Electromagnetic Locking Coupler for Fail-Safe Subsurface Safety Valves
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Solution Overview
Problem
Subsurface safety valves in oil production tubings experience high failure rates due to clogging or leaks in hydraulic actuation means, which can lead to unsafe valve closure and environmental contamination.
Innovation Solution
Incorporating an electromagnetic-mechanical coupler into the subsurface safety valve, which enables immediate disconnection of actuation means from flow control upon power interruption, allowing the return means to directly act on the flow restriction for safe closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hydraulic actuation means are used in subsurface safety valves, then the valve can be remotely operated, but the system experiences high failure rates due to clogging or leaks in control lines and piston chamber
Solution Approach 1:
The patent removes the hydraulic actuation system (control lines, hydraulic piston, hydraulic power unit) from the subsurface safety valve and replaces it with an electric motor-driven mechanism. This extraction eliminates the sources of hydraulic failures (clogging, leaks) while maintaining remote operation capability through electrical signaling.
Solution Approach 2:
The patent replaces the hydraulic mechanical system with an electromechanical system. The electric motor drives the flow tube directly, and electromagnetic locks (solenoids) replace the hydraulic locking mechanism. This substitution eliminates hydraulic fluid dependencies and associated failure modes while achieving the same functional goals.
2Use of energy by moving object
If secondary locking devices (collets) are used to reduce power requirements, then the power needed to maintain open position is reduced, but the locking mechanism adds device complexity
Solution Approach 1:
The patent uses multiple electromagnetic locks (solenoids) positioned at different locations along the flow tube, similar to how collets provide distributed mechanical locking. These electromagnetic locks provide distributed securing points that reduce the power needed to maintain positioning while avoiding the mechanical complexity of traditional collet systems.
Solution Approach 2:
The patent changes the locking mechanism from mechanical (collets) to electromagnetic (solenoids). This parameter change allows for more precise control of the locking force, enables remote actuation, and reduces the power required to maintain the locked state compared to mechanical spring-driven collets.
3Ease of operation
If hydraulic control lines are used for actuation, then remote control is achieved, but clogging or leaks in control lines cause valve failure
Solution Approach 1:
The patent removes the hydraulic control lines from the system and replaces them with electrical wiring and electronic control components. This extraction eliminates the physical vulnerabilities of hydraulic lines (clogging, leaking) while preserving the ability to control the valve remotely through electrical signals.
Solution Approach 2:
The patent substitutes the hydraulic control system with an electromechanical control system. The electric motor and electromagnetic locks replace the hydraulic piston and control lines, eliminating fluid-based actuation and its associated failure modes while maintaining remote operability through electrical control circuits.
4Ease of operation
If hydraulic piston is used to actuate the flow tube, then the valve can be opened by applying hydraulic pressure, but piston chamber leaks or piston failures prevent safe closure
Solution Approach 1:
The patent removes the hydraulic piston and piston chamber from the actuation system and replaces them with an electric motor directly coupled to the flow tube through a drive mechanism. This extraction eliminates the sealed chamber requirements and moving piston components that are prone to leaking and failing, while maintaining the ability to open the valve on demand.
Solution Approach 2:
The patent replaces the hydraulic piston actuation system with an electromechanical drive system. The electric motor provides direct mechanical drive to the flow tube, eliminating the need for hydraulic pressure transmission through a piston. This substitution removes the failure points associated with piston seals, chamber leaks, and hydraulic pressure maintenance.
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 enhances operational safety and reliability by ensuring quick and safe valve closure even in power failure scenarios, reducing infrastructure costs and minimizing environmental risks.
Implementation Method 1
an electromagnetic-mechanical coupler formed by an electromagnet and a ferromagnetic bulkhead
Implementation Method 2
a spring, which provides the valve return to the closed position
Data Source
AI summary
An electromagnetic-mechanical locking device applied to a subsurface safety valve comprising an electromagnetic-mechanical coupler formed electromagnet (4), ferromagnetic bulkhead (5) in solidarity to the mobile part (6), actuated by spring (9), in addition to locking element (7), and when activated, the electromagnet (4) creates a magnetic field that attracts the ferromagnetic bulkhead (5), along with the mobile part (6), moving this set towards the electromagnet (4), and compressing the locking element (7). During the movement, the mobile part (6) shifts the locking element (7) to the locking position, until it reaches its coupling on the flow tube (3), where it is maintained with compression locking element (7), configuring a trigger device. When the power supplied to the electromagnet (4) ceases, the electromagnetic attraction force of the ferromagnetic bulkhead (5) is cancelled, and the locking element (7), until then retracted, is distended, causing the return of the mobile part (6) to initial position.