Downhole power source

Abstract

A power source system including a plurality of cells. The power source system uses electrical charge or current generated by a reaction in at least one of the cells to provide at least one operating material to at least one other of the cells. Optionally, the power source system uses the electrical charge generated by the reaction in the at least one of the cells to provide the at least one operating material to the at least one other of the cells only when the state of charge of the at least one of the cells is equal to or below a threshold or when the use of the cell is equal to or above a threshold. Optionally, in an initial or non-operational state, one or more or each of the cells is dry or without the at least one operating material and the power source system is configured to selectively switch at least one of the plurality of cells from the non-operational state to an operational state by providing the at least one operating material to the at least one cell.

Claims

1. A power source system comprising: a plurality of cells, each cell being switchable from a non-operational state to an operational state by providing at least one operating material to the cell; and a controller configured to record and/or monitor energy usage from the cells, wherein the power source system is configured to use electrical charge or current generated by a reaction in at least one of the cells to provide the at least one operating material to at least one other of the cells when the energy usage from the at least one of the cells determined by the controller is equal to or above a threshold.

2. The power source system of claim 1, comprising at least one storage vessel for storing the at least one operating material; and wherein the power source system is configured to use the electrical charge generated by the reaction in the at least one of the cells to provide the at least one operating material from the at least one storage vessel to the at least one other of the cells.

3. The power source system of claim 1, wherein, in an initial or non-operational state, one or more or each of the cells are dry or without the at least one operating material; and the power source system is configured to selectively switch at least one of the plurality of cells from the non-operational state to an operational state by providing the at least one operating material to the at least one cell wherein in the operational state, the at least one operating material is active or usable in an electrochemical reaction.

4. The power source system of claim 1, wherein the reaction is or comprises a reaction that utilizes the at least one operating material, and wherein the reaction is or comprises an electrochemical reaction.

5. The power source system of claim 1, wherein the operating material is, or comprises, or is comprised in, a fluid, liquid, gas, a colloid or a solution.

6. The power source system of claim 1, wherein one or more or each cell comprises: a separator that comprises one of: a membrane, a porous separator or a solid electrolyte membrane; at least two chambers, which are separated by the separator; and at least two electrodes, wherein the at least two electrodes comprise at least a cathode and an anode and wherein at least one electrode is provided in one of the chambers on one side of the separator and at least one other electrode is provided in another one of the chambers on another side of the separator.

7. The power source system of claim 6, wherein the system is configured to use the electrical charge generated by the reaction in the at least one of the cells to provide at least two respective different operating materials to respective different chambers of the at least one other of the cells.

8. The power source system of claim 1, wherein the power source system is configured to enable or control transmission of at least one operating material from a storage vessel to at least one of the plurality of cells when the usage of the at least one of the plurality of cells is substantially equal to or above the threshold or when tea state of charge of the at least one of the plurality of cells is equal to or below a threshold.

9. The power source system of claim 1, wherein the plurality of cells is arranged sequentially and/or in a cascaded manner, and the electrical charge or current generated by at least one of the plurality of cells directly or indirectly enables transmission of the at least one operating material to the at least one other of the plurality of cells.

10. The power source system of claim 1, wherein the power source system is adapted for use downhole.

11. The power source system of claim 1, wherein: the system comprises a transfer system for providing the at least one operating material to selected cells; a storage vessel is in direct or indirect fluid communication with the transfer system or at least one of the plurality of cells; the transfer system is operable using the charge or current generated by at least one of the cells and/or by the controller; and the transfer system is configured to pump, and/or induce a movement or flow of the at least one operating material to or from at least one or each of the plurality of cells.

12. The power source system of claim 11, wherein the transfer system is controlled by the controller, and wherein the controller is configured to monitor one of: a usage of cells and state of charge of the cells.

13. The power source system of claim 12, wherein the controller is programmed with or configured to calculate an initial capacity of at least one or each cell and to calculate an amount of energy depleted from the at least one or each cell.

14. The power source system of claim 1, wherein the power source system is adapted for location within a substantially annular void within a wellbore.

15. A method of using a power source system according to claim 1, the method comprising using electrical charge from the reaction in at least one of the cells of the power source system to provide the at least one operating material to the at least one other of the cells of the power source system when a usage of the at least one of the cells is equal to or above a threshold or a state of charge of the at least one of the cells is equal to or below a threshold.

16. The method of claim 15, the method further comprising one or more of: connecting the power source system to a downhole tool or downhole device; locating the power source system permanently or semi-permanently downhole, or on or in a subsea tree.

17. A downhole arrangement, the downhole arrangement comprising the power source system according to claim 1 and a downhole tool, wherein at least a portion of the downhole tool is configured to be powered by the power source system.

18. The downhole arrangement of claim 17, wherein the arrangement comprises at least a portion of a wellbore casing and at least a portion of a string, and the power source system is located within an annular region between the at least a portion of wellbore casing and the at least a portion of string, and the downhole arrangement comprises a communication system, wherein the communication system is powered by the power source system and adapted for communication with a transmitter, receiver or transceiver located at surface.

19. A power source system comprising at least one or a plurality of, cells; and a controller configured to record and/or monitor energy usage from the cells, wherein the power source system is configured to convert at least one of the cells from a non-operational state to an operational state, or to make at least one operational cell from at least one of the cells, by providing at least one operating material to the at least one cell with the at least one of the cells in-situ, downhole or remotely located, by providing at least one operating material to the at least one cell using electrical charge or current generated by one of: a reaction in at least one other of the cells; at least one operational cell; and a downhole generator when the energy usage from the at least one of the cells determined by the controller is equal to or above a threshold.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) These and other aspects of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, which:

(2) FIG. 1 an example of a prior art flow cell apparatus;

(3) FIG. 2 an exemplary representation of a power source system;

(4) FIG. 3 a representation of another example of a power source system;

(5) FIG. 4 a perspective view of another example of a power source system;

(6) FIG. 5a a representation of a downhole arrangement comprising a power source system;

(7) FIG. 5b a representation of a cross section of the downhole arrangement of FIG. 5a;

(8) FIG. 6 a flow diagram of a method for using a power source system such as that of any of FIGS. 2 to 4;

(9) FIG. 7a a flow diagram of a method for using a power source system such as that of any of FIGS. 2 to 4; and

(10) FIG. 7b a continuation of the flow diagram of FIG. 7a.

DETAILED DESCRIPTION OF DRAWINGS

(11) Referring firstly to FIG. 1 of the accompanying drawings, there is shown a prior art flow cell, generally denoted 5. The flow cell 5 comprises an electrochemical cell 10. A first tank 15 contains a first electroactive fluid 20. A second tank 25 contains a second electroactive fluid 30. The electrochemical cell 10 comprises a membrane 35 separating the fluids 20, 30. The first electroactive fluid 20 is circulated from the first tank 15 thought a first compartment 40 of the electrochemical cell 10 by a first pump 45. The second electroactive fluid 30 is circulated from the second tank 25 through a second compartment 50 of the electrochemical cell 10 by a second pump 55. Ion exchange, which provides a flow of electric current, occurs through the membrane 35 and a potential difference may be measured across electrical contacts 60, 65.

(12) FIG. 2 shows an exemplary representation of a power source system, generally denoted 100. In the simplified representation of the power source system 100 shown in FIG. 2, only a single cell 105 is shown for illustrative purposes but it will be appreciated that the system optionally but generally comprises a plurality of cells 105. The embodiment shown comprises two storage vessels 110A, 110B. Each storage vessel 110A, 110B is adapted to contain a respective operating material (not shown). In this example, the storage vessel 110A contains an operating material in the form of an oxidant forming one half of a REDOX couple, and the other storage vessel 110B contains a reductant forming the other half of a REDOX couple. Each storage vessel 110A, 110B is in direct fluid communication with a transfer system 150. Each storage vessel 110A, 110B is in indirect fluid communication with the cell 105.

(13) The cell 105 comprises two electrodes 110+, 110−. One electrode 110− is a cathode. One electrode 110+ is an anode. In will be appreciated that in optional embodiments, the electrode may be non-porous or porous such that each electrode 110+, 110− is permeable to operating material, as described below.

(14) The cell 105 comprises a separator 115. The separator 115 is a porous membrane. One would appreciate that in other embodiments encompassing the inventive concept disclosed herein, the separator 115 may comprise a solid electrolyte or an ion exchange membrane such as NAFION. The separator 115 partitions an interior of the cell 105 into two compartments 120+, 120−. The separator 115 is arranged within the cell 105 between the electrodes 110+, 110−. The separator 115 is arranged within the cell 105 such that it electrically isolates one electrode 110+ from the other electrode 110−. As such, the separator 115 is arranged to prevent electrical short circuit between the electrodes 110+, 110−. The separator 115 comprises a non-conductive material, such as a polymeric material or a polyolefin based material. One would appreciate that in alternative embodiment encompassing the inventive concept disclosed herein, the electrodes 110+ and 110− may be positioned differently within the cell, such as abutting a face or interior surface of the cell. In other embodiments, the call may not comprise electrodes 110+ and 110−. For example, in alternative embodiments, the reactants may operate as at least part the electrodes.

(15) The transfer system 150 is adapted to induce a movement or flow of operating material from storage vessels 110A, 110B to the cell 105. The transfer system 150 comprises a pump (not shown). The transfer system 150 is adapted to pump operating materials from the storage vessels 110A, 110B to the cell 105.

(16) The transfer system 150 is communicatively linked to the controller 160. The transfer system 150 is communicatively linked to the controller 160 by a communications link 165. In use, the transfer system 150 is controlled by the controller 160.

(17) The controller 160 comprises an electronic system. The controller 160 comprises at least one microprocessor (CPU) and/or microcontroller. The controller comprises a memory (not shown), wherein the memory may comprise a non-volatile memory and/or a volatile memory.

(18) The controller 160 is adapted to record and/or monitor a usage of the cell 105. The controller is adapted to record and/or monitor data from at least one sensor (not shown). Data relating to the usage of the cell 105 is stored in the memory. Data relating to the at least one sensor is stored in the memory. In use, the controller 160 is adapted to calculate an initial and/or maximum capacity (i.e. the amount of electric charge that can be delivered) of the cell 105 or retrieve a predetermined or provided value from the memory. The controller 160 is adapted to calculate an amount of energy depleted from the cell 105. The controller 160 is adapted to operate the transfer system 150. The controller 160 is adapted to measure and/or is programmed with, parameters which comprise data relating to temperature and/or pressure within an operating environment of the power source system 100. The measured and/or programmed parameters may comprise data relating to quantity and type of use of the power source system 100, such as use to actuate a device 165.

(19) In use, the controller 160 is programmed with, or adapted to calculate, a threshold. The threshold is associated with the cell 105. The threshold corresponds to a proportion of a calculated charge available based on a usage of the cell 105.

(20) One would appreciate that in an alternative embodiment, the controller 160 may be adapted to measure and/or record a voltage at a terminal of the power source system 100. In such an embodiment, the voltage may be indicative, or related, to a capacity of a primary cell 220 (as described below in relation to FIG. 3) and/or at least one cell 105. In such an embodiment, the threshold may be predetermined, selected or programmed to a voltage that corresponds to a capacity of the cell.

(21) The controller 160 is coupled to the device 165. The device 165 is an electrical load, i.e. a resistive load, that draws current from the power source system 100. For example the device 165 may comprise sensors that are monitored by the controller 160. The device 165, which may be a downhole tool or the like, is powered by the cell 105.

(22) The controller 160 is adapted to control a flow of operating material into the cell 105. For example, in embodiments, the controller 160 is adapted to control the flow of the at least one operating material into and/or out of at least one of a plurality of cells based on parameters which include at least one of: a quantity of the at least one operating material; a flow rate of the at least one operating material; a pressure of the at last one operating material and/or a pressure in the cell 105.

(23) In some embodiments, the controller 160 controls a closed-loop system 180 to control the flow of the at least one operating material into and/or out of the cell.

(24) The power source system 100 comprises a safety system 170. The safety system 170 is adapted to monitor and/or control at least a portion of the power source system 105. The safety system 170 is communicably coupled to the controller 160. In other embodiments encompassing the inventive concept disclosed herein, the safety system 170 is part of, or incorporated within, the controller 160.

(25) The power source system 100 comprises two electrical contacts 190+, 190−. Each electrical contact 190+, 190− is conductively connected to an electrode 110+, 110− of the power source system 100. The device 165 is adapted to be conductively connected to the electrical contacts 190+, 190−.

(26) Referring now to FIG. 3, there is shown a representation of an apparatus, generally denoted 200.

(27) The apparatus comprises a plurality of cells 205, 210, 215. The plurality of cells 205, 201, 215 are arranged in a cascaded manner, wherein an electrical charge generated by a reaction in a first cell 205 conveys at least one operating material from a storage vessel to at least one other 210, 215 of the plurality of cells 205, 210, 215.

(28) In the exemplary embodiment of FIG. 3, the power source system 200 comprises three cells 205, 210, 215. However, one would appreciate that in other embodiments encompassing the inventive concept disclosed herein, there may be one or two cells, or there may be four or more cells.

(29) In use, each cell 205, 210, 215 is adapted to operate as a power source. In use, each cell 205, 210, 215 contains one or more electrochemical cells.

(30) The power source system 200 comprises a primary cell 220. The primary cell 220 comprises at least one lithium cell 220. The primary cell 220 is adapted to generate an electrical charge.

(31) Each cell 205, 210, 215 comprises two compartments 205a, 205b, 210a, 210b, 215a, 215b.

(32) In an initial configuration, one of the compartments 205a, 205b, 210a, 210b, 215a, 215b in each cell 205, 210, 215 are devoid of operating material. In an alternative configuration that falls within the scope of the inventive concept disclosed herein, in the initial configuration, all of the compartments 205a, 205b, 210a, 210b, 215a, 215b in each cell 205, 210, 215 are devoid of operating material.

(33) In the initial configuration, the primary cell 220 is adapted to provide electrical power to a device 230. The electrical device 230 is an electrical load i.e. draws electrical current from the power source system 200. In the initial configuration, a usage monitoring system 240 is adapted to record and/or monitor a usage of the primary cell 220. In further configurations, the usage monitoring system 240 is adapted to record and/or monitor a usage of each of the cells 205, 210, 215.

(34) The power source system 200 is adapted to convey at least one operating material from an operating material storage vessel (not shown in FIG. 3) to one of the cells 205, 210, 215 when the usage of the primary cell 220 exceeds a threshold.

(35) Upon conveying at least one operating material from the at least one storage vessel to at least one of the cells 205, 210, 215, at least one cells 205, 210, 215 reverts from a non-operational state to an operational state. In the non-operational state, the cell 205, 210, 215 is adapted to generate an electrical charge. In the operational state, the cells 205, 210, 215 is adapted to operate as a power source.

(36) The power source system 200 comprises a controller and transfer system 250, 255, 260. In the embodiment shown, the controller and transfer system is shown as a distributed system spread across three cells 205, 210, 215. In other embodiments, there may be a single controller and/or a single transfer system, or some or all of the controller and/or transfer system may be distributed within the power source system 200.

(37) In use, the transfer system 250, 255, 260 is adapted to induce a movement or flow of operating material from at least one storage vessel (not shown in FIG. 3) to at least one of the cells 205, 210, 215. The transfer system 250, 255, 260 comprises a pump. The transfer system is adapted to pump at least one operating material from the at least one storage vessel to at least one of the cells 205, 210, 215.

(38) Referring now to FIG. 4, there is shown a perspective view of an exemplary embodiment of a power source system, generally denoted 300. The power source system 300 comprises a first cell 305, a second cell 310, a first storage vessel 315 and a second storage vessel 320. The power source system 300 comprises a transfer system 330. The transfer system comprises a pump, one or more valves and/or the like, and is adapted to induce a movement or flow of operating material from the storage vessels 315, 320 to the cells 305, 310.

(39) The power source system 300 comprises a controller 340. The power source system 300 comprises two electrical contacts 350+, 350−. Each electrical contact 350+, 350− is conductively connected to at least one electrode (not shown in FIG. 3) of the power source system 300. The controller monitors power usage from, and/or state of charge of, the first cell 305 and the second cell 310 and is configured to operate the transfer system 330 to transfer operating material (e.g. an electrolyte and/or reactants) from the storage vessels 315, 320 into the second cell 310 from the when the usage of the first cell 305 is above a threshold or the state of charge of the first cell 305 is below a threshold.

(40) The power source system 300 is adapted for use downhole. The power source system 300 is adapted for location within a wellbore. For example, the power source system 300 is shaped such that it may be located within a substantially annular region or void, e.g. within a wellbore, such as between a wellbore casing and a string. The power source system 300 is substantially curved, such that the power source system 300 is adapted to fit in an annular region. When viewed along an axis X, the power source system 300 is substantially arch shaped.

(41) The power source system 300 is curved, wherein an angle 360 subtended by the power source system 300 to a circle centred on axis X is between approximately 20 degrees and 60 degrees. One would appreciate that in alternative embodiments, the angle 360 may be anything between 360 degrees (i.e. a full circle) and approximately 5 degrees.

(42) Referring now to FIG. 5a, there is shown a representation of a downhole arrangement, generally denoted 400. The downhole arrangement 400 comprises a downhole tool 405 and a power source system 410, which is optionally a downhole system such as that of any of FIGS. 2 to 4. In exemplary embodiments, the downhole tool 400 may comprise at least one of: an actuator, a sliding sleeve, a valve, or a port. At least a portion of the downhole tool 400 is adapted to be powered by the power source system 410.

(43) There is shown a rig or floating vessel 440 located at a surface 455 of the sea. The rig 440 is connected to a well head or subsea tree 430 located at seabed 450. A wellbore 415 extends below the seabed 450 from the subsea tree 430. The wellbore 415 is lined with a wellbore casing 420. A string, such as a production string 425, is located within the wellbore casing 420.

(44) In the exemplary embodiment shown, the power source system 410 is located within an annular region between the at least a portion of wellbore casing 420 and at least a portion of production string 425.

(45) FIG. 5b shows a cross section of the arrangement of FIG. 5a, taken across the dashed line in FIG. 5b. The power source system 410 is substantially the shape of a segment of an annular region between a wellbore casing 420 and the string 425, wherein the angle subtended by the power source system 420 to the centre of a circle (i.e. the centre of the wellbore) is between approximately 20 degrees and 60 degrees. One would appreciate that in other embodiments encompassing the inventive concept disclosed herein, the power source system may be integrated within a tool, a sleeve, or any completion device or tool, or the like.

(46) Referring now to FIG. 6, there is shown a flow diagram, generally denoted 500.

(47) At step 505 the controller measures an energy usage, such as an energy usage incurred by an electrical load i.e. a tool or device, over a period of one day. One of skill in the art would recognise that the unit of time may be more or less than one day, and may not be restricted to precisely one day.

(48) At step 510, the controller records and an average temperature, such as an average temperature of a cell, or of an environment in the proximity of a cell, over the period of one day. The controller may also calculate the average temperature based on a plurality of temperature measurements made throughout the day.

(49) At step 515, the controller calculates a self-discharge of a cell and idle current usage. The controller may use data collected from various sensors, such as temperature and/or pressure sensors to perform the calculation. Similarly, the controller may use stored data, such as stored calibration data or a look-up table or the like, in conjunction with measured data, or alone, to perform the calculation.

(50) At step 520, the controller totals a contribution made by actuation or use of any tools or devices.

(51) At step 525, a total daily usage, i.e. usage of the capacity of the cell, that includes contributions made by actuation or use of any tools or devices and self-discharge and idle current usage is calculated.

(52) At step 530, the total calculated in step 525 is deducted from a stored capacity of the cell to determine a new capacity of the cell.

(53) At step 535, the new capacity calculated in step 530 is compared with a threshold. If the new capacity falls below the threshold, manufacture of a new cell is triggered at step 540. If the threshold does not exceed the new capacity, then the process from steps 505 to 530 is repeated in the next period of time i.e. one day.

(54) At step 545, the transfer mechanism is activated to convey operating material (e.g. electrolyte and/or one or more reactants) to a cell. At step 550, the controller confirms the cell is adequately prepared, i.e. a correct, or large enough quantity of operating material has been conveyed.

(55) At step 555, the controller updates its records stored in memory with characteristics of the new cell. At step 565, the controller communicates at least a portion of the updated records to a receiver, such as a receiver located at surface.

(56) At step 560, the controller determines whether the cell manufactured in steps 540 to 555 is a final available cell. If so, then at step 565 this information is communicated to a receiver, such as a receiver located at surface. Otherwise the process is repeated with the measurements being based on the newly formed cell.

(57) One would understand that, without deviating from the inventive concept disclosed herein, communication between the controller and a receiver, or transceiver, in particular regarding the status of at least one cell, may be undertaken at any stage in the process described by FIG. 6.

(58) Referring now to FIG. 7a, there is shown a flow diagram, generally denoted 600.

(59) At step 605 the controller measures and/or logs parameters, such as data collected by temperature and/or pressure sensors, and data related to actuations or usage of electrical loads, such as tools, over a period of time.

(60) At step 610, the controller calculates a total usage i.e. usage of the capacity of the cell, based on the parameters logged at stage 605. One would appreciate that in an alternative embodiment, the controller may calculate in real-time, or pseudo real-time, a total usage and/or remaining capacity of the cell.

(61) At step 615, if not already done so at step 610, the controller calculates a remaining capacity of the cell. At step 620, the remaining capacity of the cell calculated at step 610 or 615 is compared to a threshold. If the remaining capacity exceeds the threshold, then the process reverts to step 605. If the remaining capacity is less than the threshold, then the process continues to step 625 (FIG. 7b).

(62) At step 625, the transfer system is triggered by the controller to manufacture a new cell. At step 630, operating material is conveyed to the new cell. At step 635 the controller determines that manufacture of the new cell is complete by, for example, use of sensors to assess whether an adequate amount of operating material has been conveyed to the new cell.

(63) At step 640, the controller records or logs characteristics of the new cell. The controller may record this information in its memory and/or the controller may communicate this information to a receiver, such as a receiver located at surface.

(64) At step 645, the controller makes a determination of whether the new cell is a final cell that the power source system supports. If the power source system supports manufacture of at least one further cell, the process reverts to step 605. If the power source system does not support manufacture of at least one further cell, the process is completed. It should be understood that, without deviating from the inventive concept disclosed herein, communication between the controller and a receiver, or transceiver, in particular regarding the status of at least one cell, may be undertaken at any stage in the process described by FIGS. 7a and 7b.

(65) It will be appreciated that the embodiments of the present disclosure herebefore described are given by way of example only and are not meant to limit the scope thereof in any way.

(66) It will be appreciated that embodiments of the present disclosure provide benefits over the prior art.