Torque Generator Tool Face Control via Fluid Restrictions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current torque generators in directional drilling systems face limitations in peak torque performance and fine-tuning of tool face control, leading to issues like stick-slip, drill bit damage, and inefficient borehole cleaning, especially in drilling nonlinear bore segments.
Innovation Solution
The torque generator is configured with an outer housing independently rotatable from an inner pump, featuring fluid flow distributors and restrictions to provide high-resolution tool face control, including piston assemblies and helical fluid flow pathways, which enhance torque generation and reduce fluid pressure variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the drill string is not rotated during directional drilling to maintain tool face orientation, then directional control is achieved, but stick-slip occurs and drill cuttings accumulate creating obstructions
Solution Approach 1:
A torque generator is introduced as an intermediary device between the drill string and bottom-hole assembly. This torque generator allows the drill string to rotate independently while controlling the rotation of the bottom-hole assembly, thereby maintaining tool face orientation without the negative effects of complete drill string stationary operation. The torque generator mediates between drill string rotation and BHA orientation control.
Solution Approach 2:
The system transitions from a static drill string configuration to a dynamic one where the drill string can rotate at varying speeds while the bottom-hole assembly maintains controlled orientation. The torque generator enables dynamic adjustment of rotational characteristics, allowing the drill string to rotate for cuttings removal while the BHA maintains precise tool face control through controlled reactive torque.
2Measurement precision
If the torque generator limits peak torque to control tool face RPM, then fine-tuning of tool face is achieved, but torque performance is reduced
Solution Approach 1:
The torque generator incorporates adjustable parameters that allow dynamic tuning of its torque-RPM characteristics. By modifying internal clearances, fluid viscosity, or geometric parameters of the torque generator components, the system can optimize both peak torque output and fine-resolution control capability depending on drilling conditions.
Solution Approach 2:
The system utilizes parameter changes in the torque generator's operational characteristics to achieve both high peak torque and fine control resolution. By adjusting parameters such as fluid pressure, flow rate, or mechanical clearances within the torque generator, the system can shift between high-torque modes for breaking through formations and fine-control modes for precise tool face positioning.
Data Source
AI summary
An apparatus for controlling tool face and methods of use with a torque generator connected to a drill string for drilling linear and nonlinear subterranean bore segments. In some embodiments, the apparatus and methodologies of use comprise a tool controller having an outer housing independently rotatable from and extension conduit extending therethrough and forming an annulus therebetween. The tool controller may provide for a first fluid pathway for allowing a bypass portion of fluids to flow through the torque generator, and a second fluid pathway through the annulus for allowing a torque generator portion of fluids to flow through the annulus. In some embodiments, at least one fluid flow restrictor may be provided within the annulus to controllable cause a cascading reduction in torque generator fluid pressure as it flows through the annulus, allowing high resolution tool face control over a larger (and tunable) range of drill string speed (rpm) set points.