Non-penetration Downhole Power via Inductive Coupling

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Solution Overview

Problem

The existing methods for powering downhole devices through tubing encased conductors (TECs) are prone to reliability issues due to breaches in the TEC's integrity, which can lead to short circuits and system failures, and the use of electromagnetic coils results in large, delicate structures that are difficult to install and maintain in confined wellbore spaces.

Innovation Solution

The implementation of a proximity coupling system where a coupling conductor, configured as a toroid or partial toroid, is placed in close proximity to the TEC without breaching its surface, using a magnetic field to induce a current for power and communication, eliminating the need for physical connections and reducing the risk of short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If electromagnetic coils are used to fully encircle the TEC for power transmission, then transmission efficiency is improved, but the device size increases and installation becomes difficult

Engineering Contradiction:

Improvetransmission efficiencyVSAvoiddevice size

Core Design Contradiction:

Use of energy by moving objectVSVolume of moving object

Solution Approach 1:

The coil is positioned inside the receiver housing, which is then mounted around the TEC. This nested arrangement allows the coil to be contained within a compact structure that fits around the TEC without requiring excessive space, resolving the contradiction between efficient power transmission and compact device size.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The invention transitions from requiring the coil to fully encircle the TEC in three dimensions to a configuration where the coil is positioned within a receiver housing that mounts around the TEC. This dimensional reorganization allows efficient magnetic coupling while maintaining a compact overall footprint suitable for wellbore installation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Use of energy by moving object

If coils are mounted to encircle the TEC for electromagnetic coupling, then power transmission is improved, but the structure becomes delicate and prone to damage

Engineering Contradiction:

Improvepower transmissionVSAvoidstructural robustness

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The coil is positioned inside the receiver housing before deployment, which provides mechanical protection and structural support. This pre-positioning within a protective housing prevents the coil from being exposed to harsh wellbore conditions, thereby maintaining both power transmission capability and structural robustness.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The receiver housing acts as a protective shell that encloses the coil while allowing magnetic field penetration. This shell structure provides mechanical protection to the delicate coil components without interfering with electromagnetic coupling, resolving the contradiction between power transmission efficiency and structural robustness.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If splices or joins are created in the TEC to connect sensors, then sensor placement is enabled, but the risk of fluid leakage and short circuits increases

Engineering Contradiction:

Improvesensor placement capabilityVSAvoidpressure integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The invention replaces mechanical electrical connections (splices and joins that require breaching the TEC) with electromagnetic induction for power transmission. The coil in the receiver housing induces current in the TEC conductor without requiring physical contact or penetration, enabling sensor placement while maintaining the integrity of the TEC barrier against wellbore fluids.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The receiver housing acts as an intermediary device that interfaces with the TEC externally. It provides the necessary electrical connection point for sensors while keeping the TEC itself intact and unbreached, thus enabling adaptability for sensor placement without compromising pressure integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Adaptability or versatility

If the TEC is breached to create connections for downhole devices, then device connectivity is achieved, but the risk of short circuits increases

Engineering Contradiction:

Improvedevice connectivityVSAvoidshort circuit risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The invention replaces mechanical penetration of the TEC with electromagnetic induction. The coil in the receiver housing induces current in the TEC conductor through magnetic coupling without requiring physical contact or breaching of the TEC, achieving device connectivity while eliminating the harmful effect of potential fluid ingress and short circuits.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts the electrical connection function from the TEC itself and places it in the external receiver housing. By taking out the need for direct electrical contact with the TEC, the system achieves device connectivity while removing the source of short circuit risk associated with breaching the TEC.

Inventive Principle:

Principle #2Taking out (Extraction)

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 enhances the reliability of the downhole system by minimizing the risk of pressure integrity breaches, simplifies the deployment and maintenance of downhole devices, and allows for flexible placement without compromising the TEC's integrity, even if a device fails, as the power draw is limited, thus reducing the impact of single device failures.

Implementation Method 1

expose the coupling conductor to a magnetic field formed externally to the TEC to induce a current

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11598179B2Non-penetration connection of downhole device to tubing encased conductor

Publication Date: 2023.03.07 HALLIBURTON ENERGY SERVICES INC

AI summary

A system is provided for providing power and/or communication to/from a downhole device by inductively coupling a coupling conductor within a receiver to a core conductor of a tubing encased conductor (TEC). The receiver has an elongated housing arranged physically proximate or touching an outer surface of the TEC. A coupling conductor is disposed within the housing, extends substantially parallel to a longitudinal axis of the housing, and further extends longitudinally and in close proximity to a core conductor housed within the TEC when the housing is arranged physically proximate or touching the outer surface of the TEC. This exposes the coupling conductor to a magnetic field formed externally to the TEC to excite a current in the coupling conductor. In one or more embodiments, the receiver further includes a coupling to electrically couple the downhole device to the coupling conductor and deliver the current to the downhole device.