Downhole Multiplexed Electrical System for Wellhead Leak Reduction
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Solution Overview
Problem
Current systems for controlling downhole well tools in subterranean wells require a large number of wires or complex wireless telemetry and power systems, which can be unreliable and involve numerous penetrations at the wellhead, increasing the risk of leaks and complicating the operation.
Innovation Solution
A system utilizing a single conductor running from the surface to a downhole tubular with a control module that multiplexes the signal to control multiple downhole tools, minimizing the need for downhole electronics and reducing the number of electrical lines penetrating the wellhead, allowing for independent control of up to twelve downhole tools using a three-conductor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of wires or complex wireless telemetry systems are used to control multiple downhole tools, then the control capability is improved, but the system complexity and reliability deteriorate due to numerous penetrations and unreliable downhole electronics
Solution Approach 1:
A single electrical conductor is designed to perform multiple functions: it serves as both a communication channel for control signals and a power transmission line for downhole tools. The control module at the surface can selectively activate different tools along the conductor by modulating electrical characteristics (frequency, amplitude, or digital encoding), eliminating the need for separate wires for each tool while maintaining full control capability.
Solution Approach 2:
The patent combines multiple control and power functions into a single electrical conductor system. Instead of having separate wires for control signals and power supply for each downhole tool, the system merges these functions into one conductor that carries both control commands and electrical power to multiple tools simultaneously, significantly reducing system complexity.
2Measurement precision
If multiple wires are installed to individually actuate downhole tools, then the control precision is improved, but the number of penetrations and potential leak points increases
Solution Approach 1:
The single electrical conductor serves as a universal interface for both control signaling and power delivery to multiple downhole tools. By using this multi-functional conductor instead of multiple separate wires, the system maintains precise individual control of each tool while minimizing the number of penetrations required through the wellhead and packers, thereby reducing leak risk.
3Adaptability or versatility
If numerous electrical lines penetrate the wellhead to reach downhole tools, then the control flexibility is improved, but the operational reliability deteriorates due to increased sealing requirements and potential failure points
Solution Approach 1:
The system merges multiple electrical lines into a single conductor that extends from the surface through the wellhead to downhole tools. This consolidation maintains control flexibility because the control module can selectively address individual tools along the single conductor by varying electrical characteristics, while simultaneously improving reliability by reducing the number of seals and penetrations required.
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 simplifies the design and operation by reducing the number of penetrations and potential leak points, enhancing reliability and control over downhole tools while minimizing the complexity of the downhole electronics and electrical lines.
Implementation Method 1
a control module that multiplexes the signal to control multiple downhole tools
Data Source
AI summary
A control module for operation of downhole well tools and apparatuses is disclosed. The control module can control multiple tools, electronics, subs, etc. based on one electronic input and optionally one hydraulic input from the wellhead or surface. The control module can transmit along selected electronic lines and optionally hydraulic lines in order to control specific apparatuses of the downhole well tools. By allowing a single electronic line from the surface or shut in to control multiple tools, total electronic complexity is reduced. A three conductor control module can control operations of up to twelve downhole tools, and a two conductor control module can control operations of up to six downhole tools, in some embodiments.