Modular Downhole Generator Series Coupling
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Solution Overview
Problem
Conventional downhole mud generators in the drilling industry are limited in the amount of electrical power they can generate, making it difficult to efficiently power downhole tools during drilling operations.
Innovation Solution
The development of modular turbine generators that use a turbine wheel connected to a rotor, where the rotation generated by drilling fluid flow produces electrical power, allowing for series coupling to increase power output and compact design, and includes features like guide wheels for fluid preconditioning and pressure compensation to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional downhole mud generators are used, then the device can operate within the confines of a bottomhole assembly, but the amount of electrical power generated is limited
Solution Approach 1:
The generator is divided into modular segments that can be connected in series. Each module contains a stator, rotor, and turbine wheel assembly, allowing multiple units to be stacked together to achieve desired power output levels while maintaining manageable complexity within each individual module.
Solution Approach 2:
The turbine wheel is positioned within the rotor assembly, which is in turn positioned within the stator. This nested configuration allows the turbine to interact with drilling fluid flow while the rotor and stator generate electrical power, maximizing space utilization within the constrained BHA environment.
2Power
If the number of generator modules is increased to generate more power, then electrical power output increases, but the device complexity and space requirements increase
Solution Approach 1:
The turbine wheel is positioned within the rotor assembly, which is in turn positioned within the stator. This nested configuration allows the turbine to interact with drilling fluid flow while the rotor and stator generate electrical power, maximizing space utilization within the constrained BHA environment.
Solution Approach 2:
The turbine wheels are designed to rotate freely in response to drilling fluid flow without requiring additional mechanical drive shafts or complex transmission systems. The fluid flow itself provides the rotational force, eliminating the need for separate mechanical coupling between turbine and generator components.
3Loss of energy
If conventional generator designs are used, then the design is simpler, but the efficiency of converting drilling fluid energy to electrical power is lower
Solution Approach 1:
The turbine wheel, rotor, and stator are integrated into a single unified assembly where the turbine wheel is positioned within the rotor which is positioned within the stator. This merging of functions eliminates intermediate mechanical couplings and reduces energy losses between energy conversion stages.
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 enables the generation of higher electrical power levels suitable for downhole tools, improving drilling efficiency by providing a compact and adaptable power source that can meet the power requirements of downhole tools, while minimizing mechanical complexity and energy losses.
Implementation Method 1
a turbine wheel coupled to or integrated with the rotor and comprising one or more turbine blades that are configured to interact with fluid flowing through the borehole causing the turbine wheel to rotate and the rotor to rotate
Implementation Method 2
a first electrical generator comprising a rotor and a stator disposed in the first body, the first electrical generator being in mechanical communication with the first mechanical connector at one end and the second mechanical connector at an opposing end, the first electrical generator being in electrical communication with the first electrical connector at one end and the second electrical connector at the opposing end
Data Source
AI summary
An modular apparatus for generating electrical power in a borehole penetrating the earth includes a body comprising first and second mechanical connectors at opposing ends and first and second electrical connectors at the opposing ends, the mechanical connectors and the electrical connectors being configured to connect with the same type of corresponding connectors on another modular apparatus when the modular apparatus and the another modular apparatus are stacked together. The modular apparatus further includes: an electrical generator having a rotor and stator in mechanical communication with the first and second mechanical connectors and in electrical communication with the first and second electrical connectors; and a turbine wheel coupled to or integrated with the rotor and comprising one or more turbine blades that are configured to interact with fluid flowing through the borehole causing the turbine wheel to rotate and the rotor to rotate in order to generate the electrical power.