Valve Position Detection via Actuator Piston Sensor
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Solution Overview
Problem
During downhole drilling and recovery operations, wireline cables are prone to damage due to valve closure, leading to increased time and costs associated with tool recovery, as operators struggle to identify valve positions and prevent inadvertent closures.
Innovation Solution
A system and method for determining valve member positions using a closure cap with a sensor assembly that detects the actuator piston position, providing alerts and preventing valve closure through visual, auditory, or haptic indicators, and wireless transmission to stop actuator operation, thereby reducing wireline cable damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a valve is closed to control flow, then flow regulation is improved, but wireline cable may be sheared due to inadvertent closure
Solution Approach 1:
The sensor assembly detects the position of the actuator piston before the valve member reaches the closed position. When the piston approaches a predetermined position indicating imminent closure, the system activates an alert mechanism (visual, auditory, or haptic) to warn operators in advance, allowing them to prevent inadvertent cable shearing before it occurs.
Solution Approach 2:
The system continuously monitors the actuator piston position through the sensor assembly and provides real-time feedback to operators via alert mechanisms. This feedback loop enables operators to understand the current valve state and take appropriate action to prevent harmful cable damage while maintaining necessary flow control operations.
2Object-affected harmful factors
If operators manually monitor valve positions, then cable safety can be maintained, but operation time and complexity increase
Solution Approach 1:
The sensor assembly autonomously monitors the actuator piston position and automatically activates alert mechanisms without requiring continuous manual inspection by operators. The system serves itself by detecting its own state and providing warnings, thereby maintaining cable safety while reducing operational time and complexity.
Solution Approach 2:
The patent replaces manual mechanical monitoring with an automated sensor-based detection system. The sensor assembly uses non-contact sensing methods to detect piston position, substituting human observation and manual valve position checking with automated electronic detection,ไป่ reducing operation time while maintaining safety.
3Reliability
If a sensor assembly is installed to detect valve position, then inadvertent closure can be prevented, but device complexity increases
Solution Approach 1:
The sensor assembly is integrated into the existing actuator structure, allowing it to perform multiple functions: detecting piston position, determining valve member position, and triggering alert mechanisms. This multi-functionality reduces the need for separate components and minimizes overall system complexity while maintaining reliable inadvertent closure prevention.
Solution Approach 2:
The patent combines the sensor assembly with the closure cap structure, merging the detection function with the existing actuator housing. By integrating multiple functions into a single integrated component rather than adding separate independent systems, the overall device complexity is minimized while achieving reliable valve position monitoring and inadvertent closure prevention.
Data Source
AI summary
Embodiments of the present disclosure include a system for determining a valve member position. The system includes a valve having a flow passage extending therethrough. The system also includes a valve member positioned in a cavity that intersects the flow passage, the valve member coupled to a valve stem that axially translates the valve member between an open position and a closed position. The system includes an actuator coupled to the valve stem, the actuator providing a motive force to drive the axial movement of the valve member via the valve stem. The system includes a closure cap coupled to the actuator, the closure cap comprising a sensor feature arranged within an interior portion of the closure cap, the sensor feature arranged to react to an input from an actuator piston indicative of an actuator piston position within the interior portion of the closure cap.