Deep-Set Insert Valve Magnetic Coupling for Non-Destructive Installation
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Solution Overview
Problem
Tubing retrievable safety valves in wellbores fail over time, and restoring control of fluid flow requires cutting and drilling, which is time-consuming and potentially compromises the safety valve.
Innovation Solution
A magnetically driven downhole insert valve with a secondary follower magnet that moves in response to a magnetically coupled secondary driver magnet, allowing installation without cutting or drilling into the tubing retrievable safety valve, and includes a magnetic coupling to actuate an insert flapper valve between open and closed positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cutting and drilling into the downhole tubular is performed to provide actuation power to the insert valve, then the insert valve can be actuated, but the installation process becomes time-consuming and the tubing retrievable safety valve may be compromised
Solution Approach 1:
The patent replaces the conventional mechanical actuation system (requiring cutting and drilling) with a magnetic actuation system. The driver magnet assembly generates a magnetic field that acts on the follower magnet attached to the insert flow tube, enabling actuation of the insert valve without mechanical intervention. This substitution eliminates the need for cutting and drilling operations, thereby reducing installation time while maintaining reliable valve actuation capability
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the driver magnet assembly and the follower magnet. This magnetic field serves as the medium for transmitting actuation force without direct mechanical contact or modification of the tubular structure. The magnetic coupling allows power transmission through the tubular wall without requiring physical access or damage to the existing valve structure
2Reliability
If cutting and drilling into the downhole tubular is performed to provide actuation power to the insert valve, then the insert valve can be actuated, but the tubing retrievable safety valve structure may be compromised
Solution Approach 1:
The patent replaces mechanical actuation (cutting and drilling) with magnetic actuation. The driver magnet assembly creates a magnetic field that penetrates the tubular wall to actuate the follower magnet and insert valve without physical contact or structural modification. This preserves the integrity and strength of the tubing retrievable safety valve structure while achieving reliable insert valve actuation
Solution Approach 2:
The magnetic field acts as an intermediary that transmits actuation force through the tubular wall without compromising the structural integrity of the tubing retrievable safety valve. This allows power transmission while maintaining the strength and integrity of the existing valve structure
3Loss of time
If magnetic coupling is used to actuate the insert valve without cutting or drilling, then installation time is reduced and valve structure is preserved, but a new actuation mechanism must be implemented
Solution Approach 1:
The patent extracts the actuation function from the mechanical domain and implements it in the magnetic domain. By removing the requirement for mechanical cutting and drilling operations, the system achieves faster installation. The actuation mechanism is simplified to consist of a driver magnet assembly and a follower magnet, eliminating complex mechanical intervention while maintaining effective valve control capability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and non-destructive installation and operation of a backup or replacement valve within the tubing retrievable safety valve, maintaining fluid flow control without damaging the existing valve structure.
Implementation Method 1
A magnetically driven downhole insert valve with a secondary follower magnet that moves in response to a magnetically coupled secondary driver magnet
Data Source
AI summary
A downhole system may include an insert frame securable within a central bore of a tubing retrievable safety valve that has driver magnet configured to project a magnetic field and move axially along a control line in the tubing retrievable safety valve. The downhole system may include an insert flapper connected to the insert frame and configured to actuate between an open position and a closed position to control fluid flow through the central bore. The downhole system may include an insert flow tube configured to move along the central bore to drive the insert flapper between the closed position and the open position. Further, the downhole system may include a follower magnet secured to the insert flow tube and magnetically engaged with the driver magnet. The follower magnet is configured to move in response to movement of the driver magnet to drive movement of the insert flow tube.