WO2016153998A1

WO2016153998A1 - Temperature controlled energy storage device

Info

Publication number: WO2016153998A1
Application number: PCT/US2016/023138
Authority: WO
Inventors: Norman Ward; Christine Ruth Jarvis; Remy PANARIELLO; Rogerio Tadeu Ramos
Original assignee: Schlumberger Canada Ltd; Services Petroliers Schlumberger SA; Schlumberger Technology BV; Schlumberger Technology Corp
Current assignee: Schlumberger Canada Ltd; Services Petroliers Schlumberger SA; Schlumberger Technology BV; Schlumberger Technology Corp
Priority date: 2015-03-22
Filing date: 2016-03-18
Publication date: 2016-09-29
Anticipated expiration: 2017-09-22

Abstract

A system comprises a downhole equipment; and an apparatus coupled with the downhole equipment to power the downhole equipment, wherein the apparatus comprises an energy storage device and a temperature control element configured to heat or cool the energy storage device, the energy storage device comprising a battery cell, a battery pack, or a capacitor.

Description

TEMPERATURE CONTROLLED ENERGY STORAGE DEVICE

CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of and priority to U.S. Provisional Application Serial No.: 62/136,595, filed March 22, 2015, which is incorporated herein by reference in its entirety.

BACKGROUND

Oil wells are created by drilling a hole into the earth, in some cases using a drilling rig that rotates a drill string (e.g., drill pipe) having a drill bit attached thereto. In other cases, the drilling rig does not rotate the drill bit. For example, the drill bit can be rotated downhole. The drill bit, aided by the weight of pipes (e.g., drill collars) cuts into rock within the earth. Drilling fluid (e.g., mud) is pumped into the drill pipe and exits at the drill bit. The drilling fluid may be used to cool the bit, lift rock cuttings to the surface, at least partially prevent destabilization of the rock in the wellbore, and/or at least partially overcome the pressure of fluids inside the rock so that the fluids do not enter the wellbore. Other equipment can also be used for evaluating formations, fluids, production, other operations, and so forth. Downhole equipment can be powered by remote energy sources that power the equipment via transmission lines (e.g., electrical, optical, mechanical, or hydraulic transmission lines). Downhole equipment can also be powered by local energy sources such as local generators or energy storage devices (e.g., battery packs) coupled with the equipment. SUMMARY

Aspects of the disclosure can relate to an apparatus including an energy storage device and a temperature control element configured to heat or cool the energy storage device. In embodiments of this disclosure, the temperature control element can be coupled to the energy storage device or at least partially integrated within a structure defining the energy storage device.

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

FIGURES

Embodiments of a temperature controlled energy storage device are described with reference to the following figures. The same numbers are used throughout the figures to reference like features and components. FIG. 1 illustrates an example system in which embodiments of a temperature controlled energy storage device can be implemented.

FIG. 2 illustrates various components of an example device that can implement embodiments of a temperature controlled energy storage device.

FIG. 3 illustrates various components of an example device that can implement embodiments of a temperature controlled energy storage device.

FIG. 4 illustrates various components of an example device that can implement embodiments of a temperature controlled energy storage device.

FIG. 5 illustrates various components of an example device that can implement embodiments of a temperature controlled energy storage device.

FIG. 6 illustrates various components of an example device that can implement embodiments of a temperature controlled energy storage device.

FIG. 7 illustrates various components of an example device that can implement embodiments of a temperature controlled energy storage device.

FIG. 8 illustrates various components of an example device that can implement embodiments of a temperature controlled energy storage device.

FIG. 9 illustrates various components of an example device that can implement embodiments of a temperature controlled energy storage device. DETAILED DESCRIPTION

FIG. 1 depicts a wellsite system 100 in accordance with one or more embodiments of the present disclosure. The wellsite can be onshore or offshore. A borehole 102 is formed in subsurface formations by directional drilling. A drill string 104 extends from a drill rig 106 and is suspended within the borehole 102. In some embodiments, the wellsite system 100 implements directional drilling using a rotary steerable system (RSS). For instance, the drill string 104 is rotated from the surface, and down hole devices move the end of the drill string 104 in a desired direction. The drill rig 106 includes a platform and derrick assembly positioned over the borehole 102. In some embodiments, the drill rig 106 includes a rotary table 108, kelly 110, hook 112, rotary swivel 114, and so forth. For example, the drill string 104 is rotated by the rotary table 108, which engages the kelly 110 at the upper end of the drill string 104. The drill string 104 is suspended from the hook 112 using the rotary swivel 114, which permits rotation of the drill string 104 relative to the hook 112. However, this configuration is provided by way of example and is not meant to limit the present disclosure. For instance, in other embodiments a top drive system is used. A bottom hole assembly (BHA) 116 is suspended at the end of the drill string 104. The bottom hole assembly 116 includes a drill bit 118 at its lower end. In embodiments of the disclosure, the drill string 104 includes a number of drill pipes 120 that extend the bottom hole assembly 116 and the drill bit 118 into subterranean formations. Drilling fluid (e.g., mud) 122 is stored in a tank and/or a pit 124 formed at the wellsite. The drilling fluid can be water-based, oil- based, and so on. A pump 126 displaces the drilling fluid 122 to an interior passage of the drill string 104 via, for example, a port in the rotary swivel 114, causing the drilling fluid 122 to flow downwardly through the drill string 104 as indicated by directional arrow 128. The drilling fluid 122 exits the drill string 104 via ports (e.g., courses, nozzles) in the drill bit 118, and then circulates upwardly through the annulus region between the outside of the drill string 104 and the wall of the borehole 102, as indicated by directional arrows 130. In this manner, the drilling fluid 122 cools and lubricates the drill bit 118 and carries drill cuttings generated by the drill bit 118 up to the surface (e.g., as the drilling fluid 122 is returned to the pit 124 for recirculation).

In some embodiments, the bottom hole assembly 116 includes a logging- while-drilling (LWD) module 132, a measuring-while-drilling (MWD) module 134, a rotary steerable system 136, a motor, and so forth (e.g., in addition to the drill bit 118). The logging-while-drilling module 132 can be housed in a drill collar and can contain one or a number of logging tools. It should also be noted that more than one LWD module and/or MWD module can be employed (e.g. as represented by another logging-while-drilling module 138). In embodiments of the disclosure, the logging-while drilling modules 132 and/or 138 include capabilities for measuring, processing, and storing information, as well as for communicating with surface equipment, and so forth. The measuring-while-drilling module 134 can also be housed in a drill collar, and can contain one or more devices for measuring characteristics of the drill string 104 and drill bit 118. The measuring- while-drilling module 134 can also include components for generating electrical power for the down hole equipment. This can include a mud turbine generator (also referred to as a "mud motor") powered by the flow of the drilling fluid 122. However, this configuration is provided by way of example and is not meant to limit the present disclosure. In other embodiments, other power and/or battery systems can be employed. The measuring- while-drilling module 134 can include one or more of the following measuring devices: a weight-on-bit measuring device, a torque measuring device, a vibration measuring device, a shock measuring device, a stick slip measuring device, a direction measuring device, an inclination measuring device, and so on.

In embodiments of the disclosure, the wellsite system 100 is used with controlled steering or directional drilling. For example, the rotary steerable system 136 is used for directional drilling. As used herein, the term "directional drilling" describes intentional deviation of the wellbore from the path it would naturally take. Thus, directional drilling refers to steering the drill string 104 so that it travels in a desired direction. In some embodiments, directional drilling is used for offshore drilling (e.g., where multiple wells are drilled from a single platform). In other embodiments, directional drilling enables horizontal drilling through a reservoir, which enables a longer length of the wellbore to traverse the reservoir, increasing the production rate from the well. Further, directional drilling may be used in vertical drilling operations. For example, the drill bit 118 may veer off of a planned drilling trajectory because of the unpredictable nature of the formations being penetrated or the varying forces that the drill bit 118 experiences. When such deviation occurs, the wellsite system 100 may be used to guide the drill bit 118 back on course.

Drill assemblies can be used with, for example, a wellsite system (e.g., the wellsite system 100 described with reference to FIG. 1). For instance, a drill assembly can comprise a bottom hole assembly suspended at the end of a drill string (e.g., in the manner of the bottom hole assembly 116 suspended from the drill string 104 depicted in FIG. 1). In some embodiments, a drill assembly is implemented using a drill bit. However, this configuration is provided by way of example and is not meant to limit the present disclosure. In other embodiments, different working implement configurations are used. Further, use of drill assemblies in accordance with the present disclosure is not limited to wellsite systems described herein. Drill assemblies can be used in other various cutting and/or crushing applications, including earth boring applications employing rock scraping, crushing, cutting, and so forth.

A drill assembly includes a body for receiving a flow of drilling fluid. The body comprises one or more crushing and/or cutting implements, such as conical cutters and/or bit cones having spiked teeth (e.g., in the manner of a roller-cone bit). In this configuration, as the drill string is rotated, the bit cones roll along the bottom of the borehole in a circular motion. As they roll, new teeth come in contact with the bottom of the borehole, crushing the rock immediately below and around the bit tooth. As the cone continues to roll, the tooth then lifts off the bottom of the hole and a high-velocity drilling fluid jet strikes the crushed rock chips to remove them from the bottom of the borehole and up the annulus. As this occurs, another tooth makes contact with the bottom of the borehole and creates new rock chips. In this manner, the process of chipping the rock and removing the small rock chips with the fluid jets is continuous. The teeth intermesh on the cones, which helps clean the cones and enables larger teeth to be used. A drill assembly comprising a conical cutter can be implemented as a steel milled-tooth bit, a carbide insert bit, and so forth. However, roller-cone bits are provided by way of example and are not meant to limit the present disclosure. In other embodiments, a drill assembly is arranged differently. For example, the body of the bit comprises one or more polycrystalline diamond compact (PDC) cutters that shear rock with a continuous scraping motion.

In embodiments of the disclosure, the body of a drill assembly can define one or more nozzles that allow the drilling fluid to exit the body (e.g., proximate to the crushing and/or cutting implements). The nozzles allow drilling fluid pumped through, for example, a drill string to exit the body. For example, drilling fluid can be furnished to an interior passage of the drill string by the pump and flow downwardly through the drill string to a drill bit of the bottom hole assembly, which can be implemented using, for example, a drill assembly. Drilling fluid then exits the drill string via nozzles in the drill bit, and circulates upwardly through the annulus region between the outside of the drill string and the wall of the borehole. In this manner, rock cuttings can be lifted to the surface, destabilization of rock in the wellbore can be at least partially prevented, the pressure of fluids inside the rock can be at least partially overcome so that the fluids do not enter the wellbore, and so forth.

Modern oil and gas exploration increasingly uses electronic devices in the borehole to provide measurements, and for control and operational optimization. Although a wellsite drilling system 100 is described herein, those skilled in the art will appreciate that any wellsite system can include downhole electronic equipment (e.g., sensors, actuators, communication devices, or the like). When operating electronics as part of a drill string and/or other downhole equipment and/or strings (e.g., for well testing, well simulation, well monitoring, formation evaluation, etc.), available power in the borehole may be limited near a bottom hole assembly. In some cases, electrical power can be generated by turbines while fluids are pumped into and/or out of a well, but this technique may not be efficient when there is little or no movement of fluids. Batteries, energy cells, or capacitive elements (e.g., super-capacitors) can also be installed in electronic equipment to provide electrical power in a borehole, but batteries have a finite energy storage capacity, which limits the amount of time the equipment can be operated. In some cases, larger batteries may be used, but the amount of space available in the borehole is also finite, limiting the size of such batteries. In other cases, higher power density batteries may be used, but such batteries may be more prone to failure (e.g., in the high temperature operating conditions present downhole). The availability of energy to various sensors, actuators, communication modules (e.g., receivers or transmitters) and other downhole equipment in oil wells is a difficult issue due to the harsh environment in terms of temperature and vibration. High temperatures (e.g., 200°C and above) can be encountered down hole, but equipment may also operate at room temperature.

It has been found that batteries designed to operate well at low temperatures tend to be unstable or unsafe at higher temperatures. Batteries can use lithium (Li) or lithium alloy in at least one of the electrodes (i.e., in the anode, the cathode, or both). As such, the maximum operating temperature of a battery may be limited by the melting point of lithium (~180°C). Alloys, such as lithium magnesium alloys, can be used in an electrode to increase the effective melting point of the electrode (e.g., the temperature at which at least a portion of the electrode begins to melt). Yet, it has also been found that batteries designed to operate well at high temperatures are sometimes unable to operate effectively at lower temperatures (e.g., less than 100 °C).

FIGS. 2 through 9 illustrate embodiments of a temperature controlled energy storage device 1. In some embodiments, a bottom hole assembly 116 can include downhole equipment coupled with an energy storage device that powers the downhole equipment. For example, downhole equipment powered by the energy storage device 1 can include a sensor, an actuator (e.g., motor, servo, or switch), a transmitter, a receiver, a controller, or the like. For example, the downhole equipment can include one or more components of the logging-while-drilling (LWD) module 132, the measuring-while-drilling (MWD) module 134, the rotary steerable system 136, and so forth. The energy storage device 1 can be directly coupled (e.g., via a wired connection at two or more terminals 2) to the downhole equipment. The energy storage device 1 can also be optically or electromagnetically coupled with the downhole equipment.

As shown in FIG. 2, a temperature control element may include a heating element 3 (e.g., electrical resistance) attached to the energy storage device 1 in order to elevate a temperature of the energy storage device 1 when the energy storage device 1 is subject to a temperature below an effective operating temperature of the energy storage device 1. As shown in FIG. 3, the temperature control element can also include a cooling element or a selective temperature control element 5 (e.g., Peltier element) configured to selectively heat or cool the energy storage device 1. For example, the selective temperature control element 5 can be configured to pump heat in or out of the energy storage device 1 in order to elevate or reduce a temperature of the energy storage device 1 to an appropriate temperature for effective operability (e.g., the device may be configured so that the temperature remains within to a set or predetermined operating range).

In some embodiments, a temperature sensor can also be attached to the energy storage device 1 and configured to monitor a temperature of the energy storage device 1. A controller (e.g., programmable logic device, processing unit, or the like) can be configured to control the temperature control element based upon a detected temperature of the energy storage device 1. For example, the controller can cause the temperature control element to increase the temperature of the energy storage device 1 when the detected temperature is below an effective operating temperature or decrease the temperature of the energy storage device 1 when the detected temperature is above an effective operating temperature. In some embodiments, the temperature control element can be activated or deactivated with a switch 4, such as a bi-stable switch that can be activated by temperature. In embodiments, the switch 4 can be part of an over temperature protection system.

FIGS. 4 through 6 show embodiments where the temperature control element can be at least partially wrapped around the energy storage device 1 (e.g., battery cell). For example, FIGS. 4 and 5 show embodiments where the temperature control element can include a heating wire 3 at least partially wrapped around the energy storage device 1. Another example is shown in FIG. 6, where the temperature control element can include a heating/cooling pad 7 at least partially wrapped around the energy storage device 1. The heating/cooling pad 7 can include an electrical resistance, a Peltier element, or the like. In some embodiments, the temperature control element is in tight contact with the energy device 1. For example, the temperature control element can be printed, painted, deposited or glued to the surface of the energy storage device 1. Thermal insulating material can be added to minimize heat transfer to the environment. For example, a thermal insulator may be deposited over the wire 3, over the heating/cooling pad 7, or can be included within a structure defining the heating/cooling pad 7 (e.g., as an intermediate or outer layer). In some embodiments, the energy storage device 1 itself can be thermally insulated for improved temperature stability.

FIG. 7 shows an embodiment where the energy storage device 1 includes a cavity 8 configured to contain at least a portion of the temperature control element. For example, an electrical resistance or a Peltier element can be deposited within the cavity 8. Another embodiment is shown in FIG. 9, where the energy storage device 1 can include a cavity 11 (e.g., an indentation or well) that extends through a portion of the energy storage device 1. For illustrative purposes, FIG. 8 shows an example of an energy storage device 1 without a cavity. In some embodiments, a plug 10 is placed over the cavity 11. The plug 10 can be used to fill the energy storage device 1 with electrolyte or other fluid. In embodiments where the energy storage device 1 is a battery cell, the energy storage device 1 may further include a feed-through 9 that provides connection to internal electrodes. Although several of the figures illustrate embodiments where the energy storage device 1 is cylindrical, it should be understood that the energy storage device 1 can have non-cylindrical configurations as well. For example, the energy storage device 1 may be configured in accordance with a non-cylindrical geometry, such as a rectangular prism, a battery pack or array of energy storage elements (e.g., energy storage cells or capacitors), and so forth.

In some embodiments, the downhole anti-passivation power of an energy storage device 1 can be applied to heat other chemistries (e.g., in battery sub or the like). For example, additional energy from a lithium-thionyl chloride (LTC) battery can be applied to heat lithium polymer (Li- Poly) or lithium carbon monofluoride (CFx) batteries. A heated lithium polymer cell may release more energy than it took to heat it up if sufficiently thermally insulated. Printed wiring assemblies (PWAs) are inefficient at creating heat, and this can affect an ability to maintain a temperature of well-positioned cells during trip out with good thermal insulation. In some embodiments, LTC anti-passivation power can be used to charge rechargeable batteries, for example, in the battery sub. As used herein, the term anti-passivation refers to the prevention of the formation of a passivation layer or the reduction in the amount of a passivation layer that forms. Anti-passivation power refers to the energy used to prevent a passivation layer from occurring or the reduction in the amount of a passivation layer that forms.

In some embodiments, snap-switches can be used to force heat cells, for example, in down- hole environments where operation is close to the melting point of lithium.

In some embodiments, the temperature control element can be included in the energy storage device 1. For example, the temperature control element can include a battery canister, a separator, a collector, additional layer integrated in an energy storage cell, or the like. In this regard, the temperature control element is not necessarily an external element or one that is deposited within a cavity of the energy storage device 1.

In some embodiments, the temperature control element can be configured to transfer heat to or from the battery to a cold or hot external point (e.g., via heat pipes or other thermal conductors). For example, hot points can include locations proximate to the drill bit, and cold points can include locations in proximity of mud flow. The energy storage device 1 can also be heated or cooled down by a fluid flow around the energy storage device 1. For example, the temperature control element can include a fluid path configured to transfer heat to or from the energy storage device 1. The energy storage device 1 can also be heated or cooled down by applying or removing pressure. For example, the temperature control element may include an enclosure wherein pressure is increased to heat the energy storage device 1 and pressure is decreased to cool the energy storage device 1. In some embodiments, the temperature control element can include a positive temperature coefficient (PTC) element. PTC elements can be effective because they are their own thermostat as they change their resistance based on the applied temperature. In this regard, a PTC element can operate similar to a bi-stable switch. In some embodiments, where the energy storage device 1 includes a cavity (e.g., cavity 8) that extends through the energy storage device 1, and several energy storage devices 1 (e.g., annular batteries or cells) can be mounted on one single temperature control element that extends through cavities of the energy storage devices 1. In some embodiments, a source of power for heating or cooling the energy storage device

1 is selectable based on a location of the energy storage device 1. For example, a first source (e.g., energy from a generator) may be used to power the temperature control element at or near a surface of a drill site, while energy released from the drill bit or fluid flow may be used to power the temperature control element in downhole environments. Heat can also be generated internally from I²R losses; if R is high due to a low temperature environment, the temperature of the energy storage device 1 can be raised by this effect.

Although a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from an energy storage device and a temperature control element configured to heat or cool the energy storage device as described above. Additionally, it should be understood that references to "one embodiment" or "an embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, features shown in individual embodiments referred to above may be used together in combinations other than those which have been shown and described specifically. Accordingly, any such modification is intended to be included within the scope of this disclosure. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not just structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke means-plus- function for any limitations of any of the claims herein, except for those in which the claim expressly uses the words 'means for' together with an associated function.

Claims

What is claimed is:

1. An apparatus, comprising:

an energy storage device; and

a temperature control element configured to heat or cool the energy storage device.

2. The apparatus as recited in claim 1, wherein the energy storage device comprises a battery cell, a battery pack, or a capacitor.

3. The apparatus as recited in claim 1, wherein the temperature control element comprises at least one of a heating element or a cooling element.

4. The apparatus as recited in claim 3, wherein the temperature control element includes at least one of an electrical resistance, a Peltier element, or a positive temperature coefficient (PTC) element.

5. The apparatus as recited in claim 1, wherein the temperature control element is attached to a surface of the energy storage device.

6. The apparatus as recited in claim 5, wherein the temperature control element is printed, painted, deposited or glued to the surface of the energy storage device.

7. The apparatus as recited in claim 5, wherein the temperature control element includes a heating or cooling element is at least partially wrapped around the energy storage device.

8. The apparatus as recited in claim 1, further comprising a switch configured to activate or deactivate the temperature control element.

9. The apparatus as recited in claim 8, wherein the switch comprises a bi-stable switch.

10. The apparatus as recited in claim 9, wherein the bi-stable switch is part of an over- temperature control system.

11. The apparatus as recited in claim 1 , where the energy storage device is configured to be stacked on a second energy storage device.

12. The apparatus as recited in claim 1, wherein the temperature control element is disposed within a cavity of the energy storage device.

13. The apparatus as recited in claim 1, further comprising a temperature sensing device attached to the energy storage device or disposed within a cavity of the energy storage device.

14. A method of implementing the apparatus recited in any of the preceding claims.

15. The method as recited in claim 14, wherein the energy storage device is heated or cooled in order to maintain the temperature within a predetermined operating temperature range.

16. A system, comprising:

downhole equipment; and

the apparatus recited in any of claims 1-13, wherein the apparatus is coupled with the downhole equipment to power the downhole equipment.

17. The system as recited in claim 16, wherein the downhole equipment comprises at least one of: a sensor, an electrical motor, a transmitter, a receiver, or a controller.

18. The system as recited in claim 16, wherein anti-passivation power of a first energy storage device is applied towards heating a second energy storage device or charging a second energy device.

19. The system as recited in claim 18, wherein the first energy storage device is a non- rechargeable energy storage device and the second energy storage device is a rechargeable energy storage device.

20. The system as recited in claim 18, wherein the first energy storage device is a lithium-thionyl chloride (LTC) battery.

21. The system as recited in claim 16, wherein the temperature control element is configured to heat the energy storage device with internal power loss due to an internal resistance of the energy storage device.

22. The system as recited in claim 16, wherein the temperature control element is configured to transfer heat to or from the energy storage device from a source point having a lower or higher temperature than the energy storage device.

23. The system as recited in claim 16, wherein the temperature control element is configured to heat or cool the energy storage device with fluid flowed around the energy storage device or through a cavity of the energy storage device.

24. The system as recited in claim 16, wherein the temperature control element is configured to heat or cool the energy storage device by adjusting an internal pressure of an enclosure containing the energy storage device.

25. The system as recited in claim 16, wherein a plurality of energy storage devices are simultaneously heated or cooled by the temperature control element.

26. The system as recited in claim 25, wherein each energy storage device of the plurality of energy storage devices includes a through hole, and wherein the temperature control element is at least partially disposed within the through hole of each energy storage device of the plurality of energy storage devices.

27. The system as recited in claim 26, wherein the energy storage devices are stacked on the temperature control element.