Downhole Power Bus Control with Rechargeable Battery Charging
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Solution Overview
Problem
The oil and gas industry faces challenges with non-rechargeable batteries used in downhole operations, which require frequent replacement, occupy significant space, and are costly and time-consuming to replace, while downhole generators often only generate power when drilling mud is pumped, limiting the efficiency and reliability of downhole tools.
Innovation Solution
A downhole power system combining rechargeable batteries that can be charged in situ using downhole generators, such as RPM and piezoelectric generators, with a bus power controller managing power distribution to optimize the use of multiple power sources, reducing the need for frequent battery replacements and enhancing tool reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-rechargeable batteries are used for downhole operations, then power supply is reliable, but battery replacement frequency increases and service time increases
Solution Approach 1:
The patent implements a system where rechargeable batteries are deployed downhole and recharged in situ using downhole generators. Instead of discarding depleted batteries and replacing them with new ones, the system recovers energy continuously by capturing mechanical energy from drilling operations through RPM generators or pressure fluctuations through piezoelectric generators, thereby eliminating the need for battery replacement trips.
Solution Approach 2:
The downhole power system is designed to be self-sufficient by incorporating generators that automatically recharge batteries using energy from the drilling process itself. The system serves itself by converting mechanical energy from drill string rotation or pressure changes directly into electrical energy for battery recharging, without requiring external intervention or surface-based power sources.
2Device complexity
If non-rechargeable batteries are used, then power supply is simple, but space required for batteries increases
Solution Approach 1:
The patent merges multiple functions into a single integrated system: the batteries serve both as power sources and as energy storage devices, while the generators (RPM or piezoelectric) are integrated into the existing downhole tool string. This combination eliminates the need for separate surface-based charging equipment and reduces overall system volume by utilizing space-efficient rechargeable cells that can be cycled multiple times.
Solution Approach 2:
The system transitions from using large-volume non-rechargeable batteries to compact rechargeable batteries with higher energy density. By changing the battery chemistry and capacity parameters, the system achieves the same operational duration with significantly reduced volume, allowing the batteries to fit within standard downhole tool configurations.
3Power
If downhole generators are used, then power can be generated in situ, but power generation is limited to when drilling mud is pumped
Solution Approach 1:
The patent employs multiple types of generators with different operating principles to ensure continuous power generation regardless of drilling conditions. RPM generators capture energy from drill string rotation during normal drilling, while piezoelectric generators capture energy from pressure fluctuations during both drilling and tripping operations. This multi-functional approach ensures that at least one generator type is always producing power, eliminating downtime.
Solution Approach 2:
The system dynamically switches between different power generation modes based on operational conditions. When drilling mud is being pumped, piezoelectric generators are active; when tripping or running pipe without mud circulation, RPM generators take over. The power management system continuously monitors and adjusts the active generation mode to maintain uninterrupted power supply to downhole tools.
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 reduces the space required for power sources, decreases service time, minimizes exposure to environmental factors, and increases the efficiency and reliability of downhole operations by allowing rechargeable batteries to be charged on demand and strategically positioning power sources to optimize power distribution.
Implementation Method 1
rechargeable batteries that are chargeable downhole using one or more downhole generators, such as RPM and piezoelectric generators
Implementation Method 2
rechargeable batteries that are chargeable downhole using one or more downhole generators, such as RPM and piezoelectric generators
Data Source
AI summary
The disclosure provides a downhole power system that includes a combination of different power sources, which includes downhole power generators and rechargeable batteries that can be recharged downhole, a downhole bus and a bus power controller that manages the distribution of power from the different power sources to downhole tools connected to the downhole bus, such as tools of a BHA. The different power sources can be strategically positioned along the downhole bus/BHA. An example of a downhole distributed power system includes: (1) a downhole bus, (2) different power sources connected to and strategically positioned on the downhole bus, and (3) one or more controllers to perform operations that includes managing distribution of power, from the different power sources, to downhole tools connected to the downhole bus, wherein the different power sources include one or more power generators and one or more rechargeable batteries that are chargeable downhole.