Wired Downhole Mud Motors With In-Situ Bend Adjustment
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Solution Overview
Problem
Conventional downhole motors in directional drilling face limitations in bend settings, leading to premature failure, require multiple trips to the surface for adjustments, and lack integrated data collection capabilities, especially when used without rotary steerable systems, which are expensive and complex.
Innovation Solution
A downhole motor with a bend adjustment assembly that allows for adjustable bend settings and integrated electronics for data collection, including sensors and a hydraulic pump for actuation, enabling real-time adjustments and data logging without the need for surface intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed bend setting is used in conventional downhole motors, then the motor structure is simple and reliable, but the motor requires multiple trips to the surface for bend setting adjustments and cannot adapt to different wellbore sections
Solution Approach 1:
The patent implements a dynamic bend adjustment mechanism that allows the bend setting to be changed from a fixed value to an adjustable value. The adjustment mandrel can rotate relative to the housing to change the bend angle, and the locking mechanism can lock at different positions to maintain the selected bend setting. This enables the motor to adapt to different wellbore sections without requiring trips to the surface.
Solution Approach 2:
The adjustment mandrel is nested within the housing, and the locking mechanism components are nested within the adjustment mandrel. The sensor assembly is integrated within the locking mechanism. This nested structure allows the bend adjustment functionality to be incorporated into the existing motor structure without significantly increasing the overall size or complexity.
2Shape
If high bend settings (1-3 degrees or greater) are used to achieve curved wellbore sections, then the desired inclination can be achieved, but the rotational speed is limited to below approximately 50 RPM leading to premature bearing failure
Solution Approach 1:
The dynamic bend adjustment mechanism allows the operator to change the bend setting from high (1-3 degrees) to low (0.5-1.5 degrees) as the drill bit transitions from curved to lateral wellbore sections. This enables the motor to operate at higher rotational speeds (above 50 RPM) in lateral sections where high bend settings are not needed, thereby preventing premature bearing failure while still achieving the desired wellbore curvature when required.
3Loss of information
If conventional downhole motors without rotary steerable systems are used, then the operational cost is lower, but integrated data collection capabilities are lacking especially when sensors fail or severe stick slip occurs
Solution Approach 1:
The patent integrates multiple functions into a single system: the sensor assembly detects drilling parameters (RPM, torque, stick slip, vibration, inclination), the processor analyzes this data, and the hydraulic pump actuates the bend adjustment mechanism based on the analyzed data. This multi-functional integration enables data collection and automated bend adjustment without requiring expensive rotary steerable systems.
Solution Approach 2:
The sensor assembly continuously monitors drilling parameters and provides feedback to the processor. The processor analyzes this feedback data and automatically adjusts the bend setting via the hydraulic pump and locking mechanism. This closed-loop feedback system enables real-time adaptation to drilling conditions, improving data collection capability while maintaining operational simplicity.
4Manufacturing precision
If multiple trips to the surface are made to adjust bend settings, then the correct bend setting can be selected for each wellbore section, but significant time is lost and productivity is reduced
Solution Approach 1:
The dynamic bend adjustment mechanism allows the bend setting to be changed in-situ without tripping the motor to the surface. The adjustment mandrel can be rotated to change the bend angle, and the locking mechanism can lock at different positions to maintain the selected setting. This eliminates non-productive time while maintaining the ability to select the correct bend setting for each wellbore section.
Solution Approach 2:
The sensor assembly and processor work together to automatically determine the optimal bend setting based on real-time drilling data, and the hydraulic pump automatically actuates the adjustment mechanism to implement the selected setting. This self-service capability eliminates the need for surface intervention, maximizing drilling productivity while maintaining bend setting accuracy.
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
Enables continuous adjustment of bend settings and real-time data collection, reducing tool failure and operational complexity, enhancing drilling efficiency and data accuracy.
Implementation Method 1
a lock piston configured to lock the bend adjustment assembly in the first position and the second position. In some embodiments, the downhole motor comprises a hydraulic pump configured to actuate the lock piston
Implementation Method 2
a solenoid valve configured to lock the lock piston into at least one of the locked and unlocked positions in response to receiving a locking signal
Implementation Method 3
the sensor package comprises a pressure sensor configured to measure a pressure of a fluid flowing through the driveshaft housing
Implementation Method 4
the sensor package comprises a temperature sensor
Implementation Method 5
the electronics package comprises an electromagnetic communication link
Data Source
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AI summary
A downhole motor for directional drilling includes a driveshaft assembly including a driveshaft housing and a driveshaft rotatably disposed within the driveshaft housing, a bearing assembly including a bearing housing and a bearing mandrel rotatably disposed within the bearing housing, wherein the bearing mandrel is configured to couple with a drill bit, a bend adjustment assembly configured to adjust a bend setting of the downhole motor, and an electronics package coupled to the driveshaft assembly, wherein the electronics package is configured to receive data from sensors of the downhole motor.