Downhole Power Generation System with Flow Diverters
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Solution Overview
Problem
Downhole fluid driven generators face reliability issues due to high mechanical loads and excessive heat generation at high flow rates, leading to potential mechanical failures and costly overloading of power control circuitry.
Innovation Solution
The implementation of a downhole electrical generator system with controllably exposed secondary flow channels and turbines, allowing for adjustable fluid flow diversion to manage power output, featuring axially or peripherally spaced generators and controllable flow diverters actuated by electrical or hydraulic actuators, to optimize power generation and reduce mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If fluid flow rate increases to generate more power, then power output increases, but mechanical loads on generator components increase causing potential mechanical failures
Solution Approach 1:
The patent applies dynamics by making the flow channel configuration adjustable through movable flow diverters that can change the distribution of fluid flow to turbines based on operating conditions. This allows the system to adapt its mechanical load characteristics dynamically, operating multiple turbines at optimized flow rates rather than relying on a single turbine operating across all flow rates, thereby maintaining reliability while generating required power.
Solution Approach 2:
The patent segments the power generation function by dividing it into multiple separate turbines, each capable of operating independently at its optimal flow rate. This segmentation allows the system to handle a wide range of total flow rates by activating and adjusting individual turbines, preventing any single turbine from experiencing excessive mechanical loads that would compromise reliability.
2Power
If fluid flow rate increases to generate more power, then power output increases, but excessive heat generation occurs in the generator and power conversion electronics
Solution Approach 1:
The system dynamically adjusts power generation by controlling flow diverters to distribute fluid flow across multiple turbines based on demand. This prevents any single turbine from generating excessive power that would lead to overheating, and allows for staged power generation that matches actual load requirements, reducing unnecessary heat generation in both mechanical and electronic components.
Solution Approach 2:
The patent implements partial action by activating only the number of turbines necessary to meet current power demands. Rather than operating all turbines at full capacity regardless of need, the system adjusts flow distribution to match actual requirements, avoiding excessive power generation that would result in wasted energy and excessive heat generation.
3Device complexity
If a single turbine operates across all flow rates, then device complexity is reduced, but the turbine must operate inefficiently at flow rates outside its design point
Solution Approach 1:
The patent resolves this contradiction by implementing a dynamic flow distribution system with movable diverters that can reallocate fluid flow among multiple turbines based on operating conditions. While the overall system is more complex than a single turbine, the dynamic control allows each turbine to operate near its design point across a wide range of total flow rates, significantly improving efficiency compared to a fixed single-turbine design.
Solution Approach 2:
The system achieves multi-functionality by designing it to handle multiple operating regimes through multiple turbines, each optimized for specific flow rate ranges. This universal design allows the power generation system to efficiently operate across the entire expected flow rate spectrum, rather than being optimized for a single design point, thereby improving overall productivity.
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 effectively manages power output and reduces mechanical stress on generators, preventing overheating and extending drilling time by allowing for controlled power generation and distribution, thereby enhancing the reliability and efficiency of downhole power generation.
Implementation Method 1
a turbine operatively coupled to a fluid driven electrical generator
Implementation Method 2
a turbine operatively coupled to a fluid driven electrical generator
Data Source
AI summary
An apparatus for generating electrical power downhole comprises a housing located in a drillstring. A primary flow channel is formed through the housing. At least two secondary flow channels are located in the housing and arc laterally displaced from the primary flow channel, A fluid driven electrical generator is positioned in each of the at least two secondary flow channels. A controllable flow diverter is associated with each of the secondary flow channels to controllably divert at least a portion of a fluid flow m the primary flow channel to at least one of the at least two secondary flow channels to drive the generator therein.