Downhole Transfer System Rectangular Winding
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Solution Overview
Problem
Existing downhole data transfer systems face inefficiencies due to frequency drift caused by downhole temperatures and environmental factors, leading to low data transmission rates and potential damage to electrical control lines, which can result in sensor malfunction and increased risk of uncontrolled events like blowouts.
Innovation Solution
A downhole transfer system featuring a transceiver assembly with a conductive winding having a rectangular cross-sectional shape with a significantly larger axial extension than radial extension, and a downhole tool with a similar winding configuration, operating at frequencies above 14 MHz to enhance power and data transfer efficiency without the need for electrical control lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical control lines are run along the production liner to power sensors and transmit data, then sensors can function and transmit data, but the control lines may become damaged over time causing sensor malfunction and the wired connection weakens the completion structure
Solution Approach 1:
The patent extracts the electrical control lines from the completion structure by using wireless power and data transmission. Sensors are powered and communicate with the surface through electromagnetic coupling between a transmitter in the production liner and a receiver at the sensor location, eliminating the need for physical electrical connections that would compromise structural integrity.
Solution Approach 2:
The patent replaces the mechanical electrical control lines with an electromagnetic field-based transmission system. Power and data are transmitted wirelessly through electromagnetic coupling, substituting the mechanical wired connection with a field-based system that does not compromise the completion structure.
2Strength
If wireless power and data transmission is used to avoid electrical control lines, then completion structure strength is maintained, but data transmission rate is limited by the coupling efficiency and frequency drift
Solution Approach 1:
The patent implements dynamic frequency adjustment to compensate for temperature-induced drift in the resonant frequency of the magnetic coupling system. The system continuously monitors and adjusts the operating frequency to maintain optimal coupling efficiency, enabling faster and more reliable data transmission without compromising structural integrity.
Solution Approach 2:
The patent changes the operating parameters of the magnetic coupling system, specifically adjusting the frequency to match the resonant frequency of the coupling system under downhole conditions. This parameter optimization maximizes power and data transfer efficiency while maintaining the wireless architecture that preserves completion strength.
3Device complexity
If sensors operate autonomously with battery power downhole, then no electrical control lines are needed, but battery power is limited due to high temperatures and pressures causing quick discharge
Solution Approach 1:
The patent extracts the power source from the downhole environment by transmitting power wirelessly from the surface through the production liner. This eliminates the need for batteries or other power sources that would be subjected to harsh downhole conditions, thereby removing the energy duration limitation while also eliminating electrical control lines.
Solution Approach 2:
The patent replaces the chemical energy storage system (batteries) with an electromagnetic power transmission system. Power is delivered continuously from the surface through magnetic coupling, substituting the limited-capacity battery system with an unlimited power source that is not affected by temperature and pressure.
4Loss of information
If the downhole tool must be located opposite each sensor for extended periods to download data at 50 Hz, then data can be transmitted, but oil production is stopped during such intervention
Solution Approach 1:
The patent uses dynamic frequency adjustment and optimized magnetic coupling to enable rapid data transmission. The system can transfer data at much higher rates than the conventional 50 Hz, allowing complete data download in minutes rather than hours, thereby minimizing production interruption while ensuring all sensor data is captured.
Solution Approach 2:
The patent implements periodic power and data transmission at optimized frequencies during the tool's passage. By using pulsed electromagnetic transmission at resonant frequencies, the system maximizes data transfer rate during the brief window when the tool is opposite each sensor, reducing the need for prolonged stationing and minimizing production loss.
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 configuration allows for faster and more reliable data transmission and power transfer, reducing the risk of sensor malfunction and maintaining well integrity by minimizing Eddy currents and avoiding the need for electrical control lines, thus improving the operational efficiency of oil production.
Implementation Method 1
a downhole transfer system for transferring data through a well tubular metal structure... an assembly conductive winding made from a conductor... and a downhole tool comprises... a tool conductive winding made from a conductor
Implementation Method 2
minimizing Eddy currents... the conductor of the assembly conductive winding has a cross-sectional shape having an axial extension along the axial direction and a radial extension perpendicular to the axial extension, the axial extension being at least 50% larger than the radial extension
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a downhole transfer system for transferring data through a well tubular metal structure arranged in a borehole of a well, comprising a well tubular metal structure having an axial direction and being arranged in the borehole providing an annulus between the borehole and the well tubular metal structure, a transceiver assembly comprising a tubular metal part mounted as part of the well tubular metal structure, the tubular metal part having an inner face, an outer face and a wall, an assembly conductive winding, such as a copper ring, connected with the inner face, a power consuming device, such as a sensor, arranged in the annulus and connected with the outer face and the power consuming device is connected to the assembly conductive winding by means of an electrical conductor, a downhole tool comprises a tool body, a tool body outer face and a tool conductive winding, wherein the assembly conductive winding has an axial extension along the axial direction and a radial extension perpendicular to the axial extension, the axial extension being at least 50% larger than the radial extension.