Downhole turbine

• US 7,451,835 B1
• Filed: 11/14/2007
• Issued: 11/18/2008
• Est. Priority Date: 11/14/2007
• Status: Active Grant

• Current Assignee: Schlumberger Technology Corporation (Schlumberger NV)
• Original Assignee: NovaDrill, Inc. (Schlumberger NV)
• Inventors: Hall, David R., Wise, Daryl, Nelson, Nathan, Dahlgren, Scott, Lundgreen, David
• Primary Examiner(s): DANG, HOANG C
• Application Number:
  US11/940,091
• Time in Patent Office: 370 Days
• Field of Search: 175/107, 175/73, 166/65.1
• US Class Current: 175/107
• CPC Class Codes: E21B 10/62 characterised by parts, e.g. cutting elements, which are detachable or adjustable E21B10/64 takes precedence; for roller bits E21B10/20; for augers E21B10/44
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes

Abstract

In one aspect, a downhole assembly has a downhole tool string component with a bore adapted to accommodate drilling mud. A fluid barrier is disposed within the bore and has a cylindrical portion substantially aligned with the bore. A drive shaft is sealed within and substantially coaxial with the cylindrical portion and has a first magnet disposed on its outer surface. A turbine assembly is disposed around the cylindrical portion of the fluid barrier and has an inner diameter and outer surface. The outer surface of the turbine assembly has a plurality of turbine blades. The inner diameter of the turbine assembly has a second magnet disposed within a region defined by the turbine blades and is in magnetic communication with the first magnet of the drive shaft, wherein when the drilling mud engages the turbine blades the first and second magnets rotate the drive shaft with the turbine assembly.

Claims

1. A downhole assembly, comprising:

a downhole tool string component comprising a bore adapted to accommodate drilling mud;

a fluid barrier disposed within the bore and comprising a cylindrical portion substantially aligned with the bore;

a drive shaft sealed within and substantially coaxial with the cylindrical portion and comprising a first magnet disposed on its outer surface;

a turbine assembly disposed around the cylindrical portion of the fluid barrier comprising an inner diameter and outer surface;

the outer surface of the turbine assembly comprises a plurality of turbine blades;

the inner diameter of the turbine assembly comprising a second magnet disposed within a region defined by the turbine blades and being in magnetic communication with the first magnet of the drive shaft;

wherein when the drilling mud engages the turbine blades the first and second magnets rotate the drive shaft with the turbine assembly and wherein the drive shaft is in communication with at least one gear box disposed within the fluid barrier.

2. The downhole assembly of claim 1, wherein the drive shaft is in communication with at least one generator disposed within the fluid barrier.

3. The downhole assembly of claim 2, wherein the drive shaft is in communication with a first and second generator disposed within the fluid barrier.

4. The downhole assembly of claim 3, wherein the first generator is a 1 kW generator and the second generator is a 2.5 kW generator.

5. The downhole assembly of claim 1, wherein the downhole string component converts energy from the drilling mud flow into at least 10 foot-pounds of rotational energy.

6. The downhole assembly of claim 1, wherein the at least one gear box is disposed intermediate the downhole tool string component and the at least one generator.

7. The downhole assembly of claim 2, wherein a rotor of the at least one generator has a rotational speed 1.5 to 8 times faster than the rotational speed of the driveshaft.

8. The downhole assembly of claim 1, wherein the drive shaft is in communication with a steering jack.

9. The downhole assembly of claim 1, wherein the first and second magnet comprise samarium-cobalt.

10. The downhole assembly of claim 2, wherein the rotational speed of the turbine will stall at an optimal speed required by the at least one generator to work at peak efficiency.

11. The downhole assembly of claim 1, wherein the turbine assembly has an approximate length of 17 inches to 29 inches.

12. The downhole assembly of claim 1, wherein the outer surface of the turbine assembly is tapered.

13. The downhole assembly of claim 1, wherein the plurality of turbine blades is press-fit to the outer surface of the turbine assembly.

14. The downhole assembly of claim 1, wherein the drive shaft is hollow.

15. The downhole assembly of claim 1, wherein the drive shaft comprises a large diameter portion and a small diameter portion.

16. The downhole assembly of claim 1, wherein the drive shaft comprises at least one cap.

17. The downhole assembly of claim 1, wherein the fluid barrier isolates an oil environment from the drilling mud.

18. The downhole assembly of claim 1, wherein the fluid barrier comprises a material selected from the group consisting of titanium, Inconel, Inconel 718, or combinations thereof.

19. The downhole assembly of claim 1, wherein the fluid barrier comprises at least one joint.