Downhole transducer assembly

• US 10,472,934 B2
• Filed: 05/09/2017
• Issued: 11/12/2019
• Est. Priority Date: 05/21/2015
• Status: Active Grant

• Current Assignee: Novatek IP, LLC
• Original Assignee: Novatek IP, LLC
• Inventors: Marshall, Jonathan, Dahlgren, Scott
• Primary Examiner(s): Harcourt, Brad
• Application Number:
  US15/590,882
• Publication Number:
  US 20170241242A1
• Time in Patent Office: 917 Days
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: F01C 1/34 having the movement defined in group F01C1/08 or F01C1/22 and relative reciprocation between the co-operating members
• CPC Class Codes: F01D 15/10 Adaptations for driving, or combinations with, electric generators
• CPC Class Codes: F01D 5/06 Rotors for more than one axial stage, e.g. of drum or multiple disc type; Details thereof, e.g. shafts, shaft connections F01D5/022, F01D5/023 take precedence
• CPC Class Codes: F03B 1/02 Buckets; Bucket-carrying rotors
• CPC Class Codes: F05B 2220/20 within closed fluid conduits, e.g. pipes
• CPC Class Codes: F05D 2220/20 within closed fluid conduits, e.g. pipes

Abstract

A downhole drill pipe may comprise a transducer disposed therein, capable of converting energy from flowing fluid into electrical energy. A portion of a fluid flowing through the drill pipe may be diverted to the transducer. After passing the transducer, the diverted portion of the fluid may be discharged to an exterior of the drill pipe. To generate electrical energy while not obstructing the main fluid flow from passing through the drill pipe, the transducer may be disposed within a lateral sidewall of the drill pipe with an outlet for discharging fluid exposed on an exterior of the lateral sidewall.

Claims

1. A downhole transducer assembly, comprising:

a drill pipe capable of passing a fluid flow there through; and

a course capable of diverting a portion of the fluid flow to a transducer capable of converting energy from the diverted portion into electrical energy, the transducer including a positive displacement motor attached to a generator, the positive displacement motor including a rotor and a stator, the stator including a nonelastic interior surface;

wherein the rotor includes a helically shaped exterior, eccentrically rotatable within the stator, the stator having a helically shaped interior, wherein the helically shaped interior of the stator includes more lobes than the helically shaped exterior of the rotor.

2. The downhole transducer assembly of claim 1, wherein the rotor comprises diamond on an exterior thereof.

3. The downhole transducer assembly of claim 2, wherein the rotor is formed entirely of polycrystalline diamond.

4. The downhole transducer assembly of claim 1, wherein the stator includes diamond on the nonelastic interior surface.

5. The downhole transducer assembly of claim 1, further comprising an outlet capable of discharging the diverted portion of the fluid flow to an exterior of the drill pipe, and wherein the outlet is exposed on an exterior of a lateral sidewall of the drill pipe.

6. The downhole transducer assembly of claim 1, wherein the transducer is disposed within a lateral sidewall of the drill pipe.

7. The downhole transducer assembly of claim 1, wherein the transducer does not obstruct a main fluid flow passing through the drill pipe.

8. The downhole transducer assembly of claim 1, wherein the diverted portion of the fluid flow comprises 1-10 gallons/minute (0.003785-0.03785 m³/min).

9. The downhole transducer assembly of claim 1, wherein the diverted portion of the fluid flow experiences a pressure drop of 500-1000 pounds/square inch (3,447-6,895 kPa) over the transducer.

10. The downhole transducer assembly of claim 1, a material of the helically shaped exterior and the helically shaped interior preventing wear on the helically shaped exterior and the helically shaped interior.

11. A downhole transducer assembly, comprising:

a drill pipe capable of passing a fluid flow there through; and

a course capable of diverting a portion of the fluid flow to a transducer capable of converting energy from the diverted portion into electrical energy, the transducer including a turbine attached to a generator, wherein the turbine is adjustable relative to the diverted portion of fluid flow.

12. The downhole transducer assembly of claim 11, wherein blades of the turbine are angled in a direction of adjustability of the turbine relative to the diverted portion of fluid flow.

13. The downhole transducer assembly of claim 11, wherein the turbine is adjustable from the exterior of the drill pipe.

14. The downhole transducer assembly of claim 11, the course diverting the portion of the fluid flow tangentially relative to a rotational axis of the turbine.

15. The downhole transducer assembly of claim 11, the turbine configured to slide along a shaft of the turbine relative to the course.

16. The downhole transducer assembly of claim 15, the turbine configured to move out of a flow path of the portion of the fluid flow.

17. The downhole transducer assembly of claim 15, further comprising a ramp, the ramp configured to slide the turbine along the shaft.

18. The downhole transducer assembly of claim 15, the turbine being positioned at least partially in contact with the portion of the fluid flow based on a position of the turbine with respect to the portion of the fluid flow.

19. A downhole transducer assembly, comprising

a drill pipe capable of passing a fluid flow there through;

and

a course capable of diverting a portion of the fluid flow to a transducer capable of converting energy from the diverted portion into electrical energy, the transducer including a turbine attached to a generator, wherein the turbine is interchangeable.

20. The downhole transducer assembly of claim 19, wherein the transducer comprises a series of turbines attached to a generator.