Downhole Drilling Motor Integrated Generator

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Solution Overview

Problem

Supplying power to downhole drilling equipment is challenging due to increasing well depths and harsh conditions, leading to direct connection issues with surface power sources and the need for frequent battery replacements, which are costly and time-consuming.

Innovation Solution

Integration of a downhole power generation system within the drilling motor, utilizing hydraulic drives with bypasses that convert drilling fluid flow into mechanical energy through turbines, impellers, or progressing cavity mechanisms to generate electrical power, leveraging kinetic energy and piezoelectric effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery systems are used to power downhole equipment, then electrical power can be supplied to downhole tools, but the batteries require frequent replacement which is costly and time-consuming

Engineering Contradiction:

Improvecontinuous power supplyVSAvoidbattery replacement time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system generates its own electrical power using the drilling fluid flow and kinetic energy from the drilling motor to drive a generator, eliminating the need for external battery replacement. The power generation system serves itself by utilizing resources already present in the drilling operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the chemical energy storage system (batteries) with a mechanical energy conversion system (generator driven by turbines or impellers). This substitution converts the mechanical kinetic energy already present in the drilling fluid flow into electrical energy, eliminating the need for battery replacement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If direct connections to surface power sources are made, then electrical power can be supplied to downhole equipment, but increasing well depths make direct connections challenging

Engineering Contradiction:

Improveelectrical power supplyVSAvoidpower transmission system

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent extracts the power generation capability from the surface and places it directly at the downhole location. By integrating the generator and turbine/impeller system within the drilling motor itself, the system eliminates the need for complex surface-to-downhole power transmission connections.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The drilling motor serves multiple functions: it provides mechanical drive for the drill bit and simultaneously houses the power generation system. The hydraulic drive system that powers the motor also drives the turbine or impeller to generate electricity, creating a multi-functional integrated system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If batteries are replaced mid-operation, then power supply continuity can be maintained, but removal and rerunning of the drill string is required which is costly and risks wellbore damage

Engineering Contradiction:

Improvepower supply continuityVSAvoidwellbore damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The downhole system generates its own electrical power continuously during drilling operations using the kinetic energy from the drilling fluid flow. This self-powered operation eliminates the need for battery replacement and associated drill string removal, avoiding wellbore damage risks entirely.

Inventive Principle:

Principle #25Self-service

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

Provides a reliable and efficient means of powering downhole equipment, reducing the need for battery replacements and minimizing operational disruptions and costs by generating electricity on-site during drilling operations.

Implementation Method 1

hydraulic drives with bypasses that convert drilling fluid flow into mechanical energy through turbines

Methodology Applied

Scientific EffectHydraulic drive: Hydraulic Press

Implementation Method 2

hydraulic drives with bypasses that convert drilling fluid flow into mechanical energy through turbines, impellers, or progressing cavity mechanisms to generate electrical power

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

leveraging kinetic energy and piezoelectric effects

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS10250103B2Electricity generation within a downhole drilling motor

Publication Date: 2019.04.02 HALLIBURTON ENERGY SERVICES INC

AI summary

A progressing cavity-type drilling motor having an electrical generator disposed within the rotor of the drilling motor. In some embodiments, the electrical generator produces electrical energy from a flow of drilling fluid through a bore in the rotor. In other embodiments, the electrical generator produces electrical energy by harnessing the kinetic energy of the rotor as the drilling motor is used to drill into a formation. The electrical energy generated by the generator can be stored or used to power sensors, actuators, control systems, and other downhole equipment.