Downhole Tangential Turbine Assembly for Reduced Flow Power
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Solution Overview
Problem
Existing downhole turbines require high fluid flow rates, limiting drilling fluid availability for other operations and necessitating the retrieval of a detachable section to pass devices through the drill string.
Innovation Solution
A tangential turbine assembly is integrated within a drill pipe section, where a portion of the drilling fluid is diverted perpendicular to the turbine's axis, allowing it to rotate and be discharged externally, utilizing polycrystalline diamond (PCD) bearings and a check valve to optimize energy production with reduced fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an axial turbine is used to generate power downhole, then electrical power can be generated from kinetic energy of drilling fluid, but a large amount of drilling fluid (around 800 gallons/minute) is required to rotate the turbine, limiting the ability to control other drilling operations
Solution Approach 1:
The patent transitions from an axial turbine configuration (fluid flow parallel to turbine axis) to a radial turbine configuration (fluid flow perpendicular to turbine axis). This dimensional change in fluid flow direction allows the turbine to extract energy more efficiently from the drilling fluid, reducing the required flow rate from 800 gallons/minute to a much lower rate while maintaining comparable power generation capability.
2Power
If an axial turbine with outwardly projecting rotor vanes is used, then energy can be extracted from flowing drilling fluid, but devices cannot be passed through the drill string past the generator without retrieving a detachable section
Solution Approach 1:
The patent inverts the conventional axial turbine arrangement by using a radial turbine configuration where the turbine wheel is positioned perpendicular to the drill string axis. This inversion allows the turbine to be located in the annulus surrounding the drill string rather than blocking the central passage, enabling devices to be passed through the drill string without retrieving detachable sections while still extracting energy from the drilling fluid flow.
3Ease of operation
If a detachable section is made retrievable to pass devices through the drill string, then device passage is enabled, but the entire drill string must be removed or the detachable section must be retrieved, increasing operational complexity
Solution Approach 1:
The patent segments the drill string system into modular components: the drill string remains intact while the turbine assembly is positioned in the annulus. This segmentation allows devices to be passed through the drill string without requiring retrieval of any detachable sections, as the turbine configuration inherently clears the central passage while maintaining drill string integrity.
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 tangential turbine design achieves similar energy production with significantly less drilling fluid flow, allowing unobstructed passage of devices through the drill string and reducing fluid pressure requirements, while minimizing friction and wear.
Implementation Method 1
a turbine located on the axis of a drill pipe, which has outwardly projecting rotor vanes, mounted on a mud-lubricated bearing system to extract energy from the flow
Implementation Method 2
utilizing polycrystalline diamond (PCD) bearings and a check valve to optimize energy production with reduced fluid flow
Implementation Method 3
utilizing polycrystalline diamond (PCD) bearings and a check valve to optimize energy production with reduced fluid flow
Implementation Method 4
an on-axis electrical generator which houses magnets and coils
Data Source
AI summary
A downhole turbine assembly may comprise a tangential turbine disposed within a section of drill pipe. A portion of a fluid flowing through the drill pipe may be diverted to the tangential turbine generally perpendicular to the turbine's axis of rotation. After rotating the tangential turbine, the diverted portion may be discharged to an exterior of the drill pipe.