Drilling Fluid Flow Diverter for Variable Power Generation
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Solution Overview
Problem
Current downhole drilling tools face challenges in providing a robust and adaptable power source due to limited battery life and wear from constant drilling fluid flow, which is insufficient for the increasing size and complexity of MWD and LWD systems that require varying power levels for different components.
Innovation Solution
A flow diversion system that isolates drilling fluid from a secondary flow bore, allowing a variable flow rate to be directed into a power generation assembly, including a turbine, to generate a variable power supply for MWD tools, reducing wear and accommodating different power requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a turbine is disposed in the drilling fluid flow bore to generate power, then a steady source of power is provided, but wear on the turbine increases due to constant drilling fluid flow
Solution Approach 1:
The patent extracts the turbine from the main drilling fluid flow path by providing a separate secondary flow bore. The diverter directs a portion of drilling fluid from the first flow bore into the second flow bore where the turbine is disposed. This separation allows the turbine to be isolated from the full impact of constant drilling fluid flow while still receiving sufficient fluid to generate power, thereby reducing wear while maintaining power generation capability.
2Adaptability or versatility
If complex downhole tools with varying power requirements are deployed, then functionality increases, but the power source must accommodate varying power levels which increases complexity
Solution Approach 1:
The patent implements a dynamic flow diversion system where the diverter can be selectively positioned to direct varying amounts of drilling fluid into the secondary flow bore. This allows the turbine to receive adjustable fluid flow rates, enabling the power source to adapt to varying power requirements of different downhole tool components. The movable diverter mechanism provides dynamic control over power distribution without requiring multiple separate power sources or complex electrical systems.
3Duration of action of stationary object
If drilling fluid is constantly flowed over the turbine to provide steady power, then power supply is maintained, but wear on turbine components increases
Solution Approach 1:
The patent applies partial action by directing only a portion of the total drilling fluid flow into the secondary flow bore where the turbine is located. The diverter controls the amount of fluid diverted, allowing the turbine to receive sufficient fluid for continuous power generation without exposing it to the full force and volume of the main drilling fluid stream. This partial exposure maintains power supply continuity while reducing the wear caused by constant full-flow exposure.
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 system provides a robust and variable power supply, reducing wear on turbine components and enabling the operation of complex downhole tools by optimizing fluid flow and power generation, eliminating the need for surface-dependent power sources like disposable batteries.
Implementation Method 1
The turbine is disposed in the drilling fluid flow bore and rotated by the drilling fluid flowing therein
Data Source
AI summary
An embodiment of the apparatus includes a housing having a first flow bore and a second flow bore, the first flow bore having a drilling fluid flowing therein, a device disposed in the second flow bore to receive a fluid flow, and a diverter disposed between the first and second flow bores, the diverter having a first position preventing the drilling fluid from flowing into the second flow bore and a second position allowing a portion of the drilling fluid to flow into the second flow bore and through the device. Another embodiment includes a variable second position directing the drilling fluid into the second flow bore at a variable flow rate. A further embodiment includes a drill collar as the housing and a power generation assembly as the device to receive the fluid flow. Embodiments of a method of diverting a fluid flow in a downhole tool include diverting a portion of a first fluid flow to a second flow bore, and further varying a flow rate of the fluid to the second flow bore.