Downhole Power Generator Using Fluid Flow Kinetic Energy
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Solution Overview
Problem
The operational life of batteries used in downhole environments for power systems in the oil and gas exploration and extraction industry is significantly reduced due to challenging environmental conditions, leading to frequent replacements and operational delays.
Innovation Solution
A power generator is designed to harness fluid flow energy by using a drivable member, such as an impeller or grooved member, within a cylindrical housing, where the relative motion between generator magnets and electrically conductive members induces an electric current, and is configured to trickle charge batteries, with a magnetic coupling and pressure barrier for protection and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batteries are used to power downhole systems, then the systems can operate in harsh environments, but the operational life is significantly reduced due to challenging environmental conditions
Solution Approach 1:
The power generator enables the downhole system to generate its own power from the flowing fluid, making the system self-sufficient and eliminating dependence on finite battery resources. The system serves itself by converting the kinetic energy of the flowing fluid into electrical energy to power its own components.
Solution Approach 2:
The patent replaces the chemical energy storage system (batteries) with a mechanical energy conversion system (power generator with drivable member, magnets, and conductive coils). This substitution transforms the limited chemical energy of batteries into continuous mechanical-to-electrical energy conversion from the flowing fluid.
2Reliability
If batteries are frequently replaced due to reduced operational life, then power supply continuity can be maintained, but operational delays increase
Solution Approach 1:
The power generator enables continuous power generation as long as fluid flows through the conduit. The drivable member continuously converts the kinetic energy of the flowing fluid into electrical energy, providing uninterrupted power supply without the need for periodic battery replacements and associated operational interruptions.
3Reliability
If a power generator is designed to withstand harsh downhole conditions (150°C and 70 MPa), then reliability in extreme environments is improved, but device complexity increases
Solution Approach 1:
The power generator housing serves multiple functions: it contains the drivable member, magnets, and conductive coils; it withstands the harsh pressure and temperature environment; and it provides structural support within the conduit. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in complexity.
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
The power generator effectively extends the operational life of downhole systems by generating power from fluid flow, reducing the need for battery replacements and minimizing delays, while withstanding harsh conditions up to 150°C and 70 MPa pressures.
Implementation Method 1
the relative motion between generator magnets and electrically conductive members induces an electric current
Implementation Method 2
the drivable member is drivable by fluid flowing from the inlet to the plurality of outlets of the power generator so as to produce relative motion
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A power generator (105) for use in a bore (5), the power generator comprising at least one drivable member (130a-d); and at least one generation apparatus; the generation apparatus comprising at least one generator magnet (150) for producing a magnetic field; and at least one electrically conductive member (160) located or locatable within the magnetic field; wherein the drivable member is drivable by fluid flowing in the bore so as to produce relative motion of the at least one magnet and the at least one electrically conductive member in order to induce a current in the at least one electrically conductive member.