Statorless Shear Valve Pulse Generator for Clogging-Resistant Drilling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional mud pulse systems in drilling operations are prone to clogging due to entrained materials and operate slowly, as they require significant angular momentum to clear blockages and work against differential pressure, limiting their effectiveness in transmitting data from downhole tools.

Innovation Solution

A pulse generator apparatus and method that uses a flow control member with an actuator outside the flow section to selectively block and unblock fluid flow, creating pressure variances without clogging, allowing for efficient data transmission through a shear valve mechanism that can handle entrained solids and operate at higher speeds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If conventional valves with small fluid passages are used, then the valve structure is compact, but the passages become clogged by entrained materials

Engineering Contradiction:

Improvevalve sizeVSAvoidclogging resistance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

Instead of trying to prevent materials from entering small passages, the invention inverts the approach by creating large open passages that naturally prevent clogging, then using a shear valve mechanism to rapidly close when needed. The valve body with large passages and shearable flow control member fundamentally reverses the conventional small-passage design philosophy.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention employs a dynamic shear valve mechanism where the flow control member can rapidly transition from an open position (allowing free flow and preventing clogging) to a closed position (creating pressure pulses). This dynamic switching capability resolves the contradiction by maintaining open passages most of the time while enabling valve function when required.

Inventive Principle:

Principle #15Dynamics

2Stress or pressure

If conventional valves work against differential pressure, then the valve provides pressure control, but the valve operation becomes slow

Engineering Contradiction:

Improvepressure controlVSAvoidvalve response speed

Core Design Contradiction:

Stress or pressureVSSpeed

Solution Approach 1:

The shear valve mechanism utilizes the kinetic energy and momentum of the flowing fluid itself to rapidly shear the flow control member from the closed to open position. This mechanical energy transfer enables extremely fast valve operation without requiring the valve to slowly overcome differential pressure, as the fluid flow provides the shearing force needed for rapid transition.

Inventive Principle:

Principle #18Mechanical vibration

3Reliability

If conventional valves require big angular momentum to free blockages, then the valve can be opened, but the actuation system requires excessive force

Engineering Contradiction:

Improveblockage clearance capabilityVSAvoidactuation force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The invention converts the harmful effect of entrained materials that cause blockages into a beneficial shearing action. The flow control member is designed to be shearable, allowing the kinetic energy of the fluid flow (including materials entrained in it) to automatically shear the member free if blocked, eliminating the need for high-force actuation systems. The fluid's own motion becomes the mechanism for clearing blockages.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution effectively prevents clogging and enhances operational speed, enabling reliable communication of drilling data by creating pressure pulses that can pass through lost circulation materials, maintaining system functionality and reducing costly drill string removals.

Implementation Method 1

A pulse generator apparatus and method that uses a flow control member with an actuator outside the flow section to selectively block and unblock fluid flow, creating pressure variances

Methodology Applied

Scientific EffectFluid flow restriction and pressure variance creation:

Implementation Method 2

an actuator configured to move the flow control member between a first position wherein the flow control member at least partially blocks flow in the flow section and a second position wherein the flow control member reduces the at least partial blockage of the flow in the flow section

Methodology Applied

Scientific EffectMechanical actuation for flow control:

Data Source

PatentUS11702895B2Statorless shear valve pulse generator

Publication Date: 2023.07.18 BAKER HUGHES CO

AI summary

An apparatus for generating pressure variances in a fluid flowing in a downhole tool having a longitudinal axis includes a flow section having an outer wall, a flow control member selectively blocking flow in the flow section, and an actuator moving the flow control member between a first position wherein the flow control member at least partially blocks flow in the flow section and a second position wherein the flow control member reduces the at least partial blockage of the flow in the flow section. The actuator may be disposed outside the outer wall of the flow section.