Choke system for wellhead assembly having a turbine generator

• US 10,458,206 B2
• Filed: 10/06/2016
• Issued: 10/29/2019
• Est. Priority Date: 10/06/2016
• Status: Active Grant

• Current Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Original Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Inventors: Al-Dossary, Faisal M., Al-Zahrani, Mohammed S.
• Primary Examiner(s): Michener, Blake E
• Application Number:
  US15/286,707
• Publication Number:
  US 20180100374A1
• Time in Patent Office: 1,118 Days
• Field of Search: 166 911
• CPC Class Codes: E21B 33/03 Well heads; Setting-up thereof
• CPC Class Codes: E21B 34/025 Chokes or valves in wellheads and sub-sea wellheads for variably regulating fluid flow
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: E21B 43/12 Methods or apparatus for controlling the flow of the obtained fluid to or in wells E21B43/25 takes precedence; valve arrangements E21B34/00
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: F01D 21/006 Arrangements of brakes brakes per se F16D
• CPC Class Codes: F05B 2220/602 with energy recovery turbines
• CPC Class Codes: H02P 3/04 Means for stopping or slowing by a separate brake, e.g. friction brake, eddy-current brake brakes F16D, H02K49/00

Abstract

A wellhead assembly for use with a well that includes a production tree, a production line for carrying produced fluid from the production tree, and a choke in the production line. The choke assembly includes a turbine member that rotates in response to fluid flowing through the production line. The kinetic energy of the rotating turbine is converted into electricity by a generator that is coupled with the turbine member. Selectively impeding turbine rotation with a brake system introduces a pressure drop in the production line fluid, and which regulates flow of the production line fluid. The turbine member can be disposed in a straight run of the production line, or adjacent a bend in the production line.

Claims

1. A wellhead assembly for producing fluid from a wellbore comprising:

a production tree having production piping that selectively contains a flow of the fluid; and

a choke assembly comprising,

a braking system comprising a caliper system having a pad that selectively and directly engages a shaft with a force that retards rotation of the shaft, and

a turbine member disposed in a path of the flow of fluid and coupled with the shaft.

2. The wellhead assembly of claim 1, further comprising a generator coupled with the shaft, and wherein the generator is disposed between the braking system and the turbine member.

3. The wellhead assembly of claim 2, further comprising an electrical load in electrical communication with the generator.

4. The wellhead assembly of claim 3, wherein the electrical load comprises a device selected from the group consisting of a light, a gauge, a detector, and a flowmeter.

5. The wellhead assembly of claim 1, wherein the shaft comprises a first shaft, and wherein the turbine member is mounted to a second shaft, wherein gears are attached to ends of the first and second shafts that are meshed with one another, and wherein the first and second shafts are generally perpendicular to one another.

6. The wellhead assembly of claim 1, wherein a magnitude of the force varies and is dependent on a designated pressure drop created in the flow of the fluid by the turbine member.

7. The wellhead assembly of claim 1, wherein the braking system is responsive to pressure in the production piping.

8. The wellhead assembly of claim 7, further comprising a pressure sensor in pressure communication with the production piping at a location downstream of the choke assembly, and which is in signal communication with the braking system.

9. The wellhead assembly of claim 1, wherein the turbine member comprises a hub that is generally coaxial with the production piping and turbine elements that project radially outward from the hub, wherein the turbine elements are arranged about the hub so that lateral edges of each turbine element overlap a leading edge of an adjacent turbine element to define gaps between adjacent turbine elements that are oblique to an axis of the hub.

10. The wellhead assembly of claim 1, wherein the turbine member comprises spaced apart hubs that are each arranged generally parallel with an axis of the production piping, and turbine elements that each span between the hubs and along helical paths.

11. A method of producing fluid from a wellbore comprising:

directing fluid produced from the wellbore through production piping that is attached to a production tree and across a turbine member coupled to a shaft that are rotated by the fluid;

generating electricity from rotation of the turbine member;

monitoring conditions in the production piping; and

selectively impeding rotation of the turbine member and shaft with a brake system having a pad that directly engages the shaft to selectively impede the rotation, the brake system having a power source that is separate and distinct from the electricity generated by rotation of the turbine member.

12. The method of claim 11, wherein impeding rotation of the turbine member increases a pressure drop in fluid flowing past the turbine member and which regulates fluid flow through the production piping.

13. The method of claim 11, wherein the electricity generated with the rotation of the turbine member is used to power devices adjacent an opening of the wellbore.

14. The method of claim 11, wherein rotation of the turbine member is impeded by an amount that is based on fluid pressure which is measured downstream of the turbine member.

15. A choke assembly for regulating flow from a wellbore comprising:

a housing having a chamber that receives a flow of fluid from the wellbore;

a turbine member and a shaft in the chamber that rotate in response to the flow of fluid in the chamber;

a generator coupled with the turbine member and that generates electricity in response to rotation of the turbine member; and

a braking system having a pad in selective direct coupling with the shaft to selectively impede the rotation, the braking system having a power source that is separate and distinct from the generator.

16. The choke assembly of claim 15, wherein the braking system pad comprises calipers that selectively directly engage and impart a retarding force to the shaft coupled with the turbine member.

17. The choke assembly of claim 16, further comprising a pressure sensor in production piping downstream of the chamber and that is in communication with the braking system.

18. The choke assembly of claim 15, wherein the turbine member comprises generally planar hubs that are spaced apart from one another and each are rotatable about an axis that is substantially perpendicular with a direction of the flow of fluid, and elongated helically shaped turbine elements that span between the hubs.

19. The choke assembly of claim 15, wherein the generator is disposed between the braking system and the turbine member.