Vortex energy harvester for downhole applications

• US 10,287,854 B2
• Filed: 12/16/2015
• Issued: 05/14/2019
• Est. Priority Date: 12/16/2015
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Jaaskelainen, Mikko, Park, Brian V.
• Primary Examiner(s): Cuevas, Pedro J
• Application Number:
  US15/765,219
• Publication Number:
  US 20180291711A1
• Time in Patent Office: 1,245 Days
• Field of Search: 290 1 R, 290 43, 290 54, 310330
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: E21B 47/16 through the drill string or casing , e.g. by torsional acoustic waves
• CPC Class Codes: H02N 2/18 producing electrical output from mechanical input, e.g. generators for measurement devices G01
• CPC Class Codes: H02N 2/185 using fluid streams

Abstract

The present invention relates to a system for vortex energy harvesting for downhole applications and a method thereof, the system comprising: one or more electro acoustic technology assemblies mounted downhole in close proximity to a fiber optic cable that is part of a fiber optic distributed acoustic sensing system connected back to a surface distributed acoustic sensing interrogator; and one or more vortex energy harvesters attached to each of the electro acoustic technology assemblies and exposed to a fluid flow in the downhole application.

Claims

1. A system comprising:

one or more electro acoustic technology assemblies mounted downhole in close proximity to a fiber optic cable that is part of a fiber optic distributed acoustic sensing (DAS) system connected back to a surface distributed acoustic sensing interrogator; and

one or more vortex energy harvesters attached to each of the electro acoustic technology assemblies and exposed to a fluid flow in a downhole application.

2. The system of claim 1 further comprising enclosed batteries within the electro acoustic technology assemblies to power an operation of the electro acoustic technology assemblies.

3. The system of claim 1 further comprising enclosed sensors within the one or more electro acoustic technology assemblies to sense parameters of interest.

4. The system of claim 3 further comprising enclosed microprocessor circuitry within the one or more electro acoustic technology assemblies to:

collect data from the enclosed sensors,

amplify the data, and

transmitting the to the surface by actuating the fiber optic cable acoustically.

5. The system of claim 1 wherein the one or more vortex energy harvesters are attached to the one or more electro acoustic technology assemblies and comprise:

a rigidly mounted base to which is mounted a flexible mounted bellows;

a piezo electric crystal mounted between the base and the top of the flexible mounted bellows; and

a circuit board comprising a harvesting power supply.

6. The system of claim 5 wherein the rigidly mounted base, the piezo electric crystal, and the circuit board are enclosed within a cylindrically shaped enclosure.

7. The system of claim 1 wherein the one or more vortex energy harvesters are attached to the one or more electro acoustic technology assemblies and comprise:

a cylindrically shaped extension passing through a mount plate that to be attached to a downhole casing wall so that the extension is exposed to a fluid flow within the casing;

one or more piezo electric crystals mounted to the cylindrically shaped extension outside of the casing;

the piezo electric crystals and the portion of the extension outside the casing being surrounded by a protective housing; and

one or more pivot pins located outside the casing and within the protective housing;

the portion of the cylindrically shaped extension outside of the casing mounted onto the one or more pivot pins.

8. The system of claim 1 wherein turbulators to be attached near the one or more vortex energy harvesters.

9. The system of claim 1 wherein the one or more electro acoustic technology assemblies are deployed within and exposed to the fluid flow in the downhole application.

10. The system of claim 1 wherein the one or more electro acoustic technology assemblies and the optical fiber cable of the fiber optic distributed acoustic sensing (DAS) system connected back to the surface distributed acoustic sensing interrogator are mounted on the outside of a production casing and the one or more vortex energy harvesters are mounted inside the casing in the flow of production fluids and connected through a sealed hole in the casing to the one or more electro acoustic technology assemblies.

11. The system of claim 1 wherein the one or more electro acoustic technology assemblies and the optical fiber cable of the fiber optic distributed acoustic sensing (DAS) system connected back to the surface distributed acoustic sensing interrogator are mounted on the outside of a production casing and the one or more vortex energy harvesters are mounted inside the casing in a recessed side pocket mandrel wherein the resulting diameter change creates vortices and each of the one or more vortex energy harvesters comprises one or more spring metal fingers to which are mounted piezo crystals.

12. The system of claim 1 wherein the one or more vortex energy harvesters attached to each of the electro acoustic technology assemblies and exposed to the fluid flow in the downhole application to at least one of charge a battery and provide direct power to a sensor and transmission system.

13. A method comprising:

providing one or more electro acoustic technology assemblies mounted downhole in close proximity to a fiber optic cable that is part of a fiber optic distributed acoustic sensing (DAS) system connected back to a surface distributed acoustic sensing interrogator;

providing one or more vortex energy harvesters attached to each of the electro acoustic technology assemblies and exposed to a fluid flow in a downhole application wherein each of the one or more vortex energy harvesters is vibrated by vortex induced vibration by the fluid flow across the one or more vortex energy harvesters and each vortex energy harvester comprises at least one piezo electric crystal that is compressed and extended, creating electrical charge between ends of the at least one piezo electric crystal; and

wherein the resulting electrical charge is harvested and used to at least one charge a battery and provide direct power to the one or more electro acoustic technology assemblies.

14. The method claim 13 further comprising providing enclosed sensors within the electro acoustic technology assemblies to sense parameters of interest.

15. The method of claim 14 further comprising providing enclosed microprocessor circuitry within the electro acoustic technology assemblies to collect the data from the enclosed sensors, amplifying the data, and transmits the data to the surface by actuating the fiber optic cable acoustically.

16. The method of claim 13 further comprising providing turbulators attached near the one or more vortex energy harvesters to ensure turbulent flow around the one or more vortex energy harvesters.

17. The method of claim 13 wherein the one or more electro acoustic technology assemblies and the optical fiber cable of the fiber optic distributed acoustic sensing (DAS) system connected back to the surface distributed acoustic sensing interrogator are mounted on the outside of a production casing and one or more vortex energy harvesters are mounted inside the casing in the flow of production fluids and connected through a sealed hole in the casing to the one or more electro acoustic technology assemblies and wherein each of the one or more vortex energy harvesters is vibrated by vortex induced vibration by the fluid flow across the one or more vortex energy harvesters and each vortex energy harvester comprises at least one piezo electric crystal that is compressed and extended, creating electrical charge between ends of the at least one piezo electric crystal and the resulting electrical charge is harvested and used to at least one charge a battery and provide direct power to the one or more electro acoustic technology assemblies.

18. The method of claim 13 wherein the one or more electro acoustic technology assemblies and the optical fiber cable of the fiber optic distributed acoustic sensing (DAS) system connected back to the surface distributed acoustic sensing interrogator are mounted on the outside of a production casing and one or more vortex energy harvesters are mounted inside the casing in a recessed side pocket mandrel wherein the resulting diameter change creates turbulent vortices and each of the one or more vortex energy harvesters comprises one or more spring metal fingers to which are mounted piezo crystals that when bent by the turbulence create electric charges and the resulting electrical charge is harvested and used to at least one charge a battery and provide direct power to the one or more electro acoustic technology assemblies.

19. A vortex energy harvester comprising:

a cylindrically shaped extension passing through a mount plate that is to be attached to a downhole casing wall so that the extension is exposed to a fluid flow within the casing;

one or more piezo electric crystals mounted to the cylindrically shaped extension outside of the casing the piezo electric crystals and the portion of the extension outside the casing being surrounded by a protective housing; and

one or more pivot pins located outside the casing and within the protective housing, the portion of the cylindrically shaped extension outside of the casing mounted onto the one or more pivot pins.