Electricity generation within a downhole drilling motor

• US 10,250,103 B2
• Filed: 09/14/2018
• Issued: 04/02/2019
• Est. Priority Date: 09/11/2014
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Gawski, Victor, Snyder, John
• Primary Examiner(s): Riyami, Abdullah
• Assistant Examiner(s): Mikailoff, S.
• Application Number:
  US16/131,507
• Publication Number:
  US 20190013716A1
• Time in Patent Office: 200 Days
• CPC Class Codes: H02K 7/1823 structurally associated with turbines or similar engines
• CPC Class Codes: Y02E 10/20 Hydro energy

Abstract

A progressing cavity-type drilling motor having an electrical generator disposed within the rotor of the drilling motor. In some embodiments, the electrical generator produces electrical energy from a flow of drilling fluid through a bore in the rotor. In other embodiments, the electrical generator produces electrical energy by harnessing the kinetic energy of the rotor as the drilling motor is used to drill into a formation. The electrical energy generated by the generator can be stored or used to power sensors, actuators, control systems, and other downhole equipment.

Claims

1. An apparatus for generating electricity in a downhole drilling operation, the apparatus comprising:

a progressing cavity motor attached to a downhole tool in a wellbore, the motor comprising;

a stator;

a rotor within the stator, wherein the rotor rotates within the stator with passage of one or more drilling fluids through a space between the progressing cavity stator and rotor;

the rotor comprising a central bypass bore, the bore comprising an inlet and an outlet, wherein the inlet, the outlet and the bore define a bypass flow path for the one or more drilling fluids to flow through the rotor;

a turbine disposed within the bore;

a shaft coupled to the turbine, wherein as the one or more drilling fluids flow through the bypass flow path, the one or more drilling fluids drive the turbine to rotate the shaft; and

a generator disposed within the bore, wherein rotation of the shaft drives the generator to generate the electricity.

2. The apparatus of claim 1, wherein the inlet comprises a nozzle for regulating the flow of the one or more drilling fluids through the bore.

3. The apparatus of claim 2, wherein the nozzle dynamically changes an amount of the one or more drilling fluids which is permitted to flow through the bore.

4. The apparatus of claim 1, wherein the generator comprises a generator rotor within a generator stator, wherein the generator generates the electricity by rotation of the generator rotor within the generator stator.

5. The apparatus of claim 1, wherein a movement of the rotor is at least one of rotational acceleration or deceleration.

6. The apparatus of claim 1, wherein the turbine is a reaction turbine.

7. The apparatus of claim 1, wherein the turbine is an impulse turbine.

8. The apparatus of claim 1, further comprising an electronics package coupled to the generator rotor.

9. The apparatus of claim 8, wherein the electronics package comprises a battery, wherein the battery stores the electricity generated by the generator.

10. A method for generating electricity, comprising:

disposing a progressing cavity motor within a downhole tool in a wellbore, wherein the motor comprises;

a stator;

a rotor within the stator, the rotor being rotated relative to the stator by passage of a drilling fluid through a space between the stator and the rotor, the rotor comprising a central bypass bore;

a turbine disposed within the bore of the rotor;

a shaft coupled to the turbine; and

a generator disposed within the bore and coupled to the shaft;

flowing the drilling fluid through the bore of the rotor, the bore comprising an inlet and an outlet, wherein the inlet, the outlet and the bore define a bypass flow path for the drilling fluid to flow through the rotor;

rotating the turbine with the drilling fluid flowing through the bypass flow path;

rotating the shaft by the rotation of the turbine; and

generating the electricity by driving the generator, wherein the rotation of the shaft drives the generator.

11. The method of claim 10, further comprising regulating the flow of the drilling fluid through the bore using a nozzle of the inlet.

12. The method of claim 11, wherein the nozzle dynamically changes an amount of drilling fluid permitted to flow through the bore.

13. The method of claim 10, further comprising converting the electricity generated by the generator into a form usable by downhole equipment.

14. The method of claim 10, wherein the generator comprises a generator rotor within a generator stator, wherein the generator generates the electricity by rotation of the generator rotor within the generator stator.

15. The method of claim 10, wherein the turbine is a reaction turbine.

16. The method of claim 10, wherein the turbine is an impulse turbine.

17. The method of claim 10, further comprising storing the generated electricity in a battery coupled to the generator.