High amplitude pulse generator for down-hole tools

• US 10,605,076 B2
• Filed: 07/06/2016
• Issued: 03/31/2020
• Est. Priority Date: 07/06/2016
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Odegbami, Olumide O., Chambers, Larry DeLynn, Carter, Daniel Patrick
• Primary Examiner(s): Wu, Zhen Y
• Application Number:
  US16/311,541
• Publication Number:
  US 20190203592A1
• Time in Patent Office: 1,364 Days
• Field of Search: 340 83, 367 83
• CPC Class Codes: E21B 21/08 Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure valve arrangements therefor E21B21/10
• CPC Class Codes: E21B 47/20 by modulation of mud waves, e.g. by continuous modulation
• CPC Class Codes: E21B 47/22 by negative mud pulses using a pressure relieve valve between drill pipe and annulus
• CPC Class Codes: E21B 47/24 by positive mud pulses using a flow restricting valve within the drill pipe

Abstract

Well systems comprise communicating devices for use in subterranean formations. An example well system comprises a mud valve system having a stator and a rotor to modulate drilling mud flow to provide increased pulse amplitude signals up-hole for improved and faster signaling from down-hole tools while also providing for better detection capability up-hole. The improved signaling technique permits for deeper well applications.

Claims

1. A mud valve system for creating increased pulse amplitude signals in a wellbore, comprising:

an inner housing body with a plurality of vent ports formed therein and configured to direct drilling mud flow to a stator;

an outer housing body enveloping the inner housing body and forming a flow channel therebetween;

the stator having a plurality of stator lobes forming a plurality of stator channels therebetween;

a rotor positioned adjacent the stator and having a plurality of rotor lobes forming a plurality of rotor channels therebetween, the rotor rotatable from a closed position to an open position and from the open position to the closed position relative to the stator, the closed position restricting drilling mud flow from the plurality of stator channels to the plurality of vent ports creating an increased positive pulse amplitude signal up-hole, and the open position increasing drilling mud flow from the plurality of stator channels through the plurality of rotor channels to the plurality of vent ports into the flow channel creating an increased negative pulse amplitude signal up hole, for communicating data from at least one down-hole device, and

at least one vent port configured in the outer housing body and is in fluid communication with at least one of the plurality of vent ports in the inner housing.

2. The mud valve system of claim 1, wherein the at least one vent port configured in the outer housing body is in fluid communication with an annulus.

3. The mud valve system of claim 1, wherein the at least one vent port configured in the outer housing body is replaceable.

4. The mud valve system of claim 1, wherein a total amount of stator channels is the same as a total amount of rotor channels.

5. The mud valve system of claim 1, further comprising a drive unit to rotate the rotor.

6. The mud valve system of claim 1, wherein the drive unit is controllable to select a rotation rate of the rotor for selecting a data rate.

7. The mud valve system of claim 1, wherein the mud valve system is operatively connectable to the at least one down-hole device for permitting the at least one down-hole device to communicate up-hole using the mud valve.

8. The mud valve system of claim 1, wherein the increased positive pulse amplitude signal and the increased negative pulse amplitude signal provides for improved detection ability at a receiver up-hole.

9. The mud valve system of claim 1, wherein the flow channel is in fluid connection with each of the plurality of vent ports in the inner housing for conveying drilling mud down-hole.

10. A method for creating increased pulse amplitude signals in a wellbore, comprising:

rotating a rotor in a valve at a desired rate to a first position to restrict flow of drilling mud down-hole, the first position causing an increased positive pulse amplitude signal up-hole for signaling;

rotating a rotor in the valve at a desired rate to a second position to increase drilling mud flow down-hole, the second position causing an increased negative pulse amplitude signal up-hole for signaling, and

venting a portion of the drilling fluid into an annulus, while the rotor is in a second position.

11. The method of claim 10, wherein the step of rotating rotates the rotor to the second position permitting a plurality of channels formed in the rotor to align with a plurality of channels formed in a stator within the valve.

12. The method of claim 11, wherein the step of rotating rotates the rotor to the second position increasing drilling mud flow down-hole and into an annulus.

13. The method of claim 10, wherein the step of rotating rotates the rotor to the first position permitting a plurality of lobes formed in the rotor to block flow of the drilling mud from flowing through a plurality of channels formed in the stator.

14. The method of claim 10, further comprising alternating rotating the rotor from the first position to the second position to create a plurality of increased pulse amplitude for communicating up-hole.

15. The method of claim 10, further comprising controlling a rotation rate of the rotor to provide an optimal signal for detection by a detector up-hole.

16. The method of claim 10, wherein the rotating steps generate the increased positive pulse amplitude signal and the increased negative pulse amplitude signal that are detectable up to at least 9000 meters of well depth.

17. The method of claim 10, wherein the first position causes a momentary buildup of pressure detectable up-hole as the increased positive pulse amplitude signal.

18. The method of claim 10, wherein the second position causes a momentary reduction of pressure detectable up-hole as the increased negative pulse amplitude signal.