Magnetic Control Valve for High-Temperature Drilling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current mud pulsers used in downhole operations deteriorate in high-temperature environments due to oil fillings, elastomers, and electrical high-pressure connectors, making them unsuitable for prolonged use in temperatures above 300° F (149° C).
Innovation Solution
A control valve assembly utilizing a magnetic circuit with a solenoid to create a magnetic field, which shifts a plunger and produces pressure pulses in the wellbore, eliminating the need for oil fillings and electrical high-pressure connectors by using magnetic materials and a solenoid to generate pulses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mud pulser components (oil fillings, elastomers, electrical connectors) are used, then the device can operate at lower temperatures, but the components deteriorate over time in high-temperature environments above 300° F
Solution Approach 1:
The patent removes problematic components (oil fillings, elastomers, electrical high-pressure connectors) from the mud pulser system and replaces them with high-temperature resistant alternatives such as magnetic circuits, solenoids, and metal components that can withstand temperatures above 300° F without deterioration
Solution Approach 2:
The invention changes the material parameters and operational parameters of the mud pulser components to withstand high-temperature environments, specifically using magnetic materials and solenoid actuators that maintain reliability at temperatures where traditional components would fail
2Reliability
If magnetic circuit components are used to eliminate oil fillings and electrical connectors, then high-temperature reliability is improved, but the device complexity increases
Solution Approach 1:
The patent replaces traditional mechanical and electrical components (electrical connectors, elastomeric seals) with a magnetic circuit system using solenoids and magnetic materials, which eliminates the need for high-pressure electrical connections and oil-filled components while achieving high-temperature reliability
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
The solution provides reliable and durable pressure pulses in high-temperature environments, extending the operational life of downhole tools and maintaining effective communication of downhole data to the uphole system.
Implementation Method 1
A solenoid is mounted at the body about at least a part of the magnetic material of at least one of the body and the plunger. The solenoid is selectively activated to create a magnetic field across the gap in the magnetic circuit.
Implementation Method 2
The magnetic field causes the plunger to shift, narrowing the gap and disengaging from the one of the fluid inlet and the fluid outlet to produce a pressure pulse in the wellbore.
Data Source
AI summary
A control valve assembly for use in a wellbore includes a body having a fluid inlet and a fluid outlet. A portion of the body is formed from magnetic material. A plunger is mounted within the body. A portion of the plunger is formed from a magnetic material. A magnetic circuit having a gap is defined within the control valve assembly. The portion of the body formed from magnetic material defines a first portion of the magnetic circuit and the portion of the plunger formed from magnetic material forms another portion of the magnetic circuit. A solenoid is mounted at the body. The solenoid is selectively activated to create a magnetic field across the gap in the magnetic circuit. The magnetic field causes the plunger to shift, narrowing the gap disengaging from the one of the fluid inlet and the fluid outlet to produce a pressure pulse in the wellbore.