Downhole Valve Sleeve Sensing With Circumferential Error Correction
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Solution Overview
Problem
Existing downhole sliding sleeve valve assemblies face challenges in accurately determining the relative position of the sleeve and housing due to misalignment, bending, and other structural deviations, which can lead to errors in valve operation.
Innovation Solution
The use of circumferentially spaced inductive proximity sensors that process signals from markers on the sleeve and housing to provide position information, correcting for errors by integrating or subtracting signals from primary and reference sensors, allowing for precise alignment and operation of the valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sensor is used to detect sleeve position, then the device complexity is reduced, but the measurement precision deteriorates due to misalignment and structural deviations
Solution Approach 1:
The sensor assembly is segmented into multiple circumferentially spaced sensors (at least two) that independently detect position information. Each sensor provides measurements from different angular positions, allowing the system to detect and correct for misalignment and structural deviations through signal processing of multiple independent measurements rather than relying on a single sensor.
Solution Approach 2:
The solution transitions from single-point measurement to multi-point circumferential measurement by spacing sensors around the sleeve. This adds a circumferential dimension to the position detection, enabling the system to identify and compensate for angular misalignment and bending errors that would be invisible to a single sensor.
2Measurement precision
If multiple circumferentially spaced sensors are used to correct alignment errors, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The multiple sensors serve multiple functions simultaneously: they detect the absolute position of the sleeve, identify angular misalignment between housing and sleeve, detect bending or bowing of the assembly, and provide redundant measurements for error correction. This multi-functionality justifies the increased complexity by delivering comprehensive diagnostic and measurement capabilities from a single sensor array.
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
This solution enables accurate determination of the sleeve's position relative to the housing, reducing errors from misalignment and structural deviations, ensuring reliable operation of the downhole valve assembly.
Implementation Method 1
the first and second primary sensors comprise inductive proximity sensors
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A downhole valve assembly comprises a sleeve concentric with a housing and movable relative to a port through the housing to control flow of fluid through the port. A sensor assembly provides indicates the relative positions of the sleeve and housing, and comprises first and second sensors on e.g. the housing which detect markers on e.g. the sleeve. The sensor outputs are produced by processing (e.g. combining, integrating, summing, subtracting or otherwise processing) the signal components of each of the first and second sensors to correct for misalignment of the sleeve with the housing. The sensor output provides position information for more than one plane, and the output signal therefore allows for correction of errors in the position information arising from misalignment of the sleeve with the housing.