The present disclosure relates to systems, assemblies, and methods for selectively diverting fluid flow in a downhole drilling environment.
In connection with the recovery of hydrocarbons from the earth, wellbores are generally drilled using a variety of different methods and equipment. According to one common method, a roller cone bit or fixed cutter bit is rotated against the subsurface formation to form the well bore. The rotating bit is suspended in the well bore by a tubular drill string. Drilling fluid is pumped through the drill string and discharged at or near the drill bit to assist in drilling operations. In some systems, the flow of drilling fluid through the drill string is altered by diverting a portion of the main flow and discharging the diverted portion from the drill string.
A drilling fluid supply system 20 includes one or more mud pumps 22 (e.g., duplex, triplex, or hex pumps) to forcibly flow drilling fluid (often called “drilling mud”) down through a flow passage of the drill string 14 (e.g., a central bore of the drill string). The drilling fluid supply system 20 may also include various other components for monitoring, conditioning, and storing drilling fluid. A controller 24 operates the fluid supply system 20 by issuing operational control signals to various components of the system. For example, the controller 24 may dictate operation of the mud pumps 22 by issuing operational control signals that establish the speed, flow rate, and/or pressure of the mud pumps 22.
The controller 24 is a computer system including a memory unit that holds data and instructions for processing by a processor. The processor receives program instructions and sensory feedback data from memory unit, executes logical operations called for by the program instructions, and generates command signals for operating the fluid supply system 20. An input/output unit transmits the command signals to the components of the fluid supply system and receives sensory feedback from various sensors distributed throughout the drilling rig 10. Data corresponding to the sensory feedback is stored in the memory unit for retrieval by the processor. In some examples, the controller 24 operates the fluid supply system 20 automatically (or semi-automatically) based on programmed control routines applied to feedback data from the sensors throughout the drilling rig. In some examples, the controller operates the fluid supply system 20 based on commands issued manually by a user.
The drilling fluid is discharged from the drill string 14 through or near the drill bit 19 to assist in the drilling operations (e.g., by lubricating and/or cooling the drill bit), and subsequently routed back toward the surface 18 through an annulus 26 formed between the wellbore 12 and the drill string 14. The re-routed drilling fluid flowing through the annulus 26 carries cuttings from the bottom of the wellbore 12 toward the surface 18. At the surface, the cuttings can be removed from the drilling fluid and the drilling fluid can be returned to the fluid supply system 20 for further use.
In the foregoing description of the drilling rig 10, various items of equipment, such as pipes, valves, fasteners, fittings, etc., may have been omitted to simplify the description. However, those skilled in the art will realize that such conventional equipment can be employed as desired. Those skilled in the art will further appreciate that various components described are recited as illustrative for contextual purposes and do not limit the scope of this disclosure. Further, while the drilling rig 10, is shown in an arrangement that facilitates straight downhole drilling, it will be appreciated that directional drilling arrangements are also contemplated and therefore are within the scope of the present disclosure.
The valve piston 108 is movable axially between an upper position (shown in
The valve piston 108 moves in response to pressure variations in the housing's bore 106. In particular, a pressure difference between the housing's bore 106 and the annulus 26 provides a net hydraulic pressure force bearing downward on the radial shoulder 116 of the valve piston 108. Accordingly, the valve piston 108 includes a series of radial openings 117 to expose the upper side of the shoulder 116 to drilling fluid (see
An increase in pressure caused by an increased flow rate (e.g., when the mud pumps 22 are activated) builds a hydraulic force that overcomes the upward spring force of the biasing member 114 and pushes the valve piston 108 in a downward direction. Conversely, a decrease in pressure caused by a decreased flow rate (e.g., when the mud pumps 22 are deactivated) weakens the hydraulic force, which allows the biasing member 114 to push the valve piston 108 back towards the upper position.
The barrel cam 110, further discussed below in conjunction with
The valve piston 108 actuates a valve body 130 adjustable between an open condition and a closed condition as the valve piston 108 moves. In particular, the valve body 130 is designed to assume an open condition when the valve piston 108 is in the lower position (see
Referring to
With the stationary pin 128 at position P1, the valve body 130 is in an open condition because the valve piston 108 is in the lower position. To reach position Pl, the valve piston 108, together with the barrel cam 110, is moved downward by hydraulic force into the lower position due to high pressure in the housing's bore 106 caused by operating the mud pumps 22 at a high flow setting. At this point, the mud pumps 22 are deactivated (or merely adjusted to an appropriately lower flow setting), which causes a pressure decrease in the bore of the housing 102. The decrease in hydraulic pressure force allows the biasing member 114 to “pull” the valve piston 108 towards the upper position, which moves the barrel cam 110 upwards relative to the stationary pin 128. This upward movement of the barrel cam 110 results in the stationary pin 128 moving to a lower position on the track path from position P1 to position P2. The axially upward movement of the barrel cam 110 from position P1 to position P2 represents a movement of the valve piston 108 from the lower position to the upper position—a full stroke of the valve piston 108. Thus, at position P2, the upper position of the valve piston 108, the valve body 130 is in a closed condition.
When the mud pumps 22 are reactivated to restore the high flow condition, the valve piston 108 is pushed downward. As the valve piston 108 bears on the barrel cam 110, the stationary pin 128 traverses the upward angled path of the slot 139 from position P2 to P3. Interaction between the pin 128 and the angled slot path causes a slight rotation of the barrel cam 110, and provides a dead-end to prevent further downward movement of the barrel cam 110, and therefore the valve piston 108. Thus, the valve piston 108 is prevented from traversing a full axial stroke from the upper position to the lower position. In this situation, the valve piston 108 is not moved downward enough to open the valve body 130; so the valve body 130 remains in the closed condition. When the mud pumps 22 are again deactivated, the barrel cam 110 is pulled upward (by result of the biasing member 114 pulling on the valve piston 108 and barrel cam 110 as discussed above) relative to the stationary pin 128, until the pin 128 arrives at position P4. The valve body 130 remains in the closed condition as the valve piston 108 is moved back to the upper position. When the mud pumps 22 are once again reactivated, the barrel cam 110 is pushed downward until the pin arrives at position P1. The axial movement from P4 to P1 allows the valve piston to execute a full stroke from the upper position to the lower position, adjusting the valve body 130 to the open condition. From position Pl, the cycle can be repeated.
In this example, a flow restrictor 250 is employed to retard the downward motion of the valve piston 208 and the barrel cam 210. As shown, the flow restrictor 250 is located in control fluid chamber 252 defined by an annulus between an inner surface of the housing 202 and outer surfaces of various components of the flow-diverter assembly 204 (e.g., the outer surfaces of the valve piston 208 and the barrel cam 210). In particular, the flow restrictor 250 is incorporated in the flange 218 supporting the biasing member 214 of the valve piston 208. The control fluid chamber 252 is sealed from the flow of drilling fluid at the upper end by the sealing engagement between the valve piston's radial shoulder 216. The flow restrictor 250 separates the control fluid chamber 252 into adjacent compartments and constricts the flow of control fluid (e.g., oil) between the compartments as the valve piston 208 moves to create a dampening effect. As described below, the retarded movement of the valve piston 208 and the barrel cam 210 allows a locking system 260 to activate, preventing further downward motion and therefore “locking” the valve body 230 in its present open/closed condition.
In this example, the locking system 260 features a locking piston 262 oriented oppositely from the valve piston 208. Thus, the locking piston 262 is urged downward by a biasing member 264, and urged upward by hydraulic pressure forces created by the flow of drilling fluid 1. As shown in
Movement between positions P1 and P2 is substantially identical to the previous example, with the exception that this example involves an angled path that causes a slight rotation of the barrel cam 210 independent of the valve piston 208. As described above, with the stationary pin 228 at position P1, the valve body 230 is in an open condition because the valve piston 208 is in the lower position. To reach position Pl, the valve piston 208, together with the barrel cam 210, is moved downward by hydraulic force into the lower position due to high pressure in the housing's bore 206 caused by operating the mud pumps 22 at a high flow setting. At this point, the mud pumps 22 are deactivated (or merely adjusted to an appropriately lower flow setting), which causes a pressure decrease in the bore of the housing 202, allowing the biasing member 214 to pull the valve piston 208 across a full stroke to the upper position, which moves the barrel cam 210 correspondingly upwards relative to the stationary pin 228. This upward movement of the barrel cam 210 results in the stationary pin 228 moving to a lower position on the track path from position P1 to position P2. Thus, at position P2, the upper position of the valve piston 208, the valve body 230 is in a closed condition.
When the mud pumps 22 are reactivated to restore the high flow condition, the valve piston 208 is pushed downward. As the valve piston 208 bears on the barrel cam 210, the stationary pin 228 traverses the upward angled path of the slot 239 from position P2 to P3. The flow restrictor 250 retards the downward motion of the valve piston 208 and the barrel cam 210, which allows the locking piston 262 to move upward to engage the coupler 222 to suspend the barrel cam 210 and the valve piston 208 in place with the stationary pin 228 at position P3. Being suspended at position P3 of the barrel cam 210, the valve piston 208 is prevented from traversing a full stroke to the lower position. In this situation, the valve piston 208 is not moved downward enough to open the valve body 230; so the valve body 230 remains in the closed condition. With the locking piston 262 activated, cycling the mud pumps 22 OFF and ON at the high flow rate will cause the barrel cam 210 and valve piston 208 to cycle between positions P2 and P3 (as illustrated in the graph 240).
To advance passed position P3, the mud pumps 22 must be deactivated, disengaging the locking piston 262 from the coupler 222, and then reactivated at a predetermined index flow rate. The index flow rate creates sufficient hydraulic pressure forces to overcome the spring force of the valve piston's biasing member 214, but not the locking piston's biasing member 264. This condition allows the valve piston 208 and the barrel cam 210 to move downward across a full stroke to position P4, without encountering the locking piston 262 to place the valve body 230 in an open condition.
When the mud pumps 22 are again deactivated, the barrel cam 210 is pulled upward relative to the stationary pin 228, until the pin 228 arrives at position P5. Note that the path from position P4 to P5 is short of a full stroke for the valve piston 208, leaving the valve body 230 in an open position. When the mud pumps 22 are once again reactivated at a high flow setting, the barrel cam 210 is pushed downward by the valve piston 208 until the stationary pin 228 arrives at position P6 where further downward movement is prevented by the locking piston 262. Thus, the valve body 230 is now locked in the open position. With the locking piston 262 activated, cycling the mud pumps 22 OFF and ON at the high flow rate will cause the barrel cam 210 and valve piston 208 to cycle between positions P5 and P6 (as illustrated in the graph 240).
To advance passed position P6, the mud pumps 22 must be deactivated, disengaging the locking piston 262 from the coupler 222, and then reactivated at the predetermined index flow rate. This condition allows the valve piston 208 and the barrel cam 210 to move downward back to the lower position, without encountering the locking piston 262. The valve body 230 remains in the open position throughout the movement from P6 to Pl. However, at position P1 the valve body 230 is unlocked and can move freely to the closed condition at position P2.
The use of terminology such as “upper,” “lower,” “above,” and “below” throughout the specification and claims is for describing the relative positions of various components of the system and other elements described herein. Unless otherwise stated explicitly, the use of such terminology does not imply a particular position or orientation of the system or any other components relative to the direction of the Earth gravitational force, or the Earth ground surface, or other particular position or orientation that the system other elements may be placed in during operation, manufacturing, and transportation.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the following claims.
Filing Document | Filing Date | Country | Kind |
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PCT/US2014/044911 | 6/30/2014 | WO | 00 |