Downhole Tool Control via Fluid-Driven Generator and Electromagnetic Actuation
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Solution Overview
Problem
Existing methods for controlling downhole tools in wellbores face limitations such as reliability issues, size constraints, downtime, and safety concerns due to the use of tripping devices like balls and battery-powered remotely controlled devices, which are costly and pose fire hazards.
Innovation Solution
A modular apparatus comprising a generator, rotor, electronic circuit, and valve that uses wellbore fluid flow to generate electricity and control the valve for activating or deactivating downhole tools, eliminating the need for batteries and surface-connected electric cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tripping devices like balls are used to control downhole tools, then the downhole tool can be operated in a predetermined manner, but the reliability decreases and downtime increases due to limited usage次数 and the time required for the ball to reach its destination
Solution Approach 1:
The patent replaces the mechanical tripping device system (balls, plugs, darts) with an electromagnetic control system. A mandrel with electromagnetic actuators is lowered into the wellbore and positioned near the downhole tool. The actuators generate electromagnetic fields that interact with corresponding components in the downhole tool to activate or deactivate it remotely, eliminating the need for physical tripping devices to travel through the wellbore.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary between the surface control system and the downhole tool. The mandrel containing electromagnetic actuators serves as an intermediary device that transmits control signals through the wellbore fluid without requiring physical contact or mechanical interaction with the downhole tool, thereby improving reliability and reducing downtime.
2Ease of operation
If batteries are used in remotely controlled activating devices, then remote operation of downhole tools is achieved, but safety concerns arise due to fire hazards and strict transportation regulations are required
Solution Approach 1:
The patent extracts and removes the battery component from the remote control system. Instead of using battery-powered actuators in the downhole tool or on the mandrel, the system uses electromagnetic fields generated by the mandrel to actuate the downhole tool. This eliminates the fire hazard associated with batteries while maintaining remote operation capability.
3Ease of operation
If wire lines or electric cables are used to operate downhole tools remotely, then surface control is achieved, but the complexity increases due to the need to arrange and maintain the wire line from the surface all the way down
Solution Approach 1:
The patent replaces the mechanical wire line or electric cable system with an electromagnetic field-based control system. The mandrel with electromagnetic actuators transmits control signals through the wellbore fluid without requiring physical connection to the downhole tool, thereby eliminating the complexity of arranging and maintaining wire lines from surface to downhole while maintaining surface control capability.
4Ease of operation
If conventional tripping devices are used, then downhole tools can be activated, but the cost increases and the size of the tripping device becomes a constraint
Solution Approach 1:
The patent replaces bulky mechanical tripping devices with a compact electromagnetic control system. The mandrel contains electromagnetic actuators that generate fields to actuate the downhole tool without requiring large physical dimensions. This reduces the size constraints while maintaining the ability to activate downhole tools, and eliminates the need for multiple large tripping devices, thereby reducing costs.
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 provides a cost-effective, reliable, and safe means to remotely control downhole tools without batteries or wirelines, allowing for repeated operation and adaptation to various tools and functions, while minimizing complexity and environmental risks.
Implementation Method 1
a generator for generating electricity; a rotor connected to the generator... The generator is configured to generate electricity to at least the electronic circuit when a flow of wellbore fluid drives the rotor
Implementation Method 2
a sensor for sensing movement of the rotor, the sensor being electrically connected to the electronic circuit
Implementation Method 3
a valve for wellbore fluid and for activating or deactivating a tool or function of the downhole tool, the valve being controllable by being electrically connected to the electronic circuit
Data Source
AI summary
An apparatus for controlling a downhole tool comprises a generator for generating electricity; a rotor connected to the generator; an electronic circuit electrically connected to the generator; a sensor for sensing movement of the rotor, the sensor being electrically connected to the electronic circuit; and a valve for wellbore fluid and for activating or deactivating a tool or function of the downhole tool, the valve being controllable by being electrically connected to the electronic circuit. The generator is configured to generate electricity to at least the electronic circuit when a flow of wellbore fluid drives the rotor. A corresponding method of controlling a downhole tool comprises configuring the electric circuit to open or close the valve depending on a variation or pattern of a flow rate, controlling the downhole tool.