Apparatus for downhole power generation

• US 20150068298A1
• Filed: 06/04/2014
• Published: 03/12/2015
• Est. Priority Date: 08/18/2009
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Inman, Paul Noel, Wilson, Neil Scott, Herrera, Adan Hernandez
• Granted Patent: US 9,534,577 B2
• Time in Patent Office: Days
• US Class Current: 73/152.54
• CPC Class Codes: E21B 21/10 Valve arrangements in drilling-fluid circulation systems
• CPC Class Codes: E21B 34/105 retrievable, e.g. wire line retrievable, i.e. with an element which can be landed into a landing-nipple provided with a passage for control fluid
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: E21B 47/00 Survey of boreholes or wells monitoring pressure or flow of drilling fluid E21B21/08
• CPC Class Codes: F03B 13/02 Adaptations for drilling wells
• CPC Class Codes: F03B 13/10 Submerged units incorporating electric generators or motors
• CPC Class Codes: F03B 15/06 Regulating, i.e. acting automatically
• CPC Class Codes: Y02E 10/20 Hydro energy

Abstract

Apparatus is provided for use in power generation, including a fluid-flow-driven power generator for use in a fluid-containing pipe such as a drill pipe as used in oil and gas exploration and extraction. Parts of the generator are removable from the pipe—for example while a drill pipe is downhole within a drilling well—to leave a clear through bore for survey and fishing operations and to enable replacement of the removed parts. The flow-driven generator comprises an impeller connected to a magnet assembly to rotate the magnet assembly when fluid flows past the impeller. This causes relative movement between the magnet assembly and an adjacent electrical coil assembly, the relative movement and magnetic coupling generating an electrical current in the coil assembly. This generated electrical current is used to power electrical devices within the pipe.

Claims

1. An electrical power generator, for use in a fluid-containing pipe, comprising:

an annular power generation assembly comprising a fluid-flow-driven impeller connected to one of a magnet assembly or an electrical coil assembly, the magnet assembly and the coil assembly being arranged for magnetic coupling between them and being mounted to enable relative movement between them, such that fluid flowing past the impeller causes relative rotation between the magnet assembly and the coil assembly for the generation of electrical power;

a flow controller located closer to the longitudinal axis of the pipe than the annular power generation assembly, which flow controller is detachable from the annular power generation assembly and can be removed to leave an axially-located through bore;

a first fluid flow path past the impeller and a second fluid flow path through an aperture of the flow controller, wherein the flow controller includes an adjustment mechanism for adjusting the size of the aperture of the flow controller to control the proportion of the fluid flowing within the pipe that flows past the impeller in the first fluid flow path; and

an output voltage detector that generates a signal indicative of the output voltage, and wherein the flow controller is responsive to the signal indicative of the output voltage to automatically adjust the size of the aperture of the nozzle to control the flow of fluid past the impeller, thereby to provide feedback control of the output voltage;

wherein the flow controller comprises an adaptive flow control nozzle and is responsive to conditions within the fluid-containing pipe to automatically adjust the size of the aperture of the adaptive flow control nozzle.

2. The generator of claim 1, including a sensor selected from the group comprising a pressure sensor and a fluid flow rate sensor, which sensor generates a signal indicative of sensed conditions within the fluid-containing pipe, and wherein the flow controller is responsive to the signal indicative of sensed conditions to automatically adjust the size of the aperture of the flow control nozzle.

3. The generator according to claim 1, wherein the first fluid flow path is located towards the outer circumference of the pipe.

4. An electrical power generator, for use in a fluid-containing pipe, comprising:

a magnet assembly;

a coil assembly;

a fluid-flow-driven impeller connected to one of the magnet assembly and the coil assembly so as to cause rotation of the connected assembly in response to fluid flow through the pipe;

wherein the magnet assembly and the coil assembly are arranged to enable magnetic coupling between them, and the magnet assembly and the coil assembly are mounted to enable relative movement between them in response to fluid flow through the pipe, such that said relative movement generates an electric current within the coil assembly; and

a fluid flow controller including at least one sensor and a flow control nozzle having a fluid flow aperture and an adjustment mechanism;

wherein the impeller is located within a first fluid flow path and the fluid flow controller is located within a second fluid flow path within the fluid-containing pipe, and the fluid flow controller'"'"'s adjustment mechanism provides adjustment of the fluid flow aperture in response to conditions in the fluid containing pipe detected by the sensor, thereby to control the proportion of fluid flowing in the pipe that flows through the first fluid flow path.

5. A fluid flow controller for use in a fluid-containing pipe, comprising:

at least one sensor for measuring conditions in the fluid-containing pipe; and

a flow controller having a fluid flow aperture and an adjustment mechanism;

wherein the flow controller is responsive to signals indicative of conditions in the fluid-containing pipe, which conditions are measured by the at least one sensor, to adjust the size of the fluid flow aperture using the adjustment mechanism.

6. A measurement while drilling (MWD) system comprising:

a drilling platform; and

a drill string comprising;

a fluid-containing pipe through which drilling fluid can be pumped to lubricate the drill head,

at least one sensor for measuring conditions in the fluid-containing pipe, and

a flow control nozzle having a fluid flow aperture and an adjustment mechanism,

wherein the flow controller is responsive to signals indicative of conditions in the fluid-containing pipe, which conditions are measured by the at least one sensor, to adjust the size of the fluid flow aperture using the adjustment mechanism.

7. An apparatus comprising:

a housing;

a cylindrical stator positioned within the housing such that there is an annular gap between an outer surface of the cylindrical stator and an inner surface of the housing;

a rotor mounted within the stator;

a pipe within the rotor;

a fluid-flow-driven impeller connected to the rotor so as to cause rotation of the rotor in response to fluid flow through the pipe;

wherein the stator and the rotor are arranged to enable magnetic coupling between them, and the stator and the rotor are mounted to enable relative movement between them in response to fluid flow through the pipe, such that said relative movement generates an electric current within the rotor; and

a slot cut in the outer surface of the cylindrical stator forming a channel along the inner surface of the housing from a first end of the cylindrical stator to a second end of the cylindrical stator.

8. The apparatus of claim 7 further comprising a wire passing through the slot from the first end of the cylindrical stator to the second end of the cylindrical stator.

9. The apparatus of claim 7 further comprising:

an end housing mounted within the housing such that there is an end-housing gap between the stator and the end housing.

10. The apparatus of claim 9 further comprising:

an oil reservoir contained within the end-housing gap.