Abstract:
The present invention provides means to extend the flow rate range over which a downhole turbine  70  will return a power output sufficient to meet the minimum downhole power requirements. In one embodiment, the present invention relates to an arrangement of axial vanes  77  that are situated such that the rotation of the rotor  76  generates an increasing drag force, thereby extending the upper limit of the flow rate range. In another embodiment, the present invention relates to an arrangement of restriction assemblies  75  that can be used to maximize the fluid velocity relative to the fluid flow rate past the stator  74  to achieve the necessary speed and power to rotate rotor  76 , thereby extending the lower limit of the flow rate range. In another embodiment, the axial vanes  77  and restriction assemblies  75  are used in combination to further extend both the upper and lower limits of the flow rate range of the downhole turbine  70.

Description:
BACKGROUND 
     In many downhole drilling and measurement systems, a downhole power source is required. The power source can include direct power output from the torque and rotation of the drill string, electrical storage batteries, and turbines, among others. In a drilling environment where mud flow is present, there is an opportunity to use part of this hydraulic power to drive a turbine. The turbine can, in turn, rotate a variety of electrical, mechanical, or other devices to convert the hydraulic energy into a desired power output. 
     Turbines, although efficient, must be operated within a narrow rotational speed range for optimum power output. The rotational speed of the turbine is related to the flow rate or velocity of the drilling mud. It is desirable to extend or maximize the range of flow rates (minimum to maximum) over which optimum power output can be achieved, such that the downhole operation can be used with the broadest possible hydraulic parameters desired in the drilling process. 
     Various techniques have been developed for manipulating flow through a turbine, such as U.S. Pat. No. 6,402,465, issued to Maier. The Maier patent provides a ring valve for turbine flow control for industrial turbines with compressible flow. In this case, the overall mass flow focuses control on the apparatus and fails to disclose the use of an incompressible flow, velocity approach. There are various other downhole systems, such as measurement while drilling (MWD) tools, turbodrills, etc., that use turbines for power generation. However, so far as known to applicants, these devices fail to provide techniques capable of extending flow ranges. 
     SUMMARY OF THE INVENTION 
     The present invention provides means to extend the flow rate range over which a turbine will return a power output sufficient to meet the minimum downhole power requirements. In one aspect, the present invention relates to an arrangement of axial vanes that are situated such that the rotation of the turbine generates an increasing drag force. This force acts on the turbine to reduce the rate of increase in speed such that the actual rotations per minute (rpm) is lower than what it would have been if the axial vanes were not present. This in effect, increases the flow range. 
     In another aspect the invention relates to an arrangement of gate(s) or piston element(s) that extend radially between the turbine stator blades. At low flow these elements are extended to maximize fluid velocity relative to the flow rate to achieve the speed and power to operate the turbine systems. At high flow, the element(s) retract progressively to reduce the velocity relative to the flow rate such that the speed and power are limited in such a fashion to extend the flow rate. Method of extension can either be actively controlled or passively controlled. 
     One embodiment of the present invention provides a turbine useful for power generation downhole. The turbine can have a stator having a fluid flow path sufficient to impart tangential and axial vector flow components on a fluid flowing past the stator, a rotor hydraulically communicating with the stator, impelled by the vectored fluid flow, a shaft coupled to the rotor, and, one or more braking vanes connected to the rotor, imparting a drag force on the rotor as the rotor and braking vanes rotate. The turbine can drive a generator coupled to the shaft. The shaft can also be coupled to: mechanical transmissions, such as gears, cams, cogs, screws, and the like; hydraulic transmissions, such as pumps, pistons, plungers, and the like; or electrical generators, such as a motor. Each of the mechanical transmissions, hydraulic transmissions, or electrical generators can be used for conversion of shaft power to usable work. 
     In another embodiment, the turbine can have a stator having a fluid flow path sufficient to impart tangential and axial vector flow components on a fluid flowing past the stator, a rotor hydraulically communicating with the stator, impelled by the vectored fluid flow, a shaft coupled to the rotor, and, one or more restriction assemblies connected to the stator to selectively control a flow velocity of a fluid past the stator. The restriction assembly can be connected to the stator at a fluid flow path inlet or outlet. 
     The restriction assemblies can be actively controlled or passively controlled. Active control can be obtained by hydraulic activation through pressure drops, auxiliary power acting on the restriction assemblies, or pistons actuated by an external source. Passive control can be supplied by springs, elastomeric elements, or plastic elements that impart a force on the restriction elements. 
     In another embodiment, the turbine can have a stator having a fluid flow path sufficient to impart tangential and axial vector flow components on a fluid flowing past the stator, a rotor hydraulically communicating with the stator, impelled by the vectored fluid flow, a shaft coupled to the rotor, one or more restriction assemblies connected to the stator to selectively control a flow velocity of a fluid past the stator, and, one or more braking vanes connected to the rotor, imparting a drag force on the rotor as the rotor and braking vanes rotate. 
     The present invention provides a method of extending the flow range of a downhole turbine comprising a stator having a fluid flow path imparting tangential and axial vector flow components on a fluid flowing past the stator; a rotor hydraulically communicating with the stator and impelled by the vectored fluid flow, and a shaft coupled to the rotor. The flow range can be extended by installing one or more braking vanes on the rotor to impart a drag force on the rotor as the rotor and braking vanes rotate, and increasing the fluid flow rate to activate the movement of the turbine. 
     The flow range can be extended by attaching one or more restriction assemblies to the stator to selectively control a flow velocity of a fluid through the stator and activating the one or more restriction assemblies to moderate the fluid flow velocity past the stator. The flow range can also be extended by installing one or more braking vanes on the rotor to impart a drag force on the rotor as the rotor and braking vanes rotate, and, attaching one or more restriction assemblies to the stator to selectively control a flow velocity of a fluid through the stator, and increasing fluid flow while concurrently moderating the restriction assemblies to moderate fluid flow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic drawing illustrating a cross-section of a downhole turbine (prior art). 
         FIG. 2  is a schematic drawing of a downhole turbine with braking vanes according to one embodiment of the invention. 
         FIG. 3  is a schematic drawing of a downhole turbine with braking vanes according to one embodiment of the invention. 
         FIG. 4  is a schematic drawing of a downhole turbine with braking vanes according to one embodiment of the invention. 
         FIG. 5  is a schematic drawing of a downhole turbine with braking vanes according to one embodiment of the invention. 
         FIG. 6  is a graphical representation of the power dissipated as a function of turbine rotation speed for a downhole turbine with braking vanes according to one embodiment of the invention. 
         FIG. 7  is a schematic drawing of a downhole turbine with restriction elements according to one embodiment of the invention. 
         FIG. 8  is a schematic drawing of a downhole turbine with restriction elements according to another embodiment of the invention. 
         FIG. 9  is a schematic drawing of a downhole turbine with restriction elements according to another embodiment of the invention. 
         FIG. 10  is a schematic drawing of a downhole turbine with restriction elements and braking vanes according to another embodiment of the invention. 
         FIG. 11  is a schematic drawing of a downhole turbine with restriction elements according to another embodiment of the invention. 
         FIG. 12  is a schematic drawing of a downhole turbine having both restriction elements and braking vanes according to one embodiment of the invention. 
         FIG. 13  is a schematic drawing of a downhole turbine having both restriction elements and braking vanes according to another embodiment of the invention. 
         FIG. 14  is a schematic drawing of a downhole turbine having both restriction elements and braking vanes according to another embodiment of the invention. 
         FIG. 15   a  is a graphical representation of the overall estimated power and operating points of a downhole turbine without a brake as a function of turbine rotation speed with a water flow rate of 300 gpm. 
         FIG. 15   b  is a graphical representation of the overall estimated power and operating points of a downhole turbine with a brake, according to one embodiment of this invention, as a function of turbine rotation speed with a water flow rate of 300 gpm. 
         FIG. 16   a  is a graphical representation of the overall estimated power and operating points of a downhole turbine without a brake as a function of turbine rotation speed with a water flow rate of 720 gpm. 
         FIG. 16   b  is a graphical representation of the overall estimated power and operating points of a downhole turbine with a brake, according to one embodiment of this invention, as a function of turbine rotation speed with a water flow rate of 720 gpm. 
         FIG. 17   a  is a graphical representation of the overall estimated power and operating points of a downhole turbine without gates as a function of turbine rotation speed with a water flow rate of 200 gpm. 
         FIG. 17   b  is a graphical representation of the overall estimated power and operating points of a downhole turbine with gates, according to one embodiment of this invention, as a function of turbine rotation speed with a water flow rate of 200 gpm. 
         FIG. 17   c  is a graphical representation of the overall estimated power and operating points of a downhole turbine with gates, according to one embodiment of this invention, as a function of turbine rotation speed with a water flow rate of 680 gpm. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a schematic drawing illustrating the cross-section of a typical, prior art, downhole turbine  10 . Fluids, such as drilling muds, water, oil, or other fluids flowing through the turbine  10  are flowing in the direction as indicated by flow direction arrows  12 . Stator  14  is a stationary element that directs the fluid flow and imparts a flow vector, having both axial and tangential components, on the fluids that flow over rotor  16 . The vectored fluid flow produces a torque on rotor  16  causing rotor  16  to rotate with an angular velocity. Rotor  16  is coupled to shaft  18 , which converts this hydraulic energy into mechanical power. Shaft  18  can be coupled to various other devices such as mechanical, electrical, hydraulic, or other means to convert this shaft power to usable work. This is a well known practice utilized in the prior art. In addition to stator  14  and rotor  16 ,  FIG. 1  shows other various mechanical elements of a downhole turbine  10 , which are not described herein. The rotor  16  can be connected to shaft  18  that can be coupled to an electrical generator (not shown). The generator converts the hydraulic power of the fluid flow into electrical power. 
       FIG. 2  is a schematic drawing illustrating a downhole turbine  20  according to one embodiment of the invention. The direction of fluid flow is given by directional arrow  22 . The downhole turbine  20  can have stator  24  and rotor  26 . Stator  24  is a stationary element that directs the fluid flow and imparts a flow vector, having both axial and tangential components, on the fluids that enter the flow path between the interior wall of the turbine and the exterior surfaces of rotor  26 . The vectored fluid flow produces a torque on rotor  26  causing rotor  26  to rotate with an angular velocity. Rotor  26  is coupled to shaft  28 , which converts this hydraulic energy into mechanical power. Shaft  28  can be coupled to various other devices such as mechanical, electrical, hydraulic, or other means to convert this shaft power to usable work.  FIG. 2  shows other various mechanical elements of a downhole turbine stator  24  and turbine rotor assembly  26 , which are not described herein. The rotor  26  is connected to shaft  28 , that is coupled to an electrical generator (not shown). The generator converts the hydraulic power of the fluid flow into electrical power. 
     Downhole turbine  20  can have turbine rotor braking vanes  27 , located downstream of rotor  26 . Turbine rotor braking vanes  27  may also be referred to as axial braking vanes or braking fins herein. Braking vanes  27  are provided to induce drag force along with rotation of the turbine rotor  26 . Braking vanes  27  can be rectangular shaped fins, or can be of a variety of other shapes suitable for increasing the drag force.  FIGS. 3 and 4  are representations of one embodiment of portions of downhole turbine  20 . Illustrated in  FIGS. 3 and 4  are elements of downhole turbine  20  including stator  24 , rotor  26 , and braking vanes  27 . Rotor  26  and braking vanes  27  rotate in the direction indicated by directional arrow  29 . 
     In an alternative embodiment, downhole turbine  20 , having braking vanes  27 , can be as illustrated in  FIG. 5 . Downhole turbine  20  can be operated without stator  24  where stator  24  is not used or required. 
     The drag force imparted by braking vanes  27  can allow the flow rate range of turbine  20  to be extended. The drag force from the brake fins  27  increases in proportion to the square of the rotation speed so that a higher (as opposed to just linear) drag force is induced at the higher speeds than the lower speeds. Drag force, drag torque, and power dissipated can be estimated as follows: 
     Brake Fin Drag Force (F d ): 
     
       
         
           
             
               F 
               d 
             
             = 
             
               
                 1 
                 2 
               
               · 
               
                 C 
                 D 
               
               · 
               ρ 
               · 
               
                 
                   ( 
                   
                     ω 
                     · 
                     
                       r 
                       d 
                     
                   
                   ) 
                 
                 2 
               
               · 
               
                 A 
                 fins 
               
             
           
         
       
     
     Brake Fin Drag Torque (T bf ):
 
 T   bf   =F   d   ·r   d  
 
     Brake Fin Power Dissipated (P bf ): 
               P   bf     =         -     T   bf       ·   ω     =         -     1   2       ·     C   D     ·   ρ   ·     A   fins     ·     r   d   3     ·     ω   3       =       -     1   2       ·     C   D     ·   ρ   ·     A   fins     ·     r   d   3     ·       (       2   ·   π     60     )     3     ·     n   3                 
where C D  is the fin drag coefficient, r d  is the fin distance from the center of rotation, ω is the angular velocity, A fins  is the area of the fins, ρ is the fluid density, and n is the revolutions per minute of the rotor  26  and braking fins  27 .
 
     The power dissipated (P bf , in Watts), for a set of nominal dimensions, use of a single pair of braking fins  27  located on a rotor hub, and hydraulic flow with water can be estimated using the above equations, and shown graphically, as given in  FIG. 6 . The above equations and  FIG. 6  indicate that the power dissipated increases as a function of turbine rotation speed, n 3 . Thus, while the drag force is present at the lower point of the turbine operating range (rpm and flow rate), the drag force is much higher at the upper range. The increased drag force effectively increases the flow rate range, minimum to maximum, over which the turbine can be used, as is further exemplified in Example 1 below. 
       FIG. 7  illustrates another embodiment of the present invention useful for extending the flow rate range. The direction of fluid flow through downhole turbine  60  is given by directional arrow  62 . The downhole turbine  60  can have stator  64  and rotor  66 . Extension or restriction elements  65  can be used to block off selected portions of the stator  64  and increase the local flow velocity over portions of the stator  64  that is imparted to the inlet of rotor  66 , resulting in higher speeds relative to flow at the lower end of the flow range. As the flow range increases, the extension elements  65  retract, and the velocity of the fluid is moderated such that speed and power can be obtained normally due to the blade flow angles. The effective result is that the lower end speed and power is increased due to this selective local flow velocity increase. This velocity increase imparts more fluid momentum to the rotor  66 , thereby allowing turbine operation at lower flow rates. 
     The position of elements  65  relative to stator  64  can be passively controlled. Increased flow and drag force can be used to move elements  65  in such a way that the access to stator flow area would be increased at higher flow rates. Passive means of control, such as springs applying force to pistons or gates, can be used to actuate elements  65 . Similarly, elastomer or plastic gates incorporating spring-like behavior in their structure can be used as extension elements  65 . In these alternative actuation means, increased flow and drag force can be used to compress the springs or deflect the elements  65  in such a way that the flow area would be modulated, thereby allowing the turbine to be maintained within an optimal or desired range. 
     The position of elements  65  relative to stator  64  can also be actively controlled. Computer or operator control of the position of elements  65  can be employed such that the position of gate elements  65  is actively controlled in response to the flow rate or rotor rotation speed. Active means of control, such as hydraulic activation through pressure drops, auxiliary power acting on the gates, pistons, etc. can be used to activate and/or position extension elements  65 . 
     The operation of the turbine may be analyzed using the following basic turbine equations for calculating the effects of the gates: 
     Basic turbine torque from tangential velocities: 
     
       
         
           
             T 
             = 
             
               
                 ⅆ 
                 
                   ⅆ 
                   t 
                 
               
               ⁢ 
               
                 m 
                 · 
                 
                   ( 
                   
                     
                       
                         
                           v 
                           
                             ax 
                             ⁢ 
                             _ 
                             ⁢ 
                             stator 
                           
                         
                         · 
                         tan 
                       
                       ⁢ 
                       
                           
                       
                       ⁢ 
                       α 
                     
                     + 
                     
                       
                         
                           v 
                           
                             ax 
                             ⁢ 
                             _ 
                             ⁢ 
                             rotor 
                           
                         
                         · 
                         tan 
                       
                       ⁢ 
                       
                           
                       
                       ⁢ 
                       β 
                     
                     - 
                     
                       ω 
                       · 
                       
                         r 
                         rotor 
                       
                     
                   
                   ) 
                 
                 · 
                 
                   r 
                   rotor 
                 
               
             
           
         
       
     
     Average velocities, incompressible flow: 
     
       
         
           
             
               v 
               
                 ax 
                 ⁢ 
                 _ 
                 ⁢ 
                 stator 
               
             
             = 
             
               Q 
               
                 A 
                 stator 
               
             
           
         
       
     
     
       
         
           
             
               v 
               
                 ax 
                 ⁢ 
                 _ 
                 ⁢ 
                 rotor 
               
             
             = 
             
               Q 
               
                 A 
                 rotor 
               
             
           
         
       
     
     Mass flow rate, revolutions per minute: 
     
       
         
           
             
               
                 
                   
                     
                       ⅆ 
                       
                         ⅆ 
                         t 
                       
                     
                     ⁢ 
                     m 
                   
                   = 
                   
                     ρ 
                     · 
                     
                       v 
                       ax 
                     
                     · 
                     A 
                   
                 
               
             
             
               
                 
                   ω 
                   = 
                   
                     
                       2 
                       · 
                       π 
                       · 
                       n 
                     
                     60 
                   
                 
               
             
           
         
       
     
     Combining the above equations to results in torque and power as a function of areas and rpm: 
                   T   =     ρ   ·   Q   ·     (           Q   ·   tan     ⁢           ⁢   α       A   stator       +         Q   ·   tan     ⁢           ⁢   β       A   rotor       -         2   ·   π   ·   n     60     ·     r   rotor         )     ·     r   rotor                   P   =     ρ   ·   Q   ·     (           Q   ·   tan     ⁢           ⁢   α       A   stator       +         Q   ·   tan     ⁢           ⁢   β       A   rotor       -         2   ·   π   ·   n     60     ·     r   rotor         )     ·     r   rotor     ·       2   ·   π   ·   n     60                   
where v ax  is the axial flow velocity, α is the stator flow exit angle, β is the rotor flow exit angle, Q is the total flow rate of the fluid, r is the mean radius of the rotor, A stator  is the axial flow area of the stator, A rotor  is the axial flow area of the rotor, and n and ω are as defined earlier.
 
     As can be seen in the equations, torque and power increase as A stator  decreases from the effect of the gates. These equations are simplified for clarity and/or to demonstrate the fundamental principle being utilized here, that by selectively increasing the flow velocity at the stator exit by reducing the flow area of the stator increases power transmission at low flow rates. Additional equations and mathematical assumptions may be used to determine the overall effects of the various efficiencies and system losses and interactions, all in a manner well known in this industry. 
     In an alternative embodiment, downhole turbine  60  can be as illustrated in  FIG. 8 . Restriction elements  65  can be located on rotor  66 , and downhole turbine  60  can be operated without stator  64 . In another alternative embodiment, as illustrated in  FIG. 9 , restriction elements  65  can be located on rotor  66 , and downhole turbine  60  can be operated with stator  64 . In yet another alternative embodiment, as illustrated in  FIG. 10 , restriction elements  65  and braking vanes  67  can be located on rotor  66 , and downhole turbine  60  can be operated with stator  64 . 
     In another alternative embodiment, downhole turbine  60  can be as illustrated in  FIG. 11 . Restriction elements  65  can be located on stator  64  and restriction elements  69  can be located on rotor  66 . Restriction elements  65  and  69  can be of similar or different designs. 
     The embodiments described above can be used independently or in combination to affect the rotor and/or the stator, such as in  FIG. 12 . These methods can be combined to further increase the flow range of a turbine  70 . The direction of fluid flow through downhole turbine  70  is given by directional arrows  72 . The downhole turbine  70  can have stator  74  and rotor  76 . Extension or restriction elements  75  can be used to restrict flow of a fluid through portions of the stator  74  to increase the local flow velocity of the fluid over portions of the stator  74 . The increased hydraulic energy of the fluid can be imparted to the inlet of rotor  76 , resulting in higher rotation speeds at lower fluid flow rates, as discussed earlier. Braking vanes  77  can be provided to induce drag force along with rotation of the rotor  76 , where the drag force increases with rotation speed, as discussed earlier. In this manner, the flow rate range of the turbine can be extended to both higher and lower fluid flow rates. 
     In an alternative embodiment, downhole turbine  70 , having braking vanes  77 , can be as illustrated in  FIG. 13 . Restriction elements  75  can be located on rotor  76 , and downhole turbine  70  can be operated without stator  74 . 
     In another alternative embodiment, downhole turbine  70 , having braking vanes  77 , can be as illustrated in  FIG. 14 . Restriction elements  75  can be located on stator  74  and restriction elements  79  can be located on rotor  76 . Restriction elements  75  and  79  can be of similar or different design. 
     Additional variations and combinations of the above methods that apply the above principles and scope of this invention do not exceed the scope of the present invention. 
     EXAMPLE 1 
     The extension of the flow rate range resulting from use of a braking fin is depicted graphically in  FIGS. 15   a - 15   b  and  16   a - 16   b . Using a turbine and overall electrical and mechanical system parameters in a typical system to drill and measure 8.5 inch well bores, the overall estimated power and operating points can be modeled for systems with and without braking fins.  FIGS. 15   a  and  16   a  illustrate the computation results for a system without braking fins at 300 gpm and 720 gpm water flow, respectively.  FIGS. 15   b  and  16   b  illustrate the computation results for a system with braking fins at similar flow rates such that a direct comparison can be made. Each graph shows two power calculation results—the curved dashed line represents the net power resulting from the shaft rotation, and the solid curved line represents the power that can be generated from an electrical, mechanical, or hydraulic device operated by the rotor rotation, used to convert shaft rotation power to usable work (a power generation system). The linear dashed line represents the threshold power required to operate the tools. The tool operating point is typically taken as the greater rpm point of intersection of the normal operating power requirement (linear dashed line) and the power generated from the power generation system (curved solid line). 
     The normal operating power required for the tools is approximately 120 watts. Comparing  FIGS. 15   a  and  15   b , at a water flow rate of 300 gpm, the tool operating point is approximately 100 rpm lower with a braking fin than for a power generation system operated without a braking fin. Comparing  FIGS. 16   a  and  16   b , at a water flow rate of 720 gpm, the tool operating point is approximately 400 rpm lower with a braking fin  27  than for a power generation system operated without a braking fin  27 . 
     Since turbine rpm is roughly linear with flow, this 4:1 ratio of turbine rpm reduction at the high and low end of the flow rate range respectively will result in a broader flow range. For this example, the flow rate range is estimated to be 40 gpm higher at the upper end of the flow rate range and 10 gpm higher at the lower end of the flow rate range. 
     EXAMPLE 2 
     The extension of the flow rate range resulting from use of gates or extension elements is depicted graphically in  FIGS. 17   a - 17   c , where the lines represent data as previously described for  FIGS. 15   a - 15   b  and  16   a - 16   b . Again, using a turbine and overall electrical and mechanical system parameters in a typical system used to drill and measure 8.5 inch well bores, the overall estimated power and operating points can be modeled for systems with and without gates.  FIG. 17   a  shows the model results for a system without restriction elements, where the stator area is not restricted, i.e. 100% open, and at a water flow rate of 200 gpm. Without restriction elements, the power generated from the turbine is below the threshold power required to operate the tool. At the same 200 gpm water flow rate, restricting flow through the stator, where the stator area is 50% open, results in power generation that allows the tools to operate, as shown in  FIG. 17   b . At a flow rate of 680 gpm water, the restriction elements operate so as to not restrict flow through the stator, resulting in similar model results for systems with and without restriction elements, as shown in  FIG. 17   c . Use of restriction elements to restrict flow through the stator at low flow rates effectively allowed the tools to operate at the lower flow rate, thereby extending the flow rate range. 
     Numerous embodiments and alternatives of the present invention have been disclosed. While the above disclosure includes what is believed to be the best mode for carrying out the invention, as contemplated by the inventor, not all possible alternatives have been disclosed. For that reason, the scope and limitation of the present invention is not to be restricted to the above disclosure, but is instead to be defined and construed by the appended claims.