Downhole Hydraulic Pump Control Using Low-Power Electrical Lines
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Solution Overview
Problem
Existing wellbore operations require hydraulic control lines from the surface, which are prone to issues due to increased pressures and temperatures at greater depths, limiting the effective control of wellbore equipment.
Innovation Solution
A control system that uses a single electrical power line from the surface to operate wellbore equipment, eliminating the need for hydraulic control lines, and includes a hydraulic pump, accumulator, valve bank, and unpressurized fluid reservoir, with modular components that can be rearranged across well zones to manage hydraulic pressure and fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic control lines are used from the surface to operate wellbore equipment, then equipment can be controlled, but the system reliability deteriorates due to increased pressures and temperatures at greater depths
Solution Approach 1:
The patent removes hydraulic control lines from the surface and extracts the hydraulic power generation function to the downhole environment. A hydraulic pump is deployed in the wellbore zone, powered by an electrical motor through an electrical power line, eliminating the need for hydraulic control lines to traverse from the surface where they are exposed to harmful high pressures and temperatures.
Solution Approach 2:
The patent replaces the mechanical hydraulic control line system with an electrical power transmission system. Instead of using hydraulic lines to transmit control pressure from the surface, the system uses electrical power lines to drive a downhole hydraulic pump, substituting mechanical hydraulic transmission with electrical transmission and local hydraulic generation.
2Ease of operation
If hydraulic control lines are used from the surface, then equipment operation is enabled, but the device complexity increases due to the need for surface-based hydraulic systems
Solution Approach 1:
The patent extracts the hydraulic power generation function from the surface environment and places it downhole. The hydraulic pump and electrical motor are deployed in the wellbore zone, eliminating the need for complex surface-based hydraulic control systems, accumulators, and pressure regulation equipment while simplifying the overall system architecture.
Solution Approach 2:
The patent substitutes the complex mechanical hydraulic control line infrastructure with a simpler electrical power transmission system. Electrical power lines are used to drive downhole pumps, eliminating the need for surface hydraulic accumulators, pressure regulators, and extensive hydraulic piping, thereby reducing device complexity.
3Adaptability or versatility
If modular components are used in the control system, then adaptability improves for different well zones, but the device complexity increases due to multiple components
Solution Approach 1:
The patent divides the control system into modular functional components including hydraulic pumps, electrical motors, accumulators, and valve banks that can be independently deployed in different wellbore zones. These modular units can be selectively placed and configured to match specific operational requirements of different well zones, enhancing adaptability while maintaining manageable system complexity through standardized interfaces.
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 robust operation of wellbore equipment at any depth without hydraulic control lines, enhancing system reliability and flexibility by using low-power electrical connections and modular design.
Implementation Method 1
a hydraulic pump...configured to receive hydraulic fluid from the unpressurized hydraulic fluid reservoir and to pressurize the hydraulic fluid
Implementation Method 2
an accumulator...configured to store pressurized hydraulic fluid from the hydraulic pump
Data Source
AI summary
An example control system includes a hydraulic pump disposed in a wellbore, a valve bank disposed in the wellbore, and an unpressurized hydraulic fluid reservoir. The hydraulic pump is fluidically connected with the valve bank. The valve bank is fluidically connected with the unpressurized hydraulic fluid reservoir. The unpressurized hydraulic fluid reservoir is fluidically connected with the hydraulic pump. The control system is configured to flow pressurized hydraulic fluid exiting from the hydraulic pump to the valve bank to be distributed from the valve bank to the wellbore equipment.