A well can be drilled into a subterranean structure for the purpose of recovering fluids from a reservoir in the subterranean structure. Examples of fluids include hydrocarbons, fresh water, or other fluids. Alternatively, a well can be used for injecting fluids into the subterranean structure.
Once a well is drilled, completion equipment can be installed in the well. Examples of completion equipment include a casing or liner to line a wellbore. Also, flow conduits, flow control devices, pumps, and other equipment can also be installed to perform production or injection operations.
In general, according to some implementations, an apparatus includes a circuit to receive power and data over a communication medium, where the circuit is to separate the power and the data. An electronic switch couples the power output by the circuit to a downhole electrical component (a pump and/or an electro-hydraulic actuator) for use in a well. According to other implementations, an electro-hydraulic actuator includes an outer housing defining a first hydraulic chamber and a second hydraulic chamber, where a seal for one of the hydraulic chambers is achieved without use of an elastomeric seal.
Other features will become apparent from the following description, from the drawings, and from the claims.
Some embodiments are described with respect to the following figures:
As used here, the terms “above” and “below”; “up” and “down”; “upper” and “lower”; “upwardly” and “downwardly”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or diagonal relationship as appropriate.
Various types of components for use in a well can perform electrical communications and can be powered by electrical power. In some examples, a surface unit (located at an earth surface above a well) can include a telemetry module to perform data communication and one or more power supplies to provide power to downhole electrical components. In some examples, the surface unit can include a main power supply (e.g. a main AC or alternating current power supply) and an auxiliary power supply (e.g. an auxiliary AC power supply). The main power supply can be used to deliver power to certain components of a downhole tool, such as sensors, flow control devices, and so forth. The auxiliary power supply can be used to power other components, such as a pump (e.g. electro-hydraulic pump, solenoid pump, piezoelectric pump, and shape memory alloy pump) or an electro-hydraulic actuator. In some examples, separate electrical lines are used to provide power from the main power supply and the auxiliary power supply to corresponding downhole electrical components. Use of separate power supplies, such as the main power supply and the auxiliary power supply, and corresponding separate electrical lines, can be complex and inefficient. For example, use of the separate electrical lines can result in a larger number of electrical connections, which can lead to reduced reliability and increased rig time (time involved in assembling and deploying a tool string at a well site).
In accordance with some embodiments, instead of using separate electrical lines to deliver power from separate power supplies to downhole electrical components, a shared communication medium can be used to deliver both power and data to various downhole components (including pumps and/or electro-hydraulic actuators), which can be connected to the shared electrical communication medium in parallel. As discussed in further detail below, the shared communication medium for delivering power and data can include a twisted wire pair or a coaxial cable. The shared communication medium can be used to carry power to both components such as pumps and/or electro-hydraulic actuators, as well as other components in a tool, such as a modem and so forth.
The surface unit 100 also includes a telemetry module 110, which can be a modem or other type of telemetry module. The telemetry module 110 is used to perform data communication. The telemetry module 110 is able to input or output a data signal 112. The data signal 112 can be received over the shared communication medium 116 by the telemetry module 110 from a downhole component, such as a sensor. In other examples, the data signal 112 can be a command signal or other signal that is output by the telemetry module 110 for delivery to a downhole component.
The AC power signal 108 can have a relatively low frequency, while the data signal 112 can have a relatively high frequency (higher than the frequency of the AC power signal 108).
In the output direction (from the surface unit 100 to a downhole component), the output data signal from the telemetry module 110 and the output AC power signal from the power supply 106 can be combined by modulation transformer 114. The combined power and data (represented as combined signal 117 in
The combined signal 117 includes the AC power signal delivered in common mode over the twisted wire pair. Summing the signals on the electrical wires of the twisted wire pair produces the AC power signal. The data signal in the combined signal 117 is delivered in differential mode over the twisted wire pair—subtracting the signals on the electrical wires of the twisted wire pair produces the data signal.
Note that in the reverse direction, when data signal from a downhole component is communicated uphole to the surface unit 100, the modulation transformer 114 is able to separate the uphole data signal from the combined signal on the twisted wire pair 116 to provide to the telemetry module 110.
Further details regarding a downhole electrical module 118 according to some examples are depicted in
The modulation transformer 202 is able to sum the signals on the wires of the twisted wired pair 116 to provide a common mode signal at output 208 in
The switch 210 is some examples can be an electronic switch, rather than an electro-mechanical relay that can consume relatively large amounts of power. In some examples, the electronic switch 210 is a semiconductor switch that is formed using semiconductor technology. The semiconductor switch can be a bidirectional (bilateral) triode thyristor. An example bidirectional triode thyristor 302 is shown in
In other examples, the electronic switch 210 can include transistor(s), such as power transistor(s) to allow power communication through the electronic switch 210.
The output of the electronic switch 210 is connected to an electrical component 212 that is to be powered by the AC power signal 207 provided through the electronic switch 210. In some examples, the electrical component 212 can be an electro-hydraulic actuator that has a motor 214, a hydraulic pump 216, and an actuator 218 that has a piston 220 moveable by hydraulic pressure created by the hydraulic pump 216. In other examples, other types of electrical components can be powered by power delivered through the electronic switch 210 of
A capacitor 222 in the electrical component 212 allows for a phase shift to drive the motor 214.
The telemetry module 206 provides an output to the electronic switch 210 (such as to the gate 308 of the thyristor 302 of
In some examples, the actuator 218 can include a position sensor 224 to measure a position of the piston 220. The measured position can be communicated by the position sensor 224 over communication line 226 to the telemetry module 206, which can provide a data signal representing the measured position through the modulation transformer 202 to the twisted wire pair 116 for communication to the surface unit 100.
Although a specific arrangement is depicted in
An inductive coupler performs communication (data and/or power) using induction between the inductive coupler portions (e.g. coils) of the inductive coupler.
The pairs 152 and 154 of coils provide a transformer that is able to perform signal summation (to extract a common-mode signal) and signal subtraction (to provide a differential-mode signal) such that the AC power signal and data signal can be coupled through the inductive coupler 156.
The downhole electrical modules 118 are connected in parallel to the shared communication medium 150. The components of the downhole electrical modules 118 can be similar to those depicted in
In addition, an inductive coupler 160 (similar in design to the inductive coupler 156) is able to inductively couple power and data between the shared communication medium 150 and a shared communication medium 163, which is connected to downhole electrical modules 164 in lateral branch A.
Similarly, an inductive coupler 162 (similar in design to the inductive coupler 156) is able to inductively couple power and data between the shared communication medium 150 and a shared communication medium 165, which is connected to downhole electrical modules 166 in lateral branch B. Deployment of additional inductive couplers would allow for communication of power and data with equipment in additional lateral branches.
The surface unit 100-1 includes the AC power supply 106 and telemetry module 110. However, instead of a modulation transformer as in the surface unit 100 of
Downhole electrical modules 118-1 are connected to the coaxial cable 402 to receive the AC power and data signals communicated over the coaxial cable 402. The coaxial cable 402 can also be used to communicate data signals in the uphole direction from the downhole electrical modules 118 to the surface unit 100-1.
The data signal 203 output by the demultiplexer 502 is provided to the telemetry module 206, and the AC power signal 207 output by the demultiplexer 502 is provided to the input of the electronic switch 210, which is able to couple the AC power signal 207 to the electrical component 212.
In addition, an inductive coupler 430 (similar in design to the inductive coupler 420) is able to inductively couple power and data between the coaxial cable 410 and a coaxial cable 432, which is connected to downhole electrical modules 434 in lateral branch A.
Similarly, an inductive coupler 431 (similar in design to the inductive coupler 410) is able to inductively couple power and data between the coaxial cable 410 and a coaxial cable 435, which is connected to downhole electrical modules 436 in lateral branch B.
The electro-hydraulic actuator 500 has an outer housing 501 (e.g. metal housing), which contains a first chamber 504 and a second chamber 506, which are filled with a hydraulic fluid (the first and second chambers 504 and 506 constitute first and second hydraulic chambers). The first chamber 504 has two parts: a first part on the left of the second chamber 506, and a second part on the right of the chamber 506. The first part of the first chamber 504, which is defined in part by a bulkhead 522, includes the motor 214 and the hydraulic pump 216. Wires 524 extend through the bulkhead 522 to the motor 214.
The second part of the first chamber 504 is adjacent the right side 508 of the piston 220 (which is sealingly engaged due to presence of a seal 514 with the housing 501). A fluid path 510 interconnects the first and second parts of the first chamber 504. In some examples, the fluid path 510 can be provided by a tube welded to the outer housing 502—in other examples, other types of fluid paths can be employed.
When a valve 512 (which can be a solenoid valve or other type of valve) is closed, the second chamber 506 is isolated from the first chamber. Note that an O-ring seal can be provided on the piston 220 to engage an inner surface of the outer housing 502 to provide sealing engagement between the piston 220 and the outer housing 502.
A tension spring 516 is located in the second chamber 506, on the left side 518 of the piston 220. The tension spring 516 tends to pull the piston 220 to the left (in the diagram) and can create sufficient pulling force to place the piston 220 and actuator rod 520 connected to the piston 220 in a first position when pressure is balanced between the first and second chambers 504 and 506. In other examples, instead of using the tension spring 516, a compression spring can be used instead, where the compression spring is placed on the right side 508 of the piston 220.
Since the first chamber 504 is the only one of the two chambers 504 and 506 that potentially is in contact with wellbore fluids, welded metal bellows 526 and 528 can be used to create a fully enclosed first chamber 504. The bellow 526 is welded to the outer housing 502 and the actuator rod 520. The bellow 526 is deformable to allow longitudinal movement of the actuator rod 520 when hydraulically actuated by the pump 216. In other examples, the bellow 526 can have another arrangement.
The bellow 528 is placed in a tubular structure 530, and is welded to the tubular structure 530. One side of the bellow 528 is in fluid communication with the first chamber 504 through fluid path 531. The bellow 528 provides pressure compensation of the first chamber 504 with respect to the external well pressure. The combination of the bellow 528 and the tubular structure 530 provides an equalizing device to equalize the pressure inside the first chamber 504 with the wellbore pressure.
In operation, the motor 502 is activated, such as by use of the electronic switch 210 of
To move the piston 220 and actuator rod 520 back from the second position to the first position, the valve 512 can be opened (by use of a command) to allow fluid communication between the first and second chambers 504 and 506, which balances the pressure between the two chambers. Once the pressure in the chambers 504 and 506 are balanced, the tension spring 516 is able to move the piston 220 and actuator rod 520 back to the first position.
A hydraulic diagram for the arrangement of
In the
The hydraulic distributor 602 has two positions. In
The hydraulic distributor 602 also has a bottom position. In the bottom position, the fluid path from the reservoir to the pump intake is closed, while the fluid path from the second chamber 506 (left of the piston 220) to the pump intake is open. The pump output is connected to the second part of the first chamber (right side of the piston 220) and the reservoir. As a result, when the pump is activated, the fluid will circulate from the second chamber 506 (left of the piston 220) to the reservoir, which creates a pressure drop in the second chamber 506. The pressure drop causes a differential pressure to develop across the piston 220, which moves the piston 220 back to its first position.
When the reversible pump 216-1 flows from the first chamber 504 to the second chamber 506, this will over-pressurize the second chamber 506 to move the piston 220 from the first position to the second position.
On the other hand, when the pump flow is reversed, this will under-pressurize the second chamber 506 and make the piston 220 move from the second position to the first position.
In the foregoing description, numerous details are set forth to provide an understanding of the subject disclosed herein. However, implementations may be practiced without some or all of these details. Other implementations may include modifications and variations from the details discussed above. It is intended that the appended claims cover such modifications and variations.
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