the central bore of the production tubing.

17. The method of claim 16, wherein the non-metallic sealing ring of the safety valve assembly further comprises a flanged end, the flanged end further comprising at least one notch.

18. The method of claim 17, wherein the lower end of the spring housing of the safety valve assembly further comprises at least one concentric slot capable of receiving the flanged end of the non-metallic sealing ring.

19. The method of claim 18 further comprising the step of providing a gap between the flanged end of the non-metallic sealing ring and the at least one concentric slot of the lower end of the spring housing.

20. The method of claim 16, wherein the retainer ring of the safety valve assembly further comprises at least one tab, and the lower end of the spring housing of the safety valve assembly further comprises at least one groove operable to receive the at least one tab of the retainer ring thereby locking the retainer ring in position adjacent to the non-metallic sealing ring.