Downhole Tool Actuation via Shared Conductors and Current Sensing
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Solution Overview
Problem
Existing technologies face challenges in electrically actuating multiple downhole well tools with minimal electrical conductors and without sensitive electronics in hostile environments.
Innovation Solution
A system utilizing multi-core Tubing Encased Conductors (TEC) to minimize electrical connections and brushed DC motors for actuation, combined with position indication through power draw variations and current algorithms, to control multiple downhole flow control valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple electrical conductors are used to supply power to multiple downhole well tools, then each tool can be independently actuated, but the number of electrical connections increases and device complexity increases
Solution Approach 1:
Multiple downhole tools are combined into a single assembly that shares common electrical conductors. The system uses a single multi-conductor electrical cable that distributes power to multiple tools through internal wiring, eliminating the need for separate external conductors for each tool while maintaining independent actuation capability
Solution Approach 2:
The electrical conductor system is designed to serve multiple functions simultaneously - a single multi-conductor cable provides power distribution to multiple different tools (valves, packers, pumps) throughout the wellbore, making the electrical infrastructure universal rather than dedicated to individual tools
2Measurement precision
If sensitive electronics are used in downhole well tools, then precise control and monitoring are achieved, but the tools become vulnerable to hostile downhole environments
Solution Approach 1:
The system replaces sensitive electronic control systems with robust mechanical actuation mechanisms. Electrical conductors provide power to simple mechanical actuators (motors, hydraulic pumps) that perform the actual work, eliminating the need for complex sensitive electronics downhole while maintaining control capability
Solution Approach 2:
Complex control electronics and sensitive instrumentation are extracted from the hostile downhole environment and relocated to the surface. The downhole tools retain only the essential actuation mechanisms that can withstand harsh conditions, while surface-based systems handle complex control functions
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
Enables efficient and reliable actuation of downhole tools with reduced electrical connections and complex electronics, allowing selective control of fluid flow in isolated well zones.
Implementation Method 1
brushed DC motors for actuation
Data Source
AI summary
A system for use with a subterranean well can include a system controller with a computer, a power supply and at least one current sensor, multiple downhole well tools, each of the downhole well tools including a motor and a member displaceable by the motor; and an umbilical connected between the system controller and the downhole well tools, at least one conductor of the umbilical being connected to the motor of each of the downhole well tools. A downhole well tool example can include an actuator assembly configured to displace a member of the downhole well tool, the actuator assembly including a motor, a load yoke displaceable by the motor, and an elongated position indicator bar having at least one profile formed thereon. Friction between the load yoke and the position indicator bar varies as the load yoke displaces relative to the position indicator bar.