U.S. patent application number 14/911326 was filed with the patent office on 2016-07-07 for axial oscillation device.
This patent application is currently assigned to COT Acquisition, LLC. The applicant listed for this patent is CAULDRON OIL TOOLS, LLC. Invention is credited to Aref Alali, Colin Donoghue, Trevor Kettles.
Application Number | 20160194917 14/911326 |
Document ID | / |
Family ID | 52468714 |
Filed Date | 2016-07-07 |
United States Patent
Application |
20160194917 |
Kind Code |
A1 |
Alali; Aref ; et
al. |
July 7, 2016 |
Axial Oscillation Device
Abstract
A downhole pressure pulsing apparatus comprising: an upper sub
that comprises a tube having a hollow interior through which fluid
can flow; a middle sub that comprises a tube having a hollow
interior through which fluid can flow; a lower sub that comprises a
tube having a hollow interior through which fluid can flow; wherein
said upper sub is connected to said middle sub by a connection such
that the hollow interior of said upper sub 1 is in fluid
communication with said middle sub's hollow interior; wherein said
middle sub is connected to said lower sub by a connection such that
the hollow interior of said middle sub is in fluid communication
with said lower sub's hollow interior; an impeller assembly,
wherein said impeller assembly comprises an impeller that is
rotatably mounted inside said middle sub's hollow interior; a
stator, wherein said stator is housed inside said upper sub's
hollow interior and wherein said stator directs fluid flow into
said impeller; a cam assembly mounted within said lower sub's
hollow interior; a restrictor assembly that varies total flow area
in order to generate pressure pulses, wherein said restrictor
assembly is mounted within said lower sub's hollow interior; and
wherein said cam assembly converts rotational motion created by
said impeller assembly to reciprocating axial motion within said
restrictor assembly.
Inventors: |
Alali; Aref; (Humble,
TX) ; Kettles; Trevor; (Humble, TX) ;
Donoghue; Colin; (Humble, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CAULDRON OIL TOOLS, LLC |
Humble |
TX |
US |
|
|
Assignee: |
COT Acquisition, LLC
Houston
TX
|
Family ID: |
52468714 |
Appl. No.: |
14/911326 |
Filed: |
August 15, 2014 |
PCT Filed: |
August 15, 2014 |
PCT NO: |
PCT/US2014/051163 |
371 Date: |
February 10, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61866034 |
Aug 14, 2013 |
|
|
|
61943139 |
Feb 21, 2014 |
|
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Current U.S.
Class: |
175/322 |
Current CPC
Class: |
E21B 7/24 20130101 |
International
Class: |
E21B 7/24 20060101
E21B007/24 |
Claims
1. A downhole pressure pulsing apparatus, comprising: an upper sub
that comprises a tube having a hollow interior through which fluid
can flow; a middle sub that comprises a tube having a hollow
interior through which fluid can flow; a lower sub that comprises a
tube having a hollow interior through which fluid can flow; wherein
said upper sub is connected to said middle sub by a connection such
that the hollow interior of said upper sub is in fluid
communication with said middle sub's hollow interior; wherein said
middle sub is connected to said lower sub by a connection such that
the hollow interior of said middle sub is in fluid communication
with said lower sub's hollow interior; an impeller assembly,
wherein said impeller assembly comprises an impeller that is
rotatably mounted inside said middle sub's hollow interior; a
stator, wherein said stator is housed inside said upper sub's
hollow interior and wherein said stator directs fluid flow into
said impeller; a cam assembly mounted within said lower sub's
hollow interior; a flow restrictor assembly that varies total flow
area in order to generate pressure pulses, wherein said flow
restrictor assembly is mounted within said lower sub's hollow
interior; and wherein said cam assembly converts rotational motion
created by said impeller assembly to reciprocating axial motion
within said restrictor assembly.
2. A downhole pressure pulsing apparatus according to claim 1,
wherein said axial impeller assembly comprises: an impeller housing
having a hollow interior; an impeller rotatably mounted within said
impeller housing wherein fluid flow causes impeller rotation; a
lower threaded connection to connect said impeller assembly to said
cam assembly.
3. A downhole pressure pulsing apparatus according to claim 2,
wherein said axial impeller's rotational speed is directly
proportional to the rate of fluid flow directed by said stator into
said impeller.
4. A downhole pressure pulsing apparatus according to claim 1,
wherein said cam assembly comprises: a cam housing having a hollow
interior; a barrel cam having at least one cam profile, wherein
said barrel cam is mounted inside said cam housing's hollow
interior; at least one cam follower; at least one barrel cam
retainer is mounted within said lower sub's hollow interior; top
inner diameter threads to connect said impeller assembly to said
cam housing; lower inner diameter thread to connect the rocket
holder.
5. A downhole pressure pulsing apparatus according to claim 4,
wherein said at least one cam follower engages said at least one
cam profile to convert said impeller's rotational motion to said
barrel cam's axial reciprocation; and wherein said barrel cam
retainer restrains said barrel cam from rotational motion.
6. A downhole pressure pulsing apparatus according to claim 1,
wherein said flow restrictor assembly comprises: a rocket holder; a
rocket; and a venturi; wherein said rocket is constrained by said
rocket holder to the desired range of axial motion; and wherein
said rocket can reciprocate axially into and out of said
venturi.
7. A downhole pressure pulsing apparatus according to claim 1,
wherein said impeller rotates said cam assembly; and wherein said
cam assembly engages said flow restrictor assembly to generate
axial motion within said flow restrictor assembly to vary total
flow area.
8. A downhole pressure pulsing apparatus according to claim 1,
further comprising a pressure actuated device that reacts to
pressure pulses generated by said flow restrictor assembly in order
to oscillate axially.
9. A downhole pressure pulsing apparatus according to claim 7,
further comprising a housing for location in a drill string, said
housing defining a through bore to permit fluid passage through
said pressure pulsing apparatus and a shock tool mounted on said
drill string; wherein said pressure pulsing apparatus generates
axial reciprocation in said drill string in a well bore: wherein
said drill string comprises a drill bit, drilling motor, or rotary
drilling system, a measurement while drilling tool, and drill pipe;
and wherein said flow restrictor assembly generates pressure pulses
within said drill string and said shock tool converts pressure
pulses into axial oscillation.
10. A downhole pressure pulsing apparatus according to claim 6,
further comprising a hydromechanical indexing apparatus that
switches pulsation on and off as fluid flow starts and stops by
moving said venturi axially move away from said rocket; wherein
said hydro-mechanical indexing apparatus is mounted within said
lower sub's hollow interior and comprises a base plate, a housing
for a base plate, an indexing barrel having a top and a bottom and
an indexing profile, at least one indexing pin that engages said
indexing profile, a wash pipe, a shear pin mechanism having a
bottom, and a spring; wherein said indexing barrel is attached to
said venturi and said indexing barrel and said venturi can move
axially within said lower sub's hollow interior; wherein said
indexing profile comprises an engagement position and a
disengagement position; wherein said base plate is connected to the
top of said indexing barrel; wherein said spring pushes said
indexing barrel upward and fluid flow pushes said indexing barrel
downward when fluid flow is sufficient to overcome said spring;
wherein said indexing barrel's upward and downward movement causes
said indexing pin to move within said indexing profile between said
indexing profile's engagement position and said indexing profile's
disengagement position; wherein said shear pin mechanism is
connected to said indexing barrel's bottom; wherein a shear pin is
inserted into said indexing barrel and said shear pin mechanism;
wherein said wash pipe is connected to said shear pin mechanism's
bottom and is positioned inside said lower sub's hollow interior to
form an annulus between said wash pipe's outer diameter and said
lower sub's inner diameter; and wherein said spring is located in
said annulus between said wash pipe's outer diameter and said lower
sub's inner diameter.
11. A downhole pressure pulsing apparatus according to claim 10, in
a drilling operation, where the axial oscillation of a drill string
using said downhole pressure pulsing apparatus, facilitates the
weight transfer to a bit due to lower friction between said drill
string and a formation.
12. A downhole pressure pulsing apparatus according to claim 10,
where said downhole pressure pulsing apparatus can be used to
reduce the possibility of a drill string getting stuck in a well
bore or freeing a stuck object in a well bore.
13. A downhole pressure pulsing apparatus according to claim 10,
where said apparatus facilitates running tubular into a well bore.
Description
BACKGROUND
[0001] The invention relates generally to the oil and gas industry
and more specifically to devices and methods to convert pressure
pulses into axial movement of a drill string to reduce friction and
drag. Downhole static and dynamic friction can exacerbate drag and
weight stacking, whether using a rotary steerable or downhole motor
assembly. Drag and weight stacking can lead to tool face control
issues in slide drilling, low rate of penetration, high torque,
premature buckling, extensive bit wear, short lateral sections, and
difficulty in running subsequent casing strings.
[0002] There are multiple challenges involved within daily drilling
operations on a global scale today that limit drilling efficiencies
and increase lifting costs to the operator. Friction reduction
technology has been used to reduce the negative effect of highly
inter-bedded formations, ineffective weight transfer, low rate of
penetration, sinusoidal and helical buckling, erratic reactive
torque, poor tool face control, high tortuosity in extended reach
wells and casing running, as well as objects becoming stuck in
holes and needing to be fished out. An embodiment, in combination
with a shock tool or sub, provides a means to reduce friction
between a drill string and a formation or wellbore. Having the
ability to reduce static friction negates most of the problems
listed above that are widely seen in today's extended reach
drilling operations around the globe.
SUMMARY
[0003] An embodiment comprises a tool placed within a drill string
to create a pressure pulse within a drilling fluid system when
drilling fluid is being pumped through the drill string, it then
converts the pressure pulse into axial movement of the drill string
using a shock tool or sub. A valve system in an embodiment
alternates the total flow area thereby creating high and low
pressure pulses. The shock tool or sub then transforms the pressure
pulses into mechanical axial motion along the axis of the drill
string to facilitate friction reduction in the wellbore thus
allowing the operator to drill further, faster and with more
confidence. Drive mechanisms such as positive displacement motors
(PDM) and turbines are known in the industry. An embodiment can
comprise an axial impeller that spins at high rpm. An embodiment
can comprise a cam system that spins with the axial impeller and
causes the valve system's rocket to axially reciprocate. Axial
reciprocation of the rocket in a venturi then varies the total flow
area and generates high and low pressure pulses. Alternating high
and low pressure pulses act on the pump open area of a shock tool
or sub to generate axial motion along the drill string. Various
impeller designs allow the tool to work at different frequencies.
Impeller variation enables operation with different types of
measurement while drilling tools. Additionally, a bottom sub can be
changed out to convert a standard tool to one having an on/off
switch. This mechanism engages or disengages the orifice from the
rocket as and when required through cycling a mud pump. An increase
or decrease in standpipe pressure confirms the position of the
tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a side view of an embodiment.
[0005] FIG. 2 is a sectional view of an embodiment.
[0006] FIG. 3 is a cross sectional view of the lower internals of
an embodiment.
[0007] FIG. 4 is a cross sectional view of the upper internals of
an embodiment.
[0008] FIG. 5 is a cross sectional view of an embodiment's sub 35
which turns the tool off and on.
[0009] FIG. 6 is a cross sectional view of an embodiment's sub 35
before shearing the pin.
[0010] FIG. 7 is a cross sectional view of an embodiment's sub 35
when the tool is activated with no pulsing.
[0011] FIG. 8 is a cross sectional view of an embodiment's sub 35
is in reset position.
[0012] FIG. 9 is a cross sectional view of an embodiment's sub 35
when the tool is in pulsing position.
[0013] FIG. 10 is a cross sectional view of an embodiment's sub 35
when it is in reset position.
DETAILED DESCRIPTION
[0014] Reduction of friction brings substantial and valuable
improvements in the quality of drilling operation. A tool in
accordance with an embodiment can change total flow area to create
pressure pulses. Alternate high and low pressure pulses act on the
pump open area of a shock tool or sub and cause a mandrel on a
shock tool or sub to extend and retract at high frequency. A
mandrel's axial motion will gently oscillate a drill string and
reduce friction between a drill string and a formation. Mechanical
axial motion of a shock tool or sub can overcome static friction
between mechanically stuck objects.
[0015] FIG. 1 is a side view of a drill string's lower end
comprising a drill string component 4. Drill string component 4 can
comprise a shock tool or sub, drill collar, drill pipe, downhole
motor or measurement while drilling (MWD) tool and is connected to
an upper outer sub 1 via API oilfield connection. Upper outer sub 1
is connected to a mid-outer sub 2 via proprietary oilfield
connection 21 as illustrated in (FIGS. 1 & 2). Mid outer sub 2
is connected to a lower outer sub 3 via proprietary oilfield
connection 24 as illustrated in (FIGS. 1 & 3a). Lower outer sub
3 is connected to the top of a lower string component 5 via API
oilfield connection. Lower string component 5 (FIG. 1) can comprise
a drill collar, drill pipe, downhole motor or MWD tool.
[0016] FIGS. 2 and 4 illustrate an embodiment's axial impeller
assembly 22 in greater detail. An axial impeller assembly 22 (FIG.
2) comprises an impeller sleeve 6 that houses an axial impeller 20.
Impeller sleeve's 6 upper end (FIG. 2) is positioned using an upper
radial bushing 19 (FIG. 2) that is located in mid outer sub 2. As
shown in FIG. 4, axial impeller assembly 22 is located in mid-outer
sub 2 and rotates freely in mid outer sub 2 (FIG. 4).
[0017] FIGS. 3a and 4 show assembly 23 comprising a barrel cam
sleeve 8 (FIG. 3a) that has a barrel cam 10 (FIG. 3a) inserted into
it and located with three barrel cam followers 17, 25, and 26 which
locate into barrel cam sleeve 8. A flow restrictor assembly
according to an embodiment comprises: a rocket holder; a rocket;
and a venturi.
[0018] A rocket holder can be threaded to the lower inner diameter
thread of a barrel cam. A rocket can be linked to a rocket holder
by threaded connection, such as a male thread on a rocket engaging
a female thread on the rocket holder. A venturi is located in a
lower sub's hollow interior. When a rocket enters a venturi, total
flow area is reduce and pressure increases. When a rocket is out of
a venturi, total flow area is increased and pressure is lower.
Variation of total flow area results in pressure pulses at the
restrictor assembly. Depending on the restriction of the total flow
area, the pulse amplitude may be varied and controlled. The rocket
holder 12 (FIG. 3a) is connected to the lower end of the barrel cam
10 by way of proprietary connection. The rocket 29 (FIG. 3a) is
then connected to rocket holder 12 (FIG. 3a) through a proprietary
connection. The lower part of the axial impeller 6 is connected to
the upper part of the barrel cam sleeve 8 by way of a proprietary
connection 9.
[0019] Base plate 14 is located into the pin connection 24 within
bottom sub 3 (FIG. 4). The barrel cam retainer 13 (FIG. 3a) is
located into the pin of connection 24 within the bottom sub 3 (FIG.
4), by way of splined keyways. These splined keyways follow through
to base plate 14 (FIG. 3a).
[0020] In FIGS. 1, 2, 3a, and 4 drilling fluid is pumped through
the upper outer sub 1 (FIG. 1) into an axial impeller sleeve 6
located in mid-outer sub 2 (FIG. 4). Axial impeller sleeve 6
contains the axial impeller 20. Drilling fluid flow rotates the
axial impeller 20, and thereby rotates axial impeller sleeve 6.
Axial impeller sleeve 6 is connected to a barrel cam sleeve 8 via a
proprietary connection 9. Barrel cam sleeve 8 rotates on top of a
barrel cam retainer 13 (FIG. 3a). Three barrel cam followers 17,
25, and 26 (FIG. 3a) locate into the barrel cam sleeve 8 and rotate
with barrel cam sleeve 8. Barrel cam follower 26 runs in barrel cam
profile 11 (FIG. 3a), barrel cam 17 runs in the barrel cam profile
27 (FIG. 3a) and barrel cam 25 runs in the barrel cam profile 28
(FIG. 3a). Cam profiles 11, 27, and 28 (FIG. 3a) provide axial
motion that can be adjusted to suit the axial travel distance
required. The barrel cam 10 is restrained from rotating with barrel
cam sleeve 8 by barrel cam retainer 13. Barrel cam 10 can only move
axially and moves rocket holder 12 and rocket 29 axially (FIG. 3a).
Rocket holder 12 is connected to the lower part of barrel cam 10 by
a proprietary connection. Rocket 29 is connected to the rocket
holder 12 by a proprietary connection. While pumping fluid though
an embodiment, rocket 29 moves axially in and out of venturi 30 of
base plate 14 (FIG. 3a). When rocket 29 is positioned out of the
venturi 30 maximum total flow area is achieved (FIG. 3b). When the
rocket 29 is positioned in venturi 30 total flow is reduced (FIG.
3a). The increase and decrease of total flow area as shown in FIG.
3a and FIG. 3b illustrate the fluid bypass area restricting and
unrestricting flow via axial movement of the rocket 29 thereby
creating pressure pulses in the fluid. Frequency of pressure pulses
is directly proportional to rotation of the impeller 20 which is
directly proportional to fluid flow rate through outer upper sub 1.
A stator 51 is housed within upper-sub 1 (FIG. 4). Flow is directed
through stator 51 and directed into axial impeller 20 (FIG. 4).
Rotation of impeller assembly 22 causes rotation of cam assembly 23
(FIG. 4). An example cam assembly comprises: cam housing or sleeve
having a hollow interior; a barrel cam, mounted inside the cam
housing's hollow interior; one or more cam followers; one or more
cam retainers which are placed in the lower sub; top inner diameter
threads to connect the impeller assembly to the cam housing/sleeve;
lower inner diameter thread to connect the rocket holder. An
example cam assembly mounted can be mounted within said lower sub's
hollow interior. Cam assembly 23 converts rotational motion to
axial motion. Axial motion of cam assembly 23 moves rocket 29
axially in and out of venturi 30, and creates pressure pulses.
Pressure pulses can then be used in conjunction with a pressure
activated mechanical shock sub or tool. Pressure pulses act on the
pump open area of a shock sub or tool creating axial vibration
within a tubular string.
[0021] An alternative embodiment can comprise bottom sub 35 as
shown in FIG. 5, instead of bottom sub 3. Bottom sub 35 enables an
embodiment to have selective pulsation by activating and
de-activating pulses as required.
[0022] Sub 35 (FIG. 5) is designed to switch an embodiment on or
off. Sub 35 comprises a housing for a base plate 14, an indexing
barrel 36, a wash pipe 37, a shear pin mechanism/housing 38 and a
spring 39 (FIG. 5). Base plate 14 is connected to the top of
indexing barrel 36. Indexing barrel 36 is a flow or pressure
activated body that comprises an indexing profile 40 with three
pins 41 inserted into the indexing profile 40 via the sub's outer
body 35 (FIG. 5). The indexing system operates with fluid flow.
When pumping fluid through sub 35, fluid exerts pressure on the
upper surface 42 of an indexing system. A shear pin
mechanism/housing 38 (FIG. 5) is connected to the lower part of an
indexing barrel 36 via a proprietary connection. Shear pin 43 is
inserted into bottom sub 35 (FIG. 5) with an NPT threaded port 44
that is located on the outer diameter of a shear pin mechanism and
housing 38. Wash pipe 37 is connected to the lower part of the
shear pin housing 38. A preloaded spring 39 is inserted into the
annulus between the wash pipe 37 outer diameter and the internal
diameter of the bottom sub 35. Spring 39 sits on bottom internal
face 46 of bottom sub 35 (FIG. 5).
[0023] Indexing Pins 41 are initially placed in a position half way
in profile 40 in relation to the shear pin 43 (FIG. 6). Shear pin
43 is designed to be sheared by a higher flow rate than the
drilling flow rate. When shear pin 43 is sheared by a high flow
rate, indexing barrel 36 will move downward axially following the
indexing profile 40 until it ends in pocket 47 (FIG. 7). The
initial downward axial motion of indexing barrel 36, with the help
of the force exerted by fluid pressure on upper surface 42, will
put pins 41 at the highest point of profile 40 (FIG. 7) which
corresponds to the maximum distance between base plate 14 located
in upper surface 42 and rocket 29. In this position, rocket 29 will
not enter the venturi 30 and does not change total flow area to
create a high pressure pulse. Due to the shape of indexing profile
40, indexing barrel 36 turns clockwise. Turning the pump off, will
allow preloaded spring 39 to push the shear pin housing 38 and
indexing barrel 36 upward. When the indexing barrel 36 moves upward
and clockwise, pins 41 will reach the reset position at pocket 48
as shown in FIG. 8. In this position, indexing barrel 36, upper
surface 42, and venturi 30 will be at the closest position to
rocket holder 12, hence venturi 30 and rocket 29 will have maximum
engagement. As shown in FIG. 9, when pumping fluid again through
the string, fluid flow exerts a force on upper ring 42 which pushes
indexing barrel 36 downward. While indexing barrel 36 is moving
downward and clockwise following profile 40, pins 41 will end up in
pockets 49. In this position indexing barrel 36, the upper ring 42,
and the venturi 30 will be at an optimum position relative to the
rocket holder 12, hence the venturi 30 and the rocket 29 will have
an optimum engagement. In this position an embodiment will generate
total flow area variation causing pressure pulses. Turning the pump
off will allow the preloaded spring 39 to push the shear pin
housing 38 and the indexing barrel 36 upward. When the indexing
barrel 36 moves upward and clockwise, the pins 41 reach the reset
position at pocket 50 as shown in FIG. 8. In this position indexing
barrel 36, upper surface 42 and venturi 30 will be at the closest
position to rocket holder 12, so venturi 30 and rocket 29 will have
maximum engagement. As shown in FIG. 10, when pumping fluid again
through the string, fluid flow exerts force on the upper surface 42
which pushes indexing barrel 36 downward. While indexing barrel 36
is moving downward and clockwise, pins 41 will end up in pockets 47
as shown in FIG. 7. In this position indexing barrel 36, upper
surface 42 and venturi 30 will be at the furthest distance from
rocket 29.
[0024] In the embodiment described above, the indexing mechanism
will have two reset positions, one disengagement position and one
engagement position. In reset positions there is no pulsation as
there is no fluid passing through the embodiment. In the
disengagement position, there will be no pulsation as the rocket 29
and venturi 30 will have no engagement as shown in FIG. 7. The only
position in which the embodiment will start pulsing is when the
rocket 29 and venturi 30 are engaged as shown in FIG. 9. In the
disengaged position, the total flow area will have less surface
pressure indication than when in the engaged position, thus
enabling an operator to determine whether an embodiment is in the
on or off position.
* * * * *