Rotary Pulser Bypass Flow Design for Cleaner Mud Pulses
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Solution Overview
Problem
Existing mud pulse telemetry systems in drilling operations suffer from low data rates and high power consumption due to the inefficiencies of traditional pulsers, which generate pressure pulses with significant turbulence and require larger rotors, leading to increased power demands and operational challenges.
Innovation Solution
A rotary pulser with a shroud assembly and bypass elements that allows fluid to bypass the stator and rotatable element, reducing turbulence and enabling cleaner, crisper pressure pulses, thereby improving data transmission efficiency and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pulsers generate pressure pulses through the stator and rotatable element, then pressure pulses are created for data transmission, but significant turbulence occurs leading to larger rotor requirements and increased power consumption
Solution Approach 1:
The flow path is segmented into two separate channels: a primary passage through the stator and rotatable element for generating pressure pulses, and a bypass passage that allows fluid to flow around the rotatable element. This segmentation enables the system to maintain reliable pressure pulse generation while reducing turbulence and power consumption through the bypass path.
Solution Approach 2:
The bypass elements act as intermediaries that provide an alternative flow path for the drilling fluid. By introducing these bypass elements, the system can reduce the direct interaction between fluid and rotatable element, thereby minimizing turbulence and the power required to drive the rotor while maintaining adequate pressure pulse generation for reliable data transmission.
2Reliability
If traditional pulsers generate pressure pulses with significant turbulence, then data transmission can occur, but the pulse shapes become less crisp and harder to decode
Solution Approach 1:
By segmenting the flow into primary and bypass passages, the system maintains well-defined, crisp pressure pulses in the primary passage while the bypass passage handles the turbulent flow. This segmentation preserves pulse shape precision for reliable decoding while still enabling adequate data transmission.
Solution Approach 2:
The bypass elements extract or remove the turbulent flow component from the primary pressure pulse path. By taking out the turbulent portion of the flow through the bypass passage, the system preserves clean, precise pressure pulses in the primary passage for accurate data transmission and decoding.
3Power
If larger rotors are used to handle turbulent flow, then adequate power can be supplied, but the device complexity and power requirements increase
Solution Approach 1:
Segmenting the flow into primary and bypass passages allows the system to use a smaller rotor in the primary passage while the bypass passage handles the bulk of the turbulent flow. This reduces device complexity and rotor size requirements while maintaining adequate power supply capability for the pulser operation.
Solution Approach 2:
The bypass elements extract the turbulent flow from the rotor-driven passage, allowing the rotor to be smaller and less complex. The bypass passage handles the high-turbulence flow that would otherwise require a larger rotor, thereby reducing device complexity while maintaining power supply capability.
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 rotary pulser design enhances data transmission rates and reduces power requirements by minimizing turbulence and rotor-induced loads, resulting in sharper pulse shapes that are easier to decode at the surface.
Implementation Method 1
The rotary pulser also includes a rotatable element adjacent to the downhole end of the stator and rotatable to selectively obstruct the at least one passage to generate a pressure pulse in the fluid when the fluid passes through the rotary pulser
Implementation Method 2
The rotary pulser also includes one or more bypass elements located along an outer region of the shroud assembly. The one or more fluid bypass elements are configured to permit fluid to bypass the stator and the rotatable element when a fluid passes through the drill string and the rotary pulser
Data Source
AI summary
A rotary pulser is described that includes a shroud assembly, a stator supported by the shroud assembly. The stator has an uphole end, a downhole end spaced from the uphole end, and at least one passage that extends from the uphole end to the downhole end. The rotary pulser includes a rotatable element adjacent to the downhole end of the stator and rotatable to selectively obstruct the at least one passage to generate a pressure pulse in the fluid when the fluid passes through the rotary pulser. The rotary pulser also includes one or more bypass elements that are configured to permit fluid to bypass the stator and the rotatable element when a fluid passes through the drill string and the rotary pulser.