Selective Flow Pulsing Rotor for Drill String Friction Reduction
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Solution Overview
Problem
Existing drilling technologies face challenges in reducing friction with boreholes, enhancing tool face control, and improving drilling efficiency, particularly in extended drill string lengths, with a need for adjustable and selective flow pulsing systems that can be activated only when needed.
Innovation Solution
A flow pulsing system with a housing, stator, and rotor, featuring a dart and nozzle configuration, allowing selective engagement, adjustable frequency and magnitude, and reconfiguration to optimize pressure pulses and reduce friction, while resisting clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a flow pulsing apparatus is used to oscillate a drill string, then friction with a borehole is reduced, but device complexity increases
Solution Approach 1:
The flow pulsing apparatus is divided into distinct functional segments: a pulsing element with lobes that rotates within a stator having lobe cavities, creating segmented flow pulses. The drill string itself is segmented with the pulsing apparatus as a separate module that can be selectively activated. This segmentation allows the friction-reducing function to be isolated to specific zones without complicating the entire drill string design.
Solution Approach 2:
The apparatus introduces dynamic oscillations to the otherwise static drill string system. The rotor rotates at variable speeds to create time-varying flow pulses that dynamically reduce friction along the borehole wall. This dynamic approach allows the system to adapt friction reduction to different drilling conditions without permanent structural modifications.
2Productivity
If flow pulsing frequency is increased to enhance drilling efficiency, then productivity improves, but energy consumption increases
Solution Approach 1:
The apparatus employs periodic flow pulsing rather than continuous high-frequency vibration. The rotor completes discrete rotation cycles creating periodic pressure pulses that propagate down the drill string. This periodic action maintains drilling efficiency by periodically disrupting friction zones while allowing energy recovery during the non-pulsing phases, reducing overall energy consumption compared to continuous operation.
Solution Approach 2:
The system allows dynamic adjustment of pulsing frequency and amplitude parameters. The rotor speed can be varied to optimize the balance between drilling efficiency and energy consumption. By changing operational parameters rather than maintaining fixed high-frequency operation, the system achieves productivity improvements while controlling energy usage according to actual drilling conditions.
3Ease of operation
If selective activation capability is added to the flow pulsing system, then ease of operation improves, but device complexity increases
Solution Approach 1:
A selective activation mechanism serves as an intermediary between the control system and the flow pulsing apparatus. This intermediary component enables remote or automated activation without requiring direct mechanical control of the rotor, simplifying operation while containing complexity in a dedicated activation module rather than distributing it throughout the entire system.
Solution Approach 2:
The flow pulsing apparatus is designed to be self-activating under certain downhole conditions. Sensors or pressure differential mechanisms automatically trigger rotor rotation when specific conditions are met, eliminating the need for external activation commands. This self-service capability improves ease of operation by making the system autonomous while avoiding the complexity of sophisticated control systems.
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
Enhances drilling efficiency by reducing friction, improving tool face control, and allowing extended drill string lengths through selective and adjustable pressure pulsing, minimizing pressure loss, and preventing clogging.
Implementation Method 1
The rotor includes an axis offset from the central axis, a plurality of lobes that mate with the plurality of lobe cavities
Implementation Method 2
a flow pulsing apparatus may be used to oscillate a drill string to reduce friction with a borehole
Implementation Method 3
a releasable nozzle configured to control a first fluid flow through the inner bore and the thru bore
Implementation Method 4
a flow pulsing apparatus may be used to oscillate a drill string to reduce friction with a borehole
Data Source
AI summary
Embodiments disclosed herein are directed to a flow pulsing system including a rotor, a stator, a dart which is configured to releasably couple with the rotor, and a nozzle releasably coupled to the rotor which is configured to control a fluid flow through the rotor. In some embodiments, the system uses a screen disposed therein which includes an inner bore in fluid communication with a plurality of lobe cavities along the rotor. In some embodiments, the system uses a stationary valve and an oscillating valve having a plurality of oscillating valve ports which are in fluid communication with the plurality of lobe cavities.