Intelligent Tool Bus Network for Bottom Hole Assembly Fault Tolerance
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Solution Overview
Problem
The existing tool bus networks in downhole applications are prone to failures due to single-point vulnerabilities, making troubleshooting difficult and costly, especially in harsh environments, and lack efficient channel utilization and convenience in configuration and maintenance.
Innovation Solution
An intelligent tool bus network that allows automatic node enumeration and configuration, enabling the generation of a tool string layout map, fault detection, and sectioning of the bus into sub-buses, with master nodes controlling switches to maintain communication and reconfigure the network independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a bus network topology is used for downhole communication, then the network is simple and reliable, but it is prone to failure due to single point of failure
Solution Approach 1:
The bus network is divided into multiple segments separated by intelligent nodes with switches. Each segment can operate independently, so a failure in one segment does not affect the entire network. The segmentation principle resolves the contradiction by maintaining simplicity of individual segments while improving overall reliability through modular architecture.
Solution Approach 2:
The network transitions from a static bus topology to a dynamic reconfigurable network where intelligent nodes can change their connection states. Switches at intelligent nodes can dynamically connect or disconnect segments based on operational needs and fault conditions, enabling the network to adapt and maintain reliability while preserving simplicity.
2Ease of repair
If the BHA is extracted from the well bore for troubleshooting, then the failure can be investigated, but the extraction time is non-productive time and may change or obscure the point of failure
Solution Approach 1:
The system performs self-diagnosis and self-troubleshooting capabilities. Intelligent nodes can automatically detect failures, identify their locations, and provide diagnostic information while remaining in the well bore. This eliminates the need for extraction, saving time and preserving the fault condition for accurate analysis.
Solution Approach 2:
The network implements feedback mechanisms where intelligent nodes continuously monitor bus conditions and provide real-time diagnostic information about failures. This feedback enables troubleshooting without extraction, as the system can identify and communicate fault locations while still downhole.
3Reliability
If the electronics are sealed within pressurized chambers, then they are protected from harsh environments, but they are not easily tested or probed
Solution Approach 1:
Intelligent nodes serve as intermediary components between the sealed electronics and external diagnostic systems. These nodes provide communication interfaces and diagnostic capabilities that can probe and test electronics through the sealed chambers without compromising the protective sealing, enabling both protection and testability.
4Reliability
If the bus network is reconfigured in response to faults, then communication can be maintained, but the network complexity increases
Solution Approach 1:
The network performs preliminary actions by pre-configuring multiple connection paths and having switches ready to reconfigure. When faults occur, the system can quickly switch between predetermined paths or segments, maintaining communication continuity without requiring complex real-time reconfiguration calculations or decisions.
Data Source
AI summary
An intelligent tool bus network for a bottom hole assembly (BHA) that can enumerate the nodes on the bus to build a tool string layout map. During the enumeration, an enumeration master node (EMN) sequentially powers and tests additional sections of the bus and additional tool electronics. At each node, the EMN records the results of the tests in an enumeration log. For each good node, communication is established with the EMN to retrieve a node ID and node metadata. Using the enumeration log, the EMN builds a tool string layout map that includes information of each node, their relative location, and their operating status. The intelligent tool bus network also facilitates sectioning a bus into a plurality of sub-busses upon a sectioning event and rejoining the sub-busses. The sectioning event occurs as a result of a fault on the bus or a planned section division multiplexing event.