Patent Application
20190186236
This section is intended to provide background information to facilitate a better understanding of the described embodiments. Accordingly, it should be understood that these statements are to be read in this light and not as admissions of prior art.
Downhole electrical generators and batteries, among others, are often used to generate and supply energy power to downhole equipment, including flow control devices, telemetry devices, sensors, and packers. However, a generator located in a downhole environment includes several limitations including restricting tubing or interfering with fluid flow through a wellbore or annulus of the wellbore. As an alternative to downhole generators, conditions occurring during operations can generate kinetic, mechanical, rotational, and thermal energy, among others types of energy. The generated energy can be converted into electrical energy to supply power to downhole drilling equipment and devices. For instance, power generated by a high-velocity fluid can drive a downhole generator where the kinetic energy of the fluid is converted into mechanical/rotational energy as it flows through a motor. The fluid flow causes a rotor within the motor to rotate a motor shaft. The rotation of the motor shaft generates electricity that can be used to power various downhole drilling equipment, such as a rotating valve sleeve.
For a detailed description of the embodiments of the invention, reference will now be made to the accompanying drawings in which:
This disclosure describes a method and system for internal and external power generation in an oilfield environment using a downhole flow control system. In a downhole environment, multiple components, including valves, sensors, and downhole tools, often use a source of energy to operate at full capacity. Yet, rather than relying on power from an above-ground source, a flow control system of the embodiments uses rotational and fluid energy generated during downhole operations to generate and supply electrical energy.
The wellbore 118 includes a casing 144 that is cemented in place or otherwise secured to a wall of the wellbore 118 or a previously hung casing. The wellbore 118 may include several cased sections or the wellbore 118 may not contain any casing, often referred to as an “openhole”. In one or more embodiments, perforation tunnels 146 can be formed in the subsurface formation 120, as well as, the casing 144 using a perforation tool (not shown) such as a perforating gun, hydro-jetting, or other tools as known in the art. The perforation tunnels 146 can be formed in one or more zones of the subsurface formation 120 based on formation characteristics (e.g., formation type, density, resistivity, porosity, etc.) surrounding the wellbore 118. One or more annular sealing devices 148 are mounted on the completion string 114 between the valves 130. The annular sealing devices 148 can include mechanically, hydraulically, electromechanically, chemically, or temperature-activated packers, plugs, or other isolation devices to isolate the zones of the subsurface formation 120 or other sections of the wellbore 118.
The multi-zone or fracturing system 142 can produce or deliver a fluid to and/or from one or more downhole locations and into the perforation tunnels 146, including both new and existing perforation tunnels 146. The injected fluid can include a fracturing fluid, a completion fluid, a treatment fluid, formation sand, and the like, that is stored in a storage unit 154, for example, a tank, pipeline, or the like. The perforation tunnels 146, which may be formed deep into the subsurface formation 120, also increase the surface area for produced hydrocarbons to flow from a zone(s) of the subsurface formation 120 and into the wellbore 118 and/or an annulus area 138 of the wellbore 118.
The valves 130 receive and regulate the flow of the fluid as it flows downward or upward through the completion string 114. Additionally, during operations, the valves 130 can supply electrical power to various equipment located in the wellbore 118. Specifically, the flow of the fluid through the valves 130 is converted to rotational energy to rotate magnetic components within the valve 130, thereby, generating a varying magnetic field. An electrical conductor, such as a wire, is located in the valves 130 to receive and convert the varying magnetic field into electrical energy. The generated electrical energy can be used to power downhole devices, components, and the like, attached to and/or located near the completion string 114. Accordingly, the valves 130 provide a downhole power source and eliminate the need of an electrical control line(s) extending from a surface 156 and into the wellbore 118 to deliver downhole power.
Various types of valves 130 may be used along the length of the completion string 114. Further, the configuration and the number of valves 130 positioned in the wellbore 118 for power generation will vary depending on power requirements and the availability of other power sources, among other considerations.
Note, the oilfield environment 100 of
The valve assembly 230 includes a valve element, such as a rotatable sliding sleeve 217 to regulate the flow of the fluid 202 as it flows through the hollow body 208. As the fluid 202 flows across the valve assembly 230, a pressure differential is created to cause the sleeve 217 to rotate to configure a port(s) 256, formed in the hollow body 208, into an open or closed position. To provide an open port position, the sleeve 217 rotates to expose the openings of the port 256 so that the fluid 202 flows through the port 256 and into an annular area 238 located between the tubular string 214 and an inner wall of the wellbore 218. In a closed port position, the sleeve 217 may rotate to cover the openings of the port 256, and thus, prevent fluid flow through the port 256 and into the annular area 238. As the fluid 202 enters and exits the valve assembly 230, a velocity of the fluid 202 rotates a rotor assembly 222 attached to the sleeve 217. The rotating motion of the rotor assembly 222 provides a rotatable, turbine effect to generate energy, as will be further explained.
In the embodiments, the rotor assembly 222 includes a rotatable bearing 224 with one or more openings 226. For the convenience of this discussion, the rotor assembly 222 will be described as including multiple openings 226. In the embodiments, the openings 226 are arranged longitudinally within and spaced along a circumference of the rotatable bearing 224. The openings 226 are formed at an angled orientation with respect to the direction of fluid flow and may be in the form of a hole, oval, slot, or any other type of opening capable of receiving the fluid 202. As the fluid flows across the rotatable bearing 224, the openings 226 receive the fluid 202 and cause the rotor assembly 202, including the rotatable bearing 224, to rotate.
The openings 226 are designed to convert the energy created by the velocity of the fluid 202 into mechanical/rotational energy to provide torque to other downhole equipment and devices. As will be further discussed, the mechanical/rotational energy generated by the rotational motion of the rotatable bearing 224 is used in conjunction with one or more electric lines or conductors (not shown) disposed within the valve assembly 230 to provide a power generation system.
Depending on the parameter conditions associated with the fluid 202, the rotational speed of the rotatable bearing 224 can correspond with the rotational speed of the sleeve 217. As depicted in
One or more electrical conductors 328, depicted as dashed lines, are located in a groove 334 of a stator 336 to be protect from the fluid 302 flowing into and across the valve assembly 330. In particular, the electrical conductors 328 are displaced at a relative distance from the magnet(s) 310. In embodiments, the conductors 328 and the magnets 310 may be distributed circumferentially about a central axial flow path of the fluid 302 as it flows into the valve assembly 330. As the magnet(s) 310 located in the rotatable bearing 324 rotates, a varying magnetic field is created where the conductors 328 convert the varying magnetic field into an electric current to generate internal electrical power. In this regard, electrical power is created without the need for a passageway-restricting power generator located in the internal passageway 332 of the valve assembly 330.
It will be appreciated that the electrical energy generated internally within the valve assembly 330 by rotation of the rotatable bearing 324 is available for use and/or stored for downhole use. In one more embodiments, the electrical energy provides an electric current to form a downhole power generator circuit (DPG) and/or can be stored as power in a battery on or near the valve assembly 330. As an example, the stored electrical power can power a downhole valve actuation/monitoring system, gauges, or the like.
In some applications, the force and pressure of the fluid 302 causes damage and/or failure to the valve assembly 330 and/or other downhole components. For example, the force at which the fluid 302 enters the valve assembly 330 can impinge on and damage the sleeve 317. Accordingly, the rotating motion of the rotor assembly 322 can minimize erosion of the flowing fluid 302 by dissipating the flow energy of the fluid 302 across the opening (i.e., circumference) of the bearing 324 and not just the area exposed to the slots.
The rotor assembly 422 is made of multiple magnetic rotor blades 423. The housing 410 is configured to protect the blades 423, for example, while running a tubular string into a well with the valve assembly 430 mounted thereon. In other embodiments, the valve assembly 430 is run without the housing 410 and the actual casing of the well acts as the housing 410. In this way, an outer diameter of the housing 410 that is equal to or slightly larger than the rotor blades 423 is run into the well to ensure the blades 423 are centered and protected either before and/or after installation of the blades 423. In the examples, the rotor blades 423 are made of magnetic materials and/or one or more magnets or magnetic material (not shown) is embedded within the structure of the rotor blades 423. As the fluid 402 enters the annular area 438, the sleeve 417 directs the flow of the fluid 402 pass the rotor blades 423 where the velocity of the fluid 202 rotates the blades 423 to create a varying magnetic field.
As shown in
It should be understood that the embodiments are not limited to the particular embodiments as shown in
The valve assemblies depicted in
In embodiments, the electrical power generated in the valve assembly 530 can be used to operate and power an onboard computer (CPU) 510 that can interface with and provide power to other components within the power generation system 500 as well as other downhole components located along the tubular string 514. As an example, the onboard CPU 510 may interface with and power a master CPU 512 to control one or more valves 530 located along a length of the tubular string 514. In this configuration, the master CPU 512 controls operation of the valves 530 by sending logic and rules in the form of control signals to the onboard CPU 510. Accordingly, the onboard CPU 510 may indirectly control the valves 530 autonomously based on the logic and rules received. The use of the onboard CPU 510 with the master CPU 512 provides redundancy during malfunctioning or failure of the onboard CPU 510. In one or more embodiments, the rules and logic include instructions for optimizing the inflow characteristics of the valve 530 or actuating the valves 530, among other actions. For example, the onboard CPU 510 may be instructed to maintain a constant window of flow differential through the valves 530 (e.g., 1000±50 psi (6.8×104 Pascal) at a 20% choke open position) for a set period of time. Further, the onboard CPU 510 may be instructed to shut-in the valves 530 in the event of a catastrophic event. In the preferred embodiments, the master CPU 512 may hold complete override privileges related to the operation of the valves 530. In some cases, where manual input is not possible due to a lack of human intervention, the onboard CPU 510 can make a pre-programmed decision to provide autonomous control (i.e., without outside control from other components) of the valves 530.
In the embodiments, the valves 530 may include any hydraulically operated valve, including a safety valve. The valves 530 can be equipped with a Hydraulic Module (HM) 516 which has a measured amount of hydraulic fluid that can operate the valve 530 from a fully open position to a fully closed position. In preferred embodiments, the HM 516 may interface with the onboard CPU 510 and thus, is powered and controlled by the onboard CPU 510 based on specific logic and rules programmed at the master CPU 512.
In the embodiments, a position of the valves 530 can be controlled using a valve mounted configurable gauge (VCG) 518 that is configured to interface with the onboard CPU 510. The VCG 518 can perform other functions including capturing and measuring data within the tubular string 514 in real-time. The real-time data may include, but is not limited to, position feedback, temperature and pressure, and water cut in production. Since the VCG 518 interfaces with the onboard CPU 510, the real-time data of the VCG 518 can be monitored against the logic and rules programmed at the master CPU 512. Accordingly, the onboard CPU 510 can provide real-time decisions to autonomously control the valves 530. Optionally, a tubing mounted permanent downhole gauge system (PDG) 520 can interface with and provide the onboard CPU 510 with measurable parameter data related to the tubular string 514.
The power generated at the valves 530 is used to create a DPG 507, power the onboard CPU 510, and various other modules that may interface with the onboard CPU 510. In the described embodiments, the master CPU 512, the HM 516, the VCG 518, and the PDG 520 may rely on the onboard CPU 510 as a source of power to form the interdependent power generation system 500. It would understood that the modules of the power generation system 500 including, but not limited to, the DPG 507, the RBA 508, the onboard CPU 510, the master CPU 512, the HM 516, and the VCG 518, may be located within the tubular string 514 and in close proximity to the valves 530. In the embodiments, the master CPU 512 may include a surface computer located, for example, in a control room. In other embodiments, the master CPU 512 may be located in a downhole environment and remotely controlled from a remote location, e.g., the control room. It should be further understood that although the power generation system 500 is illustrated as providing power to downhole components, the system 500 could additionally power above ground surface components.
In addition, to the embodiments described above, many examples of specific combinations are within the scope of the disclosure, some of which are detailed below:
Example 1. A valve assembly for use in controlling flow of a fluid in a wellbore, comprising a housing including an internal passageway, a conductor located adjacent to the internal passageway, a rotor assembly located outside of the internal passageway and comprising a magnet having a magnetic field and rotatable with the rotor assembly, and a flow path to receive a flow of the fluid therethrough to rotate the rotor assembly, herein rotation of the rotor assembly and the magnet relative to the conductor produces electrical energy in the conductor.
Example 2. The valve assembly of Example 1, wherein the magnet is embedded within a rotatable bearing of the rotor assembly to produce internal electrical energy.
Example 3. The valve assembly of Example 1, wherein the magnet is embedded within a blade of the rotor assembly to generate external electrical energy.
Example 4. The valve assembly of Example 1, further comprising a central processing unit (CPU) powered by the electrical energy.
Example 5. The valve assembly of Example 1, further comprising a battery configured to store the electrical energy.
Example 6. The valve assembly of Example 5, wherein the battery further comprises a rechargeable battery array configured to be rechargeable by the electrical energy.
Example 7. The valve assembly of Example 1, wherein the rotatable assembly configured to rotate continuously or intermitted to change the magnetic field of the magnet.
Example 8. A control system for downhole applications, comprising, a valve assembly configured to control a flow of a fluid in a wellbore, comprising, a housing including an internal passageway, a conductor located adjacent to the internal passageway, a rotor assembly located outside of the internal passageway comprising a magnet having a magnetic field and rotatable with the rotor assembly, and a flow path to receive a flow of the fluid therethrough to rotate the rotor assembly, wherein rotation of the rotor assembly and the magnet relative to the conductor produces electrical energy in the conductor, and a central processing unit (CPU) configured to control one or more valves, wherein the electrical energy is used to power the CPU.
Example 9. The control assembly of Example 8, further comprising a master central processing unit (CPU) configured to interface with and to provide control signals to the CPU and wherein the CPU supplies power to the master CPU.
Example 10. The control assembly of Example 9, wherein the control signals comprise logic to actuate the one or more valves.
Example 11. The control assembly of Example 9, wherein the control signals comprise logic to optimize flow characteristics of the one or more valves.
Example 12. The control assembly of Example 8, wherein the CPU is a slave to a master CPU and wherein the master CPU directly controls the one or more valves.
Example 13. The control assembly of Example 8, wherein the CPU autonomously controls the one or more valves via a pre-programmed signal when a master CPU is inoperable.
Example 14. The control assembly of Example 8, wherein the CPU monitors real-time downhole parameter data against a control signal of a master CPU.
Example 15. The control assembly of Example 8, further comprising a gauge system configured to measure parameters for the downhole applications and to provide real-time downhole parameter data.
Example 16. The control assembly of Example 8, wherein the CPU is configured to power and control one or more components attached to the one or more valves.
Example 17. A method for operating a valve assembly, comprising maintaining ports of the valve assembly in an open position to permit a fluid to flow through an internal passageway of the valve assembly, flowing the fluid through an opening of a rotor assembly located outside of the internal passageway to rotate the rotor assembly, wherein the rotation rotates a magnet attached to the rotor assembly to vary a magnetic field of the magnet, and exposing a conductor located adjacent to the rotor assembly to the varying magnetic field to produce electrical energy in the conductor.
Example 18. The method of Example 17, further comprising supplying the electrical energy to a central processing unit (CPU) to control a function of a valve located in a downhole environment.
Example 19. The method of Example 18, further comprising interfacing a master CPU with the CPU, wherein the CPU supplies power to the master CPU.
Example 20. The method of Example 17, further comprising storing the electrical energy in a battery for further use in a downhole environment.
This discussion is directed to various embodiments of the present disclosure. The drawing figures are not necessarily to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. It is to be fully recognized that the different teachings of the embodiments discussed may be employed separately or in any suitable combination to produce desired results. In addition, one skilled in the art will understand that the description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.
Certain terms are used throughout the description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function, unless specifically stated. In the discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. In addition, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. The use of “top,” “bottom,” “above,” “below,” and variations of these terms is made for convenience, but does not require any particular orientation of the components.
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except to the extent that they are included in the accompanying claims.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2016/055637 | 10/6/2016 | WO | 00 |
