Torque Generator with Bypass Conduit for Drilling Stability

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Solution Overview

Problem

Directional drilling methods face issues such as 'stick-slip' phenomena, accumulation of drill cuttings, and tool face instability, especially in boreholes with multiple nonlinear segments or long horizontal segments, which can lead to drill bit damage and inefficient drilling operations.

Innovation Solution

A torque generator system within the bottom-hole assembly that allows independent rotation of the drill bit relative to the drill string, using a housing with a bearing pack, pump, nozzles, and a bypass conduit to control fluid flow and torque, enabling controlled drilling of linear and nonlinear bore segments by adjusting the rotational speed of the drill string.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the drill string is stopped for directional drilling, then the tool face can be oriented in a desired direction, but the drill string tends to stick-slip and the drill cuttings accumulate

Engineering Contradiction:

Improvetool face orientationVSAvoiddrilling operation stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system separates the drilling function from the directional control function. The drill string can rotate continuously for drilling and cuttings removal, while the bottom-hole assembly with bent housing provides independent directional control. This segmentation eliminates the need to stop the drill string for directional changes, resolving the stick-slip and cuttings accumulation problems.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bent housing acts as an intermediary element between the drill string and the drill bit. It transmits rotational motion from the drill string while introducing the desired directional offset. This intermediary mechanism allows continuous rotation for stable drilling while achieving directional control without stopping.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the drill string is rotated at high speed, then the rate of penetration increases, but the tool face becomes unstable during directional drilling

Engineering Contradiction:

Improverate of penetrationVSAvoidtool face stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

By separating the rotational function (drill string) from the directional control function (bent housing and bottom-hole assembly), the system allows high rotational speeds for penetration while maintaining tool face stability through the geometric constraint of the bent housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the geometric parameters of the drilling path through the bent housing rather than changing the rotational speed of the drill string. This allows maintaining high rotational speed for productivity while achieving directional control through geometric offset, not speed modulation.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If the drill string is stopped for directional drilling, then reactive torque can be used to orient the tool face, but the drill string winds up and drastically changes the tool face

Engineering Contradiction:

Improvetool face orientationVSAvoidtool face drift

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The system separates orientation control from the drill string rotation. The bent housing provides a fixed geometric offset that maintains tool face orientation independent of drill string rotation or reactive torque effects, eliminating tool face drift caused by winding up.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bent housing serves as an intermediary that decouples the drill string rotation from the drill bit orientation. This intermediary element absorbs the effects of reactive torque and winding, maintaining stable tool face orientation throughout the drilling operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This system reduces 'stick-slip' occurrences, enhances borehole cleaning, and maintains tool face stability, improving the rate of penetration and minimizing drill bit wear by allowing consistent weight-on-bit and controlled directional drilling.

Implementation Method 1

a pump having a pump chamber, the pump being inside and supported by the housing; one or more nozzles inside and supported by the housing, uphole or downhole from the pump and in fluid communication with the pump chamber

Methodology Applied

Scientific EffectFluid flow control:

Implementation Method 2

a bearing pack rotationally coupled to the housing, the bearing pack being connectable to a drill string

Methodology Applied

Scientific EffectFriction reduction: Lubrication

Data Source

PatentUS10648237B2Torque generator

Publication Date: 2020.05.12 CT ENERGY

AI summary

A torque generator for use in a bottom-hole assembly. The torque generator has a bearing pack rotationally coupled to a housing and a pump and one or more nozzles inside and supported by the housing. The one or more nozzles are in fluid communication with the pump chamber. The torque generator also has a bypass conduit extending through the pump and bypassing the pump and the one or more nozzles. The bypass conduit has a discharge end that is downhole from the pump and the one or more nozzles.