Angled Rotor Bypass Channel for Mud Pulse Telemetry Wear Reduction
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Solution Overview
Problem
Existing mud pulse telemetry systems in drilling operations face challenges with valve wear and failure due to high differential pressure requirements, leading to mechanical and abrasive issues in creating pressure pulses for efficient data transmission.
Innovation Solution
A fluid pressure pulse generator comprising a stator and rotor with angled rotor bypass channels that rotate relative to the stator, creating fluid pressure pulses by moving in and out of fluid communication, reducing wear and enhancing pulse generation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If negative pulsing valves are used to create pressure pulses by opening and closing a bypass stream, then pressure differentials are achieved, but the valves become prone to washing and mechanical wear due to high differential pressure requirements
Solution Approach 1:
The patent replaces the traditional mechanical valve system (which opens and closes bypass streams) with a rotor-stator mechanical pulse generator system. The rotor with angled bypass channels rotates relative to the stator to create pressure pulses, eliminating the need for high-differential-pressure mechanical valves that are prone to wear and washing. This substitution of mechanical valve actuation with a rotary positive displacement mechanism resolves the contradiction between achieving pressure differentials and avoiding mechanical wear.
2Productivity
If conventional rotor-stator valves are used to create pressure pulses, then pulse generation is achieved, but mechanical and abrasive wear occurs due to valve impact against the valve seat
Solution Approach 1:
The patent employs a dynamic rotor-stator configuration where the rotor rotates continuously to generate pressure pulses through the interaction of angled bypass channels with stator elements. This dynamic rotary mechanism eliminates the repeated impact and closure actions of conventional valves, thereby maintaining pulse generation efficiency while significantly reducing mechanical and abrasive wear on components.
3Stress or pressure
If high differential pressure is applied to ensure complete valve closure, then sufficient pressure drop is achieved, but mechanical stress and abrasive erosion increase
Solution Approach 1:
The patent replaces the high-differential-pressure valve closure mechanism with a rotary rotor-stator system that generates pressure pulses through controlled displacement of drilling fluid. The angled bypass channels in the rotor create pressure differentials through rotation rather than through high-force valve closure, thereby achieving the necessary pressure drop without subjecting components to excessive mechanical stress and abrasive erosion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively generates fluid pressure pulses with reduced wear on components, improving the reliability and efficiency of mud pulse telemetry systems by minimizing mechanical stress and abrasive erosion.
Implementation Method 1
The rotor projections are axially adjacent the stator projections and the rotor is rotatable relative to the stator such that the rotor projections move in and out of fluid communication with the stator flow channels to generate fluid pressure pulses in fluid flowing through the stator flow channels
Implementation Method 2
The angled rotor bypass channel extending through or along a surface of the at least one rotor projection and having a fluid inlet and a fluid outlet downhole and lateral relative to the fluid inlet
Data Source
AI summary
A fluid pressure pulse generator for a telemetry tool comprising a stator and a rotor. The stator comprising a stator body and a plurality of radially extending stator projections spaced around the stator body, whereby adjacently spaced stator projections define stator flow channels extending therebetween. The rotor comprising a rotor body and a plurality of radially extending rotor projections spaced around the rotor body. The rotor projections are axially adjacent the stator projections and the rotor is rotatable relative to the stator such that the rotor projections move in and out of fluid communication with the stator flow channels to generate fluid pressure pulses in fluid flowing through the stator flow channels. At least one of the rotor projections has an angled rotor bypass channel which moves in and out of fluid communication with the stator flow channels as the rotor rotates relative to the stator, the angled rotor bypass channel extending through or along a surface of the at least one rotor projection and having a fluid inlet and a fluid outlet downhole and lateral relative to the fluid inlet. The angled rotor bypass channel providing a self-correction mechanism causing the rotor to rotate to an open flow position when there is failure of the telemetry tool.