Magnetic Actuator Valve for High-Temperature Downhole Pulsing
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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-activated plunger to create pressure pulses, where the body and plunger are partially made of magnetic material, eliminating the need for oil fillings and electrical connectors, and using corrosion-resistant materials like Vacoflux and Inconel to withstand harsh conditions.
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 in moderate temperature environments, 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. By extracting these temperature-sensitive components, the system can operate reliably in high-temperature environments above 300° F without component deterioration.
Solution Approach 2:
The invention changes the material parameters of the mud pulser components by using high-temperature-resistant materials such as magnetic materials for the plunger and body, and corrosion-resistant materials like Vacoflux and Inconel. This parameter change enables operation in extreme thermal environments.
2Temperature
If magnetic materials are used for the plunger and body, then the system can operate in high temperature environments, but the device complexity increases due to the magnetic circuit design
Solution Approach 1:
The patent combines the plunger and body into a magnetic circuit system where both components are made from magnetic materials. This merging allows the magnetic field to directly actuate the plunger through the body, eliminating the need for intermediate components and simplifying the overall magnetic circuit design despite using complex magnetic materials.
Solution Approach 2:
The invention replaces traditional mechanical actuation systems with a magnetic field-based system. The solenoid generates a magnetic field that directly moves the magnetic plunger through the magnetic body, eliminating the need for mechanical linkages, seals, and connectors that would fail in high-temperature environments.
3Object-affected harmful factors
If corrosion-resistant materials like Vacoflux and Inconel are used, then the device can withstand harsh downhole conditions, but the manufacturing cost and difficulty increase
Solution Approach 1:
The patent employs composite material construction by combining corrosion-resistant materials (Vacoflux, Inconel) with magnetic materials in specific components. This composite approach provides both corrosion resistance and magnetic properties where needed, while using standard materials elsewhere to maintain ease of manufacture.
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 pulse generation in high-temperature environments, enabling effective communication of downhole data to the uphole system without the limitations of existing technologies.
Implementation Method 1
A solenoid is mounted at the body about at least a part of the magnetic material in 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 move thereby narrowing the gap to produce a pressure pulse in the wellbore.
Data Source
AI summary
A control valve assembly for a downhole wellbore including a body formed partially from a magnetic material. A plunger is moveably mounted in the body. A portion of the plunger is formed from a magnetic material. A magnetic circuit having a gap is arranged within the control valve assembly. The portion of the body formed from a 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 and is selectively activated to create a magnetic field across the gap in the magnetic circuit causing the plunger to move thereby narrowing the gap to produce a pressure pulse in the wellbore.