Integrated Sensor Power Section for Drilling
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Solution Overview
Problem
Conventional drilling operations face delays and accuracy issues due to the distance between the drill bit and sensors, as equipment like mud motors move the MWD package away from the drill bit, impeding timely feedback on borehole azimuth and inclination data.
Innovation Solution
A power section for a bottom hole assembly with a stator and rotor, integrated with a sensor package that includes a payload housing for downhole sensors, allowing for real-time data collection and transmission, and a flex shaft to transmit rotational force, enabling accurate and timely measurement of borehole trajectory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a mud motor is used to power the drill bit, then drilling power is provided, but the MWD package is moved away from the drill bit causing delays in trajectory data feedback
Solution Approach 1:
The patent combines the MWD sensor package with the mud motor power section into a single integrated assembly. The sensors are positioned within the power section housing, allowing the power transmission function and measurement function to coexist in the same physical location, eliminating the time delay caused by separate MWD package positioning.
2Device complexity
If sensors are positioned far from the drill bit, then the power section structure is simpler, but the accuracy of borehole trajectory determination deteriorates
Solution Approach 1:
The sensor package is integrated within the power section housing, placing measurement instruments close to the drill bit without requiring a separate complex MWD package assembly. This merging approach achieves both structural simplicity and measurement precision by utilizing the existing power section as the sensor mounting location.
3Ease of manufacture
If traditional separate MWD package and power section are used, then manufacturing is easier, but integration of sensors into power section improves operational efficiency
Solution Approach 1:
The patent integrates the sensor package directly into the power section housing, creating a unified assembly that improves operational efficiency by eliminating feedback delays. The integration is achieved through modular design where sensor components can be installed within the existing power section structure, balancing manufacturing ease with operational productivity.
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 the accuracy and speed of borehole trajectory determination by integrating sensors directly into the power section, reducing delays and improving the precision of drilling operations.
Implementation Method 1
a rotor, the rotor rotatable eccentrically within the stator
Data Source
AI summary
The disclosure includes a power section for a bottom hole assembly for use in a wellbore. The power section may include a stator, the stator including a housing, a stator insert, a payload housing and a bent sub having a bend direction. The payload housing may be positioned on an outer surface of the housing, and the payload housing may include a payload pocket. The power section may include a rotor, the rotor rotatable eccentrically within the stator. The payload housing may positioned on the stator housing so as to be always aligned with the bend direction.