Electromagnetic Mud Pulser for High-Temperature Drilling
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Solution Overview
Problem
Current mud pulsers used in drilling systems deteriorate at high temperatures and are not suitable for use in wells above 300 degrees Fahrenheit due to oil fillings, elastomers, and electrical high pressure connectors.
Innovation Solution
A flow control device with an electromagnetic circuit using soft magnetic or magnetic materials to generate pressure pulses, where a closing member moves between open and closed positions to produce pulses in the fluid flow path when the coil is energized, eliminating the need for oil fillings and electrical connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mud pulsers with oil fillings, elastomers and electrical high pressure connectors are used, then pressure pulse generation is achieved, but the components deteriorate at high temperatures above 300 degrees Fahrenheit
Solution Approach 1:
The patent removes oil fillings, elastomers, and electrical high pressure connectors from the mud pulser design. These extracted components were the source of deterioration at high temperatures, and their elimination allows the device to operate reliably above 300 degrees Fahrenheit without degradation.
Solution Approach 2:
The invention changes the material parameters and construction of the mud pulser by using high-temperature-resistant materials and a simplified electromagnetic design. This parameter change enables the device to withstand and operate at temperatures exceeding 300 degrees Fahrenheit, extending the operational temperature limit.
2Reliability
If oil fillings and elastomers are used in the electromagnetic circuit, then the electromagnetic circuit functions, but the components deteriorate over time in high temperature environments
Solution Approach 1:
The patent extracts and removes oil fillings and elastomers from the electromagnetic circuit design. These materials were causing deterioration over time, particularly in high-temperature drilling environments. Their removal eliminates the degradation mechanism while maintaining electromagnetic functionality through alternative design approaches.
Solution Approach 2:
The invention replaces mechanical and chemical components (oil fillings, elastomers) with an electromagnetic-based system that uses magnetic fields and electromagnetic induction to achieve the same flow control function, thereby eliminating materials that deteriorate over time.
3Reliability
If a closing member made from soft magnetic or magnetic material is used in the electromagnetic circuit, then pressure pulses are generated without oil fillings or electrical connectors, but the device complexity increases
Solution Approach 1:
The patent merges the closing member with the electromagnetic circuit by making the closing member itself from soft magnetic or magnetic material. This integration eliminates the need for separate oil fillings, elastomers, and electrical high pressure connectors, simplifying the overall device while achieving high-temperature reliability.
Solution Approach 2:
The closing member serves multiple functions simultaneously: it acts as both the electromagnetic circuit component and the flow control element. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity while maintaining reliability at high temperatures.
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 provides reliable pressure pulse generation in high-temperature environments, extending the lifespan of drilling system components and ensuring continuous data transmission during drilling operations.
Implementation Method 1
an electromagnetic circuit that includes a closing member made from a soft magnetic or magnetic material as a part of the electromagnetic circuit, wherein the closing member moves from a first open position to a second closed position to close the fluid flow path to produce a pressure pulse in a fluid flowing through the fluid flow path when the electromagnetic circuit is formed
Data Source
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AI summary
In one aspect, an apparatus for use in a drilling assembly is disclosed that in one embodiment includes a flow control device that further includes: a fluid flow path having an inlet and an outlet; an electromagnetic circuit that includes a closing member made from a soft magnetic or magnetic material as a part of the electromagnetic circuit, wherein the closing member moves from a first open position to a second closed position to close the fluid flow path to produce a pressure pulse in a fluid flowing through the fluid flow path when the electromagnetic circuit is formed.