The present application relates to downhole power generation. Specifically, the present application relates to a downhole power generation system with alternative flow paths, which enable a power generation mode and a bypass mode.
In certain downhole operations, power is needed to run various components of a downhole assembly. For example, power is need to drive actuators for valves and other components, and to power various sensors and communication devices. In many cases, power is generated downhole via a downhole power generation device that is coupled to the downhole assembly. Some of the devices may be designed to use mechanical power from the fluid flow to generate electric power downhole such as the mechanisms using flow induced vibration, turbomachinery, and the like. However, when such power generation mechanism is designed to run continuously, it must endure a large amount of stress and wear. This leads to a short operating device life. This is a problem because maintenance of such devices is extremely difficult and often impossible, and the expected life of such devices is much shorter than the life of the well. Additionally, such power generation devices typically generate more power than is needed to carry out the functions of the downhole assembly. Thus, the stress and wear seen by the power generation mechanism in generating the excess power does not translate into increased utility.
In general, in one aspect, the disclosure relates to a downhole power generation system. The downhole power generation system includes a tubular power generation device configured to be disposed in an annular space around a portion of a production tubing, wherein the power generation device is switchable between a power generation mode and a bypass mode. The power generation device includes a power generation path configured to receive a flow of fluid therethrough during the power generation mode. The power generation device also includes a turbomachinary system comprising a rotor disposed within the power generation path, the rotor comprising a rotor hub and a plurality of rotor blades extending from the rotor hub. The rotor hub is partially defined by a central orifice configured to receive the production tubing therethrough, wherein the rotor rotates when the flow of fluid traverses the power generation path. The power generation device also includes a bypass path configured to receive the flow of fluid therethrough during the bypass mode. The power generation device also includes a power generation port and a bypass port. The power generation port is coupled to the power generation path through which fluid enters the power generation path. The bypass port is coupled to the bypass path through which fluid enters the bypass port. The power generation system further includes a power generation unit coupled to the turbomachinary system and configured to convert rotation of the rotor into electricity.
In another aspect, the disclosure can generally relate to a downhole power generation device. The downhole power generation device includes a tubular housing configured to be disposed within an annular space and around a portion of production tubing. The housing includes a flow compartment configured to receive a flow of fluid therethrough when the power generation device is in a power generation mode, and an electronics compartment comprising a controller and a power generation unit. The downhole power generation device further includes a turbomachinary system comprising a rotor disposed within the flow compartment and comprising a rotor hub and a plurality of rotor blades, wherein the rotor rotates when the flow of fluid traverses the flow compartment. The downhole power generation device also includes a port coupled to the flow compartment, through which fluid enters the flow compartment.
In another aspect, the disclosure can generally relate to a downhole power generation system. The downhole power generation system includes a tubular power generation device configured to be disposed in an annular space around a portion of a production tubing, wherein the power generation device is partially defined by an orifice for receiving the production tubing. The power generation device comprises a first end through which a flow of fluid can enter the power generation device, a second end opposite the first end, and a power generation path extending from the first end and the second end. The power generation path comprises a rotor disposed around the orifice, the rotor comprising a rotor hub and a plurality of inward facing rotor blades, wherein the rotor rotates when a flow of fluid traverses the rotor. The power generation device further may include at least one bearing disposed around the rotor hub, at least one stationary coil disposed around the rotor hub, and at least one rotating magnet disposed around the rotor hub and configured to rotate with the rotor and with respect to the at least one coil, generating electricity.
These and other aspects, objects, features, and embodiments will be apparent from the following description and the appended claims.
The drawings illustrate only example embodiments of the present disclosure, and are therefore not to be considered limiting of its scope, as the disclosures herein may admit to other equally effective embodiments. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or positions may be exaggerated to help visually convey such principles. In the drawings, reference numerals designate like or corresponding, but not necessarily identical, elements. In one or more embodiments, one or more of the features shown in each of the figures may be omitted, added, repeated, and/or substituted. Accordingly, embodiments of the present disclosure should not be limited to the specific arrangements of components shown in these figures.
Example embodiments directed to a downhole power generation system and method will now be described in detail with reference to the accompanying figures. Like, but not necessarily the same or identical, elements in the various figures are denoted by like reference numerals for consistency. In the following detailed description of the example embodiments, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure herein. However, it will be apparent to one of ordinary skill in the art that the example embodiments disclosed herein may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. The example embodiments illustrated herein include certain components that may be replaced by alternate or equivalent components in other example embodiments as will be apparent to one of ordinary skill in the art.
Referring now to the drawings,
In certain example embodiments, the power generation system 102 is disposed in an annular space 114 around a portion of the production tubing 106.
In certain example embodiments, a first portion of the production tubing 106a adjacent the first portion of the annular space 114a and the first end 104 of the power generation system 102 is not perforated, such that production fluid flowing into the first portion of the wellbore 108a does not flow directly into the first portion of the production tubing 106a. Rather, in certain example embodiments, production fluid flowing into the first portion of the wellbore 108a is forced to flow through the power generation system 102 and into the second portion of the annular space 114b. In certain example embodiments, a second portion of the production tubing 106b adjacent the second portion of the annular space 114b contains flow control valves 202, which allow the production fluid to flow from the second portion of the annular space 114b into the production tubing 106. The production fluid can then travel to the surface 112 where it is recovered.
In certain example embodiments, the inside of the production tubing 106 is only in communication with the annular space 114 via the power generation system 102, and thus production fluid is forced to travel through the power generation system 102 in order to enter the production tubing 106 and ultimately be recovered. In certain example embodiments, flow of production fluid through the power generation system 102 engages a power generation mechanism in the power generation system. This allows the power generation system 102 to generate power, which is stored in a power storage device 210, such as a rechargeable battery, capacitor, or the like.
In certain example embodiments, and as best shown in
In certain example embodiments, the bypass path 206 is isolated from the power generation mechanism 208 and provides a path for production fluid to flow through the power generation system 102 without interacting with the power generation mechanism 208. The power generation mechanism 208 is bypassed and does not generate power when fluid flows only through the bypass path 206.
Both the power generation path 204 and the bypass path 206 provide a path for production fluid to travel through. In certain example embodiments, the power generation path 204 and the bypass path 206 can be opened and closed in order to direct production fluid through the selected path. In certain example embodiments, the bypass path 206 is closed when the power generation path 204 is open. Thus, production fluid must travel through the power generation path 204 and activate the power generation mechanism 208, thereby generating power. Alternatively, in certain example embodiments, the bypass path 206 is opened when the power generation path 204 is closed. As such, production fluid flows through the bypass path 206 and the flow is isolated from the power generation mechanism 208. Thus, the power generation mechanism is not active. This allows the power generation mechanism to rest when power generation is not needed, which increases the overall life of the power generation mechanism. In certain example embodiments, the bypass path 206 and the power generation path 204 can be open at the same time.
In certain example embodiments, the power generation system 102 can be controlled to switch between a power generation mode and a bypass mode. Accordingly, when the power generation system 102 is in the power generation mode, the power generation path 204 is open, production fluid flows therethrough. The power generation mechanism 208 is activated, and power is generated. In certain example embodiments, the generated power is saved in the power storage device 210. The power stored in the power storage device can then be used to power various electronic parts of the downhole assembly, such as actuators, valves, sensors, communication modules, and other devices. When the power generation system 102 is in the bypass mode, the power generation path 204 is closed, production fluid flows through the bypass path 206, and power is not generated.
In certain example embodiments, the power generation system 102 includes a control system 212, which includes various control components such as a microprocessor, sensors, controllers, and the like. In certain example embodiments, the control system 212 controls the switching of the power generation system 102 between the power generation mode and the bypass mode. In certain example embodiments, the control system 212 controls the switching based on one or more parameters or predetermined operational conditions. For example, in a first group of embodiments, the control system 212 controls the switching based on actual power demand by measuring the amount of power currently stored in the power storage device 210. In certain such embodiments, the control system 212 senses the power level of the power storage device 210 via one or more sensors and compares the power level to a first threshold level. If the measured power level is below the first threshold level, then the control system 212 switches the power generation system 102 into the power generation mode. In certain example embodiments, when the power generation system 102 is in the power generation mode, the control system 212 may switch the power generation system 102 to the bypass mode after a certain period of time, or when the measured power level of the power storage device 210 is above a second threshold value. In certain example embodiments, the second threshold value is higher than the first threshold value. Effectively, the power generation system 102 is used to generate power when the stored power is relatively low and not used when the stored power is still relatively high, rather than continuously generating power regardless of actual demand. This reduces the amount of wear on the power generation mechanism 208, increasing the overall lifespan of the power generation system 102.
In another group of example embodiments, not exclusive of embodiments in the first group, the control system 212 controls switching between the power generation mode and the bypass mode based on current operational conditions, operational demands, and/or a preprogrammed protocol. For example, in one embodiment, the control system 212 switches the power generation system 102 to the power generation mode in anticipation of a power-consuming event such as actuating a valve. In certain example embodiments, the power generation system 102 is put in the power generation mode during or after such an event. In certain example embodiments, the power generation system 102 is put in the bypass mode after such an event occurs. In certain example embodiments, the control system 212 switches the power generation system 102 to the power generation mode at certain time intervals. In certain example embodiments, the control system 212 is preprogrammed to control the power generation system 102 in accordance to a protocol or program. The protocol or program defines the conditions under which the power generation system 102 is to be put in the power generation mode and the conditions under which the power generation system 102 is to be put in the bypass mode. Such conditions may include stored power level, time interval, actuation, certain events, and so forth. This allows the power generation system 102 to autonomously switch between the power generation mode and bypass mode without intervention, and further allows the power generation system 102 to provide maximum utility and reduce waste.
In certain example embodiments, switching between the power generation mode and the bypass mode includes mechanical actuation, such as driving a motor, which mechanically opens and closes the power generation path 204 and the bypass path 206. In certain example embodiments, the switching includes expansion and contraction, or axial movement of a plug or packer type device in the power generation path 204 and the bypass path 206, in which the device blocks the respective path when expanded.
The power generation path 406 further includes a turbomachinary system 409 disposed within the power generation path 406. The turbomachinery system 409 includes a rotor 410 disposed within the power generation path 406.
In certain example embodiments, the power generation device 400 includes a housing 422. The housing 422 includes a flow compartment 424 and an electronics compartment 426. In certain example embodiments, the flow compartment 424 includes a wall 428 separating the power generation path 406 and the bypass path 408. In certain example embodiments, an opening 430 in the wall 430 allows fluids to flow out of the power generation path 406 after it flows past the turbomachinery system 409. The electronics compartment 426 houses the power generation unit 416 and the electronic components 418, and isolates them from the production fluid. In certain example embodiments, the electronics compartment 426 is isolated via a sealed coupling 414, which transmits the torque from turbomachinery rotor 410 to the power generation unit 416 and prevents production fluid from seeping into the electronics compartment.
In certain example embodiments, the power generation device 700 further includes one or more coils 706, one or more rotating magnets 708, and one or more bearings 710. The coils 706 are coupled to and stationary with respect to the tubular housing 702. The rotating magnet 708 is coupled to the rotor hub 712. Thus, when the rotor 705 rotates, the rotating magnet 708 rotates with the rotor 705 and the coils 706 remain stationary with the tubular housing 702. Rotation of the rotating magnet 708 with respect to the coils 706 generates electricity. In certain example embodiments, the coils 706 and the rotating magnet 708 are disposed around the generator housing 704 and adjacent each other. In certain example embodiments, the rotating magnet 708 is disposed between a plurality of coils 706. In certain example embodiments, the bearings 710 are disposed around the generator housing 704 and in between the generator housing 704 and the rotor hub 712 . In certain example embodiments, the bearings 710, the coils 706, and the rotating magnet 708 form a tubular layer between the rotor hub 712 and the generator housing 704. In certain example embodiments, the coils 706 and the rotating magnet 708 are oriented in a different configuration than the illustrated example. For example, the coils 706 can be coupled to the rotor 705 and the rotating magnet can be coupled to the generator housing 704. In certain example embodiments, the tubular housing 702 may include an inner tubular wall disposed within the generator housing 704 which separates the rotor 705 and the production tubing 106.
In certain example embodiments, the power generation device 700 includes a bypass path (not shown in
Although embodiments described herein are made with reference to example embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope and spirit of this disclosure. Those skilled in the art will appreciate that the example embodiments described herein are not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments using the present disclosure will suggest themselves to practitioners of the art. Therefore, the scope of the example embodiments is not limited herein.
The present application is related to U.S. patent application Ser. No. ______, titled “System and Method for Autonomous Downhole Power Generation,” and filed concurrently herewith; and U.S. patent application Ser. No. ______, titled “Downhole Power Generation System and Method,” and filed concurrently herewith.