U.S. patent application number 10/896386 was filed with the patent office on 2006-01-26 for methods and apparatus for in situ generation of power for devices deployed in a tubular.
Invention is credited to Clark J. Bergeron, Charles A. Cantrelle, Scott L. Kruegel, Paulo S. Tubel.
Application Number | 20060016606 10/896386 |
Document ID | / |
Family ID | 35655917 |
Filed Date | 2006-01-26 |
United States Patent
Application |
20060016606 |
Kind Code |
A1 |
Tubel; Paulo S. ; et
al. |
January 26, 2006 |
Methods and apparatus for in situ generation of power for devices
deployed in a tubular
Abstract
A device, system, and methods of power generation in situ in a
hydrocarbon well are disclosed. A power generator for deployment in
a hydrocarbon well tubular may comprise a housing adapted for
deployment within a hydrocarbon well tubular; a mechanical to
electrical power converter disposed at least partially within the
housing, the mechanical to electrical power converter adapted to
create an electric current when physically stressed; and a current
converter operatively coupled to the mechanical to electrical power
converter. Devices may be deployed downhole and operatively coupled
to the power generator for their electrical power. It is emphasized
that this abstract is provided to comply with the rules requiring
an abstract which will allow a searcher or other reader to quickly
ascertain the subject matter of the technical disclosure. It is
submitted with the understanding that it will not be used to
interpret or limit the scope of meaning of the claims.
Inventors: |
Tubel; Paulo S.; (The
Woodlands, TX) ; Cantrelle; Charles A.; (The
Woodlands, TX) ; Kruegel; Scott L.; (The Woodlands,
TX) ; Bergeron; Clark J.; (The Woodlands,
TX) |
Correspondence
Address: |
DUANE, MORRIS, LLP
3200 SOUTHWEST FREEWAY
SUITE 3150
HOUSTON
TX
77027
US
|
Family ID: |
35655917 |
Appl. No.: |
10/896386 |
Filed: |
July 22, 2004 |
Current U.S.
Class: |
166/386 ;
166/177.6; 166/65.1 |
Current CPC
Class: |
E21B 41/0085
20130101 |
Class at
Publication: |
166/386 ;
166/177.6; 166/065.1 |
International
Class: |
E21B 29/02 20060101
E21B029/02 |
Claims
1. A power generator for deployment in a hydrocarbon well tubular,
comprising: a. a housing adapted for deployment within a
hydrocarbon well tubular; and b. a mechanical to electrical power
converter disposed at least partially within the housing, the
mechanical to electrical power converter adapted to create an
electric current when physically stressed by a force present within
the hydrocarbon well tubular
2. The power generator of claim 1, wherein the mechanical to
electrical power converter comprises stressable material, further
comprising at least one of (i) a piezoelectric material or (ii) a
magneto-restrictive material.
3. The power generator of claim 1, further comprising a current
converter operatively coupled to the mechanical to electrical power
converter.
4. The power generator of claim 3, wherein the current converter
comprises at least one of (i) an alternating current to direct
current converter or (ii) a direct current to alternating current
converter.
5. The power generator of claim 1, further comprising a mechanical
vibration amplifier operatively coupled to the mechanical to
electrical power converter and adapted to increase power generated
by the mechanical to electrical power converter.
6. The power generator of claim 1, further comprising a power
storage medium.
7. The power generator of claim 6, wherein the power storage medium
comprises at least one of (i) a battery pack or (ii) a capacitor
bank.
8. The power generator of claim 1, further comprising an inductor
operatively coupled to the mechanical to electrical power
converter, the inductor adapted to cancel a capacitive part of
impedance of the mechanical to electrical power converter.
9. The power generator of claim 8, wherein the cancellation
minimizes the impedance.
10. A power generator, comprising: a. a mechanical vibration
amplifier; b. a mechanical to electrical power converter
operatively coupled to the mechanical vibration amplifier and
adapted to create an electrical current when vibrated; c. a power
conditioner operatively coupled to the power converter; and d. a
power storage medium operatively coupled to the power
converter.
11. The power generator of claim 10, further comprising a coating
adapted to retard erosion of a predetermined portion the power
module.
12. The power generator of claim 11, wherein: a. the coating
comprises a ceramic; and b. the predetermined portion of the power
module comprises the mechanical to electrical power converter.
13. The power generator of claim 10, wherein the mechanical to
electrical power converter is adapted to be deployed at least
partially within the tubular and to be exposed to hydrocarbon flow
within the tubular.
14. The power generator of claim 10, wherein: a. the power module
comprises a doughnut shaped design; and b. the mechanical to
electrical power converter is disposed in a pressure balanced
apparatus as part of a downhole tool.
15. The power generator of claim 14, further comprising a pressure
bellows operatively coupled to the mechanical to electrical power
converter and adapted to cause a force to be exerted onto the
mechanical to electrical power converter in the presence of fluid
flowing in the tubular.
16. The power generator of claim 10, wherein: a. the power module
comprises a plurality of housings; and b. the mechanical to
electrical power converter comprises a plurality of the mechanical
to electrical power converter, each housing at least partially
containing one of the plurality of mechanical to electrical power
converters.
17. A method of generating power from within a tubular, comprising:
a. deploying a power generator within a tubular, the power
generator comprising a mechanical vibration amplifier, a mechanical
to electrical power converter, a power conditioner, and a power
storage medium; b. operatively coupling the power generator to a
source of vibration; and c. providing an outlet for electricity
generated by the power generator.
18. The method of claim 17, further comprising operatively coupling
a device within the tubular that requires electric power to the
outlet of the power generator.
19. The method of claim 18, wherein the device is an acoustic
generator adapted to vibrate the tubular.
20. A system for downhole control, comprising: a. a control module
adapted to be deployed downhole; b. a wireless transceiver
operatively in communication with the control module, the wireless
transceiver adapted to be deployed downhole; and c. a power
generator operatively coupled to the wireless transceiver, the
power generator comprising a stressable material adapted to create
an electric current when physically stressed.
21. The system of claim 20, wherein the system is adapted for use
with an intelligent completion system.
22. The system of claim 21, wherein the control module comprises at
least one of (i) a sensor, (ii) a gauge, (iii) a meter, or (iv) a
flow control device.
23. The system of claim 20, wherein the transceiver comprises at
least one if (i) an active transceiver or (ii) a repeater.
24. The system of claim 20, wherein the power generator is adapted
for use as a separate power station to be deployed as part of a
production tubing and is further adapted to be used to generate and
store power to be transferred to a mobile system temporarily
attached to the power generator.
25. The system of claim 20, wherein the power generator is deployed
through tubing for use with at least one of (i) a permanent service
in the wellbore or (ii) a system that performs a temporary service
in the wellbore.
26. The system of claim 20, wherein the system is adapted for
deployment at a subsea level at a hydrocarbon transmission pipeline
to provide information related to the flow of hydrocarbon through
the pipeline, the information comprising at least one of (i)
pressure, (ii) temperature, or (iii) flow.
27. The system of claim 20, wherein: a. fluid flowing in a downhole
pipe creates a vibration usable by the stressable material to allow
generation of electricity by the stressable material; and b. the
electricity generated is used to power a sensor operatively in
communication with the power generator.
28. The system of claim 20, wherein: a. the system is disposed
proximate a subsea wellhead and control assembly to generate
electricity as hydrocarbons flow from downhole to a surface
location; and b. electrical power generated by the power generator
provides at least partial power for electronics and
electromechanical devices located proximate the subsea
wellhead.
29. A method of deploying a downhole tool, comprising: a. deploying
a control module downhole; b. deploying a wireless transceiver
downhole, the wireless transceiver operatively in communication
with the control module; c. deploying a power generator downhole,
the power generator operatively coupled to the wireless
transceiver, the power generator comprising a stressable material
adapted to create an electric current when physically stressed; d.
exposing the power generator to a source of physical stress
downhole; and e. generating electrical current using the power
generator when exposed to the physical stress.
30. The method of claim 29, wherein the physical stress is obtained
using vibration generated at least partially by production
flow.
31. The method of claim 29, wherein the power generator comprises
at least one of (i) a piezoelectric material or (ii) a
magentoresistive material.
32. The method of claim 29, wherein the power generator comprises a
power storage system deployed downhole.
33. The method of claim 32, further comprising storing a portion of
the electricity generated by the power system in the power storage
system deployed downhole.
Description
FIELD OF THE INVENTION
[0001] The inventions are related to generation of electrical power
within a tubular. More specifically, the inventions are related to
generation of electrical power within a hydrocarbon well tubular
for use with electrically power devices also deployed in the
hydrocarbon well.
BACKGROUND OF THE INVENTION
[0002] For decades, operators have opened and closed valves across
producing zones and used electrical cables for communications and
power delivery for gauges deployed in the well. The idea was
generally to allow a primary zone to produce to the end of its life
and then to open a second zone for access to additional reserves.
Traditionally, these valves were opened and closed mechanically
through wireline. Such interventions, in shallow waters or onshore,
are relatively inexpensive operations and usually involve only
minimal loss of production time.
[0003] As the industry moved farther offshore, the cost of support
vessels for such operations and the complexity of re-entering
subsea wells soon combined to make the cost of intervention
sufficiently high as to scuttle the economics of any but the most
significant secondary reserves.
[0004] Over time, traditional mechanical actuation was replaced
with remotely actuated hydraulics systems. The hydraulic systems
deployment complexities have likely contributed to several failures
offshore during the past few years, leading many service companies
to the conclusion that, while hydraulics have their place,
all-electric systems are the future of intelligent completions.
Typically, electrical cables have been used to provide power and
communications for gauges and flow control devices in the wellbore,
raising the completions costs significantly. Cables are also one of
the major sources of failures that impact the production of
hydrocarbons. These failures created the risk of not being able to
control the flow valve and to lose the ability to acquire data from
downhole affecting the operator's ability to optimize
production.
[0005] In addition, the high costs and risks of wellhead design
with cable entrance capability as well as downhole hardware
deployment with cable feedthrough connectors make the deployment of
intelligent completions and gauges uneconomical.
[0006] It would therefore be desirable to eliminate surface system
power generators and power cables running from the surface to allow
smaller intelligent completions systems that can be deployed deeper
in wellbores due to no losses through cables and elimination of
flyback currents on cables. Such systems may further allow sensors
to be deployed in well zones that may have not been accessible
using electrical cables, e.g. using wireless communications modules
powered by downhole power generators.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The features, aspects, and advantages of the present
invention will become more fully apparent from the following
description, appended claims, and accompanying drawings in
which:
[0008] FIG. 1 is a block diagram of an exemplary embodiment of a
power generator;
[0009] FIG. 2 is a block diagram of an exemplary embodiment of a
power generator;
[0010] FIG. 3 is a partial perspective of an exemplary doughnut
shaped configuration;
[0011] FIG. 4 is a partial perspective of a second exemplary
configuration;
[0012] FIG. 5 is a partial perspective of an exemplary system in
partial cutaway illustrating use of the power generator in a system
downhole; and
[0013] FIG. 6 is a flowchart of an exemplary method.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0014] Referring now to FIG. 1, downhole power generator 50 may be
configured to be actuated downhole and used to generate electricity
in well 10 (FIG. 5), e.g. by using stressable material 52 such as
piezoelectric or magneto-restrictive stressable material 52.
Downhole power generator 50 may provide for direct action between
wellbore fluid flow and stressable material 52 to generate
electrical energy and may be used to help eliminate inefficiencies
related to picking up pressure fluctuations occurring inside the
tubing walls.
[0015] The main sources of energy in a wellbore include flow,
vibration, pressure, and noise. Power generator 50 may be used to
provide a non-movable or sealed hardware approach to harness or
otherwise use the energy. In a preferred method, force generated by
the flow is routed to power generator 50 which converts the
mechanical motion of the force into electrical energy.
[0016] Power generator 50 may comprise housing 74 which has been
adapted for deployment within a hydrocarbon well tubular and in
which a mechanical-to-electrical-power converter, e.g. power
converter 51, current converter 72, and/or power storage medium 73,
are at least partially disposed.
[0017] Mechanical to electrical power converter 51 will comprise
stressable material 52 that, when stressed, creates an electrical
current, e.g. by a stack of piezoelectric, magneto-restrictive
material or any other material that would cause vibration near the
power generator area. In currently preferred embodiments,
stressable material 52 is either piezoelectric or
magneto-restrictive material that will be stressed by the flow
vibration created in the well. For example, stressable material 52
may be stressed by the vibration of the production tubing in the
well, by the force exerted by the flow in the well, or by the
generation of acoustic signals at downhole wireless gauges.
[0018] Mechanical to electrical power converter 51 will typically
convert vibrational stress to alternating current. In experimental
environments involving piezoelectric material, the amplitude and
frequency of the induced voltage was found to be directly
proportional to the mechanical deformation of the piezoelectric
material. The electrical charges developed by stressing the
piezoelectric material decayed with time because of the internal
resistance. Experiments performed in the past have indicated that
at a one kilohertz frequency a power output of as much as one
hundred watts per cubic centimeter and efficiency of as high as
seventy percent has been obtained from piezoelectric material.
[0019] Current converter 72 may be used to convert alternative
current produced by stressable material 52 into direct current for
storage in power storage medium 73, e.g. a capacitor bank or a
rechargeable battery pack.
[0020] In some embodiments, power generator 50 will include
mechanical vibration amplifier 70 that will interface with
stressable material 52. Mechanical vibration amplifier 70 may
comprise a mechanical vibration amplifier to provide a higher level
of vibration to increase the power generation capability of power
generator 50. For example, mechanical vibration amplifier 70 may be
used to directly or augmentingly compress and release stressable
material 52 to generate electricity.
[0021] In a currently preferred embodiment, piezoelectric
assemblies 52 are mounted on the inside of tubing 10 (FIG. 5) and
exposed to hydrostatic pressure in the well. A ceramic coating may
be used to coat stressable material 52 to prevent or otherwise
inhibit erosion as the hydrocarbons flow by stressable material 52.
The ceramic coating application to stressable material 52, e.g. a
piezoelectric assembly, may be performed at room temperature which
helps eliminate concerns and problems related to applying coatings
at extremely high temperatures that could damage stressable
material 52.
[0022] Referring now to FIG. 2, downhole power generator 50 may be
used to provide a direct interaction between the wellbore fluid
flow and stressable material 52, e.g. a piezoelectric stack, to
generate energy. One or more electronics modules may be required to
gather, rectify, and store the energy generated by stressable
material 52.
[0023] In a preferred embodiment, power conditioner 53 comprises
rectifier 53, tank circuit 54, harvester 55 and regulator 56. An
inductor may be operatively coupled to mechanical to electrical
power converter 51, the inductor adapted to cancel a capacitive
part of impedance of the mechanical to electrical power converter
51. This cancellation may minimize the impedance.
[0024] Power conditioner 53 may comprise a rectifier or bridge.
[0025] Tank circuit 54 may be present to accept the output of power
conditioner 53 and act as a voltage regulator, e.g. a voltage
doubler. The output of tank circuit 54 may be routed to one or more
additional power conditioners. For example, the output of tank
circuit 54 may be routed to power harvester 55, which may include a
harvesting monitor switch, and then on to voltage regulator 56.
[0026] Electrical energy may be stored in storage medium 73 which
may include a capacitor bank, a rechargeable battery pack, or the
like, or a combination thereof.
[0027] Electrical energy, once generated and processed, e.g. by the
circuitry illustrated in FIG. 2, may then be made available though
numerous pathways, e.g. via wire or coaxial cable to one or more
tools such as acoustic tool 60.
[0028] Referring now to FIG. 3, downhole power generator 10 may be
configured in a doughnut or substantially toroid shape design, e.g.
where stressable material 52 is located in pressure balanced
apparatus 58 as part of a downhole tool. Hydrocarbon flow can
impact pressure bellows 59 coupled to downhole power generator 10
(FIG. 1) causing a force to be exerted onto stressable material 52
due to flow, causing electricity to be created. Note that only a
few pressure bellows 59 and that only a few stressable materials 52
are marked in FIG. 3.
[0029] Referring now to FIG. 4, downhole power generator 50 may be
configured as a device, e.g. tool 58, that can be interfaced to
acoustic tool 60 such as an acoustic generator (FIG. 6) that causes
pipe 20 to vibrate inside wellbore 10. In this exemplary
embodiment, one or more housings 74 containing stressable material
52 may be arranged as part of a tool, e.g. tool 58. The vibration
causes stressable material 52 to generate energy which is routed at
least partially to power storage medium 73 (FIG. 1).
[0030] Referring to FIG. 5, in an exemplary intelligent completion
system well 10 with wireless communications module 60 and power
generator 50, use of a downhole power generation may eliminate use
of an electrical cable and reduce the cost of the completions
system. This may be especially true if power generator 50 is
deployed downhole cooperatively with wireless communications system
60. Accessibility to such power generation may allow deployment of
intelligent completions in areas that were not accessible to cable
based systems, e.g. by having in situ power generation and wireless
communications.
[0031] Casing 20, autolock 21, packer 22, line handler 24, packer
26, and tie back seal stem 28 are all shown as illustrations of
typical devices in downhole well 10 and are not meant to limit the
present invention in any way. Other such typical devices may be
sensors, control modules, or the like, as those terms are used
herein, i.e. with respect to placement downhole.
[0032] Traditionally, development of completion equipment has been
based on the deployment of single devices that perform an
individual function inside the wellbore and work independently of
any other component of the completion. Consequently, the actuation
of hydro-mechanical equipment and the acquisition of downhole
parameters from electronics sensors have been difficult and costly.
Further, measurement of downhole parameters during the production
has typically been performed by tools that are lowered into, and
retrieved from, the wellbore via wireline. Other methods of
measuring downhole parameters may include installation of pressure
and/or temperature tools and flow meters permanently in the
production tubing string. These tools are typically placed on the
outside of the production tubing and are connected to the surface
data acquisition system through cables mounted along the outside of
the tubing string. The actuation of downhole devices to control
flow is normally performed manually, e.g. using a mechanical device
attached to coil tubing or wireline, lowered into the wellbore and
used to shift such devices as sliding sleeves or to set a
packer.
[0033] Further, wireless communications systems and the power
generation system of the present inventions may also be used to
create wireless-based sensor modules which may be located almost
anywhere in wellbore 10. The interface of these systems to
intelligent completion systems may be used to allow for complete
and independent hydrocarbon flow control and communications in and
out of the wellbore in any section of well 10.
[0034] In an embodiment, downhole power generator 50 may be coupled
with wireless communications system 60 and provide the capability
to communicate through the production tubing, e.g. 20, using stress
waves to transmit and receive digital data and commands inside
wellbore 10. A system using wireless communications systems, e.g.
60, and power generator 50 may be used in applications requiring
information related to well status, geological formations, and
production status. Wells where multiple zones are being produced,
deep gas wells, and multilaterals may benefit from the development
of such a system due to the ease of deployment and the elimination
of cables that restrict the placement of gauges in the well. A
system according to the present inventions may positively impact
intelligent well applications, permit an increase in hydrocarbon
production, and lead to a decrease in the operating costs by
decreasing the number of interventions required in the well.
[0035] System 100 may be adapted for downhole control and comprise
a control module adapted (not shown in the figures) to be deployed
downhole; wireless transceiver 60 operatively in communication with
the control module, where wireless transceiver 60 is adapted to be
deployed downhole; and power generator 50 operatively coupled to
wireless transceiver 60. In certain embodiments, system 100 may be
further adapted for use with an intelligent completion system, as
that term will be familiar to one of ordinary skill in these
arts.
[0036] The control module may further comprise a sensor, a gauge, a
meter, a flow control device, or the like, or a combination
thereof. For example, system 100 may be adapted for deployment at a
subsea level at a hydrocarbon transmission pipeline to provide
information related to the flow of hydrocarbon through the
pipeline, the information comprising pressure, temperature, flow,
or the like, or a combination.
[0037] Transceiver 60 may comprise an active transceiver, a
repeater, or the like, or a combination thereof.
[0038] Power generator 50 comprises stressable material 52 adapted
to create an electric current when physically stressed. Power
generator 50 may be a separate power station deployed as part of
the production tubing, e.g. 20, and may be adapted to be used to
generate and store power to be transferred to mobile system
temporarily attached to power generator 50. Power generator 50 may
be deployed through tubing 20 for use with permanent or with
systems that perform a temporary service in wellbore 10.
[0039] Fluid flowing in a downhole pipe may create vibrations, e.g.
in pipe 20 used downhole, where the vibrations are usable by
stressable material 52 to allow generation of electricity by
stressable material 52. The electricity generated may then be used
to provide power for a sensor (not shown in the figures)
operatively in communication with power generator 50, e.g. disposed
within or otherwise connected to power generator 50.
[0040] Systems 100 may be disposed proximate a subsea wellhead and
control assembly may generate electricity as hydrocarbons flow from
downhole to a surface location. Electrical power generated by power
generator 50 may provide at least partial power for electronics and
electro-mechanical devices located proximate the subsea
wellhead.
[0041] In the operation of exemplary embodiments, referring now to
FIG. 6, in a preferred embodiment, power generation may be achieved
by stressing stressable material 52 (FIG. 1) such as piezoelectric
or magneto-restrictive material, where the stress arises, at least
on part, from production flow vibration induced in production
tubing 20 (FIG. 5). A mechanical vibration amplifier, e.g. 70 (FIG.
1) may be used to increase the power generated by stressable
material 52. A battery pack and/or capacitor bank, e.g. 73 (FIG. 1)
may be used to store the energy generated by stressable material
52. The amplitude and frequency of the induced voltage is typically
directly proportional to the mechanical deformation of stressable
material 52. The electrical charges developed by stressing
stressable material 52 will typically decay with time because of
the internal resistance so that DC power cannot be generated. An AC
to DC converter, e.g. 72 (FIG. 1), may be included as part of the
power circuit. The power output of stressable material 52 may be
optimized by using an inductor to cancel the capacitive part of the
impedance minimizing the source impedance. At resonance, the output
power is typically limited by the resistive component of stressable
material 52.
[0042] Electrical power may be generated from within tubular 20
(FIG. 5) by deploying power generator 50 (FIG. 1) within tubular 20
(FIG. 5), where power generator 50 comprises mechanical vibration
amplifier 70 (FIG. 1), mechanical to electrical power converter 51
(FIG. 1), power conditioner 72 (FIG. 1), and power storage medium
73 (FIG. 1) (e.g., steps 210-220). Power generator 50 is
operatively coupled to a source of vibration, e.g. fluid flows or
tubular 20 (e.g., step 230). Electrical current is generated using
power generator 50 when exposed to the physical stress (e.g., step
240). An outlet for electricity generated by power generator 50 may
be provided to allow access to the electricity generated by power
generator 50.
[0043] For systems, e.g. the system illustrated in FIG. 5, a device
that requires electric power such as acoustic module 60 may be
operatively coupled within tubular 20 (FIG. 5) to the outlet of
power generator 50. Acoustic generator 60 may itself be adapted to
vibrate tubular 20.
[0044] A system comprising a downhole tool, e.g. as illustrated in
FIG. 5, may be implemented by deploying a control module (not shown
in the figures) downhole (step 200). In an embodiment, a device
such as wireless transceiver 60 (FIG. 5) may be deployed downhole,
either before or after deployment of the control module where
wireless transceiver 60 is operatively in communication with the
control module (step 210). Power generator 50 (FIG. 5) may be
deployed downhole where power generator 50 is operatively coupled
to wireless transceiver 60, e.g. using wires or cables (step 220).
As described above, power generator 50 comprises stressable
material 52 (FIG. 1) adapted to create an electric current when
physically stressed. Power generator 50 is exposed to a source of
physical stress downhole, e.g. production fluid flow or vibration
(step 230). Power generator 50 generates electrical current when
exposed to the physical stress and the power generated is used by
the device, e.g. wireless transceiver 60.
[0045] A portion of the electricity generated by power system 50
may be stored in power storage system 73 deployed downhole, e.g.
power generator 50 may comprise power storage system 73.
[0046] It will be understood that various changes in the details,
materials, and arrangements of the parts which have been described
and illustrated above in order to explain the nature of this
invention may be made by those skilled in the art without departing
from the principle and scope of the invention as recited in the
following claims.
* * * * *