Closed-Loop Pressure Intensification for Ultra-High-Pressure Drilling Jets
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Solution Overview
Problem
Existing drilling technologies face challenges in generating ultra-high pressure fluid jets for efficient drilling, particularly in deep formations, due to pump failures from erosion and particle abrasion, and limitations in drilling fluid weight, which restrict their use in deep wells.
Innovation Solution
A closed loop hydraulic system that transfers pressure energy from drilling fluid to a closed loop circuit, using an oscillation tool, pressure intensifier pump, and pressure transfer tool, without direct contact with drilling fluid, to generate ultra-high pressure fluid jets for drilling applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If downhole intensifier pump is used to generate ultra-high pressure, then ultra-high pressure can be generated down hole, but the pump reliability deteriorates due to erosion and particle abrasion from drilling fluid
Solution Approach 1:
The patent introduces a closed-loop hydraulic system that acts as an intermediary between the drilling fluid and the intensifier pump. The oscillation tool converts drilling fluid pressure into hydraulic pressure in a closed-loop system, which then drives the intensifier pump. This mediator approach prevents direct contact between abrasive drilling fluid and the pump, resolving the contradiction between generating ultra-high pressure and maintaining pump reliability.
Solution Approach 2:
The patent extracts the drilling fluid from the intensifier pump system by implementing a closed-loop hydraulic circuit. The drilling fluid is taken out of the direct path and only interacts with the oscillation tool, while the intensifier pump operates independently with clean hydraulic fluid, thereby eliminating erosion and particle abrasion issues.
2Stress or pressure
If downhole intensifier pump is used to generate ultra-high pressure, then ultra-high pressure can be generated, but the pump life deteriorates due to erosion and particle abrasion
Solution Approach 1:
The closed-loop hydraulic system serves as a protective intermediary, allowing the intensifier pump to generate ultra-high pressure while being isolated from the harmful effects of drilling fluid. The hydraulic fluid in the closed-loop circuit protects the pump components from erosion and abrasion, thereby extending pump life while maintaining ultra-high pressure generation capability.
Solution Approach 2:
The patent implements prior cushioning by establishing a closed-loop hydraulic system that cushions the intensifier pump against the harmful effects of drilling fluid before contact occurs. The separation mechanism is built into the system design, preventing erosion and abrasion before they can damage the pump, thus extending its operational life.
3Speed
If motor is utilized in the drilling assembly to increase bit rotation, then higher bit rotation is achieved, but the additional rotation is never delivered to drill bit due to inherent design of pumps
Solution Approach 1:
The patent segments the rotation transmission path by separating the motor function from the pump function. The motor rotates the drill string independently, while the pump system operates as a separate module that converts pressure to fluid jet energy. This segmentation allows the motor's rotational energy to be delivered directly to the bit without being absorbed or blocked by the pump mechanism.
Solution Approach 2:
The patent introduces a closed-loop hydraulic system as an intermediary that decouples the motor rotation from the pump operation. The motor drives the drill string rotation directly, while the closed-loop hydraulic system independently manages the pressure conversion and fluid jet generation, allowing both functions to operate without interfering with each other.
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
Prevents pump failures and maintains high bit rotation, enhancing drilling efficiency by generating ultra-high pressure fluid jets without limitations on drilling depth or fluid type, suitable for deep wells and other downhole applications.
Implementation Method 1
an oscillation tool configured to transfer a pressure energy from the received drilling fluid to a closed loop hydraulic circuit and pressurize the closed loop hydraulic fluid circulating therein
Implementation Method 2
a pressure intensifier pump connected downstream of the oscillation tool, configured to increase hydraulic pressure of closed loop hydraulic fluid to an ultra-high pressure
Implementation Method 3
a pressure transfer tool connected downstream of the pressure intensifier pump, configured to transfer the ultra-high pressure from the closed loop hydraulic fluid to the low-pressure drilling fluid, thereby increasing the low-pressure drilling fluid to ultra-high pressure drilling fluid
Data Source
AI summary
An apparatus for generating an ultra-high pressure fluid jet during drilling comprises a drilling motor; a housing structure connected with the drilling motor; and a drill bit assembly connected at the downstream end of the housing structure. The housing structure comprises an oscillation tool configured to transfer a pressure energy from pumped drilling fluid to a closed loop hydraulic circuit and pressurize the same therein; a pressure intensifier pump configured to increase hydraulic pressure of closed loop hydraulic fluid to an ultra-high pressure; and a pressure transfer tool configured to transfer the ultra-high pressure from the closed loop hydraulic fluid to the low-pressure drilling fluid, without any communication between the drilling fluid and closed loop hydraulic fluid and without requiring the drilling fluid to enter pressure intensifier pump. The ultra-high pressure of drilling fluid is directed to the drill bit assembly to aid drilling efficiency in drilling applications.