Downhole hydraulic energy harvesting system and method for energy harvesting from a fluid source

Abstract

A well system that includes an electric device disposed in a wellbore and more than one energy harvesting device attached to the electric device and adapted to transform external energy in the wellbore to electric power. A method that includes the steps of deploying an electric device in a wellbore, wherein more than one energy harvesting device is attached to the electric device, transforming, with the more than one energy harvesting device, external energy in the wellbore to electric power, and supplying the electric power from the more than one energy harvesting device to the electric device.

Description

DOWNHOLE HYDRAULIC ENERGY HARVESTING SYSTEM AND METHOD FOR ENERGY HARVESTING FROM A FLUID SOURCECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to United States Provisional Application 63 / 670,150 dated July 12, 2024, the entirety of which is incorporated by reference.FIELD OF THE DISCLOSURE

[0002] Aspects of the disclosure relate to downhole systems used to investigate geological stratum. More specifically, aspects of the disclosure relate to harvesting energy in a downhole wellbore environment.BACKGROUND

[0003] During downhole operations, downhole tools may require electrical power to operate, and there are instances where there are either insufficient or no power available from the surface. When this occurs, the amount of electrical energy may limit the planned activities of engineers. In some instances, anticipated activities must be completely curtailed. In other instances, the downhole tools must be recovered at the surface and fresh batteries are installed in the downhole tools. The downhole tools are then lowered back into the wellbore.

[0004] In many instances, wellbores extend thousands of feet in various geological stratum. The wellbore itself may follow a complicated path that curves along a desired pathway. The recovery of the downhole tools from great depths within a wellbore may take significant amounts of time. The inactive time can cause significant delays in production as well as economic expense.

[0005] Various systems may be used within the downhole environment. In several types of systems, downhole tools are suspended from a cable known as a wireline. This wireline can be used to feed electrical energy to the suspended downhole systems. There are instances where some of these downhole tools are not connected by a wireline. In such instances, some components in the downhole tools use primary, non-rechargeablebatteries, or on some occasions, use rechargeable batteries. One example of these batteries is a Lithium-Ion battery system.

[0006] The batteries described above have limited energy capacity and therefore may have limited available continuous power. Therefore, there is a need for a more efficient system which is able to provide continuous power to downhole tools.

[0007] There is a need to provide an apparatus and methods for charging downhole apparatus that easier to operate than conventional apparatus and methods.

[0008] There is a further need to provide apparatus and methods that do not have the drawbacks discussed above, such as long recovery times for downhole systems, wherein the recovery is prompted by lack of available electrical energy.

[0010] There is a still further need to reduce economic costs associated with operations and apparatus described above with conventional tools and provide extended stay duration times for downhole apparatus.

[0011] There is a further need to provide electrical energy for downhole systems in extended reach wellbores thereby allowing engineers the ability to obtain data and recovery hydrocarbon from every increasingly complex wellbores.

[0012] There is a further need to provide for systems that provide electrical energy to downhole systems that are fault tolerant so that in the event of unexpected occurrences within a wellbore, electrical energy is consistently provided so that operations may proceed.

[0013] There is a further need for downhole energy harvesting systems that are maintenance friendly and that have long service lives to minimize downtime and increase efficiency of wellbore operations.SUMMARY

[0014] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized below, may be had by reference to embodiments, some of which areillustrated in the drawings. It is to be noted that the drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments without specific recitation. Accordingly, the following summary provides just a few aspects of the description and should not be used to limit the described embodiments to a single concept.

[0015] In one example embodiment, a downhole energy harvesting system is disclosed. The system may comprise an electric device disposed in a wellbore. The system may further comprise at least one energy harvesting device connected to the electric device and adapted to transform external energy in the wellbore to electric power.

[0016] In another example embodiment, a method is disclosed. The method may comprise deploying an electric device in a wellbore, wherein at least one energy harvesting device is attached to the electric device. The method may further comprise transforming, with the at least one energy harvesting device, external energy in the wellbore to electric power. The method may further comprise supplying the electric power from the at least one energy harvesting device to the electric device.

[0017] In another example embodiment, an article of manufacture is disclosed. The article of manufacture is configured to have a non-volatile memory, the non-volatile memory having a series of executable method instructions for downhole hydraulic energy harvesting, the method instructions controlling at least one mechanical device, the method instructions comprising deploying an electric device in a wellbore, wherein at least one energy harvesting device is attached to the electric device. The method may further comprise transforming, with the at least one energy harvesting device, external energy in the wellbore to electric power. The method may further comprise supplying the electric power from the at least one energy harvesting device to the electric device.BRIEF DESCRIPTION OF THE DRAWINGS

[0018] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which areillustrated in the drawings. It is to be noted; however, that the appended drawings illustrate only typical embodiments of this disclosure and are; therefore, not be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

[0019] FIG. 1 is a diagram illustrating a detailed hydraulic energy harvesting apparatus in one aspect of the disclosure.

[0020] FIG. 2 is a diagram illustrating a method of energy harvesting in one example embodiment of the disclosure.

[0021] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures (“FIGS”). It is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.DETAILED DESCRIPTION

[0022] In the following, reference is made to embodiments of the disclosure. It should be understood; however, that the disclosure is not limited to specific described embodiments. Instead, any combination of the following features and elements, whether related to different embodiments or not, is contemplated to implement and practice the disclosure. Furthermore, although embodiments of the disclosure may achieve advantages over other possible solutions and / or over the prior art, whether or not a particular advantage is achieved by a given embodiment is not limiting of the disclosure. Thus, the following aspects, features, embodiments, and advantages are merely illustrative and are not considered elements or limitations of the claims except where explicitly recited in a claim. Likewise, reference to “the disclosure” shall not be construed as a generalization of inventive subject matter disclosed herein and should not be considered to be an element or limitation of the claims except where explicitly recited in a claim.

[0023] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. Theseterms may be only used to distinguish one element, components, region, layer or section from another region, layer, or section. Terms such as “first”, “second”, and other numerical terms, when used herein, do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed herein could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

[0024] When an element or layer is referred to as being “on”, “engaged to”, “connected to”, or “coupled to” another element or layer, it may be directly on, engaged, connected, coupled to the other element or layer, or interleaving elements or layers may be present. In contrast, when an element is referred to as being “directly on”, “directly engaged to”, “directly connected to”, or “directly coupled to” another element or layer, there may be no interleaving elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed terms.

[0025] Some embodiments will now be described with reference to the figures. Like elements in the various figures will be referenced with like numbers for consistency. In the following description, numerous details are set forth to provide an understanding of various embodiments and / or features. It will be understood; however, by those skilled in the art, that some embodiments may be practiced without many of these details, and that numerous variations or modifications from the described embodiments are possible. As used herein, the terms “above” and “below”, “up” and “down”, “upper” and “lower”, “upwardly” and “downwardly”, and other like terms indicating relative positions above or below a given point are used in this description to more clearly describe certain embodiments.

[0026] To solve the previously mentioned problem, aspects of the disclosure provide a system for harnessing power from downhole flowing fluids or pumped fluid from surface. The system shown provides a maintenance free system that may be installed within a downhole tool. Other embodiments allow for the system to be a stand-alone unit. As illustrated in FIG. 1 , a representation of the non-limiting example is shown, where apumped fluid 120, either from a formation or pumped through an annulus 118 from surface, is directed into a system 10. The system 10 may contain an electric device 20 used to harvest energy. In embodiments, the harvested energy is in the form of a flowing fluid. In the illustrated embodiment, production tubing 100 is placed within a wellbore wall 102. This placement forms an annulus 118 between the exterior of the production tubing 100 and the wellbore wall 102. In embodiments, a well production 122 flow spins a turbine 110 or an impeller that is connected to a generator 108 which converts hydraulic energy into electrical power 106. The generated electrical power may be used to directly power downhole tools and associated sensors or to recharge onboard batteries for downhole operations.

[0027] In one embodiment, the system 10 may direct flow to an energy capturing device such as a turbine 110 or an impeller, whereby the turbine or the impeller may be located inside a downhole tool. In embodiments, flow proceeds down the annulus 118 and enters a well production 122 flow. The well production 122 flow may be directed into at least one passage 112 from an inlet 104 to channel the flow to the turbine 110. A packer system 114 may be deployed in an up-hole position to direct the well production 122 into the passages 112. After passing through the turbine 110, the well production 122 may be directed out of the system 10 through an outlet 116. As will be understood, the flow may be from naturally producing well fluids or artificially created by pumps at a surface elevation. In another embodiment, the energy capturing member could be an external impeller with a rod that attaches to a generator rotor inside the tool. Internal turbines and / or impellers may be designed to be non-fouling; being debris tolerant. Materials used for such turbines and / or impellers may be erosion resistant materials to provide long-life operation.

[0028] In one embodiment, a downhole alternator or generator can convert the energy from the flowing reservoir fluids which may be attached to the tool. As mentioned earlier, the flow may be directed to spin an impeller or a turbine connected to a generator / alternator which may produce electricity for downhole use. The produced electrical power may be used as a direct power source or in an instance where the tool uses rechargeable batteries, to provide electrical power for recharge of the batteries., Inother embodiments, capacitors may be recharged. In the case of rechargeable batteries, lithium ion, solid-state or other types of batteries may be used.

[0029] In one embodiment, the electrical power may be amplified by using at least one packer 114 or a series of packers. In further embodiments, other means may be used to create a seal between the tool and production tubing to ensure all of the flow passing through the tool. In the same embodiment, the seal may be created using a rubber or other element which may help restrict the flow around the tool to help focus the flow to the energy capturing member at an energy producing area. In one embodiment, the sealing element may also be used to anchor to the tubing and hold the tool in place while performing an energy harvesting task.

[0030] In one embodiment, the method may be used in any application where downhole tools with batteries are used, such as, but not limited to any exploration logging tools, intervention tools, wireline formation evaluation tools, autonomous invention tool, long duration production tools, production equipment, etc. In one example of usage, the method may be used for an autonomous intervention tool which may need to travel through a well. Moreover, the energy harvesting task may also take place while the tool travels in the well to help recover some energy as the tool travels through the well.

[0031] Referring to FIG. 2, a method 200 for energy harvesting from a fluid source is illustrated. The method may comprise deploying an electric device in a wellbore, wherein at least one energy harvesting device is attached to the electric device at 202. The method may further comprise, at 204, transforming, with the at least one energy harvesting device, external energy in the wellbore to electric power. As will be understood, the harvesting of energy from a flowing fluid may be used to accomplish this step. The harvesting may occur based upon the rotary motion of a turbine or an impeller. Such devices may be located inside the body of a downhole tool, in one non-limiting embodiment. The method may further provide for, at 206, supplying the electric power from the at least one energy harvesting device to the electric device. In embodiments, the supplying may be to an energy storage device, such as a battery that may be recharged by motion of a generator initiated by the turbine or impeller. Other components that may be supplied electrical energy may include a tool-based heating system, a coolingsystem, a sensor or sensor arrangement, a transmitter, a receiver, or a transceiver. Other possibilities exist, such as downhole computing apparatus and data storage devices. In further embodiments, the step of deploying the electric device into the wellbore may also encompass inflating a packer system such that fluid traveling within the wellbore is channeled through the energy harvesting device. Such deployment of a packer system may increase the overall efficiency of the amount of energy recovered during the method performance.

[0032] As will be understood, fluid flow may be encouraged during the method. For example, the method may be accomplished with the wellbore in a sealed configuration. Pumps located at the surface elevation may pump down fluid in the annulus area of the wellbore. The sealed condition of the wellbore and incompressibility of the fluid will cause overall fluid flow to occur down the annulus, with a return of fluid through the production tubing. The blocking of the fluid through deployment of the packer as well as inlets provided within the device, necessitates fluid flow through the system, turning the turbine and associated generator.

[0033] In some embodiments, valving may be incorporated into the body of the system. This valving may limit the possibility of backflow within the system. The valving may also act as a pressure relief mechanism for preventing pressures from exceeding certain limitations within the wellbore. As will be understood, each wellbore is unique and efforts are made to limit the stresses placed upon the geological structure causing damage to the overall wellbore profile.

[0034] In some embodiments, the flow established within the wellbore may occur through various means. For example, the flow may be initiated through pumping from an up-hole environment. In other embodiments, a natural pressure differential may be present in the wellbore, allowing a flow of fluid to naturally occur. Other causes for flow may include thermal differences within the wellbore.

[0035] As will be understood, the deployment of packer systems within the wellbore is an optional step. Other possibilities exist, including having a tight-fitting system within theproduction tubing, causing a natural restriction. In further embodiments, other types of seals, such as rubber or neoprene seals can be used within the wellbore.

[0036] The systems described may be controlled through computer-controlled valves that permit or restrict flow within the downhole hydraulic energy harvesting system. In instances where sufficient energy is within the overall system and there is no further need for provision of electrical energy, computer control may be used to restrict flow within the system and stop electrical production. Systems may be monitored through telemetry systems that allow for sending signals back and forth to the surface. The systems described may be part of a downhole tool or may be a stand-alone component. The system may also be a modular unit that can be installed within a downhole tool, for instances where it is expected that rechargeable power may be needed. In instances where rechargeable batteries are used, such batteries may be stored remotely from the other components of the system.

[0037] Embodiments of the disclosed system may incorporate debris limiting features. Such debris limiting features may include variable size openings (inlets) to the turbine. As will be understood, larger size openings will limit or eliminate clogging allowing any debris traveling up the wellbore to pass through the overall system without accumulating within specific sections.

[0038] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the disclosure. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the systems and methods described herein. The foregoing descriptions of specific examples are presented for purposes of illustration and description. They are not intended to be exhaustive of or to limit this disclosure to the precise forms described. Obviously, many modifications and variations are possible in view of the above teachings. The examples are shown and described in order to best explain the principles of this disclosure and practical applications, to thereby enable others skilled in the art to best utilize this disclosure and various examples with various modifications as are suited to the particular use contemplated. It is intended that the scope of this disclosure be defined by the claims and their equivalents below.

[0039] As will be understood, method steps for completion may be stored in the random access memory, read only memory, flash memory, computer hard disk drives, compact disks, floppy disks and solid-state drives. Such articles of manufacture may allow the method steps to be transported from wellsite to wellsite allowing field engineers the ability to program steps. The method steps may be performed manually by engineers at the wellsite or may be performed from a remote location. Such operations from a remote location allow for more centralized control of operations and increased economic benefit as the number of field personnel required to be deployed to a wellsite is greatly reduced.

[0040] Data from recharging sequences may be monitored and recorded allowing engineers the ability to track recharging processes. Through this data retention, expected full recharge times may be established and efficiency maximized for field operations.

[0041] Aspects of the disclosure satisfy the long standing needs for the industry. Aspects provide an apparatus and methods for charging downhole apparatus that easier to operate than conventional apparatus and methods.

[0042] Aspects further provide apparatus and methods that do not have the drawbacks discussed above, such as long recovery times for downhole systems, wherein the recovery is prompted by lack of available electrical energy.

[0043] Aspects further reduce economic costs associated with operations and apparatus described above with conventional tools and provide extended stay duration times for downhole apparatus.

[0044] Aspects further provide electrical energy for downhole systems in extended reach wellbores thereby allowing engineers the ability to obtain data and recovery hydrocarbon from every increasingly complex wellbores.

[0045] Aspects further provide for systems that provide electrical energy to downhole systems that are fault tolerant so that in the event of unexpected occurrences within a wellbore, electrical energy is consistently provided so that operations may proceed.

[0046] Aspects further provide for downhole energy harvesting systems that are maintenance friendly and that have long service lives to minimize downtime and increase efficiency of wellbore operations.

[0047] Example embodiments provided in the claims are described next. The example embodiments should not be considered limiting. In one example embodiment, a downhole energy harvesting system is disclosed. The system may comprise an electric device disposed in a wellbore. The system may further comprise at least one energy harvesting device connected to the electric device and adapted to transform external energy in the wellbore to electric power.

[0048] In another example embodiment, the system may be configured wherein the at least one energy harvesting device is comprised of at least one of a turbine and an impeller and at least one of a generator and alternator connected to the at least one of the turbine and the impeller.

[0049] In another example embodiment, the system may be configured wherein the external energy is hydraulic energy and the at least one of the turbine and the impeller are configured to rotate around an axis from a flow of fluid contacting the at least one of the turbine and the impeller.

[0050] In another example embodiment, the system may be configured wherein the electric device includes a rechargeable battery.

[0051] In another example embodiment, the system may further comprise at least one of a heating system, a cooling system, a sensor, a transmitter, a receiver and a transceiver.

[0052] In another example embodiment, a method is disclosed. The method may comprise deploying an electric device in a wellbore, wherein at least one energy harvesting device is attached to the electric device. The method may further comprise transforming, with the at least one energy harvesting device, external energy in thewellbore to electric power. The method may further comprise supplying the electric power from the at least one energy harvesting device to the electric device.

[0053] In another example embodiment, the method may be performed wherein the external energy is in the form of energy from a fluid.

[0054] In another example embodiment, the method may be performed wherein the electric device is at least one of a battery, a heating system, a cooling system, a sensor, a transmitter, a receiver, or a transceiver.

[0055] In another example embodiment, the method may further comprise storing the supplied electric power.

[0056] In another example embodiment, the method may be performed wherein the storing of the supplied electric power is in a rechargeable battery.

[0057] In another example embodiment, the method may further comprise directing the external energy in the wellbore through at least one packer device to increase a velocity of fluid within the wellbore.

[0058] In another example embodiment, the method may be performed wherein the directing of the external energy is through a body of the electric device deployed in the wellbore.

[0059] In another example embodiment, the method may be performed wherein the electric device is a downhole wellbore tool.

[0060] In another example embodiment, the method may further comprise pumping a fluid from an annulus of the wellbore to create a fluid velocity within the wellbore annulus.

[0061] In another example embodiment, the method may further comprise injecting the pumped fluid into a drill pipe to a downhole location after the pumping of the fluid from the annulus.

[0062] In another example embodiment, the method may be performed wherein the pumping of the fluid is accomplished at a surface elevation.

[0063] In another example embodiment, an article of manufacture is disclosed. The article of manufacture is configured to have a non-volatile memory, the non-volatile memory having a series of executable method instructions for downhole hydraulic energy harvesting, the method instructions controlling at least one mechanical device, the method instructions comprising deploying an electric device in a wellbore, wherein at least one energy harvesting device is attached to the electric device. The method may further comprise transforming, with the at least one energy harvesting device, external energy in the wellbore to electric power. The method may further comprise supplying the electric power from the at least one energy harvesting device to the electric device.

[0064] In another example embodiment, the article of manufacture may be configured wherein a form of the article of manufacture is a universal serial bus device.

[0065] In another example embodiment, the article of manufacture may be configured wherein the method instructions further comprise recharging a battery with the supplied electric power.

[0066] In another example embodiment, the article of manufacture may be configured wherein a form of the article of manufacture is one of a hard disk, a solid-state drive, computer memory, a web-based memory system, and a compact disk.

[0067] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

[0068] While embodiments have been described herein, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments are envisioned that do not depart from the inventive scope. Accordingly, the scope of the present claims or any subsequent claims shall not be unduly limited by the description of the embodiments described herein.

Claims

CLAIMSWhat is claimed is:1 . A downhole energy harvesting system, comprising: an electric device disposed in a wellbore; and at least one energy harvesting device connected to the electric device and adapted to transform external energy in the wellbore to electric power.

2. The system according to claim 1 , wherein the at least one energy harvesting device is comprised of: at least one of a turbine and an impeller; and at least one of a generator and alternator connected to the at least one of the turbine and the impeller.

3. The system according to claim 1 , wherein the external energy is hydraulic energy and the at least one of the turbine and the impeller are configured to rotate around an axis from a flow of fluid contacting the at least one of the turbine and the impeller.

4. The system according to claim 1 , wherein the electric device includes a rechargable battery.

5. The system according to claim 1 , further comprising at least one of a heating system, a cooling system, a sensor, a transmitter, a receiver, and a transceiver.

6. A method, comprising: deploying an electric device in a wellbore, wherein at least one energy harvesting device is attached to the electric device; transforming, with the at least one energy harvesting device, external energy in the wellbore to electric power; andsupplying the electric power from the at least one energy harvesting device to the electric device.

7. The method according to claim 6, wherein the external energy is in the form of energy from a fluid.

8. The method of claim 6, wherein the electric device is at least one of a battery, a heating system, a cooling system, a sensor, a transmitter, a receiver, or a transceiver.

9. The method according to claim 6, further comprising storing the supplied electric power.

10. The method according to claim 9, wherein the storing of the supplied electric power is in a rechargeable battery.11 . The method according to claim 6, further comprising: directing the external energy in the wellbore through at least one packer device to increase a velocity of fluid within the wellbore.

12. The method according to claim 11 , wherein the directing of the external energy is through a body of the electric device deployed in the wellbore.

13. The method according to claim 12, wherein the electric device is a downhole wellbore tool.

14. The method according to claim 6, further comprising: pumping a fluid from an annulus of the wellbore to create a fluid velocity within the wellbore annulus.

15. The method according to claim 14, further comprising:injecting the pumped fluid into a drill pipe to a downhole location after the pumping of the fluid from the annulus.

16. The method according to claim 14, wherein the pumping of the fluid is accomplished at a surface elevation.

17. An article of manufacture, having a non-volatile memory, the non-volatile memory having a series of executable method instructions for downhole hydraulic energy harvesting, the method instructions controlling at least one mechanical device, the method instructions comprising: deploying an electric device in a wellbore, wherein at least one energy harvesting device is attached to the electric device; transforming, with the at least one energy harvesting device, external energy in the wellbore to electric power; and supplying the electric power from the at least one energy harvesting device to the electric device.

18. The article of manufacture according to claim 17, wherein a form of the article of manufacture is a universal serial bus device.

19. The article of manufacture according to claim 17, wherein the method instructions further comprise recharging a battery with the supplied electric power.

20. The article of manufacture according to claim 17, wherein a form of the article of manufacture is one of a hard disk, a solid-state drive, computer memory, a webbased memory system, and a compact disk.

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