Electrical generator and electric motor for downhole drilling equipment

• US 10,240,435 B2
• Filed: 06/14/2013
• Issued: 03/26/2019
• Est. Priority Date: 05/08/2013
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Snyder, John Kenneth, Gawski, Victor
• Primary Examiner(s): Buck, Matthew R
• Assistant Examiner(s): Lembo, Aaron L
• Application Number:
  US14/780,435
• Publication Number:
  US 20160053588A1
• Time in Patent Office: 2,111 Days
• CPC Class Codes: E21B 4/04 Electric drives E21B4/12 takes precedence
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes

Abstract

An electrical generator positionable downhole in a well bore includes a tubular housing having a first longitudinal end and a second longitudinal end, the housing having an internal passageway with a plurality of layers. The layers comprise at least a first protective layer, a second protective layer, and an electrically conductive layer positioned between the first and second protective layers. The layers define an internal cavity. A shaft with magnetic inserts is movably positioned in the internal cavity. Electrical current is generated when the shaft is moved. Alternatively, the device may be supplied with electrical power and used as a downhole motor.

Claims

1. An electrical generator positionable in a wellbore, the electrical generator comprising:

a tubular housing having a first longitudinal end and a second longitudinal end, said tubular housing having an internal passageway, said passageway having a plurality of layers positioned therein, said layers comprising at least a first protective layer, a second protective layer, and an electrically conductive layer positioned between the first and second protective layers, said layers defining an internal fluid cavity with a longitudinal axis, said electrically conductive layer electrically coupled at a first end to a first electrical end conductor positioned proximal to the first longitudinal end of the tubular housing and electrically coupled at a second end to a second electrical end conductor positioned proximal to the second longitudinal end of the tubular housing, and

a shaft with two or more magnetic inserts positioned at different longitudinal locations along a length thereof, said shaft movable longitudinally in the internal fluid cavity of the housing;

wherein the electrically conductive layer comprises one or more conductive strips configured as one or more spirals formed about an inner surface of the tubular housing, the one or more conductive strips configured as one or more spirals positioned proximate the two or more magnetic inserts.

2. The electrical generator of claim 1, wherein the first protective layer is positioned along an inner surface of the tubular housing, the electrically conductive layer is along an inner surface of the first protective layer and the second protective layer is positioned along an inner surface of the electrically conductive layer.

3. The electrical generator of claim 1, wherein at least one of the first protective layer and the second protective layer is electrically non-conductive.

4. The electrical generator of claim 1, wherein the electrically conductive layer comprises a first electrically conductive layer and said generator further comprises a second electrically conductive layer that is electrically insulated from the first electrically conductive layer.

5. The electrical generator of claim 4, wherein the second electrically conductive layer is positioned along an inner surface of the second protective layer, and a third protective layer is positioned along an inner surface of the second electrically conductive layer.

6. The electrical generator of claim 1, wherein the electrically conductive layer is positioned along the inner surface of the first protective layer.

7. The electrical generator of claim 4, wherein the second electrically conductive layer is positioned parallel to the first electrically conductive layer.

8. The electrical generator of claim 1 wherein the first end conductor is in electronic communication with the second end conductor via at least one conductive layer positioned in the tubular housing.

9. The electrical generator of claim 8 wherein an electrical current generated in the conductive layer is received at either the first end or the second end conductor via at least one conductive layer positioned in the tubular housing.

10. The electric generator of claim 1, wherein the two or more magnetic inserts are positioned in general end to end alignment at different longitudinal locations along a length thereof.

11. An electrical generator positionable in a wellbore, the electrical generator comprising:

a tubular housing having a first longitudinal end and a second longitudinal end, said tubular housing having an internal passageway, said passageway having a plurality of layers positioned therein, said layers comprising at least a first protective layer, a second protective layer, and an electrically conductive layer positioned between the first and second protective layers, said layers defining an internal fluid cavity with a longitudinal axis, said electrically conductive layer electrically coupled at a first end to a first electrical end conductor positioned proximal to the first longitudinal end of the tubular housing and electrically coupled at a second end to a second electrical end conductor positioned proximal to the second longitudinal end of the tubular housing; and

a shaft with two or more magnetic inserts positioned at different longitudinal locations along a length thereof, said shaft movable longitudinally in the internal fluid cavity of the housing;

wherein the electrically conductive layer comprises one or more conductive strips configured as one or more serpentine paths formed along an inner surface of the tubular housing, the one or more conductive strips configured as one or more serpentine paths positioned proximate the two or more magnetic inserts.

12. A method of generating electricity in a well drilling operation, the method comprising:

positioning an electrical generator in a wellbore, the generator including

a tubular housing having a first longitudinal end, a second longitudinal end, said tubular housing having an internal passageway, said passageway having a plurality of layers positioned therein, said layers comprising at least a first protective layer, a second protective layer, and an electrically conductive layer positioned between the first and second protective layers, said layers defining an internal fluid cavity with a longitudinal axis, said electrically conductive layer electrically coupled at a first end to a first electrical end conductor positioned proximal to the first longitudinal end of the tubular housing and electrically coupled at a second end to a second electrical end conductor positioned proximal to the second longitudinal end of the tubular housing, and,

a shaft having two or more magnetic inserts positioned at different longitudinal locations along a length thereof, said shaft movably positioned in the internal fluid cavity of the housing;

moving the shaft longitudinally within the electrically conductive layer;

inducing a flow of current in the electrically conductive layer as the two or more magnetic inserts pass thereby; and

receiving electric current from the electrically conductive layer at the first electrical end conductor or the second electrical end conductor.

13. The method of claim 12, wherein the electrically conductive layer comprises one or more conductive strips configured as one or more spirals formed about an inner surface of the tubular housing.

14. The method of claim 12, wherein the electrically conductive layer comprises one or more conductive strips configured as one or more serpentine paths formed along an inner surface of the tubular housing.

15. The method of claim 12, wherein moving the shaft longitudinally within the electrically conductive layer comprises vibrational movement of the shaft linearly, resulting from vibrations transmitted from the drill bit interacting with a formation being drilled.

16. The method of claim 12, wherein moving the shaft longitudinally within the electrically conductive layer comprises tensile loading on a drill string coupled to the shaft resulting from upward back reaming operations in the well drilling operations.

17. The method of claim 12, wherein moving the shaft longitudinally within the electrically conductive layer comprises tensile loading on a drill string coupled to the shaft resulting from application of an overpull load on a downhole tool.

18. The method of claim 12, wherein moving the shaft longitudinally within the electrically conductive layer comprises contacting a poppet valve with a drilling fluid and moving a stem in the poppet valve linearly wherein the stem is coupled to the shaft of the generator.

19. The method of claim 12, wherein moving the shaft longitudinally within the electrically conductive layer comprises movement of the shaft in the generator by a re-set spring.

20. The method of claim 12, wherein moving the shaft longitudinally within the electrically conductive layer comprises application of weight to a drill string coupled to the shaft.