Abstract:
A rotationally actuated flapper valve including a flapper; a sinuous edge perimetrically about the flapper; and a congruous sinuous edge disposed at another component of the valve, the component being rotatable to misalign the congruous sinuous edge with the sinuous edge of the flapper whereby the flapper is urged out of a closed position and method.

Description:
BACKGROUND 
     Valves such as fluid loss control valves, safety valves, shut-off valves, etc. are very well known in downhole industries and especially so in the hydrocarbon recovery industry. Commonly, valves including but not limited to safety valves comprise a flapper and a flow tube operably configured to work together in a housing. The flapper can be driven off its seat by extension of the flow tube through the flapper. Although traditional safety valve configurations are ubiquitous and function well for their intended purpose, there is significant expense involved in manufacture due to material volume, machining work, etc. Reduction in costs while retaining function of flapper based valves will be welcomed by the art. 
     SUMMARY 
     A rotationally actuated flapper valve including a flapper having a non planar interaction surface thereon; a congruous component of the valve, the interaction surface and the congruous component being selectively alignable and misalignable and when misaligned the flapper is at least partially open. 
     A rotationally actuated flapper valve including a flapper; a sinuous edge perimetrically about the flapper; and a congruous sinuous edge disposed at another component of the valve, the component being rotatable to misalign the congruous sinuous edge with the sinuous edge of the flapper whereby the flapper is urged out of a closed position. 
     A method for actuating a flapper of a valve includes rotating one component of the valve relative to another component of the valve, the rotating causing misaligning if aligned or aligning if misaligned a nonplanar surface on one of the flapper or another component of the valve; and encouraging the flapper to another position pursuant to the rotating. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Referring now to the drawings wherein like elements are numbered alike in the several figures: 
         FIG. 1  is a partial cross sectional view of an embodiment of a rotationally-actuated flapper valve in a closed position; 
         FIG. 2  is the valve of  FIG. 1  illustrated in a partially open position; 
         FIG. 3  is the valve of  FIG. 1  in a fully open position; 
         FIG. 4  is a perspective view of the valve that illustrated a valve pivot; 
         FIG. 5  is an alternate embodiment of a rotationally-actuated flapper valve in a partially open position; 
         FIG. 6  is the valve of  FIG. 5  in a fully open position; 
         FIG. 7  is a perspective view of another alternate embodiment of a rotationally actuated flapper in a fully open position; 
         FIG. 8  is a cross sectional view of the valve of  FIG. 7  in a partially open position; 
         FIG. 9  is another cross sectional view of the valve of  FIG. 7  in a fully open position; 
         FIG. 10  is cross sectional view of another alternate embodiment of the rotationally actuated valve in a partially open position; 
         FIG. 11  is a view of a portion of the valve illustrated in  FIG. 10  with components in a position where the valve is fully open. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , an embodiment of the rotationally actuated flapper valve  10  is illustrated in a fully closed position with a flapper  12  engaged with a flapper seat  14 . Each of the flapper  12  and the seat  14  are embodied with a sinuous edge  16  and  18 , respectively. These edges are perimetrical about the flapper and seat and are generally congruous shapes, and in one embodiment are complementary shapes. When the flapper and seat are aligned, the flapper may be closed against the seat and in some embodiments will seal there against. Rotation of the seat or the flapper will cause the flapper and seat to move apart hence opening the flapper  12  to a degree. The degree to which the flapper opens is dependent in part of the angle of the slopes of the sinuous edges  16  and  18 . Angles approaching 45 degrees will permit the greatest flapper displacement and hence the greatest angular change relative to the seat  14 . Maximum movement of the flapper due to contact between edges  16  and  18  is achieved when a highest point of the sinuous edge  16  on flapper  12  is aligned with the highest point of the sinuous edge  18  on the seat  14 . 
     Misalignment of the flapper and the seat causes a lack of ability to seal and in fact can be used to cause the flapper to open, as is the intent in this embodiment. The high points of the sinuous edges  16  and  18  interfere with one another to cause a pivoting movement of the flapper  12  about a pivot  20  (see  FIG. 4 ). 
     In the embodiment illustrated in  FIGS. 1-4 , the valve  10  is depicted in the closed, partially open and open positions to provide a clear understanding of the valve  10 . In this embodiment the configuration relies upon the sinuous edge detail  16  and  18 , a helical groove  22  and a groove follower  24 , and a helical spur gear  26  driven by a suitable drive  28 . 
     Operation is best described sequentially referring to  FIGS. 1-3 . In  FIG. 1 , the flapper  12  is closed and the seat  14  is at a position relative to the housing and the flapper that allows the flapper to engage in a sealing relationship with the seat  14 . Upon actuation of a drive  28 , which may be an electric motor (illustrated with electrical connections  30  and  32  in  FIG. 1 ), hydraulic motor (illustrated with hydraulic fluid inlet  34  and outlet  36  in  FIG. 2 ), etc. that is in driving communication with the spur gear  26 , the seat  14  rotates about its own axis thereby misaligning the sinuous edge  18  of the seat  14  with the sinuous edge  16  of the flapper  12 . This causes the flapper  12  to be urged in an axial direction away from the seat  14 . Because the flapper  12  is hingedly connected to a housing  38  within which the seat  14  rotates, the flapper will pivot about pivot  20  pursuant to the axial load thereon. The degree of pivot of the flapper  12  is, as noted above, related to the angle of the sinuous edges but it is often less than fully open due to limitations of possible slopes. Limitations may be related to geometry alone or may be related to frictional increases, as the slope gets steeper. In order to efficiently achieve a fully open condition as illustrated in  FIG. 3 , the seat  14  moves axially at the same time that it moves rotationally. This occurs pursuant to the follower  24  riding in helical groove  22  as the drive  28  forces the seat  14  to rotate. The spur gear  26  is helically configured in order to stay engaged with the drive  28  as the seat  14  changes position axially. Because the seat  14  moves in the direction of the flapper, the contact point  40  between the seat  14  and the flapper  12  continues to urge the flapper  12  until it is fully open as shown in  FIG. 3 . 
     The flapper is closed in this embodiment by a return spring  42 , visible in  FIG. 4 . 
     Referring now to  FIGS. 5 and 6 , an alternate embodiment that rotationally actuates two opposed flapper valves simultaneously is illustrated. It will be apparent to one having read the foregoing that this embodiment includes a mirror image of the components in the first discussed embodiment. A single drive  28  actuates both of the mirrored configurations and they operate identically to each other but in opposite directions. For clarity each of the components in the mirrored section are endowed with a 100 series equivalent of the numerals used in the first described embodiment. 
     Referring to  FIGS. 7-9 , yet another embodiment of a rotationally actuated flapper valve is illustrated. In  FIG. 7 , a perspective view with the valve open provides an overview of the configuration. The valve  210  includes a flapper  212  and a flapper seat  214 . The flapper seat in this embodiment is distinct from those in the previously described embodiments in that it employs a ramp sleeve  250 , which is rotatable to cause full open movement of the flapper  212 . The flapper is still initially motivated by rotational movement of the seat  214  but in order to move the flapper to the fully open position, the sleeve is added. The sleeve  250  is also the motivator for the seat  214  as it is connected to the seat  214  through fingers  251 . Sleeve  250  includes, in one embodiment, a ring gear (or at least a partial ring gear)  252  extending annularly about the sleeve  250 . The ring gear  252  is employed to cause rotation of the sleeve  250  and thereby open or close the flapper  212 . Any suitable drive may be employed to actuate the ring such as the drive  28  illustrated in the foregoing embodiments. In the sleeve  250  is formed an angular groove or opening  254 . As illustrated, the configuration is an opening that extends completely through the sleeve  250  but it can also be configured to be a recess into the sleeve from the inside dimension surface of the sleeve  250 , if desired. In any event, the groove  254  is of complex shape in one embodiment wherein the groove  254  both is helically configured relative to the sleeve axial direction and is also angled relative to that axial direction as illustrated in  FIG. 9 . Numerals  256  and  258  designate particular walls of the groove  254 . In  FIG. 9 , the observer can see the angle of the walls. The angles seen in  FIG. 9  are relatively steep while the angle of the same walls in an area of the walls that can be seen in  FIG. 8  is substantially less steep. This is so because the walls are configured to provide a surface upon which a cam, which may be a cam roller  260  as illustrated, can bear with a load normal to the wall during movement of the flapper  212 . Referring to  FIG. 8 , the cam roller&#39;s position relative to the flapper  212  is apparent. The cam roller  260  is supported by an extension  262  of the flapper  212  located opposite the location of the body of the flapper relative to the pivot  220 . Therefore, a movement of the extension  262  in one direction will cause movement of the flapper  212  in an opposite direction. By urging the cam roller  260  to either end of the groove  254  from the central region of the groove causes the roller to climb the angled groove and urge the flapper  212  into an open position. During the movement of flapper  212  about pivot  220  (see  FIGS. 8 and 9  sequentially) the cam roller  260  is moved to a significantly different orientation. The groove  254  is configured to match the motion of the cam roller by keeping the walls  256  and  258  normal to the roller  260  in order to improve efficiency of mechanical movement. Reversal of movement of the sleeve  250  will close the flapper  212  by urging the cam roller  260  back to a central location  264  of the groove  254 . 
     Referring now to  FIGS. 10 and 11 , another alternate embodiment of the rotationally actuated flapper valve  310  is illustrated. In this embodiment, a flapper  314  is similar to those in the foregoing embodiments in that a sinuous edge  316  is included. Edge  316  mates and in some embodiments seals with a congruous (or in one embodiment complementary) edge  318 , that is configured at an end of a flow tube  370 , when the flapper is aligned and closed. The flow tube  370  is rotationally and axially moveable within a housing  372  and is biased to a valve closed position by a biasing member  374  such as a coil spring as illustrated. The flow tube  370  includes a biasing member attachment feature  376  such as a flange as shown. The tube  370  is constrained to rotational movement for a number of degrees of rotation when the valve is in the closed position by a groove  378  in a constraint sleeve  380 . It is to be appreciated that the groove  378  is configured to extend laterally along the constraint sleeve  380  for a number of degrees and then to extend axially of the sleeve  380 . This ensures that the flow tube  370  must rotate first and then extend longitudinally pursuant to rotational actuation explained further hereunder. The movement of the flow tube  370  first begins to open the flapper  312  due to misalignment of the sinuous edges  316  and  318  as is the case in the foregoing embodiments and then the flapper is openable fully by the extension of the flow tube through the seat  314  with inherent protection of the flapper behind the flow tube in the fully open position. Extension of the flow tube  370  only occurs when the constraint sleeve  380  allows that movement. This requires that a lug on the flow tube  382  that is engaged with the groove  378  has moved rotationally far enough for the lug to have moved into the axial portion of the groove  378 . 
     Initiating the movement just described is a drive  328 , which may be an electric motor, hydraulic motor, etc. as in the foregoing embodiments engaged with a gear  352 . Careful reference to  FIGS. 10 and 11  will reveal that the flow tube  370  is in close concentric communication with a drive tube  384 . The flow tube  370  includes a helical profile  386  and the drive tube  384  includes a helical profile  388 . The profiles  386  and  388  are congruous and in one embodiment complementary to one another and in any event are configured so that the rotational movement of the drive tube  384  will transfer rotational motion to the flow tube  370  and when permitted by the constraint sleeve  380  will cause axial motion. The axial motion is due to a climbing of each profile relative to the other similar to a large pitch captured nut jack screw arrangement. 
     In operation, and beginning from a closed flapper position, the drive  328  is actuated to impart rotational motion to the drive tube  384 . Because the flow tube is constrained in axial movement due to constraint sleeve groove  378 , the movement of the flow tube is solely rotational. The rotational movement misaligns the sinuous edges  316  and  318  causing the flapper  312  to partially open. When the rotational movement just described succeeds in moving the lug  382  to the axially oriented portion of the groove  378 , further rotational movement of the flow tube is prevented by the constraint sleeve  380 . At this point in actuation of the valve  310 , the rotational movement of drive tube  384  is translated to axial movement of the flow tube  370  by the action of the profiles  386  and  388 . The flow tube  370  is then axially extended through the flapper  314  a sufficient distance to fully open and protect the flapper  312 . This position is illustrated in  FIG. 11  where the flapper  314  in a completely open position is illustrated behind the flow tube  370  and the spring  374  is illustrated compressed. Further, an axial distance between flange  376  and gear  352  can be seen to have increased from  FIG. 10  to  FIG. 11 . Depending upon the degree to which opening of the flapper is desired; the axial extension portion of this embodiment may or may not be employed. It is possible to simply employ the rotational portion by rotating the flow tube directly with a drive. 
     While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.