Downhole Solid State Switches for Pump Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The high cost and inefficiency of using multiple cables to power and control downhole pumps, particularly in extreme conditions like high temperatures and pressures, limit the effectiveness of mechanical switching solutions for controlling current phases in oil and gas extraction operations.

Innovation Solution

The implementation of solid state semiconductor switches within a downhole pipe assembly, connected to a power source above the surface, which can control the conduction of electric current to pumps, allowing for bi-directional current and voltage blocking, and are mounted with heat sinks to manage thermal energy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple separate cables are used to power and control each pump, then reliable power delivery and control is achieved, but cable cost and system complexity increase significantly

Engineering Contradiction:

Improvepower delivery reliabilityVSAvoidcable system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple separate cables for powering and controlling individual pumps are merged into a single multi-conductor cable that delivers power to multiple pumps. The cable assembly integrates multiple conductors (including phases A, B, C, neutral, and ground) into one unified structure, reducing the number of separate cable installations while maintaining reliable power delivery to each pump through integrated switching control.

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If mechanical switches are used to control current to pumps, then cable usage is reduced, but reliability under extreme conditions (high temperature and pressure) deteriorates

Engineering Contradiction:

Improveswitching system simplicityVSAvoidswitch operation reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Mechanical switches are replaced with solid-state electronic switching devices that control current flow to the pumps. The solid-state switches are integrated into a control system that can reliably operate under extreme downhole conditions of high temperature and pressure, eliminating the reliability issues associated with mechanical components while maintaining the benefit of reduced cable complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If solid state semiconductor switches are used in high temperature environments, then switching reliability is maintained, but heat dissipation becomes a critical challenge

Engineering Contradiction:

Improveswitch operation reliabilityVSAvoidheat dissipation requirement

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

Heat sinks serve as intermediary thermal management components between the solid state semiconductor switches and the surrounding environment. The heat sinks conduct away excess heat generated by the switches during operation, preventing thermal buildup that would compromise reliability. The system incorporates dedicated thermal pathways and heat dissipation structures that enable the switches to operate reliably in high temperature downhole conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Device complexity

If fewer cables are used to reduce cost, then capital expenditure decreases, but control precision over individual pumps is reduced

Engineering Contradiction:

Improvecable quantityVSAvoidcurrent control precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The cable system is segmented into multiple independent conductors within a single cable assembly, allowing individual control of current flow to each pump. The switching system is segmented into separate solid-state switch modules that can independently control each pump's power delivery. This segmentation maintains precise control capability while using fewer external cable installations, reducing both cost and complexity.

Inventive Principle:

Principle #1Segmentation

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 number of cables needed, lowers operational costs, and maintains switch functionality in extreme conditions by effectively controlling current phases to individual pumps while dissipating heat efficiently.

Implementation Method 1

one or more solid state semiconductor switches configured to be disposed within a downhole pipe assembly. The one or more switches are configured to operate in a closed state to conduct electric current supplied by a power source disposed above a surface to pumps disposed beneath the surface

Methodology Applied

Scientific EffectSemiconductor conduction: Conduction (electrical)

Implementation Method 2

The switch assemblies are connected with an inner wall of the pipe assembly by heat sinks to transfer heat from the switches to the passageway of the pipe assembly

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10110013B2Downhole switch assemblies and methods

Publication Date: 2018.10.23 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

A switch assembly includes one or more solid state semiconductor switches configured to be disposed within a downhole pipe assembly. The one or more switches are configured to operate in a closed state to conduct electric current supplied by a power source disposed above a surface to pumps disposed beneath the surface to cause the pumps to extract a resource from beneath the surface via the pipe assembly. The one or more switches also are configured to operate in an open state to stop conducting the electric current from the power source to the pumps.