Electric Wireline Winch Battery Power Redundancy
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Solution Overview
Problem
Conventional hydraulic drive systems in wireline systems for oil and gas exploration are costly to maintain, prone to leaks, and less efficient compared to electrical systems, with potential issues from over-pressurization and temperature fluctuations.
Innovation Solution
An electric-powered wireline system that uses an electric winch motor driven by a battery pack and redundant power sources, including internal generators and an external energy source via an umbilical, to provide continuous and efficient power for wellbore intervention operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic drive system is used to power the winch, then the system can provide sufficient power for wireline operations, but the system requires frequent maintenance and repairs due to leaks, hose bursts, and component failure
Solution Approach 1:
The patent replaces the hydraulic drive system with an electric motor to power the winch. The electric motor is driven by a generator that converts mechanical energy from the truck engine into electrical energy, eliminating hydraulic components such as hoses, pumps, and motors that are prone to leaks and failures. This substitution of mechanical/hydraulic systems with electrical systems resolves the contradiction by providing comparable power with significantly reduced maintenance requirements.
2Power
If a hydraulic drive system is used, then the winch can be powered adequately, but the system consumes more horsepower and is less efficient compared to electrical systems
Solution Approach 1:
The patent substitutes the hydraulic power transmission system with an electrical power transmission system. The generator converts mechanical energy to electrical energy, which is then used to drive the electric motor. Electrical systems are inherently more efficient than hydraulic systems because they eliminate energy losses associated with fluid friction, heat generation in hydraulic components, and mechanical inefficiencies in hydraulic couplings. This substitution maintains adequate winch power while significantly reducing energy consumption and improving overall system efficiency.
3Adaptability or versatility
If a hydraulic system is used, then the winch can operate under various conditions, but the system is susceptible to failure from temperature fluctuations and over-pressurization
Solution Approach 1:
The patent replaces the hydraulic system with an electrical system that is inherently more resistant to environmental conditions. Electric motors and generators do not suffer from the same temperature-related issues as hydraulic fluids, which can become too viscous in cold temperatures or too thin in hot temperatures. Additionally, the electrical system eliminates the risk of over-pressurization that plagues hydraulic systems, as electrical power can be regulated through electronic controls without the need for pressure relief valves or burst disks. This substitution maintains operational adaptability across various environmental conditions while significantly improving system reliability.
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 electric-powered wireline system reduces maintenance needs, ensures continuous operation with redundant power sources, and achieves significant power savings, making it more efficient and reliable than traditional hydraulic systems.
Implementation Method 1
a battery pack arranged within the operations cabin and including one or more rechargeable batteries communicably coupled to the first and second electric generators and the umbilical
Implementation Method 2
a first engine and a first electric generator each arranged within the operations cabin, the first engine being operable to drive the first electric generator to generate electrical power
Data Source
AI summary
A wireline system includes an operations cabin with a plurality of electrical devices, and a winch that includes an electric winch motor operable to drive a drum to manipulate a wireline cable. A first engine and a first electric generator are each arranged within the operations cabin and generate electrical power, a second electric generator driven by a second engine via a power takeoff to generate electrical power, and an umbilical extends from the operations cabin to an external energy source to provide electrical power. A battery pack is arranged within the operations cabin and includes rechargeable batteries communicably coupled to the electric generators and the umbilical, wherein the battery pack solely provides electrical power to the electric winch motor and the electrical devices, and wherein the electric generators and the external energy source provide electrical power to recharge the rechargeable batteries.