Inductive Coupling Power Transfer in Wellbore Tubulars

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Solution Overview

Problem

Downhole power transmission systems face challenges with cable corrosion and connector failures in caustic well environments, leading to reliability issues and costly repairs.

Innovation Solution

The implementation of multi-phase inductive coupling portions permanently installed within the wellbore, which shield power cables from corrosive fluids and eliminate the need for prone-to-failure connectors, using a tubular configuration with non-magnetic and non-metallic materials to enhance power transmission efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cables are used to transmit power from topside to downhole equipment, then power transmission is enabled, but cable corrosion and connector failures occur in caustic well environments

Engineering Contradiction:

Improvepower transmission reliabilityVSAvoidcable corrosion and connector failures

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical cable and connector system with an inductive power transmission system using magnetic coupling. Power is transmitted through electromagnetic induction between a stationary stator assembly and a rotating rotor assembly, eliminating the need for physical cable connections that are susceptible to corrosion and connector failures in caustic well environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnetic field as an intermediary medium to transfer power from the stator to the rotor. The inductive coupling creates a magnetic field that acts as a mediator, allowing power transmission without direct physical contact between the power source and the downhole equipment, thereby avoiding corrosion issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If traditional cable systems are used, then power can be supplied to downhole equipment, but the system requires connectors that are prone to failure

Engineering Contradiction:

Improvepower supply capabilityVSAvoidconnector requirements

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent eliminates mechanical connectors by using electromagnetic induction for power transmission. The stator and rotor assemblies create a magnetic coupling that transfers power without requiring physical cable connections or connectors, simplifying the system and eliminating connector failure modes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Power

If cables are exposed to corrosive fluids, then power transmission is achieved, but cable corrosion occurs leading to reliability issues

Engineering Contradiction:

Improvepower transmissionVSAvoidcable service life

Core Design Contradiction:

PowerVSDuration of action of stationary object

Solution Approach 1:

The patent replaces the cable-based power transmission system with an inductive coupling system where power is transmitted through magnetic fields. This eliminates the need for cables that are exposed to corrosive fluids, thereby extending system service life and improving reliability in harsh well environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic field serves as an intermediary that enables power transmission without requiring physical cables to be in contact with corrosive fluids. The stator and rotor assemblies generate and respond to magnetic fields, allowing power transfer while keeping the power transmission medium isolated from the corrosive environment.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 significantly reduces the risk of cable corrosion and connector failures, improving the reliability and efficiency of power transmission to downhole equipment, such as ESPs, by using inductive coupling to transmit power through the wellbore without the need for external connectors.

Implementation Method 1

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

A downhole-type electric stator is carried by the tubular and is configured to receive and electromagnetically interact with an electric rotor-impeller.

Methodology Applied

Scientific EffectElectromagnetic interaction: Electromagnetic Induction

Data Source

PatentUS11686161B2System and method of transferring power within a wellbore

Publication Date: 2023.06.27 UPWING ENERGY LLC

AI summary

A multi-phase, inductive coupling first portion is carried by a tubular. The coupling first portion is configured to inductively transmit current with a corresponding multi-phase, inductive coupling second portion. A downhole-type electric stator is carried by the tubular and is configured to receive and electromagnetically interact with an electric rotor-impeller. The coupling first portion is electrically connected to windings of the stator.