Downhole Power Generator in Side Pocket Mandrel
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Solution Overview
Problem
Current technologies face challenges in achieving real-time data transmission and power generation inside wells for hydrocarbon production, as battery-powered wireless communications systems are limited by temperature and data capacity, and downhole power generators often fail due to placement in the flow stream, causing debris buildup and production issues.
Innovation Solution
A system comprising a power generator, wireless communications transmitter, and controller placed inside a side pocket mandrel, which harnesses fluid flow to generate power using rotatable impellers and magnets, and uses pressure pulser valves to transmit data through acoustic or electromagnetic waves without obstructing the production path, with features like pressure compensation and diverter mechanisms to prevent debris entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a power generator is placed in the flow stream path to harvest energy from fluid flow, then power generation capability is improved, but the generator can fail leading to debris buildup which decreases production
Solution Approach 1:
The system divides the flow path into two separate channels: a main production tubing that carries hydrocarbon flow, and a side pocket mandrel with its own fluid conduit that carries a portion of the fluid flow to the power generator. This segmentation allows the generator to be isolated from the main production path, so if the generator fails, debris cannot block the main production flow.
Solution Approach 2:
A diverter mechanism acts as an intermediary between the main production flow and the side pocket flow. It selectively directs a portion of the fluid to the power generator while allowing the main production flow to continue uninterrupted through the production tubing. This intermediary protects the main production system from generator failures.
2Use of energy by moving object
If a power generator is placed in the flow stream to generate power, then energy harvesting is improved, but workover tools cannot be deployed below the generator through the tubing
Solution Approach 1:
The system separates the power generation function from the main production tubing by placing the generator in a side pocket mandrel. This segmentation creates an independent channel for energy harvesting that does not interfere with the main tubing, allowing workover tools to be deployed freely through the production tubing without encountering the generator.
Solution Approach 2:
The power generator is moved from the one-dimensional main production tubing path to a side pocket dimension. This spatial repositioning allows the generator to harvest energy from a portion of the fluid flow while leaving the main production path clear for workover tool deployment.
3Reliability
If batteries are used as the primary power source for wireless communications inside a well, then the communications system can operate, but the operating temperature is limited and the life of the system is limited
Solution Approach 1:
The system uses a power generator that harvests energy directly from the flowing fluid to provide continuous power to the wireless communications system. This self-service approach eliminates the need for batteries, allowing the communications system to operate continuously at high temperatures without being constrained by battery temperature limits or finite capacity.
4Power
If the generator is placed in the flow stream to harvest energy, then power generation is achieved, but debris can accumulate and decrease production
Solution Approach 1:
The system segments the fluid flow into a main production stream and a side pocket stream. The side pocket mandrel with its separate conduit directs a portion of the flow to the generator, isolating the generator from the main production path. This segmentation prevents debris generated by the generator from accumulating in the main production tubing and blocking hydrocarbon flow.
Solution Approach 2:
The power generation function is extracted from the main production system and placed in a separate side pocket mandrel. This extraction removes the potential source of debris and harmful factors from the critical production path, allowing the main tubing to remain clear for uninterrupted hydrocarbon production.
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
Enables reliable, real-time data transmission and power generation inside wells without reducing production, as the system effectively harvests energy from fluid flow and transmits data using acoustic or electromagnetic waves, preventing debris accumulation and ensuring continuous operation.
Implementation Method 1
harnesses fluid flow to generate power using rotatable impellers and magnets
Implementation Method 2
uses pressure pulser valves to transmit data through acoustic or electromagnetic waves
Implementation Method 3
transmits data using acoustic or electromagnetic waves
Data Source
AI summary
A downhole communications system comprises a power generator disposed proximate a predetermined portion of a side pocket mandrel in such a way as to not impede fluid flow within a wellbore into which the side pocket mandrel is disposed and a wireless communications transmitter operatively in communication with the power generator. Placed at least partially within a side pocket mandrel, the system allows fluid flowing proximate the side pocket mandrel to engage the power generator to create electric energy which may be used to power the wireless communications transmitter and allow data interchange between the wireless communications transmitter and a predetermined well device.