Flow Line Turbine Generator for Drilling Mud Power

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Solution Overview

Problem

Drilling rigs often face challenges in generating electricity in remote or offshore locations, where access to commercial electric grids is limited, and reliance on diesel or gasoline engines can be inefficient and environmentally harmful.

Innovation Solution

The integration of a flow line turbine generator into the drilling rig system, which utilizes the return flow of drilling mud to generate electricity. This system includes a generator coupled to a shaft that rotates in response to the mud flow, with blades designed to allow wellbore cuttings to pass through, and an electrical storage device to store generated electricity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If diesel or gasoline engines are used to generate electricity, then electricity can be produced, but fuel consumption increases and environmental harm worsens

Engineering Contradiction:

Improvefuel consumptionVSAvoidenvironmental harm

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The system uses the drilling mud return flow, which is already part of the drilling operation, to generate electricity through the turbine generator. This self-service approach converts a waste product (return flow) into a useful resource (electricity) without requiring external fuel sources, thereby reducing fuel consumption and environmental harm.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The drilling mud return flow, which would otherwise be wasted, is converted into a power source. The kinetic energy in the return flow is harnessed by the turbine to generate electricity, transforming a potentially harmful waste product into a beneficial resource that reduces dependence on fossil fuels.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Power

If a flow line turbine generator is integrated into the drilling rig, then electricity generation improves, but device complexity increases

Engineering Contradiction:

Improveelectrical power productionVSAvoidsystem complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The turbine generator is integrated into the existing drilling rig system, merging the electricity generation function with the drilling operations. The turbine is positioned in the return flow path, combining the mud handling system with the power generation system, thereby increasing electrical power production without requiring a completely separate system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The drilling rig system is designed to perform multiple functions: drilling operations, mud handling, and electricity generation. The return flow serves dual purposes - it continues to carry cuttings from the wellbore while simultaneously driving the turbine generator to produce electricity, thereby reducing the need for separate dedicated equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If blades are designed to allow wellbore cuttings to pass through, then the turbine generator reliability improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improveturbine generator reliabilityVSAvoidblade spacing precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The blades are designed with specific local characteristics - sufficient spacing between them to allow cuttings to pass through while maintaining enough surface area to capture kinetic energy from the return flow. This local quality optimization ensures reliability by preventing clogging while maintaining power generation efficiency.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The blade spacing is designed to be intentionally larger than the minimum required for structural integrity, providing excessive clearance to ensure that cuttings can always pass through. This partial action approach prioritizes reliability over maximum manufacturing precision, allowing for easier manufacturing while ensuring proper function.

Inventive Principle:

Principle #16Partial or excessive action

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 increases rig electrical power production, reduces fuel consumption and associated environmental impacts, and provides a reliable emergency power source for critical equipment and personnel safety systems.

Implementation Method 1

a flow line turbine generator positioned in a return flow of drilling mud

Methodology Applied

Scientific EffectTurbine: Turbine

Implementation Method 2

The flow line turbine generator generates electricity using a return flow of the drilling mud

Methodology Applied

Scientific EffectKinetic energy conversion:

Data Source

PatentUS12221861B2Generating electricity with a wellbore drilling mud flow

Publication Date: 2025.02.11 SAUDI ARABIAN OIL CO

AI summary

A well system and a method for generating electricity with a wellbore drilling mud flow in a well system. The well system has a drilling rig positioned above a wellbore and a flow line turbine generator coupled to the drilling rig. The drilling rig has a wellhead assembly coupled to the wellbore, a drill string suspended from the drilling rig and extending through the wellhead assembly into the wellbore, a mud tank, and a mud pump fluidly coupled to the mud tank. The mud pump flows a drilling mud from the mud tank into the drill string. The flow line turbine generator is positioned between the wellhead assembly and the mud tank. The flow line turbine generator generates electricity using a return flow of the drilling mud from the wellbore through the wellhead assembly to the mud tank.