Magnetic Field Disruption For In-Well Power Conversion

Abstract

The system invention is based on the use of electromagnetics that convert flow and mechanical motion into electrical power. The system is housed in a side pocket mandrel. Flow is diverted from the main bore through the side pocket, which houses a pressure vessel. At least one magnet is housed in the pressure vessel, and at least one coil is wound around the pressure vessel. As the diverted flow from the well passes through the side pocket, the pressure vessel may rotate or vibrate, creating a disturbance to the magnetic field, thereby creating current. An electronics harvesting module is connected to the ends of the coil which can harvest, regulate, and store power.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/010,812, filed on Jun. 11. 2014.

BACKGROUND OF THE INVENTION

The deployment of gauges and flow control systems in wellbores require the use of electrical cables and/or hydraulic lines to provide the power in the wellbore necessary for the proper operation of these devices. The cables and tubes are normally placed on the outside of the pipe and strapped to the tubing.

The deployment of cables and tubing requires a significant amount of time and effort with additional equipment required on the rig. The risk involved for accidents and delays in the deployment of the production tubing is significant. Also, the cables and tubing may create a significant challenge when the production pipe is removed from the well. The crushing of the tubing or cut of the tubing may cause the production pipe to be stuck in the well and a fishing job required to remove the broken tubing.

The use of packers in the wells creates another challenge to the deployment of cables. The packers normally do not allow for tubing and cables to pass through the packer. A special and more expensive packer is normally used if the operator wants to run gauges below the packer.

The use of Intelligent Completions in subsea wells has also created a significant challenge to wellhead manufacturers for connections of multiple hydraulic power lines and electric lines. Maintaining the integrity of multiple lines during the deployment of gauges and flow control systems in wells is also very challenging for the operators.

Finally, the ability to deploy sensors closer to the sandface for production surveillance and reservoir performance monitoring as well as fluid characterization is important for production optimization. The need for the development of wet connectors to interface the cable at the upper completion to the lower completion cable for power and communications will be required for proper deployment of sensors and Intelligent Systems.

The use of wireless communications and elimination of cables is desirable in the oilfields to improve reliability, decrease costs and improved the time it takes to deploy the production tubing in the well. Multiple wireless communications systems have been developed for oilfield applications. The systems have to be used in service applications instead of permanent applications due to the short life of the batteries used to operate the communications module.

The deployment of wireless systems for communications in the wellbore may be a game changer since the elimination of cables and connectors may increase the reliability of completion system and provide for production optimization. The elimination of cables and connectors will also decrease significantly the time required to deploy pipe in the well reducing the installation cost significantly and also reducing the equipment required on the rig flow and reducing the number of persons required to install the entire system in the well.

The development of power generators that can be used inside wellbores to provide the necessary long term energy for the operation of downhole systems is critical for the operation of the next generation of Intelligent Wells.

The generator would collect wellbore energy such as flow and vibration converting it into useful electrical power through the use of magnetics.

SUMMARY

The concept for the system is based on the use of magnetics that convert flow and mechanical motion into electrical power.

In an exemplary embodiment, the system comprises a mandrel with a main bore and a side pocket where a portion of the well's fluid is diverted from the main bore through the side pocket. In such exemplary embodiment, the system further comprises a pressure vessel disposed within the side pocket. The pressure vessel rotates or vibrates from the flow diverted through the side pocket. In such exemplary embodiment, the system further comprises an electronics harvesting module connected to the ends of the coils that harvests, regulates, and stores power from the coil. At least one magnet is disposed within the pressure vessel, and at least one coil is wound around the pressure vessel.

In an embodiment of the system, the electronics harvesting module stores power with rechargeable batteries, capacitors, or any other retainer of electricity.

In another embodiment of the system, the system comprises at least one piezoelectric wafer or at least one flexible piezo instead of at least one magnet.

In a preferred embodiment, the system can convert motion into electric power based on the movement along the long axis of the coil/magnets by the small magnets. The magnets will vibrate in their sealed pressure vessel based on a stream of flow diverted from the well into the side pocket of the mandrel.

While preferred aspects and embodiments of the system are shown and described herein, it will be understood that the invention may be embodied otherwise than herein specifically illustrated or described, and that certain changes in form and arrangement of parts and the specific manner of practicing the system may be made within the underlying idea or principles of the system.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the system will become better understood with regard to the follow description, appended claims, and accompanying drawings where:

The various drawings supplied herein are representative of one or more embodiments of the present invention.

FIG. 1 shows a cutaway of an exemplary embodiment of the present system.

DESCRIPTION OF EMBODIMENTS

In the Summary above and in the Description of Embodiments, and the claims below, and in the accompanying drawings, reference is made to particular features of the system. It is to be understood that the disclosure of the system in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the system, or a particular claim, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the system, and in the system generally.

Referring now to FIG. 1, an exemplary embodiment of mandrel 1 of the system is shown. The mandrel 1 is comprised of a maw bore 2 and a side pocket 3, also known as a “side pocket mandrel” in the oil & gas industry.

Referring additionally to FIG. 1, an exemplary embodiment of a pressure vessel 4 is shown disposed within the side pocket 3. Lines of flow through the mandrel 1 is shown m FIG. 1 and diverted through the side pocket 3. Flow through the side pocket 3 facilitates the rotation or vibration of the pressure vessel 4.

Further referring to FIG. 1, in an exemplary embodiment, at least one magnet 5 is disposed within the pressure vessel 4. Moreover, at least one coil 6 is wound around the pressure vessel 4. In certain embodiments, a piezoelectric wafer or a flexible piezo can be used in the place of a magnet 5 to facilitate downhole power generation.

In a preferred embodiment, the system will be developed to convert mechanical and flow energy in the wellbore to electrical power to operate sensors and flow control modules in the well. The system m such embodiments will utilize vibrational energy generated by the wellbore flow to generate electrical energy using electromagnetics technology.

Still referring to FIG. 1, in an exemplary embodiment, a magnetic field will be created and exerted onto the coil 6 from at least one magnet 5 disposed within the coil 6 wound pressure vessel 4. Any disturbance to the balanced magnetic field of the pressure vessel 4 will induce a current onto the coil 6. In a preferred embodiment, multiple small permanent magnets will be mounted adjacent to a fixed pressure vessel 4 to vibrate based on the amount of flow passing near the small magnets.

Further referring to FIG. 1, in an exemplary embodiment, an electronics harvesting module 7 is connected to the ends of the coil 6 that harvests, regulates, and stores power from the coil 6. In a preferred embodiment, the electronics harvesting module 7 will rectify the AC signal into a DC signal for storage in an energy storage medium such as super capacitors, batteries, or any other retainer or storage medium of electricity.

In an exemplary embodiment, energy stored in the energy storage medium, such as super capacitors or batteries, can he used, for example, to power dog sensors, operate a flow control module, or power communications circuits. The system can be used for main power with batteries, or any other energy storage medium, being used as a backup power d there is no flow in the well for extended period of time.

Claims

1. A system for generating in situ power inside as well comprising;

a. a mandrel with a main bore and a side pocket wherein a portion of a well's fluid flows through the side pocket;

b. a pressure vessel disposed within the side pocket wherein a module within the pressure vessel rotates or vibrates from the flow diverted through the side pocket;

c. at least one magnet disposed within the pressure vessel;

d. at least one coil wound around the pressure vessel; and

e. an electronics harvesting module connected to the ends of the coil that harvests, regulates, and stores power from the coil.

2. The system of claim 1 wherein the electronics harvesting module stores power with rechargeable batteries.

3. The system of claim 1 wherein the electronics harvesting module stores power with capacitors.

4. The system of claim 1 wherein the electronics harvesting module stores power with a retainer of electricity.

5. A system for generating in situ power inside a well comprising:

a. a mandrel with a main bore and a side pocket wherein a portion of a well's fluid flows through the side pocket;

b. as pressure vessel disposed within the side pocket wherein as module within the pressure vessel rotates or vibrates from the flow diverted through the side pocket;

c. at least one piezoelectric wafer disposed within the pressure vessel;

d. at least one coil wound around the pressure vessel; and

e. an electronics harvesting module connected to the ends of the coil that harvests, regulates, and stores power from the coil.

6. A system for generating in situ power inside a well comprising:

a. a mandrel with a main bore and a side pocket wherein a portion of a well's fluid flows through the side pocket;

b. a pressure vessel disposed within the side pocket wherein a module within the pressure vessel rotates or vibrates from the flow diverted through the side pocket;

c. at least one flexible piezo disposed within the pressure vessel

d. at least one coil wound around the pressure vessel; and

e. an electronics harvesting module connected to the ends of the coil that harvests, regulates, and stores power from the coil.