In one aspect, an apparatus for use in a drilling assembly is disclosed that in one embodiment includes a flow control device that further includes: a fluid flow path having an inlet and an outlet; an electromagnetic circuit that includes a closing member made from a soft magnetic or magnetic material as a part of the electromagnetic circuit, wherein the closing member moves from a first open position to a second closed position to close the fluid flow path to produce a pressure pulse in a fluid flowing through the fluid flow path when the electromagnetic circuit is formed.
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1. A method of producing a pressure pulse in a fluid flow path of a downhole tool, the method comprising:
energizing a magnetic member separated by a gap from a movable member in the fluid flow path to form a magnetic flux in the gap, the movable member including a closing member;
moving the movable member in response to the magnetic flux to close the gap; and
engaging the closing member with an inlet of the fluid flow path, pursuant to the closing the gap, to produce the pressure pulse.
10. An apparatus for use in a downhole tool, comprising:
a movable member in a fluid flow path of the downhole tool, the movable member including a closing member; and
a magnetic member that is separated from the movable member by a gap, the magnetic member energizable to form a magnetic flux in the gap that moves the movable member to close the gap, wherein moving the movable member to close the gap engages the closing member with an inlet of the fluid flow path to produce a pressure pulse.
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The present invention is a continuation of U.S. patent application Ser. No. 14/714,442, filed May 18, 2015, the contents of which are incorporated herein by reference in their entirety.
This disclosure relates generally to drilling system that include a drilling assembly that include a mud pulse telemetry system in a drilling assembly for transmitting signals between downhole locations and a surface location during drilling of wellbores.
Wells (also referred to as wellbores or boreholes) are formed in earth formations for the production of hydrocarbons (oil and gas). A drill string including a drilling assembly (also referred to as a bottomhole assembly or “BHA”) attached to a drill pipe is conveyed into the wellbore for drilling a wellbore. A drill bit connected to the end of the drilling assembly is rotated by rotating the drill pipe and/or by a motor in the drilling assembly to form the wellbore. A fluid (referred to as “mud”) is supplied under pressure into the drill string, which fluid discharges at the bottom of the drill bit and returns to the surface along with rock cuttings cut by the drill bit. The drill string commonly includes a number of sensors, including a pressure sensor, vibration sensor, temperature sensor, accelerometers, gyroscopes, etc. and also tools referred to a logging-while-drilling tools that may include resistivity, acoustic and nuclear sensors for proving information or characteristics of the formations through which the wellbore is being drilled. The data obtained from such sensors and tools is processed in the drilling assembly to obtain certain parameters and some such information is transmitted during drilling to a surface computer system for further processing and to control the drilling operation. Mud pulse telemetry in which a pulsing device (also referred to as a “pulser”) generates pressure pulses in the fluid passing through the drilling assembly is commonly used to transmit signals from the drilling assembly to the surface. The data or information is transmitted as coded pressure pulses, which are decoded by the surface computer. During drilling, a typical mud pulser substantially continuously generates pressure pulses over long time periods, often several days. In addition, a number of wellbores are currently drilled in formations having temperatures above 300 degrees Fahrenheit. A majority of currently utilized mud pulsers include oil fillings, elastomers and/or electrical high pressure connectors, which tend to deteriorate over time and are not suitable for use in high temperature wells.
The disclosure herein provides pulsers that are suitable for high temperature use and also may be made without the use of oil fillings, elastomers or electrical high pressure connectors.
In one aspect, an apparatus for use in a drilling assembly is disclosed that in one embodiment includes a flow control device that further includes: a fluid flow path having an inlet and an outlet; an electromagnetic circuit that includes a closing member made from a soft magnetic or magnetic material as a part of the electromagnetic circuit, wherein the closing member moves from a first open position to a second closed position to close the fluid flow path to produce a pressure pulse in a fluid flowing through the fluid flow path when the electromagnetic circuit is formed.
In another aspect, a method of producing pressure pulses in a wellbore during drilling of the wellbore is disclosed, which method in one embodiment includes: conveying a drilling assembly in the wellbore, the drilling assembly including a flow control device that further includes a fluid flow path having an inlet and an outlet, a coil between a first soft magnetic or magnetic member and a second soft magnetic or magnetic member and a closing member made from a soft magnetic or magnetic material, wherein when the coil is energized, an electromagnetic circuit is formed that moves the closing member from a first open position to a second closed position to close the fluid path to produce a pressure pulse in a fluid flowing through the fluid flow path.
Examples of the more important features of a certain apparatus and methods have been summarized rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are additional features that will be described hereinafter, which will form the subject of the claims.
For a detailed understanding of the apparatus and methods disclosed herein, reference should be made to the accompanying drawings and the detailed description thereof, wherein like elements are generally given same numerals and wherein:
During drilling, a suitable drilling fluid 131 from a mud pit (source) 132 is pumped into the drill string 120 by a mud pump 134. The drilling fluid 131 passes from the mud pump 134 into the drill string 120 and discharges at the bottom 151 of the borehole 126 through openings 152 in the drill bit 150. The drilling fluid 131 circulates uphole through the annular space 127 (annulus) between the drill string 120 and the borehole 126 and returns to the mud pit 132 via a return line 135. The drilling fluid 131 lubricates the drill bit 150, carries the rock cutting made by drill bit 150 to the surface and maintains pressure in the wellbore 126 above the formation pressure along the wellbore 126 to prevent blow outs. A sensor S1 placed in the line 138 provides information about the fluid flow rate. Surface sensors S2 and S3 associated with the drill string 120 respectively provide information about the torque and rotational speed of the drill string 120. Additional sensor (not shown) may be utilized to provide the hook load and other desired parameters relating to the drilling operations.
In one embodiment of the disclosure, the drill bit 150 is rotated by only rotating the drill pipe 122. In another embodiment of the disclosure, a downhole motor 155 (mud motor) disposed in the drilling assembly 190 rotates the drill bit 150. The drill pipe 122 may be rotated to supplement the rotational power of the mud motor 155 and to effect changes in the drilling direction. In the embodiment of
In one embodiment of the disclosure, a drilling sensor module 159 is placed near the drill bit 150. The drilling sensor module 159 contains sensors, circuitry and processing software and algorithms relating to the dynamic drilling parameters. Such parameters include, but are not limited to bit bounce, stick-slip, backward rotation, torque, shocks, borehole and annulus pressure, acceleration and other parameters of the drill bit and drilling assembly condition. The drilling assembly 190 further includes a number of logging-while-drilling (LWD) tools or sensors (collectively designated by numeral 180). The LWD tools may include a resistivity tool, an acoustic tool, an active source nuclear tool, a gamma ray tool, a formation testing tool to provide information about various parameters or characteristics of the formation 102. The various tools include processors and electronic circuitry that process information from their respective tools and provides information about the various parameters of interest to be transmitted to the surface. The drilling assembly 190 also includes electronic circuitry and processors that process signals from the sensors 159 and provide information of parameters to be transmitted to the surface. The drilling assembly 190 further includes a power unit 179 that generates power for use by the various devices in the drilling assembly and a telemetry unit 172 that includes a fluid control device or pulser 185 made according to one embodiment of the disclosure that generated pressure pulses corresponding to information desired to be sent to the surface. The operation of the pulser 185 is controlled by a processor associated with the telemetry unit 172.
The processor associated with the pulser 185 causes the pulser 185 to generate pressure pulses corresponding to the signals to be sent to the surface. Sensor 145 detects such pressure pulses and provides information relating thereto to a surface control unit 140. The system 140 may be a computer-based system that processes the received pulses and provides information to an operator to takes action or takes action by itself in accordance with programs provided to the control unit 140. The control unit 140 displays desired drilling parameters and other information on a display/monitor 142 utilized by an operator to control the drilling operations. The control unit 140 activates alarms 144 when certain unsafe or undesirable operating conditions occur. Certain embodiments of fluid control devices 185 for use in the system 100 are described below in reference to
Referring to
The magnetic flux path or circuit 270 is formed each time the coil 250 is energized. The magnetic flux path 270 is formed from the core 256 to the support member 248, from the support member 248 to the plunger 240, from the plunger 240 to the inlet member 230 and from the inlet member 230 to the inlet guide 220. The non-magnetic spacer 264 prevents shorts in the circuit 270. In the embodiment of the flow control device 200, the coil 260 may be placed in a sealed and clean 1-bar environment. In the particular embodiment of the device 200 in
Still referring to
Although the flow control device herein is described as a mud pulser for generating pressure pulses in a drilling assembly, the device may be utilized for any other suitable purpose or for performing any other function, including, but not limited to: control of mud hydraulic driven steering tools, expandable reamers and expandable stabilizers; setting of packers; operating sliding sleeves and production valves; control of additive dosing devices; and control and/or operation of devices at the surface.
The foregoing disclosure is directed to the certain exemplary embodiments and methods. Various modifications will be apparent to those skilled in the art. It is intended that all such modifications within the scope of the appended claims be embraced by the foregoing disclosure. The words “comprising” and “comprises” as used in the claims are to be interpreted to mean “including but not limited to”.
Kruspe, Thomas, Scholz, Eckard
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