Downhole turbine with an adjustable shroud

• US 10,697,241 B2
• Filed: 10/28/2015
• Issued: 06/30/2020
• Est. Priority Date: 10/28/2015
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Chambers, Larry DeLynn, Marzouk, Joe, Odegbami, Olumide O., Agnihotri, Mukul M.
• Primary Examiner(s): Nguyen, Ninh H.
• Assistant Examiner(s): Haghighian, Behnoush
• Application Number:
  US15/753,433
• Publication Number:
  US 20180245403A1
• Time in Patent Office: 1,707 Days
• Field of Search: 415145, 175107
• CPC Class Codes: E21B 4/02 Fluid rotary type drives
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: F01D 11/20 Actively adjusting tip-clearance
• CPC Class Codes: F01D 11/22 by mechanically actuating the stator or rotor components, e.g. moving shroud sections relative to the rotor
• CPC Class Codes: F01D 11/24 by selectively cooling-heating stator or rotor components
• CPC Class Codes: F03B 13/02 Adaptations for drilling wells
• CPC Class Codes: F04D 29/622 Adjusting the clearances between rotary and stationary parts
• CPC Class Codes: F05B 2250/02 variable
• CPC Class Codes: F05B 2270/1033 Power (if explicitly mentioned)
• CPC Class Codes: F05D 2240/11 Shroud seal segments
• CPC Class Codes: H02K 7/1823 structurally associated with turbines or similar engines

Abstract

A method and apparatus according to which an output of a power generation system is controlled. In one embodiment, the power generation system includes a turbine and a feedback control system. The turbine includes a rotor to which a first portion of a power fluid is communicated, the first portion imparting torque to the rotor; a shaft to which the rotor is connected; a shroud extending circumferentially about the rotor and the shaft; and a bypass gap between the rotor and the shroud, through which a second portion of the power fluid is communicated. The feedback control system axially displaces the shroud relative to the rotor, thereby adjusting the size of the bypass gap and, consequently, the ratio of the first portion relative to the second portion.

Claims

1. A power generation system comprising:

a shaft;

a rotor connected to the shaft and adapted to receive a first portion of a power fluid, which first portion of the power fluid imparts rotation to the rotor and the shaft;

a shroud extending circumferentially about the rotor and the shaft;

a bypass gap defined between the rotor and the shroud, the bypass gap being adapted to communicate a second portion of the power fluid therethrough; and

a feedback control system adapted to displace the shroud axially relative to the rotor;

wherein displacement of the shroud axially relative to the rotor adjusts a size of the bypass gap and, consequently, a ratio of the first portion of the power fluid relative to the second portion of the power fluid;

wherein the feedback control system comprises;

a shroud actuator connected to the shroud and adapted to axially displace the shroud relative to the rotor;

a sensor adapted to detect an output of the power generation system; and

a controller adapted to control the shroud actuator, based on an output setpoint and the detected output of the power generation system, to axially displace the shroud causing the output of the power generation system to be adjusted closer to the output setpoint;

and

wherein;

(i) the output of the power generation system is rotation of the shaft; and

the sensor is adapted to detect the rotation of the shaft;

(ii) the power generation system further comprises an electric generator connected to the shaft and adapted to convert the rotation of the shaft into an electric output;

the output of the power generation system is the electric output of the electric generator; and

the sensor is adapted to detect the electric output of the electric generator;

(iii) the power generation system further comprises a pump connected to the shaft and adapted to convert the rotation of the shaft into a hydraulic output;

the output of the power generation system is the hydraulic output of the pump; and

the sensor is adapted to detect the hydraulic output of the pump;

or

(iv) any combination of (i), (ii), and (iii).

2. The power generation system as recited in claim 1,

wherein the rotor comprises a plurality of blades extending radially outward from the shaft, each blade defining a proximal portion, a distal portion, a leading edge, and a trailing edge;

and

wherein each of the plurality of blades is tapered so that a length of the blade from the proximal portion to the distal portion is smaller at the leading edge than at the trailing edge.

3. The power generation system as recited in claim 2,

wherein the proximal portion of each of the blades is connected to the shaft;

and

wherein each of the plurality of blades extends spirally from the leading edge to the trailing edge thereof.

4. The power generation system as recited in claim 2,

wherein the shroud is generally tubular and defines first and second end portions, an interior of the shroud varying in diameter from the first end portion to the second end portion thereof;

and

wherein the bypass gap is defined between the interior of the shroud and the respective distal portions of the blades.

5. The power generation system as recited in claim 3, wherein the interior diameter of the shroud varies in steps from the first end portion to the second end portion thereof.

6. The power generation system as recited in claim 1,

wherein the bypass gap is at least partially defined by a plurality of bypass openings formed through the shroud;

wherein a third portion of the power fluid is communicated through the bypass openings; and

wherein displacement of the shroud axially relative to the rotor adjusts a quantity and/or size of the bypass openings through which the third portion of the power fluid may be communicated and, consequently, a ratio of the third portion relative to the first portion.

7. The power generation system as recited in claim 1,

wherein the sensor communicates a first signal;

wherein the feedback control system further comprises a transmitter that receives the first signal from the sensor and communicates a second signal; and

wherein the controller receives the second signal from the transmitter, receives a third signal, and communicates a fourth signal to the shroud actuator.

8. The power generation system as recited in claim 7,

wherein the first and second signals correspond to the output of the power generation system;

wherein the third signal corresponds to the output setpoint for the output of the power generation system; and

wherein the fourth signal causes the shroud actuator to axially displace the shroud to adjust the output of the power generation system closer to the output setpoint.

9. A method for comprising:

communicating a first portion of a power fluid to a rotor, the rotor being connected to a shaft of a power generation system, the first portion of the power fluid imparting rotation to the rotor and the shaft;

communicating a second portion of the power fluid through a bypass gap defined between the rotor and a shroud that extends circumferentially about the rotor and the shaft;

detecting, using a sensor, an output of the power generation system;

axially displacing, using an actuator connected to the shroud, the shroud relative to the rotor to adjust a size of the bypass gap and, consequently, a ratio of the first portion relative to the second portion; and

controlling, using a controller and based on an output setpoint and the detected output of the power generation system, the axial displacement of the shroud causing the output of the power generation system to be adjusted closer to the output setpoint;

wherein;

(i) the output of the power generation system is the rotation of the shaft; and

the sensor detects the rotation of the shaft;

(ii) the power generation system further comprises an electric generator connected to the shaft to convert the rotation of the shaft into an electric output;

the output of the power generation system is the electric output of the electric generator; and

the sensor detects the electric output of the electric generator;

(iii) the power generation system further comprises a pump connected to the shaft to convert the rotation of the shaft into a hydraulic output;

the output of the power generation system is the hydraulic output of the pump; and

the sensor detects the hydraulic output of the pump;

or

(iv) any combination of (i), (ii), and (iii).

10. The method as recited in claim 9,

wherein the rotor comprises a plurality of blades extending radially outward from the shaft, each blade defining a proximal portion, a distal portion, a leading edge, and a trailing edge;

and

wherein each of the plurality of blades is tapered so that a length of the blade from the proximal portion to the distal portion is smaller at the leading edge than at the trailing edge.

11. The method as recited in claim 10,

wherein the proximal portion of each of the blades is connected to the shaft;

and

wherein each of the plurality of blades extends spirally from the leading edge to the trailing edge thereof.

12. The method as recited in claim 10,

wherein the shroud is generally tubular and defines first and second end portions, an interior of the shroud varying in diameter from the first end portion to the second end portion thereof;

and

wherein the bypass gap is defined between the interior of the shroud and the respective distal portions of the blades.

13. The method as recited in claim 11, wherein the interior diameter of the shroud varies in steps from the first end portion to the second end portion thereof.

14. The method as recited in claim 9,

wherein the bypass gap is at least partially defined by a plurality of bypass openings formed through the shroud;

wherein the method further comprises communicating a third portion of the power fluid through the bypass openings; and

wherein axially displacing the shroud relative to the rotor adjusts a quantity and/or size of the bypass openings through which the third portion of the power fluid may be communicated and, consequently, a ratio of the third portion relative to the first portion.

15. The method as recited in claim 9, wherein axially displacing the shroud relative to the rotor to adjust a size of the bypass gap comprises:

receiving, with a transmitter, a first signal from the sensor, the first signal corresponding to the output of the power generation system;

transmitting, with the transmitter, a second signal to the controller, the second signal corresponding to the first signal;

receiving and comparing, with the controller, the second signal and a third signal, the third signal corresponding to the output setpoint for the output of the power generation system; and

transmitting, with the controller, a fourth signal to the actuator, the fourth signal causing the actuator to displace the shroud axially to adjust the output of the power generation system closer to the output setpoint.

16. A method for controlling an output of a turbine, the method comprising:

providing a turbine including a shaft, a rotor connected to the shaft, a shroud extending about the rotor so that a bypass gap is defined between the shroud and the rotor, and an actuator connected to the shroud to axially displace the shroud relative to the rotor;

communicating a fluid to the turbine, the fluid comprising a first portion communicated to the rotor and a second portion communicated to the bypass gap, the first portion of the fluid imparting a torque to the rotor;

monitoring an output of the turbine with one or more sensors;

transmitting, with a transmitter, a first signal representing the output of the turbine, as monitored by the one or more sensors, to a controller;

communicating a second signal to the controller, the second signal representing a setpoint for the output of the turbine; and

communicating a third signal, based on the first and second signals, from the controller to the actuator, the third signal causing the actuator to displace the shroud axially.

17. The method of claim 16, wherein displacing the shroud axially changes a size of the bypass gap and, consequently, a ratio of the first portion relative to the second portion of the fluid, so that the output of the turbine is adjusted closer to the setpoint.

18. The method as recited in claim 16,

wherein the method further comprises providing an electric generator connected to the shaft to convert the torque of the shaft into an electric output;

and

wherein the output of the turbine comprises at least one of;

the torque of the shaft and the electric output of the generator.

19. The method as recited in claim 16,

wherein the method further comprises providing a pump connected to the shaft to convert the torque of the shaft into a hydraulic output;

and

wherein the output of the turbine comprises at least one of;

the torque of the shaft and the hydraulic output of the pump.