The present invention relates generally to downhole tools and, more particularly but without limitation, to abrasive perforating tools.
The present invention comprises an abrasive perforating tool with three operating positions created by upper and lower valve sleeves that shift sequentially from a first or nondeployed position to a second, deployed position. In a first “flow through” position, the two nondeployed valve sleeves create a first flow path directing abrasive fluid entering the housing straight through the main bore to the outlet end of the tool. In a second “perforating” position, the first or lower sleeve is shifted to the deployed position to block flow out the end of the tool and to redirect flow to the nozzles in the side of the housing. Finally, the upper valve sleeve is shifted to the deployed position to form the third or “bypass” position, in which flow is diverted through a bypass channel to reestablish flow out the bottom of the tool.
In the preferred embodiment, each of the valve sleeves is telescopically supported in a shear sleeve that is fixed to the housing. The valve sleeves and their respective shear sleeves are arranged axially in the tool housing, that is, the upper and lower valve sleeves are arranged end-to-end, rather than concentrically or telescopically. Each of the two valve sleeves is held by shear pins, and the shear pins for each valve sleeve are independent. That is, when increased fluid pressure is applied to break the shear pins for the first valve sleeve, no pressure is exerted on the shear pins holding the second sleeve in its nondeployed position. This reduces the likelihood that the shear pins on the second sleeve will fail and cause premature deployment of the second sleeve.
In the preferred practice of the invention, the valve sleeves are ball-actuated. Thus, each valve sleeve is provided with a ball seat in its central bore. Most preferably, the ball seat in the first sleeve is at or near the lower end of the sleeve. This improves stability of the sleeve as the fluid pressure acts on it making it less likely that the sleeve will deform or buckle, which in turn may lead to failure of the fluid seals.
The components of the inventive tool are configured so that when the tool shifts to the second, perforating position, an efficient flow is created to minimize resistance allowing for higher fluid pressures for perforating. More specifically, in this position, fluid passes from the inlet through the main bore of the housing and the central bores of the valve sleeves directly out the nozzles. Both valve sleeves are sealingly mounted inside the tool housing; no flow is diverted around either sleeve in the perforating position. This configuration also allows the thickness of the housing's sidewall to be maximized in turn permitting the use of longer nozzles that are more resistant to erosion from the abrasive fluid. Still further, the thicker sidewall allows for the use of larger O-rings providing a stronger seal.
Turning now to the drawings in general and to
The BHA 12 may include a variety of tools. In the example shown, the BHA 12 includes a coiled tubing connector 20, a dual back pressure valve 22, a hydraulic disconnect 24, the inventive bypass perforator tool 10, a motor 26, and a mill 28 on the end.
With reference now to
At least one and preferably several nozzles 120 are supported in openings 122 (
Referring now also to
The first valve assembly 130 comprises a first shear sleeve or retainer sleeve 134 and a first valve sleeve 136, also seen in
The second valve assembly 132 comprises a second shear or retainer sleeve 146 and a second valve sleeve 148, seen also in
With continuing reference to
Preferably, the first valve sleeve 136 is sealingly mounted inside the tool housing 100 so that there is no fluid flow between the sleeve 136 and the inner diameter of the housing's main bore 118. This fluid-tight seal may be accomplished with one or more seals, such as O-rings designated generally at 166 (
In the exemplary embodiment, movement of the first valve sleeve 136 from the non-deployed position to the deployed position is ball-actuated, that is, the shift is initiated by dropping a ball, such as a first ball 170 (
The first valve sleeve 136 is releasably secured to the first retainer sleeve 134 for movement from the non-deployed position to the deployed position. Although the mechanism of this releasable attachment may vary, one exemplary mechanism is a shear pin. Thus, in the in preferred embodiment, at least one shear pin 176 (
With reference again to
In the exemplary embodiment, movement of the second valve sleeve 148 from the non-deployed position to the deployed position is ball-actuated, that is, the shift is initiated by dropping a ball, such as the second ball 190 (
The second valve sleeve 148 is releasably secured to the second retainer sleeve 146 for movement from the non-deployed position to the deployed position. Although the mechanism of this releasable attachment may vary, one exemplary mechanism is a shear pin. Thus, in the preferred embodiment, at least one shear pin 194 (
Now it will be appreciated that the first and second valve assemblies 130 and 132, and more particularly, the first and second valve sleeves 136 and 148, are arranged end-to-end in the housing body 106. In the initial operating position, when both sleeves are in the non-deployed position, the upper end 160 of the first (lower) sleeve 136 is spaced a distance axially below the lower end of the second (upper) valve sleeve 148. Thus, the main bores 164 and 184 of the valve sleeves 136 and 138 are co-axial and form a continuous flow path with the main bore 118 of the housing 100.
Referring still to
An alternate or bypass flow path is provided through a bypass channel 206, which preferably is formed in the sidewall 116 of the housing body 106. In the embodiment shown, only a single bypass channel 206 is used. However, two or more such channels may be formed in the tool. As is shown in
A bypass inlet 208 is formed near the upper end 200 of the housing body 106 and is continuous with the housing inlet 112 (
A bypass outlet 210 is formed near the lower end 202 of the housing body 106 and is also continuous with the housing outlet 114 (
With reference now to
As shown in
Turning to
Now it will be apparent that the abrasive perforating tool of the present invention provides many advantages. One advantage is the ability to regain high-rate fluid flow through the tool after perforating. This allows a thorough cleanout of the well, which is difficult to obtain using current technology. Another advantage is the ability to operate a motor or other fluid driven tool below the perforating tool after completing the perforating operation but without withdrawing the tool string.
Thus, the invention further comprises a method for treating a well. The method comprises first running a tool string down the well. The tool string comprises a conduit and a bottom hole assembly that includes an abrasive perforating tool. Once the bottom hole assembly has been positioned at the desired depth, fluid is passed through the tool string without perforating. The above-described perforating tool allows pressurized fluid flow prior to perforating to carry out other well procedures, or to operate other fluid-driven tool beneath the perforator in the bottom hole assembly, or both.
At the desired point in the well treatment process, that is, after passing fluid through the tool string without perforating, the well is abrasively perforated without withdrawing the tool string. This may be accomplished by dropping the first ball in the preferred perforating tool to divert fluid to the nozzles and changing the fluid to comprise an abrasive fluid.
After the perforating process is completed, the abrasive fluid is stopped and another suitable well treatment fluid continues to be passed through the tool string again after perforating and without withdrawing the tool string. This is accomplished by dropping the second ball in the above-described perforator to bypass the nozzles and resume flowing fluid through the outlet of the tool. Again, the above-described perforating tool allows pressurized fluid flow after perforating to carry out additional well procedures, or to operate other fluid driven tools beneath the perforator in the bottom hole assembly, or both.
As used herein, the terms “up,” “upward,” “upper,” and “uphole,” and similar terms refer only generally to the end of the drill string nearest the surface. Similarly, “down,” “downward,” “lower,” and “downhole” refer only generally to the end of the drill string furthest from the well head. These terms are not limited to strictly vertical dimensions. Indeed, many applications for the tool of the present invention include non-vertical well applications.
The contents of U.S. Pat. No. 8,066,059, entitled “Methods and Devices for One Trip Plugging and Perforating of Oil and Gas Wells,” issued on Nov. 29, 2011, and U.S. Pat. No. 8,448,700, entitled “Abrasive Perforator with Fluid Bypass,” issued on May 28, 2013, are incorporated herein by reference.
The embodiments shown and described above are exemplary. Many details are often found in the art and, therefore, many such details are neither shown nor described. It is not claimed that all of the details, parts, elements, or steps described and shown were invented herein. Even though numerous characteristics and advantages of the present invention have been described in the drawings and accompanying text, the description is illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of the parts, within the principles of the invention to the full extent indicated by the broad meaning of the terms. The description and drawings of the specific embodiment herein do not point out what an infringement of this patent would be, but rather provide an example of how to use and make the invention. Likewise, the abstract is neither intended to define the invention, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. Rather, the limits of the invention and the bounds of the patent protection are measured by and defined in the following claims.
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