Method and apparatus for generating electrical energy downhole

• US 20060113803A1
• Filed: 11/05/2004
• Published: 06/01/2006
• Est. Priority Date: 11/05/2004
• Status: Active Grant

• Current Assignee: Schlumberger Technology Corporation (SLB)
• Original Assignee: David R. Hall
• Inventors: Hall, David R., Dahlgren, Scott, Fox, Joe R.
• Granted Patent: US 7,190,084 B2
• Time in Patent Office: Days
• US Class Current: 290/54
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: F03B 13/02 Adaptations for drilling wells
• CPC Class Codes: H02K 7/1823 structurally associated with turbines or similar engines

Abstract

A method and apparatus that uses the flow of drilling fluid to generate electrical energy in a downhole environment. A substantially cylindrical housing comprises a wall having an inlet, an outlet, and a hollow passageway therebetween. A flow of drilling fluid through the hollow passageway actuates a generator located therein, such that the generator generates electricity to power downhole tools, sensors, and networks. The miniaturization of the generator within the housing wall facilitates an unobstructed flow of drilling fluid through the central borehole of a drill string, while allowing for the introduction of tools and other equipment therein.

Claims

1. A downhole generator apparatus for producing electricity in a downhole environment, comprising:

a substantially cylindrical housing comprising a wall having an inlet, an outlet, and a hollow passageway therebetween, said hollow passageway adapted to accommodate a flow of drilling fluid;

a turbine rotatably secured within said hollow passageway of said wall, said turbine adapted to rotate in response to said flow of drilling fluid through said hollow passageway; and

at least one generator operatively connected to said turbine and contained within said hollow passageway, said generator adapted to generate electricity upon rotation of said turbine.

2. The downhole generator apparatus of claim 1, further comprising a conductor coupled to said at least one generator to transmit said electricity to at least one of a storage receptacle, a mechanical device, and an electrical device.

3. The downhole generator apparatus of claim 1, further comprising bearings disposed between said turbine and said hollow passageway.

4. The downhole generator apparatus of claim 1, wherein said substantially cylindrical housing is selected from the group consisting of a downhole tool, a drill pipe, a network node, and a pipe insert member.

5. The downhole generator apparatus of claim 1, wherein said substantially cylindrical housing further comprises at least one network node component integrated into said wall.

6. The downhole generator apparatus of claim 7, wherein said at least one network node component is operatively coupled to said at least one generator to receive electricity therefrom.

7. The downhole generator apparatus of claim 1, wherein said turbine comprises a material selected from the group consisting of steel, tungsten, diamond and carbide.

8. The downhole generator apparatus of claim 1, wherein said inlet of said hollow passageway and said outlet of said hollow passageway each correspond to a location selected from the group consisting of an inner surface of said wall, an outer surface of said wall, and an end of said wall.

9. The downhole generator apparatus of claim 1, further comprising a filter proximate said inlet to filter said flow of drilling fluid.

10. The downhole generator apparatus of claim 1, further comprising a nozzle secured within said hollow passageway substantially adjacent said turbine to regulate said flow of drilling fluid from said inlet to said outlet.

11. The downhole generator apparatus of claim 1, wherein said at least one generator further comprises:

a rotor operatively connected to said turbine, said rotor comprising at least one permanent magnet; and

at least one stator fixed substantially adjacent said rotor, wherein rotation of said rotor causes a magnetic flux in said stator to generate said electricity.

12. The downhole generator apparatus of claim 11, wherein said at least one stator comprises coils, including pot core coils.

13. A system for generating electricity in a downhole environment, comprising:

a drill string having a central bore therethrough;

a substantially cylindrical housing adapted to reside within at least a portion of said central bore, said housing comprising a wall having an inlet, an outlet, and a hollow passageway therebetween, said hollow passageway adapted to promote a downward flow of drilling fluid therethrough;

a turbine rotatably secured within said hollow passageway of said wall, said turbine adapted to rotate in response to said flow of drilling fluid through said hollow passageway; and

at least one generator operatively connected to said turbine and contained within said hollow passageway, said generator adapted to generate electricity upon rotation of said turbine.

14. The system of claim 13, further comprising a conductor coupled to said at least one generator to transmit said electricity to at least one of a storage receptacle, a mechanical device, and an electrical device.

15. The system of claim 13, further comprising bearings disposed between said turbine and said hollow passageway.

16. The system of claim 13, wherein said substantially cylindrical housing further comprises at least one network node component integrated into said wall.

17. The system of claim 16, wherein said at least one network node component is operatively coupled to said at least one generator to receive electricity therefrom.

18. The system of claim 13, wherein said turbine is coated by a material selected from the group consisting of steel, tungsten, diamond and carbide.

19. The system of claim 13, wherein each of said inlet and said outlet of said hollow passageway corresponds to a location selected from the group consisting of an inner surface of said wall, an outer surface of said wall, and an end of said wall.

20. The system of claim 13, further comprising a filter proximate said inlet to filter said flow of drilling fluid.

21. The system of claim 13, further comprising a nozzle secured within said hollow passageway substantially adjacent said turbine to regulate said flow of drilling fluid from said inlet to said outlet.

22. The system of claim 13, wherein said at least one generator further comprises:

a rotor operatively connected to said turbine, said rotor comprising at least one permanent magnet; and

at least one stator fixed substantially adjacent said rotor, wherein rotation of said rotor causes a magnetic flux in said stator to generate said electricity.

23. The system of claim 22, wherein said at least one stator comprises coils, including pot core coils.

24. A method for generating electricity in a downhole drill string, comprising:

providing a downhole drill string having a central bore;

integrating a substantially cylindrical housing into said downhole drill string, said substantially cylindrical housing having a bore substantially corresponding to said central bore;

integrating into a wall of said substantially cylindrical housing a hollow passageway having an inlet and an outlet, said hollow passageway adapted to accommodate a flow of drilling fluid;

securing within said hollow passageway a turbine and at least one generator, said turbine adapted to rotate in response to said flow of drilling fluid;

rotating, by said flow of drilling fluid, said turbine; and

generating, via said at least one generator, electricity in response to rotation of said turbine.

25. The method of claim 24, wherein said providing a substantially cylindrical housing further comprises:

adapting said substantially cylindrical housing to reside within at least a portion of said central bore; and

securing said substantially cylindrical housing within said central bore.

26. The method of claim 24, further comprising filtering said flow of drilling fluid proximate said inlet.

27. The method of claim 24, further comprising regulating, via a nozzle, said flow of drilling fluid between said inlet and said outlet.