DOWNHOLE TOOL WITH LONGITUDINALLY OFFSET FLUID PORTS

BACKGROUND

Downhole systems may be used to drill, service, or perform other operations on a wellbore in a surface location or a seabed for a variety of exploratory or extraction purposes. For example, a wellbore may be drilled to access valuable subterranean resources, such as liquid and gaseous hydrocarbons and solid minerals, stored in subterranean formations and to extract the resources from the formations. Wellbore drilling, remedial, or other operations may be performed using a variety of downhole tools, including those driven by, or which otherwise use, fluid flow therethrough. The fluid flowing through the downhole tools may flow through one or more bores or fluid conduits within the tool. For example, a progressive cavity pump may utilize fluid flow through the center of the tool to convert energy from the flowing fluid into rotational power that drives downhole rotation of a bit or other tool. In another example, a turbine or positive displacement motor may utilize flow through a set of turbine blades to create rotation and generate power to operate one or more tools.

In addition to flowing axially through portions of the tool, fluid may also flow radially toward or away from a longitudinal axis of the tool. For instance, a turbodrill may have a plurality of ports extending angularly to direct flow away from a radially offset fluid conduit toward the longitudinal axis of the tool and potentially into a central conduit. The central conduit may receive fluid from the ports and direct the fluid downward through the turbodrill toward a bit. In other cases, a tool may use ports to direct fluid away from a longitudinal axis and toward, or even out of, an outer radial surface of the tool.

SUMMARY

In some embodiments, a rotational tool includes a shaft, a housing enclosing at least a portion of the shaft, and one or more fluid conduits outside at least a portion of the shaft and the housing. The shaft includes a central conduit extending longitudinally through at least a portion thereof. First and second fluid ports provide fluid communication between the one or more fluid conduits and the central conduit. The second fluid port is longitudinally offset from the first fluid port.

In some further embodiments, a downhole tool includes a shaft having an outer surface and a longitudinal axis. The shaft has a central conduit extending longitudinally through a portion of the shaft and the central conduit has a central conduit flow area. The shaft includes a plurality of fluid ports extending radially between the central conduit and an outer surface of the shaft. A combined flow area of the plurality of fluid ports is between 50% and 120% the central conduit flow area. The plurality of fluid ports includes at least a first fluid port and a second fluid port, each having openings at the outer surface of the shaft, and which are longitudinally offset.

In yet additional embodiments, a downhole tool has an inner fluid conduit and one or more outer fluid conduits offset from a longitudinal axis and the inner fluid conduit. The inner fluid conduit extends longitudinally through a portion of a shaft that has an outer surface. A first fluid port, a second fluid port, and a third fluid port each provide fluid communication between the inner fluid conduit and the one or more outer fluid conduits. The first fluid port, second fluid port, and third fluid port each have an opening at the outer surface of the shaft. The openings of the first, second, and third fluid ports do not longitudinally overlap one another and are angularly offset.

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Additional features of embodiments of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such embodiments. The features of such embodiments may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such embodiments as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1-1 is a schematic representation of a conventional fluid port configuration in a downhole tool, according to some embodiments of the present disclosure;

FIG. 1-2 is a schematic representation of fluid flowing within tool of FIG. 1-1;

FIG. 2 is a cross-sectional view of a downhole tool having a longitudinally offset fluid port configuration, and showing fluid flow therethrough, according to some embodiments of the present disclosure;

FIG. 3-1 is a side view of a shaft of a downhole tool, the shaft including a longitudinally and angularly offset fluid port configuration, according to some embodiments of the present disclosure;

FIG. 3-2 is another side view of the shaft of FIG. 3-1, illustrating relative longitudinal offsets of the fluid ports and the openings thereof, according to some embodiments of the present disclosure;

FIG. 4-1 is a partial side cutaway view of a downhole tool having a longitudinally and angularly offset fluid ports extending from longitudinal slots within the downhole tool, according to some embodiments of the present disclosure;

FIG. 4-2 is an perspective view of the downhole tool of FIG. 6-2, according to some embodiments of the present disclosure;

FIG. 5 is a partial side cutaway view of a downhole tool having a longitudinally and angularly offset fluid ports extending from longitudinal and radial slots within the downhole tool, according to some embodiments of the present disclosure;

FIG. 6 schematically illustrates an end cross-section of a downhole tool having offset fluid ports extending in a radial path from a central conduit, according to some embodiments of the present disclosure;

FIG. 7 schematically illustrates an end cross-section of a downhole tool having offset fluid ports extending in a variety of radial paths from a central conduit, according to some embodiments of the present disclosure; and

FIG. 8 is a cross-sectional view of an embodiment of a coupling having longitudinally offset fluid ports, according to some embodiments of the present disclosure.

DETAILED DESCRIPTION

Some embodiments of this disclosure generally relate to devices, systems, and methods for directing fluid flow between one or more outer fluid conduits and one or more inner fluid conduits in a downhole tool. While the present disclosure may describe embodiments in which the fluid flow through may pass through a downhole motor such as a positive displacement motor or turbine-driven motor, it should be understood that such fluid flow may be utilized in other tools, including downhole tools and tools outside a downhole industry. For example, such flow may be used in rotary steerable systems, generators, measurement-while-drilling tools, logging-while-drilling tools, milling tools, drill bits, vibration tools, reamers, reverse circulation drilling tools, tubulars, couplings, bypass valves, machining tools, other tools, or combinations of the foregoing. While the present disclosure may describe example embodiments in which the fluid flow from one or more angularly offset conduits flows toward a central conduit or axis of a downhole tool, it should be understood that additional or other embodiments of the present disclosure contemplate fluid ports used to allow fluid flow away from a central conduit or axis using one or more angularly offset conduits.

FIG. 1-1 depicts an embodiment of a downhole tool 100, such as a turbodrill or other turbine-driven motor or tool, in a wellbore 102. The downhole tool 100 may include a shaft 104 having one or more fluid ports 106 therein. The fluid ports 106 provide fluid communication between fluid conduits 108 and 110. In the illustrated embodiment, the fluid conduits 108 may be outer fluid conduits and the fluid conduit 110 may be an inner fluid conduit 110. In particular, the fluid conduit 110 may be nearer (or even centered along) a longitudinal axis 115, while one or more fluid conduits 108 may be radially outward and farther from the longitudinal axis 115. In some embodiments, the fluid conduit 108 may be an annular conduit extending around at least a portion of the shaft 104 or other component, and thee fluid conduit 110 may be a central conduit extending through a portion of the shaft 104. The fluid ports 106 may be distributed angularly (e.g., circumferentially) about the shaft 104, and may provide fluid communication between the conduits 108 as 110 as the shaft 104 rotates about the longitudinal axis 115. In some embodiments, a fluid 112 may flow through the downhole tool 100 (e.g., through one or more turbines 114) to cause the shaft 104 to rotate. The fluid 112 may be a drilling fluid, such as an oil-based drilling mud, a water-based drilling mud, or other drilling fluid or mud.

As shown in FIG. 1-2, the radially offset conduit 108 may carry the fluid 112 through the downhole tool 100 (e.g., in a downhole direction) and the fluid ports 106 may direct the fluid 112 from the annular fluid conduit 108 into the central fluid conduit 110. The plurality of fluid ports 106 may be longitudinally aligned. For instance, each of the fluid ports 106 may begin at the same, first longitudinal position around the outside of the shaft 106, and terminate at the same, second longitudinal position inside the shaft 104 (e.g., at the fluid conduit 110). In some embodiments, the longitudinal overlap of the fluid ports 106 reduces the strength of the shaft 104 in the region having the fluid ports 106. In particular, the fluid ports 106 may limit the amount of material (e.g., steel, titanium, aluminum, composite, etc.) that may be used in the shaft 104 around the circumference of the shaft 104 at the location of the fluid ports 106, and between the fluid conduits 108 and 110. The shaft 104 may transmit torque generated by the turbine 114 or other component, and the reduced amount of material may reduce the strength in the shaft 104 along the longitudinal portion of the shaft 104 where the fluid ports 106 are located. The reduction in strength due to the presence of the fluid ports 106, in combination with the torque levels to be placed on the shaft 104, may also place a limit on the size of the fluid ports 106 and the volume or cross-sectional area that any single port may have within the shaft 104. The limited size of the fluid ports may also cause a pressure drop upon exit of fluid 112 from the fluid ports 106 (i.e., fluid pressure is higher entering the fluid ports 106 than exiting the fluid ports 106).

FIG. 2 is a schematic embodiment of a downhole tool 200 including a shaft 204 according to some embodiments of the present disclosure. As discussed herein, the downhole tool 200 may include a turbodrill, turbine motor, positive displacement motor, another tool, some component thereof, or any combination of the foregoing. The shaft 204 may include longitudinally spaced and offset fluid ports 216, 218, 220. In some embodiments, the shaft 204 may include a first fluid port 216 in a downhole position (e.g., nearer to a downhole end of the downhole tool 200), a second fluid port 218 in an intermediate position (e.g., between a downhole end and an uphole end of the downhole tool 200), and a third fluid port 220 in an uphole position (e.g., nearer to an uphole end of the downhole tool 200). In other embodiments, the shaft 204 may include more than three fluid ports that may be located in more than three positions. In yet other embodiments, the shaft 204 may include two fluid ports.

The first fluid port 216 may be located in a first port region 222. For example, the first fluid port 216 may extend through the shaft 204 at a first port angle 217 relative to the longitudinal axis 215 of the shaft 204. The first fluid port 216 may have a first end portion 223 that meets a central fluid conduit 210, and may extend longitudinally uphole to a second end portion 225 that meets an annular fluid conduit 208 around at least a portion of the shaft 204. The longitudinal region between the first and second end portions 223, 225 of the first fluid port 216 may define the first port region 222.

The second fluid port 218 may be located in a second port region 224, and may extend through the shaft 204 at a second port angle 219. The second fluid port 218 may have a first end portion 227 that meets the central conduit 210, and may extend longitudinally uphole to a second end portion 229 that meets the annular fluid conduit 208. The longitudinal region between the first and second end portions 227, 229 of the second fluid port 218 may define the second port region 224.

The third fluid port 220 may be located in a third port region 226, and may extend through the shaft at a third port angle 221. The third fluid port 220 may have a first end portion 231 that meets the central conduit 210, and may extend longitudinally uphole to a second end portion 233 that meets the annular fluid conduit 208. The longitudinal region between the first and second end portions 231, 233 of the third fluid port 220 may define the third port region 226.

In some embodiments, the first port region 222, the second port region 224, and the third port region 226 may be longitudinally offset such that there is no longitudinal overlap (e.g., no portion of one port region is located at a same longitudinal location as any portion of another port region) between the first port region 222, the second port region 224, and the third port region 226. In other embodiments, one or more of the first port region 222, the second port region 224, or the third port region 226 may partially, longitudinally overlap with one of the other port regions (e.g., a portion of one port region is longitudinally aligned with a portion of another port region). In yet other embodiments, at least a portion of each of the first port region 222, the second port region 224, and the third port region 226 may longitudinally overlap with at least a portion of one of the other port regions. In still further example embodiments, there may be full overlap of each of the first, second, and third port regions 222, 224, 226 (see FIG. 1-1).

In some example embodiments, the first port region 222 may longitudinally overlap the second port region 224. For instance, relative to the total length of the first port region 222, the amount of overlap may be within a range having lower and/or upper values including any of 1%, 10%, 25%, 40%, 50%, 60%, 75%, 90%, or any value therebetween. For example, between 1% and 90% of the first port region 222 may longitudinally overlap the second port region 224. In other embodiments, between 5% and 80% of the first port region 222 may longitudinally overlap the second port region 224. In yet another embodiment, the between 10% and 60% of the first port region 222 may longitudinally overlap the second port region 224. In still other embodiments, less than 1% or greater than 90% of the first port region 222 may longitudinally overlap the second port region 224. The overlap between the first and second port regions 222, 224 is illustrative, and similar a similar overlap may occur between the second and third port regions 224, 226. The overlap between the first and second port regions 224, 226 may be the same as, or different than, the overlap between the second and third port regions 226, 228.

In some embodiments, the first fluid port 216 may be angled relative to the longitudinal axis 215 of the shaft 204. The first fluid port 216 may form the first port angle 217, which may be in a range having lower and/or upper values including any of 10°, 30°, 45°, 60°, 80°, 90°, or any value therebetween. For example, the first port angle 217 may be between 10° and 90°. In another example, the first fluid port 216 may be between 20° and 80°. In yet another example, the first port angle 217 may be between 40° and 70°. In other examples, the first port angle 217 may be less than 10° or greater than 90°. The second and third port angles 219, 221 may be angled relative to the longitudinal axis 215 of the shaft 204 in a similar manner as the first port angle 217, and may therefore also be within the ranges discussed for the first port angle 217.

In some embodiments, at least two of the port angles 217, 219, 221 may be equal. For example, the first port angle 217 may be 60°, the second port angle 219 may be 60°, and the third port angle 221 may be 45°. In other embodiments, each of the port angles 217, 219, 221 may be equal. For example, the port angles 217, 219, 221 may each be 60°. In yet other embodiments, each of the port angles 217, 219, 221 may be different. For example, the first port angle 217 may be 40°, the second port angle 219 may be 50°, and third port angle 221 may be 60°.

In FIG. 2, the first fluid port 216 and the second fluid port 218 are depicted as being positioned opposite one another (i.e., angularly offset by 180°, and the second fluid port 218 and third fluid port 220 positioned opposite one another. The first and third fluid ports 216, 220 are shown as being longitudinally offset, but at the same angular orientation (i.e., an angular offset of 0°. In other embodiments, however, a shaft may have fluid ports distributed at other angular intervals. For instance, three fluid ports may be distributed at 60° angular intervals, four fluid ports may be distributed at 45° angular intervals, or fluid ports may be at other equal or unequal angular intervals. In some examples, the shaft 204 may therefore include more or fewer fluid ports than the three depicted in FIG. 2, in which case, the fluid ports may be angularly spaced about the shaft 204 such that each fluid port has an equal angular interval therebetween. In yet another example, one or more of the fluid ports may be angularly aligned with at least one other fluid port. In another example, the fluid ports may be angularly spaced at unequal intervals.

FIGS. 3-1 and 3-2 are side views of an embodiment of a shaft 304 that may include a plurality of fluid ports 316, 318, 320 extending from a central conduit 310. The fluid ports 316, 318, 320 may be distributed longitudinally along the shaft 304 and at equal angular intervals about the shaft 304. For example, a first fluid port 316 may extend from the central conduit 310 and be angularly offset at a 120° angle relative to a second fluid port 318 and the third fluid port 320 (e.g., about a longitudinal axis 315 from the second and third fluid ports 318, 320). The second fluid port 318 may be angularly offset at a 120° angle relative to a first and third fluid ports 320.

As shown in FIG. 3-2, the first fluid port 316 may be positioned at and define a first port region 322, while the second fluid port 318 may be positioned at and define a second port region 324 and the third fluid port 320 may be positioned at and define a third port region 326. The first port region 322 may include a first internal port region 328 and a first external port region 330. For example, the first internal port region 328 may include the longitudinal portion of the shaft 304 that includes the part of the first fluid port 316 within the shaft 304, and may not include the longitudinal portion of the shaft 304 defined by the opening of the first fluid port 316 on an external surface of the shaft 304, which would be included in the first external port region 330. Collectively, the first internal port region 328 and the first external port region 330 define a fluid conduit that provides fluid communication between the central conduit 310 of the shaft 304 and the surrounding space around the shaft 304.

A first port ratio may defined between the longitudinal length of the first internal port region 328 and the longitudinal length of the first external port region 330. In some embodiments, the first internal port region 328 may be stronger in torque applications than the first external port region 330. The first port ratio may, therefore, describe the relative longitudinal size of the open portion of the first fluid port to the longitudinal size of the closed portion of the first fluid port. For example, a first port ratio that is greater than 1:1 may describe a first fluid port 316 having a majority of the first fluid port 316 within the shaft 304 and longitudinally displaced from the position of the opening or mouth of the first fluid port 316. In some embodiments, the first port ratio may be increased by increasing the cross-sectional size (e.g., diameter) of the first fluid port 316 and/or decreasing the cross-sectional size of the opening to the first fluid port 316. In other embodiments, the first port ratio may be increased by increasing the first port angle (e.g., as described in relation to FIG. 2) of the first fluid port 316.

The second fluid port 318 may be positioned at and define a second port region 324. The second port region 324 may include a second internal port region 332 and a second external port region 334, which may be defined similarly to the first internal and external port regions 332, 334. The third fluid port 320 may be positioned at and define a third port region 326. The third port region 326 may include a third internal port region 336 and a third external port region 338, which may be defined similarly to the first internal and external port regions 332, 334.

As described herein, in some embodiments, at least some of the first port region 322 may longitudinally overlap at least some of the second port region 324. In other embodiments, at least some of the second port region 324 may longitudinally overlap at least some of the third port region 326. In some embodiments, at least some of the first external port region 330 may longitudinally overlap at least some of the second internal port region 332, and the first external port region 330 may not overlap the second external port region 334. In other embodiments, at least some of the second external port region 334 may longitudinally overlap at least some of the third internal port region 336 and the second external port region 334 may not overlap the third external port region 338. In some embodiment, longitudinal spacing between at least the external port regions may increase the rotational strength and torque capacity of the shaft 304 over a shaft having fluid ports located at the same longitudinal position.

The embodiments of a shaft 304 depicted in FIGS. 3-1 and 3-2 may be utilized in a rotating tool, such as a turbodrill, mud motor, or other downhole tool. In some embodiments, the shaft 304 may be used to couple together any combination of one or more shafts, tubular members, or other downhole tools. In such an embodiment, longitudinally offset fluid conduits may be positioned in the coupling, in the downhole tools, or in a combination thereof. For instance, a first tubular member or other downhole tool may have one or more annular fluid conduits and may be coupled to a second tubular member or other downhole tool having a central conduit. For example, an uphole end portion of the shaft 304 may couple to a downhole tool that has one or more outer or annular fluid conduits, and a downhole end portion of the shaft 304 may couple to a downhole tool having a central fluid conduit. In another example, the shaft 304 may be inverted from the perspective shown in FIGS. 3-1 and 3-2 and may be coupled at an uphole end of the shaft 304 to a downhole tool that has a central conduit, and to a downhole tool on the downhole end portion that has one or more radially outward or even annular fluid conduits. In some embodiments, the shaft 304 may be tubular with a bore extending fully therethrough, while in other embodiments the shaft 304 may be solid along at least a portion thereof.

While the embodiments depicted in FIG. 2 through FIG. 3-2 include a shaft having parallel lateral sides (e.g., a cylindrical shaft), a shaft according to the present disclosure may have other shapes, such as a tapered portion. As shown in the partial cutaway of FIG. 4-1, some embodiments of a turbodrill 400 may include one or more fluid ports located on a tapered shaft 404. In some embodiments, a first fluid port 416, second fluid port 418, and third fluid port (not shown due to the cut-away view) may be located downhole from the one or more fluid conduits 408 that are radially offset from a longitudinal axis 415. In some embodiments, the one or more fluid conduits 408 may be at least partially defined by a space between the shaft 404 and a housing 440 of the turbodrill 400 or other tool. For example, an annular space between a tapered surface 445 of the shaft 404 and the housing 440 may direct fluid flow downhole or uphole and toward a plurality of slots in the shaft 404. The shaft 404 and the housing 440 may rotate relative to one another and the slots may maintain fluid communication with the annular space and, therefore, the one or more fluid conduits 408.

In some embodiments, one or more of the fluid ports may have an associated fluid slot. For example, the shaft 404 depicted in FIG. 4-1 includes a first fluid slot 442 that provides fluid flow path between the one or more fluid conduits 408 and the first fluid port 416. The shaft 404 may include a second fluid slot 444 that provides a flow path between the one or more radially offset fluid conduits 408 and the second fluid port 418. The shaft 404 may include a third fluid slot (not shown) that provides a flow path between the one or more radially offset fluid conduits 408 and the third fluid port. In some embodiments, the first fluid slot 442 and second fluid slot 444 may provide a flow path and facilitate fluid communication with the first fluid port 416 and second fluid port 418, respectively, while allowing the first fluid port 416 and second fluid port 418 to be longitudinally offset, according to at least some embodiments of the present disclosure.

FIG. 4-2 is a perspective view of the embodiment of the shaft 404 of FIG. 4-1 without the housing 440. The first fluid port 416 and second fluid port 418 may be angularly offset 120° or some other amount from one another. The first fluid slot 442 may extend longitudinally between the first fluid port 416 and a tapered surface 445 of the shaft 404, and the second fluid slot 444 may extend longitudinally between the second fluid port 418 and the tapered surface 445. The first and second fluid slots 442, 444 may, thereby, provide or increase fluid communication between a fluid conduit at least partially bounded by the tapered surface 445 (e.g., an annular or external fluid conduit) and the central conduit 410 of the shaft 404.

FIG. 4-2 further illustrates the plurality of fluid slots 442, 444 extending in a longitudinal direction that is about parallel to the longitudinal axis 415 of the shaft 404. In other embodiments, one or more fluid slots may be angled, curved, circumferential, or otherwise non-parallel to the longitudinal axis 415, or may have combinations of the foregoing features. FIG. 5 illustrates another embodiment of a turbodrill 500 having a shaft 504 with one or more fluid slots that are non-parallel relative to a longitudinal axis 515. In some embodiments, a first fluid port 516 may have an associated first fluid slot 542 and a second fluid port 518 may have an associated second fluid slot 544. The first fluid slot 542 and second fluid slot 544 are optionally parallel to one another. In other embodiments, the first fluid slot 542 and second fluid slot 544 may be non-parallel with respect to one another. For example, the first fluid slot 542 may be parallel to the longitudinal axis 515 and the second fluid slot 544 may have at least a portion that is curved and/or inclined relative to the longitudinal axis 515 such that at least a portion of the second fluid slot 544 is non-parallel to the longitudinal axis 515.

In some embodiments, one or more of the fluid slots may be angled, curved, otherwise oriented in a non-parallel manner relative to the longitudinal axis 515, or have combinations of the foregoing, in a rotational direction relative to the longitudinal axis 515 (e.g., clockwise or counterclockwise about the longitudinal axis 515). Such orientation may urge fluid flow through the fluid slot during operation and rotation of the turbodrill 500 or other downhole tool. The second fluid slot 544 may be angled or otherwise oriented in a counterclockwise direction when viewed from an uphole position oriented downhole (i.e., the rotation vector of the shaft 504 is oriented in a downhole direction). In other words, the second fluid slot 544 may extend in a clockwise direction uphole and away from the second fluid port 518.

The rotational orientation of the second fluid slot 544 shown in FIG. 5 may urge fluid downhole when the shaft 504 rotates in a clockwise direction about the longitudinal axis 515, when viewed from an uphole position oriented downhole (i.e., the rotation vector of the shaft 504 is oriented in a downhole direction). The movement of the angled second fluid slot 544 may cause the second fluid slot 544 to apply a downhole force on uphole fluid and force or draw the fluid into the second fluid port 518. While the second fluid slot 544 is described as being oriented to urge fluid into the second fluid port 518, it should be understood that any or each of the fluid ports on a shaft may include a fluid slot configured to urge fluid therethrough. For example, the first fluid slot 542 may be oriented non-parallel relative to the longitudinal axis 515 and may urge fluid into the first fluid port 516.

In some embodiments, the orientation of the fluid slots may include an angular displacement 546 of the fluid slot (e.g., second fluid slot 544 in FIG. 5) and/or a slot angle 548 relative to the longitudinal axis 515. The angular displacement 546 of a fluid slot may be the angular interval the fluid slot extends around the circumference of the shaft 504 relative to the longitudinal axis 515, and potentially between an uphole end and a downhole end for the fluid slot. For example, a fluid slot that is parallel to the longitudinal axis 515 may have an angular displacement 546 of 0°. In some embodiments, the angular displacement 546 may be in a range having lower and/or upper values including any of 0°, 20°, 45°, 70°, 90°, 135°, 180°, 270°, 360°, or any value therebetween. For example, the angular displacement 546 may be between 1° and 360°. In another example, the angular displacement 546 may be between 5° and 180°. In yet another example, the angular displacement 546 may be between 10° and 90°. In still other embodiments, the angular displacement 546 may be greater than 360°.

In some embodiments, the angular displacement 546 may be the same for each fluid slot on the shaft 504. In other embodiments, at least two of the fluid slots may have angular displacements 546 that are different. For example, the angular displacement 546 may be greater for a fluid port that is farther from the one or more radially offset conduits 508 (e.g., a longitudinally longer fluid slot) than a fluid port that is closer to the one or more radially offset (e.g., a longitudinally shorter fluid slot). For example, the angular displacement of the first fluid slot 542 may be greater than the angular displacement of the second fluid slot 544, or vice versa.

The slot angle 548 may affect the amount of force that the fluid slot applies to a fluid during rotation of the shaft 504. For example, a greater slot angle 548 relative to the longitudinal axis 515 may allow the fluid slot to apply a greater force during rotation. For example, a fluid slot having a slot angle of 0° may be parallel to the longitudinal axis 515. In some embodiments, the slot angle 548 may be constant along a fluid slot (e.g., a straight or linear fluid slot). In other embodiments, the slot angle 548 may change along a length of a fluid slot (e.g., a curved fluid slot). In some embodiments, the slot angle 548 may be in a range having lower and/or upper values including any of 0°, 15°, 30°, 45°, 60°, or any value therebetween. For example, the slot angle 548 may between 1° and 60°. In another example, the slot angle 548 may be between 5° and 50°. In yet another example, the slot angle 548 may be between 10° to 40°. In still other examples, the slot angle 548 may be greater than 60°.

Referring now to FIGS. 6 and 7, embodiments of a tool according to embodiments of the present disclosure are schematically shown in cross-section, with fluid ports depicted in a single plane to show some example rotational positions of the fluid ports. It should be understood that the fluid ports depicted in FIG. 6 and FIG. 7 may have various longitudinal spacing as described herein. FIG. 6 illustrates a shaft 604 and housing 640 that define an annular fluid conduit 608 that is radially offset from a central fluid conduit 610. A first fluid port 616, second fluid port 618, and third fluid port 620 may provide fluid communication between the fluid conduits 608, 610.

The embodiment of the shaft 604 shown in FIG. 6 is circular in the illustrated, transverse cross-section, while in other embodiments, the shaft 604 may have other cross-sectional shapes, such as square, octagonal, other polygonal, elliptical, irregular, or combinations thereof The shaft 604 may have an outer surface 650 that is in contact with the fluid conduit 608. The quantity of fluid that may pass through the first fluid port 616, second fluid port 618, third fluid port 620, or combinations thereof, may be at least partially dependent upon a first flow area 652, a second flow area 654, and a third flow area 656, respectively. Each flow area 652, 654, 656 may be the area of the flow port in a direction perpendicular to the flow of fluid therethrough. In some embodiments, a flow area may be constant for a fluid port. For example, a flow area at or near the outer surface 650 may be the same as a flow area at or near the central conduit 610. In other embodiments, a flow area may change along a length of a fluid port. As used herein, and unless otherwise specified, the flow area of a fluid port should be understood to refer to the smallest flow area of the flow port.

Fluid ports according to some embodiments of the present disclosure are depicted as being circular in cross-sectional shape. In other embodiments, a fluid port may have other cross-sectional shapes, such as square, octagonal, other polygonal, elliptical, irregular, or combinations thereof. In some embodiments, a fluid port may have a cross-sectional shape that may change along a length thereof. For example, a fluid port may be flared and circular near the outer surface 650 and may be square at or near the central conduit 610.

In some embodiments, the first flow area 652, second flow area 654, and third flow area 656 may be equal. In other embodiments, at least two of the first flow area 652 second flow area 654, and third flow area 656 may be different from each other. For example, the first flow area 652 may be greater than the second flow area 654 and/or the third flow area 656. In another example, the first flow area 652 and second flow area 654 may both be larger than the third flow area 656. In another embodiment, each flow area 652, 654, 656 may be different.

The combined flow area of the fluid ports may be at least partially dependent on a flow area of the fluid conduit 608 (e.g., inlet flow) and/or a flow area of the central fluid conduit 610 (e.g., outlet flow). In some embodiments, the combined flow area of the fluid ports (sum of first flow area 652, second flow area 654, and third flow area 656) may be a percentage of the flow area of the central conduit 610 in range having lower and/or upper values including any of 25%, 50%, 75%, 90%, 100%, 110%, 120%, or any value therebetween. For example, the combined flow area of the fluid ports may be between 50% and 120% of the flow area of the central fluid conduit 610. In another example, the combined flow area of the fluid ports may be between 60% and 110% of the flow area of the central fluid conduit 610. In yet another example, the combined flow area of the fluid ports may be between 70% and 100% the flow area of the central fluid conduit 610.

In some embodiments, the first fluid port 616, second fluid port 618, and third fluid port 620 may extend radially from the outer surface 650 to the central fluid conduit 610 along a linear path that is perpendicular to the longitudinal axis 615. In other embodiments, the first fluid port 616, second fluid port 618, and third fluid port 620 may extend radially from the outer surface 650 to the central fluid conduit 610 along a linear path that is inclined and non-perpendicular relative to the longitudinal axis 615. Such linear path may include a longitudinal component. As described herein, the angular and/or rotational path of the first fluid port 616, second fluid port 618, and third fluid port 620 may be radial with no angular displacement (i.e., no rotation about the shaft 604).

FIG. 7 illustrates an embodiment of a shaft 704 having fluid ports that extend radially from a central conduit 710 to an outer surface 750 along a path that has an angular displacement. Accordingly, such paths between the central conduit 710 and the outer surface 750 may include an angular or rotational component relative to a longitudinal axis 715 of the shaft 704. For example, a first fluid port 716 may be a curved fluid port that spirals outward from the central conduit 710 and may have an angular displacement. In another example, a second fluid port 718 may be a curved fluid port that follows a path that does not intersect the longitudinal axis 715 of the shaft 704. In yet another example, a third fluid port 720 may be a non-curved, linear fluid port that has a non-zero angular displacement, and which optionally does not intersect the longitudinal axis 715 of the shaft 704. The shaft 704 may have any combination of the foregoing fluid ports and any number of fluid ports. In some embodiments, the shaft 704 may have fluid ports that are each curved or are each liner in the cross-sectional view. In other embodiments, the shaft 704 may have a combination of curved and linear fluid ports. In yet other embodiments, the shaft 704 may have fluid ports with paths that intersect the longitudinal axis 715, do not intersect the longitudinal axis 715, or combinations thereof. In yet further embodiments, the shaft 704 may have fluid ports that follow a radial path, a linear path, a curved path, a longitudinal path, an angular/circumferential path, or combinations thereof.

In some embodiments, a fluid port having a port rotation angle, or angular interval, that is measured from a first angular position of a first end portion of the fluid port at the central conduit to a second angular position of a second end portion of the fluid port at the outer surface 750 of the shaft 704. For example, the first fluid port 716 may have a first port rotation angle 758, the second fluid port 718 may have a second port rotation angle 760, and the third fluid port 720 may have a third port rotation angle 762. The first port rotation angle 758, second port rotation angle 760, and third port rotation angle 762 may be in a range having lower and/or upper values including any of 0°, 15°, 25°, 45°, 65°, 75°, 90°, or any value therebetween. For example, one or more of the port rotation angles 758, 760, 762 may be between 1° and 90°. In another example, one or more of the port rotation angles 758, 760, 762 may be between 5° and 80°. In yet another example, one or more of the port rotation angles 758, 760, 762 may be between 10° and 60°.

FIG. 8 depicts another shaft 804 according to some embodiments of the present disclosure. The shaft 804 may be configured to couple at least two downhole components and optionally to direct fluid between components that may be otherwise incompatible regarding fluid conduits. For example, the shaft 804 may couple a solid or non-tubular component 864 to a tubular component 866, and may direct fluid from an exterior 868 of the non-tubular component 864 to a fluid conduit 870 within the tubular component 866. The shaft 804 may include a plurality of fluid ports, such as a first fluid port 816 and a second fluid port 818, as shown in FIG. 8. The fluid ports 816, 818 may be configured to direct a fluid radially between an outer surface 850 of the shaft 804 (which may be in fluid communication with the exterior 868 of the non-tubular component 864), and a central conduit 810, which may be in fluid communication with the fluid conduit 870 of the tubular component 866. Fluid may flow radially outward (i.e., from the fluid conduit 870, through the fluid ports 816, 818 and to the outer surface 850) or radially inward (i.e., from the outer surface 850, through the fluid ports 816, 818, and to the fluid conduit 870).

In some embodiments, the shaft 804 may have a first connection feature 872 and/or a second connection feature 874 that allows the shaft 804 to be coupled to the non-tubular component 864 and/or to the tubular component 866. It should be understood that the non-tubular component 864 may be considered non-tubular or solid insofar as it may not include a fluid conduit co-axially aligned with a longitudinal axis 815 or in communication with the fluid conduit 870; however, the non-tubular component 864 may include other recesses, openings, passageways, apertures, etc. as desired for the operation and use of the non-tubular component 864. For example, the non-tubular component 864 may be a downhole tool, as described herein, that utilizes or routes fluid flow through one or more radially outward fluid conduits and not through a central conduit. The non-tubular component may, however, have other or additional internal components.

In some embodiments, the first connection feature 872 and/or second connection feature 874 may be a threaded connection, such as the threaded box connections shown in FIG. 8, although other suitable connection features may be used to rotationally and/or axially fix the components. For instance, a connection may rotationally fix the shaft 804 to the non-tubular component 864 and/or the tubular component 866 such that they rotate together to transmit torque through the first connection feature 872 and/or second connection feature 874. In other embodiments, the first connection feature 872 and/or second connection feature 874 may be rotatable connection, for example, including an annular bearing such that the shaft 804 may rotate relative to the non-tubular component 864 and/or the tubular component 866.

When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Terms such as “may,” “optional,” and the like, indicate that features are included in some embodiments, but may be excluded in other embodiments. It should be understood that any directions or reference frames are merely relative directions or movements. For example, any references to “up” and “down” or “above” and “below” are merely descriptive of the relative position or movement of the related elements.

While embodiments of rotational tools have been primarily described with reference to wellbore operations, the rotational tools described herein may be used in applications other than the drilling or remediation of a wellbore. In other embodiments, rotational tools according to the present disclosure may be used outside a wellbore or other downhole environment used for the exploration or production of natural resources. For instance, rotational tools of the present disclosure may be used in a borehole used for placement of utility lines. In other examples, rotational tools of the present disclosure may be used in wireline applications, maintenance applications, manufacturing applications, marine applications, or aerospace applications. Accordingly, the terms “wellbore,” “borehole,” and the like should not be interpreted to limit tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

Any element described in relation to an embodiment or a figure herein may be combinable with any element of any other embodiment or figure described herein. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value. Where various values for ranges are included, any two values are intended to be usable as lower and upper limits of a range, or any value may be used as a limit for an open-ended range. Values between specifically recited values are also contemplated as endpoints for a range. The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.

A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.

The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. Changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

DOWNHOLE TOOL WITH LONGITUDINALLY OFFSET FLUID PORTS

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