A flow control system for power generation

Abstract

A valve assembly for use in controlling flow of a fluid in a wellbore includes a housing including an internal passageway, a conductor located adjacent to the internal passageway, a rotor assembly located outside of the internal passageway, and a flow path to receive a flow of the fluid therethrough to rotate the rotor assembly. The rotor assembly includes a magnet having a magnetic field and rotatable with the rotor assembly, where rotation of the rotor assembly and the magnet relative to the conductor produces electrical energy in the conductor.

We claim: 
     
         1 . A valve assembly for use in controlling flow of a fluid in a wellbore, comprising;
 a housing including an internal passageway;   a conductor located adjacent to the internal passageway;   a rotor assembly located outside of the internal passageway and comprising:
 a magnet having a magnetic field and rotatable with the rotor assembly; and 
   a flow path to receive a flow of the fluid therethrough to rotate the rotor assembly, wherein rotation of the rotor assembly and the magnet relative to the conductor produces electrical energy in the conductor.   
     
     
         2 . The valve assembly of  claim 1 , wherein the magnet is embedded within a rotatable bearing of the rotor assembly to produce internal electrical energy. 
     
     
         3 . The valve assembly of  claim 1 , wherein the magnet is embedded within a blade of the rotor assembly to generate external electrical energy. 
     
     
         4 . The valve assembly of  claim 1 , further comprising a central processing unit (CPU) powered by the electrical energy. 
     
     
         5 . The valve assembly of  claim 1 , further comprising a battery configured to store the electrical energy. 
     
     
         6 . The valve assembly of  claim 5 , wherein the battery further comprises a rechargeable battery array configured to be rechargeable by the electrical energy. 
     
     
         7 . The valve assembly of  claim 1 , wherein the rotatable assembly configured to rotate continuously or intermitted to change the magnetic field of the magnet. 
     
     
         8 . A control system for downhole applications, comprising:
 a valve assembly configured to control a flow of a fluid in a wellbore, comprising;
 a housing including an internal passageway; 
 a conductor located adjacent to the internal passageway; 
 a rotor assembly located outside of the internal passageway comprising:
 a magnet having a magnetic field and rotatable with the rotor assembly; and 
 
 a flow path to receive a flow of the fluid therethrough to rotate the rotor assembly, wherein rotation of the rotor assembly and the magnet relative to the conductor produces electrical energy in the conductor; and 
   a central processing unit (CPU) configured to control one or more valves, wherein the electrical energy is used to power the CPU.   
     
     
         9 . The control assembly of  claim 8 , further comprising:
 a master central processing unit (CPU) configured to interface with and to provide control signals to the CPU; and   wherein the CPU supplies power to the master CPU.   
     
     
         10 . The control assembly of  claim 9 , wherein the control signals comprise logic to actuate the one or more valves. 
     
     
         11 . The control assembly of  claim 9 , wherein the control signals comprise logic to optimize flow characteristics of the one or more valves. 
     
     
         12 . The control assembly of  claim 8 , wherein the CPU is a slave to a master CPU and wherein the master CPU directly controls the one or more valves. 
     
     
         13 . The control assembly of  claim 8 , wherein the CPU autonomously controls the one or more valves via a pre-programmed signal when a master CPU is inoperable. 
     
     
         14 . The control assembly of  claim 8 , wherein the CPU monitors real-time downhole parameter data against a control signal of a master CPU. 
     
     
         15 . The control assembly of  claim 8 , further comprising a gauge system configured to measure parameters for the downhole applications and to provide real-time downhole parameter data. 
     
     
         16 . The control assembly of  claim 8 , wherein the CPU is configured to power and control one or more components attached to the one or more valves. 
     
     
         17 . A method for operating a valve assembly, comprising:
 maintaining ports of the valve assembly in an open position to permit a fluid to flow through an internal passageway of the valve assembly;   flowing the fluid through an opening of a rotor assembly located outside of the internal passageway to rotate the rotor assembly, wherein the rotation rotates a magnet attached to the rotor assembly to vary a magnetic field of the magnet; and   exposing a conductor located adjacent to the rotor assembly to the varying magnetic field to produce electrical energy in the conductor.   
     
     
         18 . The method of  claim 17 , further comprising supplying the electrical energy to a central processing unit (CPU) to control a function of a valve located in a downhole environment. 
     
     
         19 . The method of  claim 18 , further comprising interfacing a master CPU with the CPU, wherein the CPU supplies power to the master CPU. 
     
     
         20 . The method of  claim 17 , further comprising storing the electrical energy in a battery for further use in a downhole environment.