Downhole blower system with integrated construction
This disclosure describes various implementations of a downhole-blower system that can be used to boost production in a wellbore. The downhole-blower system includes a blower and an electric machine coupled to the blower that can be deployed in a wellbore, and that can, in cooperation, increase production through the wellbore.
1. A blower system comprising:
a stator comprising:
a plurality of stator sub-assemblies arranged on a longitudinal axis and comprising a plurality of stator vanes; and
a plurality of electric machine windings attached to the respective plurality of stator vanes;
a rotor positioned and carried to rotate within the stator about the longitudinal axis, the rotor comprising:
a plurality of vane sections, each comprising a plurality of rotor vanes;
a plurality of magnetic sections arranged between the plurality of vane sections, the plurality of stator vanes and the plurality of rotor vanes configured to drive a fluid between the stator and the rotor when the rotor is rotated within the stator.
2. The system of claim 1 , wherein the plurality of magnetic sections are arranged alternately between the plurality of vane sections and configured to produce magnetic fields.
3. The system of claim 1 , wherein a magnetic section of the plurality of magnetic sections is arranged in a two or more-pole arrangement.
4. The system of claim 1 , further comprising a sleeve in which a vane section is positioned.
5. The system of claim 1 , wherein a vane section comprises an extension member configured to support the vane section.
6. The system of claim 1 , wherein the rotor is a first rotor, the plurality of vane sections is a first plurality of vane sections, the plurality of magnetic sections is a first plurality of magnetic sections, and wherein the blower system comprises:
a second rotor arranged coaxially with the first rotor, the second rotor positioned and carried to rotate within the stator about the longitudinal axis, the second rotor comprising:
a second plurality of vane sections, each vane section of the second plurality of vane sections comprising a second plurality of rotor vanes;
a second plurality of magnetic sections arranged between the second plurality of vane sections.
7. The system of claim 6 , further comprising a tie bolt configured to lock the first rotor and the second rotor to form a shaft assembly.
8. The system of claim 1 , wherein a stator sub-assembly vanes are constructed with electrical steel laminations configured to drive fluid flowed through the blower system.
9. The system of claim 1 , wherein each stator sub-assembly comprises a slot in which a respective electric machine winding is positioned, wherein the slot is formed as an angled vane configured to drive the fluid flowed through the blower system.
10. The system of claim 1 , wherein the fluid is a first fluid, wherein the plurality of stator vanes and the plurality of rotor vanes are configured to generate power when a second fluid is compressively driven between the stator and the rotor.
11. The system of claim 1 , wherein a stator sub-assembly comprises a sealing can in a space between the stator sub-assembly and a vane section, wherein the sealing can is configured to prevent back flow of fluid within the blower system.
12. The system of claim 11 , wherein the sealing can comprises a non-metallic material.
13. A blower system comprising:
a stator comprising:
electric stator components; and
fluidic stator components interspersed with the electric stator components; and
a rotor carried to rotate within the stator, the rotor comprising:
electric rotor components comprising:
a plurality of stator sub-assemblies arranged on the longitudinal axis; and
a plurality of electric machine windings attached to the respective plurality of stator sub-assemblies, the plurality of electric machine windings configured to produce magnetic fields in the plurality of stator sub-assemblies; and
fluidic rotor components interspersed with the electric rotor components, the stator and the rotor configured to drive a fluid flowed between the stator and the rotor.
14. The system of claim 13 , wherein the fluidic stator components comprise:
a plurality of stator vanes formed in the plurality of stator sub-assemblies;
a plurality of slots formed in the respective plurality of stator sub-assemblies, wherein each slot is formed as an angled vane configured to drive the fluid.
15. The system of claim 13 , wherein the fluidic rotor components comprise:
a plurality of vane sections carried to rotate about the longitudinal axis, each vane configured to drive the fluid.
16. The system of claim 15 , wherein the electric rotor components comprise:
a plurality of magnetic sections arranged between the plurality of vane sections, the plurality of magnetic sections configured to produce magnetic fields in the plurality of stator sub-assemblies.
17. A method comprising:
energizing a plurality of electric machine windings attached to a respective plurality of stator vanes of a plurality of stator sub-assemblies arranged on a longitudinal axis to produce magnetic fields in the plurality of stator sub-assemblies;
rotating a plurality of rotor vanes arranged on the longitudinal axis in response to energizing the plurality of electric machine windings, the plurality of rotor vanes interspersed with the plurality of stator sub-assemblies; and
driving a fluid flowed in between the plurality of stator sub-assemblies and the plurality of rotor vanes in response to rotating the plurality of rotor vanes.
18. The method of claim 17 , wherein driving the fluid comprises compressing the fluid.
19. The method of claim 17 , wherein the fluid is a first fluid, and wherein the method further comprises:
driving a second fluid between the plurality of stator sub-assemblies and the plurality of rotor vanes; and
generating power in response to driving the second fluid between the plurality of stator sub-assemblies and the plurality of rotor vanes.