Magnetic Subsurface Safety Valve Coupling for Thicker Pressure Barriers
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Solution Overview
Problem
Existing safety valves for preventing uncontrolled releases of hydrocarbons in wellbores face challenges due to the need for non-ferrous materials like Inconel, which are expensive and difficult to work with, and the limited operational range due to magnetic coupling strength decreasing with distance, leading to potential leaks and increased costs.
Innovation Solution
The use of a spatially rotated array of magnets in the magnetic coupling between the drive and actuator portions of the subsurface safety valve, which biases magnetic flux towards the operative side, allowing for increased coupling force and the use of ferrous materials, thereby reducing costs and enhancing operational range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a magnetic coupling is used between drive and actuator portions, then the safety valve can be actuated remotely, but the coupling force decreases with distance limiting operational range
Solution Approach 1:
The patent applies asymmetry by orienting magnet assemblies non-uniformly within the drive and actuator portions. The magnets are arranged with specific polarities facing each other across the pressure separator, creating an asymmetric magnetic field configuration that maximizes coupling force at the interface while minimizing flux leakage to other components. This asymmetric arrangement allows the magnetic coupling to maintain sufficient force over the required distance through the pressure separator.
Solution Approach 2:
The pressure separator acts as an intermediary element between the drive and actuator portions. The patent configures the magnetic assemblies to couple through this intermediate component, which physically separates the hydraulic drive side from the pressured actuator side while allowing magnetic field penetration. The intermediary structure enables remote actuation while maintaining force transmission through the separating barrier.
2Reliability
If non-ferrous materials like Inconel are used in magnetic coupling components, then magnetic flux containment is improved, but manufacturing cost and difficulty increase
Solution Approach 1:
The patent replaces expensive non-ferrous materials like Inconel with cheaper ferrous materials for components surrounding the magnetic assemblies. By using readily available ferrous materials that can be easily manufactured and replaced if needed, the design reduces manufacturing cost and complexity while maintaining adequate magnetic flux containment through proper magnetic assembly configuration rather than relying on expensive material properties.
Solution Approach 2:
The patent changes the material parameter from non-ferrous to ferrous materials, fundamentally altering the magnetic properties of the surrounding components. This parameter change allows the use of standard ferrous materials that are easier and cheaper to manufacture, while the magnetic assembly design compensates for any differences in magnetic permeability through optimized magnet orientation and arrangement.
3Reliability
If the distance between magnetic assemblies is increased to accommodate pressure separator thickness, then operational safety is improved, but coupling force decreases
Solution Approach 1:
The asymmetric orientation of magnet assemblies is configured to direct maximum magnetic flux through the pressure separator interface. By positioning magnets with alternating polarities facing each other across the separator, the design creates concentrated flux paths that maintain coupling force even when the separator thickness increases for safety requirements.
Solution Approach 2:
The magnetic assemblies are pre-configured with specific orientations and polarities during manufacturing to establish optimal coupling before installation. This preliminary arrangement ensures that when the pressure separator is installed at its required thickness for safety, the magnetic coupling is already optimized to maintain sufficient force across that predetermined distance.
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 design increases the coupling force without increasing length, allows for thicker pressure separators, and reduces the need for expensive non-ferrous materials, thus improving the safety valve's operational range and cost-effectiveness.
Implementation Method 1
a drive portion and an actuator portion that are magnetically coupled and used to open and close the subsurface safety valve
Implementation Method 2
biases magnetic flux towards the operative side
Data Source
AI summary
A safety valve comprises a drive portion and an actuator portion. The drive portion comprises a first magnet assembly. A first magnetic field emitted from the first magnet assembly is biased towards a first operative side of the first magnet assembly. The first operative side is oriented toward a center of the wellbore. The actuator portion comprises a second magnet assembly magnetically coupled to the first magnet assembly.