Downhole Wet Connection Using AC to Prevent Corrosion

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Solution Overview

Problem

Downhole direct current wet connections in hydrocarbon exploration and production are prone to reliability issues due to corrosion from fluids like salt water, which reduces their effectiveness in powering electrical loads.

Innovation Solution

A downhole wet connection system that forms alternating current connections using a first electrode deployed near a load and a second electrode along a string, with an umbilical for direct current transmission, power converters to convert DC to AC, and a controller to modulate frequency and current density, along with insulators to prevent corrosion, enhancing power and data transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If direct current wet connections are used to power downhole loads, then power transmission is achieved, but corrosion from fluids like salt water reduces reliability

Engineering Contradiction:

Improveconnection reliabilityVSAvoidcorrosion from fluids

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an intermediary substance (conductive fluid or gel) between the electrodes to facilitate electrical contact while protecting them from corrosive downhole fluids. This intermediary layer allows current transmission while isolating the electrodes from direct contact with corrosive salt water and other fluids in the wellbore environment.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces traditional mechanical direct current connections with an alternating current system that uses electromagnetic induction. This substitution eliminates the need for direct physical contact between electrodes, thereby eliminating corrosion-related reliability issues while maintaining power transmission capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If electrodes are directly connected in wet environments, then electrical connection is established, but corrosion reduces effectiveness

Engineering Contradiction:

Improveconnection effectivenessVSAvoidservice life of electrodes

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent employs an intermediary conductive medium that enables electrical connection while protecting the electrodes from corrosive environments. This mediator extends the service life of electrodes by preventing direct exposure to corrosive fluids while maintaining effective electrical connection throughout the operational period.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

By replacing direct mechanical electrode contact with an alternating current electromagnetic induction system, the patent eliminates corrosion mechanisms that limit electrode service life, thereby extending the operational duration of the downhole power transmission system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If alternating current is used instead of direct current, then corrosion is reduced, but additional components like power converters are required

Engineering Contradiction:

Improveconnection reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the direct current mechanical connection system with an alternating current electromagnetic induction system. This substitution improves reliability by eliminating corrosion, and the added complexity of power converters is offset by the elimination of corrosion maintenance and extended service life.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the electrical parameter from direct current to alternating current, which fundamentally alters the interaction with corrosive fluids. This parameter change improves reliability, and the associated complexity of adding power conversion capability is justified by the significant improvement in connection reliability and service life.

Inventive Principle:

Principle #35Parameter changes

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 system improves the reliability and efficiency of power and data transmission to downhole loads by reducing electrical losses and corrosion, enabling stable operation over extended periods.

Implementation Method 1

a power converter that converts the direct current into alternating current and provides the alternating current across the alternating current wet connection

Methodology Applied

Scientific EffectElectrical Energy Conversion:

Implementation Method 2

transmitting an alternating current from the second electrode, across the wet connection, to the first electrode

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS10934785B2Downhole wet connection systems

Publication Date: 2021.03.02 HALLIBURTON ENERGY SERVICES INC

AI summary

Downhole wet connection systems, and methods and apparatuses to provide an electrical connection between two downhole strings. In one embodiment, a wet connection system having a first electrode coupled to a load and deployed in a wellbore. The wet connection system also includes a second electrode deployed along a string deployed in the wellbore and proximate to the first electrode. Further, the first electrode and the second electrode form a wet connection to transmit alternating current from the second electrode to the first electrode.