Tubing Encapsulated Conductor Bridging for Low-Resistance Wellbore Power

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Solution Overview

Problem

The high electrical resistance of the metal sheath in Tubing Encapsulated Conductors (TECs) used for wellbore operations leads to increased power requirements for downhole electrical equipment, limiting its functionality and types of equipment that can be used.

Innovation Solution

Incorporating a conductive bridging component with conductive legs that pierce the encapsulation layer of the TEC to establish a direct conductive path between the metal sheath and the production tubing, reducing electrical resistance and improving power delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the metal sheath is used as the ground side electrical path in the TEC, then the TEC provides electrical insulation and structural integrity, but the high electrical resistance of the metal sheath causes high power requirements that limit equipment functionality

Engineering Contradiction:

Improveelectrical insulationVSAvoidpower requirements

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

A conductive bridging component is introduced as an intermediary element between the metal sheath and the encapsulation layer. This bridging component provides a dedicated low-resistance electrical path for the ground side current, mediating between the insulated conductor and the metal sheath ground, thereby reducing overall electrical resistance without compromising the electrical insulation provided by the encapsulation layer.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The TEC structure is enhanced by combining multiple materials with complementary properties: the metal sheath provides structural integrity and grounding, the encapsulation layer provides electrical insulation, and the conductive bridging component (made of conductive material) provides low-resistance electrical pathways. This composite structure allows simultaneous achievement of insulation, structural strength, and reduced electrical resistance.

Inventive Principle:

Principle #40Composite materials

2Use of energy by moving object

If the TEC is connected to production tubing hanger, then the electrical resistance is significantly reduced, but this connection is only available after deployment operations, causing inconsistent power requirements during different operational phases

Engineering Contradiction:

Improvepower requirementsVSAvoidoperational flexibility

Core Design Contradiction:

Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The conductive bridging component is pre-installed on the TEC during manufacturing, establishing a low-resistance electrical path before the TEC is deployed. This preliminary action ensures that the reduced electrical resistance configuration is available from the start of deployment operations, eliminating the need to wait for connection to the production tubing hanger and providing consistent power requirements across all operational phases.

Inventive Principle:

Principle #10Preliminary action

3Use of energy by moving object

If conductive bridging component is added to reduce electrical resistance, then power delivery is improved, but the device complexity increases

Engineering Contradiction:

Improvepower delivery efficiencyVSAvoidTEC structure

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

Rather than redesigning the entire TEC structure, the conductive bridging component is applied locally at specific points where electrical contact is needed. The bridging component makes localized contact with the metal sheath through the encapsulation layer, providing low-resistance pathways only where necessary, thereby minimizing the increase in device complexity while achieving improved power delivery efficiency.

Inventive Principle:

Principle #3Local quality

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 conductive bridging component significantly reduces electrical resistance, enabling more efficient power supply to downhole electrical equipment, improving its functioning, and allowing a wider range of equipment to be used during wellbore operations.

Implementation Method 1

a conductive bridging component with conductive legs that pierce the encapsulation layer of the TEC to establish a direct conductive path between the metal sheath and the production tubing, reducing electrical resistance

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12338690B1Conductive bridging of a tubing encapsulated conductor for powering equipment in wellbore operations

Publication Date: 2025.06.24 HALLIBURTON ENERGY SERVICES INC

AI summary

A system includes a production tubing string. The system can also include a tubing encapsulated conductor (TEC). At least a portion of the TEC can contact the production tubing string at one or more locations along a length of the production tubing string. The TEC can include an interior wire to transmit electric power from a power source to at least one piece of electrical equipment during a wellbore operation performed with respect to the wellbore. The TEC can also include a metal sheath positioned around the interior wire and an encapsulation layer positioned on an outer side of the metal sheath. Further, the TEC can include a conductive bridging component positioned to pierce the encapsulation layer to contact the metal sheath and to facilitate an electrical coupling between the metal sheath and the production tubing string at a location along the length of the production tubing string.