U.S. patent application number 12/778623 was filed with the patent office on 2011-11-17 for downhole turbine communication.
Invention is credited to Scott Dahlgren, David R. Hall.
Application Number | 20110280105 12/778623 |
Document ID | / |
Family ID | 44911671 |
Filed Date | 2011-11-17 |
United States Patent
Application |
20110280105 |
Kind Code |
A1 |
Hall; David R. ; et
al. |
November 17, 2011 |
Downhole Turbine Communication
Abstract
In one aspect of the present invention a downhole drill string
assembly includes a bore there through to receive a flow of
drilling fluid, a signal generator that produces a signal in the
drilling fluid by rotating within the flow, a processing unit
disposed within the assembly, and a flow guide that directs
drilling fluid to the signal generator. The flow guide is in
communication with the processing unit so that in response to
commands received from the processing unit, the signal generator
produces a signal in the drilling fluid by the flow guide changing
its position.
Inventors: |
Hall; David R.; (Provo,
UT) ; Dahlgren; Scott; (Alpine, UT) |
Family ID: |
44911671 |
Appl. No.: |
12/778623 |
Filed: |
May 12, 2010 |
Current U.S.
Class: |
367/83 |
Current CPC
Class: |
E21B 47/20 20200501 |
Class at
Publication: |
367/83 |
International
Class: |
E21B 47/18 20060101
E21B047/18 |
Claims
1. A downhole drill string assembly, comprising: a bore there
through to receive a flow of drilling fluid; a signal generator
that produces a signal in the drilling fluid when rotating within
the flow; a processing unit disposed within the assembly; and a
flow guide that directs drilling fluid to the signal generator;
wherein the flow guide is in communication with the processing unit
so that in response to commands received from the processing unit,
the signal generator produces a signal in the drilling fluid by the
flow guide changing its position.
2. The assembly of claim 1, wherein flow guide is in communication
with the processing unit so that in response to commands received
from the processing unit the flow guide alters the flow of the
drilling fluid such that a signal is produced.
3. The assembly of claim 1, wherein the signal generator comprises
a turbine disposed within the bore and exposed to the drilling
fluid.
4. The assembly of claim 3, wherein the flow guide is in
communication with the processing unit so that in response to
commands received from the processing unit, the flow guide alters
an angle of attack of the drilling fluid across the turbine.
5. The assembly of claim 3, wherein the flow guide is in
communication with the processing unit so that in response to
commands received from the processing unit, the flow guide alters
the flow of the drilling fluid across the turbine such that the
turbine produces a signal.
6. The assembly of claim 3, wherein the signal generator comprises
a rotary valve disposed within the bore, is located down stream
from and in mechanical communication with the turbine, and exposed
to the drilling fluid.
7. The assembly of claim 5, wherein the rotary valve comprises a
stator plate and a rotor plate with each comprising a plurality of
ports.
8. The assembly of claim 7, wherein as the rotor plate rotates
around a center axis, the ports on the rotor plate and the ports on
the stator plate align or misalign thus altering the flow of the
drilling fluid such that a signal is produced.
9. The assembly of claim 1, further comprising a signal sensor
disposed within the bore and exposed to the drilling fluid and in
communication with the processing unit.
10. The assembly of claim 9, wherein in response to a signal
received by the signal sensor, the signal generator repeats the
signal.
11. The assembly of claim 1, further comprising a plurality of
signal generators located within the drill string.
12. The assembly of claim 1, wherein the flow guide is up stream
and proximal to the signal generator.
13. The assembly of claim 1, wherein the flow guide determines the
frequency of the signal.
14. The assembly of claim 1, wherein the flow guide determines the
bandwidth of the signal.
15. The assembly of claim 1, wherein the signal is a sound
wave.
16. The assembly of claim 1, wherein the signal is a pressure
wave.
17. The assembly of claim 1, wherein the flow guide comprises a
plurality of flow blades.
18. The assembly of claim 17, wherein the plurality of flow blades
is mechanically connected to a rotatable plate that moves the
blades.
Description
BACKGROUND OF THE INVENTION
[0001] Measurement while drilling is a system that can be used to
communicate between a downhole tool and surface equipment in a
downhole drill string. Such system may include mud pulse telemetry,
which sends signals through the fluid in the drill string's bore.
The prior art discloses mud pulse telemetry systems.
[0002] One such mud pulse telemetry system is disclosed in U.S.
Pat. No. 5,215,152 to Duckworth, which is herein incorporated by
reference for all that it contains. Duckworth discloses a rotating
pulse valve for use in a mud pulse telemetry system is presented.
In accordance with the invention, a valve is diametrically mounted
in a channel of a segment of a drill string wherein drilling fluids
flows. The valve comprises blades which are configured so as to be
impelled (i.e., rotated) by the flow of the drilling fluid. An
escapement mechanism is employed to restrain the valve in selected
positions thereby at least partially obstructing the flow of the
drilling fluid which results in generating positive pressure pulses
or waves in the drilling fluid in response to downhole
conditions.
[0003] Another such mud pulse telemetry system is disclosed in U.S.
Pat. No. 6,097,310 to Harrell, which is herein incorporated by
reference for all that it contains. Harrell discloses a mud pulse
telemetry system uses a downhole pulser to produce sequences of
positing and/or negative pulses according to a selected pattern.
Positive pulses, a negative pulses, and combinations thereof may be
produced. A flow rate sensor at the surface measures changes in the
flow rate at the top of the wellbore instead of or in addition to
changed in the pressure. The flow rate changes are detectable even
though the pressure pulses themselves may have a poor signal to
noise ratio. This enables the invention to function effectively in
underbalanced drilling wherein the use of light muds with a high
gas content is required. One embodiment of the invention uses a
conventional downhole pulser with the main valve closed and the
pilot valve operating in a direct pulse mode.
BRIEF SUMMARY OF THE INVENTION
[0004] In one aspect of the present invention a downhole drill
string assembly includes a bore there through to receive a flow of
drilling fluid, a signal generator that produces a signal in the
drilling fluid by rotating within the flow, a processing unit
disposed within the assembly, and a flow guide that directs
drilling fluid to the signal generator. The flow guide is in
communication with the processing unit so that in response to
commands received from the processing unit, the signal generator
produces a signal in the drilling fluid by the flow guide changing
its position.
[0005] The flow guide may be located up stream and proximal to the
signal generator. It may be comprised of a plurality of flow blades
wherein the plurality of flow blades is mechanically connected to a
rotatable plate. The flow guide may alter the flow of the drilling
fluid such that the flow guide itself produces a signal. If the
signal is generated from the flow guide itself or from the signal
generator, the flow guide determines the frequency and the
bandwidth of the signal. The signal produced may be a sound wave or
a pressure wave.
[0006] The signal generator may include a turbine which would be
exposed to the drilling fluid. A fluid guide, in communication with
the processing unit, may alter the angle of attack of the drilling
fluid across the turbine or the fluid may be altered by the flow
guide so that the turbine produces a signal.
[0007] In the presence of a turbine, the signal generator may
include a rotary valve. The rotary valve is located down stream and
in mechanical communication with the turbine, and exposed to the
drilling fluid. The rotary valve may comprise a stator plate and a
rotor plate. Both the stator plate and the rotor may comprise a
plurality of ports. The rotor plate may rotate around a center axis
according to the rotation of the turbine. As the rotor plate
rotates, the port on the rotor plate and the ports on the stator
plate align or misalign, thus, altering the flow of the drilling
fluid producing a signal.
[0008] The downhole drill string assembly may also include a signal
sensor. The signal sensor would be exposed to the drilling fluid
and in communication with the processing unit. In response to a
signal received by the signal sensor, the signal generator may
repeat the signal.
[0009] A plurality of signal generators may be disposed within the
drill string.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a cross-sectional view of an embodiment of a drill
string.
[0011] FIG. 2 is a partial cross-sectional view of an embodiment of
a downhole tool.
[0012] FIG. 3 is an exploded view of an embodiment of a rotary
valve.
[0013] FIG. 4 is a perspective view of an embodiment of a downhole
tool.
[0014] FIG. 5 is a perspective view of an embodiment of a downhole
tool.
[0015] FIG. 6 is a partial cross-sectional view of an embodiment of
a downhole tool.
[0016] FIG. 7 is a perspective view of an embodiment of the flow
guide.
[0017] FIG. 8 is a partial cross-sectional view of an embodiment of
a downhole tool.
[0018] FIG. 9a is a partial cross-sectional view of an embodiment
of a downhole tool.
[0019] FIG. 9b is a partial cross-sectional view of an embodiment
of a downhole tool.
[0020] FIG. 10 is a partial cross-sectional view of an embodiment
of a downhole tool.
[0021] FIG. 11 is a perspective view of an embodiment of a downhole
tool.
DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED
EMBODIMENT
[0022] FIG. 1 discloses an embodiment of a downhole tool string
100. The tool string 100 may be suspended by a derrick 108 within
an earthen formation 105. The tool string 100 may compose a drill
bit 104 and one or more downhole components 103. The downhole tool
string 100 may be in communication with surface equipment 106.
[0023] FIG. 2 discloses an embodiment of a downhole tool 103 with a
first end 202 and a second end 203. First end 202 may connect to a
portion of drill string that extends to the surface of a borehole,
and the second end 203 may connect to a bottom hole assembly or
drill bit or other drill string segments. Downhole tool 103
comprises a flow guide 204 and a signal generator that may include
a turbine 205 and a rotary valve 206. The rotary valve 206 may be
may mechanically connected to the turbine 205. The turbine 205 or
the rotary valve 206 of the signal generator may produce a signal
207 in the drilling fluid.
[0024] FIG. 3 discloses an embodiment of the rotary valve 206 that
is exposed to the drilling fluid. The rotary valve 206 may comprise
a stator plate 301 and a rotor plate 302. Both the stator plate 301
and the rotor plate 302 may contain a plurality of ports 303. The
rotor plate 302 may rotate relative to the turbine and about its
central axis 304. The stator plate 301 may stay stationary. As the
rotor plate 302 rotates, the plurality of ports 303 align and
misalign altering the flow of the drilling fluid. As the drilling
fluid is altered, a signal is generated at a first frequency.
[0025] Changing the rotational speed of the turbine will change the
frequency that the ports align and misalign, thereby, changing the
signal's frequency. In some embodiments, the signal generated by
the signal generator may be a sound wave, a pressure wave or
combinations thereof.
[0026] FIG. 4 discloses an embodiment of a downhole tool containing
the flow guide 204, and a signal generator. In this embodiment, the
signal generator comprises the turbine 205 and the rotary valve
206. The flow guide 204 may comprise a plurality of flow blades
401. The flow blades 401 may be used to direct the flow of the
drilling fluid across the turbine blades. In this embodiment, the
flow blades 401 are arranged parallel to the drilling fluid, so the
flow blade 401 are directing the drilling fluid in a direction
consistent with the fluid's flow.
[0027] FIG. 5 discloses an embodiment with the flow blades 401
angled. The flow guide 204 now directs the fluid to engage the
turbine's blade at a different angle, which, in the embodiment of
FIG. 5, is more aggressive than show in FIG. 4. This will cause the
turbine to rotate at a faster rate, and thus, change the generated
signal's frequency.
[0028] Thus, the signal's frequency is dependent on the flow
guide's position. The position of the flow blade may cause a more
or less aggressive attack angle. In some embodiments, the flow
blades 401 may even rotate such that the fluid flow is blocked off.
By changing the generated signal's frequency, encoded signals may
be transmitted through the fluid in the drill string's bore. One
advantage of the present invention, the is quick response time to
change the turbine's rotation, and thereby, change the signal
generators frequency change.
[0029] Communicating quickly in a well bore is essential,
especially in emergency situations. Further, when multiple sensors
and downhole instrumentation are trying to send signals to the
surface through the signal generator, quick signals are desirable.
The prevent invention's response time to changing the signal
generator's frequency enables more encode messages to be sent to
the surface in a shorter amount of time.
[0030] FIG. 6 discloses an embodiment of the signal produced by the
signal generator. As the flow guide changes the flow of the
drilling fluid, the frequency of the signal 604 changes. FIG. 6
discloses an embodiment of modulated signal 604.
[0031] FIG. 7 discloses a flow guide 701 comprising a rotatable
plate 702 and a plurality of flow blades 703. The flow blades 703
may attach to the guide through a pivot point 704. The rotatable
plate 702 may contain slots 705 disposed around its circumference.
The slots 705 may be adapted to receive tabs 706 disposed on the
flow blades 703. The tabs follow in the slots when the rotatable
plate turns causing the flow blades 703 to rotate on their pivot
point 704.
[0032] FIG. 8 discloses a downhole tool string comprising a
plurality of signal generators. A plurality of signal generators
may be disposed along the bore to facilitate a signal traveling up
the bore. A plurality of signal generators may be useful in
situations where the signal doesn't have enough strength to travel
to the top of the drill string on its own. A signal generator 801
is associated with a signal sensor 802 and is contained within the
bore. The signal sensor 802 may receive a first signal 803 from
traveling up the bore. As the signal sensor 802 receives a first
signal 803, the signal generator 801 may repeat the first signal
803 by producing a second signal 804 identical to the first signal.
The sensor may be in electrical communication with a flow guide of
the second signal generator to repeat the signal. In other
embodiments, the second signal generator comprises a piezoelectric
or magnetostrictive material that generates the desired encoded
signal.
[0033] FIG. 9a discloses a downhole tool string comprising a
plurality of signal generators 902. The signal produced by a signal
generator can be a pressure wave, sound wave, or other type of
signal within the scope of the invention. In this embodiment, the
arrows 901 represent the pressure that is associated with the
system when a pressure wave is not produced from a signal
generator.
[0034] FIG. 9b discloses the same downhole tool string as in FIG.
9a but the signal generators 902 are producing a pressure wave
which is represented by the arrows 903. The pressure wave generated
from the signal generators 902 go up the bore and thus oppose the
pressure that is normally felt down the bore. In this embodiment, a
plurality of signal generators may be utilized to sense the
pressure build-up and re-transmit the signal upward.
[0035] FIG. 10 is another embodiment of a signal generator. This
embodiment shows a signal generator without a rotary valve. The
flow guide 1003 alters the flow across the turbine 1001. In this
embodiment, a frequency emitted by the rotation of the turbine 1001
itself is used as the transmission signal 1002.
[0036] FIG. 11 discloses another embodiment of a signal generator
where the amount of flow over the turbine controls the turbine's
rotation speed, and therefore, the frequency emitted by the signal
generator. Here, a plurality of plates is used to restrict the
flow. The flow guide 1101 may be comprised of a first plate 1102
comprising of a plurality of ports 1104 and a second plate 1103
comprising of a plurality of ports 1105. The first plate 1102 may
be stationary and the second plate 1103 may rotate around a center
axis. As the second plate 1103 rotates, the ports 1105 align and
misalign with the ports 1104. As the ports 1105 and ports 1104
change relative to each other, the flow of the drilling fluid is
altered and thus redirected across the turbine 1106. As the fluid
flow is altered, a signal may be produced.
[0037] Whereas the present invention has been described in
particular relation to the drawings attached hereto, it should be
understood that other and further modifications apart from those
shown or suggested herein, may be made within the scope and spirit
of the present invention.
* * * * *