Measurement while drilling pulser with turbine power generation unit

• US 20080179093A1
• Filed: 01/25/2007
• Published: 07/31/2008
• Est. Priority Date: 01/25/2007
• Status: Active Grant

• Current Assignee: Teledrill Inc.
• Original Assignee: Teledrill Inc.
• Inventors: Lerner, Daniel Maurice, Kusko, David John, Vecseri, Gabor
• Granted Patent: US 8,138,943 B2
• Time in Patent Office: Days
• US Class Current: 175/40
• 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

Disclosed are a system, device, and method for generating pulse signals that correlate to geological information in a wellbore. The system and method comprises a pulse generating device longitudinally and axially positioned within an annular drill collar flow channel such that the drilling fluid flows through the annular drill collar flow channel and the drilling fluid is guided into two sets of selectively reversible flow, upper and lower flow connecting channels, wherein the connecting channels are connected to an inner flow channel and the annular drill collar flow channel, and wherein the annular drill collar flow channel is acted upon by one or more flow throttling devices thereby transmitting signals. The device utilizes a turbine residing near and within proximity of a flow diverter that diverts drilling mud into and away from turbine blades such that the force of the drilling mud causes the turbine blades and the turbine to rotationally spin around a coil assembly.

Claims

1. An apparatus for generating pressure pulses in a drilling fluid, flowing within a drill string, comprising:

a pulse generating device longitudinally and axially positioned within an annular drill collar flow channel such that said drilling fluid flows through said annular drill collar flow channel and said drilling fluid is guided into two sets of selectively reversible flow, upper and lower flow connecting channels, wherein said connecting channels are connected to an inner flow channel and said annular drill collar flow channel, and wherein said annular drill collar flow channel is acted upon by one or more flow throttling devices thereby transmitting signals, wherein said device utilizes a turbine residing near and within proximity of a flow diverter that diverts drilling mud in said annular flow channel into and away from turbine blades such that the force of the drilling mud causes said turbine blades and said turbine to rotationally spin around a coil assembly.

2. The apparatus of claim 1, wherein said apparatus for generating pulses includes a pilot, a pilot bellows, a flow throttling device, a sliding pressure chamber, and a pulser guide pole, wherein upper and lower inner flow connecting channels provide for reversal of flow and wherein said pilot seals a middle inner flow channel from said lower inner flow channel and such that said flow throttling device and said pilot are capable of bi-directional axial movement along or within said guide pole.

3. The apparatus of claim 1, wherein said coil assembly generates electrical power for operating a motor and other operating equipment useful for instrumentation, said motor comprising a drive shaft centrally located between said motor and a magnetic pressure coupling wherein said motor and said coupling are mechanically coupled such that said motor rotates said magnetic pressure coupling outer magnets and moves said pilot actuator assembly.

4. The apparatus of claim 1, wherein a magnetic coupling is formed by a location external and internal to said magnetic pressure cup where outer magnets are placed in relation to inner magnets, said inner magnets located in a position inside said magnetic pressure cup, said coupling allowing for translating rotational motion of said motor and outer magnets to linear motion of said inner magnets via a magnetic polar interaction, wherein linear motion of said inner magnets move said pilot actuator assembly, thereby linearly moving a pilot into a pilot seat, closing a pilot seat orifice, lifting a flow throttling device into a flow throttling orifice and thereby generating a pulse wherein further rotation of said motor drive shaft, and outer magnets move said pilot actuator assembly and said pilot away from said pilot seat causing said flow throttling device to move away from said flow throttling orifice, thereby ending the positive pulse.

5. The apparatus of claim 1, wherein said motor is connected to a drive shaft through a mechanical device including a worm gear, barrel cam face cam, or other mechanical means for converting the rotational motion of said motor into linear motion to propel said pilot actuator assembly.

6. The apparatus of claim 1, wherein said apparatus includes a pulser guide pole capable of providing a path for said pilot and said flow throttling device for operation in a bi-directional axial movement.

7. The apparatus of claim 1, wherein said pilot actuator assembly is comprised of a rear pilot shaft, front pilot shaft, and pilot.

8. The apparatus of claim 1 wherein differential pressure is minimal in that a slight force acting on a small cross-sectional area of a pilot seat defines a pressure that is required to either engage or disengage said pilot.

9. The apparatus of claim 1, wherein said motor may be synchronous, asynchronous or stepper and is activated to fully rotate or to rotate incrementally in various degrees depending on wellbore conditions or the observed signal intensity and/or duration of drilling.

10. The apparatus of claim 1, wherein said turbine resides within said annular flow channel of a flow guide and wherein said annular flow channel has diverting vanes that direct flow of drilling mud through and around a surface of said turbine.

11. The apparatus of claim 1, wherein said turbine includes a turbine shroud comprising turbine magnets that rotate with the motion of said turbine around said coil assembly causing electrical power to be generated and allowing for decreased battery requirements, a decrease in cost of said battery, decreased operational downtime, and subsequently decreased cost of said apparatus.

12. The apparatus of claim 1, wherein energy consumption may also be further reduced by pre-filling the bellows chamber with a lubricating fluid, gel or paste.

13. The apparatus of claim 1, wherein said turbine blades outside diameters around a pulser housing is smaller than a flow guide extension inner diameter, thereby allowing said turbine to be removed concurrently with said pulser housing.

14. The apparatus of claim 1, wherein said apparatus for generating pulses includes allowing a bellows to move linearly, concurrent with said pilot actuator assembly, wherein the design of said bellows interacts with said pilot actuator assembly and a bellows chamber allowing said bellows to conform to the space constraints of said bellows chamber providing flexible sealing without said bellows being displaced by the pressure differential created by the drilling fluid.

15. The apparatus of claim 1, wherein said bellows may include a double loop configuration designed for said flexible sealing thereby requiring less energy consumption during displacement of said bellows.

16. The apparatus of claim 1, wherein said pulse in said drilling mud is sensed by said instrumentation located uphole and wherein said pulse is communicated optionally with wireless devices, to a computer with a programmable controller for interpretation.

17. A centralizer device adapted to be a concentric stream-line design secured within a drill collar for a measurement-while-drilling device wherein drilling fluid flows, comprising an apparatus of concentric design useful for securing a pulser apparatus longitudinally within said drill collar, wherein said drill collar is designed with rounded leading edges such that annular flow through said drill collar is more fully developed and laminar-like.

18. The device of claim 17, wherein said centralizer provides a means for securing said measurement-while-drilling device.

19. The device of claim 18, wherein said centralizer is adaptable to be secured within drill collars of various diameters and dimensions.

20. A method for generating pressure pulses in a drilling fluid, flowing within a drill string, comprising:

a pulse generating device longitudinally and axially positioned within an annular drill collar flow channel such that said drilling fluid flows through said annular drill collar flow channel and said drilling fluid is guided into two sets of selectively reversible flow, upper and lower flow connecting channels, wherein said connecting channels are connected to an inner flow channel and said annular drill collar flow channel, and wherein said annular drill collar flow channel is acted upon by one or more flow throttling devices thereby transmitting signals, wherein said device utilizes a turbine residing near and within proximity of a flow diverter that diverts drilling mud in said annular flow channel into and away from turbine blades such that the force of the drilling mud causes said turbine blades and said turbine to rotationally spin around a coil assembly.

21. The method of claim 20, wherein apparatuses for generating pulses includes a pilot, a pilot bellows, a flow throttling device, a sliding pressure chamber, and a pulser guide pole, wherein upper and lower inner flow connecting channels provide for reversal of flow in said flow throttling device and wherein said pilot seals a middle inner flow channel from said lower inner flow channel such that said flow throttling device and said pilot are capable of bi-directional axial movement along said guide pole.

22. The method of claim 20, wherein said coil assembly generates electrical power for operating a motor and other operating equipment useful for instrumentation, said motor comprising a drive shaft centrally located between said motor and a magnetic pressure coupling wherein said motor and said coupling are mechanically coupled such that said motor rotates or linearly moves said magnetic pressure coupling outer magnets and moves said pilot actuator assembly, wherein said assembly opens and closes either a linear or rotational pilot valve.

23. The method of claim 20, wherein a magnetic coupling is formed by a location external and internal to said magnetic pressure cup where outer magnets are placed in relation to inner magnets, said inner magnets located in a position inside said magnetic pressure cup, said coupling allowing for translating rotational motion of said motor and outer magnets to linear motion of said inner magnets via a magnetic polar interaction, wherein linear motion of said inner magnets move said pilot actuator assembly, thereby linearly moving a pilot into a pilot seat, closing a pilot seat orifice, lifting a flow throttling device into a flow throttling orifice and thereby generating a pulse wherein further rotation of said motor drive shaft, and outer magnets move said pilot actuator assembly and said pilot away from said pilot seat causing said flow throttling device to move into said flow throttling orifice, thereby generating another pulse.

24. The method of claim 20, wherein said motor is connected to a drive shaft through a mechanical device including a worm gear, barrel cam face cam, or other mechanical means for converting the rotational motion of said motor into linear motion to propel said pilot actuator assembly.

25. The method of claim 20, wherein said apparatus includes a pulser guide pole capable of providing a path for said pilot and said flow throttling device for operation in a bi-directional axial movement.

26. The method of claim 20, wherein said pilot actuator assembly is comprised of a rear pilot shaft, front pilot shaft, and pilot.

27. The method of claim 20, wherein differential pressure is minimal in that a slight force acting on a small cross-sectional area of a pilot seat defines a pressure that is required to either engage or disengage said pilot.

28. The method of claim 20, wherein said motor may be synchronous, asynchronous, or stepper and is activated to fully rotate or to rotate incrementally in various degrees depending on wellbore conditions or the observed signal intensity and/or duration of drilling.

29. The method of claim 20, wherein said turbine resides within said annular flow channel of a flow guide and wherein said annular flow channel has diverting vanes that direct flow of drilling mud through and around a surface of said turbine.

30. The method of claim 20, wherein said turbine includes a turbine shroud comprising turbine magnets that rotate with the motion of said turbine around said coil assembly causing electrical power to be generated and allowing for decreased battery requirements, a decrease in cost of said battery, decreased operational downtime, and subsequently decreased cost of said apparatus.

31. The method of claim 20, wherein energy consumption may also be further reduced by pre-filling a bellows chamber with a lubricating fluid, gel or paste.

32. The method of claim 20, wherein said turbine blades outside diameters around a pulser housing is smaller than a flow guide extension inner diameter, thereby allowing said turbine to be removed concurrently with said pulser housing.

33. The method of claim 20, wherein said apparatus for generating pulses includes allowing a bellows to move linearly, concurrent with said pilot actuator assembly, wherein the design of said bellows interacts with said pilot actuator assembly and a bellows chamber allowing said bellows to conform to the space constraints of said bellows chamber providing flexible sealing without said bellows being displaced by the pressure differential created by the drilling fluid.

34. The method of claim 20, wherein said bellows may include a double loop configuration designed for said flexible sealing thereby requiring less energy consumption during displacement of said bellows.

35. The method of claim 20, wherein said pulse in said drilling mud is sensed by said instrumentation located within an uphole device and wherein said pulse is communicated optionally with wireless devices, to a computer with a programmable controller for interpretation.

36. A method for generating pressure pulses in a drilling fluid flowing downward within a drill string, comprising a configuration including a guide pole channel and orifice chamber in the proximity of a pilot seat and pilot orifice wherein the diameter of said guide pole channel is smaller near said pilot seat and pilot orifice thereby creating a higher pressure in said guide pole channel than is exhibited by said drilling fluid flowing downward within said drill string.

37. The method of claim 36, wherein said higher pressure creates a more discernable pulse with a flow throttling device when a pilot moves away from said pilot seat thereby permitting flow of drilling fluid through said pilot orifice or moving said pilot toward said pilot seat thereby closing said pilot orifice, wherein said pressure differential between the drilling fluid pressure and an orifice chamber moves said flow throttling device rapidly, thereby enabling forceful restriction of said flow throttling device orifice and little or no noise in a signal-to-noise ratio and wherein said pulses are extremely reproducible with corresponding signals that are readily defined uphole.

38. Two or more apparatuses for generating pressure pulses in a drilling fluid, flowing within a drill string, comprising:

a pulse generating device longitudinally and axially positioned within an annular drill collar flow channel such that said drilling fluid flows through said annular drill collar flow channel and said drilling fluid is guided into two sets of selectively reversible flow, upper and lower flow connecting channels, wherein said connecting channels are connected to an inner flow channel and said annular drill collar flow channel, and wherein said annular drill collar flow channel is acted upon by one or more flow throttling devices thereby transmitting signals, wherein said device utilizes a turbine residing near and within proximity of a flow diverter that diverts drilling mud in said annular flow channel into and away from turbine blades such that the force of the drilling mud causes said turbine blades and said turbine to rotationally spin around a coil assembly.

39. A system for generating pressure pulses in a drilling fluid, flowing within a drill string, comprising:

a pulse generating device longitudinally and axially positioned within an annular drill collar flow channel such that said drilling fluid flows through said annular drill collar flow channel and said drilling fluid is guided into two sets of selectively reversible flow, upper and lower flow connecting channels, wherein said connecting channels are connected to an inner flow channel and said annular drill collar flow channel, and wherein said annular drill collar flow channel is acted upon by one or more flow throttling devices thereby transmitting signals, wherein said device utilizes a turbine residing near and within proximity of a flow diverter that diverts drilling mud in said annular flow channel into and away from turbine blades such that the force of the drilling mud causes said turbine blades and said turbine to rotationally spin around a coil assembly.

40. The system of claim 39, wherein apparatuses for generating pulses includes a pilot, a pilot bellows, a flow throttling device, a sliding pressure chamber, and a pulser guide pole, wherein upper and lower inner flow connecting channels provide for reversal of flow and wherein said pilot seals a middle inner flow channel from said lower inner flow channel such that said flow throttling device and said pilot are capable of bi-directional axial movement along said guide pole.

41. The system of claim 39, wherein said coil assembly generates electrical power for operating a motor and other operating equipment useful for instrumentation, said motor comprising a drive shaft centrally located between said motor and a magnetic pressure coupling wherein said motor and said coupling are mechanically coupled such that said motor rotates said magnetic pressure coupling outer magnets and moves said pilot actuator assembly.

42. The system of claim 39, wherein a magnetic coupling is formed by a location external and internal to said magnetic pressure cup where outer magnets are placed in relation to inner magnets, said inner magnets located in a position inside said magnetic pressure cup, said coupling allowing for translating rotational motion of said motor, magnetic pressure cup and outer magnets to linear motion of said inner magnets via a magnetic polar interaction, wherein linear motion of said inner magnets move said pilot actuator assembly, thereby linearly moving a pilot into a pilot seat, closing a pilot seat orifice, lifting a flow throttling device into a flow throttling orifice and thereby generating a pulse wherein further rotation of said motor drive shaft, magnetic pressure cup, and outer magnets move said pilot actuator assembly and said pilot away from said pilot seat causing said flow throttling device to move into said flow throttling orifice, thereby generating a negative pulse.

43. The system of claim 39, wherein said motor is connected to a drive shaft through a mechanical device including a worm gear, barrel cam face cam, or other mechanical means for converting the rotational motion of said motor into linear motion to propel said pilot actuator assembly.

44. The system of claim 39, wherein said apparatus includes a pulser guide pole capable of providing a path for said pilot and said flow throttling device for operation in a bi-directional axial movement.

45. The system of claim 39, wherein said pilot actuator assembly is comprised of a rear pilot shaft, front pilot shaft, and pilot.

46. The system of claim 39, wherein differential pressure is minimal in that a slight force acting on a small cross-sectional area of a pilot seat defines a pressure that is required to either engage or disengage said pilot.

47. The system of claim 39, wherein said motor may be synchronous, asynchronous, or stepper and is activated to fully rotate or to rotate incrementally in various degrees depending on wellbore conditions or the observed signal intensity and/or duration of drilling.

48. The system of claim 39, wherein said turbine resides within said annular flow channel of a flow guide and wherein said annular flow channel has diverting vanes that direct flow of drilling mud through and around a surface of said turbine.

49. The system of claim 48, wherein said turbine includes a turbine shroud comprising turbine magnets that rotate with the motion of said turbine around said coil assembly causing electrical power to be generated and allowing for decreased energy requirements for batteries, a decrease in cost of said batteries, decreased operational downtime, and subsequently decreased cost of said apparatus.

50. The system of claim 39, wherein energy consumption may also be further reduced by pre-filling a bellows chamber with a lubricating fluid, gel or paste.

51. The system of claim 39, wherein said turbine blades outside diameter—

is smaller than a flow guide extension inner diameter, thereby allowing said turbine to be removed concurrently with said pulser housing.

52. The system of claim 39, wherein said apparatus for generating pulses includes allowing a bellows to move linearly, concurrent with said pilot actuator assembly, wherein the design of said bellows interacts with said pilot actuator assembly and a bellows chamber allowing said bellows to conform to the space constraints of said bellows chamber providing flexible sealing without said bellows being displaced by the pressure differential created by the drilling fluid.

53. The system of claim 39, wherein said bellows may include a double loop configuration designed for said flexible sealing thereby requiring less energy consumption during displacement of said bellows.

54. The system of claim 39, wherein said pulse in said drilling mud is sensed by said instrumentation located uphole and wherein said pulse is communicated optionally with wireless devices, to a computer with a programmable controller for interpretation.

55. The system of claim 39, wherein said higher pressure creates a more discernable pulse with a flow throttling device when a pilot moves away from said pilot seat thereby permitting flow of drilling fluid through said pilot orifice or moving said pilot toward said pilot seat thereby closing said pilot orifice, wherein said pressure differential between the drilling fluid pressure and an orifice chamber moves said flow throttling device rapidly, thereby enabling forceful restriction of said flow throttling device orifice and little or no noise in a signal-to-noise ratio and wherein said pulses are extremely reproducible with corresponding signals that are readily defined uphole.