ELECTRICAL GENERATOR AND ELECTRIC MOTOR FOR DOWNHOLE DRILLING EQUIPMENT

• US 20160053588A1
• Filed: 06/14/2013
• Published: 02/25/2016
• Est. Priority Date: 05/08/2013
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Snyder, John Kenneth, Gawski, Victor
• Granted Patent: US 10,240,435 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: E21B 4/04 Electric drives E21B4/12 takes precedence
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes

Abstract

An electrical generator positionable downhole in a well bore includes a tubular housing having a first longitudinal end and a second longitudinal end, the housing having an internal passageway with a plurality of layers. The layers comprise at least a first protective layer, a second protective layer, and an electrically conductive layer positioned between the first and second protective layers. The layers define an internal cavity. A shaft with magnetic inserts is movably positioned in the internal cavity. Electrical current is generated when the shaft is moved. Alternatively, the device may be supplied with electrical power and used as a downhole motor.

Claims

1. An electrical generator positionable in a well bore, the electrical generator comprising:

a tubular housing having a first longitudinal end and a second longitudinal end, said tubular housing having an internal passageway, said passageway having a plurality of layers positioned therein, said layers comprising at least a first protective layer, a second protective layer, and an electrically conductive layer positioned between the first and second protective layers, said layers defining an internal cavity, said electrically conductive layer electrically coupled at a first end to a first electrical end conductor positioned proximal to the first longitudinal end of the tubular housing and electrically coupled at a second end to a second electrical end conductor positioned proximal to the second longitudinal end of the tubular housing; and

a shaft with magnetic inserts, said shaft movably positioned in the internal cavity of the housing.

2. The electrical generator of claim 1, wherein the first protective layer is positioned along an inner surface of the tubular housing, the electrically conductive layer is along an inner surface of the first protective layer and the second protective layer is positioned along an inner surface of the electrically conductive layer.

3. The electrical generator of claim 1 or 2, wherein at least one of the first protective layer and the second protective layer is electrically non-conductive.

4. The electrical generator of any of claim 1, 2 or 3, wherein the electrically conductive layer comprises a first electrically conductive layer and said generator further comprises a second electrically conductive layer that is electrically insulated from the first electrically conductive layer.

5. The electrical generator of claim 4, wherein the second electrically conductive layer is positioned along an inner surface of the second protective layer, and a third protective layer is positioned along an inner surface of the second electrically conductive layer.

6. The electrical generator of any of claims 1 to 5, wherein the electrically conductive layer is positioned along the inner surface of the first protective layer.

7. The electrical generator of any of claims 4 to 6, wherein the second electrically conductive layer is positioned parallel to the first electrically conductive layer.

8. The electrical generator of any of claims 1 to 7 wherein the first end conductor is in electronic communication with the second end conductor via at least one conductive layer positioned in the tubular housing.

9. The electrical generator of claim 8 wherein an electrical current generated in the conductive layer is received at either the first end or the second end conductor via at least one conductive layer positioned in the tubular housing.

10. The electrical generator of claim 1, wherein the electrically conductive layer comprises one or more conductive strips configured as one or more spirals formed about an inner surface of the tubular housing.

11. The electrical generator of claim 1, wherein the electrically conductive layer comprises one or more conductive strips configured as one or more serpentine paths formed along an inner surface of the tubular housing.

12. A method of generating electricity in a well drilling operation, the method comprising:

positioning an electrical generator in a wellbore, the generator including

a tubular housing having a first longitudinal end, a second longitudinal end, said tubular housing having an internal passageway, said passageway having a plurality of layers positioned therein, said layers comprising at least a first protective layer, a second protective layer, and an electrically conductive layer positioned between the first and second protective layers, said layers defining an internal cavity, said electrically conductive layer electrically coupled at a first end to a first electrical end conductor positioned proximal to the first longitudinal end of the tubular housing and electrically coupled at a second end to a second electrical end conductor positioned proximal to the second longitudinal end of the tubular housing, and,

a shaft comprising one or more magnetic inserts, said shaft movably positioned in the internal cavity of the housing;

moving the shaft linearly or rotationally within the electrically conductive layer;

inducing a flow of current in the electrically conductive layer; and

receiving electric current from the electrically conductive layer at the first electrical end conductor or the second electrical end conductor.

13. The method of claim 12, wherein positioning an electrical generator in a wellbore comprises positioning an electrical generator with the first protective layer positioned along an inner surface of the tubular housing, the electrically conductive layer positioned along an inner surface of the first protective layer, and the second protective layer positioned along an inner surface of the electrically conductive layer.

14. The method of claim 12, wherein positioning an electrical generator in a wellbore comprises positioning an electrical generator with at least one of the first protective layer and the second protective layer being electrically non-conductive.

15. The method of claim 14, wherein positioning an electrical generator in a wellbore comprises positioning an electrical generator with the electrically conductive layer comprising a first electrically conductive layer and a second electrically conductive layer that is electrically insulated from the first electrically conductive layer.

16. The method of claim 15, wherein positioning an electrical generator in a wellbore comprises positioning an electrical generator with the second electrically conductive layer positioned along an inner surface of the second protective layer, and a third protective layer positioned along an inner surface of the second electrically conductive layer.

17. The method of claim 12, wherein positioning an electrical generator in a wellbore comprises positioning an electrical generator with the electrically conductive layer positioned along the inner surface of the first protective layer.

18. The method of claim 12, wherein positioning an electrical generator in a wellbore comprises positioning an electrical generator with the second electrically conductive layer positioned parallel to the first electrically conductive layer.

19. The method of claim 12, wherein the electrically conductive layer comprises one or more conductive strips configured as one or more spirals formed about an inner surface of the tubular housing.

20. The method of claim 12, wherein the electrically conductive layer comprises one or more conductive strips configured as one or more serpentine paths formed along an inner surface of the tubular housing.

21. The method of claim 12 wherein moving the shaft linearly within the electrically conductive layer comprises vibrational movement of the shaft linearly, resulting from vibrations transmitted from the drill bit interacting with a formation being drilled.

22. The method of claim 12 wherein moving the shaft linearly within the electrically conductive layer comprises tensile loading on a drill string coupled to the shaft resulting from upward back reaming operations in the well drilling operations.

23. The method of claim 12 wherein moving the shaft linearly within the electrically conductive layer comprises tensile loading on a drill string coupled to the shaft resulting from application of an overpull load on a downhole tool.

24. The method of claim 12 wherein moving the shaft linearly within the electrically conductive layer comprises contacting a poppet valve with a drilling fluid and moving a stem in the poppet valve linearly wherein the stem is coupled to the shaft of the generator.

25. The method of claim 12 wherein moving the shaft linearly within the electrically conductive layer comprises movement of the shaft in the generator by a re-set spring.

26. The method of claim 12 wherein moving the shaft linearly within the electrically conductive layer comprises application of weight to a drill string coupled to the shaft.

27. The method of claim 12 wherein moving the shaft rotationally within the electrically conductive layer comprises rotary movement of the shaft in the generator by a barrel cam device.

28. The method of claim 12 wherein moving the shaft rotationally within the electrically conductive layer comprises impinging drilling fluid in the well on turbine blades coupled to the shaft.

29. The method of claim 12 wherein moving the shaft rotationally within the electrically conductive layer comprises reciprocating rotary movement of the shaft in the generator by a barrel cam device and re-set spring.

30. The method of claim 12 or 29 wherein moving the shaft rotationally within the electrically conductive layer comprises vibrational movement of the shaft rotationally, resulting from vibrations transmitted from the drill bit interacting with a formation being drilled.

31. An electro-mechanical motor positionable in a well bore, said motor comprising:

a tubular housing having a first longitudinal end and a second longitudinal end, said tubular housing having an internal passageway, said passageway having a plurality of layers positioned therein, said layers comprising at least a first protective layer, a second protective layer, and an electrically conductive layer positioned between the first and second protective layers, said layers defining an internal cavity, said electrically conductive layer operable to create an electromagnetic field when supplied with electrical power; and

a shaft positioned in the internal cavity, said shaft having at least one magnetic insert, said shaft operable to move linearly or rotationally in the internal cavity of the housing in response to the electromagnetic field of the electrically conductive layer.

32. The electro-mechanical motor of claim 31, wherein the electrically conductive layer comprises one or more conductive strips configured as one or more spirals formed about an inner surface of the tubular housing.

33. The electro-mechanical motor of claim 31, wherein the electrically conductive layer comprises one or more conductive strips configured as one or more serpentine paths formed along an inner surface of the tubular housing.

34. A method of converting electrical current to mechanical energy in a well drilling operation, the method comprising:

positioning an electro-mechanical motor in a wellbore, the motor including

a tubular housing having a first longitudinal end, a second longitudinal end, said tubular housing having an internal passageway, said passageway having a plurality of layers positioned therein, said layers comprising at least a first protective layer, a second protective layer, and an electrically conductive layer positioned between the first and second protective layers, said layers defining an internal cavity, and

a shaft movably positioned in the internal cavity, said shaft having at least one magnetic insert;

providing a flow of electrical current in the electrically conductive layer and inducing a first magnetic field;

generating a second magnetic field with the one or more magnetic inserts; and

inducing movement in the shaft by the interaction of the first magnetic field with the second magnetic field.

35. The method of claim 34, further including actuating mechanical components of downhole drilling tools selected from the group consisting of variable gauge stabilizers, drilling traction and stroking devices, and fishing tools.

36. The method of claim 34 further including actuating mechanical components of downhole production tools selected from the group consisting of packers and downhole pumps.