Seamless Fluidic Agitator Insert for Erosion-Resistant Hydraulic Pulsing

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Solution Overview

Problem

Existing fluidic agitators used in drilling operations face issues with seam weld erosion due to turbulence, particularly when low-temperature brazing material is used, which weakens the structure and increases friction during drilling of long horizontal wells.

Innovation Solution

A seamless fluidic agitator is designed with a 3D printed insert body made from materials like metals, alloys, or ceramics, eliminating seam welds and using additive manufacturing processes like direct laser melting or binder jetting to create a robust, erosion-resistant structure that generates hydraulic pulses without vulnerable joints.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional machining processes and seam welding are used to manufacture fluidic agitators, then manufacturing precision and ease of manufacture are improved, but erosion resistance and reliability deteriorate due to vulnerable seam welds under turbulent flow

Engineering Contradiction:

Improveease of manufactureVSAvoidreliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges multiple manufacturing operations (machining, welding, coating) into a single additive manufacturing process. The seamless insert body is created directly through 3D printing technologies like direct laser melting or binder jetting, eliminating the need for separate machining and welding steps while producing an erosion-resistant seamless structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical manufacturing methods (machining and welding) with additive manufacturing technology. This substitution enables direct creation of complex fluidic channels and seamless structures without mechanical contact or joining processes, fundamentally changing how the insert body is manufactured.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If seam welds are used in fluidic agitators, then ease of manufacture is improved, but erosion resistance worsens due to material softness and turbulence exposure

Engineering Contradiction:

Improveease of manufactureVSAvoiderosion resistance

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and eliminates the vulnerable seam welds from the manufacturing process entirely. By using additive manufacturing, the insert body is created as a single seamless piece, removing the weak points that would otherwise require welding and subsequent protective measures.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs composite material strategies through additive manufacturing, where materials are deposited layer-by-layer with optimized properties. The process allows for incorporating erosion-resistant materials and creating internal structures that enhance overall durability without requiring separate protective components.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If low-temperature brazing material is used in seam welds, then ease of manufacture is improved, but strength and erosion resistance deteriorate due to soft material properties

Engineering Contradiction:

Improveease of manufactureVSAvoidstrength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent replaces the brazing process with additive manufacturing, eliminating the need for low-temperature brazing materials entirely. The direct laser melting or binder jetting processes use high-strength materials that are fused or bonded during manufacturing, creating a seamless structure with inherent strength without requiring separate joining materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 seamless design enhances erosion resistance and reduces frictional losses during drilling, improving the efficiency of weight-on-bit engagement and reducing wear on drill string components.

Implementation Method 1

The inlet chamber, the vortex chamber, and a feedback chamber create a hydraulic pulse in a fluid stream received in the enclosed cavity

Methodology Applied

Scientific EffectHydraulic pulse: Hydraulic Jump

Implementation Method 2

a vortex chamber, and a feedback chamber create a hydraulic pulse

Methodology Applied

Scientific EffectVortex: Vortex Ring

Implementation Method 3

Under the flow turbulence required to generate the hydraulic pulse, the chamber surfaces and seam welds are subject to erosion

Methodology Applied

Scientific EffectErosion resistance: Erosion

Implementation Method 4

using additive manufacturing processes like direct laser melting or binder jetting

Methodology Applied

Scientific EffectDirect laser melting: Laser Beam Welding

Implementation Method 5

using additive manufacturing processes like direct laser melting or binder jetting

Methodology Applied

Scientific EffectBinder jetting: Binder

Data Source

PatentUS11624240B2Fluidic pulse activated agitator

Publication Date: 2023.04.11 SAUDI ARABIAN OIL CO

AI summary

A fluidic agitator includes a seamless insert body having an outer enclosure wall defining an enclosed cavity and a plurality of inner channel walls arranged to define an inlet chamber, a vortex chamber, and a feedback chamber within the enclosed cavity. The inlet chamber, the vortex chamber, and the feedback chamber create a hydraulic pulse in a fluid stream received in the enclosed cavity.