Actuator Controlled Variable Flow Stator for Downhole Turbine
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Solution Overview
Problem
Existing fluid flow systems in wellbores often require complex bypass valves to distribute flow between a turbine and a bypass path, adding unnecessary complexity and inefficiency.
Innovation Solution
A flow splitting mechanism with an actuator that adjusts the position of stator blades to control the flow through a turbine, allowing for selective regulation of the flow ratio between a first flow path through the turbine and a second bypass path, using a flow splitter and an adjustment mechanism to manage flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bypass valve is used to divide flow between turbine and bypass path, then flow distribution control is achieved, but device complexity increases
Solution Approach 1:
The patent merges the flow control function into the turbine assembly itself by making the stator blades movable, eliminating the need for a separate bypass valve. The stator blades are integrated with the turbine structure, and their position is controlled by an actuator that receives signals from a controller, combining multiple functions into a single integrated component.
Solution Approach 2:
The stator blades are made movable rather than fixed, allowing dynamic adjustment of the flow area through the turbine. The actuator mechanism enables the stator blades to change their position and adjust the flow distribution between the turbine and bypass path in real-time based on operational requirements.
2Ease of operation
If a bypass valve is used to distribute flow, then flow path control is achieved, but ease of manufacture decreases
Solution Approach 1:
The flow control functionality is merged into the turbine assembly by making the stator blades movable, eliminating the need for a separate bypass valve component. This integration reduces the total number of parts that need to be manufactured and assembled, simplifying the manufacturing process while maintaining flow control capability.
3Device complexity
If fixed stator blades are used, then structural simplicity is maintained, but adaptability to different flow conditions is reduced
Solution Approach 1:
The stator blades are designed to be movable rather than fixed, enabling them to adapt to different flow conditions. The actuator mechanism allows the stator blades to change their position dynamically, adjusting the flow area to optimize performance under varying operational requirements while maintaining a relatively simple overall structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the system by allowing precise control of flow distribution between the turbine and bypass paths, enhancing operational efficiency and reducing complexity, while maintaining optimal performance for down-hole tools.
Implementation Method 1
The actuator is operable to move the at least one stator blade to adjust a flow resistance through the first flow path
Implementation Method 2
The turbine assembly includes a rotor responsive to the fluid flow through the first flow path to rotate with respect to the stator
Data Source
AI summary
Systems and methods divide flow in a wellbore into a plurality of flow paths. A first one of the flow paths extends to a down-hole turbine that is responsive to fluid flow to provide rotational motion to an electric generator or other down-hole tool. A second flow path may extend to an independent down-hole tool, to a port communicating with the wellbore, to a bypass channel extending around the turbine, or to any other down-hole location. The turbine includes a stator having adjustable blades such that an open flow area through the turbine may be selectively controlled. A flow distribution between the first and second flow paths can be controlled where specific flow areas are needed at specific flow rates, for example.