Methods and apparatus for in situ generation of power for devices deployed in a tubular

Abstract

A device, system, and methods of power generation in situ in a hydrocarbon well are disclosed. A power generator for deployment in a hydrocarbon well tubular may comprise a housing adapted for deployment within a hydrocarbon well tubular; a mechanical to electrical power converter disposed at least partially within the housing, the mechanical to electrical power converter adapted to create an electric current when physically stressed; and a current converter operatively coupled to the mechanical to electrical power converter. Devices may be deployed downhole and operatively coupled to the power generator for their electrical power. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope of meaning of the claims.

1 . A power generator for deployment in a hydrocarbon well tubular, comprising: 
 a. a housing adapted for deployment within a hydrocarbon well tubular; and    b. a mechanical to electrical power converter disposed at least partially within the housing, the mechanical to electrical power converter adapted to create an electric current when physically stressed by a force present within the hydrocarbon well tubular    
   
   
       2 . The power generator of  claim 1 , wherein the mechanical to electrical power converter comprises stressable material, further comprising at least one of (i) a piezoelectric material or (ii) a magneto-restrictive material.  
   
   
       3 . The power generator of  claim 1 , further comprising a current converter operatively coupled to the mechanical to electrical power converter.  
   
   
       4 . The power generator of  claim 3 , wherein the current converter comprises at least one of (i) an alternating current to direct current converter or (ii) a direct current to alternating current converter.  
   
   
       5 . The power generator of  claim 1 , further comprising a mechanical vibration amplifier operatively coupled to the mechanical to electrical power converter and adapted to increase power generated by the mechanical to electrical power converter.  
   
   
       6 . The power generator of  claim 1 , further comprising a power storage medium.  
   
   
       7 . The power generator of  claim 6 , wherein the power storage medium comprises at least one of (i) a battery pack or (ii) a capacitor bank.  
   
   
       8 . The power generator of  claim 1 , further comprising an inductor operatively coupled to the mechanical to electrical power converter, the inductor adapted to cancel a capacitive part of impedance of the mechanical to electrical power converter.  
   
   
       9 . The power generator of  claim 8 , wherein the cancellation minimizes the impedance.  
   
   
       10 . A power generator, comprising: 
 a. a mechanical vibration amplifier;    b. a mechanical to electrical power converter operatively coupled to the mechanical vibration amplifier and adapted to create an electrical current when vibrated;    c. a power conditioner operatively coupled to the power converter; and    d. a power storage medium operatively coupled to the power converter.    
   
   
       11 . The power generator of  claim 10 , further comprising a coating adapted to retard erosion of a predetermined portion the power module.  
   
   
       12 . The power generator of  claim 11 , wherein: 
 a. the coating comprises a ceramic; and    b. the predetermined portion of the power module comprises the mechanical to electrical power converter.    
   
   
       13 . The power generator of  claim 10 , wherein the mechanical to electrical power converter is adapted to be deployed at least partially within the tubular and to be exposed to hydrocarbon flow within the tubular.  
   
   
       14 . The power generator of  claim 10 , wherein: 
 a. the power module comprises a doughnut shaped design; and    b. the mechanical to electrical power converter is disposed in a pressure balanced apparatus as part of a downhole tool.    
   
   
       15 . The power generator of  claim 14 , further comprising a pressure bellows operatively coupled to the mechanical to electrical power converter and adapted to cause a force to be exerted onto the mechanical to electrical power converter in the presence of fluid flowing in the tubular.  
   
   
       16 . The power generator of  claim 10 , wherein: 
 a. the power module comprises a plurality of housings; and    b. the mechanical to electrical power converter comprises a plurality of the mechanical to electrical power converter, each housing at least partially containing one of the plurality of mechanical to electrical power converters.    
   
   
       17 . A method of generating power from within a tubular, comprising: 
 a. deploying a power generator within a tubular, the power generator comprising a mechanical vibration amplifier, a mechanical to electrical power converter, a power conditioner, and a power storage medium;    b. operatively coupling the power generator to a source of vibration; and    c. providing an outlet for electricity generated by the power generator.    
   
   
       18 . The method of  claim 17 , further comprising operatively coupling a device within the tubular that requires electric power to the outlet of the power generator.  
   
   
       19 . The method of  claim 18 , wherein the device is an acoustic generator adapted to vibrate the tubular.  
   
   
       20 . A system for downhole control, comprising: 
 a. a control module adapted to be deployed downhole;    b. a wireless transceiver operatively in communication with the control module, the wireless transceiver adapted to be deployed downhole; and    c. a power generator operatively coupled to the wireless transceiver, the power generator comprising a stressable material adapted to create an electric current when physically stressed.    
   
   
       21 . The system of  claim 20 , wherein the system is adapted for use with an intelligent completion system.  
   
   
       22 . The system of  claim 21 , wherein the control module comprises at least one of (i) a sensor, (ii) a gauge, (iii) a meter, or (iv) a flow control device.  
   
   
       23 . The system of  claim 20 , wherein the transceiver comprises at least one if (i) an active transceiver or (ii) a repeater.  
   
   
       24 . The system of  claim 20 , wherein the power generator is adapted for use as a separate power station to be deployed as part of a production tubing and is further adapted to be used to generate and store power to be transferred to a mobile system temporarily attached to the power generator.  
   
   
       25 . The system of  claim 20 , wherein the power generator is deployed through tubing for use with at least one of (i) a permanent service in the wellbore or (ii) a system that performs a temporary service in the wellbore.  
   
   
       26 . The system of  claim 20 , wherein the system is adapted for deployment at a subsea level at a hydrocarbon transmission pipeline to provide information related to the flow of hydrocarbon through the pipeline, the information comprising at least one of (i) pressure, (ii) temperature, or (iii) flow.  
   
   
       27 . The system of  claim 20 , wherein: 
 a. fluid flowing in a downhole pipe creates a vibration usable by the stressable material to allow generation of electricity by the stressable material; and    b. the electricity generated is used to power a sensor operatively in communication with the power generator.    
   
   
       28 . The system of  claim 20 , wherein: 
 a. the system is disposed proximate a subsea wellhead and control assembly to generate electricity as hydrocarbons flow from downhole to a surface location; and    b. electrical power generated by the power generator provides at least partial power for electronics and electromechanical devices located proximate the subsea wellhead.    
   
   
       29 . A method of deploying a downhole tool, comprising: 
 a. deploying a control module downhole;    b. deploying a wireless transceiver downhole, the wireless transceiver operatively in communication with the control module;    c. deploying a power generator downhole, the power generator operatively coupled to the wireless transceiver, the power generator comprising a stressable material adapted to create an electric current when physically stressed;    d. exposing the power generator to a source of physical stress downhole; and    e. generating electrical current using the power generator when exposed to the physical stress.    
   
   
       30 . The method of  claim 29 , wherein the physical stress is obtained using vibration generated at least partially by production flow.  
   
   
       31 . The method of  claim 29 , wherein the power generator comprises at least one of (i) a piezoelectric material or (ii) a magentoresistive material.  
   
   
       32 . The method of  claim 29 , wherein the power generator comprises a power storage system deployed downhole.  
   
   
       33 . The method of  claim 32 , further comprising storing a portion of the electricity generated by the power system in the power storage system deployed downhole.