Split Downhole Transformer for Reliable Power Transfer in Wells
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Solution Overview
Problem
Wet connectors used to power electrically powered tools downhole in wells have low reliability due to high electrical currents, elevated temperatures, and failure of isolation barriers against contaminants and production fluids, leading to frequent failures and the need for complex and risky workover operations.
Innovation Solution
A split downhole transformer system is introduced, comprising a female component with primary coils and a borehole, and a male component with secondary coils and a conduit, which interlock to form an electromagnetic bridge, allowing power to be efficiently transferred from the surface to the downhole tool while minimizing losses and exposure to contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wet connectors are used to transfer power downhole, then power transfer is enabled, but reliability deteriorates due to high currents, temperatures, and contaminant exposure
Solution Approach 1:
The connector is divided into two separate components: a male connector that remains downhole with the tool, and a female connector that remains at the surface. This segmentation eliminates the need for wet mating connectors, as each component stays in its respective environment permanently, avoiding exposure to contaminants while maintaining power transfer capability through the electromagnetic coupling of the transformer coils.
Solution Approach 2:
The split transformer acts as an intermediary device between the surface power source and the downhole tool. The primary coils receive power from the surface, and the secondary coils deliver power to the downhole tool, with the magnetic field serving as the intermediary transmission medium that transfers energy without requiring direct electrical contact across the wellbore barrier.
2Productivity
If wet connectors are used for power transfer, then power delivery is achieved, but workover operations become more frequent and complex
Solution Approach 1:
By segmenting the connector system into permanent surface and downhole components, the invention eliminates the need for complex workover operations to replace failed connectors. The sealed downhole male connector with its integrated tool remains in place indefinitely, and only the female surface connector needs to be handled during installation, dramatically simplifying maintenance and reducing workover complexity.
3Reliability
If isolation barriers are used to protect against contaminants, then protection is provided, but failure of these barriers leads to reliability issues
Solution Approach 1:
The invention extracts the vulnerable isolation barrier (seal) from the system by eliminating the wet connector entirely. Instead of relying on a seal to prevent contaminant ingress into an electrical connector, the design keeps the male connector permanently downhole where it is sealed from the start, and the female connector permanently at the surface, removing the need for a barrier between them and thus eliminating the single point of failure.
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 split downhole transformer system significantly enhances the reliability of power transfer to downhole tools, reduces the frequency of workover operations, and minimizes the risks associated with exposing downhole environments to surface conditions, thereby improving overall well maintenance and production efficiency.
Implementation Method 1
The system includes a female component with primary coils and a male component with secondary coils, which interlock to form an electromagnetic bridge, allowing power to be efficiently transferred from the surface to the downhole tool
Data Source
AI summary
A system includes production tubing installed in the well and a female component connected to the production tubing comprising a female component body located in a housing, primary coils wound through the female component body, and a borehole delineated by an inner circumferential surface of the female component body and having a borehole axis. The borehole outlines a shape. The system also includes a male component electrically connected to the electrically powered tool and configured to be inserted into the borehole of the female component. The male component includes a male component body having an external surface formed in the shape, secondary coils wound through the male component body, and a conduit extending through the male component body and having a conduit axis. The borehole axis and the conduit axis line up when the male component is inserted into the borehole of the female component. The system further includes a split downhole transformer formed by installation of the male component into the female component. Formation of the split downhole transformer allows power to transfer from a surface location to the electrically powered tool installed in the production tubing downhole in the well.