Electronic Control System for Downhole Tool Bypass Sub

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Solution Overview

Problem

Conventional downhole tools require multiple pump cycles to achieve the desired operational state, leading to inefficiencies and wasted rig time, as they automatically change states with each pump cycle, making it difficult to maintain specific tool configurations like keeping a bypass sub open until commanded to close.

Innovation Solution

An electronic control system that uses a stepper motor, planetary gearhead, and ball screw mechanism to control the operational state of downhole tools by fluidly connecting a chamber to drilling fluid or the annulus, allowing for precise control of the tool's state through signal-driven valve operation, enabling the bypass sub to open and close as needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If hydraulic pumps are used to control downhole tools, then the tool can be controlled while operational downhole, but the tool automatically changes state with each pump cycle requiring multiple cycles to achieve desired operational state

Engineering Contradiction:

Improvetool controlVSAvoidrig time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent replaces the conventional hydraulic pump system with an electronic control system that uses a motor to directly drive the valve mechanism. This substitution eliminates the need for multiple pump cycles and allows precise control of the tool state through electronic signals, thereby reducing rig time while maintaining operational control capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses hydraulic principles by fluidly connecting a chamber in the valve to drilling fluid in the bore, allowing the hydraulic pressure from drilling fluid to act on the valve mechanism. This enables reliable actuation of the valve without requiring repeated pump cycles, solving the time loss issue while maintaining ease of operation.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Adaptability or versatility

If hydraulic pumps are cycled to control the tool, then the tool state can be changed, but additional commands must be provided to maintain desired configuration

Engineering Contradiction:

Improvetool state controlVSAvoidoperator convenience

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The electronic control system replaces the hydraulic control system, allowing the tool to maintain its desired state without requiring additional pump cycles or commands. The motor-driven valve mechanism can be precisely controlled through electronic signals, eliminating the need for repeated operator interventions and improving operational convenience.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electronic control system enables the tool to maintain its operational state automatically without requiring continuous operator input. Once the valve is actuated to the desired position, the system maintains that state without needing additional pump cycles or commands, making the tool self-sufficient in maintaining its configuration.

Inventive Principle:

Principle #25Self-service

3Productivity

If conventional hydraulic control is used, then the tool can be actuated, but the bypass sub must be cycled multiple times to stay open until commanded to close

Engineering Contradiction:

Improveoperational efficiencyVSAvoidbypass sub cycling time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces the hydraulic pump cycling mechanism with an electronic motor-driven valve control system. This substitution allows the bypass sub to remain open continuously until commanded to close, eliminating the need for repeated cycling operations and significantly improving operational efficiency while reducing time loss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electronic control system enables continuous operation of the bypass sub in the open state without requiring periodic cycling. The motor-driven valve mechanism maintains the open position continuously, allowing drilling operations to proceed without interruption for valve cycling, thereby maximizing productivity and minimizing time loss.

Inventive Principle:

Principle #20Continuity of useful action

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 allows for efficient and precise control of downhole tools, reducing rig time and operator annoyance by enabling the bypass sub to remain open until commanded to close, improving operational efficiency and reducing unnecessary cycles.

Implementation Method 1

drives a motor to operate a valve, alternately fluidly connecting a chamber in the valve to drilling fluid in a bore of the downhole tool

Methodology Applied

Scientific EffectHydraulic connection:

Implementation Method 2

fluidly connecting the chamber to an annulus surrounding the downhole tool, venting mud into the annulus

Methodology Applied

Scientific EffectHydraulic connection:

Data Source

PatentUS8776896B2Electronic control system for a downhole tool

Publication Date: 2014.07.15 ARRIVAL ENERGY SOLUTIONS INC

AI summary

An electronic control system for a downhole tool controls an operational state of the downhole tool. The electronic control system receives a signal from uphole, and drives a motor to operate a valve, alternately fluidly connecting a chamber in the valve to drilling fluid in a bore of the downhole tool, causing an activation mechanism to configure the downhole tool into a first state, and fluidly connecting the chamber to an annulus surrounding the downhole tool, venting mud into the annulus.