Downhole Power Grid for Flow Control Nodes
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Solution Overview
Problem
Providing and maintaining electrical power downhole in oil and gas wells is challenging due to harsh, high-temperature, high-pressure, and corrosive environments, which affects the operation of electronic components like valves and sensors.
Innovation Solution
A wireless smart well node system that generates electrical power using fluid flow at different locations along the wellbore, with a power grid interconnecting flow control nodes to allow power sharing and central control, enabling the system to operate even when individual generators fail, and providing additional power for sensors and instruments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical power is provided downhole using individual generators at each flow control node, then each node can operate independently, but the system lacks redundancy and overall power availability is limited
Solution Approach 1:
The patent combines multiple individual generators at different flow control nodes into a unified electrical power grid. This allows power to be shared across the entire well system, providing redundancy where if one generator fails, other nodes can supply power. The grid interconnects generators and loads across multiple nodes, enabling collective power supply that exceeds what any single generator could provide.
Solution Approach 2:
The electrical power grid serves multiple functions simultaneously: it distributes power from generators to flow control nodes, provides redundancy through alternative power paths, enables central control capabilities, and supports various downhole instruments and sensors. This multi-functional approach resolves the contradiction by making the power system both reliable and sufficiently powerful.
2Ease of operation
If a distributed control system with processors at each node is used, then each node can operate autonomously, but system complexity and cost increase
Solution Approach 1:
The patent merges the control functions from multiple distributed processors into a single central control system located at the surface. The central controller communicates with all flow control nodes through the electrical power grid infrastructure, eliminating the need for individual processors at each node. This reduces device complexity while maintaining ease of operation through centralized management of all well operations.
3Productivity
If flow is shut down at a location for production control, then hydrocarbon production is optimized, but insufficient power is generated at that location to reopen flow later
Solution Approach 1:
The electrical power grid acts as an intermediary that transfers power from locations where flow is active (and generators are producing power) to locations where flow has been shut down. When a node shuts down flow for production optimization, its generator stops producing power, but the grid allows other nodes with active flow to supply the necessary power for reopening operations when needed, resolving the power insufficiency problem.
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 ensures reliable operation of downhole components, allows for selective reopening of flow, increases overall power availability, and reduces costs by using a central processor and redundant systems, enabling more efficient hydrocarbon production and enhanced monitoring capabilities.
Implementation Method 1
generates electrical power using the flow at each of these locations by directing a portion of that fluid flow through a generator
Data Source
AI summary
A plurality of flow control nodes are spaced along a production conduit for controlling a flow of formation fluids into the production conduit at different locations in the well. Each flow control node defines a flow path for entry of the formation fluids into the production conduit. A closure is operable to adjust the flow of the formation fluids into the production conduit. A generator at each zone generates electrical power in response to a portion of the flow directed through the generator. An electrical power grid interconnects the plurality of flow control nodes to collectively supply electrical power to the power grid. Each closure and other device components are operable with the electrical power from the power grid.