Abstract:
A bi-directional fluid safety valve for preventing spillage when filling tanks, vessels, fill lines, and or hoses for transportation of fluids in pipelines or tubulars with a tubular body with an external body and an internal bore having a fluid flow path from a first end to a second end, the first and second members concentrically disposed and moveable along a longitudinal axis within the tubular body; with means such as springs to longitudinally bias the first member toward the second member and means to longitudinally bias said second member toward said first member. Also provided are embodiments for connection of the tubular body to alternative connection systems.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to valves and more specifically to valves for preventing spillage when filling tanks, vessels, fill lines, and or hoses for transportation of fluids in pipelines or tubulars (Generically known or defined as OCTG). The present invention also relates to an apparatus and a method used in the completion of an oil, gas or geothermal well bore. More particularly, the invention relates to a tubular (OCTG) fill-up and circulating tool. More particularly still, the present invention relates to a “Fluid Safety Valve” that can be inserted into a tubular (OCTG), can also be attached to a Kelly or top-drive, fluid or gas containment tank, vessel, fill lines and or hoses for the transportation of fluids, including but not limited to a fill-up and or circulating tool. 
       DESCRIPTION OF THE RELATED ART 
       [0002]    In the drilling of oil, gas or geothermal well, a wellbore is formed using a drill bit that is urged downwardly at the lower end of a drill string. After drilling the wellbore to a predetermined depth, the drill string and bit are removed. Thereafter, the wellbore is typically lined with a string of steel pipe called a tubular (OCTG). The tubular (OCTG) provides support to the wellbore and facilitates the isolation of certain areas of the wellbore adjacent hydrocarbon bearing formations. 
         [0003]    During the run-in of a tubular (OCTG) string, the tubular (OCTG) string is typically filled with mud. The primary reason to fill the tubular (OCTG) string with drilling mud or fluid is to prevent the new tubular (OCTG) from collapsing due to the pressure imbalances between the inside of the tubular (OCTG) and the wellbore fluid there around and avoidance of buoyancy. Typically, the filling process occurs as the tubular (OCTG) string is assembled at the rig floor. A secondary reason to fill the tubular (OCTG) string with drilling mud or fluid is to use the drilling mud or fluid to free tubular (OCTG) string when the tubular (OCTG) becomes stuck during the run-in operation. In this situation, the drilling operator circulates drilling mud or fluid down the tubular (OCTG) to wash sand or other debris from the lowermost end of the tubular (OCTG), thereby freeing the stuck tubular (OCTG). 
         [0004]    Typically, a fill-up and circulating tool is used in conjunction with a mud pump to fill and circulate the mud in the tubular (OCTG). An example of a fill-up and circulating tool is described in U.S. Pat. No. 6,173,777 and U.S. Pat. No. 6,832,656 B2. 
         [0005]    Generally, the mud pump is turned off while the fill-up and circulating tool is still in the tubular (OCTG), thereby allowing all the mud in the mud pump and the connecting hose to flow through the tool into the tubular (OCTG). However, a problem associated with the above referenced fill-up and circulating tool arises when the tool is suddenly or accidentally removed from the tubular (OCTG) prior to shutting down of a mud pump. In this situation, a pressure surge is created in the tool due to the closed valve, thereby causing the mud pump to stop. This pressure surge may cause catastrophic failure of the mud pump or other hydraulic components. Another problem arises after the tubular (OCTG) is filled with mud. Typically, the tool is pulled out of the tubular (OCTG) and the valve arm drops down to close the valve member. However, if the mud pump is not properly turned off to allow the mud in the connecting hose to exit the tool prior to removal of the tool from the tubular (OCTG), the volume of mud continues to enter the tool. Because the valve member is closed, the mud is prevented from exiting the tool. As a result, the pressure in the tool may become so large as to cause the hose to burst, thereby causing damage to the equipment or injury to personnel on the rig floor. 
         [0006]    It is also the case today that when flowing fluids into or out of, to or from a tank or vessel or standing open pit you cannot simply allow the gases or fluids to vent into the atmosphere as the resultant fumes or fluids could be toxic to animals or humans. They could also cause or pose an environmental concern or seepage into the ground. It would therefore be necessary or precautionary to interconnect one or more tanks, vessels or compartments to allow a collective combination of fluid or gas mixtures to be collected and stored. While a secondary means of identifying the amount of fluid or gas is present in a tank would be to deploy a monitoring device, however monitoring or sounding an alarm may not prevent an over pressure situation and or resultant catastrophic failure to occur. In the case of a well bore in an oil, gas or geothermal well should the drilling rig operations encounter an unexpected pocket of gas down hole and take an exceptional return of fluids to surface, monitoring the fluid containment in a tank alone could still lead to an over-pressurization situation. Deployment of a device such as is embodied in this present invention would alleviate the situation by automatically opening or closing the fluid safety valve as required depending on the situation or closure of the valve whilst aligning a secondary tank, vessel or pipeline for the fluid containment. 
         [0007]    There is a need, therefore, for a valve that will prevent a pressure surge in the mud system when the tool is accidentally removed from the tubular (OCTG). There is a further need for a valve that will permit a volume of drilling mud or fluids in the tank, vessel or hose to exit the system even though the valve is closed. There is yet a further need for a more reliable fill-up, circulating or pressure relieving tool or apparatus. 
       BACKGROUND OF THE INVENTION 
       [0008]    In the world that we live in today, safety and environmental issues are of paramount importance. During filling operations of tanks, vessels, fill lines, hoses, pipelines or tubulars for transportation of fluids that are harmful to personnel or the environment, it is necessary to use a valve which precludes spillage when the hose or transportation device is disconnected from the structure being filled. These valves must also allow fluid to flow in the reverse direction to prevent over pressuring. For these reasons, these types of valves are generally referred to as fluid safety valves or pressure relieving valves. 
         [0009]    In one application the filling and or circulation operations of tubulars (OCTG) used primarily for the drilling and completing of oil and gas or geothermal wells, where it is necessary to run or pull tubulars (OCTG) into or out of a wellbore. When running tubulars into or out of the wellbore, it is common to fill each joint with drilling or wellbore fluid (also known as drilling mud). The drilling or wellbore fluid is a mixture of various chemicals required to support varying operations or conditions which often contain elements of a high viscous nature. When introduced to valves or restrictions, the drilling or wellbore fluid can be highly corrosive or abrasive especially when transported or delivered under pressure. A valve is normally installed below the Kelly or top drive to prevent the discharge of the drilling or wellbore fluid from spilling onto the rig floor where it is a hazard to personnel and the environment. These valves allow drilling or wellbore fluid to flow into the tubular (OCTG) while pumping but will automatically close when pumping is discontinued. These types of valves are known as “Standing or Mud Saver Valves”. There are numerous prior art patents for these types of valves. These prior art designs generally include a closure member, an abutting seat member, and a means for urging the closure member toward the seat. The prior art also tended to have no matched flow capability in opposing directions, bi-directional reverse flow capability, and a restricted or reduced flow through bore and could only be used in a vertical application. 
         [0010]    Each of the prior art valves disclose many advantages and enhancements in safety and or valve designs. However, each of the valves has certain shortcomings. The main shortcoming being the lack of a matched full flow through the valve cavity, pressure balancing, bi-directional capability and no restrictions on plane of operation. 
         [0011]    A second shortcoming is the lack of wear resistance. Many drilling or wellbore fluids, especially those used in drilling applications, contain elements of a high viscous nature and high solids content. These solids can be sand, barite, and a variety of other chemical materials used to create higher density fluids. These types of fluids can be very abrasive and therefore erosive. Prior art designs contain sharp edges, irregular or nonlinear flow paths, small cross sectional flow areas, or all of the aforementioned, causing turbulence within the valve. The combination of these factors leads to premature wear and ultimately failure. 
         [0012]    A third disadvantage to prior art designs is that the seat is held rigid as it is encountered by the closure member when the valve closes. This rigidity can cause a violent impact between the closure member and the seat. These impacts cause severe wear to the sealing surfaces leading to a possible catastrophic failure of the valve. 
         [0013]    A fourth disadvantage to prior art designs is the closure member does not have a mechanical means to limit its axial movement. This creates two problems. First, the spring urging the closure member towards the abutting seat can be compressed further than the spring manufacturer&#39;s recommended deflection, overstressing the spring, causing it to fail. Secondly, the lack of a limiting means causes chattering of the closure member against the seat, thereby causing premature failure wear. This is due to the pump pressure forces being constantly resisted by the spring. As the pump pressure fluctuates, the closure member correspondingly moves closer to and away from the seat. When the pump pressures and or flow rates are such that these fluctuations occur while the closure member is very close to the seat, chattering occurs. This chattering effect is detrimental to the sealing surfaces and can lead to catastrophic failure of the valve. 
         [0014]    A fifth disadvantage to prior art designs is the lack of ability to have a full flow capability in reverse flow or the cross sectional area for reverse flow is very small. These restricted fluid flow passages increase the amount of time necessary to relieve the pressure built up or trapped and again lead to catastrophic failure of the valve, tank or containment vessel. 
         [0015]    A sixth disadvantage to prior art designs is the absence of a means to adjust to pressures or flow rates at which the valve opens in both directions. Many valves use a ball type check for reverse flow that relies on gravity to hold it firmly against its seat. This provides no means of adjusting the pressure at which the check opens. It also will not function in orientation other than vertical. 
         [0016]    A seventh disadvantage to prior art designs is the chamber or cross sectional space housing the closure member spring is not sealed from the fluids being circulated. The circulation of fluids laden with sand or other solids can cause build up of these solids around the coils of the spring. This can reduce the deflection of the spring causing the flow area between the closure element and the seat to become restricted. This build up can also completely eliminate the spring deflection blocking all flow through the valve and can lead to potential catastrophic failure of the valve or associated equipment. 
       SUMMARY OF THE INVENTION 
       [0017]    A valve for safely filling tanks, vessels, or tubulars is disclosed remediating the foregoing disadvantages. The valve opens to permit the flow of fluids upon activation of the pump and closes automatically upon ceasing pumping to prevent drainage. It also allows fluid to flow in the reverse direction to relieve any pressure that may be contained in the tank, vessel, or tubular. The valve is pressure activated by engaging the pump to overcome a spring bias to enable flow in the forward direction. The valve also permits reverse flow by also overcoming a predetermined spring bias. 
         [0018]    It is an object of the present invention to provide a valve to be used below a top drive to permit forward and reverse fluid flow into or out of a well bore while the top drive, or associated piping is connected to the drill string and to prevent spillage onto the rig floor when the top drive is disconnected from the drill string. 
         [0019]    It is another object of the present invention to provide a valve to be used in filling and or circulating tubulars (OCTG) while it is nm into a wellbore which permits forward and reverse fluid flow while the top drive, a casing running tool (CRT), or associated fill-up and circulating tools or piping are directly or indirectly connected to the tubular (OCTG) while preventing spillage onto the rig floor when the top drive, casing running tool, or associated piping is disconnected from the tubular (OCTG). 
         [0020]    It is also an object of the present invention to provide a valve to be used as a fill up and circulating tool for the running of tubulars (OCTG) into or out of a surface or sub-sea wellbores. 
         [0021]    It is also an object of the present invention to provide a valve to be used while filling tanks, vessels, fill hoses, piping or pipelines. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  is a longitudinal cross sectional view of a first embodiment of the invention shown in the closed position. 
           [0023]      FIG. 2  is a longitudinal cross sectional view of a first embodiment of the invention shown in the open position by fluid flow in the forward direction. 
           [0024]      FIG. 3  is a longitudinal cross sectional view of a first embodiment of the invention shown in the open position by fluid flow in the reverse direction. 
           [0025]      FIG. 4  is a longitudinal cross sectional view of a second embodiment of the invention shown in the closed position. 
           [0026]      FIG. 5  is a longitudinal cross sectional view of a third embodiment of the invention shown in the closed position. 
           [0027]      FIG. 6  is a longitudinal cross sectional view of a fourth embodiment of the invention shown in the closed position. 
           [0028]      FIG. 7  is a longitudinal cross sectional view of the fourth embodiment of the invention shown in the closed position mounted within a housing. 
           [0029]      FIG. 8  is a top view of an embodiment of the poppet of the invention. 
           [0030]      FIG. 9  is a side elevation view of an embodiment of the poppet of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0031]      FIG. 1  illustrates a first embodiment of inventive valve  10  which has an external tubular body  13  with an internal bore  32  or flow path, having a first end  61  and a second end  62 . Internal bore  32  allows fluids to transfer from a pump to the structure being filled. As fluid is being pumped in a forward direction as illustrated by lines  27  on  FIG. 2 , it encounters a first member  12 , hereinafter referred to as a poppet. Poppet  12  is concentrically located within the tubular body  13  and shares the same central axis  49  with a second element  11 , hereinafter referred to as a closure element, making poppet  12  and closure element  11  concentric with one another. As the fluid passes poppet  12 , it encounters closure element  11 . Closure element  11  is urged longitudinally toward poppet  12  via closure element spring  14 , thereby resisting movement until such time as the differential pressure of the fluid exceeds the spring force of the closure element spring  14 . Poppet  12  is urged longitudinally toward the closure element  11  via poppet spring  15 . Closure element  11  and poppet  12  are permitted to travel independently of one another along their central axis  49 . Closure element  11  and poppet  12  abut at  23 . Closure element  11  is sealed to the internal bore surface  47  of body  13  via sealing element  19 . Sealing element  20  fowls a seal between the closure element limiting structure  16  and the outside diameter  51  of closure element  11 . Poppet spring  15  is held in place via retaining device  18 . Retaining device  18  is illustrated as a snap ring. Retaining device  18  may be of various forms such as threaded sleeves, press fit sleeves, etc. It must be noted that due to the design of this inventive valve, fluid is allowed to flow in both directions. This feature makes the inventive valve bi-directional. 
         [0032]    The spring rates of poppet springs  15  and closure element spring  14  are selected to permit the inventive valve to open at predetermined differential pressures. These spring rates can be selected to open the inventive valve in the forward and reverse directions at the same or different differential pressures. 
         [0033]    Threaded area  25  and threaded area  21  are provided as a means to connect the inventive valve  10  to a tank, vessel, fill line, hose, pipeline or tubular. Threaded areas  21  and  25  are merely as illustration as many other connection means may be used. Other connection means include couplers, cam-lock couplers, quick connects, clamps, barbed, unions, “WECO®” or “Hammer” unions, or many others as commonly used in industry. These various connection means may be integral to or in conjunction with external tubular body  13 . It must be noted that the inventive valve  10  may be used in either direction based on the application. The inventive valve is self contained, sealed and can also be installed in-line as illustrated in the drawings by various means of connection including but not limited to threaded connections, swage type connections, cross-overs or containment within a separate body integral or independent of a tubular (OCTG). Similarly the inventive valve could be used for surface operations or downhole applications 
         [0034]      FIG. 2  is an illustration of a first embodiment of the inventive valve  10  in the opened position due to forward flow  27 . In this position, the poppet  12  and closure element  11  have travelled in the direction of flow  27 . The poppet  12  travels until surface  30  of poppet  12  comes into contact with shoulder  29  of body  13 . The closure element  11  travels until surface  28  of closure element  11  comes into contact with surface  22  of closure element limiting structure  16 . In this position, clearance is provided between surface  33  of poppet  12  and surface  34  closure element  11 , thereby permitting fluid to flow  27  between the poppet  12  and closure element  11 . The fluid then exits apparatus at bore  31 . The travel of closure element  11  is limited such that closure element spring  14  remains within the spring manufacturer&#39;s recommended maximum deflection values. This feature prevents the closure spring  14  from becoming overstressed and permanently setting or ultimately failing the spring  14 . It will be observed that the closure element  11  will return towards the poppet  12  once the pump is disengaged. This is due to the closure element spring  14  biasing the closure element  11  towards poppet  12 . Springs are the preferred means of biasing the both the poppet  12  and the closure element  11  towards one another, but other means for exerting a force may be used. It must be noted that the velocity of the closure element  11  will be slowed by poppet  12  while returning to the position as illustrated in  FIG. 1 . This slowing effect is due to the poppet spring  15  biasing the poppet  12  toward closure element  11 . This slowing effect removes the abrupt impact due to the rigidity as in prior art designs. This unique feature significantly reduces the wear on surface  33  of the poppet  12  and surface  34  of the closure element  11 , thereby vastly increasing the longevity and reliability of the inventive valve. 
         [0035]    Referring to  FIG. 2  the surface  35  of the closure element  11  and surface  36  of body  13  are illustrated in  FIG. 2  as flat shoulders, but may however be tapered or radiused to reduce the internal fluid turbulence. The same holds true for surface  28  of closure element  11  and surface  22  of closure element limiting device  16  as well as surface  30  of poppet  12  and surface  29  of housing  13  as shown in  FIG. 1 . All internal edges, lines, tapers, etc. may be rounded or made more gradual to reduce the turbulence within the inventive valve. The edges or shoulders illustrated in  FIG. 1  through  FIG. 9  are merely shown for clarity and understanding of the figures presented. The edges or shoulders illustrated in  FIG. 1  through  FIG. 9  are also shown to display the function and features of the inventive valve. 
         [0036]      FIG. 3  is an illustration of a first embodiment of the inventive valve  10  in the open position due to reverse flow  37 . In this position, the poppet  12  has travelled in the direction of flow  37 . The poppet  12  travels until surface  38  of poppet  12  comes into contact with surface  39  of poppet spring limiting device  18  and surface  52  of poppet spring limiting device contacts surface  53  of retaining device  18 . In this position, clearance is provided between surface  33  of poppet  12  and surface  34  closure element  11 , thereby permitting fluid to flow between the poppet  12  and closure element  11 . The fluid then exits the inventive valve at bore  32 . The travel of poppet  12  is limited such that poppet spring  15  remains within the spring manufacturer&#39;s recommended maximum deflection values. This feature prevents the poppet spring  15  from becoming overstressed and permanently setting or ultimately failing the spring. It will be observed that the poppet  12  will return towards the closure element  11  once the pump is disengaged. It must be noted that the impact generated when surface  33  of poppet  12  contacts surface  34  of the closure element  11  will be softened by closure element spring  14 . This cushioning effect significantly reduces the wear on surface  33  of the poppet  12  and surface  34  of the closure element  11 , thereby vastly increasing the longevity and reliability of the inventive valve. 
         [0037]      FIG. 4  is an illustration of a second embodiment of the inventive valve  50  that utilizes a male coupling feature  40  located on housing  41  to facilitate the easy on and off connection of a coupler, commonplace in industry, such as a cam-lock type coupler. 
         [0038]      FIG. 5  is an illustration of a third embodiment of the inventive valve  60  that utilizes a bull-nose feature on closure element limiting device  43  to facilitate the easy insertion of the apparatus into an opening of a tank, vessel, tubular, etc. 
         [0039]      FIG. 6  is an illustration of a fourth embodiment of the inventive valve  70  that is designed as a self contained cartridge. This self contained inventive valve  70  may be inserted into a housing, tubular, pipe, pipeline, casing, sub, or any fluid flow transportation system or device. 
         [0040]      FIG. 7  is an illustration of the inventive valve  70  as described in  FIG. 6  mounted within housing  46 . It must be noted that the illustration of the housing is merely to serve as one example of the many mounting possibilities. It must also be noted that the orientation of the inventive valve  70  within housing  46  may be reversed. 
         [0041]      FIG. 8  is a top view of poppet  12  illustrating the vane features  58 . It must be noted that four vanes  58  are shown but only two are required. Therefore, poppet  12  may contain two or more vanes  58 . 
         [0042]      FIG. 9  is a side elevation view of poppet  12  illustrating one embodiment. This embodiment includes a spherical or domed shape feature  56  on one end and a flat surface  57  on the other. The flat surface  57  may be of the same or different profile as that of surface  56 . Surface  33  is illustrated as a chamfer or conical surface, but may be of different profiles. Surface  33  may be spherical or domed shape, flat, or a variety of other profiles. Surface  33  may be coated with a wear resistant material or may have a wear resistant material such as carbide imbedded in or mounted to this surface. Likewise, as shown in  FIG. 2 , surface  34  of closure element  11  may also be coated with a wear resistant material or may have a wear resistant material such as carbide imbedded in or mounted to this surface. Surface  34  of closure element  11  is illustrated as a chamfer or conical profile but may too be flat, spherical, domed shaped, etc.