DEVICE AND METHOD FOR USING A MAGNETIC FIELD SENSOR TO DETERMINE THE HEALTH STATE OF A SAFETY VALVE IN DOWNHOLE APPLICATIONS

Abstract

A safety valve, well system, and method are provided. The safety valve, in one aspect, includes an outer housing, a bore flow management actuator disposed within the outer housing, and a valve closure mechanism disposed within the outer housing. The safety valve, in accordance with this aspect, further includes one or more permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve, and one or more magnetic field sensors coupled to another of the fixed feature of the safety valve or the movable feature of the safety valve and positioned proximate to the one or more permanent magnets, the one or more magnetic field sensors configured to detect movement of the movable feature to determine the health of the safety valve.

Description

Title of the invention: DEVICE AND METHOD FOR USING A MAGNETIC FIELD SENSOR TO DETERMINE THE HEALTH STATE OF A SAFETY VALVE IN DOWNHOLE APPLICATIONS. REFERENCE TO A RELATED APPLICATION.

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 614,266, filed on December 22, 2023, entitled "WIRELINE RETRIEVABLE ELECTROMAGNETIC SAFETY VALVE", U.S. Provisional Application Serial No. 63 / 614,231, filed on December 22, 2023, entitled "METHODS FOR PREDICTING THE HEALTH OF A SUBTERRANEAN SAFETY VALVE IN DOWNHOLE APPLICATIONS", U.S. Provisional Application Serial No. 63 / 616,026, filed on December 29, 2023, entitled "METHODS FOR PREDICTING THE HEALTH OF A SUBTERRANEAN SAFETY VALVE IN DOWNHOLE APPLICATIONS", and U.S. Provisional Application Serial No. 63 / 616,026, filed on December 29, 2023, entitled "METHODS FOR PREDICTING THE HEALTH OF A SUBTERRANEAN SAFETY VALVE IN DOWNHOLE APPLICATIONS", Serial number is 63 / 632,224, filed on April 10, 2024, titled "METHODS FOR PREDICTING THE HEALTH CONDITION OF A SUBSURFACE SAFETY VALVE IN DOWNHOLE APPLICATIONS USING ONE OR MORE MAGNETIC ANGLE SENSORS." BACKGROUND

[0002] Downhole devices, such as subsurface safety valves (SSSVs), are well known in the oil and gas industry and are one of several fail-safe mechanisms to prevent the uncontrolled release of subsurface production fluids, if a wellbore system experiences a loss of containment. In some cases, SSSVs comprise a portion of a production string, with the entire SSSV being deployed upon completion of a wellbore. In other cases, SSSVs are deployed / retrieved by wireline. While a number of design variations are possible for SSSVs, the vast majority are flapper valves that open and close in response to longitudinal movement of a flowtube.

[0003] Since SSSVs generally provide a fail-safe mechanism, the default positioning of the gate valve is generally closed to minimize the risk of accidental release of subsurface production fluids. The gate valve may be opened by various control means from the earth surface to provide a flow path for production. Which is necessary in the technique, it is an improved SSSV which does not suffer from the problems of existing SSSVs. BRIEF DESCRIPTION

[0004] Reference is now made to the following descriptions, taken in conjunction with the accompanying drawings, in which:

[0005] [Fig.lA] shows that the sensitivity of magnetic amplitude sensors can vary depending on temperature changes;

[0006] [Fig. IB] shows that the angle generated by a magnetic field is robust to temperature changes and to a variable (but known) distance between the magnet and the angle sensor; and

[0007] [Fig.lC] illustrates a well system designed, manufactured and / or operated according to one or more embodiments of the disclosure;

[0008] [Fig.2A], [Fig.2B], [Fig.2C], [Fig.2D], [Fig.2E] and [Fig.2F] illustrate a mode of production of a downhole device, comprising a safety valve designed, manufactured and / or operated according to one or more embodiments of the disclosure;

[0009] [Fig.3A] and [Fig.3B] illustrate one embodiment of a downhole device, comprising a safety valve designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure;

[0010] [Fig.4A], [Fig.4B] and [Fig.4C] illustrate graphs showing ideal measurements of the velocity / acceleration of the main body of the flow tube as a function of time (e.g., [Fig.4A]), an actual measurement of the velocity / acceleration of the main body of the flow tube as a function of time (e.g., [Fig.4B]), and a comparison of the ideal measurements of the velocity / acceleration of the main body of the flow tube as a function of time and the actual measurement of the velocity / acceleration of the main body of the flow tube as a function of time (e.g., [Fig.4C]);

[0011] [Fig.5A], [Fig.5B], [Fig.5C] and [Fig.5D] illustrate an embodiment of a safety valve designed and manufactured according to one or more alternative embodiments of the present disclosure;

[0012] [Fig.6] illustrates one embodiment of an inflow control valve (ICV) designed, manufactured, and / or operated in accordance with one or more embodiments of the illustrated disclosure, and which may take advantage of the one or more magnetic field sensors (e.g., magnitude- or angle-based sensors) and the one or more permanent magnets described herein; and

[0013] [Fig.7A] and [Fig.7B] illustrate cross-sectional views of embodiments of a lower completion assembly with one or more inflow control valves (ICVs) as depicted in [Fig.6]. DETAILED DESCRIPTION

[0014] In the following drawings and descriptions, similar parts are generally indicated in the specification and drawings by means of the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown on an exaggerated scale or in a rather schematic form, and certain details of certain elements may not be shown for the sake of clarity and brevity. The present disclosure may be embodied in embodiments of various forms. Specific embodiments are described in detail and illustrated in the drawings, it being understood that the present disclosure is to be considered an exemplification of the principles of the disclosure and is not intended to limit the disclosure to what is illustrated and described herein.It must be recognized that the various teachings of the embodiments discussed herein may be used separately or in any suitable combination to produce the desired results.

[0015] Unless otherwise indicated, the use of the terms "connect," "engage," "couple," "attach," or any other similar term describing an interaction between elements is not intended to limit the interaction to a direct interaction between the elements and may also include an indirect interaction between the elements described. Furthermore, unless otherwise indicated, the use of the terms "top," "upper," "up," "upwell," "upstream," or other similar terms should be interpreted to mean generally toward the surface of the subterranean formation; likewise, the use of the terms "bottom," "lower," "downward," "downwell," "downstream," or other similar terms should be interpreted to mean generally toward the bottom, terminal end of a well, regardless of the orientation of the wellbore.The use of one or more of the preceding terms should not be construed to refer to positions along a perfectly vertical axis. Furthermore, unless otherwise specified, the use of the term "subterranean formation" should be construed to include both areas beneath exposed earth and areas beneath the earth covered by water, such as ocean or fresh water.

[0016] Various values ​​and / or ranges are explicitly disclosed in certain embodiments herein. However, the values / ranges of any lower bound may be combined with any upper bound to cite a range not explicitly cited. Similarly, the values / ranges of any lower bound may be combined with any other lower bound to cite a range not explicitly cited. Similarly, the values / ranges of any upper bound may be combined with any other upper bound to cite a range not explicitly cited. In addition, each Once a numerical range with a lower and an upper limit is disclosed, any number and range within the range is specifically disclosed. In particular, each range of values ​​(of the form "from about a to about b" or, equivalently, "from approximately a to b" or, equivalently, "from approximately ab") disclosed herein should be taken to state every number and range within the broader range of values, even if not explicitly cited. Thus, each individual point or value may serve as its own lower or upper limit combined with any other individual point or value or any other lower or upper limit, to cite a range not explicitly cited. Similarly, an individual value disclosed herein may be combined with another individual value or range disclosed herein to form another range.

[0017] The term "substantially XYZ," as used herein, means that the value is within 10 percent of the perfectly XYZ value. The term "significantly XYZ," as used herein, means that the value is within 5 percent of the perfectly XYZ value. The term "ideally XYZ," as used herein, means that the value is within 1 percent of the perfectly XYZ value. The moniker "XYZ" could refer to parallel, perpendicular, alignment, or other related features disclosed herein.

[0018] The present disclosure recognizes that offshore wells are being drilled in increasingly greater water depths and in environmentally vulnerable waters, and that safety valves (e.g., subsurface safety valves (SSSVs)) are therefore required. The present disclosure has further recognized that SSSVs have inherent problems and therefore require maintenance and / or replacement from time to time. In fact, there are times when the tubing retrievable safety valve (TRSV) (e.g., the electrically actuated TRSV) fails, and a wireline retrievable safety valve (WLRSV) is then lowered down the hole. Unfortunately, each of the TRSVs and WLRSVs requires its own power source, such as individual tube-encapsulated conductors (TECs).

[0019] The present disclosure has developed an improved WLRSV. In at least one embodiment, the WLRSV comprises a first portion that is lowered downhole with the TRSV and second and third portions that are lowered downhole after the TRSV no longer functions properly and / or has failed. The first portion of the WLRSV, in at least one embodiment, comprises a safety valve subassembly (e.g., a WLRSV subassembly) that would be lowered downhole with another safety valve subassembly (e.g., a TRSV subassembly), and e.g., the production string. In at least one embodiment, the safety valve subassembly would be located above the TRSV subassembly. In at least one other embodiment, the safety valve subassembly would include an electromagnetic assembly (e.g., including one or more coils) (e.g., coupleable to the primary control line (e.g., a single TEC)), as well as a sliding sleeve. The sliding sleeve, in this embodiment, would be configured to slide toward and then magnetically engage the electromagnetic assembly when the electromagnetic assembly is energized. In at least one other embodiment, the safety valve subassembly could include an electromagnetic assembly (e.g., including one or more coils) (e.g., coupleable to the primary control line (e.g., a single TEC) via the switching system discussed below), as well as the sliding sleeve.In some embodiments, the electromagnetic assembly creates a static magnetic attraction. In other embodiments, the electromagnetic assembly is an electric motor that creates torque that can drive a linear actuator.

[0020] The WLRSV, in one or more embodiments, further comprises the second portion of the WLRSV, which is lowered into the bore after the TRSV no longer functions properly and / or has failed. The second portion of the WLRSV, in accordance with one or more embodiments, may be lowered into the bore within the TRSV, for example using a locking mechanism to axially secure the second portion of the WLRSV within the TRSV. The second portion of the WLRSV, in one or more embodiments, may comprise a bore flow management actuator and a valve closing mechanism, and may be located below the first portion of the WLRSV comprising the electromagnetic assembly and the sliding sleeve.

[0021] The WLRSV, in one or more embodiments, further includes a third portion that is lowered into the hole after the second portion of the WLRSV is locked downhole (e.g., locked within the TRSV). The third portion, in one or more embodiments, is a mechanical connection apparatus. For example, in accordance with one or more embodiments of the disclosure, once the second portion of the WLRSV is locked in place, the mechanical connection apparatus may be lowered into the hole between the sliding sleeve of the first portion and the bore flow management actuator of the second portion. Essentially, the mechanical connection apparatus may be lowered into the hole to axially secure the sliding sleeve of the first portion of the WLRSV with the bore flow management actuator of the second portion of the WLRSV. Accordingly, any axial movement of the bore flow management actuator would cause the same axial movement of the sliding sleeve, and vice versa.

[0022] In operation, once the mechanical connection apparatus is in place, fluid pressure (e.g., from within the tubular member beneath the valve closure mechanism) may push the bore flow management actuator toward the valve closure mechanism. Typically, the bore flow management actuator is unable to move beyond the valve closure mechanism until a pressure differential across the valve closure mechanism is reduced / eliminated. Once the pressure differential across the valve closure mechanism is reduced / eliminated, e.g., by pumping fluid into the wellbore toward an upstream side of the valve closure mechanism, the bore flow management actuator may be pushed past the valve closure mechanism, e.g., using one or more springs (e.g., power springs and / or nose springs).Since the sliding sleeve is axially attached to the bore flow management actuator, axial movement of the bore flow management actuator also axially moves the sliding sleeve. This axial movement of the sliding sleeve brings a ferromagnetic target associated with the sliding sleeve into proximity with the electromagnetic assembly of the first portion. Accordingly, when the electromagnetic assembly is energized (e.g., before, during, or after the ferromagnetic target approaches the one or more coils), the sliding sleeve, and thus the bore flow management actuator axially attached thereto, can be maintained in the flow state.The sliding sleeve and associated bore flow management actuator will be maintained in this flow state until the electromagnetic assembly is no longer energized, such as when power is turned off or removed from the electromagnetic assembly.

[0023] The present disclosure has also developed a safety valve that allows the user to predict the health of the safety valve in downhole applications. In at least one embodiment, the present disclosure uses one or more permanent magnets, along with one or more magnetic field sensors (e.g., GMR sensors), to detect the movement of the actuatable features within the safety valve. For example, a first permanent magnet could be coupled to the flowtube main body of the safety valve, and a first magnetic field sensor can be used to detect various aspects related to the movement of the flowtube main body. For example, a measurement of the velocity / acceleration of the flowtube main body as a function of time could be obtained. In one or more embodiments, the actual measurement of the flow tube main body velocity / acceleration as a function of time could be compared to the ideal flow tube main body velocity / acceleration as a function of time, which could indicate that there is something impeding the proper movement of the flow tube main body (e.g., scale). Similar information can be obtained from a measurement of the flow tube main body movement as a function of time.

[0024] In yet another embodiment, movement versus applied force could be compared. The term "movement," in at least one embodiment, refers to movement or the rate of change over time of that movement. Similarly, "applied force," in at least one embodiment, is the applied pressure of hydraulic fluid in a hydraulic valve, the volume / flow rate of fluid pumped into a hydraulic valve, the motor current / voltage in an electric valve, or a direct measurement of force, among others. For example, one could examine the applied force required to begin movement, among other items discussed herein. This is a measure of the friction in the system as well as the actuator response time or brake release. For example, the force applied before the safety valve begins to move may be measured.Likewise, a determination of a position of the safety valve when the force increases significantly at the end of the stroke may be determined, among other measurements and / or determinations. The force, in one or more embodiments, may be measured directly or indirectly. Direct measurement includes a force measurement such as a load cell, among others. Indirect measurement includes measuring pressure in a hydraulic line or voltage / current / power in an electrical system, among others.

[0025] In another embodiment, one or more second permanent magnets are coupled to the valve closure mechanism (e.g., flapper valve, ball valve, etc.) of the safety valve, and a second magnetic field sensor may be used to detect various aspects related to the movement of the valve closure mechanism. For example, the second magnetic field sensor could be used to detect a position of the valve closure mechanism. In at least one embodiment, the second magnetic field sensor is capable of detecting whether the valve closure mechanism is open or closed. In another embodiment, the second magnetic field sensor is capable of detecting a position (e.g., an angle) of the valve closure mechanism even if it is neither fully open nor fully closed.

[0026] Most anomalies can be identified by examining the data points obtained by the magnetic field sensor(s) (e.g., over time). For For example, data points collected over time could be used to assess the health of the safety valve and, if it appears that the safety valve is experiencing problems, develop a plan to repair the safety valve. In fact, such information can be used to detect problems with the safety valve that can be corrected before the safety valve fails. Moreover, such an idea can be used on all types of safety valves, including TRSV and WLRSV.

[0027] In at least one further embodiment, the present disclosure employs a magnetic field angle sensor to detect the position of a movable element of a safety valve (e.g., the flow tube, the valve, etc.). In at least one embodiment, the magnetic field angle sensor is fixed when the permanent magnet moves, and thus detects the position of the movable element of the safety valve. In yet another embodiment, the magnetic field angle sensor moves while the permanent magnet is fixed, and thus detects the position of the movable element of the safety valve. Multiple measurements may be combined to estimate the velocity of the movable element and the acceleration / jerk of the movement of the movable element. Measurements from multiple sensors may be combined to improve the accuracy of the position / velocity / acceleration / jerk estimation.

[0028] In at least one embodiment, magnetic materials are integrated into the movable element of the safety valve, such as the flow tube, the valve, or any other movable element. The magnetic materials may be a permanent magnet or a variation in magnetic permeability (such as that of a ferromagnetic material such as iron). The magnetic field angle sensor may be a single sensor or an array of uniformly or non-uniformly spaced magnetic field angle sensors. The magnetic field angle sensors, in one embodiment, are deployed outside the housing of the movable element. The array of sensors may be configured to measure the magnetic field angle as the magnetic material moves (e.g., shifts, rotates, etc.).The position of the moving element and its velocity can be estimated from a localization algorithm that uses magnetic field angle sensor data from some or all of the sensors.

[0029] Thus, in this embodiment, the magnetic field angle is used instead of the magnetic field strength for estimating the location, velocity, acceleration, etc. of the moving element. The present disclosure has revealed that the magnetic field strength of the magnetic material deteriorates over time (e.g., due to the harsh environment downhole), but the magnetic field angle remains the same. The magnitude of the magnetic field of a permanent magnet varies depending on environmental conditions. The magnetic force is sensitive to the distance between the sensors and the ferrous tubing. This will also change with temperature. The sensitivity of magnetic amplitude sensors will also vary with temperature, as shown in [Fig.lA]. In addition, the magnetic amplitude will have a significant hysteretic effect.

[0030] The magnetic field angle sensor, on the other hand, is solely a function of the angle generated by the magnetic field. This measurement is robust to temperature changes and a varying (but known) distance between the magnet and the angle sensor, as illustrated in [Fig.lB]. Hysteresis is also greatly reduced. Accordingly, the present disclosure has recognized that the magnetic field angle sensor provides a more accurate position estimate, for example than magnetic field strength sensors.

[0031] The magnetic angle is determined, at least in one embodiment, with GMR angle sensors or with tunneling magnetoresistance (TMR) angle sensors, both of which provide much higher resolution than Hall effect sensors. Both GMR and TMR angle sensors utilize the magnetoresistive effect where electrical resistance changes with the magnetic field. Tunneling magnetoresistance is a magnetoresistive effect that occurs in a magnetic tunnel junction MTJ, which is a component composed of two ferromagnets separated by a thin insulator. If the insulating layer is thin enough (typically a few nanometers achieved through thin-film technology such as sputter deposition, laser deposition, physical vapor deposition, or molecular epitaxy), electrons can pass from one ferromagnet to the other.Since this process is forbidden in classical physics, tunnel magnetoresistance is a strictly quantum mechanical phenomenon, and falls under the study of spintronics.

[0032] In at least one embodiment, the present disclosure uses fusion of data from multiple sensors to reduce uncertainty in position estimation and thus improve the accuracy of position and velocity estimation.

[0033] [Fig. 1C] illustrates a well system 100 designed, manufactured, and / or operated according to one or more embodiments of the disclosure. The well system 100, in at least one embodiment, includes an offshore platform 110 connected to a first downhole device 170 (e.g., a first SSSV, such as a TRSV) inserted within a wellbore 130 (e.g., the wellbore extending through a subterranean formation) and a second downhole device 180 (e.g., a second SSSV, such as a WLRSV) inserted within the wellbore 130 via a primary electrical control line 120 (e.g., a single electrical control line, TEC, etc.). In at least one embodiment embodiment, the second downhole device 180 is an electrical connection for a WLRSV. For example, the electrical connection may be an inductive coupling, a capacitive coupling, or a conductive coupling with direct electrical contact, among others. An annular space 150 may be defined between the walls of the wellbore 130 (e.g., extending through one or more subterranean formations) and a conduit 140 (e.g., a production tubing). A wellhead 160 may provide a means for transmitting and sealing a conduit 140 against the wellbore 130 and provide a profile for locking a subsea blowout preventer. The conduit 140 may be coupled to the wellhead 160. The conduit 140 may be any conduit such as casing, a liner, a production tubing, or other oilfield tubulars disposed in a wellbore.The first downhole device 170, or at least a portion thereof, may be interconnected with the conduit 140 (e.g., disposed in line with the conduit 140) and positioned in the wellbore 130. The second downhole device 180, or at least a portion thereof, may be interconnected with the conduit 140 (e.g., positioned in an ID or OD of the conduit 140) and positioned in the wellbore 130.In the illustrated embodiment, the second downhole device 180 is illustrated uphole of the first downhole device 170 (e.g., a portion thereof being lowered into the hole with the first downhole device 170 and another portion thereof being lowered into the hole after failure of the first downhole device 170), but other embodiments may exist in which the second downhole device 180 is located downhole of the first downhole device 170.

[0034] The primary electrical control line 120 may extend into the wellbore 130 and may be connected to the first downhole device 170 and the second downhole device 180. The primary electrical control line 120 may provide actuating power to the first downhole device 170 and the second downhole device 180. As will be described in more detail below, power may be provided to the first downhole device 170 or the second downhole device 180 to actuate or deactivate the first downhole device 170 or the second downhole device 180.Actuation may include opening the first downhole device 170 or the second downhole device 180 to provide a flow path for subterranean production fluids to enter the conduit 140, and deactivation may include closing the first downhole device 170 or the second downhole device 180 to close a flow path for subterranean production fluids to enter the conduit 140. While the embodiment of [Fig.lC] illustrates only the first device . downhole device 170 and the second downhole device 180, other embodiments exist in which more than two downhole devices according to the disclosure are used.

[0035] In accordance with one embodiment of the disclosure, the well system 100 may further include a switching system 190a positioned between the primary electrical control line 120 and each of the first downhole device 170 and the second downhole device 180. The switching system 190a may be configured to switch incoming power from the primary electrical control line 120 between the first downhole device 170 and the second downhole device 180, depending on which of the first downhole device 170 or the second downhole device 180 the operator intends to operate (e.g., actuate). In at least one embodiment, the first downhole device 170 includes a first electrical device (e.g., electromagnetic coils, an electric motor or pump, a piezoelectric actuator, a solenoid valve, etc.) and the second downhole device 180 includes a second electrical device (e.g., electromagnetic coils, an electric motor or pump, a piezoelectric actuator, a solenoid valve, etc.), and the switching system 190a is configured to switch incoming power from the primary electrical control line 120 between the first electrical device of the first downhole device 170 and the second electrical device of the second downhole device 180. Although the well system 100 is shown in [Fig. 1C] as an offshore well system, one skilled in the art should be able to adapt the teachings contained herein to any type of well, including onshore or offshore. In the embodiment of [Fig.lC], the first downhole device 170 is a TRSV, and the second downhole device 180 is a WLRSV, and the methods, magnets, and magnetic field sensors disclosed herein may be used in one or more of the first downhole device 170 and the second downhole device 180.

[0036] Turning to Figures 2A-2F, it can be seen that they illustrate one embodiment of a downhole device, including a safety valve 200 designed, manufactured and / or operated according to one or more embodiments of the disclosure, as might be the case for the first, second and third parts of the WLRSV, as discussed above. Figures 2A-2C illustrate different views of the safety valve 200 in a first closed position, with its unpowered electromagnetic assembly and magnetic target decoupled from each other. [Fig. 2D] illustrates the safety valve 200 of Figures 2A-2C in a second closed position with power (DC power in this embodiment) supplied to the electromagnetic assembly, thereby coupling the electromagnetic assembly and the magnetic target together. [Fig. 2E] illustrates the safety valve 200 of [Fig. 2D] now in the open position, with the energized (DC powered) electromagnetic assembly and the magnetic target remaining magnetically coupled (e.g., fixedly coupled) to each other. [Fig. 2F] illustrates the safety valve 200 of [Fig. 2E] after power (DC power) has been cut off to the electromagnetic assembly, and thus the safety valve 200 returns to the first closed position. In yet another embodiment, the safety valve 200 may be indirectly returned to the first closed position, for example, if an electrical logic circuit determines that electrical power has been interrupted and triggers a closure of the safety valve 200.

[0037] Referring initially to Figures 2A-2C, the safety valve 200 is illustrated in the first closed position. The safety valve 200, in one or more embodiments, may include an outer housing 224 (e.g., a wellbore pipe) containing a central bore 225 in which components of the safety valve 200 may be disposed in the central bore 225. An upper valve assembly 234 (e.g., also the magnetic target in this embodiment) may be attached to the outer housing 224, and may further include one or more sealing members 223, such that fluid communication from a lower section 202 to an upper section 203 is prevented.

[0038] A sleeve 226 may be attached between the upper valve assembly 234 and a lower valve assembly 216. A bore flow management actuator 240 may be disposed within the sleeve 226. The bore flow management actuator 240 may include a translation sleeve 222 and a flow tube main body 208. A flow path 214 may be defined by an interior of the flow tube main body 208. As illustrated in 2A-2C, the flow path 214 may extend from an interior of a conduit 206 through an interior of the flow tube main body 208. As discussed in more detail below, when the safety valve 200 is in an open position, the flow path 214 may extend from the interior of the conduit 206 through an interior of the main flow tube body 208 and further into the lower section 202.

[0039] The safety valve 200 may further include a power spring 210 disposed between the lower valve assembly 216 and a translation sleeve shoulder 218. As illustrated in 2A-2C, the translation sleeve shoulder 218 and a flow tube shoulder 232 may be in contact when the safety valve 200 is in the first closed position. The spring power spring 210 may provide a positive spring force against the translation sleeve shoulder 218, which may maintain the flow tube main body 208 in a first position. The power spring 210 may also provide a positive spring force to return the flow tube main body 208 and the translation sleeve 222 to the first position (e.g., from a second position), as will be explained below.

[0040] The safety valve 200 may further include a nose spring 212 disposed between a translation sleeve assembly 230 and the flow tube shoulder 232. The translation sleeve assembly 230 may be disposed between a piston 220 and the translation sleeve 222 and attached to the piston. The power spring 210 and the nose spring 212 are shown as coil springs in Figures 2A-2F. However, the power spring 210 and the nose spring 212 may include any type of spring and remain within the scope of the present disclosure, such as, for example, coil springs, wave springs, or fluid springs, among others.

[0041] In the illustrated embodiment, the translation sleeve assembly 230 may allow a force applied to a distal end of the piston 220 to be transferred into the translation sleeve 222. A force may be applied to the distal end of the piston 220 via fluid communication from a channel 228 through a port 242. A force applied to the piston 220 may move the translation sleeve 222 from a first position to a second position. The nose spring 212 may provide a positive spring force against the translation sleeve assembly 230 and the flow tube shoulder 232, which may return the translation sleeve 222 from the second position to the first position, as will be discussed in more detail below.

[0042] In the first closed position, the translation sleeve 222 and the flow tube main body 208 are positioned such that the translation sleeve shoulder 218 and the flow tube shoulder 232 are in contact and the power spring 210 and the nose spring 212 are in an extended position. In the first closed position, the translation sleeve 222 can be considered to be in a first position and the flow tube main body 208 can be considered to be in a first position.

[0043] In at least one embodiment, the bore flow management actuator 240 is configured to slide from a first initial state to a first subsequent state to move a valve closure mechanism 204 between a first closed state and a first open state. In the first closed state, the valve closure mechanism 204 may isolate the lower section 202 from the flow tube main body 208. When the valve closure mechanism 204 is in a first closed state, as in Figures 2A-2C, the valve closure mechanism 204 may prevent formation fluids and pressure from flowing into the flow tube main body 208 from the lower section 202. Although Figures 2A-2C illustrate the valve closure mechanism 204 as a flapper valve, the valve closure mechanism 204 may be any suitable valve type such as a flapper-type valve or a ball-type valve, for example. As will be illustrated in more detail below, the valve closure mechanism 204 may be actuated in a first open state to allow formation fluids to flow from the lower section 202 through the flow path 214 (e.g., defined by the lower section 202, an interior of the flow tube main body 208, and an interior of the conduit 206).

[0044] When the safety valve 200 is in the first closed position, no amount of differential pressure across the valve closure mechanism 204 will allow formation fluids to flow from the lower section 202 into the flow path 214. In the first closed position, the safety valve 200 will only allow fluid flow from the conduit 206 into the lower section 202, but not from the lower section 202 into the conduit 206. In the event that the pressure in the conduit 206 is increased, the valve closure mechanism 204 will remain in the closed position until the pressure in the conduit 206 is increased above the pressure in the lower section 202 plus the closing pressure provided by the valve closure mechanism spring 205, sometimes referred to herein as the valve opening pressure.When the valve opening pressure is reached, the valve closure mechanism 204 may open and allow fluid communication from the conduit 206 into the lower section 202. In this manner, treatment fluids such as surfactants, scale inhibitors, hydrate treatments, and other suitable treatment fluids may be introduced into the subterranean formation. The configuration of the safety valve 200 may allow treatment fluids to be pumped from a surface, such as a wellhead, into the subterranean formation without actuating a control line or a balance line to open the valve.Once the pressure in conduit 206 is decreased below the valve opening pressure, the valve closing mechanism spring 205 will return the valve closing mechanism 204 to the closed position, and thus flow from conduit 206 into the lower section 202 will cease. When the valve closing mechanism 204 has returned to the closed position, flow from the lower section 202 into the flow path 214 will be prevented. If a pressure differential across the valve closing mechanism 204 is reversed, such that a pressure in the lower section 202 is . greater than a pressure in the conduit 206, the valve closing mechanism 204 will remain in a closed position, so that fluids in the lower section 202 are prevented from flowing into the conduit 206.

[0045] In the illustrated embodiment, the safety valve 200 includes a first portion 250, a second portion 260 (e.g., the second portion 260 may include the features disclosed in the paragraph above, e.g., those between the upper valve assembly 234 and the valve closure mechanism 204, and specifically the bore flow management actuator 240 and the valve closure mechanism 204), and a third portion 270. As noted above, in at least one embodiment, the first portion 250 has a minimum first portion inside diameter (IDi) and is lowered into the bore with the TRSV, and the second portion 260 and third portion 270 are lowered into the bore after the TRSV no longer functions properly and / or has failed.For example, in at least one embodiment, the second portion 260 has a second portion maximum outer diameter (OD2), the second portion maximum outer diameter (OD2) being less than the first portion minimum inner diameter (IDi) such that the second portion 260 may be lowered into the hole after the first portion 250. Further, the third portion 270 may be lowered into the hole in a separate step after the second portion 260.

[0046] In one or more embodiments, the first portion 250 includes a sliding sleeve 252, and an electromagnetic assembly 254. The sliding sleeve 252, in one or more embodiments, may also include a magnetic target 256 configured to magnetically couple with the electromagnetic assembly 254. In at least one embodiment, the magnetic target 256 is coupled to the sliding sleeve 252 and the electromagnetic assembly 254 is axially secured to the wellbore pipe. In at least one embodiment, the magnetic target 256 is configured to slide with the sliding sleeve 252 and align and couple with the electromagnetic assembly 254. The sliding sleeve 252, in one or more embodiments, further includes a sliding sleeve profile 258 located along an inner diameter (ID) thereof.In the illustrated embodiment, the electromagnetic assembly 254 is located in the outer housing 224 and the magnetic target 256 is located on the sliding sleeve 252, but the reverse could be designed.

[0047] In one or more other embodiments, the third portion 270 includes a mechanical connection apparatus 272, the mechanical connection apparatus 272 axially securing together the sliding sleeve 252 of the first portion 250 and at least a portion of the bore flow management actuator 240 of the second portion 260. In the illustrated embodiment, the connection apparatus mechanical 272 includes an uphole mechanical connection apparatus profile 274 configured to engage the sliding sleeve profile 258 of the sliding sleeve 252, as well as a downhole mechanical connection apparatus profile 276 configured to engage a bore flow management actuator profile 209 of the bore flow management actuator 240 (e.g., the translation sleeve 222 of the bore flow management actuator 240).

[0048] Referring to [Fig.2D], the safety valve 200 is illustrated in a second closed position. In the second closed position, the translation sleeve 222 may be moved from the first position to a second position, which is relatively closer to the valve closing mechanism 204. The flow tube main body 208 may remain in the first position, or only slightly downhole from the first position. When the safety valve 200 is in the second closed position, both the power spring 210 and the nose spring 212 may be in a compressed state.

[0049] To move the translation sleeve 222 to the second position, a differential pressure across the valve closing mechanism 204 may be increased by lowering the pressure in the conduit 206 or increasing the pressure in the lower section 202. A lowering of the pressure in the conduit 206 or an increase of the pressure in the lower section 202 may cause fluid flow in the lower section 202 through the channel 228 defined between the sleeve 226 and the outer housing 224 into the port 242. The port 242 may provide fluid communication into the piston tube 244, whereby fluid pressure may act on the proximal end of the piston 220.The force exerted by the fluid pressure on the proximal end of the piston 220 can move the piston 220 toward the valve closing mechanism 204 by transferring the force through the piston 220, the translation sleeve assembly 230, and the translation sleeve shoulder 218. The nose spring 212 can provide a spring force against the flow tube shoulder 232 and the translation sleeve assembly 230, and the power spring 210 can provide a spring force against the translation sleeve shoulder 218 and the lower valve assembly 216.

[0050] Although not illustrated in 2A-2F, the flow tube main body 208 may include channels that provide pressure and / or fluid communication between the flow path 214 and an interior of the sleeve 226. Collectively, the spring forces from the power spring 210 and the nose spring 212 may resist movement of the piston 220 until the differential pressure across the valve closure mechanism 204 is increased beyond the spring force provided by the power spring 210 and the nose spring 212. Increasing the differential pressure may include decreasing the pressure in the conduit 206 such that the pressure in the lower section 202 is relatively higher than the pressure in the conduit 206. As the differential pressure across the valve closing mechanism 204 is increased, the differential pressure across the piston 220 also increases. As the differential pressure across the valve closing mechanism 204 is increased beyond the spring force provided by the nose spring 212 and the power spring 210, the nose spring 212 and the power spring 210 may compress and allow the translation sleeve 222 to move to the second position. The differential pressure across the valve closing mechanism 204 may be increased by pumping liquid out of the conduit 206, for example.In the event that the lower section 202 is fluidly coupled to an unperforated pipe section or when there is a blockage in a conduit 206 fluidly coupled to the lower section 202 that prevents transmission of pressure from the lower section 202 to the piston 220, a pressure differential across the valve closure mechanism 204 may be induced by pipe swelling.

[0051] In the second closed position, the safety valve 200 remains safe because no fluid from the lower section 202 can flow into the flow path 214. In the second closed position, there is no amount of differential pressure across the valve closure mechanism 204, the differential pressure being a relatively higher pressure in the lower section 202 and a relatively lower pressure in the conduit 206, which should cause the valve closure mechanism 204 to open to allow fluids from the lower section 202 to flow into the flow path 214, because the pressure from the lower section 202 acts on the valve closure mechanism 204. If the pressure is increased in the conduit 206, the differential pressure across the valve closure mechanism 204 decreases and the translation sleeve 222 can return to the first position illustrated in Figures 2A-2C.Unlike conventional safety valves which generally require a control line to provide the pressure necessary to actuate a piston to move a translation sleeve, the safety valve 200 may only require the pressure provided by the wellbore fluids in the lower section 202 to move the translation sleeve.

[0052] Still referring to [Fig. 2D], the piston 220 may be securely attached to the translation sleeve assembly 230. Although illustrated as a single piston in Figures 2A-2F, the piston 220 may comprise a plurality of pistons and remain within the scope of the disclosure. Since the sliding sleeve 252 and the mechanical connection apparatus 272 are rigidly attached together, and the mechanical connection apparatus 272 is rigidly attached to the bore flow management actuator 240 (e.g., the translation sleeve 222 of the bore flow management actuator 240), any movement of the translation sleeve 222 also moves the mechanical connection apparatus 272 and the sliding sleeve 252. As shown in [Fig.2D], this movement can align the electromagnetic assembly 254 and the magnetic target 256.

[0053] Before, during, or after allowing the translation sleeve 222 to move to the second position as described above and shown in [Fig. 2D], the electromagnetic assembly 254 may be energized. Energizing the electromagnetic assembly 254 may cause the electromagnetic assembly 254 to magnetically engage the magnetic target 256 to maintain the sliding sleeve 252 of the first portion 250 in its axial downhole position.

[0054] In Figures 2A-2F, the electromagnetic assembly 254 is shown as a coil circumscribing the tubular member, but there may be any number of coils in any orientation to secure the sliding sleeve 252, and thus the bore flow management actuator 240 in place. The electromagnetic assembly 254 may apply a force in a substantially radial or axial direction, for example. The force applied by the electromagnetic assembly 254 may be any amount of force, including, but not limited to, a force in a range of about 45 Newtons to about 45,000 Newtons. The electromagnetic assembly 254 may provide a means to maintain the sliding sleeve 252 and the bore flow management actuator 240 at any well depth.Hydraulic systems used in prior wellbore safety valves typically require control and balancing lines to actuate and hold a valve open, which may have pressure limitations. The limitations encountered by hydraulic systems can be overcome using the electromagnetic assembly 254 described herein, as only well pressure is required to open the safety valve 200. Again, when the translation sleeve 222 is in the second position either when the electromagnetic assembly 254 is on or when it is off, no amount of differential pressure across the valve closing mechanism 204 will open the valve closing mechanism 204, the differential pressure being a pressure difference between a relatively higher pressure in the section 202 and a relatively lower pressure in the conduit 206.

[0055] Referring to [Fig.2E], the safety valve 200 is illustrated in an open position. When the safety valve 200 is in the open position, the translation sleeve 222 can be fixed in place in the second position, as in FIGS. 2D and 2E, by the force provided by the electromagnetic assembly 254, the force being transferred through the mechanical connection apparatus 272 to the bore flow management actuator 240, for example via the translation sleeve 222. The flow tube main body 208 is illustrated as being axially offset from the first position illustrated in Figures 2A-2D to a second position in [Fig. 2E]. When the flow tube main body 208 is in the second position, the flow tube shoulder 232 and the translation sleeve shoulder 218 may be in contact and the flow tube main body 208 may have moved the valve closing mechanism 204 into an open position. The nose spring 212 may be in an uncompressed state, while the power spring 210 may be in a compressed state.

[0056] The flow tube main body 208 can be moved from the first position to the second position when the translation sleeve 222 is secured in place in the second position by the electromagnetic assembly 254, as described above. When the translation sleeve 222 is secured in the second position by the force provided by the electromagnetic assembly 254, the nose spring 212 can provide a positive spring force against the flow tube shoulder 232 and the translation sleeve assembly 230. The positive spring force of the nose spring 212 can be transferred through the flow tube main body 208 into the valve closing mechanism 204. The flow tube main body 208 will not move to the second position until the differential pressure across the valve closing mechanism 204 exists and the translation sleeve 222 is secured in position.The differential pressure may be decreased by pumping into the conduit 206, thereby increasing the pressure in the conduit 206. The pressure may be increased in the conduit 206 until the differential pressure across the valve closure mechanism 204 is decreased to a point where the positive spring force of the nose spring 212 is greater than the differential pressure across the valve closure mechanism 204. Thereafter, the nose spring 212 may extend and move the flow tube main body 208 into the second position by acting on the translation sleeve assembly 230 and the flow tube shoulder 232, which are held in place via the electromagnetic assembly 254 and one or more other features.When the flowtube main body 208 is in the second position, fluids such as oil and gas in the lower section 202 may be able to flow into the flowpath 214 and to a surface of the wellbore such as a wellhead. The safety valve 200 may remain in the open position defined by the translation sleeve 222 being in the second position and the flowtube main body 208 being in the second position, as long as the electromagnetic assembly 254 remains energized.

[0057] The safety valve 200 can be returned to the first closed position, as illustrated in [Fig.2F], by turning off the electromagnetic assembly 254. As discussed previously, the electromagnetic assembly 254 can fix the sliding sleeve 252 and the flow tube main body 208 in place in the second position when the electromagnetic assembly 254 remains energized. When the electromagnetic assembly 254 is turned off, the sliding sleeve 252 and the flow tube main body 208 can no longer be fixed in place. The power spring 210 can provide a positive spring force against the lower valve assembly 216, the translation sleeve shoulder 218, and the flow tube shoulder 232 at the top of the hole.The positive spring force of the power spring 210 can axially move the translation sleeve 222 to the first position and the flow tube main body 208 to the first position, thereby returning the safety valve 200 to the first closed position illustrated in FIGS. 2A-2C and 2F. The positive spring force of the power spring 210 can also axially move the electromagnetic assembly 254 to the position illustrated in FIGS. 2A-2C and 2F, by transmitting the positive spring force through the mechanical connection apparatus 272.

[0058] In the embodiment of Figures 2A-2F, the safety valve 200 further includes one or more permanent magnets 280 coupled to one or more actuatable (e.g., movable) features of the safety valve 200. In the illustrated embodiment of Figures 2A-2F, a first permanent magnet 285a is coupled to the flow tube main body 208, and a second permanent magnet 285b is coupled to the valve closure mechanism 204 (e.g., flapper valve, ball valve, etc.). In the illustrated embodiment of Figures 2A-2F, the safety valve 200 further includes one or more magnetic field sensors 290.In the illustrated embodiment of Figures 2A-2F, a first magnetic field sensor 295a is placed proximate (e.g., radially around) the first permanent magnet 285a, and a second magnetic field sensor 295b is placed proximate (e.g., radially around) the second permanent magnet 285b.

[0059] In this embodiment, the first magnetic field sensor 295a is configured to measure one or more aspects of a movement of the flow tube main body 208, and send this information uphole using one or more communication lines 298 (e.g., TEC lines). In this embodiment, the second magnetic field sensor 295b is configured to measure one or more aspects of a movement of the valve closure mechanism 204 (e.g., flapper valve, ball valve, etc.), and send this information uphole using one or more communication lines 298 (e.g., example, TEC lines). Although the embodiment of Figures 2A-2F places only the one or more permanent magnets on the flow tube main body 208 and the valve closure mechanism 204, other embodiments exist in which one or more other permanent magnets are coupled to other movable features of the safety valve 200. In at least one embodiment, a power and / or communication interface 299 exists between the one or more magnetic field sensors 290 and the one or more communication lines 298.

[0060] Turning now to Figures 3A and 3B, they illustrate an embodiment of a safety valve 300 designed and manufactured according to one or more alternative embodiments of the present disclosure, respectively in a closed state and in an open state. The safety valve 300 of Figures 3A and 3B resembles in many respects the safety valve 200 of Figures 2A-2F. Thus, like reference numerals have been used to indicate similar, if not identical, features. The safety valve 300, in the embodiment of Figures 3A and 3B, has an outer housing 224 (e.g., a tubular housing). The outer housing 224 in the illustrated embodiment has a central bore 225 extending therethrough, the central bore 225 being operable to convey subterranean production fluids from a subterranean formation.The central bore 225, in the illustrated embodiment, has a lower section 202 and an upper section 203.

[0061] The safety valve 300, in one or more embodiments, further includes a valve closure mechanism 204 disposed proximate the lower section 202 of the central bore 225. The valve closure mechanism 204 may isolate the lower section 202 of the central bore 225 from the upper section 203, which may prevent formation fluids and pressure from flowing through the safety valve 300 when the valve closure mechanism 204 is in a closed position. The valve closure mechanism 204 may be any type of valve such as a flapper-type valve or a ball-type valve, among others. [Fig.3A] illustrates the valve closure mechanism 204 as a flapper-type valve in the closed position, while [Fig.3B] illustrates the valve closure mechanism 204 as a flapper-type valve in the open position.

[0062] The safety valve 300 further comprises a bore flow management actuator 240, for example comprising a flow tube main body 208, disposed in the central bore 225. The flow tube main body 208, in the illustrated embodiment, is configured to move between a retracted state (for example, as illustrated in [Fig. 3A]) and an extended state (for example, as illustrated in [Fig. 3B]) to engage or disengage the mechanism valve closure 204. Accordingly, the flow tube main body 208 may determine a flow condition of subterranean production fluids through the central bore 225, simply by moving between the retracted state and the extended state. The safety valve 300 may further include a power spring 210, the power spring 210 being configured to return the flow tube main body 208 to the retracted state when necessary.

[0063] The safety valve 300 further includes a translation sleeve assembly 230 (e.g., a hydraulically actuated translation sleeve assembly) coupled to the flow tube main body 208. The translation sleeve assembly 230, which is illustrated in Figures 3A and 3B as including a piston 220, is linearly movable, which in turn moves the flow tube main body 208 between the retracted state and the extended state (e.g., by engaging the valve closing mechanism 204 to move it to the open position). In the embodiment of Figures 3A and 3B, the translation sleeve assembly 230 and the flow tube main body 208 are coupled using one or more magnets 355. Thus, when the translation sleeve assembly 230 moves downhole, it magnetically moves the flow tube main body 208 downhole.In other embodiments, however, the translation sleeve assembly 230 physically contacts the flow tube main body 208, thereby having the same effect as the magnetic connection.

[0064] The safety valve 300 illustrated in Figures 3A and 3B further includes one or more health / safety status components 360, 365, the one or more health / safety status components 360, 365 being configured to assist in determining and / or measuring the health status of the safety valve 300. In the embodiment of Figures 3A and 3B, the health / safety status components 360, 365 each include one or more permanent magnets 280 coupled to one or more actuatable (e.g., movable) features of the safety valve 300. In the illustrated embodiment of Figures 3A and 3B, the health / safety status components 360, 365 include a first permanent magnet 285a coupled to the flow tube main body 208, and a second permanent magnet 285b coupled to the valve closing mechanism 204 (e.g., flap valve, ball valve, etc.).In the illustrated embodiment of Figures 3A and 3B, the health / safety status components 360, 365 further include one or more magnetic field sensors 290 (e.g., one or more magnetic amplitude sensors). In the illustrated embodiment of Figures 3A and 3B, a first magnetic field sensor 295a is positioned proximate (e.g., radially around) the first permanent magnet 285a, and a second magnetic field sensor 295b is positioned proximate (e.g., radially around) the second permanent magnet 285b.

[0065] In this embodiment, the first magnetic field sensor 295a is configured to measure one or more aspects of a movement of the flow tube main body 208 (e.g., via the movement of the first permanent magnet 285a), and send this information uphole using one or more communication lines 298 (e.g., TEC lines). In this embodiment, the second magnetic field sensor 295b is configured to measure one or more aspects of a movement of the valve closure mechanism 204 (e.g., flapper valve, ball valve, etc.) (e.g., via the movement of the second permanent magnet 285b), and send this information uphole using one or more communication lines 298 (e.g., TEC lines).Although the embodiment of Figures 3A and 3B only placed the one or more permanent magnets 280 on the flow tube main body 208 and the valve closure mechanism 204, other embodiments exist in which the one or more permanent magnets 280 are coupled to other movable features of the safety valve 300. In at least one embodiment, a power and / or communication interface 299 exists between the one or more magnetic field sensors 290 and the one or more communication lines 298. Although the illustrated embodiment employs a first permanent magnet 285a and a first magnetic field sensor 295a, as well as a second permanent magnet 285b and a second magnetic field sensor 295b, they do not need to be used together and can be used independently of each other.

[0066] Turning to Figures 4A-4C, there can be seen illustrated graphs 400a, 400b, 400c showing ideal measurements of the position / speed / acceleration of the flow tube main body as a function of time (e.g., [Fig. 4A]), an actual measurement of the position / speed / acceleration of the flow tube main body as a function of time (e.g., [Fig. 4B]), and a comparison of the ideal measurements of the position / speed / acceleration of the flow tube main body as a function of time and the actual measurement of the position / speed / acceleration of the flow tube main body as a function of time (e.g., [Fig. 4C]).This comparison can provide important information that can be used to determine the health of the safety valve (e.g., in one embodiment, the main flow tube body 208 of the safety valve 200, or the main flow tube body 208 of the safety valve 300). Similar graphs could be obtained for the valve closure mechanism 204 of the safety valve 200, or the valve closure mechanism 204 of the safety valve 300, or even for any other moving feature that includes a permanent magnet.

[0067] The graphs of Figures 4A-4C illustrate the idea of ​​comparing expected measurements of the position / velocity / acceleration of the flow tube main body as a function of time and the actual measurement of the position / velocity / acceleration of the flow tube main body as a function of time. In many situations, the same result could be achieved by 1) making a position measurement of a characteristic; 2) determining how the position / velocity / acceleration varies with time; 3) comparing what was determined to an expected position / velocity / acceleration as a function of time; and 4) estimating a health condition of the safety valve based on the deviation between the measured value and the expected value.

[0068] Turning now to Figures 5A-5D, it can be seen that they illustrate one embodiment of a safety valve 500 designed and manufactured according to one or more alternative embodiments of the present disclosure, in a closed state (e.g., Figures 5A and 5B) and an open state (e.g., Figures 5C and 5D). The safety valve 500 resembles in many respects the safety valve 300 of Figures 3A and 3B, as well as the safety valve 200 of Figures 2A-2F. Thus, like reference numerals have been used to indicate similar, or even identical, features.

[0069] In the embodiment of Figures 5A-5D, the safety valve 500 includes another health / safety status component 560 that is configured to measure a position / speed / acceleration, etc. of a moving component of the safety valve 500. In the embodiment of Figures 5A-5D, the health / safety status component 560 employs a permanent magnet and a series of magnetic field angle sensors to measure the position / speed / acceleration, etc. of a moving component of the safety valve 500. In the illustrated embodiment of Figures 5A-5D, a permanent magnet 565 is attached to the bore flow management actuator 240, e.g., the flow tube main body 208, of the safety valve 500.In at least one embodiment, a series of magnetic field angle sensors 575 are coupled proximate to the permanent magnet 565, for example using a printed circuit board 570 (e.g., a single sensor board chip). In the embodiment of Figures 5A-5D, the series of magnetic field angle sensors 575, and thus the printed circuit board 570, are positioned outside the outer housing 224. In yet another embodiment, the safety valve 500 does not include the printed circuit board 570, but includes a plurality of discrete magnetic field angle sensors 575.

[0070] The number of magnetic field angle sensors 575 may vary considerably and remain within the scope of the disclosure. In the embodiment of Figures 5A-5D, the safety valve 500 includes two magnetic field angle sensors 575a, 575b. In yet another embodiment, the valve safety valve 500 could include a single magnetic field angle sensor 575, or even in yet another embodiment (e.g., an embodiment in which greater clarity and detail are required), the safety valve 500 could include at least 3, or even at least 4, or even at least 5, or even at least 6, or even at least 8, or even at least 10, or even at least 15, or more, magnetic field angle sensors 575.

[0071] In the embodiment of Figures 5A-5D, the safety valve 500 further includes a controller 580 coupled to the one or more magnetic field angle sensors 575. The controller 580, in one or more embodiments, is configured to convert angle measurements (e.g., measured using the array of magnetic field angle sensors 575) into position / velocity / acceleration, etc., among other measurements. The controller 580, in the illustrated embodiment, is positioned on the printed circuit board 570, whereas in other embodiments, the controller 580 is not located on the printed circuit board 570.

[0072] In the embodiment of Figures 5A-5D, the permanent magnet 565 generates a magnetic field 585. The magnetic field 585, in one or more embodiments, is configured such that the north-south axis of the permanent magnet 565 is in the direction of the array of magnetic field angle sensors 575 (as illustrated). Although illustrated in this manner, the permanent magnet 565 could also be oriented in other directions. The angle of the magnetic field 585 varies depending on the distance from the permanent magnet 565. The array of magnetic field angle sensors 575 measures the angle of the magnetic field 585. Accordingly, by knowing the angle of the magnetic field 585, the user can calculate a distance between the array of magnetic field angle sensors 575 and the permanent magnet 565.Accordingly, in at least this embodiment, the user can know the position of the flow tube main body 208 in the safety valve 500.

[0073] As shown in Figures 5B and 5D, sensor 575a measures a magnetic angle of Xi (e.g., +70 degrees in one embodiment), and sensor 575b measures a magnetic angle of X2 (e.g., -20 degrees in one embodiment). Advantageously, the angles measured by the array of magnetic field angle sensors 575 are very sensitive to a small movement of the permanent magnet 565. Experiments have shown that measuring the angle is a much more accurate measurement than measuring the magnitude of the magnetic field alone, for example as performed in the embodiment of Figures 2A-2F and 3A and 3B.

[0074] Accordingly, in at least one embodiment, a single measurement from sensor 575a may be used to determine a position of the component of the flow tube main body 208 within the safety valve 500. In addition, a time rate of change of the measurements from the sensor 575a can be used to estimate the health of the components within the safety valve 500. In addition, when the permanent magnet 565 is closer to the sensor 575b, then the angle values ​​from the sensor 575b can be used rather than those from the sensor 575a, thus providing greater clarity as to its position. The choice of which sensor to use (e.g., sensor 575a, 575b) can be determined from the angle of the measured magnetic field.

[0075] A position algorithm, for example in controller 580, may then use the magnetic angle measurements from sensors 575a and 575b. The use of multiple measurements can reduce error in the position estimation, particularly hysteresis error. The position algorithm, in one or more embodiments, may apply weighting to the multiple sensor measurements and may thus give greater weight to sensor 575 that is closer to permanent magnet 565 and less weight to sensor 575 that is further from permanent magnet 565. Alternatively, the position algorithm may use the magnetic angle measurement from a single sensor.

[0076] The magnetic angle measurement can be calculated by measuring the magnitude of the directional magnetic field in two directions (axial and radial for Figures 5A and 5B) and then looking at the ratio of the two magnitude measurements. The ratio of the two magnitude measurements is a mathematical calculation, such as an algebraic calculation such as division or a geometric calculation such as tangent or cotangent estimation.

[0077] Feedback of the position of the movable features (e.g., flow tube main body 208, valve closing mechanism 204, etc.) would allow a user to specify the degree of movement (e.g., opening) of the movable feature. For example, aspects of the present disclosure may be used (e.g., as discussed above with respect to Figures 5A and 5B) with one or more safety valves (e.g., subsurface safety valves (SSSVs), tube retrievable safety valves (TRSVs), cable retrievable safety valves (WLRSVs), barrier valves, etc.). Knowing the exact position of the movable feature of the SSSVs, TRSVs, WLRSVs, and barrier valves (FS-2 valve) would assure the operator that these valves are fully open or fully closed.Full opening is important to ensure there are no restrictions to the production flow (e.g., barrier valve) and is important to ensure there are no valve lips that could catch a tool string (e.g., TRSV). Full closure is important to ensure the valve is leak-tight, such as in an SSSV.

[0078] Additionally, the rate at which the moving feature (e.g., flow tube main body 208, valve closure mechanism 204, etc.) opens and / or closes over time reflects the accumulation of debris in the path of the moving feature. Knowledge of the rate of the moving feature facilitates qualitative estimation of the debris built up, so that predictive maintenance of the safety valve can be performed.

[0079] Although the embodiment of Figures 5A and 5D focuses on the permanent magnet 565 and the magnetic field angle sensors 575a and 575b to be deployed for measuring the position / speed / acceleration, etc. of the bore flow management actuator 240 (e.g., the flow tube main body 208) of the safety valve 500, the present disclosure should not be limited thereto. For example, the permanent magnet 565 and the magnetic field angle sensors 575a and 575b could be deployed for measuring the position / speed / acceleration, etc. of the valve closing mechanism of the safety valve 500 in another embodiment. In fact, the permanent magnet 565 and the magnetic field angle sensors 575a and 575b could be deployed for the measurement of the position / velocity / acceleration, etc. of any moving characteristic of the safety valve 500 and remain within the scope of the disclosure.Additionally, the permanent magnet 565 and magnetic field angle sensors 575a and 575b could be deployed with, or separately from, the permanent magnets 280 and magnetic field sensors 290 of the embodiments of Figures 2A-2F and Figures 3A and 3B for measuring the position / velocity / acceleration, etc. of any moving characteristic.

[0080] In yet another embodiment, not shown, the inventive aspects of the present disclosure may be used with an interval control valve (ICV), or at least its movable elements. Simple feedback of the position of our ICVs would allow the user to specify the degree of opening of the ICVs in one or more smart well completions (e.g., Halliburton's SmartWell® completions). Knowing exactly the amount of opening would allow the user to know exactly the flow restriction.

[0081] Turning to [Fig. 6], there may be illustrated an embodiment of an inflow control valve (ICV) 600 designed, manufactured and / or operated in accordance with one or more embodiments of the disclosure, and which may take advantage of the one or more magnetic field sensors (e.g., magnitude or angle based sensors) and the one or more permanent magnets described above with respect to the safety valves 200, 300, 500. In at least one embodiment, the inflow control valve (ICV) 600 generally includes a valve body 602 having a fluid flow path 604 defined therethrough. the latter extending between fluid ports 606, 608 (e.g., an inlet fluid port and an outlet fluid port). An energy recovery mechanism 610 may be disposed along the fluid flow path 604. The fluid flow path 604 may be defined by one or more channels or conduits 605 formed in the valve body 602, and may also include one or more manifolds 607 interconnecting the one or more channels or conduits 605 and the fluid ports 606, 608. In some embodiments, the energy recovery mechanism 610 is a turbine generator or a vortex generator that may be actuated by fluid flow along the fluid flow path 604.In other embodiments, the energy recovery mechanism 610 may be arranged to be actuated by fluid flow external to the valve body 602, such as production flow flowing past the inflow control valve (ICV) 600. Also arranged along the fluid flow path 604 between the fluid ports 606, 608, in one or more embodiments, is a movable feature 612 (e.g., an adjustable valve) that may be used to form a restriction in the channel 605 to control fluid flow along the fluid flow path 604. In one embodiment, the flow port 608 is fluidly connected to the outside of the tube and the flow port 606 is fluidly connected to the inside of the tube.In another embodiment, the fluid flow path 604 is part of the flow path from the outside of the tube to the inside of the tube.

[0082] The movable feature 612 (e.g., an adjustable valve) is not limited to a particular type of valve, but may be any movable feature 612 (e.g., an adjustable valve) known to those skilled in the art. Without limiting the foregoing, in some embodiments, the movable feature 612 (e.g., an adjustable valve) may be a ball valve, while in other embodiments, the movable feature 612 (e.g., an adjustable valve) may be a piston valve 613, while in still other embodiments, the movable feature 612 (e.g., an adjustable valve) may be a flapper valve, while in still other embodiments, the movable feature 612 (e.g., an adjustable valve) may be a slide valve.In the illustrated embodiment, the movable feature 612 (e.g., an adjustable valve) is shown as having a drive mechanism 614 for actuating a movable piston 615 that can move linearly to change the restriction. In other embodiments, the drive mechanism is provided by an offset tool that is carried in the wellbore on a wireline, slickline, tubing, or robot. In all cases, the movable feature 612 (e.g., a . adjustable valve) is generally movable between a first position and a second position so as to adjust the flow along the fluid flow path 604. In this regard, a first position may be fully closed and a second position may be open to a certain degree to allow fluid to flow along the fluid flow path 604. The movable feature 612 (e.g., an adjustable valve) may be adjusted to alter the flow along the fluid flow path 604 for different operations. For example, the movable feature 612 (e.g., an adjustable valve) may be in a fully open position to allow use of an electronic flow control node in fluid injection procedures, such as acidizing, hydraulic fracturing, gravel packing, and the like.Subsequently, when the movable feature 612 (e.g., an adjustable valve) is used for production, the flow along the fluid flow path 604 may be decreased by closing the movable feature 612 (e.g., an adjustable valve) to form a partial restriction in the channel 605, thereby controlling the flow of formation fluid along the fluid flow path 604.

[0083] In at least one embodiment, the movable feature 612 (e.g., an adjustable valve) is controlled by a drive mechanism 614, such as an electric actuator. The drive mechanism 614 may generally be powered by an energy harvesting mechanism 610 controlled by control electronics 616. The control electronics 616, in one or more embodiments, includes a wireless transmitter 618 for receiving wireless control signals as described herein. As used herein, the wireless transmitter is intended to be any device that can receive a wireless signal and / or transmit a wireless signal, and is not limited to a particular type of wireless signal.In one or more embodiments, the energy harvesting mechanism 610, the movable feature 612 (e.g., an adjustable valve), the drive mechanism 614, and the control electronics 616 are all carried on or otherwise packaged with the valve body 602. In one or more embodiments, the wireless transmitter 618 may further be arranged to transmit wireless signals from a sensor 620 arranged to measure an environmental condition adjacent to the inflow control valve (ICV) 600. Without limiting the disclosure, the sensor 620 may be a temperature sensor, a pressure sensor, a flow sensor, or an optical sensor. In one or more embodiments, the sensor 620 may also be carried on the valve body 602, while in other embodiments, the sensor 620 may be separate from the valve body 602.In one or more embodiments, the sensor 620 is used to monitor conditions around the control valve. inflow (ICV) sensors 600 and transmit them wirelessly to a controller, thereby enabling adjustment of the movable feature 612 (e.g., an adjustable valve) as desired based on the conditions measured by the sensor 620. In some embodiments, the valve body 602 may be sleeve-shaped (e.g., as illustrated in [Fig. 6]) while in other embodiments, the valve body 602 may have a smaller profile. In some embodiments, the valve body 602 may have a fluid flow path 604 with multiple fluid ports 606 and / or multiple fluid ports 608.In yet another embodiment, the inflow control valve (ICV) 600 may have two flow paths defined therein and interconnected with the fluid port 606, each of the flow paths terminating in a fluid port 608 such that flow to either of the fluid ports 608 may be selectively determined by the movable feature 612 (e.g., an adjustable valve).

[0084] In one or more embodiments, the inflow control valve (ICV) 600 may further include one or more permanent magnets 680 coupled to one of a movable feature thereof or a fixed feature thereof, as well as one or more magnetic field sensors 690 coupled to one of the fixed feature or the movable feature and positioned proximate to the one or more permanent magnets 680. In at least this embodiment, the one or more magnetic field sensors 690 are configured to detect movement of a movable feature of the inflow control valve (ICV) 600, such as the movable feature 612 (e.g., an adjustable valve), to determine the health and / or safety of the inflow control valve (ICV) 600.The one or more permanent magnets 680 and magnetic field sensors 690 may be designed, manufactured, and / or operated in accordance with the present disclosure, and specifically in a manner similar to those disclosed herein with respect to safety valves 200, 300, 500. For example, the magnetic field sensors 690 may measure a magnitude and / or angle of the magnetic field to determine a position / velocity / acceleration (e.g., as a function of time) of the movable feature of the inflow control valve (ICV) 600, such as the movable feature 612 (e.g., an adjustable valve). The magnetic field sensors 690 may also assist in determining the force required to move the movable feature of the inflow control valve (ICV) 600, such as the movable feature 612 (e.g., an adjustable valve), and thereby determine the health and / or safety of the drive mechanism 614.

[0085] Figures 7A and 7B illustrate cross-sectional views of embodiments of a lower completion assembly 700 with one or more inflow control valves (ICVs) 600 as depicted in [Fig. 6]. The lower completion assembly 700 generally includes at least one sand screen assembly 710. The sand screen assembly 710 has a base pipe 712 extending between a first end 714 and a second end 716 and defining an interior flow passage 718 therein. The base pipe 712 further includes at least one opening 720 extending through a sidewall thickness of the base pipe 712 and having a transverse opening area AL. In other embodiments, the base pipe 712 may include multiple openings.A sand screen 722 is disposed around a portion of the base pipe 712 and forms one or more sand screen flow paths 724 between the sand screen 722 and the base pipe 712. The sand screen 722 may be any filter media known in the industry and is not intended to be limited by the disclosure. In one embodiment, the sand screen assembly 710 may include two or more sand screens 722 deployed along the base pipe 712, such as illustrated as sand screens 722a and 722b. Although the sand screen 722 is illustrated as being spaced from the opening 720, the opening 720 may also be adjacent to the sand screen 722. The sand screen assembly 710 may further include an inflow control valve (ICV) 600.As described above, the inflow control valve (ICV) 600 may include at least one movable feature 612 (e.g., an adjustable valve), but may include two or more movable features 612 (e.g., an adjustable valve). Alternatively, as needed, rather than multiple movable features 612 (e.g., an adjustable valve) in a single inflow control valve (ICV) 600, multiple inflow control valves (ICV) 600 may be used as needed.

[0086] In any event, [Fig. 7A] illustrates an inflow control valve (ICV) 600 with a single movable feature 612 (e.g., an adjustable valve), while [Fig. 7B] shows that multiple inflow control valves (ICV) 600 may be employed, namely a first inflow control valve (ICV) 600a and a second inflow control valve (ICV) 600b. The movable feature 612 (e.g., an adjustable valve) is not limited to a particular type of valve, but may be any valve known to those skilled in the art. Without limiting the foregoing, in some embodiments, the movable feature 612 (e.g., an adjustable valve) may be a ball valve, while in other embodiments, the movable feature 612 (e.g., an adjustable valve) may be a piston valve, while in still other embodiments, the movable feature 612 (e.g., an adjustable valve) may be a poppet valve. In the illustrated embodiment, the movable feature 612 (e.g., an adjustable valve) is shown as having a drive mechanism 614 in the form of an electric actuator. In the illustrated embodiment, the drive mechanism 614 actuates a movable piston 615 that can move linearly to change the restriction. In any case, the movable feature 612 (e.g., an adjustable valve) is generally movable between a first position and a second position so as to adjust the flow along the fluid flow path 604. In this regard, a first position may be fully closed and a second position may be open to a certain degree to allow fluid to flow along the fluid flow path 604.The movable feature 612 (e.g., an adjustable valve) may be adjusted to change the cross-sectional area of ​​the fluid flow path 604, allowing different flow rates for different operations. In one or more embodiments, the inflow control valve (ICV) 600 is deployed along the base pipe 712 and the adjacent opening 720 such that the fluid flow path 604 of the inflow control valve (ICV) 600 is in fluid communication with the interior flow passage 718 via the aligned fluid port 606 and the opening 720.

[0087] In the illustrated embodiment, the fluid flow path 604 of the inflow control valve (ICV) 600 is also in fluid communication with the flow paths of the sand screen 724 via the fluid port 608. In the case where the base pipe 712 has multiple openings 720, the inflow control valve (ICV) 600 may also have multiple fluid ports 606 along the fluid flow path 604. In other embodiments with multiple openings 720 in the base pipe 712, as illustrated in [Fig. 7B], a separate inflow control valve (ICV) 600 may be deployed for each opening 720. More specifically, as illustrated in [Fig.7B], a first inflow control valve (ICV) 600a may communicate with a first opening 720a while a second inflow control valve (ICV) 600b may communicate with a second opening 720b. In such a case, one opening may be used for a first task, such as an injection opening for injecting a working fluid into an annulus adjacent a sand screen, while another opening may be used for a second task, such as a production opening for controlling the flow of formation fluid into the base pipe 712. In such embodiments, the cross-sections Ala of the injection opening . may be smaller than the cross-sectional area Alb of the production opening. Thus, the restrictions of the fluid flow path 604 can be adjusted accordingly for the operation with which the inflow control valve (ICV) 600 is used.

[0088] In each of Figures 7A and 7B, a connecting sleeve 730 is illustrated. The connecting sleeve 730 is generally disposed around a portion of the base pipe 712 and spaced therefrom to form a connecting sleeve flow path 732 between the connecting sleeve 730 and the base pipe 712. In the illustrated embodiment of Figures 7A and 7B, the inflow control valve (ICV) 600 is spaced and generally positioned along the base pipe 712 between two sand screens 722, shown as screens 722a and 722b. The connecting sleeve 730 extends between the sand screens 722a, 722b and over the inflow control valve (ICV) 600 such that the sleeve flow path 732 fluidly couples the sand screen flow paths 724 of the sand screens 722a, 722b.Additionally, the fluid flow path 604 is in fluid communication with the fluidically coupled sand screen flow paths 724 and 732. Thus, the inflow control valve (ICV) 600 may be employed to control fluid flow from a plurality of sand screens 722.

[0089] In Figures 7A and 7B, the sand screen assembly 710 is shown coupled to an additional sand screen assembly 750. In the illustrated embodiment, the sand screen assembly 750 does not have base pipe openings or ports as is the case with the sand screen assembly 710. The sand screen assembly 750 has a base pipe 752 that is non-perforated extending between a first end 754 and a second end 756 and defining an interior flow passage 758 therein. A sand screen 762 is disposed around a portion of the base pipe 752 and forms a sand screen flow path 764 between the sand screen 762 and the base pipe 752. The sand screen 762 may be any filter media known in the industry and is not intended to be limited by the disclosure.In one embodiment, a sand screen assembly 750 may include two or more sand screens 762 deployed along the base pipe 752. As illustrated, the first end 714 of the base pipe 712 is coupled to the second end 756 of the base pipe 752 to form a seal 768 therebetween. A connecting sleeve 770 extends between the sand screen 722 of the sand screen assembly 710 and the sand screen 762 of the sand screen assembly 750 such that the connecting sleeve 770 covers the seal 768 between the sand screen assemblies, thereby forming a connecting sleeve flow path 772 between the connecting sleeve 770 and the base pipes 712 and 752 so as to . fluidly couple the sand screen flow path 764 with the sand screen flow path 724. In this embodiment, the inflow control valve (ICV) 600 may be used to control the flow of formation fluid passing into the sand screen assembly 750.

[0090] As illustrated, Figures 7A and 7B show that the lower completion assembly 700, and in particular the one or more inflow control valves (ICVs) 600a, 600b, may include the one or more permanent magnets 680 and one or more magnetic field sensors 690 discussed above. It should be noted that in one or more embodiments, the one or more permanent magnets 680 and the one or more magnetic field sensors 690 are located on opposite sides of a housing, such as the valve body. In at least one other embodiment, the one or more permanent magnets 680 and one or more magnetic field sensors 690 are located on opposite sides of a pressure-containing body.It should also be noted, in one or more embodiments, that the measurements may be performed simultaneously with movement of the movable feature, including performing a single dynamic measurement or a series of dynamic measurements. In yet another embodiment, one or more static measurements may be performed while the movable feature is static, such as at the end of the actuation event. For example, the one or more static measurements may be used to determine whether additional movement action is desired and / or required, such as whether the valve has been moved too far or not far enough.

[0091] In another version, the permanent magnet is attached to the inflow control valve (ICV) during actuation and the magnetic sensor is attached to an offset tool that is introduced into the wellbore. The offset tool may be used on a cable, wireline, tubing, or robot. The offset tool engages a feature of the valve, moves the valve, and adjusts the inlet restriction of the valve. As the valve moves, the permanent magnet moves. The magnetic sensor on the offset tool detects and monitors the movement of the valve.

[0092] Therefore, the health of the safety valves 200, 300, 500 and the inflow control valve (ICV) 600 may be estimated, without limitation, by at least one of the following methods: 1) Calculating the variation of the actual velocity during a period when the predicted velocity is assumed to be constant; 2) Calculating the difference between the predicted movement (position, velocity, acceleration, etc.) versus the measured movement; 3) Calculating the initial movement of the moving feature, for example between T0 and T1, which may serve as a measure of the initial sticking / seizing of the downhole device; 4) Calculating the final movement of the moving feature, for example at T2, which can serve as a measure of the seating of the moving feature in the fully open or fully closed state; 5) Calculation of the movement over a reduced time period, for example from Tl to T2, where the initial starting effects from T0 to Tl are considered separately.

[0093] In at least one embodiment, measuring the health and safety status of the movable feature includes determining the operational status of the movable feature. For example, determining an operational status of the movable feature may include determining whether the movable feature has fully traveled. In yet another embodiment, determining an operational status of the movable feature may include determining whether the movable feature has moved. In yet another embodiment, determining an operational status of the movable feature may include determining an amount of movement that has occurred, among other things.

[0094] The foregoing health status calculations, along with any other information obtainable using the inventive aspects of the present disclosure, may then be used to take one or more health status-based actions. For example, in at least one embodiment, a user could examine one of the health status calculations and determine whether it has exceeded a threshold value. In yet another embodiment, the user could observe how the health status calculation has changed over time, or a difference between the calculated health status values.Exceeding a health metric may result in taking a corrective action, such as scheduling / performing a wellbore repair, injecting a cleaning fluid such as an acid or chelating agent, performing a cleaning cycle such as with a scraper or water jet, switching the valve between the open / closed position, or scheduling a different time to perform the next valve monitoring, among others.

[0095] Aspects disclosed herein include:

[0096] A. A safety valve, the safety valve comprising: 1) an outer housing; 2) a bore flow management actuator disposed within the outer housing; 3) a valve closing mechanism disposed within the outer housing, the bore flow management actuator being configured to slide from a first initial state to a first subsequent state to move the valve closing mechanism between a first closed state and a first open state; 4) one or more permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve; and 5) one or more magnetic field sensors coupled to one of the fixed feature of the safety valve or the movable feature of the safety valve and positioned at proximity of the one or more permanent magnets, the one or more magnetic field sensors being configured to detect movement of the moving feature to determine a health status of the safety valve.

[0097] B. A well system, the well system comprising: 1) a wellbore extending through one or more subterranean formations; 2) a production tubing disposed in the wellbore; and 3) a safety valve disposed in the wellbore, the safety valve comprising: a) an outer housing; b) a bore flow management actuator disposed within the outer housing; c) a valve closure mechanism disposed within the outer housing, the bore flow management actuator configured to slide from a first initial state to a first subsequent state to move the valve closure mechanism between a first closed state and a first open state; d) one or more permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve;and 3) one or more magnetic field sensors coupled to one of the fixed feature of the safety valve or the movable feature of the safety valve and positioned proximate to the one or more permanent magnets, the one or more magnetic field sensors configured to detect movement of the movable feature to determine a health status of the safety valve.;

[0098] C. A method, the method comprising: 1) positioning a safety valve within a wellbore extending through one or more subterranean formations, the safety valve being disposed in a production tubing, the safety valve comprising: a) an outer housing; b) a bore flow management actuator disposed within the outer housing; c) a valve closure mechanism disposed within the outer housing, the bore flow management actuator being configured to slide from a first initial state to a first subsequent state to move the valve closure mechanism between a first closed state and a first open state; d) one or more permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve;and 3) one or more magnetic field sensors coupled to one of the fixed feature of the safety valve or the movable feature of the safety valve and positioned proximate to the one or more permanent magnets, the one or more magnetic field sensors configured to detect movement of the movable feature to determine a health status of the safety valve; and 2) detecting movement of the movable feature using the one or more permanent magnets and the one or more magnetic field sensors to determine a health status of the safety valve. ;

[0099] D. A safety valve, the safety valve comprising: 1) an outer housing; 2) a bore flow management actuator disposed within the outer housing; 3) a valve closure mechanism disposed within the outer housing, the bore flow management actuator configured to slide from a first initial state to a first subsequent state to move the valve closure mechanism between a first closed state and a first open state; 4) one or more permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve;and 5) one or more magnetic field angle sensors coupled to one of the fixed feature of the safety valve or the movable feature of the safety valve and positioned proximate to the one or more permanent magnets, the one or more magnetic field angle sensors configured to detect movement of the movable feature to determine a health status of the safety valve.;

[0100] E. A well system, the well system comprising: 1) a wellbore extending through one or more subterranean formations; b) a production tubing disposed in the wellbore; and c) a safety valve disposed in the wellbore, the safety valve comprising: a) an outer housing; b) a bore flow management actuator disposed within the outer housing; c) a valve closure mechanism disposed within the outer housing, the bore flow management actuator configured to slide from a first initial state to a first subsequent state to move the valve closure mechanism between a first closed state and a first open state; d) one or more permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve;and 3) one or more magnetic field angle sensors coupled to one of the fixed feature of the safety valve or the movable feature of the safety valve and positioned proximate to the one or more permanent magnets, the one or more magnetic field angle sensors configured to detect movement of the movable feature to determine a health status of the safety valve.;

[0101] F. A method, the method comprising: 1) positioning a safety valve within a wellbore extending through one or more subterranean formations, the safety valve being disposed in a production tubing, the safety valve comprising: a) an outer housing; b) a bore flow management actuator disposed within the outer housing; c) a valve closure mechanism disposed within the outer housing, the bore flow management actuator being configured to slide from a first initial state to a first subsequent state to move the valve closure mechanism between a first closed state and a first open state; d) one or more magnets permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve; and 3) one or more magnetic field angle sensors coupled to one of the fixed feature of the safety valve or the movable feature of the safety valve and positioned proximate to the one or more permanent magnets, the one or more magnetic field angle sensors configured to detect movement of the movable feature to determine a health status of the safety valve; and 2) detecting movement of the movable feature using the one or more permanent magnets and the one or more magnetic field angle sensors to determine a health status of the safety valve.

[0102] G. An inflow control valve (ICV), the inflow control valve (ICV) comprising: 1) a valve body; 2) a fluid flow path defined within the valve body, the fluid flow path comprising a channel positioned between an inlet fluid port and an outlet fluid port; 3) a movable feature disposed along the fluid flow path between the inlet fluid port and the outlet fluid port, the movable feature configured to form a restriction in the channel to control fluid flow along the fluid flow path; 4) one or more permanent magnets coupled to one of the movable feature or a fixed feature of the valve body;and 5) one or more magnetic field sensors coupled to one of the fixed feature or the movable feature and positioned proximate to the one or more permanent magnets, the one or more magnetic field sensors configured to detect movement of the movable feature to determine a health status of the inflow control valve (ICV).;

[0103] H. A lower completion, the lower completion comprising: 1) a base pipe extending between a first end and a second end and defining an interior flow passage; 2) one or more openings extending through a sidewall thickness of the base pipe; and 3) an inflow control valve (ICV) coupled to the base pipe proximate the one or more openings, the inflow control valve (ICV) comprising: a) a valve body; b) a fluid flow path defined within the valve body, the fluid flow path comprising a channel positioned between an inlet fluid port and an outlet fluid port;c) a movable feature disposed along the fluid flow path between the inlet fluid port and the outlet fluid port, the movable feature configured to form a restriction in the channel to control fluid flow along the fluid flow path; d) one or more permanent magnets coupled to one of the; moving feature or a fixed feature of the valve body; and e) one or more magnetic field sensors coupled to one of the fixed feature or the moving feature and positioned proximate to the one or more permanent magnets, the one or more magnetic field sensors being configured to detect movement of the moving feature to determine a health status of the inflow control valve (ICV).

[0104] I. A well system, the well system comprising: 1) a wellbore extending through one or more subterranean formations; and 2) a lower completion coupled to a conduit and positioned within the wellbore, the lower completion comprising: a) a base pipe extending between a first end and a second end and defining an interior flow passage; b) one or more openings extending through a sidewall thickness of the base pipe; and c) an inflow control valve (ICV) coupled to the base pipe proximate the one or more openings, the inflow control valve (ICV) comprising: i) a valve body; ii) a fluid flow path defined within the valve body, the fluid flow path comprising a channel positioned between an inlet fluid port and an outlet fluid port;iii) a movable feature disposed along the fluid flow path between the inlet fluid port and the outlet fluid port, the movable feature configured to form a restriction in the channel to regulate fluid flow along the fluid flow path; iv) one or more permanent magnets coupled to one of the movable feature or a fixed feature of the valve body; and v) one or more magnetic field sensors coupled to one of the fixed feature or the movable feature and positioned proximate to the one or more permanent magnets, the one or more magnetic field sensors configured to detect movement of the movable feature to determine a health status of the inlet flow control valve (ICV). ;

[0105] Aspects A, B, C, D, E, F, G, H and I may comprise one or more of the following additional elements in combination: Element 1: wherein the movable feature is at least a portion of the bore flow management actuator. Element 2: wherein the bore flow management actuator comprises a flow tube main body configured to move the valve closure mechanism between the first closed state and the first open state, and further wherein the movable feature is the flow tube main body. Element 3: wherein the movable feature is the valve closure mechanism. Element 4: wherein the valve closure mechanism is a flap valve. Element 5: wherein the closure mechanism of valve is a ball valve. Item 6: wherein the one or more magnetic field sensors are configured to detect a speed of movement of the movable feature to determine the health of the safety valve. Item 7: wherein the one or more magnetic field sensors are configured to detect an acceleration as a function of the time of movement of the movable feature to determine the health of the safety valve. Item 8: wherein the one or more permanent magnets are coupled to one of the movable feature of the safety valve or the fixed feature of the safety valve and the one or more magnetic field sensors are coupled to another of the fixed feature of the safety valve or the movable feature of the safety valve.Item 9: wherein the one or more permanent magnets are coupled to the movable feature and the one or more magnetic field sensors are coupled to the fixed feature. Item 10: wherein the movable feature is at least a portion of the bore flow management actuator. Item 11: wherein the bore flow management actuator has a flow tube main body configured to move the valve closure mechanism between the first closed state and the first open state, and further wherein the movable feature is the flow tube main body. Item 12: wherein the movable feature is the valve closure mechanism. Item 13: wherein the valve closure mechanism is a poppet valve. Item 14: wherein the valve closure mechanism is a ball valve.Item 15: wherein the one or more magnetic field angle sensors are configured to detect a rate of movement of the movable feature to determine the health of the safety valve. Item 16: wherein the one or more magnetic field angle sensors are configured to detect an acceleration as a function of the time of movement of the movable feature to determine the health of the safety valve. Item 17: wherein the one or more permanent magnets are coupled to one of the movable feature of the safety valve or the fixed feature of the safety valve and the one or more magnetic field angle sensors are coupled to another of the fixed feature of the safety valve or the movable feature of the safety valve.Item 18: wherein the one or more permanent magnets are coupled to the movable feature and the one or more magnetic field angle sensors are coupled to the fixed feature. Item 19: wherein the one or more magnetic field angle sensors are two or more magnetic field angle sensors positioned in proximity. Item 20: wherein the movable feature is an adjustable valve. Item 21: wherein the adjustable valve is a sliding feature. Item 22: in . wherein the sliding feature is a piston valve. Item 23: wherein the adjustable valve is a ball valve. Item 24: wherein the adjustable valve is a poppet valve. Item 25: wherein the one or more magnetic field sensors are configured to measure a magnitude of an electric field to determine the health of the inflow control valve (ICV). Item 26: wherein the one or more magnetic field sensors are configured to measure an angle of an electric field to determine the health of the inflow control valve (ICV). Item 27: wherein the one or more magnetic field sensors are coupled to the fixed feature. Item 28: wherein the one or more permanent magnets are coupled to the movable feature.

[0106] Those skilled in the art to which the present application relates will understand that other additions, deletions, substitutions and modifications may be made to the described embodiments.

Claims

Claims

1. A safety valve, comprising: an outer housing; a bore flow management actuator disposed within the outer housing; a valve closing mechanism disposed within the outer housing, the bore flow management actuator configured to slide from a first initial state to a first subsequent state to move the valve closing mechanism between a first closed state and a first open state; one or more permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve;and one or more magnetic field sensors coupled to one of the fixed feature of the safety valve or the movable feature of the safety valve and positioned proximate to the one or more permanent magnets, the one or more magnetic field sensors configured to detect movement of the movable feature to determine the health of the safety valve.;

2. A safety valve according to claim 1, wherein the movable feature is at least a part of the bore flow management actuator.

3. The safety valve of claim 2, wherein the bore flow management actuator comprises a flow tube main body configured to move the valve closure mechanism between the first closed state and the first open state, and further wherein the movable feature is the flow tube main body.

4. A safety valve according to claim 1, wherein the movable feature is the valve closing mechanism.

5. A safety valve according to claim 4, wherein the valve closing mechanism is a flap valve, or optionally wherein the valve closing mechanism is a ball valve.

6. The safety valve of claim 1, wherein the one or more magnetic field sensors are configured to detect a movement speed of the moving feature to determine the health status of the safety valve.

7. The safety valve of claim 1, wherein the one or more magnetic field sensors are configured to detect a time-dependent acceleration of movement of the moving feature to determine the health of the safety valve.

8. The safety valve of claim 1, wherein the one or more permanent magnets are coupled to one of the movable feature of the safety valve or the fixed feature of the safety valve and the one or more magnetic field sensors are coupled to another of the fixed feature of the safety valve or the movable feature of the safety valve, or optionally wherein the one or more permanent magnets are coupled to the movable feature and the one or more magnetic field sensors are coupled to the fixed feature.

9. A well system, comprising: a wellbore extending through one or more subterranean formations; a production tubing disposed in the wellbore; and a safety valve disposed in the wellbore, the safety valve comprising: an outer housing; a bore flow management actuator disposed within the outer housing; a valve closure mechanism disposed within the outer housing, the bore flow management actuator configured to slide from a first initial state to a first subsequent state to move the valve closure mechanism between a first closed state and a first open state; one or more permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve;and one or more magnetic field sensors coupled to one of the fixed feature of the safety valve or the movable feature of the safety valve and positioned proximate to the one or more permanent magnets, the one or more sensors; magnetic field being configured to detect movement of the moving feature to determine the health of the safety valve.

10. The well system of claim 9, wherein the movable feature is at least a portion of the bore flow management actuator, or optionally wherein the bore flow management actuator comprises a flowtube main body configured to move the valve closure mechanism between the first closed state and the first open state, and further wherein the movable feature is the flowtube main body.

11. A well system according to claim 9, wherein the movable feature is the valve closing mechanism, or optionally wherein the valve closing mechanism is a flap valve, or optionally wherein the valve closing mechanism is a ball valve.

12. The well system of claim 9, wherein the one or more magnetic field sensors are configured to detect a rate of movement of the moving feature to determine the health of the safety valve.

13. The well system of claim 11, wherein the one or more magnetic field sensors are configured to detect a time-dependent acceleration of movement of the moving feature to determine the health of the safety valve.

14. The well system of claim 9, wherein the one or more permanent magnets are coupled to one of the movable feature of the safety valve or the fixed feature of the safety valve and the one or more magnetic field sensors are coupled to another of the fixed feature of the safety valve or the movable feature of the safety valve, or optionally wherein the one or more permanent magnets are coupled to the movable feature and the one or more magnetic field sensors are coupled to the fixed feature.

15. A method, comprising: positioning a safety valve within a wellbore extending through one or more subterranean formations, the safety valve being arranged in a production tube, the safety valve comprising: an external box; a bore flow management actuator disposed within the outer housing; a valve closure mechanism disposed within the outer housing, the bore flow management actuator configured to slide from a first initial state to a first subsequent state to move the valve closure mechanism between a first closed state and a first open state; one or more permanent magnets coupled to one of a movable feature of the safety valve or a fixed feature of the safety valve; and one or more magnetic field sensors coupled to one of the fixed feature of the safety valve or the movable feature of the safety valve and positioned proximate to the one or more permanent magnets, the one or more magnetic field sensors configured to detect movement of the movable feature to determine the health of the safety valve; and detecting movement of the moving feature using the one or more permanent magnets and the one or more magnetic field sensors to determine the health of the safety valve.

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