Downhole Multi-Circuit Switch for Redundant Power
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Solution Overview
Problem
Conventional methods for powering downhole equipment in wells require rig intervention when primary electric transmission systems fail, leading to delays, shutdown costs, and rig costs due to the lack of redundancy in electric cables.
Innovation Solution
Implementing a multi-circuit switch with a hydraulic actuator mechanism that allows switching between multiple electrical power cables, providing redundancy and enabling immediate switching to a spare transmission system without the need to remove the downhole equipment, thereby isolating a failed power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single power cable is used to supply electrical power to downhole equipment, then the device complexity is reduced, but the reliability is compromised due to lack of redundancy
Solution Approach 1:
The electrical power transmission system is segmented into multiple independent cables (first power cable, second power cable) that can operate independently. Each cable can be isolated or activated separately through the multi-circuit switch, allowing the system to maintain power supply even if one cable fails, thus improving reliability without requiring a single complex unified system
Solution Approach 2:
Multiple power cables are installed and configured in advance before any failure occurs. The multi-circuit switch is pre-configured with multiple positions corresponding to different cables. When a failure is detected, the system can immediately switch to a备用 (standby) cable without delay, as the redundancy is already in place and ready for immediate activation
2Productivity
If conventional single-cable systems are used, then the ease of operation is maintained, but the loss of time increases due to rig intervention requirements for cable replacement
Solution Approach 1:
The system enables self-service power restoration by automatically detecting cable failures and switching to backup cables through the multi-circuit switch without requiring external rig intervention. The downhole equipment can continue operating or be quickly reconfigured using the redundant cables already installed, eliminating the need for time-consuming manual cable replacement operations
Solution Approach 2:
Redundant power cables are installed and positioned in advance within the wellbore configuration. When a cable failure occurs, the standby cable is already in place and can be activated immediately through the multi-circuit switch, eliminating the need to wait for rig intervention and cable replacement, thus minimizing time loss
3Reliability
If multiple power cables are installed for redundancy, then the reliability is improved, but the device complexity increases due to multiple electrical connections
Solution Approach 1:
The multi-circuit switch serves multiple functions: it acts as a power distribution device, a failure detection system, a switching mechanism, and an isolation device all in one component. This universal device manages multiple power cables and their connections, allowing the system to handle redundancy complexity through a single multi-functional unit rather than requiring separate components for each function
4Ease of repair
If rig intervention is required for cable replacement, then the ease of repair is maintained through manual replacement, but the loss of time and costs increase due to shutdown requirements
Solution Approach 1:
The system enables self-service repair by allowing the downhole equipment to continue operating or be quickly reconfigured using redundant cables without requiring rig intervention. The multi-circuit switch can isolate failed cables and redirect power through backup cables, enabling the system to repair itself or minimize disruption without external intervention
Solution Approach 2:
Redundant power cables are pre-installed and configured within the wellbore before any failure occurs. When a cable needs replacement, the standby cable is already in place and can be activated immediately, eliminating the need for time-consuming rig intervention and cable replacement operations, thus reducing shutdown duration
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
This solution eliminates the need for rig intervention by providing redundant power pathways, reducing downtime and costs associated with failed power transmission systems, and ensuring continuous operation of downhole equipment.
Implementation Method 1
a downhole multi-circuit switch... equipped with a switch mechanism... The switch includes a hydraulic switch mechanism for moving between multiple positions
Data Source
AI summary
Systems and methods include a system for controlling a downhole multi-circuit switch using a downhole actuator mechanism. A command is sent, by a surface controller coupled to downhole electrically-powered equipment in a wellbore of a well, to change electrical power flow in a multi-circuit switch to a specified position of multiple positions. A connection between the surface controller and the downhole electrically-powered equipment includes at least two separate input electrical connections for supplying electrical power to the downhole electrically-powered equipment. The command is received by a downhole actuator mechanism from the surface controller. The command indicates to switch from a first electrical connection of the at least two separate input electrical connections to a second electrical connection of the at least two separate input electrical connections. The multi-circuit switch is switched by the downhole actuator mechanism based on the command to change a power source of the downhole electrically-powered equipment, including isolating a first input electrical connection.