Downhole Power Grid for BHA Tools
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Solution Overview
Problem
Downhole drilling tools face limitations in power supply due to battery life and size constraints, and existing power allocation methods like the low-voltage tool bus (LTB) often lack sufficient power, leading to inefficient power utilization and increased tool length.
Innovation Solution
An electrical power grid is established that connects downhole tools, allowing surplus power from a power generating tool to be shared with other tools through a power management controller, enabling selective connection and disconnection from the grid based on power availability, thereby optimizing power usage and reducing the need for large battery packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If battery packs are used to power downhole tools, then tools can operate independently, but battery life is limited and battery size increases tool length
Solution Approach 1:
Multiple tools are electrically connected to form a power grid where power generating tools and power consuming tools are combined into a single integrated system. This allows power to be shared across the grid, eliminating the need for each tool to have its own large battery pack, thereby reducing individual tool lengths while extending operational duration through collective power resources.
2Adaptability or versatility
If low-voltage tool bus (LTB) is used for power allocation, then power can be distributed to multiple tools, but available power is insufficient
Solution Approach 1:
The power grid implements dynamic power allocation where power generating tools (such as turbines) can adjust their power output based on real-time conditions, and power management controllers dynamically connect or disconnect tools from the grid based on power availability and demand. This dynamic approach allows the system to maximize available power from all generating sources while maintaining adaptability in power distribution to multiple tools.
3Power
If surplus power is dissipated via heat, then power generation capacity can be reduced, but electronic circuits suffer higher temperature stress
Solution Approach 1:
Instead of dissipating surplus power as harmful heat, the system converts this excess power into a beneficial resource by feeding it into the power grid where it can be utilized by other power-consuming tools. This transforms what would be waste energy and a source of thermal stress into a useful power source that extends the operational capacity of the overall system while maintaining circuit reliability.
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 prolongs battery life, reduces power generation capacity, improves tool reliability, and allows for a more integrated and compact bottom hole assembly design by efficiently sharing surplus power among tools, enhancing overall downhole tool functionality and conserving space.
Implementation Method 1
The power generating tool (e.g., a rotary steerable drilling tool) includes a power generator
Implementation Method 2
The electrical power grid electrically connects a string of downhole tools including at least a first power generating tool and a second power consuming tool
Data Source
AI summary
A downhole electrical power grid electrically connects a string of downhole tools including at least a first power generating tool and a second power consuming tool. The power generating tool includes a power generator, an electric load, and a power management controller. The power management controller is configured to automatically electrically connect and disconnect the tool from the power grid. The power generating tool may include a rotary steerable tool having a power generator, an electric actuator, and the aforementioned power management controller.