Flow Bypass Sleeve for Mud Pulse Telemetry Wear Reduction
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Solution Overview
Problem
Downhole mud pulse telemetry tools face mechanical and abrasive wear issues due to high differential pressure requirements for negative pressure pulse generation, leading to valve failure and inefficiencies in drilling operations.
Innovation Solution
A flow bypass sleeve is designed to fit inside a drill collar, featuring longitudinally extending bypass channels and apertures that divert drilling fluid around the fluid pressure pulse generator, reducing the flow area and controlling mud flow, thereby mitigating wear and improving pulse generation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If negative pressure pulse valves are used to create pressure pulses by opening and closing a bypass stream, then pressure pulses can be generated for mud pulse telemetry, but the valves are prone to mechanical and abrasive wear and failure due to high differential pressure requirements
Solution Approach 1:
The invention extracts the valve component from the pulse generation system and replaces it with a valveless pulse generator. The pulse generator creates pressure pulses by rotating a rotor with flow channels that modulate the flow area, eliminating the need for moving valves that open and close bypass streams. This extraction of the problematic valve component directly addresses the wear and reliability issues.
Solution Approach 2:
The invention replaces the mechanical valve system (with moving parts subject to wear) with a rotor-based flow modulation system. The rotor rotates to vary the flow area in a controlled manner, creating pressure pulses without the mechanical impact and wear associated with valve opening and closing operations. This substitution eliminates the harmful mechanical and abrasive wear while maintaining pulse generation capability.
2Productivity
If valves are actuated to open and close bypass streams for negative pressure pulse generation, then pressure pulses are created, but the valve impact against the valve seat causes mechanical wear and failure
Solution Approach 1:
The valve component is completely removed from the system and replaced with a rotor-based flow modulation mechanism. The rotor rotates to control flow area variations, generating pressure pulses without any valve components that could impact against seats. This extraction eliminates the source of mechanical wear while preserving pulse generation functionality.
Solution Approach 2:
The rotor rotates continuously to create periodic flow area variations, generating pressure pulses through controlled cyclic changes in flow resistance. This periodic rotation replaces the intermittent valve actuation (open-close cycles) with smooth continuous rotation, eliminating impact loads and mechanical wear on valve components while maintaining effective pulse generation.
3Stress or pressure
If high differential pressure is applied below negative pressure pulse valves to create sufficient pressure drop, then pressure pulses can be generated, but the valves become more prone to washing and failure
Solution Approach 1:
The invention replaces the valve-based pressure drop mechanism with a rotor-based flow modulation system. The rotor's rotating flow channels create pressure pulses through controlled flow area variations without requiring high differential pressures that cause valve washing. This substitution maintains effective pressure pulse generation while eliminating the reliability issues associated with high differential pressure on valves.
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 flow bypass sleeve reduces mechanical stress on valves, enhances the reliability of mud pulse generation, and optimizes drilling fluid flow, leading to more efficient and economical drilling operations by minimizing wear and maintaining optimal pressure differentials.
Implementation Method 1
a rotor which rotates relative to the stator to move in and out of fluid communication with the flow channels or orifices to create fluid pressure pulses in the drilling fluid
Implementation Method 2
the bypass channel extends across at least a portion of both the stator and the rotor such that the drilling fluid flows along the bypass channel in addition to flowing through the flow channels or orifices of the stator
Data Source
AI summary
A flow bypass sleeve for a fluid pressure pulse generator of a downhole telemetry tool. The fluid pressure pulse generator comprising a stator having one or more flow channels or orifices through which drilling fluid flows and a rotor which rotates relative to the stator to move in and out of fluid communication with the flow channels or orifices to create fluid pressure pulses in the drilling fluid flowing through the fluid pressure pulse generator. The flow bypass sleeve is configured to attach to a drill collar which housing the telemetry tool and comprises a body with a bore therethrough which receives the fluid pressure pulse generator. The body includes at least one longitudinally extending bypass channel comprising a groove longitudinally extending along an internal surface of the body or an aperture longitudinally extending through the body. The bypass channel extends across at least a portion of both the stator and the rotor when the fluid pressure pulse generator is received in the flow bypass sleeve such that the drilling fluid flows along the bypass channel as well as flowing through the flow channels or orifices. The bypass channel diverts drilling fluid around the fluid pressure pulse generator and may be dimensioned to control the amount of drilling fluid being diverted.