Magnetic Flow Valve for Borehole Debris Management
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Solution Overview
Problem
Existing downhole treatment plug designs that use a spring and ball system to control fluid flow are prone to debris accumulation, spring weakening over time, and inefficient flow management, leading to unreliable operation.
Innovation Solution
A magnetic valve system featuring repelling magnetic discs with offset holes that allow fluid flow until a predetermined rate is reached, at which point the magnetic force is overcome, causing one disc to move and close the passage, ensuring reliable flow control without the need for a ball and spring mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring and ball system is used to control fluid flow, then the ball can be held off the seat until a predetermined flow creates sufficient reaction force, but the spring coils can fill with debris preventing ball movement and the spring can weaken over time leading to unreliable operation
Solution Approach 1:
The patent replaces the mechanical spring system with a magnetic field system. Magnets are positioned to create a magnetic field that holds the ball off the seat without physical contact. The magnetic field strength is calibrated so that normal flow does not overcome it, but predetermined high flow rates generate sufficient force to move the ball and close the passage. This eliminates spring coils that could fill with debris while maintaining reliable flow control.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the ball and the seat. Instead of using a physical spring to hold the ball, the magnetic field acts as a non-contact holding mechanism. This intermediary allows the ball to be held in position without mechanical components that could accumulate debris, solving the reliability issue while maintaining the predetermined flow activation function.
2Ease of operation
If a spring is used to hold the ball off the seat, then the ball can be positioned for flow control, but the spring has its upper end laterally unsupported allowing the ball to spread the spring end apart instead of compressing the spring
Solution Approach 1:
The patent replaces the mechanically complex spring system with a simpler magnetic field system. The magnets are positioned to create a focused magnetic field that holds the ball without requiring lateral support structures. The magnetic force acts directly on the ball through the fluid, eliminating the need for complex spring support structures and making the system easier to operate and more reliable.
3Duration of action of stationary object
If a spring system is used for flow control, then the ball can be held in position, but over long periods the spring can weaken and allow the ball to seat at an inopportune time
Solution Approach 1:
The patent replaces the degradable spring system with a magnetic field system that does not suffer from material fatigue or weakening over time. Magnets maintain consistent magnetic field strength without degradation, ensuring that the ball remains reliably held in position for the intended duration. This eliminates the reliability issue of springs weakening and causing inopportune ball seating.
Solution Approach 2:
The patent changes the fundamental parameter from mechanical force (spring compression) to magnetic force. Magnetic fields can be maintained at consistent strength levels without the degradation that affects mechanical springs over time. This parameter change ensures long-term durability and consistent flow control operation.
4Productivity
If a ball and spring mechanism is used, then flow can be controlled, but the design presents considerable drawbacks including milling difficulties and erosion problems
Solution Approach 1:
The patent replaces the mechanical ball and spring system with a magnetic field system that eliminates erosion-prone components. The magnets can be positioned and secured without complex milling operations, and the magnetic field itself is resistant to erosion. This simplifies manufacturing while maintaining effective flow rate control.
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 magnetic valve system provides a reliable and durable solution for controlling fluid flow, preventing debris accumulation and ensuring consistent operation by using repelling magnetic forces to manage flow rates and close the passage effectively, reducing the need for frequent maintenance and improving long-term performance.
Implementation Method 1
opposed perforated magnetic discs that repel each other to stay apart allowing flow through the openings of the spaced discs
Implementation Method 2
When a predetermined flow rate is exceeded, the magnetic repelling force is overcome and one disc moves toward the other to shut off flow
Data Source
AI summary
A valve for a plug passage features opposed perforated magnetic discs that repel each other to stay apart allowing flow through the openings of the spaced discs. When a predetermined flow rate is exceeded, the magnetic repelling force is overcome and one disc moves toward the other to shut off flow as contact between the discs closed the openings between them. One way is to offset the openings and guide the moving disc axially while rotationally locking the moving disc. Another way is to spirally guide the moving disc so that openings initially aligned rotate out of alignment. One or more edge slots can be provided in each disc to sweep out debris that can settle between the discs that would otherwise impede the moving disc from contacting the stationary disc for passage closure.