U.S. patent application number 17/013146 was filed with the patent office on 2021-04-01 for downhole power generation.
The applicant listed for this patent is ExxonMobil Upstream Research Company. Invention is credited to Eric R. Grueschow, Michael C. Romer.
Application Number | 20210095547 17/013146 |
Document ID | / |
Family ID | 1000005078007 |
Filed Date | 2021-04-01 |
![](/patent/app/20210095547/US20210095547A1-20210401-D00000.png)
![](/patent/app/20210095547/US20210095547A1-20210401-D00001.png)
![](/patent/app/20210095547/US20210095547A1-20210401-D00002.png)
![](/patent/app/20210095547/US20210095547A1-20210401-D00003.png)
![](/patent/app/20210095547/US20210095547A1-20210401-D00004.png)
![](/patent/app/20210095547/US20210095547A1-20210401-D00005.png)
![](/patent/app/20210095547/US20210095547A1-20210401-D00006.png)
United States Patent
Application |
20210095547 |
Kind Code |
A1 |
Grueschow; Eric R. ; et
al. |
April 1, 2021 |
Downhole Power Generation
Abstract
A gas lift valve (GLV) is described herein. The GLV includes a
power generation device that uses a fluid flowing through the GLV
to generate power.
Inventors: |
Grueschow; Eric R.;
(Houston, TX) ; Romer; Michael C.; (The Woodlands,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ExxonMobil Upstream Research Company |
Spring |
TX |
US |
|
|
Family ID: |
1000005078007 |
Appl. No.: |
17/013146 |
Filed: |
September 4, 2020 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62907056 |
Sep 27, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 43/123 20130101;
E21B 41/0085 20130101 |
International
Class: |
E21B 41/00 20060101
E21B041/00; E21B 43/12 20060101 E21B043/12 |
Claims
1. A method for generating power within a wellbore, the method
comprising: passing an injection fluid into a wellbore in fluid
communication with a subsurface formation; mixing the injection
fluid with formation fluids to form a produced fluid; flowing the
produced fluid through the wellbore to a wellhead; generating power
by passing a power generation fluid through a gas lift valve (GLV);
and wherein the power generation fluid is one of a portion of the
injection fluid, a portion of the produced fluid or combination
thereof.
2. The method of claim 1, wherein the injection fluid is a
compressed gas and is passed into an annulus within the wellbore
between a well casing and a production tubing.
3. The method of claim 1, comprising determining an amount of power
to be generated by the GLV.
4. The method of claim 1, wherein the GLV is a valve configured to
control flow of the injection fluid and is associated gas lift
operations.
5. The method of claim 1, further comprising communicating from the
GLV to a control unit at the surface of the wellbore.
6. The method of claim 1, wherein the generating power further
comprising rotating a rotary assembly in the power generation
device to generate current in an electrical generator.
7. The method of claim 1, comprising disconnecting a power storage
device from the power generation device using a switch when power
storage within the power storage device is maximized.
8. The method of claim 1, further comprising performing well
optimization from the power generated by the GLV to power a device,
wherein performing well optimization comprises: obtaining data from
a sensor within the wellbore; storing the data from the sensor in a
memory device; and transmitting the data from the senor to a data
transmitter to a data receiver.
9. A hydrocarbon system comprising: a wellhead; a wellbore in fluid
communication with the wellhead and a subsurface formation; well
casing disposed within the wellbore, wherein the well casing
provides one or more fluid flow paths from the subsurface formation
to the wellhead; a production tubing disposed within the wellbore
and in fluid communication with the wellbore; a gas lift valve
(GLV) associated with the production tubing within the wellbore,
wherein the GLV comprises a power generation device that uses a
fluid flowing through the GLV to generate power.
10. The hydrocarbon system of claim 9 further comprising a coupling
configured to inject a compressed gas into the wellbore, wherein
the compressed gas is passed through the GLV to generate power.
11. The hydrocarbon system of claim 9, wherein the production
tubing includes one or more mandrels and a production packer,
wherein one of the one or more mandrels includes the GLV.
12. The hydrocarbon system of claim 9, wherein the GLV comprises: a
power generation device configured to use the fluid flowing through
the GLV to generate power; a power storage device configured to
store the power generated by the power generation device; and a
well optimization device configured to use the power stored within
the power storage device, to collect data from one or more sensors
associated with the wellbore operations, to store the data from the
sensor, and transmit the data from the sensor.
13. The hydrocarbon system of claim 12, wherein the power
generation device comprises a rotary assembly and an electrical
generator.
14. The hydrocarbon system of claim 12, wherein the well
optimization device comprises at least one of a sensor, a memory
device, or a data transmitter.
15. A gas lift valve (GLV), comprising a power generation device
that uses a fluid flowing through the GLV to generate power.
16. The GLV of claim 15, wherein the power generation device is
located within an internal chamber of the GLV.
17. The GLV of claim 15, wherein the GLV is configured to open and
to close at pressures in the tubing or annulus, depending on the
specific application and wherein an open position of the GLV
corresponds to a power generation mode of the GLV.
18. The GLV of claim 15, wherein the GLV comprises: a housing
enclosing an internal chamber; an internal nozzle; a power
generation device disposed in the internal chamber, wherein the
power generation device is configured to convert energy from a
compressed gas flowing through the GLV into electricity; and a
power storage device configured to store the power generated by the
power generation device; and a well optimization device configured
to use the power stored within the power storage device, to collect
data from one or more sensors associated with the wellbore
operations, to store the data from the sensor, and to transmit the
data from the sensor.
19. The GLV of claim 18, wherein the power generation device
comprises a rotary assembly and an electrical generator.
20. The GLV of claim 19, wherein the rotary assembly comprises a
paddlewheel or a turbine.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application 62/907,056 filed Sep. 27, 2019 entitled DOWNHOLE POWER
GENERATION, the entirety of which is incorporated by reference
herein.
FIELD
[0002] The techniques described herein relate to downhole power
generation. More particularly, the techniques described herein
relate to power-generating gas lift valves (GLVs).
BACKGROUND
[0003] This section is intended to introduce various aspects of the
art, which may be associated with embodiments of the present
techniques. This discussion is believed to assist in providing a
framework to facilitate a better understanding of particular
aspects of the present techniques. Accordingly, it should be
understood that this section should be read in this light, and not
necessarily as admissions of prior art.
[0004] During the drilling of a well, large diameter wellbores are
cased leading to narrow diameter wellbores which are also cased,
finally leading to the production zones in the reservoir. As each
section is cased, concrete is injected around the casing to hold it
in place. The well is then completed by operations to begin the
production of hydrocarbon fluids from the reservoir. The
completions include the formation of perforations through the
casing and concrete of the final section into the reservoir using a
perforation gun. Production tubing is then inserted down the
wellbore into the production zone. The production tubing may
include equipment that enables the use of artificial lift to remove
the hydrocarbon fluids from the reservoir.
[0005] Artificial lift includes a number of methods for
transporting produced hydrocarbon fluids to the surface when
reservoir pressure alone is not sufficient. Gas lift is a common
method that is particularly suited to high-volume offshore wells. A
high-pressure gas is injected into the production tubing via the
casing annulus. The high-pressure gas then travels to a number of
gas lift valves (GLVs). The GLVs provide a pathway for a designed
volume of injected gas to enter the production tubing. This
decreases the density of the fluid column, thereby decreasing the
backpressure on the production zones in the reservoir. The
available reservoir pressure can then force more hydrocarbon fluids
to the surface.
[0006] GLVs are effectively pressure regulators and are typically
installed during well completion. In many cases, a number of
"unloading valves" are used to remove completion fluid from the
annulus so that the injected gas can reach the final "operating
valve." Once the injected gas reaches the operating valve, the
operating valve is ideally the only GLV left open. Gas entering the
operating valve may then assist in the production of hydrocarbon
fluids from the reservoir.
[0007] Gas lift is an effective artificial lift method, and gas
lift wells are typically low maintenance. However, gas lift wells
still function even when they are not optimized. Specifically,
wells will typically still flow, albeit at a reduced production
rate, even if they are receiving too much (or too little) lift gas
and/or are lifting from multiple GLVs or a valve that is shallower
than the desired operating point, i.e., an unloading valve instead
of the desired operating valve. Field diagnostics and modeling have
estimated that less than 25% of gas lift wells are truly
optimized.
[0008] At this time, there is not a cost-effective, continuous
means of determining which GLVs are open. Distributed
temperature/acoustic sensors can be placed with fiber optic cable,
but this is an expensive proposition that requires significant
hardware and software resources to manage and analyze the collected
data. Carbon dioxide tracer surveys are a non-intrusive method for
determining which GLVs are open, but such surveys can only provide
production snapshots and are performed quarterly at most. In
addition, some equipment vendors are developing powered GLVs that
report their position and other parameters, but these devices
require dedicated electric/hydraulic lines. Therefore, this
solution is not amenable to retrofits, and it can be
cost-prohibitive for new installations.
SUMMARY
[0009] An embodiment described herein provides a gas lift valve
(GLV). The GLV includes a power generation device that uses a fluid
flowing through the GLV to generate power.
[0010] Another embodiment described herein provides a method for
generating power within a GLV. The method includes using a fluid
flowing through the GLV to generate power within a power generation
device.
[0011] Another embodiment described herein provides a well
completion including a GLV that fluidically couples an annulus of
the well completion to an interior of a production tubing of the
well completion. The GLV includes a power generation device
configured to use a compressed gas flowing through the GLV to
generate power, a power storage device configured to store the
power generated by the power generation device, and a well
optimization device configured to use the power stored within the
power storage device to collect, store, or transmit data about the
well completion.
DESCRIPTION OF THE DRAWINGS
[0012] The foregoing and other advantages of the present techniques
may become apparent upon reviewing the following detailed
description and drawings of non-limiting examples in which:
[0013] FIG. 1 is a schematic view of a hydrocarbon system including
a well and a gas lift system;
[0014] FIG. 2 is a simplified schematic view showing the unloading
of completion fluids from the well using the gas lift system;
[0015] FIG. 3 is a cutaway view of a portion of the well including
a power-generating GLV that fluidically couples the annulus of the
well to the interior of the production tubing;
[0016] FIG. 4A is a cross-sectional view showing an exemplary
embodiment of the power-generating GLV in the closed position;
[0017] FIG. 4B is a cross-sectional view showing the exemplary
embodiment of the power-generating GLV in the open position;
and
[0018] FIG. 5 is a process flow diagram of a method for generating
power within a GLV.
[0019] It should be noted that the figures are merely examples of
the present techniques, and no limitations on the scope of the
present techniques are intended thereby. Further, the figures are
generally not drawn to scale, but are drafted for purposes of
convenience and clarity in illustrating various aspects of the
techniques.
DETAILED DESCRIPTION
[0020] In the following detailed description section, the specific
examples of the present techniques are described in connection with
preferred embodiments. However, to the extent that the following
description is specific to a particular embodiment or a particular
use of the present techniques, this is intended to be for example
purposes only and simply provides a description of the embodiments.
Accordingly, the techniques are not limited to the specific
embodiments described below, but rather, include all alternatives,
modifications, and equivalents falling within the true spirit and
scope of the appended claims.
[0021] At the outset, and for ease of reference, certain terms used
in this application and their meanings as used in this context are
set forth. To the extent a term used herein is not defined below,
it should be given the broadest definition persons in the pertinent
art have given that term as reflected in at least one printed
publication or issued patent. Further, the present techniques are
not limited by the usage of the terms shown below, as all
equivalents, synonyms, new developments, and terms or techniques
that serve the same or a similar purpose are considered to be
within the scope of the present claims.
[0022] As used herein, the terms "a" and "an" mean one or more when
applied to any embodiment described herein. The use of "a" and "an"
does not limit the meaning to a single feature unless such a limit
is specifically stated.
[0023] The terms "about," "approximate," "approximately," "around,"
"substantial," and "substantially" mean a relative amount of a
material or characteristic that is sufficient to provide the
intended effect. The exact degree of deviation allowable in some
cases may depend on the specific context, e.g., .+-.1%, .+-.5%,
.+-.10%, .+-.15%, etc. It should be understood by those of skill in
the art that these terms are intended to allow a description of
certain features described and claimed without restricting the
scope of these features to the precise numerical ranges provided.
Accordingly, these terms should be interpreted as indicating that
insubstantial or inconsequential modifications or alterations of
the subject matter described are considered to be within the scope
of the disclosure.
[0024] As used herein, the terms "example," exemplary," and
"embodiment," when used with reference to one or more components,
features, structures, or methods according to the present
techniques, are intended to convey that the described component,
feature, structure, or method is an illustrative, non-exclusive
example of components, features, structures, or methods according
to the present techniques. Thus, the described component, feature,
structure or method is not intended to be limiting, required, or
exclusive/exhaustive; and other components, features, structures,
or methods, including structurally and/or functionally similar
and/or equivalent components, features, structures, or methods, are
also within the scope of the present techniques.
[0025] As used herein, the term "fluid" refers to gases, liquids,
and combinations of gases and liquids, as well as to combinations
of gases and solids, and combinations of liquids and solids.
[0026] The term "gas" is used interchangeably with "vapor," and is
defined as a substance or mixture of substances in the gaseous
state as distinguished from the liquid or solid state. Likewise,
the term "liquid" means a substance or mixture of substances in the
liquid state as distinguished from the gas or solid state.
[0027] A "gas lift system" is a type of artificial lift system used
to remove completion fluids from a well or increase the performance
of the well. The gas lift system generally includes a valve system
for controlling the injection of compressed, or pressurized, gas
from a source external to the well, such as a compressor, into the
borehole. The increased pressure from the injected gas forces
accumulated formation fluid up the tubing to remove the fluids as
production flow or to clear the fluids and restore the free flow of
gas from the formation into the well.
[0028] A "gas lift valve" or GLV is a valve used in a gas lift
system to control the flow of lift gas into the production tubing
conduit. Gas lift valves are typically located in a gas lift
mandrel, which also provides communication with the lift gas supply
in the tubing annulus. Operation of the gas lift valve is
determined by preset opening and closing pressures in the tubing or
annulus, depending on the specific application.
[0029] A "hydrocarbon" is an organic compound that primarily
includes the elements hydrogen and carbon, although nitrogen,
sulfur, oxygen, metals, or any number of other elements may be
present in small amounts. As used herein, the term "hydrocarbon"
generally refers to components found in natural gas, oil, or
chemical processing facilities. Moreover, the term "hydrocarbon"
may refer to components found in raw natural gas, such as CH.sub.4,
C.sub.2H.sub.2, C.sub.2H.sub.4, C.sub.2H.sub.6, C.sub.3 isomers,
C.sub.4 isomers, benzene, and the like.
[0030] A "side-pocket mandrel" is an offset heavy-wall sub in the
tubing for placing gas lift valves, temperature and pressure
probes, injection line valves, and the like.
[0031] The term "slickline" refers to a thin cable introduced into
a well to deliver and retrieve tools downhole. Similarly, the term
"wireline" refers to an electrical cable used to lower tools into a
well and/or transmit data about the conditions of the well.
[0032] The terms "well" and "wellbore" refer to holes drilled
vertically, at least in part, and may also refer to holes drilled
with deviated, highly deviated, and/or horizontal sections. The
term also includes wellhead equipment, surface casing, intermediate
casing, and the like, typically associated with oil and gas
wells.
[0033] As used herein, a "well completion" is a group of equipment
and operations that may be installed and performed to produce
hydrocarbons from a subsurface reservoir. The well completion may
include the casing, production tubing, completion fluid, gas lift
valves, and other equipment used to prepare the well to produce
hydrocarbons.
[0034] Overview
[0035] The present techniques relate to downhole power generation
using a power-generating gas lift valve (GLV) within a well. The
power-generating GLV uses the flow of fluid through the GLV to
provide a motive source for power generation. This is accomplished
using a power generation device, which may reside within an
internal chamber located between the stem and the reverse-flow
check valve of the GLV. The power generation device may include,
for example, a rotary assembly, such as a paddlewheel or a turbine,
and an electrical generator, such an AC or DC generator. The
generated power may be stored in a power storage device, and may
then be used for a variety of downhole applications, such as
operating one or more sensors or other well optimization devices.
Furthermore, the data from the sensor(s) (or other well
optimization devices) may be stored locally and then transmitted to
the surface using a variety of techniques.
[0036] Gas Lift System
[0037] FIG. 1 is a schematic view of a well 100 including a gas
lift system. The well 100 includes a wellhead 102 on top of a well
casing 104 that passes through a formation 106. The wellhead 102
includes a coupling 108 for injecting compressed gas 110 into an
annulus 112 of the well 100, for example, formed between the well
casing 104 and production tubing 114.
[0038] The production tubing 114 includes a number of side-pocket
mandrels 116A, 116B and 116C and a production packer 118. Downhole,
the production packer 118 forces produced hydrocarbon fluids 120
from the formation 106 to travel up through the production tubing
114. In addition, the production packer 118 keeps the gas flow in
the annulus 112 from entering the production tubing 114.
[0039] To conduct a gas lift operation, operators install gas lift
valves (GLVs) 122A, 122B and 122C into the side-pocket mandrels
116A, 116B and 116C, either before deployment or wireline or
slickline after deployment. Once the GLVs 122A, 122B and 122C are
installed, the compressed gas 110 is injected into the annulus 112
via the coupling 108. The compressed gas 110 then travels down the
annulus 112 until it reaches the side-pocket mandrels 116A, 116B
and 116C. Entering the side-pocket mandrels' ports, the compressed
gas 110 passes through the respective GLVs 122A, 122B and 122C and
into the production tubing 114. The GLVs 122A, 122B and 122C then
act as one-way valves by allowing the compressed gas 110 to flow
from the annulus 112 to the production tubing 114, while preventing
fluid flow in the opposite direction.
[0040] Once the compressed gas 110 enters the production tubing
114, it rises to the surface, helping to remove completion fluid
from the annulus 112 and the production tubing 114, as described
further with respect to FIG. 2. Moreover, once the completion fluid
has been removed, the compressed gas 110 is used to help lift the
hydrocarbon fluids 120 in the production tubing 114 to the surface
when reservoir pressure alone is not sufficient.
[0041] FIG. 2 is a simplified schematic view showing the unloading
of completion fluids from the well 100 using the gas lift system.
Like numbered items are as described with respect to FIG. 1. Before
start-up, the well 100 is filled with completion fluid 202, in the
annulus 112 and the production tubing 114, to provide a pressure
cap on the hydrocarbon fluids 120 coming up from a reservoir 204.
Once the production tubing 114 is in place, the completion fluid
202 is typically removed, for example, to be replaced with the
compressed gas 110 used for gas lift assist.
[0042] As shown in FIG. 2, the unloading of the completion fluid
202 is performed by injecting the compressed gas 110 into the
coupling 108 that leads to the annulus 112 of the well 100. As the
compressed gas 110 is forced down the annulus 112, the completion
fluid 202 is forced through the GLVs 122A, 122B and 122C, and up
the production tubing 114. A production line 206 is coupled to the
production tubing 114, and is used to remove the completion fluid
202, which may be referenced as a produced or production fluid.
[0043] As the liquid level 208 crosses a particular GLV 122A, 122B
and 122C, the compressed gas 110 enters the production tubing 114
through the GLV 122A, 122B and 122C. The compressed gas 110 creates
bubbles 210 that are entrained in the completion fluid 202, which
lower the density of the completion fluid 202, allowing the
pressure of the compressed gas 110 to push the completion fluid 202
to the surface. As the liquid level 208 crosses a particular GLV
122A, 122B and 122C, for example, the mid-level GLV 122B, the
pressure drop from the compressed gas 110 entering the production
tubing 114 through the particular GLV 122B causes a next higher
GLV, for example, the highest GLV 122A in the well 100, to close.
When the liquid level 208 reaches the lowest GLV 122C, which is the
operating valve in the well 100, the pressure drop causes the next
higher GLV 122B to close, leaving only the operating valve open.
Compressed gas 110 entering through the operating valve may then
assist in the production of the hydrocarbon fluids 120 from the
reservoir 204.
[0044] In some embodiments, the compressed gas 110 includes a gas
and/or liquid mixture. For example, chemicals may also be injected
into the annulus 112 to assist in the production of the hydrocarbon
fluids 120 from the reservoir 204.
[0045] As described with respect to FIG. 2, ideally, only the
operating valve, which is the lowest GLV 122C, will remain open
once the completion fluid has been removed from the annulus 112 and
the production tubing 114 via the unloading valves, which are the
two highest GLVs 122A and 122B. However, in operation, it is
difficult to monitor whether a particular GLV 122A, 122B, or 122C
is open or closed. Moreover, the well 100 will still function even
when it is not optimized. Specifically, the well 100 will still
flow, albeit at a reduced production rate, even if it is receiving
too much (or too little) compressed gas 110 and/or is lifting from
multiple GLVs 122A-C or a GLV 122A or 122B that is shallower than
the desired operating point, i.e., an unloading valve instead of
the desired operating valve.
[0046] Therefore, according to embodiments described herein, one or
more of the GLVs 122A, 122B and 122C within the well 100 is a
power-generating GLV that uses the compressed gas 110 (or other
fluid) flowing through the GLV as a motive source for generating
power locally within the GLV. The generated power may then be used
for a variety of downhole applications, such as operating one or
more well optimization devices. For example, the generated power
may be used to operate a valve position sensor. This may greatly
improve the performance of the gas lift system by providing an
efficient, cost-effective way to determine whether the GLV is in
the open or closed position. The generated power may also be used
to operate other sensors, such as pressure, temperature, and/or
flow rate sensors, receive and/or store data from other devices, or
communicate data to other locations within the well or the surface
via wired or wireless means.
[0047] Power-Generating Gas Lift Valve
[0048] FIG. 3 is a cutaway view of a portion of the well 100
including a power-generating gas lift valve (GLV) 300 that
fluidically couples the annulus 112 of the well 100 to the interior
302 of the production tubing 114. Like numbered items are as
described with respect to FIGS. 1 and 2. In various embodiments,
the power-generating GLV 300 replaces one or more of the GLVs 122A,
122B and 122C described with respect to FIGS. 1 and 2. In some
embodiments, this includes installing the power-generating GLV 300
in the side-pocket mandrel 116 during the initial completion of the
well 100. In other embodiments, this includes installing the
power-generating GLV 300 in the side-pocket mandrel 116 via
wireline or slickline after deployment. Moreover, in some
embodiments, multiple power-generating GLVs 300 are installed,
uninstalled, or replaced periodically during the lifetime of the
well 100 such that the performance of the well 100 is
optimized.
[0049] As shown in FIG. 3, the power-generating GLV 300 is mounted
within the side-pocket mandrel 116, which is constructed as a
section, or joint, of the production tubing 114 that has an oblong
expansion. The power-generating GLV 300 includes a bellows 304,
which provides the operational force that determines the pressure
at which the power-generating GLV 300 will open and close.
Depending on the installation depth of the power-generating GLV 300
in the well 100 and the pressure of the compressed gas 110, the
expected backpressure may be in a range of between about 1,000
pounds per square inch (psi) to 5,000 psi.
[0050] The power-generating GLV 300 also includes an orifice 306
that allows the compressed gas 110 to flow from the annulus 112
into the power-generating GLV 300, as well as an internal nozzle
308 that allows the compressed gas to flow from the
power-generating GLV 300 to the interior 302 of the production
tubing 114 when the power-generating GLV 300 is in the open
position, as shown in FIG. 3.
[0051] The power-generating GLV 300 includes a stem 310 and a seat
312 that prevent the compressed gas 110 within the annulus 112 from
flowing through the power-generating GLV 300 to the interior 302 of
the production tubing 114 when the power-generating GLV 300 is in
the closed position. In addition, the power-generating GLV 300
includes a reverse-flow check valve 314 that prevents the
hydrocarbon fluids 120 within the interior 302 of the production
tubing 114 from flowing through the power-generating GLV 300 to the
annulus 112 when the power-generating GLV 300 is in the closed
position.
[0052] The power-generating GLV 300 also includes an internal
chamber 316 through which the compressed gas 110 flows as it
travels from the orifice 306 to the internal nozzle 308. According
to embodiments described herein, a power generation device 318 is
located within the internal chamber 316. The power generation
device 318 is configured to convert energy from the compressed gas
110 flowing through the power-generating GLV 300 into electricity.
In various embodiments, the power generation device 318 includes a
rotary assembly (not shown) and an electrical generator (not
shown). However, the power generation device 318 may also include
any other type of device that is capable of using the compressed
gas 110 as a source for power generation. Furthermore, the
generated power may be stored in a power storage device (not
shown), and may then be used for a variety of downhole
applications, such as operating one or more well optimization
devices (not shown) within the well 100. The power generation
device 318 and associated equipment are described further with
respect to FIGS. 4A and 4B.
[0053] The cutaway view of FIG. 3 is not intended to indicate that
the power-generating GLV 300 is to include all of the components
shown in FIG. 3. Further, any number of additional components may
be included within the power-generating GLV 300, depending on the
details of the specific implementation. For example, in the
embodiment shown in FIG. 3, the power-generating GLV 300 is
installed in the side-pocket mandrel 116. However, in other
embodiments, the power-generating GLV 300 may be mounted in any
other suitable mounting point, such as, for example, a conventional
mandrel.
[0054] In various embodiments, the data collected using the
power-generating GLV 300 described herein may be used to optimize
the well 100. For example, the amount of the compressed gas 110
flowing into the annulus 112 may be optimized such that the
hydrocarbon fluids 120 are efficiently extracted from the reservoir
204. In addition, because the compressed gas 110 used for gas lift
systems is an easily-metered, single-phase fluid, expected power
generation is relatively simple to predict, and the compressed gas
110 provides a steady, reliable source for power generation.
Furthermore, because the power generation device 318 may cause a
negligible drop in pressure, such as less than around 50 psi, the
power-generating GLV 300 should not significantly increase the
operating costs for the gas lift system.
[0055] FIG. 4A is a cross-sectional view showing an exemplary
embodiment of the power-generating GLV 300 in the closed position.
Like numbered items are as described with respect to FIGS. 1, 2 and
3. As shown in FIG. 4A, the power-generating GLV 300 includes the
spring-loaded bellows 304 and a nitrogen-charged dome 400. When the
nitrogen charge pressure 402 within the dome 400 is higher than the
total pressure applied to the dome 400, which is the sum of the
injection pressure 404 that the compressed gas 110 applies to the
bellows 304 and the production pressure 406 that the hydrocarbon
fluids 120 within the interior 302 of the production tubing 114
apply to a tip 408 of the stem 310, the tip 408 of the stem 310
rests against the seat 312. This prevents the compressed gas 110
from the flowing into the internal chamber 316 of the
power-generating GLV 300, thus preventing the compressed gas 110
within the annulus 112 from flowing through the power-generating
GLV 300 to the interior 302 of the production tubing 114. Moreover,
because the power-generating GLV 300 is in the closed position,
minimal pressure is applied downward on the reverse-flow check
valve 314. Therefore, the reverse-flow check valve 314 remains
closed, preventing hydrocarbon fluids 120 within the interior 302
of the production tubing 114 from flowing through the
power-generating GLV 300 to the annulus 112.
[0056] According to the embodiment shown in FIG. 4A, the internal
chamber 316 of the power generation device 318 includes a rotary
assembly 410, such as a paddlewheel or turbine, for example,
coupled to an electrical generator 412, such as an AC or DC
generator, for example. In addition, the power generation device
318 is connected to a power storage device 414, such as a battery,
capacitor bank, thermal bank, or flywheel, for example, and a
sensor 416, such as a valve position sensor, pressure sensor,
temperature sensor, or flow rate sensor, for example. The operation
of these components is described in more detail with respect to
FIG. 4B.
[0057] FIG. 4B is a cross-sectional view showing the exemplary
embodiment of the power-generating GLV 300 in the open position.
Like numbered items are as described with respect to FIGS. 1, 2, 3,
and 4A. When the total pressure applied to the dome 400 is higher
than the nitrogen charge pressure 402 within the dome 400, the
spring-loaded bellows 304 compresses, disengaging the tip 408 of
the stem 310 from the seat 312. This allows the compressed gas 110
to flow into the internal chamber 316 of the power-generating GLV
300. Moreover, the downward application of the injection pressure
404 to the reverse-flow check valve 314 also causes the
reverse-flow check valve 314 to open. This allows the compressed
gas 110 within the annulus 112 to flow through the power-generating
GLV 300 to the interior 302 of the production tubing 114.
[0058] In various embodiments, the open position of the
power-generating GLV 300 corresponds to a power generation mode of
the power-generating GLV 300. Specifically, as the compressed gas
110 flows downward into the internal chamber 316 of the
power-generating GLV 300, the compressed gas 110 causes the rotary
assembly 410 to rotate. This provides the motive force for the
generation of power by the electrical generator 412. In various
embodiments, the rotary assembly 410 includes a paddlewheel,
turbine, or other rotating device, for example, and the electrical
generator 412 includes an AC generator or a DC generator, for
example.
[0059] According to the embodiment shown in FIG. 4B, the full
stream of the compressed gas 110 is used to rotate the rotary
assembly 410. However, in other embodiments, a slipstream of the
compressed gas 110 is diverted from the main flow path of the
compressed gas 110. The slipstream of the compressed gas 110 is
then used to rotate the rotary assembly 410, while the rest of the
stream bypasses the rotary assembly 410. This provides an easy way
to meter the rotary assembly 410 such that a suitable amount of
motive force is provided to the electrical generator 412.
[0060] The generated power is then stored in the power storage
device 414. The power storage device 414 may include, for example,
a battery, a capacitor bank, a thermal bank, or a flywheel. In
various embodiments, a switch 418 located between the electrical
generator 412 and the power storage device 414 allows the power
storage device 414 to disconnect from the electrical generator 412
when the power storage is maximized. For example, if the power
storage device 414 is a battery, the switch 418 may prevent the
battery from overcharging by automatically disconnecting the
battery from the electrical generator 412 when it is fully
charged.
[0061] The power stored within the power storage device 414 is then
used to operate the sensor 416. The sensor 416 may include, for
example, a valve position sensor configured to detect whether the
power-generating GLV 300 is in the open or closed position, a
pressure sensor configured to detect a pressure of fluid within the
well 100, a temperature sensor configured to detect a temperature
of fluid within the well 100, or a flow rate sensor configured to
detect the flow rate of the compressed gas 110 through the
power-generating GLV 300. The sensor 416 may also be replaced with
any other device that is useful for optimizing the well 100.
According to embodiments described herein, the sensor 416 and all
other devices for optimizing the well 100 are generally referred to
as "well optimization devices." Other exemplary well optimization
devices include devices for receiving and/or storing data from
other devices within the well 100, and devices for communicating
data to other locations within the well 100 or the surface via
wired or wireless means. Still other well optimization devices may
include on-board devices for adjusting one or more gas lift flow
rate or pressure regulating valves or orifices within the gas lift
valve assembly. For example, an electrically powered driver for
hydraulically or electrically adjusting opening size or
back-pressure spring force to adjust or fine-tune gas lift valve
performance. Moreover, while only one sensor 416 is shown in FIGS.
4A and 4B, any number of additional sensors (and/or other well
optimization devices) may be connected to the power storage device
414. Furthermore, while the sensor 416 is to positioned within the
internal chamber 316 of the power-generating GLV 300 according to
the embodiment shown in FIGS. 4A and 4B, the sensor 416 (and/or
other well optimization devices) may be positioned in any suitable
location within the power-generating GLV 300 or the well 100.
[0062] In some embodiments, the data collected from the sensor 416
is stored within a memory device (not shown). The memory device is
a well optimization device that may be powered by the power storage
device 414. The memory device may include, for example, a solid
state memory device, a volatile memory device, a non-volatile
memory device, or a flash memory device.
[0063] In some embodiments, the data stored in the memory device
and then sent to the surface using a variety of techniques. For
example, in some embodiments, the power-generating GLV 300 also
includes a data transmitter (not shown). The data transmitter is
another well optimization device that may be powered by the power
storage device 414. The data transmitter may be configured to
transmit the collected data to a data receiver (not shown) located
on the surface using wired or wireless means. The data transmitter
may include, for example, a wireless data transmitter, a radio
frequency (RF) data transmitter, or a Bluetooth data transmitter.
Further, in other embodiments, pressure modulation techniques are
used to send the collected data to the surface. For example, if the
sensor 416 is a valve position sensor, data collected by the valve
position sensor may be used to send a pressure signature of the
pressure-generating GLV 300 to the surface. Pressure readings at
the surface may then be used to determine whether the
pressure-generating GLV 300 is in the open or closed position.
[0064] Once the data is transmitted to the surface, it may be used
to optimize the well 100. For example, if the sensor 416 includes a
valve position sensor, the collected data may be used to determine
whether the gas lift system is operating correctly. As another
example, if the sensor 416 includes a pressure, temperature, and/or
flow rate sensor, the collected data may be used to adjust the
pressure, temperature, and/or flow rate of the compressed gas 110
such that the hydrocarbon fluids 120 are efficiently produced from
the reservoir 204.
[0065] The cross-sectional views of FIGS. 4A and 4B are not
intended to indicate that the power-generating GLV 300 is to
include all of the components shown in FIGS. 4A and 4B. Moreover,
any number of additional components may be included within the
power-generating GLV 300, depending on the details of the specific
implementation. Furthermore, it is to be understood that the
power-generating GLV 300 shown in FIGS. 3, 4A, and 4B is merely one
exemplary embodiment of the power-generating GLV described herein,
which may include any suitable type of GLV that can be designed or
adapted to include a power generation device.
[0066] In various embodiments, the power-generating GLV 300 is
retrievable. For example, the power-generating GLV 300 may be
extracted from the side-pocket mandrel 116 (or other mounting
point) using wireline, slickline, or coiled tubing, for example. In
addition, existing wells may be retrofitted with new
power-generating GLVs 300 using the same techniques.
[0067] Method for Generating Power within a Gas Lift Valve
[0068] FIG. 5 is a process flow diagram of a method 500 for
generating power within a gas lift valve (GLV). In various
embodiments, the GLV is the power-generating GLV 300 described with
respect to FIGS. 3, 4A, and 4B. Moreover, in various embodiments,
the GLV is implemented within a well completion as part of the gas
lift system of the well, as described with respect to FIGS. 1, 2
and 3. The GLV may be mounted within a side-pocket mandrel or a
conventional mandrel, and may be used to fluidically couple an
annulus of the well completion to an interior of a production
tubing of the well completion.
[0069] The method 500 begins at block 502, at which a fluid flowing
through the GLV is used to generate power within a power generation
device. The fluid may be, for example, a compressed gas that is
used for the gas lift system of the well. The power generation
device may be located within an internal chamber of the GLV, and
may use either a full stream or a slipstream of the fluid flowing
through the GLV to generate power.
[0070] In various embodiments, an open position of the GLV
corresponds to a power generation mode of the GLV. When the GLV is
in the open position, the fluid flows through the GLV to travel
from the annulus to the interior of the production tubing.
[0071] Further, in various embodiments, the power generation device
includes a rotary assembly and an electrical generator. The rotary
assembly may include, for example, a paddlewheel or a turbine, and
the electrical generator may include, for example, an AC generator
or a DC generator. The power generation fluid, which may be a
portion or all of the injection fluid, produced fluid or
combination thereof, may be used to generate the power (e.g.,
rotate or move the paddlewheel).
[0072] The method 500 may then continue to blocks 504 and 506,
which are optional (as indicated by the dotted lines in FIG. 5). At
block 504, the power generated by the power generation device is
stored within a power storage device. The power storage device may
include, for example, a battery, a capacitor bank, a thermal bank,
or a flywheel. In some embodiments, the GLV includes a switch for
disconnecting the power storage device from the power generation
device when power storage within the power storage device is
maximized.
[0073] At block 506, the power stored within the power storage
device is used to power a well optimization device. The well
optimization device may include a sensor, such as a valve position
sensor, a pressure sensor, a temperature sensor, or a flow rate
sensor. The well optimization device may also include a memory
device for storing data collected by a sensor or other well
optimization device. The well optimization device may further
include a data transmitter for transmitting data collected by a
sensor or other well optimization device to a data receiver. In
various embodiments, the data that is collected, stored, and/or
transmitted by the well optimization device(s) are used to optimize
the well completion.
[0074] The process flow diagram of FIG. 5 is not intended to
indicate that the steps of the method 500 are to be executed in any
particular order, or that all of the steps of the method 500 are to
be included in every case. Further, any number of additional steps
not shown in FIG. 5 may be included within the method 500,
depending on the details of the specific implementation.
[0075] As may be appreciated, performing hydrocarbon operations may
include injecting various fluids into a well and removing various
fluids from the well. The fluid flow is typically involves pressure
changes. The injected fluids may be provided at various pressures,
which are controlled at the wellhead and may involve different
injection fluids. As noted above, one type of hydrocarbon operation
is an artificial lift operation, which includes injecting a fluid
into the wellbore, which is an injection fluid (e.g., a
high-pressure fluid, such as in the range between 800 psi and 2500
psi). The injection fluid may be injected through a conduit or
injected into the production tubing via the casing annulus. Then,
the injection fluid may pass through one or more GLVs. The GLVs
provide a fluid pathway for a designed volume of injection fluid,
which may be an injection gas to enter the production tubing, as an
example. Then, the resulting fluid is produced through the wellbore
and the wellhead. The injection fluid is configured to decrease the
density of the fluid column, decrease the backpressure on the
production zones in the subsurface formation.
[0076] The injection fluid or the produced fluid may be used by the
GLV to generate power, as noted above. In one or more embodiments,
the injection fluid is used, as it is at a higher pressure and may
be controlled more than the produced fluid. As an example, a method
for generating power within wellbore, the method comprising:
passing an injection fluid into a wellbore in fluid communication
with a subsurface formation; mixing the injection fluid with
formation fluids to form a produced fluid; flowing the produced
fluid through the wellbore to a wellhead; generating power by
passing a power generation fluid through a gas lift valve (GLV);
and wherein the power generation fluid is one of a portion of the
injection fluid, a portion of the produced fluid or combination
thereof. The injected fluid in the method may be a compressed gas
and may be passed into an annulus within the wellbore between a
well casing and a production tubing.
[0077] In another embodiment, a hydrocarbon system is described.
This hydrocarbon system may include a wellhead; a wellbore in fluid
communication with the wellhead and a subsurface formation; well
casing disposed within the wellbore, wherein the casing provides
one or more fluid flow paths from the subsurface formation to the
wellhead; a gas lift valve (GLV) within the wellbore, wherein the
GLV comprises a power generation device that uses a fluid flowing
through the GLV to generate power. The hydrocarbon system may also
include a coupling configured to inject a compressed gas into the
wellbore, wherein the compressed gas is passed through the GLV to
generate power, and wherein the production tubing includes one or
more side-pocket mandrels and a production packer, wherein one of
the one or more side-packet mandels includes the GLV. Furthermore,
the hydrocarbon system may include a GLV that has a power
generation device configured to use the fluid flowing through the
GLV to generate power; a power storage device configured to store
the power generated by the power generation device; and a well
optimization device configured to use the power stored within the
power storage device, to collect data from one or more sensors
associated with the wellbore operations, to store the data from the
sensor, and transmit the data from the sensor.
[0078] In yet other embodiments, the produced fluid and/or the
injection fluid may be used to generate power. Electricity
generation methods involving a mass flow (e.g., turbine and/or
expander) typically generate proportionally to the throughput.
Accordingly, the amount of fluid may be adjusted to the power needs
of the equipment being supported. As such, if a small amount of
power (e.g., 1 to 100 milliWatts (mW) for a sensor), then the mass
flow and may only need a slip stream to generate the power for the
sensor (e.g., slip stream of the injected fluid or produced fluid).
By only using a slip stream, the pressure drop may be minimized as
compared to the pressure drop from using the entire stream, which
may negatively impact the gas lift operations in the hydrocarbon
system (e.g., by limiting the amount of gas that you can push
through a valve). To balance the power, the GLV may be configured
to balance the well optimization power requirement and determine
how much mass flow needed to create the optimization power
requirement. This may be obtained by creating and/or adjusting the
slip stream exhausted to the tubing or may be based on the full
stream that is passing through the GLV. Accordingly, by including
functionality to adjust the stream used in the power generation,
the GLV may be adjusted to provide more or less power to optimize
the operation of the hydrocarbon system. Accordingly, the
hydrocarbon system may be configured to communicate from the GLV or
a sensor to a control unit at the surface of the wellbore. The data
from the sensor may be used to adjust the operations. The control
unit may be used to adjust the injection rate, or adjust the
operation of one or more of the GVLs.
[0079] In yet other embodiments, the GLVs may be used for well
optimization, which may be used to change the operation of the
hydrocarbon system. As an example, for a gas lift operations,
adjustments may be made to adjust the gas lift rate so that the
injection fluid is provided at an optimal amount for production. If
gas lift rate is low (e.g., too low a volume of gas), then the
hydrostatic gradient is higher and the reservoir pressure is higher
than necessary, and the well produces is less. If the gas lift rate
is too high, then the friction pressure in the tubing is higher
than necessary and the well produces less. Any additional
information from downhole sensors (e.g., pressure and/or injection
rates at each valve) may be used to determine whether the optimal
rates or settings has be obtained or whether adjustments are needed
to enhance the operations. Accordingly, the hydrocarbon system may
include a sensor and control unit that may be configured to
communicate between the GLV, within the wellbore, sensor within the
wellbore and the control unit at the surface of the wellbore. The
data may be used to adjust the operations. The control unit may be
used to adjust the injection rate, or adjust the operation of one
or more of the GVLs.
[0080] In one or more embodiments, the present techniques may be
susceptible to various modifications and alternative forms, such as
the following embodiments as noted in paragraphs A to HH:
A. A gas lift valve (GLV), comprising a power generation device
that uses a fluid flowing through the GLV to generate power. B. The
GLV of paragraph A, wherein the power generation device is located
within an internal chamber of the GLV. C. The GLV of paragraph A,
wherein the fluid flowing through the GLV is a compressed gas that
is used for a gas lift system within a well. D. The GLV of
paragraph A, wherein the power generation device uses a full stream
of the fluid flowing through the GLV to generate the power. E. The
GLV of paragraph A, wherein the power generation device uses a
slipstream of the fluid flowing through the GLV to generate the
power. F. The GLV of paragraph A, wherein an open position of the
GLV corresponds to a power generation mode of the GLV. G. The GLV
of paragraph F, wherein the fluid flows through the GLV to travel
from an annulus of a well to an interior of a production tubing of
the well when the GLV is in the open position. H. The GLV of
paragraph A, wherein the power generation device comprises a rotary
assembly and an electrical generator. I. The GLV of paragraph H,
wherein the rotary assembly comprises a paddlewheel or a turbine.
J. The GLV of paragraph H, wherein the electrical generator
comprises an AC generator or a DC generator. K. The GLV of
paragraph A, comprising a power storage device for storing the
power generated by the power generation device. L. The GLV of
paragraph K, wherein the power storage device comprises at least
one of a battery, a capacitor bank, a thermal bank, or a flywheel.
M. The GLV of paragraph K, comprising a switch for disconnecting
the power storage device from the power generation device when
power storage within the power storage device is maximized. N. The
GLV of paragraph A, wherein the power generated by the GLV is used
to power a well optimization device. O. The GLV of paragraph N,
wherein the well optimization device comprises a sensor. P. The GLV
of paragraph O, wherein the sensor comprises at least one of a
valve position sensor, a pressure sensor, a temperature sensor, or
a flow rate sensor. Q. The GLV of paragraph O, wherein the well
optimization device comprises a memory device for storing data
collected by a sensor or other well optimization device. R. The GLV
of paragraph O, wherein the well optimization device comprises a
data transmitter for transmitting data collected by a sensor or
other well optimization device to a data receiver. S. The GLV of
paragraph A, wherein the GLV is mounted within a side-pocket
mandrel or a conventional mandrel. T. The GLV of paragraph A,
wherein the GLV is an operating valve or an unloading valve. U. A
method for generating power within a gas lift valve (GLV),
comprising using a fluid flowing through the GLV to generate power
within a power generation device. V. The method of paragraph U,
wherein the power generation device is located within an internal
chamber of the GLV. W. The method of paragraph U, wherein the fluid
flowing through the GLV is a compressed gas that is used for a gas
lift system within a well. X. The method of paragraph U, wherein
the power generation device comprises a rotary assembly and an
electrical generator. Y. The method of paragraph U, comprising
storing the power generated by the power generation device within a
power storage device. Z. The method of paragraph Y, comprising
disconnecting the power storage device from the power generation
device using a switch when power storage within the power storage
device is maximized. AA. The method of paragraph U, comprising
using the power generated by the GLV to power a well optimization
device. BB. The method of paragraph AA, wherein the well
optimization device comprises a sensor. CC. The method of paragraph
U, wherein the well optimization device comprises a memory device
for storing data collected by a sensor or other well optimization
device. DD. The method of paragraph U, wherein the well
optimization device comprises a data transmitter for transmitting
data collected by a sensor or other well optimization device to a
data receiver. EE. A well completion, comprising a gas lift valve
(GLV) that fluidically couples an annulus of the well completion to
an interior of a production tubing of the well completion, wherein
the GLV comprises: a power generation device configured to use a
compressed gas flowing through the GLV to generate power; a power
storage device configured to store the power generated by the power
generation device; and a well optimization device configured to use
the power stored within the power storage device to collect, store,
or transmit data about the well completion. FF. The well completion
of paragraph EE, wherein the power generation device is located
within an internal chamber of the GLV, and wherein the compressed
gas flows through the internal chamber to travel from the annulus
to the interior of the production tubing when the GLV is in an open
position. GG. The well completion of paragraph EE, wherein the
power generation device comprises a rotary assembly and an
electrical generator. HH. The well completion of paragraph EE,
wherein the well optimization device comprises at least one of a
sensor, a memory device, or a data transmitter.
[0081] While the present techniques may be susceptible to various
modifications and alternative forms, the examples discussed above
have been shown only by way of example. However, it should again be
understood that the present techniques are not intended to be
limited to the particular examples disclosed herein. Indeed, the
present techniques include all alternatives, modifications, and
equivalents falling within the true spirit and scope of the
appended claims.
* * * * *