Full flow pulser for measurement while drilling (MWD) device
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E21B-047/16
E21B-004/02
E21B-047/18
E21B-017/20
출원번호
US-0368150
(2012-02-07)
등록번호
US-9013957
(2015-04-21)
발명자
/ 주소
Vecseri, Gabor
Jennings, Benjamin
출원인 / 주소
Teledrill, Inc.
대리인 / 주소
Grune, Guerry L.
인용정보
피인용 횟수 :
1인용 특허 :
32
초록▼
An apparatus, method, and system described for generating pressure pulses in a drilling fluid utilizing a flow throttling device longitudinally and axially positioned within the center of a main valve actuator assembly is described. The main valve actuator assembly includes a main valve pressure cha
An apparatus, method, and system described for generating pressure pulses in a drilling fluid utilizing a flow throttling device longitudinally and axially positioned within the center of a main valve actuator assembly is described. The main valve actuator assembly includes a main valve pressure chamber, a magnetic cup encompassing a rotary magnetic coupling, and a pilot actuator assembly. Passage of drilling fluid through a series of orifices, valves, shields, and screens where the fluid eventually combines with a pilot exit fluid that flows toward a main exit flow such that as the fluid becomes a pilot fluid that ultimately combines with the main flow such that the combined fluid causes one or more flow throttling devices to generate large, rapid controllable pulses that produce transmission of well developed signals easily distinguished from other noise resulting from other vibrations due to nearby equipment that is within or exterior to the borehole such that the signals also provide predetermined height, width and shape.
대표청구항▼
1. An apparatus for generating pressure pulses in a drilling fluid, flowing within a drill string, comprising: a flow throttling device longitudinally and axially positioned within the center of a main valve actuator assembly, said main valve actuator assembly comprising a main valve pressure chambe
1. An apparatus for generating pressure pulses in a drilling fluid, flowing within a drill string, comprising: a flow throttling device longitudinally and axially positioned within the center of a main valve actuator assembly, said main valve actuator assembly comprising a main valve pressure chamber, a magnetic cup encompassing a rotary magnetic coupling containing at least one magnet adjacent to a drive shaft wherein said magnetic cup is located within a pilot actuator assembly, said assembly including a pilot orifice with a pilot valve, a pilot flow shield, a bellows and an anti-rotation block such that passage of said drilling fluid flows through a pilot flow screen and into a main flow entrance into a flow cone through a main orifice and into a main valve past a main valve pressure chamber past a set of seals and through a main valve support block then through a flow seal guide where said fluid combines with a pilot exit fluid that flows toward a main exit flow such that as said fluid becomes a pilot fluid subsequently flowing through said pilot flow screen into said pilot flow screen chamber through a pilot flow upper annulus, through a pilot flow lower annulus and into a pilot flow inlet channel, wherein said pilot fluid then flows up into said main valve feed channel until it reaches said main valve pressure chamber such that said pilot fluid flows back down said main valve feed channel through said pilot flow exit channel through said pilot orifice and said pilot valve to exit said pilot valve and said pilot fluid then flows over said pilot flow shield such that it combines with said main flow becoming the main exit flow fluid, said main exit flow fluid then exits said pilot valve support block and flows on either side of said magnetic pressure cup including said rotary magnetic coupling and then finally past a drive shaft and motor such that said fluid causes one or more flow throttling devices to generate large, rapid controllable pulses thereby allowing transmission of well developed signals easily distinguished from noise resulting from other vibrations due to nearby equipment that is within said borehole or exterior to said borehole, said signals also capable of providing predetermined height, width and shape. 2. The apparatus of claim 1, wherein said apparatus also utilizes a turbine residing near and within proximity of a flow diverter that diverts drilling mud in said annular flow channel into and away from turbine blades such that the force of the drilling mud causes said turbine blades and said turbine to rotationally spin around a coil assembly. 3. The apparatus of claim 1, wherein said coil assembly generates electrical power for operating a motor and other operating equipment useful for instrumentation, said motor comprising a drive shaft centrally located between said motor and a magnetic pressure coupling wherein said motor and said coupling are mechanically coupled such that said motor rotates said magnetic pressure coupling outer magnets and bi-directionally moves said pilot actuator assembly. 4. The apparatus of claim 1, wherein said apparatus for generating pulses includes a pilot, a pilot bellows, a flow throttling device, and a sliding pressure chamber, such that said flow throttling device and said pilot are capable of bi-directional axial movement without a guide pole. 5. The apparatus of claim 1, wherein a magnetic coupling is formed by a location external and internal to said magnetic pressure cup where outer magnets are placed in relation to inner magnets, said inner magnets located in a position inside said magnetic pressure cup, said coupling allowing for translating rotational motion of said motor and outer magnets to linear motion of said inner magnets via a magnetic polar interaction, wherein linear motion of said inner magnets move said pilot actuator assembly, thereby linearly moving a pilot into a pilot seat, closing a pilot seat orifice, lifting a flow throttling device into a flow throttling orifice and thereby generating a pulse wherein further rotation of said motor drive shaft, and outer magnets move said pilot actuator assembly and said pilot away from said pilot seat causing said flow throttling device to move away from said flow throttling orifice, thereby ending a positive pulse. 6. The apparatus of claim 1, wherein said motor is connected to a drive shaft through a mechanical device including mechanical means including a worm gear, or barrel cam face cam for converting the rotational motion of said motor into linear motion to propel said pilot actuator assembly. 7. The apparatus of claim 1, wherein said apparatus includes a path for said pilot and said flow throttling device for operation in a bi-directional axial movement. 8. The apparatus of claim 1, wherein said pilot actuator assembly is comprised of a rear pilot shaft, front pilot shaft, pilot shield, and pilot. 9. The apparatus of claim 1 wherein differential pressure is maximized with the use of said flow cone in that said cone provides for increasing the velocity of said drilling fluid through said main valve actuator assembly, thereby greatly enhancing the pressure differential and controllability of energy pulses created by engagement or disengagement of said pilot from a pilot seat. 10. The apparatus of claim 1, wherein said motor may be synchronous, asynchronous or stepper and is activated to fully rotate or to rotate incrementally in various degrees depending on wellbore conditions or the observed signal intensity and/or duration of drilling. 11. The apparatus of claim 1, wherein said turbine resides within said annular flow channel of a flow guide and wherein said annular flow channel has diverting vanes that direct flow of drilling mud through and around a surface of said turbine. 12. The apparatus of claim 1, wherein said turbine includes a turbine shroud comprising turbine magnets that rotate with the motion of said turbine around said coil assembly causing electrical power to be generated and allowing for decreased battery requirements, a decrease in cost of said battery, decreased operational downtime, and subsequently decreased cost of said apparatus. 13. The apparatus of claim 1, wherein energy consumption may also be further reduced by pre-filling the bellows chamber with a lubricating fluid, gel or paste. 14. The apparatus of claim 1, wherein said turbine blades outside diameters around a pulser housing is smaller than a flow guide extension inner diameter, thereby allowing said turbine to be removed concurrently with said pulser housing. 15. The apparatus of claim 1, wherein said apparatus for generating pulses includes allowing a bellows to move linearly, concurrent with said pilot actuator assembly, wherein the design of said bellows interacts with said pilot actuator assembly and a bellows chamber allowing said bellows to conform to the space constraints of said bellows chamber providing flexible sealing without said bellows being displaced by the pressure differential created by said drilling fluid. 16. The apparatus of claim 1, wherein said bellows may include a double loop configuration designed for said flexible sealing thereby requiring less energy consumption during displacement of said bellows. 17. The apparatus of claim 1, wherein said pulse in said drilling mud is sensed by said instrumentation located uphole and wherein said pulse is communicated with wireless devices, to a computer with a programmable controller for interpretation. 18. A method for generating pressure pulses in a drilling fluid, flowing within a drill string, comprising: a flow throttling device longitudinally and axially positioned within the center of a main valve actuator assembly, said main valve actuator assembly comprising a main valve pressure chamber, a magnetic cup encompassing a rotary magnetic coupling containing at least one magnet adjacent to a drive shaft wherein said magnetic cup is located within a pilot actuator assembly, said assembly including a pilot orifice with a pilot valve, a pilot flow shield, a bellows and an anti-rotation block such that passage of said drilling fluid flows through a pilot flow screen and into a main flow entrance into a flow cone through a main orifice and into a main valve past a main valve pressure chamber past a set of seals and through a main valve support block then through a flow seal guide where said fluid combines with a pilot exit fluid that flows toward a main exit flow such that as said fluid becomes a pilot fluid subsequently flowing through said pilot flow screen into said pilot flow screen chamber through a pilot flow upper annulus, through a pilot flow lower annulus and into a pilot flow inlet channel, wherein said pilot fluid then flows up into said main valve feed channel until it reaches said main valve pressure chamber such that said pilot fluid flows back down said main valve feed channel through said pilot flow exit channel through said pilot orifice and said pilot valve to exit said pilot valve and said pilot fluid then flows over said pilot flow shield such that it combines with said main flow becoming the main exit flow fluid, said main exit flow fluid then exits said pilot valve support block and flows on either side of said magnetic pressure cup including said rotary magnetic coupling and then finally past a drive shaft and motor such that said fluid causes one or more flow throttling devices to generate large, rapid controllable pulses thereby allowing transmission of well developed signals easily distinguished from noise resulting from other vibrations due to nearby equipment that is within said borehole or exterior to said borehole, said signals also capable of providing predetermined height, width and shape. 19. The method of claim 18, wherein said coil assembly generates electrical power for operating a motor and other operating equipment useful for instrumentation, said motor comprising a drive shaft centrally located between said motor and a magnetic pressure coupling wherein said motor and said coupling are mechanically coupled such that said motor rotates or linearly moves said magnetic pressure coupling outer magnets and moves said pilot actuator assembly, wherein said assembly opens and closes either a linear or rotational pilot valve. 20. The method of claim 18, wherein a magnetic coupling is formed by a location external and internal to said magnetic pressure cup where outer magnets are placed in relation to inner magnets, said inner magnets located in a position inside said magnetic pressure cup, said coupling allowing for translating rotational motion of said motor and outer magnets to linear motion of said inner magnets via a magnetic polar interaction, wherein linear motion of said inner magnets move said pilot actuator assembly, thereby linearly moving a pilot into a pilot seat, closing a pilot seat orifice, lifting a flow throttling device into a flow throttling orifice and thereby generating a pulse wherein further rotation of said motor drive shaft, and outer magnets move said pilot actuator assembly and said pilot away from said pilot seat causing said flow throttling device to move into said flow throttling orifice, thereby generating another pulse. 21. The method of claim 18, wherein said motor is connected to a drive shaft through a mechanical device including mechanical means including a worm gear or barrel cam face cam for converting the rotational motion of said motor into linear motion to propel said pilot actuator assembly. 22. The method of claim 18, wherein said apparatus includes a path for said pilot and said flow throttling device for operation in a bi-directional axial movement. 23. The method of claim 18, wherein said pilot actuator assembly is comprised of a rear pilot shaft, front pilot shaft, pilot shield and a pilot. 24. The method of claim 18, wherein differential pressure is minimal in that a slight force acting on a small cross-sectional area of a pilot seat defines a pressure that is required to either engage or disengage said pilot. 25. The method of claim 18, wherein said motor may be synchronous, asynchronous, or stepper and is activated to fully rotate or to rotate incrementally in various degrees depending on wellbore conditions or the observed signal intensity and/or duration of drilling. 26. The method of claim 18, wherein said turbine resides within said annular flow channel of a flow guide and wherein said annular flow channel has diverting vanes that direct flow of drilling mud through and around a surface of said turbine. 27. The method of claim 18, wherein said turbine includes a turbine shroud comprising turbine magnets that rotate with the motion of said turbine around said coil assembly causing electrical power to be generated and allowing for decreased battery requirements, a decrease in cost of said battery, decreased operational downtime, and subsequently decreased cost of said apparatus. 28. The method of claim 18, wherein energy consumption may also be further reduced by pre-filling a bellows chamber with a lubricating fluid, gel or paste. 29. The method of claim 18, wherein said turbine blades outside diameters around a pulser housing is smaller than a flow guide extension inner diameter, thereby allowing said turbine to be removed concurrently with said pulser housing. 30. The method of claim 18, wherein said apparatus for generating pulses includes allowing a bellows to move linearly, concurrent with said pilot actuator assembly, wherein the design of said bellows interacts with said pilot actuator assembly and a bellows chamber allowing said bellows to conform to the space constraints of said bellows chamber providing flexible sealing without said bellows being displaced by the pressure differential created by said drilling fluid. 31. The method of claim 18, wherein said bellows may include a double loop configuration designed for said flexible sealing thereby requiring less energy consumption during displacement of said bellows. 32. The method of claim 18, wherein said pulse in said drilling mud is sensed by said instrumentation located within an uphole device and wherein said pulse is communicated with wireless devices, to a computer with a programmable controller for interpretation. 33. A system comprising two or more apparatuses for generating pressure pulses in a drilling fluid, flowing within a drill string, comprising: two or more flow throttling devices longitudinally and axially positioned within the center of a main valve actuator assembly, said main valve actuator assembly comprising a main valve pressure chamber, a magnetic cup encompassing a rotary magnetic coupling containing at least one magnet adjacent to a drive shaft wherein said magnetic cup is located within a pilot actuator assembly, said assembly including a pilot orifice with a pilot valve, a pilot flow shield, a bellows and an anti-rotation block such that passage of said drilling fluid flows through a pilot flow screen and into a main flow entrance into a flow cone through a main orifice and into a main valve past a main valve pressure chamber past a set of seals and through a main valve support block then through a flow seal guide where said fluid combines with a pilot exit fluid that flows toward a main exit flow such that as said fluid becomes a pilot fluid subsequently flowing through said pilot flow screen into said pilot flow screen chamber through a pilot flow upper annulus, through a pilot flow lower annulus and into a pilot flow inlet channel, wherein said pilot fluid then flows up into said main valve feed channel until it reaches said main valve pressure chamber such that said pilot fluid flows back down said main valve feed channel through said pilot flow exit channel through said pilot orifice and said pilot valve to exit said pilot valve and said pilot fluid then flows over said pilot flow shield such that it combines with said main flow becoming the main exit flow fluid, said main exit flow fluid then exits said pilot valve support block and flows on either side of said magnetic pressure cup including said rotary magnetic coupling and then finally past a drive shaft and motor such that said fluid causes one or more flow throttling devices to generate large, rapid controllable pulses thereby allowing transmission of well developed signals easily distinguished from noise resulting from other vibrations due to nearby equipment that is within said borehole or exterior to said borehole, said signals also capable of providing predetermined height, width and shape. 34. A system for generating pressure pulses in a drilling fluid, flowing within a drill string, comprising: a flow throttling device longitudinally and axially positioned within the center of a main valve actuator assembly, said main valve actuator assembly comprising a main valve pressure chamber, a magnetic cup encompassing a rotary magnetic coupling containing at least one magnet adjacent to a drive shaft wherein said magnetic cup is located within a pilot actuator assembly, said assembly including a pilot orifice with a pilot valve, a pilot flow shield, a bellows and an anti-rotation block such that passage of said drilling fluid flows through a pilot flow screen and into a main flow entrance into a flow cone through a main orifice and into a main valve past a main valve pressure chamber past a set of seals and through a main valve support block then through a flow seal guide where said fluid combines with a pilot exit fluid that flows toward a main exit flow such that as said fluid becomes a pilot fluid subsequently flowing through said pilot flow screen into said pilot flow screen chamber through a pilot flow upper annulus, through a pilot flow lower annulus and into a pilot flow inlet channel, wherein said pilot fluid then flows up into said main valve feed channel until it reaches said main valve pressure chamber such that said pilot fluid flows back down said main valve feed channel through said pilot flow exit channel through said pilot orifice and said pilot valve to exit said pilot valve and said pilot fluid then flows over said pilot flow shield such that it combines with said main flow becoming the main exit flow fluid, said main exit flow fluid then exits said pilot valve support block and flows on either side of said magnetic pressure cup including said rotary magnetic coupling and then finally past a drive shaft and motor such that said fluid causes one or more flow throttling devices to generate large, rapid controllable pulses thereby allowing transmission of well developed signals easily distinguished from noise resulting from other vibrations due to nearby equipment that is within said borehole or exterior to said borehole, said signals also capable of providing predetermined height, width and shape. 35. The system of claim 34, wherein said coil assembly generates electrical power for operating a motor and other operating equipment useful for instrumentation, said motor comprising a drive shaft centrally located between said motor and a magnetic pressure coupling wherein said motor and said coupling are mechanically coupled such that said motor rotates said magnetic pressure coupling outer magnets and moves said pilot actuator assembly. 36. The system of claim 34, wherein a magnetic coupling is formed by a location external and internal to said magnetic pressure cup where outer magnets are placed in relation to inner magnets, said inner magnets located in a position inside said magnetic pressure cup, said coupling allowing for translating rotational motion of said motor, magnetic pressure cup and outer magnets to linear motion of said inner magnets via a magnetic polar interaction, wherein linear motion of said inner magnets move said pilot actuator assembly, thereby linearly moving a pilot into a pilot seat, closing a pilot seat orifice, lifting a flow throttling device into a flow throttling orifice and thereby generating a pulse wherein further rotation of said motor drive shaft, magnetic pressure cup, and outer magnets move said pilot actuator assembly and said pilot away from said pilot seat causing said flow throttling device to move into said flow throttling orifice, thereby generating a negative pulse. 37. The system of claim 34, wherein said motor is connected to a drive shaft through a mechanical device including a mechanical means including a worm gear or barrel cam face cam for converting the rotational motion of said motor into linear motion to propel said pilot actuator assembly. 38. The system of claim 34, wherein said apparatus includes a pilot, a pilot bellows, a flow throttling device, and a sliding pressure chamber, such that said flow throttling device and said pilot are capable of bi-directional axial movement without a guide pole. 39. The system of claim 34, wherein said pilot actuator assembly is comprised of a rear pilot shaft, front pilot shaft, pilot shield, and pilot. 40. The system of claim 34, wherein differential pressure is minimal in that a slight force acting on a small cross-sectional area of a pilot seat defines a pressure that is required to either engage or disengage said pilot. 41. The system of claim 34, wherein said motor may be synchronous, asynchronous, or stepper and is activated to fully rotate or to rotate incrementally in various degrees depending on wellbore conditions or the observed signal intensity and/or duration of drilling. 42. The system of claim 34, wherein said turbine resides within said annular flow channel of a flow guide and wherein said annular flow channel has diverting vanes that direct flow of drilling mud through and around a surface of said turbine. 43. The system of claim 42, wherein said turbine includes a turbine shroud comprising turbine magnets that rotate with the motion of said turbine around said coil assembly causing electrical power to be generated and allowing for decreased energy requirements for batteries, a decrease in cost of said batteries, decreased operational downtime, and subsequently decreased cost of said apparatus. 44. The system of claim 34, wherein energy consumption may also be further reduced by pre-filling a bellows chamber with a lubricating fluid, gel or paste. 45. The system of claim 34, wherein said turbine blades outside diameter is smaller than a flow guide extension inner diameter, thereby allowing said turbine to be removed concurrently with said pulser housing. 46. The system of claim 34, wherein said apparatus for generating pulses includes allowing a bellows to move linearly, concurrent with said pilot actuator assembly, wherein the design of said bellows interacts with said pilot actuator assembly and a bellows chamber allowing said bellows to conform to the space constraints of said bellows chamber providing flexible sealing without said bellows being displaced by the pressure differential created by said drilling fluid. 47. The system of claim 34, wherein said bellows may include a double loop configuration designed for said flexible sealing thereby requiring less energy consumption during displacement of said bellows.
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