Downhole Transducer Assembly Radial Flow Power Generation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing downhole turbine systems require high drilling fluid flow rates to operate, limiting drilling fluid availability for other operations and necessitating the retrieval of detachable sections to pass devices through the drill string.
Innovation Solution
A transducer assembly housed within the lateral sidewall of a drill pipe converts a diverted portion of drilling fluid into electrical energy using positive displacement motors, turbines, or Pelton wheels, reducing fluid flow requirements while maintaining high pressure drops to generate similar electricity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional downhole turbine system is used to generate electrical energy, then electrical power can be produced, but it requires high drilling fluid flow rates (around 800 gallons/minute) which limits the ability to control other drilling operations
Solution Approach 1:
The patent transitions from an axial flow configuration to a radial flow configuration where the turbine is positioned within the drill pipe and drilling fluid flows radially inward through the turbine blades. This dimensional change allows the system to extract energy from the radial flow of drilling fluid, significantly reducing the required flow rate while maintaining power generation capability.
Solution Approach 2:
The patent changes the flow parameter from axial to radial direction and operates the turbine at higher pressure drops (500-1000 psi) compared to conventional systems. This parameter change enables the turbine to generate similar electrical power with much lower flow rates (1-10 gallons/minute) by utilizing the pressure differential more effectively.
2Power
If an on-axis generator arrangement is used, then electrical power can be generated, but it creates difficulty in passing devices through the drill string
Solution Approach 1:
The patent separates the power generation function from the central axis of the drill string by positioning the turbine radially within the drill pipe wall. This segmentation allows devices to pass through the central borehole without interfering with the generator, eliminating the need to retrieve detachable sections while maintaining power generation capability.
3Power
If a large amount of drilling fluid is used to rotate the turbine, then electrical power can be generated, but it reduces the availability of drilling fluid for cooling, lubrication, and debris removal
Solution Approach 1:
Instead of requiring the full flow of drilling fluid (800 gallons/minute) to pass through the turbine, the patent uses only a partial flow (1-10 gallons/minute) radially through the turbine blades. The excess drilling fluid continues to flow through the drill pipe for its intended purposes of cooling, lubrication, and debris removal, thereby maintaining overall drilling productivity while generating electrical power.
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 solution allows for efficient electrical energy generation using significantly less drilling fluid (1-10 gallons/minute) with pressure drops of 500-1000 pounds/square inch, enabling effective power for downhole tools without the need to retrieve detachable sections.
Implementation Method 1
capable of converting energy from flowing drilling fluid into electrical energy
Implementation Method 2
A transducer assembly housed within the lateral sidewall of a drill pipe converts a diverted portion of drilling fluid into electrical energy using positive displacement motors, turbines, or Pelton wheels
Implementation Method 3
A transducer assembly housed within the lateral sidewall of a drill pipe converts a diverted portion of drilling fluid into electrical energy
Implementation Method 4
diverted to an annulus surrounding the drill pipe to experience a pressure drop of around 500-1000 pounds/square inch
Data Source
AI summary
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.