MODULAR SIGNAL INTERFACE DEVICES AND RELATED DOWNHOLE POWER AND DATA SYSTEMS

• US 20140265565A1
• Filed: 03/15/2013
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Active Application

• Current Assignee: FastCAP Systems Corporation
• Original Assignee: FastCAP Systems Corporation
• Inventors: Cooley, John J., Lane, Joseph, Epstein, James, Kalabathula, Susheel, Deane, Christopher John Sibbald, Fleming, Kyle, Signorelli, Riccardo, Green, Morris
• Application Number:
  US13/843,746
• Publication Number:
  US 20140265565A1
• Time in Patent Office: Days
• US Class Current: 307/18
• CPC Class Codes: H02J 7/0016 using shunting, discharge or bypass circuits
• CPC Class Codes: H02J 7/007184 in response to battery voltage gradient
• CPC Class Codes: H02J 7/345 using capacitors as storage or buffering devices
• CPC Class Codes: H02P 6/18 without separate position detecting elements

Abstract

A downhole power system is provided that includes an energy storage adapted to operate at high temperatures, and a modular signal interface device that serves to control the energy storage component as well as offer a means of data logging at high temperatures. The controller is fabricated from pre-assembled components that may be selected for various combinations to provide desired functionality. The energy storage may include at least one ultracapacitor.

Claims

1-11. -11. (canceled)

12. A power system adapted for buffering the power from a power source to a load comprising:

a high temperature rechargeable energy storage (HTRES); and

a controller for controlling at least one of charging and discharging of the energy storage, the controller comprising at least one modular circuit having an operating efficiency greater than 90%;

wherein the system is adapted for operation in a temperature range of between about seventy five degrees Celsius to about two hundred and ten degrees Celsius.

15. The system of claim 12, wherein the system is adapted for downhole environments.

22. The system of claim 12, wherein the MSID HTRES comprises at least one ultracapacitor.

23. The system of claim 22, wherein the system comprises a junction circuit board electrically connected to the power source, an ultracapacitor charger circuit, an ultracapacitor management system circuit, an electronic management system circuit, a state of charge monitoring circuit, or any combination thereof.

24. The system of claim 12, wherein the system comprises circular circuit boards, stackers, and a modular bus connecting the circular circuit boards.

28. The system of claim 12, wherein the HTRES comprises at least one of an ultracapacitor, an aluminum electrolytic capacitor, a tantalum capacitor, a ceramic and metal film capacitor, a hybrid capacitor, or any combination thereof.

29. The system of claim 12, wherein the system is configured to decouple of an electrical aspect of a power source from an electrical aspect of a load, wherein the electrical aspect of the power source is selected from the group consisting of voltage, current, and instantaneous power.

31. The system of claim 12, wherein the system is configured to provide power to a data system.

32. The system of claim 31, wherein the data system comprises sensors for measuring drilling data comprising shock, vibration, weight on bit (WOB), torque on bit (TOB), annular pressure, temperature, hole size, translational acceleration, rotational acceleration, whirl, stick slip, magnetic field, direction, orientation, and any combination thereof.

33. The power system of claim 12, wherein the controller further comprises a data logging system capable of monitoring, logging, communicating system health, or any combination thereof.

36. The system of claim 33, wherein the data logging system further comprises electrically coupled data storage.

43. The system of claim 12, wherein the system is configured to adopt the optimum stable lowest voltage to reduce the current draw on the power source.

53. The system of claim 12, wherein the power source comprises at least one of a wireline power source, a battery-based power source, a generator, or any combination thereof.

54. The system of claim 12, wherein the power source comprises an intermittent power source.

56. The system of claim 12, wherein the system provides power to at least one load selected from the group consisting of electronic circuitry, a transformer, an amplifier, a servo, a processor, a data storage, a pump, a motor, a sensor, a thermally tunable sensor, an optical sensor, a transducer, fiber optics, a light source, a scintillator, a pulser, a hydraulic actuator, an antenna, a single channel analyzer, a multi-channel analyzer, a radiation detector, an accelerometer, a magnetometer, and any combination thereof.

57. The system of claim 12, wherein the system is configured to provide intermittent power pulses between about 50 W and about 100 W.

58. The system of claim 12, wherein the system is configured to provide intermittent power pulses between about 100 W and about 500 W.

60. The system of claim 12, wherein the system provides real-time monitoring of drilling data comprising shocks, vibrations, stick slip, temperature, weight on bit (WOB), torque on bit (TOB), annular pressure, hole size, rotational acceleration, whirl, magnetic field, direction, orientation, and any combination thereof.

61. The system of claim 56, wherein the load is a motor comprising a brushless DC motor drive.

62. The system of claim 56, wherein the load is a motor comprising a sensorless brushless DC motor drive.

63. The system of claim 56, wherein the load is an amplifier selected from the group consisting of switched mode amplifiers and Class D amplifiers.

64. The system of claim 12, wherein the system is configured to provide power to a downhole instrument selected from the group consisting of a mud pulse telemetry tool, an electromagnetic telemetry tool, a wireline telemetry tool, a fiber optic telemetry tool, a resistivity tool, a neutron sensor, a gamma sensor, a nuclear magnetic resonance tool, an acoustic tool, a seismic measurement tool, a formation sampling tool, a downhole communications tool, a geosteering tool, a rotary steerable tool, an accelerometer, a magnetometer, and combinations thereof.

65. The system of claim 12, wherein the system is configured to provide power to an electromagnetic telemetry tool.

66. The system of claim 65, wherein the power source is an intermittent power source and the system provides up to 500 W of peak power to an electromagnetic telemetry tool.

72. The system of claim 65, wherein the system further comprises an amplifier configured to provide power to an electromagnetic telemetry tool.

73. The system of claim 72, wherein the amplifier is selected from the group consisting of switched mode amplifiers and Class D amplifiers.

13-14. -14. (canceled)

16-21. -21. (canceled)

25-27. -27. (canceled)

30. (canceled)

34-35. -35. (canceled)

37-42. -42. (canceled)

44-52. -52. (canceled)

55. (canceled)

59. (canceled)

67-71. -71. (canceled)

74. A data system, the system comprising

a controller adapted to receive power from a power source and configured for drilling optimization;

and

one or more sensor circuits configured to receive drilling data in real-time, suitable for modification of drilling dynamics;

wherein the system is adapted for operation in a temperature range of between about seventy five degrees Celsius to about two hundred and ten degrees Celsius.

75. The system of claim 74, wherein the drilling data comprises shock, vibration, weight on bit (WOB), torque on bit (TOB), annular pressure, temperature, hole size, translational acceleration, rotational acceleration, whirl, stick slip, magnetic field, direction, orientation, and any combination thereof.

76. The system of claim 74, wherein the power source comprises a high temperature rechargeable energy storage (HTRES).

77. The system of claim 76, wherein the HTRES comprises at least one ultracapacitor.

78. The system of claim 77, wherein the system further comprises a junction circuit board electrically connected to the power source, an ultracapacitor charger circuit, an ultracapacitor management system circuit, an electronic management system circuit, a state of charge monitoring circuit, or any combination thereof.

79. The system of claim 74, wherein the system comprises circular circuit boards, stackers, and a modular bus connecting the circular circuit boards.