Downhole Power Control Device with Autonomous Circuit Breaker Isolation
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Solution Overview
Problem
Current power management systems for downhole components in hydrocarbon exploration and production lack efficient autonomous control and diagnostics, leading to challenges in isolating electrical shorts and failures, and managing power distribution effectively across multiple tools in a borehole string.
Innovation Solution
A power control device with a circuit breaker system and communication capabilities that autonomously monitors and controls electrical connections, detects failures, and manages power allocation to individual or groups of downhole components, using a three-breaker system to isolate issues and maintain system functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional power management systems are used for downhole components, then system simplicity is maintained, but the ability to autonomously control and diagnose power distribution deteriorates
Solution Approach 1:
The power management system is segmented into multiple independent circuit breakers (first circuit breaker for tool power, second circuit breaker for load power, third circuit breaker for communication power) that can independently control different power paths. This segmentation enables autonomous control of specific components without affecting the entire system, resolving the contradiction by providing automated functionality through modular circuit breaker units.
Solution Approach 2:
The circuit breaker system acts as an intermediary between the power source and downhole components, automatically detecting faults and isolating problematic segments. The breakers serve as mediators that autonomously make power distribution decisions based on detected conditions, enabling automated power management while maintaining system simplicity through the use of standard circuit breaker technology.
2Reliability
If traditional power distribution is used without isolation capabilities, then device complexity is reduced, but the ability to isolate electrical shorts and failures deteriorates
Solution Approach 1:
The system uses multiple circuit breakers to segment the power distribution into isolated sections: tool power isolation, load power isolation, and communication power isolation. Each breaker can independently open to isolate faults in its respective segment, preventing fault propagation while maintaining controlled complexity through modular isolation units.
Solution Approach 2:
The circuit breakers are pre-configured with trip thresholds and protection characteristics that enable automatic fault isolation without requiring complex real-time decision logic. The preliminary setup of breaker parameters allows the system to reliably isolate faults through predetermined protection mechanisms, reducing the operational complexity while maintaining high reliability.
3Use of energy by moving object
If power is continuously supplied to all downhole components, then operational readiness is maintained, but energy consumption increases
Solution Approach 1:
The circuit breakers dynamically control power supply to different downhole components based on operational requirements and detected fault conditions. Breakers can transition between closed (power supplied) and open (power isolated) states, enabling flexible power management that reduces energy consumption by isolating non-critical or faulty components while maintaining readiness of essential systems.
Solution Approach 2:
The system employs periodic monitoring of power consumption and fault conditions, with circuit breakers automatically adjusting power distribution in periodic cycles. This periodic action allows the system to maintain operational readiness by periodically assessing component status and adjusting power supply accordingly, reducing overall energy consumption through intelligent power cycling and isolation.
Data Source
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AI summary
A power control device includes a communication device configured to be disposed in a borehole and configured to couple electrical power from a power source to a downhole component from a conductor disposed along a borehole string, a circuit breaker system including a first circuit breaker disposed at a connection between the conductor and the downhole component and configured to be closed to connect the downhole component to the conductor, and a controller configured to monitor at least one of a current level and a voltage level at the connection and at the conductor. The controller is configured to control the circuit breaker system and autonomously perform opening the first circuit breaker in response to detecting a deviation in the at least one of the current levels and voltage levels at the connection, to isolate the downhole component from the conductor and the power source.