U.S. patent application number 14/995202 was filed with the patent office on 2016-07-14 for high signal strength mud siren for mwd telemetry.
This patent application is currently assigned to GE Energy Oilfield Technology, Inc.. The applicant listed for this patent is GE Energy Oilfield Technology, Inc.. Invention is credited to Wilson Chin, Kamil Iftikhar.
Application Number | 20160201438 14/995202 |
Document ID | / |
Family ID | 55538286 |
Filed Date | 2016-07-14 |
United States Patent
Application |
20160201438 |
Kind Code |
A1 |
Chin; Wilson ; et
al. |
July 14, 2016 |
HIGH SIGNAL STRENGTH MUD SIREN FOR MWD TELEMETRY
Abstract
A measurement while drilling (MWD) tool includes a sensor, an
encoder operably connected to the sensor and a modulator operably
connected to the encoder. The modulator includes a first stator, a
rotor and a second stator. The rotor is optimally positioned
between the first and second stator. The use of a second stator
amplifies the pressure pulse signal produced by the modulator.
Inventors: |
Chin; Wilson; (Sugarland,
TX) ; Iftikhar; Kamil; (Sugarland, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GE Energy Oilfield Technology, Inc. |
Broussard |
LA |
US |
|
|
Assignee: |
GE Energy Oilfield Technology,
Inc.
Broussard
LA
|
Family ID: |
55538286 |
Appl. No.: |
14/995202 |
Filed: |
January 14, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62103421 |
Jan 14, 2015 |
|
|
|
Current U.S.
Class: |
175/40 |
Current CPC
Class: |
E21B 41/0092 20130101;
E21B 47/20 20200501; E21B 47/18 20130101 |
International
Class: |
E21B 41/00 20060101
E21B041/00 |
Claims
1. A drilling tool comprising: a sensor; an encoder operably
connected to the sensor; and a modulator operably connected to the
encoder, wherein the modulator comprises: a first stator; a rotor;
and a second stator.
2. The drilling tool of claim 1, wherein the rotor is positioned
between the first stator and the second stator.
3. The drilling tool of claim 1, further comprising a
generator.
4. The drilling tool of claim 1, wherein the first stator includes
a plurality of stator vanes and wherein the second stator includes
a plurality of stator vanes.
5. The drilling tool of claim 1, wherein the first stator is offset
in position from the second stator such that the stator vanes on
the first stator are not aligned with the stator vanes on the
second stator.
6. The drilling tool of claim 1, wherein the rotor includes a
plurality of rotor vanes.
7. The drilling tool of claim 1, wherein the rotor vanes are
pitched.
8. A modulator for use with a drilling tool encoder, the modulator
comprising: a first stator; a rotor; and a second stator.
9. The modulator of claim 8, wherein the rotor is positioned
between the first stator and the second stator.
10. The modulator of claim 8, wherein the first stator includes a
plurality of stator vanes and wherein the second stator includes a
plurality of stator vanes.
11. The modulator of claim 8, wherein the first stator is offset in
position from the second stator such that the stator vanes on the
first stator are not aligned with the stator vanes on the second
stator.
12. The modulator of claim 8, wherein the rotor includes a
plurality of rotor vanes.
13. The modulator of claim 8, wherein the rotor vanes are
pitched.
14. A drilling system adapted for use in drilling a subterranean
well, the drilling system comprising: a drill string; a drill bit;
and a measurement while drilling (MWD) tool positioned between the
drill string and the drill bit, wherein the measurement while
drilling tool comprises: a sensor; an encoder operably connected to
the sensor; and a modulator operably connected to the encoder,
wherein the modulator comprises: a first stator; a rotor; and a
second stator.
15. The drilling system of claim 14, wherein the measurement while
drilling tool comprises: a motor; and a shaft connected to the
motor and to the rotor.
16. The drilling system of claim 15, wherein the rotor is
positioned between the first stator and the second stator.
17. The drilling system of claim 16, wherein the first stator
includes a plurality of stator vanes and wherein the second stator
includes a plurality of stator vanes.
18. The drilling system of claim 17, wherein the first stator is
offset in position from the second stator such that the stator
vanes on the first stator are not aligned with the stator vanes on
the second stator.
19. The drilling system of claim 18, wherein the rotor includes a
plurality of rotor vanes.
20. The drilling system of claim 19, wherein the rotor vanes are
pitched.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 62/103,421, filed Jan. 14, 2015 and
entitled "High Signal Strength Mud Siren for MWD Telemetry," the
disclosure of which is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of telemetry
systems, and more particularly, but not by way of limitation, to
acoustic signal generators used in wellbore drilling
operations.
BACKGROUND
[0003] Wells are often drilled for the production of petroleum
fluids from subterranean reservoirs. In many cases, a drill bit is
connected to a drill string and rotated by a surface-based drilling
rig. Drilling mud is circulated through the drill string to cool
the bit as it cuts through the subterranean rock formations and to
carry cuttings out of the wellbore. The use of rotary drill bits
and drilling mud is well known in the art.
[0004] As drilling technologies have improved, "measurement while
drilling" techniques have been enabled that allow the driller to
accurately identify the location of the drill string and bit and
the conditions in the wellbore. MWD equipment often includes one or
more sensors that detect an environmental condition or position and
relay that information back to the driller at the surface. This
information can be relayed to the surface using acoustic signals
that carry encoded data about the measured condition.
[0005] Prior art systems for emitting these acoustic signals make
use of wave generators that create rapid changes in the pressure of
the drilling mud. The rapid changes in pressure create pulses that
are carried through the drilling mud to receivers located at or
near the surface. Prior art pressure pulse generators, or "mud
sirens," include a single stator, a single rotor and a motor for
controllably spinning the rotor. The selective rotation of the
rotor temporarily restricts and releases the flow of mud through
the mud siren. By controlling the rotation of the rotor, the mud
siren can create a pattern of pressure pulses that can be
interpreted and decoded at the surface.
[0006] Although generally effective, prior art mud sirens may
experience bandwidth limitations and signal degradation over long
distances due to weakness of the pressure pulses. Accordingly,
there is a need for an improved mud siren that produces a stronger
pressure pulse that will travel farther and carry additional data.
It is to this and other deficiencies in the prior art that the
present invention is directed.
SUMMARY OF THE INVENTION
[0007] The present invention includes a measurement while drilling
(MWD) tool that includes a sensor, an encoder operably connected to
the sensor and a modulator operably connected to the encoder. The
modulator includes a first stator, a rotor and a second stator.
[0008] In another aspect, the present invention includes a
modulator for use with a drilling tool encoder. The modulator
includes a first stator, a rotor and a second stator. The rotor is
positioned between the first stator and the second stator.
[0009] In yet another aspect, the present invention includes a
drilling system adapted for use in drilling a subterranean well.
The drilling system includes a drill string, a drill bit and a
measurement while drilling (MWD) tool positioned between the drill
string and the drill bit. The measurement while drilling tool
includes a sensor, an encoder operably connected to the sensor and
a modulator operably connected to the encoder. The modulator
includes a first stator, a rotor and a second stator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a depiction of a drilling system constructed in
accordance with an embodiment of the present invention.
[0011] FIG. 2 is a cross-sectional view of an embodiment of the
modulator and motor of the drilling system of FIG. 1.
[0012] FIG. 3 is a top view of a stator of the modulator of FIG.
2.
[0013] FIG. 4 is a top view of the rotor of the modulator of FIG.
2.
WRITTEN DESCRIPTION
[0014] In accordance with an embodiment of the present invention,
FIG. 1 shows a drilling system 100 in a wellbore 102. The drilling
system 100 includes a drill string 104, a drill bit 106 and a MWD
(measurement while drilling) tool 108. It will be appreciated that
the drilling system 100 will include additional components,
including drilling rigs, mud pumps and other surface-based
facilities and downhole equipment.
[0015] The MWD tool 108 may include one or more sensors 110, an
encoder module 112, a generator 114, a modulator 116, a motor
module 118 and a receiver 120. The sensors 110 are configured to
measure a condition on the drilling system 100 or in the wellbore
102 and produce a representative signal for the measurement. Such
measurements may include, for example, temperature, pressure,
vibration, torque, inclination, magnetic direction and position.
The signals from the sensors 110 are encoded by the encoder module
112 into command signals delivered to the motor module 118.
[0016] Based on the command signals from the encoder module 112,
the motor module 118 selectively rotates the modulator 116 by
varying the open area in the modulator 116 through which
pressurized drilling fluid may pass. The rapid variation in the
size of the flow path through the modulator 116 increases and
decreases the pressure of drilling mud flowing through the MWD tool
108. The variation in pressure creates acoustic pulses that include
the encoded signals from the sensors 110. The pressure pulses are
transmitted through the wellbore 102 to the receiver 120 and
processed by surface facilities to present the driller or operator
with information about the drilling system 100 and wellbore
102.
[0017] The sensors 110, encoder module 112 and motor module 118 of
the MWD tool 108 can be operated using electricity. The electricity
can be provided through an umbilical from the source, from an
onboard battery pack or through the operation of the generator 114.
The generator 114 includes a fluid-driven motor and an electrical
generator. The fluid driven motor can be a positive displacement
motor or turbine motor that converts a portion of the energy in the
pressurized drilling fluid into rotational motion. The rotational
motion is used to turn a generator that produces electrical
current. It will be appreciated that some combination of batteries,
generators and umbilicals can be used to provide power to the MWD
tool 108.
[0018] Turning to FIG. 2, shown therein is a cross-sectional
depiction of the motor module 118 and modulator 116. The motor
module 118 includes a motor 122 that turns a shaft 124. The motor
122 is an electric motor that is provided with current from the
generator 114 or other power source. Alternatively, the motor 122
is a fluid-driven motor that includes a speed and direction
controller operated by electric signals produced by the encoder
module 112.
[0019] The modulator 116 includes a housing 126, a first stator
128, a rotor 130 and a second stator 132. The first and second
stator 128, 132 are fixed in a stationary position within the
housing 126. In contrast, the rotor 130 is secured to the shaft 124
and configured for rotation with respect to the first and second
stators 128, 132. In this way, the rotor 130 is positioned between
the first and second stators 128, 132. The rotor 130 can be secured
to the shaft 124 through press-fit, key-and-slot or other locking
mechanisms.
[0020] Referring now also to FIGS. 3 and 4, shown therein are top
views of the first stator 128, rotor 130 and second stator 132. In
particular, FIG. 3 provides a top view of an embodiment of the
first and second stators 128, 132. FIG. 4 provides a top view of
the rotor 130. The first and second stators 128, 132 each include a
plurality of stator vanes 134 and stator passages 136 between the
stator vanes 134. Although four stator vanes 134 and four stator
passages 136 are shown, it will be appreciated that the first and
second stators 128, 132 may include additional or fewer vanes and
passages. It will further be appreciated that the first and second
stators 128, 132 may have vanes with different geometries and
configurations. In the embodiment depicted in FIG. 2, the first and
second stators 128, 132 are rotationally offset within the housing
126 such that the stator vanes 134 on the first stator 128 are not
aligned with the stator vanes 134 on the second stator 132.
[0021] The rotor 130 includes a series of rotor vanes 138 and rotor
passages 140. The rotor vanes 138 can be pitched to promote the
acceleration of fluid passing through the rotor 130. Although four
rotor vanes 138 and four rotor passages 140 are shown, it will be
appreciated that the rotor 130 may include additional or fewer
vanes and passages.
[0022] During use, drilling fluid passes through the housing 126
and through the stator passages 136 of the first stator 128,
through the rotor passages 140 of the rotor 130 and through the
stator passages 136 of the second stator 132. The rotational
position of the rotor 130 with respect to the first and second
stators 128, 132 dictates the extent to which the velocity of the
drilling fluid increases and decreases as it passes through the
modulator 116. By varying the rotational position of the rotor 130,
the changes in fluid velocity and the resulting changes in the
pressure of the drilling fluid can be rapidly and precisely
adjusted. Unlike prior art mud sirens, the use of a second stator
132 within the modulator 116 significantly increases the amplitude
of the pressure pulses emanating from the modulator 116. The
increased strength of the pressure pulse signals provides
additional data carrying capacity and extends the distance that the
pressure pulses can travel before degrading. Accordingly, the use
of the second stator 132 within the modulator 116 presents a
significant advancement over the prior art.
[0023] It is to be understood that even though numerous
characteristics and advantages of various embodiments of the
present invention have been set forth in the foregoing description,
together with details of the structure and functions of various
embodiments of the invention, this disclosure is illustrative only,
and changes may be made in detail, especially in matters of
structure and arrangement of parts within the principles of the
present invention to the full extent indicated by the broad general
meaning of the terms in which the appended claims are expressed. It
will be appreciated by those skilled in the art that the teachings
of the present invention can be applied to other systems without
departing from the scope and spirit of the present invention.
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