WO2016153994A1

WO2016153994A1 - Generating electricity by fluid movement

Info

Publication number: WO2016153994A1
Application number: PCT/US2016/023123
Authority: WO
Inventors: Remy PANARIELLO; Rogerio Tadeu Ramos
Original assignee: Schlumberger Technology Corporation; Schlumberger Canada Limited; Services Petroliers Schlumberger; Schlumberger Technology B.V.
Priority date: 2015-03-22
Filing date: 2016-03-18
Publication date: 2016-09-29

Abstract

A device for generating electricity by fluid movement includes a fluid-driven electrical generator (e.g., a turbine) located along a central shaft. The generator may generate electricity while fluid is flowing over it, such as while tripping into or out of a hole.

Description

GENERATING ELECTRICITY BY FLUID MOVEMENT

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of and priority to U.S. Provisional Application Serial No.: 62/136,598, filed March 22, 2015, which is incorporated herein by reference in its entirety.

BACKGROUND

Oil wells are created by drilling a hole into the earth, in some cases using a drilling rig that rotates a drill string (e.g., drill pipe) having a drill bit attached thereto. In other cases, the drilling rig does not rotate the drill bit. For example, the drill bit can be rotated downhole. The drill bit, aided by the weight of pipes (e.g., drill collars) cuts into rock within the earth. Drilling fluid (e.g., mud) is pumped into the drill pipe and exits at the drill bit. The drilling fluid may be used to cool the bit, lift rock cuttings to the surface, at least partially prevent destabilization of the rock in the wellbore, and/or at least partially overcome the pressure of fluids inside the rock so that the fluids do not enter the wellbore. Other equipment can also be used for evaluating formations, fluids, production, other operations, and so forth.

Downhole equipment can be powered by remote energy sources that power the equipment via transmission lines (e.g., electrical, optical, mechanical, or hydraulic transmission lines). Downhole equipment can also be powered by local energy sources such as local generators or energy storage devices (e.g., battery packs) coupled with the equipment. In some cases, rechargeable energy storage devices (e.g., rechargeable battery cells or packs) are used to power downhole equipment.

SUMMARY

Aspects of the disclosure can relate to a device for generating electricity by fluid movement, e.g., while tripping into or out of a hole. In embodiments, the device can include a fluid-driven electrical generator (e.g., a turbine) located along a central shaft. The device can further include a fluid diverter located along the central shaft, the fluid diverter being configured to alter movement of fluid within a hole, e.g., while the central shaft is tripping into or out of the hole, to cause the fluid to flow towards the fluid-driven electrical generator in a path suitable for driving the fluid-driven electrical generator to generate electricity.

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

FIGURES

Embodiments of a device for generating electricity by fluid movement are described with reference to the following figures. The same numbers are used throughout the figures to reference like features and components.

FIG. 1 illustrates an example system in which embodiments of a device for generating electricity by fluid movement while tripping can be implemented.

FIG. 2 illustrates various components of an example device that can implement embodiments of a device for generating electricity by fluid movement while tripping.

FIG. 3 illustrates various components of an example device that can implement embodiments of a device for generating electricity by fluid movement while tripping. DETAILED DESCRIPTION

FIG. 1 depicts a wellsite system 100 in accordance with one or more embodiments of the present disclosure. The wellsite can be onshore or offshore. A borehole 102 is formed in subsurface formations by directional drilling. A drill string 104 extends from a drill rig 106 and is suspended within the borehole 102. In some embodiments, the wellsite system 100 implements directional drilling using a rotary steerable system (RSS). For instance, the drill string 104 is rotated from the surface, and down hole devices move the end of the drill string 104 in a desired direction. The drill rig 106 includes a platform and derrick assembly positioned over the borehole 102. In some embodiments, the drill rig 106 includes a rotary table 108, kelly 110, hook 112, rotary swivel 114, and so forth. For example, the drill string 104 is rotated by the rotary table 108, which engages the kelly 110 at the upper end of the drill string 104. The drill string 104 is suspended from the hook 112 using the rotary swivel 114, which permits rotation of the drill string 104 relative to the hook 112. However, this configuration is provided by way of example and is not meant to limit the present disclosure. For instance, in other embodiments a top drive system is used.

A bottom hole assembly (BHA) 116 is suspended at the end of the drill string 104. The bottom hole assembly 116 includes a drill bit 118 at its lower end. In embodiments of the disclosure, the drill string 104 includes a number of drill pipes 120 that extend the bottom hole assembly 116 and the drill bit 118 into subterranean formations. Drilling fluid (e.g., mud) 122 is stored in a tank and/or a pit 124 formed at the wellsite. The drilling fluid can be water-based, oil- based, and so on. A pump 126 displaces the drilling fluid 122 to an interior passage of the drill string 104 via, for example, a port in the rotary swivel 114, causing the drilling fluid 122 to flow downwardly through the drill string 104 as indicated by directional arrow 128. The drilling fluid 122 exits the drill string 104 via ports (e.g., courses, nozzles) in the drill bit 118, and then circulates upwardly through the annulus region between the outside of the drill string 104 and the wall of the borehole 102, as indicated by directional arrows 130. In this manner, the drilling fluid 122 cools and lubricates the drill bit 118 and carries drill cuttings generated by the drill bit 118 up to the surface (e.g., as the drilling fluid 122 is returned to the pit 124 for recirculation).

In some embodiments, the bottom hole assembly 116 includes a logging-while-drilling (LWD) module 132, a measuring-while-drilling (MWD) module 134, a rotary steerable system 136, a motor, and so forth (e.g., in addition to the drill bit 118). The logging-while-drilling module 132 can be housed in a drill collar and can contain one or a number of logging tools. It should also be noted that more than one LWD module and/or MWD module can be employed (e.g. as represented by another logging-while-drilling module 138). In embodiments of the disclosure, the logging-while drilling modules 132 and/or 138 include capabilities for measuring, processing, and storing information, as well as for communicating with surface equipment, and so forth. The measuring-while-drilling module 134 can also be housed in a drill collar, and can contain one or more devices for measuring characteristics of the drill string 104 and drill bit 118. The measuring- while-drilling module 134 can also include components for generating electrical power for the down hole equipment. This can include a mud turbine generator (also referred to as a "mud motor") powered by the flow of the drilling fluid 122. However, this configuration is provided by way of example and is not meant to limit the present disclosure. In other embodiments, other power and/or battery systems can be employed. The measuring- while-drilling module 134 can include one or more of the following measuring devices: a weight-on-bit measuring device, a torque measuring device, a vibration measuring device, a shock measuring device, a stick slip measuring device, a direction measuring device, an inclination measuring device, and so on.

In embodiments of the disclosure, the wellsite system 100 is used with controlled steering or directional drilling. For example, the rotary steerable system 136 is used for directional drilling. As used herein, the term "directional drilling" describes intentional deviation of the wellbore from the path it would naturally take. Thus, directional drilling refers to steering the drill string 104 so that it travels in a desired direction. In some embodiments, directional drilling is used for offshore drilling (e.g., where multiple wells are drilled from a single platform). In other embodiments, directional drilling enables horizontal drilling through a reservoir, which enables a longer length of the wellbore to traverse the reservoir, increasing the production rate from the well. Further, directional drilling may be used in vertical drilling operations. For example, the drill bit 118 may veer off of a planned drilling trajectory because of the unpredictable nature of the formations being penetrated or the varying forces that the drill bit 118 experiences. When such deviation occurs, the wellsite system 100 may be used to guide the drill bit 118 back on course.

Drill assemblies can be used with, for example, a wellsite system (e.g., the wellsite system 100 described with reference to FIG. 1). For instance, a drill assembly can comprise a bottom hole assembly suspended at the end of a drill string (e.g., in the manner of the bottom hole assembly 116 suspended from the drill string 104 depicted in FIG. 1). In some embodiments, a drill assembly is implemented using a drill bit. However, this configuration is provided by way of example and is not meant to limit the present disclosure. In other embodiments, different working implement configurations are used. Further, use of drill assemblies in accordance with the present disclosure is not limited to wellsite systems described herein. Drill assemblies can be used in other various cutting and/or crushing applications, including earth boring applications employing rock scraping, crushing, cutting, and so forth.

A drill assembly includes a body for receiving a flow of drilling fluid. The body comprises one or more crushing and/or cutting implements, such as conical cutters and/or bit cones having spiked teeth (e.g., in the manner of a roller-cone bit). In this configuration, as the drill string is rotated, the bit cones roll along the bottom of the borehole in a circular motion. As they roll, new teeth come in contact with the bottom of the borehole, crushing the rock immediately below and around the bit tooth. As the cone continues to roll, the tooth then lifts off the bottom of the hole and a high-velocity drilling fluid jet strikes the crushed rock chips to remove them from the bottom of the borehole and up the annulus. As this occurs, another tooth makes contact with the bottom of the borehole and creates new rock chips. In this manner, the process of chipping the rock and removing the small rock chips with the fluid jets is continuous. The teeth intermesh on the cones, which helps clean the cones and enables larger teeth to be used. A drill assembly comprising a conical cutter can be implemented as a steel milled-tooth bit, a carbide insert bit, and so forth. However, roller-cone bits are provided by way of example and are not meant to limit the present disclosure. In other embodiments, a drill assembly is arranged differently. For example, the body of the bit comprises one or more polycrystalline diamond compact (PDC) cutters that shear rock with a continuous scraping motion. In embodiments of the disclosure, the body of a drill assembly can define one or more nozzles that allow the drilling fluid to exit the body (e.g., proximate to the crushing and/or cutting implements). The nozzles allow drilling fluid pumped through, for example, a drill string to exit the body. For example, drilling fluid can be furnished to an interior passage of the drill string by the pump and flow downwardly through the drill string to a drill bit of the bottom hole assembly, which can be implemented using, for example, a drill assembly. Drilling fluid then exits the drill string via nozzles in the drill bit, and circulates upwardly through the annulus region between the outside of the drill string and the wall of the borehole. In this manner, rock cuttings can be lifted to the surface, destabilization of rock in the wellbore can be at least partially prevented, the pressure of fluids inside the rock can be at least partially overcome so that the fluids do not enter the wellbore, and so forth.

Modern oil and gas exploration increasingly uses electronic devices in the borehole to provide measurements, and for control and operational optimization. When operating electronics as part of a drill string and/or other downhole equipment and/or strings (e.g., for well testing, well simulation, well monitoring, formation evaluation, etc.), available power in the borehole may be limited near a bottom hole assembly. Energy storage devices (e.g., battery cells, battery packs, capacitors, energy cells, and the like) can also be installed in electronic equipment to provide electrical power in a borehole. Yet, batteries have a finite energy storage capacity, which limits the amount of time the equipment can be operated. In some cases, larger batteries may be used, but the amount of space available in the borehole is also finite, limiting the size of such batteries. In other cases, higher power density batteries may be used, but such batteries may be more prone to failure (e.g., in the high temperature operating conditions present downhole).

FIG. 2 illustrate an embodiment of a device 200 for generating electricity, e.g., while tripping. The term "tripping" often refers to the act of running a drill string into or pulling a drill string out of a wellbore. Tripping pipe can be performed for a variety of reasons. For example reasons for tripping pipe can include replacing a worn-out drill bit, replacing damaged drill pipe, repairing downhole equipment, and so forth. As used herein, the term "tripping" can include any travel into or out of a hole (e.g., wellbore). For example, tripping the device 200 into the hole can include lowering the device 200 downwards to a depth within the hole, and tripping the device 200 out of the hole can include raising the device 200 upwards towards the surface from a depth within the hole. In embodiments, the device 200 can be implemented in a drill string. For example, the device 200 can be included in or coupled to the bottom hole assembly 116.

Referring to FIGS. 1 and 2, a bottom hole assembly 116 can include downhole equipment powered by the device 200 with electricity generated by the device 200, e.g., while tripping, or with electricity from an energy storage device that can be recharged by the device 200 while the bottom hole assembly 116 is, e.g., tripping into or out of a hole (e.g., a wellbore). For example, downhole equipment powered by the device 200 or by a rechargeable energy storage device can include a sensor, an actuator (e.g., motor, servo, or switch), a transmitter, a receiver, a controller, or the like. In some embodiments, the downhole equipment can include one or more components of the logging-while-drilling (LWD) module 132, the measuring-while-drilling (MWD) module 134, the rotary steerable system 136, and so forth. In some embodiments, the device 200 can be used to heat energy storage devices while tripping in or tripping out of the hole. For example, downhole batteries can be manufactured to withstand high temperatures (e.g., above 100°C), but these batteries may not work well at lower temperatures (e.g., below 50 °C). The electricity generated by the device 200 while tripping can be used to heat batteries to an effective operating temperature. The device 200 can be directly coupled (e.g., via a wired connection) to an energy storage device or downhole equipment. The device 200 can also be optically or electromagnetically coupled with the energy storage device or the downhole equipment. Although a wellsite drilling system 100 is described herein, those skilled in the art will appreciate that any system can include electronic equipment (e.g., sensors, actuators, communication devices, controllers, energy storage device, or the like) which may be powered by the device 200 with electricity generated by the device 200 while tripping or with electricity from an energy storage device that can be recharged by the device 200 while tripping into or out of a hole, through a tunnel, or any other passage having at least one inner surface.

In an embodiment shown in FIG. 2, the device 200 is shown within a wellbore 201. The device 200 includes a shaft 202 carrying at least one fluid-driven electrical generator 204 (e.g., turbine). When the shaft 202 (e.g., portion of a drill string) is lowered or lifted from a well for any reason, such as replacing a drill bit, there is a differential velocity between the fluid in the wellbore 201 and the shaft 202. The fluid (e.g., mud) can be used to activate the fluid-driven electrical generator 204. For example, when a wellbore 201 is drilled, there is normally an annular gap between the drill string and the wellbore wall. This annular gap can be used for the circulation of drilling mud in order to bring cuttings up to the surface. When mud circulation stops, the fluid or mud in the annular space stops moving in relation to the wellbore 201. When the shaft 202 is tripping, the fluid flow (e.g., mud flow) can be directed towards or through the fluid-driven electrical generator 204 in a path suitable for driving the fluid-driven electrical generator 204 to generate electricity. In some embodiments, the fluid-driven electrical generator 204 may be a turbine, for example, where the fluid can be directed along a path such that the fluid exerts a driving force on one or more blades of the turbine and induces a rotation, thereby causing the turbine to generate electricity.

In some embodiments, the fluid-driven electrical generator 204 can be at least partially enclosed by a guard structure 203. The guard structure 203 can protect the fluid-driven electrical generator 204 external against mechanical shocks and wear and prevent contact between fluid- driven electrical generator 204 and the wellbore 201. The guard structure 203 can also be configured to force the fluid towards or through the fluid-driven electrical generator 204 in a path suitable for driving the fluid-driven electrical generator 204 to generate electricity. In this regard, the guard structure 203 can be operable as a fluid diverter to alter movement of fluid within the wellbore 201 while the central shaft is tripping into or out of the wellbore 201 to cause the fluid to flow towards the fluid-driven electrical generator 204 in a path suitable for driving the fluid-driven electrical generator 204 to generate electricity.

Flow of drilling fluid in the annulus (between the wellbore 201 and the shaft 202) can be utilized to generate electricity when the fluid is flowing relative to the generator, e.g., while tripping or while fluid is being circulated. As such, while the above has been described with reference to generating electricity during tripping, in addition, electricity may also be generated while fluid is flowing over the generator, e.g., while a fluid such as mud is being circulated during drilling. The generator may be located at an exterior of the drill pipe, and the flow of circulating fluid over the generator, e.g., over blades of a turbine, generates electricity. FIG. 3 illustrates another embodiment of a device 300 for generating electricity, e.g., while tripping. Embodiments of device 300 can include one or more portions of device 200 as described in accordance with embodiments of this disclosure. Embodiments of device 200 can also include one or more portions of device 300 as described in accordance with embodiments of this disclosure. It should be further understood that any reference herein to device 200 or device 300 can apply to embodiments of either device.

Referring now to FIG. 3, when a wellbore 301 is drilled, there is normally an annular gap between the drill string 302 and the wellbore wall. This annular gap can be used for the circulation of drilling mud in order to bring cuttings up to the surface. When mud circulation stops, the fluid or mud in the annular space stops moving in relation to the wellbore 301. Then the drill string 302 is tripping into or out of the wellbore 301, for example, to replace a drill bit 306 or other downhole equipment, resulting in a differential velocity between the fluid in the wellbore 301 and the drill string 302.

In embodiments, the device 300 includes a fluid diverter assembly that can include a fluid restrictor 303 proximate to a fluid-driven electrical generator (e.g., fluid-driven electrical generator 204) (not shown in FIG. 3). The fluid restrictor 303 can be inflated, extended, expanded, or otherwise deployed to restrict the annular space, at least partially preventing fluid from flowing around the fluid-driven electrical generator without imparting a driving force on the fluid-driven electrical generator. In embodiments, the fluid restrictor 303 can include at least one inflatable member, one or more actuatable flaps configured to extend outwards from the drill string 302 when deployed, a retractable basket-like or disk-shaped surface configured to expand outwards about the drill string 302 when deployed, or the like.

In embodiments, the fluid diverter assembly further includes one or more openings (e.g., openings 304 and 305) in a shaft located along the drill string 302. The one or more openings can be configured to direct at least a portion of the fluid through the shaft towards the fluid-driven electrical generator. For example, the one or more openings can include at least a first opening 304 located on the shaft before the fluid-driven electrical generator and at least a second opening 305 located on the shaft after the fluid-driven electrical generator. In some embodiments, the one or more openings are configured to be selectively sealed or unsealed by one or more valves coupled to the one or more openings. For example, two valves, one on either side of the fluid restrictor 303 and the fluid-driven electrical generator can be opened while the fluid restrictor 303 is activated or deployed. The valves then create a direct path to the diverted fluid towards or through the fluid- driven electrical generator in a path suitable for driving the fluid-driven electrical generator to generate electricity. For example, fluid can be forced into one of the valves/openings (e.g., upper or lower valve/opening depending on the direction of the tripping) into an appropriate path for driving the fluid-driven electrical generator and out through the other valve/opening, thereby causing the fluid-driven electrical generator (e.g., turbine to generate electricity).

In embodiments, the device 300 or a system implementing the device 300 can include control circuitry (e.g., a processor, microcontroller, programmable logic device, ASIC, or the like) that is configured to control the fluid restrictor 303 and/or the one or more valves (e.g., valves 304 and 305). For example, the control circuitry may be configured to drive one or more actuators (e.g., motors, servos, linear actuators, electromechanical switches, or the like) that cause the fluid restrictor 303 to deploy and retract and/or one or more actuators (e.g., motors, servos, linear actuators, electromechanical switches, or the like) that cause the valves (e.g., valves 304 and 305) to open and close in response to a received command or one or more sensor outputs (e.g., indications that the drill string is tripping, battery capacity levels, temperature readings, and so forth). Although a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from a device for generating electricity by fluid movement while tripping into or out of a hole as described above. Additionally, it should be understood that references to "one embodiment" or "an embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, features shown in individual embodiments referred to above may be used together in combinations other than those which have been shown and described specifically. Accordingly, any such modification is intended to be included within the scope of this disclosure. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not just structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke means-plus-function for any limitations of any of the claims herein, except for those in which the claim expressly uses the words 'means for' together with an associated function.

Claims

What is claimed is:

1. A device, comprising:

a central shaft; and

a turbine located along the central shaft, the turbine being configured to generate electricity when fluid comes into contact with and actuates one or more blades of the turbine while the turbine is tripping into or out of a hole.

2. The device as recited in claim 1, further comprising a guard structure at least partially encasing the turbine.

3. The device as recited in claim 1, further comprising a fluid diverter located along the central shaft, the fluid diverter being configured to alter movement of fluid within a hole while the central shaft is tripping into or out of the hole to cause the fluid to flow into contact with the one or more blades of the turbine.

4. The device as recited in claim 3, wherein the fluid diverter includes a fluid restrictor proximate to the turbine, the fluid restrictor being configured to at least partially prevent fluid from flowing around the turbine without coming into contact with the one or more blades.

5. The device as recited in claim 4, wherein the fluid restrictor comprises at least one of an inflatable member, one or more actuatable flaps configured to extend outwards from the central shaft when deployed, or a retractable basket-like or disk- shaped surface configured to expand outwards about the central shaft when deployed.

6. The device as recited in claim 4, wherein the fluid diverter further includes one or more openings in the central shaft configured to direct at least a portion of the fluid through the central shaft towards the turbine.

7. The device as recited in claim 6, wherein the one or more openings include at least a first opening on the central shaft before the turbine and at least a second opening on the central shaft after the turbine.

8. The device as recited in claim 6, wherein the one or more openings are configured to be selectively sealed or unsealed by one or more valves coupled to the one or more openings.

9. The device as recited in claim 4, further comprising control circuitry configured to activate or deactivate the fluid diverter.

10. A device, comprising:

a central shaft;

a fluid-driven electrical generator located along the central shaft; and

a fluid diverter located along the central shaft, the fluid diverter being configured to alter movement of fluid within a hole while the central shaft is tripping into or out of the hole to cause the fluid to flow towards the fluid-driven electrical generator in a path suitable for driving the fluid-driven electrical generator to generate electricity.

11. The device as recited in claim 10, wherein the fluid-driven electrical generator is configured to power downhole equipment or charge an energy storage device with the electricity generated by the fluid-driven electrical generator while tripping into or out of the hole.

12. The device as recited in claim 10, wherein the fluid diverter includes a fluid restrictor proximate to the fluid-driven electrical generator, the fluid restrictor being configured to at least partially prevent fluid from flowing around the fluid-driven electrical generator without imparting a driving force on the fluid-driven electrical generator.

13. The device as recited in claim 12, wherein the fluid restrictor comprises at least one of an inflatable member, one or more actuatable flaps configured to extend outwards from the central shaft when deployed, or a retractable basket- like or disk- shaped surface configured to expand outwards about the central shaft when deployed.

14. The device as recited in claim 10, wherein the fluid diverter further includes one or more openings in the central shaft configured to direct at least a portion of the fluid through the central shaft towards the fluid-driven electrical generator.

15. The device as recited in claim 14, wherein the one or more openings include at least a first opening on the central shaft before the fluid-driven electrical generator and at least a second opening on the central shaft after the fluid-driven electrical generator and the one or more openings are configured to be selectively sealed or unsealed by one or more valves coupled to the one or more openings.

16. The device as recited in claim 10, wherein the fluid-driven electrical generator comprises a turbine.

17. A system, comprising:

downhole equipment; and

the device recited in any of the preceding claims, wherein the device is configured to generate electricity for utilization by the downhole equipment while the downhole equipment and the device are tripping into or out of a hole.

18. The system as recited in claim 17, further comprising an energy storage device coupled to the device and the downhole equipment, wherein the device is configured to charge the energy storage device with the generated electricity.

19. The system as recited in claim 18, wherein the energy storage device is configured to power the downhole equipment.

20. The system as recited in claim 18, wherein the energy storage device comprises at least one of: a rechargeable battery cell, a rechargeable battery pack, or a capacitor.

21. The system as recited in claim 17, wherein the downhole equipment comprises at least one of: a sensor, an electrical motor, a transmitter, a receiver, a controller, or an energy storage device.

22. A method, comprising:

introducing a shaft carrying a fluid-driven electrical generator into a hole; and

diverting fluid within the hole from a first fluid path to a second fluid path towards the fluid-driven electrical generator while tripping the shaft into or out of the hole, thereby causing the fluid-driven electrical generator to generate electricity.

23. The method as recited in claim 22, further comprising:

powering downhole equipment with the generated electricity or charging an energy storage device with the generated electricity.

24. The method as recited in claim 22, wherein the fluid-driven electrical generator comprises a turbine.

25. A device, comprising:

a central shaft; and

a turbine located along an outside of the central shaft, the turbine being configured to generate electricity when fluid comes into contact with and actuates one or more blades of the turbine.