Flow Diverter Encoder Modulation for Downhole Data Transmission

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Solution Overview

Problem

Conventional rotary steerable drilling systems face challenges in efficiently transmitting downhole data to the surface due to limited space below the mud motor, which often prevents the use of conventional mud-pulsers for data transmission.

Innovation Solution

Incorporating a flow diverter with an encoder in the drill string sub, allowing for the modulation of relative rotation to encode and transmit data as chopper noise, eliminating the need for a conventional mud-pulser and enabling data transmission through the mud motor during idle times or by switching between steering and modulation patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional mud-pulser is used for data transmission, then data can be transmitted reliably to the surface, but the space requirement below the mud motor increases and the device complexity increases

Engineering Contradiction:

Improvedata transmission reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the data transmission function with the existing flow diverter component used for steering. The flow diverter's rotation is modulated to encode data, merging two functions (steering and data transmission) into a single component, thereby eliminating the need for a separate mud-pulser and reducing device complexity while maintaining data transmission capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flow diverter is designed to serve multiple functions: it controls the drilling fluid flow for steering purposes and simultaneously encodes data through modulation of its rotation. This multi-functionality allows the system to transmit data without requiring additional specialized equipment below the mud motor

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Loss of information

If a conventional mud-pulser is used for data transmission, then data can be transmitted to the surface, but the space available below the mud motor must be sufficient to accommodate it

Engineering Contradiction:

Improvedata transmission capabilityVSAvoidspace below mud motor

Core Design Contradiction:

Loss of informationVSVolume of moving object

Solution Approach 1:

The patent merges the data transmission function into the existing flow diverter component, which already occupies space below the mud motor. By encoding data through modulation of the flow diverter's rotation rather than adding a separate mud-pulser, the system eliminates the need for additional space while maintaining data transmission capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flow diverter serves dual purposes: steering control through fluid flow direction and data transmission through rotation modulation. This multi-functionality allows the system to utilize existing space efficiently without requiring additional volume below the mud motor

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Stability of the object's composition

If the flow diverter rotates relative to the surrounding formation for straight drilling, then each side of the borehole is flushed evenly, but data cannot be transmitted

Engineering Contradiction:

Improveborehole trajectory stabilityVSAvoiddata transmission capability

Core Design Contradiction:

Stability of the object's compositionVSLoss of information

Solution Approach 1:

The patent introduces dynamic modulation of the flow diverter's rotation. During straight drilling, the flow diverter maintains its geostationary position for trajectory stability, but can be dynamically modulated around this position to encode data. This dynamic capability allows the system to switch between stable drilling mode and data transmission mode using the same component

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Data transmission is achieved through periodic modulation of the flow diverter's rotation relative to its geostationary position. The encoder modulates the rotation in periodic patterns that encode data bits, allowing information transmission while maintaining the overall geostationary operation needed for stable borehole trajectory

Inventive Principle:

Principle #19Periodic action

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

This solution allows for reliable data transmission to the surface without additional equipment, utilizing chopper noise to communicate data effectively and reducing the need for conventional mud-pulsers, while maintaining primary steering functionality.

Implementation Method 1

modulate the relative rotation in accordance with an information signal for transmitting information representing the downhole data to be detected uphole

Methodology Applied

Scientific EffectChopper noise:

Data Source

PatentUS11280182B2Rotary steerable drilling system, a drill string sub therefor and a method of operating such system

Publication Date: 2022.03.22 SHELL USA INC

AI summary

A drill string sub for a rotary steerable drilling system wherein a flow diverter is configured, which flow diverter is configured rotatable about a drill string longitudinal axis at a relative rotation frequency relative to the drill string sub, to preferentially direct drilling fluid into a selected azimuth segment which is stationary relative to the flow diverter. A downhole data unit is configured to provide an information signal representing downhole data. An encoder operatively connected to the flow diverter to modulate the relative rotation in accordance with the information signal for transmitting information representing the downhole data to be detected uphole.