Dynamic Clamp Circuit for Downhole Overvoltage Protection
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Solution Overview
Problem
Downhole tools face damage due to sudden disconnection from power, leading to overvoltage issues as surface power supplies continue to produce higher voltages, which can be catastrophic.
Innovation Solution
A dynamic clamp circuit is implemented at the surface to manage voltage by consuming excess energy from the power system, preventing overvoltage by dynamically adjusting the clamp voltage based on sensed commands from the voltage controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface power supplies increase voltage to compensate for cable voltage drop, then downhole voltage is maintained, but overvoltage damage occurs when load is suddenly disconnected
Solution Approach 1:
A clamp circuit is introduced as an intermediary component between the power cable and downhole tool. This clamp circuit includes a voltage source and switching element that activate to clamp excessive voltage when the downhole tool disconnects, preventing overvoltage damage while allowing normal voltage compensation during operation
Solution Approach 2:
The clamp circuit is configured to preemptively counteract the harmful overvoltage effect before it can damage the downhole tool. By monitoring voltage conditions and activating the clamp switch when voltage exceeds safe levels, the system applies counter-action in advance to prevent the catastrophic damage that would otherwise occur
2Reliability
If downhole protection measures are implemented, then overvoltage damage is prevented, but cost and space requirements increase
Solution Approach 1:
The protection function is extracted from the downhole tool and relocated to the surface clamp circuit. This removes the need for complex protection electronics, capacitor banks, and associated components on the downhole tool, simplifying its design while maintaining overvoltage protection through the surface-based clamp circuit
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
The dynamic clamp circuit effectively reduces overvoltage risks, reduces the need for large capacitor banks, and frees up space on downhole tools, enhancing reliability and reducing costs.
Implementation Method 1
A dynamic clamp circuit at the surface consumes excess energy from a power system
Data Source
AI summary
A power system a method for enhanced voltage protection. The system may comprise a surface high voltage power supply, a voltage controller connected to the surface high voltage power supply that sends commands to the surface high voltage power supply to control an output voltage of the surface high voltage power supply, one or more power cables attached to the surface high voltage power supply, a downhole tool connected to the one or more power cables at an end opposite of the surface high voltage power supply, and a dynamic clamp circuit connected to the surface high voltage power supply. A method may comprise creating a setpoint with a dynamic clamp circuit based at least in part on the command, activating the dynamic clamp circuit when the output voltage is higher than the setpoint, and absorbing excess energy from the high voltage power supply with the dynamic clamp circuit.