Wellhead Turbine Choke for Kinetic Energy Recovery and Flow Regulation
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Solution Overview
Problem
Conventional wellhead assemblies lack an efficient mechanism to convert the kinetic energy of flowing fluids into electricity while regulating fluid flow and pressure, which is essential for optimizing energy use and operational efficiency in hydrocarbon production.
Innovation Solution
A wellhead assembly incorporating a choke system with a turbine element that rotates in response to fluid flow, coupled with a generator and braking system, which converts kinetic energy into electricity and regulates fluid flow by selectively impeding rotation based on monitored conditions, such as pressure, using a pressure sensor and calipers or magnetic fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a turbine element is allowed to rotate freely in response to fluid flow, then kinetic energy conversion is maximized, but fluid flow regulation capability is lost
Solution Approach 1:
The turbine element's rotational state is made dynamic, transitioning between freely rotating configuration for energy conversion and rotationally impeded configuration for flow regulation, allowing the system to adapt to different operational requirements
Solution Approach 2:
The braking system changes the rotational parameter of the turbine element by applying retarding contact or magnetic fields, enabling transition between free rotation and impeded rotation states to achieve both energy conversion and flow regulation
2Ease of operation
If a braking system is added to impede turbine rotation for flow regulation, then fluid flow control is improved, but device complexity increases
Solution Approach 1:
The braking system replaces complex mechanical flow control mechanisms with a turbine-based system that uses electromagnetic or magnetic braking, simplifying the overall device structure while maintaining flow regulation capability
Solution Approach 2:
The turbine element serves multiple functions: it converts kinetic energy to electricity during free rotation and regulates fluid flow when rotationally impeded, eliminating the need for separate energy conversion and flow control devices
3Measurement precision
If calipers or magnetic fields are used to retard turbine rotation, then flow regulation precision is improved, but manufacturing complexity increases
Solution Approach 1:
Mechanical braking components are replaced with magnetic fields generated by magnets or electromagnetic coils, which can be precisely controlled through electrical signals and are easier to manufacture with consistent precision
4Use of energy by moving object
If the turbine element is coupled with a generator, then energy utilization is improved, but device complexity and space requirements increase
Solution Approach 1:
The generator is integrated with the turbine element in a compact arrangement where the turbine shaft directly couples to the generator, merging the energy conversion and electricity generation functions into a single integrated unit that minimizes space and complexity
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 system effectively converts kinetic energy into electricity to power devices at the wellhead, while regulating fluid flow by managing the turbine's rotation, thereby enhancing energy utilization and operational efficiency in hydrocarbon production.
Implementation Method 1
a turbine element in the housing that rotates in response to a flow of fluid from the production piping through the housing
Implementation Method 2
a generator coupled with the turbine element
Implementation Method 3
calipers that are in selective retarding contact with the shaft
Implementation Method 4
or can be a magnet that strategically forms a magnetic field to selectively impede rotation of the shaft and the turbine element
Data Source
AI summary
A wellhead assembly for use with a well that includes a production tree, a production line for carrying produced fluid from the production tree, and a choke in the production line. The choke assembly includes a turbine member that rotates in response to fluid flowing through the production line. The kinetic energy of the rotating turbine is converted into electricity by a generator that is coupled with the turbine member. Selectively impeding turbine rotation with a brake system introduces a pressure drop in the production line fluid, and which regulates flow of the production line fluid. The turbine member can be disposed in a straight run of the production line, or adjacent a bend in the production line.