This disclosure relates to a system and method for excavating a formation, such as to form a well bore for the purpose of oil and gas recovery, to construct a tunnel, or to form other excavations in which the formation is cut, milled, pulverized, scraped, sheared, indented, and/or fractured, (hereinafter referred to collectively as “cutting”). The cutting process is a very interdependent process that preferably integrates and considers manly variables to ensure that a usable bore is constructed. As is commonly known in the art, many variables have an interactive and cumulative effect of increasing cutting costs. These variables may include formation hardness, abrasiveness, pore pressures, and formation elastic properties. In drilling wellbores, formation hardness and a corresponding degree of drilling difficulty may increase exponentially as a function of increasing depth. A high percentage of the costs to drill a well are derived from interdependent operations that are time sensitive, i.e., the longer it takes to penetrate the formation being drilled, the more it costs. One of the most important factors affecting the cost of drilling a wellbore is the rate at which the formation can be penetrated by the drill bit, which typically decreases with harder and tougher formation materials and formation depth.
There are generally two categories of modern drill bits that have evolved from over a hundred years of development and untold amounts of dollars spent on the research, testing and iterative development. These are the commonly known as the fixed cutter drill bit and the roller cone drill bit. Within these two primary categories, there are a wide variety of variations, with each variation designed to drill a formation having a general range of formation properties. These two categories of drill bits generally constitute the bulk of the drill bits employed to drill oil and gas wells around the world.
Each type of drill bit is commonly used where its drilling economics are superior to the other. Roller cone drill bits can drill the entire hardness spectrum of rock formations. Thus, roller cone drill bits are generally run when encountering harder rocks where long bit life and reasonable penetration rates are important factors on the drilling economics. Fixed cutter drill bits, on the other hand, are used to drill a wide variety of formations ranging from unconsolidated and weak rocks to medium hard rocks.
In the case of creating a borehole with a roller cone type drill bit, several actions effecting rate of penetration (ROP) and bit efficiency may be occurring. The roller cone bit teeth may be cutting, milling, pulverizing, scraping, shearing, sliding over, indenting, and fracturing the formation the bit is encountering. The desired result is that formation cuttings or chips are generated and circulated to the surface by the drilling fluid. Other factors may also affect ROP, including formation structural or rock properties, pore pressure, temperature, and drilling fluid density. When a typical roller cone rock bit tooth presses upon a very hard, dense, deep formation, the tooth point may only penetrate into the rock a very small distance, while also at least partially, plastically “working” the rock surface.
One attempt to increase the effective rate of penetration (ROP) involved high-pressure circulation of a drilling fluid as a foundation for potentially increasing ROP. It is common knowledge that hydraulic power available at the rig site vastly outweighs the power available to be employed mechanically at the drill bit. For example, modern drilling rigs capable of drilling a deep well typically have in excess of 3000 hydraulic horsepower available and can have in excess of 6000 hydraulic horsepower available while less than one-tenth of that hydraulic horsepower may be available at the drill bit. Mechanically, there may be less than 100 horsepower available at the bit/rock interface with which to mechanically drill the formation.
An additional attempt to increase ROP involved incorporating entrained abrasives in conjunction with high pressure drilling fluid (“mud”). This resulted in an abrasive laden, high velocity jet assisted drilling process. Work done by Gulf Research and Development disclosed the use of abrasive laden jet streams to cut concentric grooves in the bottom of the hole leaving concentric ridges that are then broken by the mechanical contact of the drill bit. Use of entrained abrasives in conjunction with high drilling fluid pressures caused accelerated erosion of surface equipment and an inability to control drilling mud density, among other issues. Generally, the use of entrained abrasives was considered practically and economically unfeasible. This work was summarized in the last published article titled “Development of High Pressure Abrasive-Jet Drilling,” authored by John C. Fair, Gulf Research and Development. It was published in the Journal of Petroleum Technology in the May 1981 issue, pages 1379 to 1388.
Another effort to utilize the hydraulic horsepower available at the bit incorporated the use of ultra-high pressure jet assisted drilling. A group known as FlowDril Corporation was formed to develop an ultra-high-pressure liquid jet drilling system in an attempt to increase the rate of penetration. The work was based upon U.S. Pat. No. 4,624,327 and is documented in the published article titled “Laboratory and Field Testing of an Ultra-High Pressure, Jet-Assisted Drilling System” authored by J. J. Kolle, Quest Integrated Inc., and R. Otta and D. L. Stang, FlowDril Corporation; published by SPE/IADC Drilling Conference publications paper number 22000. The cited publication disclosed that the complications of pumping and delivering ultrahigh-pressure fluid from surface pumping equipment to the drill bit proved both operationally and economically unfeasible.
Another effort at increasing rates of penetration by taking advantage of hydraulic horsepower available at the bit is disclosed in U.S. Pat. No. 5,862,871. This development employed the use of a specialized nozzle to excite normally pressured drilling mud at the drill bit. The purpose of this nozzle system was to develop local pressure fluctuations and a high speed, dual jet form of hydraulic jet streams to more effectively scavenge and clean both the drill bit and the formation being drilled. It is believed that these hydraulic jets were able to penetrate the fracture plane generated by the mechanical action of the drill bit in a much more effective manner than conventional jets were able to do. ROP increases from 50% to 400% were field demonstrated and documented in the field reports titled “DualJet Nozzle Field Test Report-Security DBS/Swift Energy Company,” and “DualJet Nozzle Equipped M-1LRG Drill Bit Run”. The ability of the dual jet (“DualJet”) nozzle system to enhance the effectiveness of the drill bit action to increase the ROP required that the drill bits first initiate formation indentations, fractures, or both. These features could then be exploited by the hydraulic action of the DualJet nozzle system.
Due at least partially to the effects of overburden pressure, formations at deeper depths may be inherently tougher to drill due to changes in formation pressures and rock properties, including hardness and abrasiveness. Associated in-situ forces, rock properties, and increased drilling fluid density effects may set up a threshold point at which the drill bit drilling mechanics decrease the drilling efficiency.
Another factor adversely effecting ROP in formation drilling, especially in plastic type rock drilling, such as shale or permeable formations, is a build-up of hydraulically isolated crushed rock material, that can become either mass of reconstituted drill cuttings or a “dynamic filtercake”, on the surface being drilled, depending on the formation permeability. In the case of low permeability formations, this occurrence is predominantly a result of repeated impacting and re-compacting of previously drilled particulate material on the bottom of the hole by the bit teeth, thereby forming a false bottom. The substantially continuous process of drilling, re-compacting, removing, re-depositing and re-compacting, and drilling new material may significantly adversely effect drill bit efficiency and ROP. The re-compacted material is at least partially removed by mechanical displacement due to the cone skew of the roller cone type drill bits and partially removed by hydraulics, again emphasizing the importance of good hydraulic action and hydraulic horsepower at the bit. For hard rock bits, build-up removal by cone skew is typically reduced to near zero, which may make build-up removal substantially a function of hydraulics. In permeable formations the continuous deposition and removal of the fine cuttings forms a dynamic filtercake that can reduce the spurt loss and therefore the pore pressure in the working area of the bit. Because the pore pressure is reduced and mechanical load is increased from the pressure drop across the dynamic filtercake, drilling efficiency can be reduced.
There are many variables to consider to ensure a usable well bore is constructed when using cutting systems and processes for the drilling of well bores or the cutting of formations for the construction of tunnels and other subterranean earthen excavations. Many variables, such as formation hardness, abrasiveness, pore pressures, and formation elastic properties affect the effectiveness of a particular drill bit in drilling a well bore. Additionally, in drilling well bores, formation hardness and a corresponding degree of drilling difficulty may increase exponentially as a function of increasing depth. The rate at which a drill bit may penetrate the formation typically decreases with harder and tougher formation materials and formation depth.
When the formation is relatively soft, as with shale, material removed by the drill bit will have a tendency to reconstitute onto the teeth of the drill bit. Build-up of the reconstituted formation on the drill bit is typically referred to as “bit balling” and reduces the depth that the teeth of the drill bit will penetrate the bottom surface of the well bore, thereby reducing the efficiency of the drill bit. Particles of a shale formation also tend to reconstitute back onto the bottom surface of the bore hole. The reconstitution of a formation back onto the bottom surface of the bore hole is typically referred to as “bottom balling”. Bottom balling prevents the teeth of a drill bit from engaging virgin formation and spreads the impact of a tooth over a wider area, thereby also reducing the efficiency of a drill bit. Additionally, higher density drilling muds that are required to maintain well bore stability or well bore pressure control exacerbate bit balling and the bottom balling problems.
When the drill bit engages a formation of a harder rock, the teeth of the drill bit press against the formation and densify a small area under the teeth to cause a crack in the formation. When the porosity of the formation is collapsed, or densified, in a hard rock formation below a tooth, conventional drill bit nozzles ejecting drilling fluid are used to remove the crushed material from below the drill bit. As a result, a cushion, or densification pad, of densified material is left on the bottom surface by the prior art drill bits. If the densification pad is left on the bottom surface, force by a tooth of the drill bit will be distributed over a larger area and reduce the effectiveness of a drill bit.
There are generally two main categories of modern drill bits that have evolved over time. These are the commonly known fixed cutter drill bit and the roller cone drill bit. Additional categories of drilling include percussion drilling and mud hammers. However, these methods are not as widely used as the fixed cutter and roller cone drill bits. Within these two primary categories (fixed cutter and roller cone), there are a wide variety of variations, with each variation designed to drill a formation having a general range of formation properties.
The fixed cutter drill bit and the roller cone type drill bit generally constitute the bulk of the drill bits employed to drill oil and gas wells around the world. When a typical roller cone rock bit tooth presses upon a very hard, dense, deep formation, the tooth point may only penetrate into the rock a very small distance, while also at least partially, plastically “working” the rock surface. Under conventional drilling techniques, such working the rock surface may result in the densification as noted above in hard rock formations.
With roller cone type drilling bits, a relationship exists between the number of teeth that impact upon the formation and the drilling RPM of the drill bit. A description of this relationship and an approach to improved drilling technology is set forth and described in U.S. Pat. No. 6,386,300 issued May 14, 2002. The '300 patent discloses the use of solid material impactors introduced into drilling fluid and pumped though a drill string and drill bit to contact the rock formation ahead of the drill bit. The kinetic energy of the impactors leaving the drill bit is given by the following equation: Ek=½ Mass(Velocity)2. The mass and/or velocity of the impactors may be chosen to satisfy the mass-velocity relationship in order to structurally alter the rock formation.
In the drawings and description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawings are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present invention is susceptible to embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
To excavate the wellbore 70, the swivel 28, the swivel quill 26, the kelly 50, the pipe string 55, and a portion of the drill bit 60, if used, may each include an interior passage that allows circulation fluid to circulate through each of the aforementioned components. The circulation fluid may be withdrawn from a tank 6, pumped by a pump 2, through a through medium pressure capacity line 8, through a medium pressure capacity flexible hose 42, through a gooseneck 36, through the swivel 28, through the swivel quill 26, through the kelly 50, through the pipe string 55, and through the bit 60.
The excavation system 1 further comprises at least one nozzle 64 on the lower 55B of the pipe string 55 for accelerating at least one solid material impactor 100 as they exit the pipe string 100. The nozzle 64 is designed to accommodate the impactors 100, such as an especially hardened nozzle, a shaped nozzle, or an “impactor” nozzle, which may be particularly adapted to a particular application. The nozzle 64 may be a type that is known and commonly available. The nozzle 64 may further be selected to accommodate the impactors 100 in a selected size range or of a selected material composition. Nozzle size, type, material, and quantity may be a function of the formation being cut, fluid properties, impactor properties, and/or desired hydraulic energy expenditure at the nozzle 64. If a drill bit 60 is used, the nozzle or nozzles 64 may be located in the drill bit 60.
The nozzle 64 may alternatively be a conventional dual-discharge nozzle. Such dual discharge nozzles may generate: (1) a radially outer circulation fluid jet substantially encircling a jet axis, and/or (2) an axial circulation fluid jet substantially aligned with and coaxial with the jet axis, with the dual discharge nozzle directing a majority by weight of the plurality of solid material impactors into the axial circulation fluid jet. A dual discharge nozzle 64 may separate a first portion of the circulation fluid flowing through the nozzle 64 into a first circulation fluid stream having a first circulation fluid exit nozzle velocity, and a second portion of the circulation fluid flowing through the nozzle 64 into a second circulation fluid stream having a second circulation fluid exit nozzle velocity lower than the first circulation fluid exit nozzle velocity. The plurality of solid material impactors 100 may be directed into the first circulation fluid stream such that a velocity of the plurality of solid material impactors 100 while exiting the nozzle 64 is substantially greater than a velocity of the circulation fluid while passing through a nominal diameter flow path in the lower end 55B of the pipe string 55, to accelerate the solid material impactors 100.
Each of the individual impactors 100 is structurally independent from the other impactors. For brevity, the plurality of solid material impactors 100 may be interchangeably referred to as simply the impactors 100. The plurality of solid material impactors 100 may be substantially rounded and have either a substantially non-uniform outer diameter or a substantially uniform outer diameter. The solid material impactors 100 may be substantially spherically shaped, non-hollow, formed of rigid metallic material, and having high compressive strength and crush resistance, such as steel shot, ceramics, depleted uranium, and multiple component materials. Although the solid material impactors 100 may be substantially a non-hollow sphere, alternative embodiments may provide for other types of solid material impactors, which may include impactors 100 with a hollow interior. The impactors may be substantially rigid and may possess relatively high compressive strength and resistance to crushing or deformation as compared to physical properties or rock properties of a particular formation or group of formations being penetrated by the wellbore 70.
The impactors may be of a substantially uniform mass, grading, or size. The solid material impactors 100 may have any suitable density for use in the excavation system 1. For example, the solid material impactors 100 may have an average density of at least 470 pounds per cubic foot.
Alternatively, the solid material impactors 100 may include other metallic materials, including tungsten carbide, copper, iron, or various combinations or alloys of these and other metallic compounds. The impactors 100 may also be composed of non-metallic materials, such as ceramics, or other man-made or substantially naturally occurring non-metallic materials. Also, the impactors 100 may be crystalline shaped, angular shaped, sub-angular shaped, selectively shaped, such as like a torpedo, dart, rectangular, or otherwise generally non-spherically shaped.
The impactors 100 may be selectively introduced into a fluid circulation system, such as illustrated in
Introducing the impactors 100 into the circulation fluid may be accomplished by any of several known techniques. For example, the impactors 100 may be provided in an impactor storage tank 94 near the rig 5 or in a storage bin 82. A screw elevator 14 may then transfer a portion of the impactors at a selected rate from the storage tank 94, into a slurrification tank 98. A pump 10, such as a progressive cavity pump may transfer a selected portion of the circulation fluid from a mud tank 6, into the slurrification tank 98 to be mixed with the impactors 100 in the tank 98 to form an impactor concentrated slurry. An impactor introducer 96 may be included to pump or introduce a plurality of solid material impactors 100 into the circulation fluid before circulating a plurality of impactors 100 and the circulation fluid to the nozzle 64. The impactor introducer 96 may be a progressive cavity pump capable of pumping the impactor concentrated slurry at a selected rate and pressure through a slurry line 88, through a slurry hose 38, through an impactor slurry injector head 34, and through an injector port 30 located on the gooseneck 36, which may be located atop the swivel 28. The swivel 36, including the through bore for conducting circulation fluid therein, may be substantially supported on the feed, or upper, end of the pipe string 55 for conducting circulation fluid from the gooseneck 36 into the latter end 55a. The upper end 55A of the pipe string 55 may also include the kelly 50 to connect the pipe 56 with the swivel quill 26 and/or the swivel 28. The circulation fluid may also be provided with rheological properties sufficient to adequately transport and/or suspend the plurality of solid material impactors 100 within the circulation fluid.
The solid material impactors 100 may also be introduced into the circulation fluid by withdrawing the plurality of solid material impactors 100 from a low pressure impactor source 98 into a high velocity stream of circulation fluid, such as by venturi effect. For example, when introducing impactors 100 into the circulation fluid, the rate of circulation fluid pumped by the mud pump 2 may be reduced to a rate lower than the mud pump 2 is capable of efficiently pumping. In such event, a lower volume mud pump 4 may pump the circulation fluid through a medium pressure capacity line 24 and through the medium pressure capacity flexible hose 40.
The circulation fluid may be circulated from the fluid pump 2 and/or 4, such as a positive displacement type fluid pump, through one or more fluid conduits 8, 24, 40, 42, into the pipe string 55. The circulation fluid may then be circulated through the pipe string 55 and through the nozzle 64. The circulation fluid may be pumped at a selected circulation rate and/or a selected pump pressure to achieve a desired impactor and/or fluid energy at the nozzle 64.
The pump 4 may also serve as a supply pump to drive the introduction of the impactors 100 entrained within an impactor slurry, into the high pressure circulation fluid stream pumped by mud pumps 2 and 4. Pump 4 may pump a percentage of the total rate of fluid being pumped by both pumps 2 and 4, such that the circulation fluid pumped by pump 4 may create a venturi effect and/or vortex within the injector head 34 that inducts the impactor slurry being conducted through the line 42, through the injector head 34, and then into the high pressure circulation fluid stream.
From the swivel 28, the slurry of circulation fluid and impactors may circulate through the interior passage in the pipe string 55 and through the nozzle 64. As described above, the nozzle 64 may alternatively be at least partially located in the drill bit 60. Each nozzle 64 may include a reduced inner diameter as compared to an inner diameter of the interior passage in the pipe string 55 immediately above the nozzle 64. Thereby, each nozzle 64 may accelerate the velocity of the slurry as the slurry passes through the nozzle 64. The nozzle 64 may also direct the slurry into engagement with a selected portion of the bottom surface 66 of wellbore 70. The nozzle 64 may also be rotated relative to the formation 52 depending on the excavation parameters. To rotate the nozzle 64, the entire pipe string 55 may be rotated or only the nozzle 64 on the end of the pipe string 55 may be rotated while the pipe string 55 is not rotated. Rotating the nozzle 64 may also include oscillating the nozzle 64 rotationally back and forth as well as vertically, and may further include rotating the nozzle 64 in discrete increments. The nozzle 64 may also be maintained rotationally substantially stationary.
The circulation fluid may be substantially continuously circulated during excavation operations to circulate at least some of the plurality of solid material impactors 100 and the formation cuttings away from the nozzle 64. The impactors 100 and fluid circulated away from the nozzle 64 may be circulated substantially back to the excavation rig 5, or circulated to a substantially intermediate position between the excavation rig 5 and the nozzle 64.
If a drill bit 60 is used, the drill bit 60 may be rotated relative to the formation 52 and engaged therewith by an axial force (WOB) acting at least partially along the wellbore axis 75 near the drill bit 60. The bit 60 may also comprise a plurality of bit cones 62, which also may rotate relative to the bit 60 to cause bit teeth secured to a respective cone to engage the formation 52, which may generate formation cuttings substantially by crushing, cutting, or pulverizing a portion of the formation 52. The bit 60 may also be comprised of a fixed cutting structure that may be substantially continuously engaged with the formation 52 and create cuttings primarily by shearing and/or axial force concentration to fail the formation, or create cuttings from the formation 52. To rotate the bit 60, the entire pipe string 55 may be rotated or only the bit 60 on the end of the pipe string 55 may be rotated while the pipe string 55 is not rotated. Rotating the drill bit 60 may also include oscillating the drill bit 60 rotationally back and forth as well as vertically, and may further include rotating the drill bit 60 in discrete increments.
Also alternatively, the excavation system 1 may comprise a pump, such as a centrifugal pump, having a resilient lining that is compatible for pumping a solid-material laden slurry. The pump may pressurize the slurry to a pressure greater than the selected mud pump pressure to pump the plurality of solid material impactors 100 into the circulation fluid. The impactors 100 may be introduced through an impactor injection port, such as port 30. Other alternative embodiments for the system 1 may include an impactor injector for introducing the plurality of solid material impactors 100 into the circulation fluid.
As the slurry is pumped through the pipe string 55 and out the nozzles 64, the impactors 100 may engage the formation with sufficient energy to enhance the rate of formation removal or penetration (ROP). The removed portions of the formation may be circulated from within the wellbore 70 near the nozzle 64, and carried suspended in the fluid with at least a portion of the impactors 100, through a wellbore annulus between the OD of the pipe string 55 and the ID of the wellbore 70.
At the excavation rig 5, the returning slurry of circulation fluid, formation fluids (if any), cuttings, and impactors 100 may be diverted at a nipple 76, which may be positioned on a BOP stack 74. The returning slurry may flow from the nipple 76, into a return flow line 15, which may be comprised of tubes 48, 45, 16, 12 and flanges 46, 47. The return line 15 may include an impactor reclamation tube assembly 44, as illustrated in
The reclamation tube assembly 44 may operate by rotating tube 45 relative to tube 16. An electric motor assembly 22 may rotate tube 44. The reclamation tube assembly 44 comprises an enlarged tubular 45 section to reduce the return flow slurry velocity and allow the slurry to drop below a terminal velocity of the impactors 100, such that the impactors 100 can no longer be suspended in the circulation fluid and may gravitate to a bottom portion of the tube 45. This separation function may be enhanced by placement of magnets near and along a lower side of the tube 45. The impactors 100 and some of the larger or heavier cuttings may be discharged through discharge port 20. The separated and discharged impactors 100 and solids discharged through discharge port 20 may be gravitationally diverted into a vibrating classifier 84 or may be pumped into the classifier 84. A pump (not shown) capable of handling impactors and solids, such as a progressive cavity pump may be situated in communication with the flow line discharge port 20 to conduct the separated impactors 100 selectively into the vibrating separator 84 or elsewhere in the circulation fluid circulation system.
The vibrating classifier 84 may comprise a three-screen section classifier of which screen section 18 may remove the coarsest grade material. The removed coarsest grade material may be selectively directed by outlet 78 to one of storage bin 82 or pumped back into the flow line 15 downstream of discharge port 20. A second screen section 92 may remove a re-usable grade of impactors 100, which in turn may be directed by outlet 90 to the impactor storage tank 94. A third screen section 86 may remove the finest grade material from the circulation fluid. The removed finest grade material may be selectively directed by outlet 80 to storage bin 82, or pumped back into the flow line 15 at a point downstream of discharge port 20. Circulation fluid collected in a lower portion of the classified 84 may be returned to a mud tank 6 for re-use.
The circulation fluid may be recovered for recirculation in a wellbore or the circulation fluid may be a fluid that is substantially not recovered. The circulation fluid may be a liquid, gas, foam, mist, or other substantially continuous or multiphase fluid. For recovery, the circulation fluid and other components entrained within the circulation fluid may be directed across a shale shaker (not shown) or into a mud tank 6, whereby the circulation fluid may be further processed for re-circulation into a wellbore.
The excavation system 1 creates a mass-velocity relationship in a plurality of the solid material impactors 100, such that an impactor 100 may have sufficient energy to structurally alter the formation 52 in a zone of a point of impact. The mass-velocity relationship may be satisfied as sufficient when a substantial portion by weight of the solid material impactors 100 may by virtue of their mass and velocity at the exit of the nozzle 64, create a structural alteration as claimed or disclosed herein. Impactor velocity to achieve a desired effect upon a given formation may vary as a function of formation compressive strength, hardness, or other rock properties, and as a function of impactor size and circulation fluid rheological properties. A substantial portion means at least five percent by weight of the plurality of solid material impactors that are introduced into the circulation fluid.
The impactors 100 for a given velocity and mass of a substantial portion by weight of the impactors 100 are subject to the following mass-velocity relationship. The resulting kinetic energy of at least one impactor 100 exiting a nozzle 64 is at least 0.075 Ft.Lbs or has a minimum momentum of 0.0003 Lbf.Sec.
Kinetic energy is quantified by the relationship of an object's mass and its velocity. The quantity of kinetic energy associated with an object is calculated by multiplying its mass times its velocity squared. To reach a minimum value of kinetic energy in the mass-velocity relationship as defined, small particles such as those found in abrasives and grits, must have a significantly high velocity due to the small mass of the particle. A large particle, however, needs only moderate velocity to reach an equivalent kinetic energy of the small particle because its mass may be several orders of magnitude larger.
The velocity of a substantial portion by weight of the plurality of solid material impactors 100 immediately exiting a nozzle 64 may be as slow as 100 feet per second and as fast as 1000 feet per second, immediately upon exiting the nozzle 64.
The velocity of a majority by weight of the impactors 100 may be substantially the same, or only slightly reduced, at the point of impact of an impactor 100 at the formation surface 66 as compared to when leaving the nozzle 64. Thus, it may be appreciated by those skilled in the art that due to the close proximity of a nozzle 64 to the formation being impacted, the velocity of a majority of impactors 100 exiting a nozzle 64 may be substantially the same as a velocity of an impactor 100 at a point of impact with the formation 52. Therefore, in many practical applications, the above velocity values may be determined or measured at substantially any point along the path between near an exit end of a nozzle 64 and the point of impact, without material deviation from the scope of this invention.
In addition to the impactors 100 satisfying the mass-velocity relationship described above, a substantial portion by weight of the solid material impactors 100 have an average mean diameter of between approximately 0.050 to 0.500 of an inch.
To excavate a formation 52, the excavation implement, such as a drill bit 60 or impactor 100, must overcome minimum, in-situ stress levels or toughness of the formation 52. These minimum stress levels are known to typically range from a few thousand pounds per square inch, to in excess of 65,000 pounds per square inch. To fracture, cut, or plastically deform a portion of formation 52, force exerted on that portion of the formation 52 typically should exceed the minimum, in-situ stress threshold of the formation 52. When an impactor 100 first initiates contact with a formation, the unit stress exerted upon the initial contact point may be much higher than 10,000 pounds per square inch, and may be well in excess of one million pounds per square inch. The stress applied to the formation 52 during contact is governed by the force the impactor 100 contacts the formation with and the area of contact of the impactor with the formation. The stress is the force divided by the area of contact. The force is governed by Impulse Momentum theory whereby the time at which the contact occurs determines the magnitude of the force applied to the area of contact. In cases where the particle is contacting a relatively hard surface at an elevated velocity, the force of the particle when in contact with the surface is not constant, but is better described as a spike. However, the force need not be limited to any specific amplitude or duration. The magnitude of the spike load can be very large and occur in just a small fraction of the total impact time. If the area of contact is small the unit stress can reach values many times in excess of the in situ failure stress of the rock, thus guaranteeing fracture initiation and propagation and structurally altering the formation 52.
A substantial portion by weight of the solid material impactors 100 may apply at least 5000 pounds per square inch of unit stress to a formation 52 to create the structurally altered zone Z in the formation. The structurally altered zone Z is not limited to any specific shape or size, including depth or width. Further, a substantial portion by weight of the impactors 100 may apply in excess of 20,000 pounds per square inch of unit stress to the formation 52 to create the structurally altered zone Z in the formation. The mass-velocity relationship of a substantial portion by weight of the plurality of solid material impactors 100 may also provide at least 30,000 pounds per square inch of unit stress.
A substantial portion by weight of the solid material impactors 100 may have any appropriate velocity to satisfy the mass-velocity relationship. For example, a substantial portion by weight of the solid material impactors may have a velocity of at least 100 feet per second when exiting the nozzle 64. A substantial portion by weight of the solid material impactors 100 may also have a velocity of at least 100 feet per second and as great as 1200 feet per second when exiting the nozzle 64. A substantial portion by weight of the solid material impactors 100 may also have a velocity of at least 100 feet per second and as great as 750 feet per second when exiting the nozzle 64. A substantial portion by weight of the solid material impactors 100 may also have a velocity of at least 350 feet per second and as great as 500 feet per second when exiting the nozzle 64.
Impactors 100 may be selected based upon physical factors such as size, projected velocity, impactor strength, formation 52 properties and desired impactor concentration in the circulation fluid. Such factors may also include; (a) an expenditure of a selected range of hydraulic horsepower across the one or more nozzles, (b) a selected range of circulation fluid velocities exiting the one or more nozzles or impacting the formation, and (c) a selected range of solid material impactor velocities exiting the one or more nozzles or impacting the formation, (d) one or more rock properties of the formation being excavated, or (e), any combination thereof.
If an impactor 100 is of a specific shape such as that of a dart, a tapered conic, a rhombic, an octahedral, or similar oblong shape, a reduced impact area to impactor mass ratio may be achieved. The shape of a substantial portion by weight of the impactors 100 may be altered, so long as the mass-velocity relationship remains sufficient to create a claimed structural alteration in the formation and an impactor 100 does not have any one length or diameter dimension greater than approximately 0.100 inches. Thereby, a velocity required to achieve a specific structural alteration may be reduced as compared to achieving a similar structural alteration by impactor shapes having a higher impact area to mass ratio. Shaped impactors 100 may be formed to substantially align themselves along a flow path, which may reduce variations in the angle of incidence between the impactor 100 and the formation 52. Such impactor shapes may also reduce impactor contact with the flow structures such those in the pipe string 55 and the excavation rig 5 and may thereby minimize abrasive erosion of flow conduits.
Referring to
A portion of the formation 52 ahead of the impactor 100 substantially in the direction of impactor travel T may be altered such as by micro-fracturing and/or thermal alteration due to the impact energy. In such occurrence, the structurally altered zone Z may include an altered zone depth D. An example of a structurally altered zone Z is a compressive zone Z1, which may be a zone in the formation 52 compressed by the impactor 100. The compressive zone Z1 may have a length L1, but is not limited to any specific shape or size. The compressive zone Z1 may be thermally altered due to impact energy.
An additional example of a structurally altered zone 102 near a point of impaction may be a zone of micro-fractures Z2. The structurally altered zone Z may be broken or otherwise altered due to the impactor 100 and/or a drill bit 60, such as by crushing, fracturing, or micro-fracturing.
An additional theory for impaction mechanics in cutting a formation 52 may postulate that certain formations 52 may be highly fractured or broken up by impactor energy.
An impactor 100 may penetrate a small distance into the formation 52 and cause the displaced or structurally altered formation 52 to “splay out” or be reduced to small enough particles for the particles to be removed or washed away by hydraulic action. Hydraulic particle removal may depend at least partially upon available hydraulic horsepower and at least partially upon particle wet-ability and viscosity. Such formation deformation may be a basis for fatigue failure of a portion of the formation by “impactor contact,” as the plurality of solid material impactors 100 may displace formation material back and forth.
Each nozzle 64 may be selected to provide a desired circulation fluid circulation rate, hydraulic horsepower substantially at the nozzle 64, and/or impactor energy or velocity when exiting the nozzle 64. Each nozzle 64 may be selected as a function of at least one of (a) an expenditure of a selected range of hydraulic horsepower across the one or more nozzles 64, (b) a selected range of circulation fluid velocities exiting the one or more nozzles 64, and (c) a selected range of solid material impactor 100 velocities exiting the one or more nozzles 64.
To optimize ROP, it may be desirable to determine, such as by monitoring, observing, calculating, knowing, or assuming one or more excavation parameters such that adjustments may be made in one or more controllable variables as a function of the determined or monitored excavation parameter. The one or more excavation parameters may be selected from a group comprising: (a) a rate of penetration into the formation 52, (b) a depth of penetration into the formation 52, (c) a formation excavation factor, and (d) the number of solid material impactors 100 introduced into the circulation fluid per unit of time. Monitoring or observing may include monitoring or observing one or more excavation parameters of a group of excavation parameters comprising; (a) rate of nozzle rotation, (b) rate of penetration into the formation 52, (c) depth of penetration into the formation 52, (d) formation excavation factor, (e) axial force applied to the drill bit 60, (f) rotational force applied to the bit 60, (g) the selected circulation rate, (h) the selected pump pressure, and/or (i) wellbore fluid dynamics, including pore pressure.
One or more controllable variables or parameters may be altered, including at least one of (a) rate of impactor 100 introduction into the circulation fluid, (b) impactor 100 size, (c) impactor 100 velocity, (d) drill bit nozzle 64 selection, (e) the selected circulation rate of the circulation fluid, (f) the selected pump pressure, and (g) any of the monitored excavation parameters.
To alter the rate of impactors 100 engaging the formation 52, the rate of impactor 100 introduction into the circulation fluid may be altered. The circulation fluid circulation rate may also be altered independent from the rate of impactor 100 introduction. Thereby, the concentration of impactors 100 in the circulation fluid may be adjusted separate from the fluid circulation rate. Introducing a plurality of solid material impactors 100 into the circulation fluid may be a function of impactor 100 size, circulation fluid rate, nozzle rotational speed, wellbore 70 size, and a selected impactor 100 engagement rate with the formation 52. The impactors 100 may also be introduced into the circulation fluid intermittently during the excavation operation. The rate of impactor 100 introduction relative to the rate of circulation fluid circulation may also be adjusted or interrupted as desired.
The plurality of solid material impactors 100 may be introduced into the circulation fluid at a selected introduction rate and/or concentration to circulate the plurality of solid material impactors 100 with the circulation fluid through the nozzle 64. The selected circulation rate and/or pump pressure, and nozzle selection may be sufficient to expend a desired portion of energy or hydraulic horsepower in each of the circulation fluid and the impactors 100.
An example of an operative excavation system 1 may comprise a bit 60 with an 8½ inch bit diameter. The solid material impactors 100 may be introduced into the circulation fluid at a rate of 12 gallons per minute. The circulation fluid containing the solid material impactors may be circulated through the bit 60 at a rate of 462 gallons per minute. A substantial portion by weight of the solid material impactors may have an average mean diameter of 0.100″. The following parameters will result in approximately a 27 feet per hour penetration rate into Sierra White Granite. In this example, the excavation system may produce 1413 solid material impactors 100 per cubic inch with approximately 3.9 million impacts per minute against the formation 52. On average, 0.00007822 cubic inches of the formation 52 are removed per impactor 100 impact. The resulting exit velocity of a substantial portion of the impactors 100 from each of the nozzles 64 would average 495.5 feet per second. The kinetic energy of a substantial portion by weight of the solid material impacts 100 would be approximately 1.14 Ft Lbs., thus satisfying the mass-velocity relationship described above.
Another example of an operative excavation system 1 may comprise a bit 60 with an 8½″ bit diameter. The solid material impactors 100 may be introduced into the circulation fluid at a rate of 12 gallons per minute. The circulation fluid containing the solid material impactors may be circulated through the nozzle 64 at a rate of 462 gallons per minute. A substantial portion by weight of the solid material impactors may have an average mean diameter of 0.075″. The following parameters will result in approximately a 35 feet per hour penetration rate into Sierra White Granite. In this example, the excavation system 1 may produce 3350 solid material impactors 100 per cubic inch with approximately 9.3 million impacts per minute against the formation 52. On average, 0.0000428 cubic inches of the formation 52 are removed per impactor 100 impact. The resulting exit velocity of a substantial portion of the impactors 100 from each of the nozzles 64 would average 495.5 feet per second. The kinetic energy of a substantial portion by weight of the solid material impacts 100 would be approximately 0.240 Ft Lbs., thus satisfying the mass-velocity relationship described above.
In addition to impacting the formation with the impactors 100, the bit 60 may be rotated while circulating the circulation fluid and engaging the plurality of solid material impactors 100 substantially continuously or selectively intermittently. The nozzle 64 may also be oriented to cause the solid material impactors 100 to engage the formation 52 with a radially outer portion of the bottom hole surface 66. Thereby, as the drill bit 60 is rotated, the impactors 100, in the bottom hole surface 66 ahead of the bit 60, may create one or more circumferential kerfs. The drill bit 60 may thereby generate formation cuttings more efficiently due to reduced stress in the surface 66 being excavated, due to the one or more substantially circumferential kerfs in the surface 66.
The excavation system 1 may also include inputting pulses of energy in the fluid system sufficient to impart a portion of the input energy in an impactor 100. The impactor 100 may thereby engage the formation 52 with sufficient energy to achieve a structurally altered zone Z. Pulsing of the pressure of the circulation fluid in the pipe string 55, near the nozzle 64 also may enhance the ability of the circulation fluid to generate cuttings subsequent to impactor 100 engagement with the formation 52.
Each combination of formation type, bore hole size, bore hole depth, available weight on bit, bit rotational speed, pump rate, hydrostatic balance, circulation fluid rheology, bit type, and tooth/cutter dimensions may create many combinations of optimum impactor presence or concentration, and impactor energy requirements. The methods and systems of this invention facilitate adjusting impactor size, mass, introduction rate, circulation fluid rate and/or pump pressure, and other adjustable or controllable variables to determine and maintain an optimum combination of variables. The methods and systems of this invention also may be coupled with select bit nozzles, downhole tools, and fluid circulating and processing equipment to effect many variations in which to optimize rate of penetration.
Referring now to
The mechanical cutters, utilized on many of the surfaces of the drill bit 110, may be any type of protrusion or surface used to abrade the rock formation by contact of the mechanical cutters with the rock formation. The mechanical cutters may be Polycrystalline Diamond Coated (PDC), or any other suitable type mechanical cutter such as tungsten carbide cutters. The mechanical cutters may be formed in a variety of shapes, for example, hemispherically shaped, cone shaped, etc. Several sizes of mechanical cutters are also available, depending on the size of drill bit used and the hardness of the rock formation being cut.
Referring now to
Still referring to
As described earlier, the drill bit 110 may also comprise mechanical cutters and gauge cutters. Various mechanical cutters are shown along the surface of the drill bit 110. Hemispherical PDC cutters are interspersed along the bottom face and the side walls of the drill bit 110. These hemispherical cutters along the bottom face break down the large portions of the rock ring 142 and also abrade the bottom surface 122 of the well bore 120. Another type of mechanical cutter along the side arms 214A, 214B are gauge cutters 230. The gauge cutters 230 form the final diameter of the well bore 120. The gauge cutters 230 trim a small portion of the well bore 120 not removed by other means. Gauge bearing surfaces 206 are interspersed throughout the side walls of the drill bit 110. The gauge bearing surfaces 206 ride in the well bore 120 already trimmed by the gauge cutters 230. The gauge bearing surfaces 206 may also stabilize the drill bit 110 within the well bore 120 and aid in preventing vibration.
Still referring to
Referring now to
Referring now to
Still referring to
Each side arm 214A, 214B fits in the excavated exterior cavity 146 formed by the side nozzles 200A, 200B and the mechanical cutters 208 on the face 212 of each side arm 214A, 214B. The solid material impactors from one side nozzle 200A rebound from the rock formation and combine with the drilling fluid and cuttings flow to the major junk slot 204A and up to the annulus 124. The flow of the solid material impactors, shown by arrows 205, from the center nozzle 202 also rebound from the rock formation up through the major junk slot 204A.
Referring now to
Referring now to
Referring now to
Still referring to
Referring now to
Referring now to
Although the drill bit 110 is described comprising orientations of nozzles and mechanical cutters, any orientation of either nozzles, mechanical cutters, or both may be utilized. The drill bit 110 need not comprise a center portion 203. The drill bit 110 also need not even create the rock ring 142. For example, the drill bit may only comprise a single nozzle and a single junk slot. Furthermore, although the description of the drill bit 110 describes types and orientations of mechanical cutters, the mechanical cutters may be formed of a variety of substances, and formed in a variety of shapes.
Referring now to
Still referring to
The PDCs 280 located on the face 212 of each side arm 214A, 214B are sufficient to cut the inner wall 126 to the correct size. However, mechanical cutters may be placed throughout the side wall of the drill bit 150 to further enhance the stabilization and cutting ability of the drill bit 150.
Referring to
A solid-material-impactor bin or reservoir 314 is operably coupled to a solid-impactor transport device such as a shot-feed conveyor 316 which, in turn, is operably coupled to a distribution tank 318. A conduit 320 connects the tank 318 to a valve 322, and the conduit further extends and is connected to an injector vessel 324.
A hydraulic-actuated cylinder 326 is fluidicly coupled to the vessel 324 via a hydraulic flow line 327. The cylinder 326 includes a piston 326a that reciprocates in a cylinder housing 326b in a conventional manner. The housing 326b defines a variable-volume chamber 326c in fluid communication with the line 327, and further defines a variable-volume chamber 326d into which hydraulic cylinder fluid is introduced, and from which the hydraulic fluid is discharged, under conditions to be described.
A valve 328 is fluidicly coupled to the line 306 via a hydraulic line 332, and the line 332 also extends to the vessel 324, thereby fluidicly coupling the valve to the vessel. A valve 334 is fluidicly coupled to the vessel 324. A hydraulic line 335 fluidicly couples an orifice 336 to the valve 334, and the line also extends to the line portion 312b of the line 312. A valve 337 is fluidicly coupled to the vessel 324 via a hydraulic line 338 that also extends to a reservoir or tank 340. A pump 342 is fluidicly coupled to the tank 340 via a hydraulic line 344 that also extends to the tank 318.
A conduit 346 connects the tank 318 to a valve 348, and the conduit further extends and is connected to an injector vessel 350. A hydraulic-actuated cylinder 352 is fluidicly coupled to the vessel 350 via a hydraulic flow line 353. The cylinder 352 includes a piston 352a that reciprocates in a cylinder housing 352b in a conventional manner. The housing 352b defines a variable-volume chamber 352c in fluid communication with the line 353, and further defines a variable-volume chamber 352d into which hydraulic cylinder fluid is introduced, and from which the hydraulic fluid is discharged, under conditions to be described.
A valve 354 is fluidicly coupled to the line 306 via a hydraulic line 358, and the line 358 also extends to the vessel 350, thereby fluidicly coupling the valve to the vessel. A valve 360 is fluidicly coupled to the vessel 350, and an orifice 362 is fluidicly coupled to the valve via a hydraulic line 364 that also extends to the line portion 312b of the line 312. A valve 366 is fluidicly coupled to the vessel 350 via a hydraulic line 368 that also extends to the line 338.
A conduit 370 connects the tank 318 to a valve 372, and the conduit further extends and is connected to an injector vessel 374. A hydraulic-actuated cylinder 376 is fluidicly coupled to the vessel 374 via a hydraulic line 378, and the cylinder includes a piston 376a that reciprocates in a cylinder housing 376b in a conventional manner. The housing 376b defines a variable-volume chamber 376c in fluid communication with the line 378, and further defines a variable-volume chamber 376d into which hydraulic cylinder fluid is introduced, and from which the hydraulic fluid is discharged, under conditions to be described.
A hydraulic line 380 fluidicly couples the valve 308 to the vessel 374. A valve 382 is fluidicly coupled to the vessel 374, and an orifice 384 is fluidicly coupled to the valve via a hydraulic line 386 that also extends to the line portion 312b of the line 312. A valve 388 is fluidicly coupled to the vessel 374 via a hydraulic line 390 that also extends to the line 338. In an exemplary embodiment, it is understood that all of the above-described lines and line portions define flow regions through which fluid may flow over a range of fluid pressures.
Prior to the general operation of the injection system 300, all of the valves in the injection system may be closed, including the valves 322, 348, 372, 328, 337, 354, 366, 308, 388, 334, 360 and 382. Moreover, the pump 304 may cause liquid such as drilling fluid to flow from the mud tank 302, through the line 306, the line portion 312a, the orifice 310 and the line portion 312b, and to the pipe string 55. It is understood that the pressure in the line 306 and the line portion 312a is substantially equal to the supply pressure of the pump 304, and that the pressure in the line portion 312b is less than the pressure in the line 306 and the line portion 312a due to the pressure drop caused by the orifice 310. It is further understood that the portion of the line 306 extending to the valve 308, and the lines 327, 353, 378, 332, 358, 380, 338, 368 and 390 may be full of drilling fluid. Moreover, it is understood that the injector vessels 324, 350 and 374 may also be full of drilling fluid. The reservoir 314 is filled with material such as, for example, the solid material impactors 100 discussed above in connection with
For clarity purposes, the individual operation of the injector vessel 324 will be described. Initially, the injector vessel 324 is full of drilling fluid and the valve 337 is open, while the valves 322, 348, 372, 328, 354, 366, 308, 388, 334, 360 and 382 remain closed. As a result of the valve 337 being open, the pressure in the injector vessel 324 is substantially equal to atmospheric pressure. The pump 304 continues to cause drilling fluid to flow from the mud tank 302, through the line 306, the line portion 312a, the orifice 310 and the line portion 312b, and to the pipe string 55.
To operate the injector vessel 324, the valve 322 is opened and the conveyor 316 transports solid material impactors 100 from the reservoir 314 to the tank 318. Solid material impactors 100 are also transported from the tank 318 and into the injector vessel 324 via the conduit 320 and the valve 322, thereby charging the injector vessel with the solid material impactors. In an exemplary embodiment, the solid material impactors 100 may be fed into the injector vessel 324 with drilling fluid, in a solution or slurry form, and/or be may be gravity fed into the injector vessel 324 via the conduit 320 and the valve 322. The solid material impactors 100 and the drilling fluid present in the injector vessel 324 mix to form a suspension of liquid in the form of drilling fluid and the solid material impactors 100, that is, to form an impactor slurry.
As a result of the introduction of the solid material impactors 100 into the injector vessel 324, drilling fluid present in the injector vessel is displaced and the volume of the displaced drilling fluid flows to the tank 340 via the line 338 and the valve 337. It is understood that the pump 342 may be operated to cause at least a portion of the displaced drilling fluid in the tank 340 to flow into the tank 318 via the line 344.
After the injector vessel 324 has been charged, that is, after the desired and relatively high volume of the solid material impactors 100 has been introduced into the injector vessel, the valve 322 is closed to prevent further introduction of solid material impactors 100 into the injector vessel, and the valve 337 is closed to prevent any further flow of drilling fluid to the tank 340. The cylinder 326 is then operated so that hydraulic cylinder fluid is introduced into the chamber 326d and, in response, the piston 326a applies pressure to the drilling fluid in the line 327, thereby pressurizing the line 327 and the injector vessel 324. The cylinder 326 pressurizes the line 327 and the injector vessel 324 until the pressure in the line 327 and the injector vessel 324 is greater than the pressure in the line portion 312b, and is less than, substantially or nearly equal to, or greater than, the pressure in the line 306 and the line portion 312a which, in turn and as noted above, is substantially equal to the supply pressure of the pump 304.
The valve 328 is opened and, in response, a portion of the drilling fluid in the line 332 may flow through the valve 328 so that the respective pressures in the line portion 312a, the line 306, the line 332 and the injector vessel 324 further equalize to a pressure that still remains greater than the pressure in the line portion 312b.
The valve 334 is opened, thereby permitting the impactor slurry to flow through the line 335 and the orifice 336, and to the line portion 312b. It is understood that the pressure in the line 335 may be less than the pressure in the line 306 due to several factors such as, for example, the pressure drop associated with the flow of the impactor slurry through one or more components such as, for example, the valve 334 and the orifice 336. Notwithstanding this pressure drop, the pump 304 continues to maintain a pressurized flow of drilling fluid into the injector vessel 324 via the line 306, the valve 328 and the line 332. Due to the pressurized flow of drilling fluid, and the pressure drop across the orifice 310, the pressure in the line 335 is still greater than the pressure in the line portion 312b of the line 312. As a result, the impactor slurry having the desired and relatively high volume of solid material impactors 100 is injected into the line portion 312b of the line 312, and therefore to the pipe string 55, at a relatively high pressure.
In an exemplary embodiment, it is understood that gravity may be employed to assist in the flow of the slurry from the injector vessel 324 to the line portion 312b via the line 335 and the orifice 336. In an exemplary embodiment, it is understood that the flow of impactor slurry delivered to the pipe string 55 via the line portion 312b of the line 312 may be accelerated and discharged to remove a portion of the formation 52 (
After the impactor slurry has been completely discharged from the injector vessel 324, the valves 328 and 334 are closed, thereby preventing any flow of drilling fluid from the tank 302, through the pump 304, the line 306, the line 332, the injector vessel 324, the valve 334, the orifice 336 and the line 335, and to the line portion 312b of the line 312. The cylinder 326 is then operated so that the hydraulic cylinder fluid in the chamber 326d is discharged therefrom. During this discharge, the pressurized drilling fluid still present in the line 327 and the injector vessel 324 applies pressure against the piston 326a. As a result, the pressure in the line 327 and the injector vessel 324 is reduced, and may be reduced to atmospheric pressure. The valve 337 may be opened, thereby permitting a volume of the pressurized drilling fluid that may still be present in the injector vessel 324 to be displaced, thereby causing additional drilling fluid to flow from the line 338 to the tank 340. As a result, the pressure in the injector vessel 324 may be vented, thereby facilitating its return to atmospheric pressure.
At this point, the injector vessel 324 is again in its initial condition, with the injector vessel full of drilling fluid and the valve 337 open, and the valves 322, 348, 372, 328, 354, 366, 308, 388, 334, 360 and 382 closed. The pump 304 continues to cause drilling fluid to flow from the mud tank 302, through the line 306, the line portion 312a, the orifice 310 and the line portion 312b, and to the pipe string 55.
In an exemplary embodiment, the above-described operation of the injector vessel 324 may be repeated by again opening the valve 322 to again charge the injector vessel 324, that is, to again permit introduction of the solid material impactors 100 into the injector vessel 324, as discussed above.
The individual operation of the injector vessel 350 will be described. In an exemplary embodiment, the individual operation of the injector vessel 350 is substantially similar to the operation of the injector vessel 324, with the conduit 346, the valve 348, the injector vessel 350, the cylinder 352, the piston 352a, the housing 352b, the chamber 352c, the chamber 352d, the valve 354, the line 353, the line 358, the valve 360, the orifice 362, the line 364 and the valve 366 operating in a manner substantially similar to the above-described operation of the conduit 320, the valve 322, the injector vessel 324, the cylinder 326, the piston 326a, the housing 326b, the chamber 326c, the chamber 326d, the valve 328, the line 327, the line 332, the valve 334, the orifice 336, the line 335 and the valve 337, respectively. The line 368 operates in a manner similar to the line 338, except that both the line 368 and the line 338 are used to vent the injector vessel 350 during its operation.
More particularly, the injector vessel 350 is initially full of drilling fluid and the valve 366 is open, while the valves 322, 348, 372, 328, 354, 337, 308, 388, 334, 360 and 382 remain closed. As a result of the valve 366 being open, the pressure in the injector vessel 350 is substantially equal to atmospheric pressure. The pump 304 continues to cause drilling fluid to flow from the mud tank 302, through the line 306, the line portion 312a, the orifice 310 and the line portion 312b, and to the pipe string 55.
To operate the injector vessel 350, the valve 348 is opened and the conveyor 316 transports solid material impactors 100 from the reservoir 314 to the tank 318. Solid material impactors 100 are also transported from the tank 318 and into the injector vessel 350 via the conduit 346 and the valve 348, thereby charging the injector vessel with the solid material impactors. In an exemplary embodiment, the solid material impactors 100 may be fed into the injector vessel 350 with drilling fluid, in a solution or slurry form, and/or may be gravity fed into the injector vessel 350 via the conduit 346 and the valve 348. The solid material impactors 100 and the drilling fluid present in the injector vessel 350 mix to form a suspension of liquid in the form of drilling fluid and the solid material impactors 100, that is, to form an impactor slurry.
As a result of the introduction of the solid material impactors 100 into the injector vessel 350, drilling fluid present in the injector vessel is displaced and the volume of the displaced drilling fluid flows to the tank 340 via the lines 368 and 338 and the valve 366. It is understood that the pump 342 may be operated to cause at least a portion of the displaced drilling fluid in the tank 340 to flow into the tank 318 via the line 344.
After the injector vessel 350 has been charged, that is, after the desired and relatively high volume of the solid material impactors 100 has been introduced into the injector vessel, the valve 346 is closed to prevent further introduction of solid material impactors 100 into the injector vessel, and the valve 366 is closed to prevent any further flow of drilling fluid to the tank 340. The cylinder 352 is then operated so that hydraulic cylinder fluid is introduced into the chamber 352d and, in response, the piston 352a applies pressure to the drilling fluid in the line 353, thereby pressurizing the line 353 and the injector vessel 350. The cylinder 352 pressurizes the line 353 and the injector vessel 350 until the pressure in the line 353 and the injector vessel 350 is greater than the pressure in the line portion 312b, and is less than, substantially or nearly equal to, or greater than, the pressure in the line 306 and the line portion 312a which, in turn and as noted above, is substantially equal to the supply pressure of the pump 304.
The valve 354 is opened and, in response, a portion of the drilling fluid in the line portion 358 may flow through the valve 354 so that the respective pressures in the line portion 312a, the line 306, the line 358 and the injector vessel 350 further equalize to a pressure that still remains greater than the pressure in the line portion 312b.
The valve 360 is opened, thereby permitting the impactor slurry to flow through the line 364 and the orifice 362, and to the line portion 312b. It is understood that the pressure in the line 364 may be less than the pressure in the line 306 due to several factors such as, for example, the pressure drop associated with the flow of the impactor slurry through one or more components such as, for example, the valve 360 and the orifice 362. Notwithstanding this pressure drop, the pump 304 continues to maintain a pressurized flow of drilling fluid into the injector vessel 350 via the line 306, the valve 354 and the line 358. Due to the pressurized flow of drilling fluid, and the pressure drop across the orifice 310, the pressure in the line 364 is still greater than the pressure in the line portion 312b of the line 312. As a result, the impactor slurry having the desired and relatively high volume of solid material impactors 100 is injected into the line portion 312b of the line 312, and therefore to the pipe string 55, at a relatively high pressure.
In an exemplary embodiment, it is understood that gravity may be employed to assist in the flow of the slurry from the injector vessel 350 to the line portion 312b via the line 364 and the orifice 362. In an exemplary embodiment, it is understood that the flow of impactor slurry delivered to the pipe string 55 via the line portion 312b of the line 312 may be accelerated and discharged to remove a portion of the formation 52 (
After the impactor slurry has been completely discharged from the injector vessel 350, the valves 354 and 360 are closed, thereby preventing any flow of drilling fluid from the tank 302, through the pump 304, the line 306, the line 358, the injector vessel 350, the valve 360, the orifice 362 and the line 364, and to the line portion 312b of the line 312. The cylinder 352 is then operated so that the hydraulic cylinder fluid in the chamber 352d is discharged therefrom. During this discharge, the pressurized drilling fluid still present in the line 353 and the injector vessel 350 applies pressure against the piston 352a. As a result, the pressure in the line 353 and the injector vessel 350 is reduced, and may be reduced to atmospheric pressure. The valve 366 may be opened, thereby permitting a volume of the pressurized drilling fluid that may still be present in the injector vessel 350 to be displaced via the line 368, thereby causing additional drilling fluid to flow from the line 338 to the tank 340. As a result, the pressure in the injector vessel 350 may be vented, thereby facilitating its return to atmospheric pressure.
At this point, the injector vessel 350 is again in its initial condition, with the injector vessel fill of drilling fluid and the valve 366 open, and the valves 322, 348, 372, 328, 354, 337, 308, 388, 334, 360 and 382 closed. The pump 304 continues to cause drilling fluid to flow from the mud tank 302, through the line 306, the line portion 312a, the orifice 310 and the line portion 312b, and to the pipe string 55.
In an exemplary embodiment, the above-described operation of the injector vessel 350 may be repeated by again opening the valve 348 to again charge the injector vessel 350, that is, to again permit introduction of the solid material impactors 100 into the injector vessel 350, as discussed above.
The individual operation of the injector vessel 374 will be described. In an exemplary embodiment, the individual operation of the injector vessel 374 is substantially similar to the operation of the injector vessel 324, with the conduit 370, the valve 372, the injector vessel 374, the cylinder 376, the piston 376a, the housing 376b, the chamber 376c, the chamber 376d, the valve 308, the line 378, the line 380, the valve 382, the orifice 384, the line 386 and the valve 388 operating in a manner substantially similar to the above-described operation of the conduit 320, the valve 322, the injector vessel 324, the cylinder 326, the piston 326a, the housing 326b, the chamber 326c, the chamber 326d, the valve 328, the line 327, the line 332, the valve 334, the orifice 336, the line 335 and the valve 337, respectively. The line 390 operates in a manner similar to the line 338, except that both the line 390 and the line 338 are used to vent the injector vessel 374 during its operation.
More particularly, the injector vessel 374 is initially full of drilling fluid and the valve 388 is open, while the valves 322, 348, 372, 328, 354, 366, 308, 337, 334, 360 and 382 remain closed. As a result of the valve 388 being open, the pressure in the injector vessel 374 is substantially equal to atmospheric pressure. The pump 304 continues to cause drilling fluid to flow from the mud tank 302, through the line 306, the line portion 312a, the orifice 310 and the line portion 312b, and to the pipe string 55.
To operate the injector vessel 374, the valve 372 is opened and the conveyor 316 transports solid material impactors 100 from the reservoir 314 to the tank 318. Solid material impactors 100 are also transported from the tank 318 and into the injector vessel 374 via the conduit 370 and the valve 372, thereby charging the injector vessel with the solid material impactors. In an exemplary embodiment, the solid material impactors 100 may be fed into the injector vessel 374 with drilling fluid, in a solution or slurry form, and/or may be gravity fed into the injector vessel 374 via the conduit 370 and the valve 372. In an exemplary embodiment, the solid material impactors 100 may be gravity fed into the injector vessel 374 via the conduit 370 and the valve 372. The solid material impactors 100 and the drilling fluid present in the injector vessel 374 mix to form a suspension of liquid in the form of drilling fluid and the solid material impactors 100, that is, to form an impactor slurry.
As a result of the introduction of the solid material impactors 100 into the injector vessel 374, drilling fluid present in the injector vessel is displaced and the volume of the displaced drilling fluid flows to the tank 340 via the lines 390 and 338 and the valve 337. It is understood that the pump 342 may be operated to cause at least a portion of the displaced drilling fluid in the tank 340 to flow into the tank 318 via the line 344.
After the injector vessel 374 has been charged, that is, after the desired and relatively high volume of the solid material impactors 100 has been introduced into the injector vessel, the valve 372 is closed to prevent further introduction of solid material impactors 100 into the injector vessel, and the valve 388 is closed to prevent any further flow of drilling fluid to the tank 340. The cylinder 376 is then operated so that hydraulic cylinder fluid is introduced into the chamber 376d and, in response, the piston 376a applies pressure to the drilling fluid in the line 378, thereby pressurizing the line 378, the line 380 and the injector vessel 374. The cylinder 376 pressurizes the line 378 and the injector vessel 374 until the pressure in the line 378 and the injector vessel 374 is greater than the pressure in the line portion 312b, and is less than, substantially or nearly equal to, or greater than, the pressure in the line 306 and the line portion 312a which, in turn and as noted above, is substantially equal to the supply pressure of the pump 304.
The valve 308 is opened and, in response, a portion of the drilling fluid in the line portion 306 may flow through the valve 308 so that the respective pressures in the line portion 312a, the line 306, the line 380 and the injector vessel 374 further equalize to a pressure that still remains greater than the pressure in the line portion 312b.
The valve 382 is opened, thereby permitting the impactor slurry to flow through the line 386 and the orifice 384, and to the line portion 312b. It is understood that the pressure in the line 386 may be less than the pressure in the line 306 due to several factors such as, for example, the pressure drop associated with the flow of the impactor slurry through one or more components such as, for example, the valve 382 and the orifice 384. Notwithstanding this pressure drop, the pump 304 continues to maintain a pressurized flow of drilling fluid into the injector vessel 374 via the line 306, the valve 308 and the line 380. Due to the pressurized flow of drilling fluid, and the pressure drop across the orifice 310, the pressure in the line 386 is still greater than the pressure in the line portion 312b of the line 312. As a result, the impactor slurry having the desired and relatively high volume of solid material impactors 100 is injected into the line portion 312b of the line 312, and therefore to the pipe string 55, at a relatively high pressure.
In an exemplary embodiment, it is understood that gravity may be employed to assist in the flow of the slurry from the injector vessel 374 to the line portion 312b via the line 386 and the orifice 384. In an exemplary embodiment, it is understood that the flow of impactor slurry delivered to the pipe string 55 via the line portion 312b of the line 312 may be accelerated and discharged to remove a portion of the formation 52 (
After the impactor slurry has been completely discharged from the injector vessel 374, the valves 308 and 382 are closed, thereby preventing any flow of drilling fluid from the tank 302, through the pump 304, the line 306, the line 380, the injector vessel 374, the valve 382, the orifice 384 and the line 386, and to the line portion 312b of the line 312. The cylinder 376 is then operated so that the hydraulic cylinder fluid in the chamber 376d is discharged therefrom. During this discharge, the pressurized drilling fluid still present in the line 378 and the injector vessel 374 applies pressure against the piston 376a. As a result, the pressure in the line 378 and the injector vessel 374 is reduced, and may be reduced to atmospheric pressure. The valve 388 is opened, thereby permitting a volume of the pressurized drilling fluid that may still be present in the injector vessel 374 to be displaced via the line 390, thereby causing additional drilling fluid to flow from the line 338 to the tank 340. As a result, the pressure in the injector vessel 374 may be vented, thereby facilitating its return to atmospheric pressure.
At this point, the injector vessel 374 is again in its initial condition, with the injector vessel full of drilling fluid and the valve 388 open, and the valves 322, 348, 372, 328, 354, 366, 308, 337, 334, 360 and 382 closed. The pump 304 continues to cause drilling fluid to flow from the mud tank 302, through the line 306, the line portion 312a, the orifice 310 and the line portion 312b, and to the pipe string 55.
In an exemplary embodiment, the above-described operation of the injector vessel 374 may be repeated by again opening the valve 372 to again charge the injector vessel 374, that is, to again permit introduction of the solid material impactors 100 into the injector vessel 374, as discussed above.
Referring to the table in
For example and with reference to the row of operational steps corresponding to the time period labeled “Time 3” in the table shown in
Moreover, and again during the injection of impactor slurry into the line portion 312b and to the pipe string 55 by the injector vessel 324, the injector vessel 376 may be charged with the desired volume of solid material impactors 100 by opening the valve 372 and permitting the solid material impactors 100 to be transported from the tank 318 to the injectorvessel 376 via the valve and the conduit 370. During the charging of the injector vessel 376 with the solid material impactors 100, the valves 322 and 348 are closed to prevent any charging of the injector vessels 324 and 350, respectively, so that only the injector vessel 374 is charged with the solid material impactors.
With reference to the row of operational blocks corresponding to the time period labeled “Time 4” in the table shown in
During the charging of the injector vessel 324, the injector vessel 350 may inject impactor slurry into the line portion 312b of the line 312, and to the pipe string 55, through the open valve 360, the orifice 362 and the line 364. During the injection by the injector vessel 350, the valves 334 and 382 are closed to prevent any injection into the line portion 312b by the injector vessels 324 and 376, respectively.
Moreover, and again during the charging of the injector vessel 324, the injector vessel 374 may be pressurized using the cylinder 376 until the pressure in the injector vessel is greater than the pressure in the line portion 312b, and is less than, substantially or nearly equal to, or greater than, the pressure in the line 306 which, as noted above, is substantially equal to the supply pressure of the pump 304. During the pressurization of the injector vessel 374 by the cylinder 376, the pistons 326a and 352a do not apply pressure against the drilling fluid in the lines 327 and 353, respectively, so that only the injector vessel 374 is pressurized.
With reference to the row of operational blocks corresponding to the time period labeled “Time 5” in the table shown in
During the pressurization of the injector vessel 324, the injector vessel 350 may be charged with the desired volume of solid material impactors 100 by opening the valve 348 and permitting the solid material impactors 100 to be transported from the tank 318 to the injector vessel 350 via the valve and the conduit 346. During the charging of the injector vessel 350 with the solid material impactors 100, the valves 322 and 372 are closed to prevent any charging of the injector vessels 324 and 374, respectively, so that only the injector vessel 350 is charged with the solid material impactors.
Moreover, and again during the pressurization of the injector vessel 324, the injector vessel 374 may inject impactor slurry into the line portion 312b of the line 312, and to the pipe string 55, through the open valve 382, the orifice 384 and the line 386. During the injection by the injector vessel 374, the valves 334 and 360 are closed to prevent any injection into the line portion 312b by the injector vessels 324 and 350, respectively.
In view of the foregoing, it is understood that, during at least portions of one or more time periods during the operation of the system 300, one of the injector vessels 324, 350 and 374 will be undergoing charging, that is, receiving a desired volume of solid material impactors 100, while another of the injector vessels will be undergoing pressurization to a pressure substantially or nearly equal to the supply pressure of the pump 304, and while yet another of the injector vessels will be injecting impactor slurry into the line portion 312b and to the pipe string 55. As a result, a constant, generally uniformly distributed and relatively-high-pressure injection of impactor slurry will be injected into and flow through a flow region defined by the line portion 312b of the line 312 and to the pipe string 55 during the operation of the system 300, with the impactor slurry having a relatively high volume of solid material impactors 100. It is understood that, during a particular time period during the operation of the system 300, the charging of one of the injector vessels 324, 350 and 374 may occur before, during and/or after the pressurization of another of the injector vessels 324, 350 and 374 which, in turn, may occur before, during and/or after the injection of impactor slurry by yet another of the injector vessels 324, 350 and 374. It is understood that, during a particular time period of operation of the system 300, the charging of one of the injector vessels 324, 350 and 374 may occur simultaneously with, at least partially simultaneously with, or not simultaneously with the pressurization of another of the injector vessels 324, 350 and 374 which, in turn, may occur simultaneously with, at least partially simultaneously with, or not simultaneously with the injection of impactor slurry by yet another of the injector vessels 324, 350 and 374.
It is understood that the sequence of operation of each of the injector vessels 324, 350 and 374 is substantially the same, but that the initiation of the operational sequence of each injector vessel is controlled relative to the initiation of the operational sequences of the other injector vessels. The sequential injection of impactor slurry by the injector vessels 324, 350 and 374 may be controlled to achieve the desired or required mass flow rate of impactor slurry in the line portion 312b.
It is further understood that a wide variety of time-staggering configurations between the initiations of operation of the injector vessels 324, 350 and 374 may be employed during the operation of the system 300. Also, it is understood that the order of operation depicted in
Moreover, it is understood that the above-described initial conditions of the system 300, and/or one or more of the injector vessels 324, 350 and 374 may be arbitrary and that additional operational steps may be necessary to carry out the above-described operation of the system. For example, if the injector vessel 324 is not initially full of drilling fluid, it is understood that the injector vessel 324 may be filled with drilling fluid.
It is understood that the quantity of injector vessels in the system 300 may be decreased to two injector vessels or one injector vessel, or may be increased to an unlimited number. In an exemplary embodiment, the quantity of injector vessels in the system 300 may be increased to an unlimited number for one or more reasons such as, for example, redundancy and/or maintenance reasons. It is further understood that the quantity of injector vessels may be dictated by many factors, including the desired or required mass flow rates of the solid material impactors 100 and/or the impactor slurry containing drilling fluid and the solid material impactors 100, the desire or requirement to smooth the injection of impactor slurry, and/or the desire or requirement to more evenly distribute the solid material impactors 100 within the flowing impactor slurry.
Further, it is understood that the valves 322, 348, 372, 328, 354, 366, 308, 388, 334, 360 and 382 may be controlled in any conventional manner, including the opening and closing thereof. Also, it is understood that each of the valves 322, 348, 372, 328, 354, 366, 308, 388, 334, 360 and 382 may be controlled to fully open, fully close, partially open and/or partially close, in order to achieve operational goals and/or requirements such as, for example, the desired or required mass flow rate of impactor slurry and/or the solid material impactors 100.
In an exemplary embodiment, as illustrated in
In an exemplary embodiment, as illustrated in
A tubular portion 324i extends from the body 324a and is connected to a tubular portion 324j via a clamping ring 324k, and a tubular portion 324l extends from the tubular portion 324j. The valve 322 is connected to the tubular portion 324j via a clamping ring 325. The valve 322 will be described in greater detail below. It is understood that the tubular portions 324i, 324j and 324l collectively define the conduit 320 that connects the tank 318 to the body 324a of the injector vessel 324. It is further understood that one or more additional intervening parts may extend between the tubular portion 324l and the tank 318, and that these one or more additional intervening parts may collectively define the conduit 320 that connects the tank 18 to the body 324a of the injector 324, along with the tubular portions 324i, 324j and 324l.
A tubular portion 324m extends from the body 324a and is connected to a tubular portion 324n via a clamping ring 324o. A tee 402 is connected to the tubular portion 324n via a clamping ring 404. The valve 337 is connected to the tee 402 via a clamping ring 408. The valve 328 is connected to the body 324a of the injector vessel 324 via intervening parts not shown and in a manner to be described below.
The line 338 is connected to the tee 402 via a clamping ring 410. The line 332 is connected to the body 324a of the injector vessel 324 via intervening parts not shown and in a manner to be described below. It is understood that only portions of the lines 327, 332 and 338 are shown in
In an exemplary embodiment, as illustrated in
The orifice 336 is connected to the interior surface of and radially extends within the line 335, and includes a countersunk opening 336a and a through-bore 336b extending therefrom. In an exemplary embodiment, the countersunk opening 336a defines an angle A. In an exemplary embodiment, the angle A may be 30 degrees, resulting in the orifice 336 defining a 30-degree-metering throat that is adapted to meter fluid flow through the orifice 336. It is understood that the angle A may vary widely.
The tubular portions 324e and 324f define passages 324ea and 324fa, respectively. The valve 334 includes a generally hour-glass-shaped support member 334a, through which a window 334b extends, and an end of which is connected to the tubular portion 324f via the clamping ring 324h. A support collar 334c is coupled to the other end of the support member 334a, and a housing base 334d is coupled to and extends through the collar 334c, and defines a bore 334da. A hydraulic-actuated and/or pneumatic-actuated cylinder 334e is connected to the housing base 334d, and includes a piston 334ea that reciprocates in a housing 334eb in response to cylinder fluid being introduced into, and discharged from, the housing, in a conventional manner.
An end of a rod 334ec is connected to and extends downward from the piston 334ea, extending through the bore 334da and into the support member 334a. The other end of the rod 334ec is connected to a coupling 334ed which in turn, is connected to a coupling 334ee via a pin 334ef. An end of a shaft 334eg is connected to the coupling 334ee, and the shaft extends downwards through the support member 334a, through the passages 324fa and 324ea of the tubular portions 324f and 324e, respectively, through the chamber 324aa, the bore 324bba of the disc 324bb of the tubular spool 324b, and the passage 324ba of the tubular spool, and at least partially within the plug seat 324bc. The disc 324bb is adapted to support and/or stabilize the shaft 334eg. A plug element 334eh is connected to the other end of the shaft 334eg, and at least partially extends within the line 335 at an axial position above the orifice 336. The plug element is 334eh is adapted to move up and down in response to the reciprocating motion of the piston 334ea, and thus engage and disengage, respectively, the plug seat 324bc to close and open, respectively, the valve 334.
In an exemplary embodiment, as illustrated in
The valve 322 includes a generally hour-glass-shaped support member 322a, through which a window 322b extends, and an end of which is connected to the tubular portion 324j via the clamping ring 325. A support collar 322c is coupled to the other end of the support member 322a, and a housing base 322d is coupled to and extends through the collar 322c, and defines a bore 322da. A hydraulic-actuated and/or pneumatic-actuated cylinder 322e is connected to the housing base 322d, and includes a piston 322ea that reciprocates in a housing 322eb in response to cylinder fluid being introduced into, and discharged from, the housing, in a conventional manner.
An end of a rod 322ec is connected to and extends downward from the piston 322ea, extending through the bore 322da and into the support member 322a. The other end of the rod 322ec is connected to a coupling 322ed which, in turn, is connected to a coupling 322ee via a pin 322ef. An end of a shaft 322eg is connected to the coupling 322ee, and the shaft extends downwards through the support member 322a, through the passage 324ja of the tubular portion 324j, and at least partially within the plug seat 324jb. A plug element 322eh is connected to the other end of the shaft 322eg, and at least partially extends within the passage 324ia. The plug element 322eh is adapted to move up and down in response to the reciprocating motion of the piston 322ea, and thus engage and disengage, respectively, the plug seat 324jb to close and open, respectively, the valve 322.
In an exemplary embodiment, as illustrated in
The valve 337 includes a generally hour-glass-shaped support member 337a, through which a window 337b extends, and an end of which is connected to the tee 402 via the clamping ring 408. A support collar 337c is coupled to the other end of the support member 337a, and a housing base 337d is coupled to and extends through the collar 337c, and defines a bore 337da. A hydraulic-actuated and/or pneumatic-actuated cylinder 337e is connected to the housing base 337d, and includes a piston 337ea that reciprocates in a housing 337eb in response to cylinder fluid being introduced into, and discharged from, the housing, in a conventional manner.
An end of a rod 337ec is connected to and extends downward from the piston 337ea, extending through the bore 337da and into the support member 337a. The other end of the rod 337ec is connected to a coupling 337ed which, in turn, is connected to a coupling 337ee via a pin 337ef. An end of a shaft 337eg is connected to the coupling 337ee, and the shaft extends downwards through the support member 337a, through the passage 402a of the tee 402, and at least partially within the plug seat 324nb. A plug element 337eh is connected to the other end of the shaft 337eg, and at least partially extends within the passage 324na of the tubular portion 324n. The plug element is 337eh is adapted to move up and down in response to the reciprocating motion of the piston 337ea, and thus engage and disengage, respectively, the plug seat 324nb to close and open, respectively, the valve 337.
In an exemplary embodiment, as illustrated in
The valve 328 is connected to the coupling member 416 via a clamping ring 420. The valve 328 includes a generally hour-glass-shaped support member 328a, through which a window 328b extends, and an end of which is connected to the coupling member 416 via the clamping ring 420. A support collar 328c is coupled to the other end of the support member 328a, and a housing base 328d is coupled to and extends through the collar 328c, and defines a bore 328da. A hydraulic-actuated and/or pneumatic-actuated cylinder 328e is connected to the housing base 328d, and includes a piston 328ea that reciprocates in a housing 328eb in response to cylinder fluid being introduced into, and discharged from, the housing, in a conventional manner.
An end of a rod 328ec is connected to and extends downward from the piston 328ea, extending through the bore 328da and into the support member 328a. The other end of the rod 328ec is connected to a coupling 328ed which, in turn, is connected to a coupling 328ee via a pin 328ef. An end of a shaft 328eg is connected to the coupling 328ce, and the shaft extends downwards through the support member 328a, through the coupling member 416, through the passage 412a of the tee 412, and at least partially within the passage 324qa of the tubular portion 324q. A plug element 328eh is connected to the other end of the shaft 328eg, and at least partially extends within the passage 324qa of the tubular portion 324q. The plug element 328eh is adapted to move up and down in response to the reciprocating motion of the piston 328ea, and thus disengage and engage, respectively, the plug seat 324qb to open and close, respectively, the valve 328.
In an exemplary embodiment, as illustrated in
Initially, the chamber 324aa of the body 324a of the injector vessel 324 is full of drilling fluid and the valve 337 is open, that is, the plug element 337eh is disengaged from the plug seat 324nb, while the valves 322, 348, 372, 328, 354, 366, 308, 388, 334, 360 and 382 remain closed. As a result of the valve 337 being open, the pressure within the chamber 324aa is substantially equal to atmospheric pressure. The pump 304 continues to cause drilling fluid to flow from the mud tank 302, through the line 306, the line portion 312a, the orifice 310 and the line portion 312b, and to the pipe string 55.
To operate the injector vessel 324, the valve 322 is opened by moving the piston 322ea downward so that, as a result, the rod 322ec, the coupling 322ed, the pin 322ef, the coupling 322ee, the shaft 322eg and the plug element 322eh move downward and the plug element disengages from the plug seat 324jb. In an exemplary embodiment, it is understood that the piston 322ea, and therefore the valve 322, may be controlled in any conventional manner. The conveyor 316 transports solid material impactors 100 from the reservoir 314 to the tank 318. Solid material impactors 100 flow from the tank 318 and into the chamber 324aa of the body 324a of the injector vessel 324 via the conduit 320, that is, via at least the passages 324la, 324ja and 324ia, and via the valve 322, that is, via between the gap between the plug element 322eh and the plug seat 324jb, thereby charging the injector vessel with the solid material impactors. In an exemplary embodiment, the solid material impactors 100 may be fed into the injector vessel 324 with drilling fluid, in a solution or slurry form, and/or may be may be gravity fed into the injector vessel 324 via the conduit 320 and the valve 322. The solid material impactors 100 and the drilling fluid present in the chamber 324aa of the body 324a of the injector vessel 324 mix to form a suspension of liquid in the form of drilling fluid and the solid material impactors 100.
As a result of the introduction of the solid material impactors 100 into the chamber 324aa, drilling fluid present in the chamber is displaced and the volume of the displaced drilling fluid flows to the tank 340 via a volume displacement 422 in the chamber, the passage 324ma, the gap between the plug seat 324nb and the plug element 337eh of the open valve 337, the passage 402a and the line 338. It is understood that the pump 342 may be operated to cause at least a portion of the displaced drilling fluid in the tank 340 to flow into the tank 318 via the line 344.
After the injector vessel 324 has been charged, that is, after the desired and relatively high volume of the solid material impactors 100 has been introduced into the chamber 324aa, the valve 322 is closed to prevent further introduction of solid material impactors 100 into the injector vessel, that is, the piston 322ea is moved upward so that, as a result, the coupling 322ed, the pin 322ef, the coupling 322ee, the shaft 322eg and the plug element 322eh move upward and the plug element engages the plug seat 324jb. The valve 337 is closed to prevent any further flow of drilling fluid to the tank 340, that is, the piston 337ea is moved upward so that, as a result, the rod 337ec, the coupling 337ed, the pin 337ef, the coupling 337ce, the shaft 337eg and the plug element 337eh move upward and the plug element engages the plug seat 324nb. In an exemplary embodiment, it is understood that the piston 337ea, and therefore the valve 337, may be controlled in any conventional manner.
In an exemplary embodiment, as illustrated in
The valve 328 is opened by moving the piston 328ea upward so that, as a result, the rod 328ec, the coupling 328ed, the pin 328ef, the coupling 328ee, the shaft 328eg and the plug element 328eh move upward and the plug element disengages from the plug seat 324qb. In an exemplary embodiment, it is understood that the piston 328ea, and therefore the valve 328, may be controlled in any conventional manner. In response, a portion of the drilling fluid in the line 332, the passage 412a, the passage 324qa and/or the passage 324pa, may flow through the valve 328 so that the respective pressures in the line portion 312a, the line 306, the line 332, the passage 412a, the passage 324qa, the passage 324pa and the chamber 324aa further equalize to a pressure that still remains greater than the pressure in the line portion 312b.
In an exemplary embodiment, as illustrated in
As a result of the opening of the valve 334, an impactor slurry 426, that is, the suspension of liquid in the form of drilling fluid and the solid material impactors 100, flows through the chamber 324aa, the openings 342bba, 342bbb and 342bbc, the passage 324ba of the spool 324b, the line 335, and the countersunk opening 336a and the through-bore 336b of the orifice 336.
As a result of the flow of the impactor slurry 426, the impactor slurry is permitted to be injected into the line portion 312b. It is understood that the pressure in the line 335 may be less than the pressure in the line 306 due to several factors such as, for example, the pressure drop associated with the flow of the impactor slurry 426 through one or more components such as, for example, the valve 334 and the orifice 336. Notwithstanding this pressure drop, the pump 304 continues to maintain a pressurized flow of drilling fluid 428 into the chamber 324aa via the line 306, the line 332, the passage 412a, the passage 324qa, the gap between the plug seat 324qb and the plug element 328eh of the valve 328 and the passage 324pa. Due to the pressurized flow of drilling fluid 428, and the pressure drop across the orifice 310, the pressure in the line 335 is still greater than the pressure in the line portion 312b of the line 312. As a result, the impactor slurry 426 having the desired and relatively high volume of solid material impactors 100 is injected into the line portion 312b of the line 312, and therefore to the pipe string 55, at a relatively high pressure.
In an exemplary embodiment, it is understood that gravity may be employed to assist in the flow of the impactor slurry 426 from the injector vessel 324 to the line portion 312b via the line 335 and the orifice 336. In an exemplary embodiment, it is understood that the flow of impactor slurry delivered to the pipe string 55 via the line portion 312b of the line 312 may be accelerated and discharged to remove a portion of the formation 52 (
In an exemplary embodiment, as illustrated in
In an exemplary embodiment, in response to the closing of the valve 334 and thus the engagement of the plug element 334eh and the plug seat 324bc, the contact line defined by the engagement between the plug element of the valve and the plug seat may be 15 degrees from the longitudinal axis of the tubular spool 324b. In an exemplary embodiment, the contact lines defined by the engagement between the plug element 334eh of the valve 334 and the plug seat 324bc of the tubular spool 324b, corresponding to two 180-degree-circumferentially-spaced locations on the plug element, may define a 30-degree angle therebetween.
The cylinder 326 is then operated so that the hydraulic cylinder fluid in the chamber 326d is discharged therefrom. During this discharge, the pressurized drilling fluid still present in the line 327 and the injector vessel 324 applies pressure against the piston 326a. As a result, the pressure in the line 327, the passage 324fa, the passage 324ea and the chamber 324aa of the injector vessel 324 is reduced, and may be reduced to atmospheric pressure. The valve 337 is opened, that is the plug element 337eh disengages from the plug seat 324nb, thereby permitting a volume of the pressurized drilling fluid that may still be present in the chamber 324aa to be displaced so that the volume of the displaced drilling fluid flows to the tank 340 via a volume displacement 430 in the chamber, the passage 324ma, the passage 324na, the gap between the plug seat 324nb and the plug element 337eh of the open valve 337, the passage 402a and the line 338. As a result, the pressure in the injector vessel 324 may be vented, thereby facilitating its return to atmospheric pressure.
At this point, the injector vessel 324 is again in its initial condition, with the injector vessel full of drilling fluid and the valve 337 open, and the valves 322, 348, 372, 328, 354, 366, 308, 388, 334, 360, 382 and 406 closed. The pump 304 continues to cause drilling fluid to flow from the mud tank 302, through the line 306, the line portion 312a, the orifice 310 and the line portion 312b, and to the pipe string 55.
In an exemplary embodiment, the above-described operation of the injector vessel 324 may be repeated by again opening the valve 322 to again charge the injector vessel 324, that is, to again permit introduction of the solid material impactors 100 into the injector vessel 324, as discussed above.
In an exemplary embodiment, it is understood that the embodiments of the injector vessels 350 and 374 depicted in
In an exemplary embodiment, it is understood that the embodiments of the injector vessels 324, 350 and 374 depicted in
Referring to
A solid-material-impactor bin or reservoir 3014 is operably coupled to a solid-impactor transport device such as a shot-feed conveyor 3016 which, in turn, is operably coupled to a distribution tank 3018. A conduit 3020 connects the tank 3018 to a valve 3022, and the conduit further extends and is connected to an injector vessel 3024.
A hydraulic-actuated cylinder 3026 is fluidicly coupled to a valve 3028 via a hydraulic flow line 3030 that also extends to the line 3006. Line portions 3030a and 3030b are defined and separated by the valve 3028. The cylinder 26 includes a piston 3026a that reciprocates in a cylinder housing 3026b in a conventional manner. The housing 3026b defines a variable-volume chamber 3026c in fluid communication with the line 3030, and further defines a variable-volume chamber 3026d into which hydraulic cylinder fluid is introduced, and from which the hydraulic fluid is discharged, under conditions to be described.
A hydraulic line 3032 fluidicly couples the line 3030 to the vessel 3024, and a valve 3034 is fluidicly coupled to the vessel 3024. A hydraulic line 3035 fluidicly couples an orifice 3036 to the valve 3034, and the line also extends to the line portion 3012b of the line 3012. A valve 3037 is fluidicly coupled to the vessel 3024 via a hydraulic line 3038 that also extends to a reservoir or tank 3040. A pump 3042 is fluidicly coupled to the tank 3040 via a hydraulic line 3044 that also extends to the tank 3018.
A conduit 3046 connects the tank 3018 to a valve 3048, and the conduit further extends and is connected to an injector vessel 3050. A hydraulic-actuated cylinder 3052 is fluidicly coupled to a valve 3054 via a hydraulic flow line 3056 that also extends to the line 3006. Line portions 3056a and 3056b are defined and separated by the valve 3054. The cylinder 3052 includes a piston 3052a that reciprocates in a cylinder housing 3052b in a conventional manner. The housing 3052b defines a variable-volume chamber 3052c in fluid communication with the line 3056, and further defines a variable-volume chamber 3052d into which hydraulic cylinder fluid is introduced, and from which the hydraulic fluid is discharged, under conditions to be described.
A hydraulic line 3058 fluidicly couples the line 3056 to the vessel 3050. A valve 3060 is fluidicly coupled to the vessel 3050, and an orifice 3062 is fluidicly coupled to the valve via a hydraulic line 3064 that also extends to the line portion 3012b of the line 3012. A valve 3066 is fluidicly coupled to the vessel 3050 via a hydraulic line 3068 that also extends to the line 3038.
A conduit 3070 connects the tank 3018 to a valve 3072, and the conduit further extends and is connected to an injector vessel 3074. A hydraulic-actuated cylinder 3076 is fluidicly coupled to the valve 3008 via a hydraulic line 3078, and the cylinder includes a piston 3076a that reciprocates in a cylinder housing 3076b in a conventional manner. The housing 3076b defines a variable-volume chamber 3076c in fluid communication with the line 3056, and further defines a variable-volume chamber 3076d into which hydraulic cylinder fluid is introduced, and from which the hydraulic fluid is discharged, under conditions to be described.
A hydraulic line 3080 fluidicly couples the line 3078 to the vessel 3074. A valve 3082 is fluidicly coupled to the vessel 3074, and an orifice 3084 is fluidicly coupled to the valve via a hydraulic line 3086 that also extends to the line portion 3012b of the line 3012. A valve 3088 is fluidicly coupled to the vessel 3074 via a hydraulic line 3090 that also extends to the line 3038. In an exemplary embodiment, it is understood that all of the above-described lines and line portions define flow regions through which fluid may flow over a range of fluid pressures.
Prior to the general operation of the injection system 3000, all of the valves in the injection system may be closed, including the valves 3022, 3048, 3072, 3028, 3037, 3054, 3066, 3008, 3088, 3034, 3060 and 3082. Moreover, the pump 3004 may cause liquid such as drilling fluid to flow from the mud tank 3002, through the line 3006, the line portion 3012a, the orifice 3010 and the line portion 3012b, and to the pipe string 55. It is understood that the pressure in the line 3006 and the line portion 3012a is substantially equal to the supply pressure of the pump 3004, and that the pressure in the line portion 3012b is less than the pressure in the line 3006 and the line portion 3012a due to the pressure drop caused by the orifice 3010. It is further understood that the portion of the line 3006 extending to the valve 3008, the line portions 3030b, 3056b, 3030a and 3056a, and the lines 3078, 3032, 3058, 3080, 3038, 3068 and 3090 may be full of drilling fluid. Moreover, it is understood that the injector vessels 3024, 3050 and 3074 may also be full of drilling fluid. The reservoir 3014 is filled with material such as, for example, the solid material impactors 100 discussed above in connection with
For clarity purposes, the individual operation of the injector vessel 3024 will be described. Initially, the injector vessel 3024 is full of drilling fluid and the valve 3037 is open, while the valves 3022, 3048, 3072, 3028, 3054, 3066, 3008, 3088, 3034, 3060 and 3082 remain closed. As a result of the valve 3037 being open, the pressure in the injector vessel 3024 is substantially equal to atmospheric pressure. The pump 3004 continues to cause drilling fluid to flow from the mud tank 3002, through the line 3006, the line portion 3012a, the orifice 3010 and the line portion 3012b, and to the pipe string 55.
To operate the injector vessel 3024, the valve 3022 is opened and the conveyor 3016 transports solid material impactors 100 from the reservoir 3014 to the tank 3018. Solid material impactors 100 are also transported from the tank 3018 and into the injector vessel 3024 via the conduit 3020 and the valve 3022, thereby charging the injector vessel with the solid material impactors. In an exemplary embodiment, the solid material impactors 100 may be fed into the injector vessel 3024 with drilling fluid, in a solution or slurry form, and/or be may be gravity fed into the injector vessel 3024 via the conduit 3020 and the valve 3022. The solid material impactors 100 and the drilling fluid present in the injector vessel 3024 mix to form a suspension of liquid in the form of drilling fluid and the solid material impactors 100, that is, to form an impactor slurry.
As a result of the introduction of the solid material impactors 100 into the injector vessel 3024, drilling fluid present in the injector vessel is displaced and the volume of the displaced drilling fluid flows to the tank 3040 via the line 3038 and the valve 3037. It is understood that the pump 3042 may be operated to cause at least a portion of the displaced drilling fluid in the tank 3040 to flow into the tank 3018 via the line 3044.
After the injector vessel 3024 has been charged, that is, after the desired and relatively high volume of the solid material impactors 100 has been introduced into the injector vessel, the valve 3022 is closed to prevent further introduction of solid material impactors 100 into the injector vessel, and the valve 3037 is closed to prevent any further flow of drilling fluid to the tank 3040. The cylinder 3026 is then operated so that hydraulic cylinder fluid is introduced into the chamber 3026d and, in response, the piston 3026a applies pressure to the drilling fluid in the line 3030, thereby pressurizing the line 3030, the line 3032 and the injector vessel 3024. The cylinder 3026 pressurizes the line portion 3030a, the line 3032 and the injector vessel 3024 until the pressure in the line portion 3030a, the line 3032 and the injector vessel 3024 is greater than the pressure in the line portion 3012b, and is less than, substantially or nearly equal to, or greater than, the pressure in the line 3006 and the line portion 3012a which, in turn and as noted above, is substantially equal to the supply pressure of the pump 3004.
The valve 3028 is opened and, in response, a portion of the drilling fluid in the line portion 3030b may flow through the valve 3028 and into the line portion 3030a so that the respective pressures in the line portions 3012a, 3030a and 3030b, the line 3032 and the injector vessel 3024 further equalize to a pressure that still remains greater than the pressure in the line portion 3012b.
The valve 3034 is opened, thereby permitting the impactor slurry to flow through the line 3035 and the orifice 3036, and to the line portion 3012b. It is understood that the pressure in the line 3035 may be less than the pressure in the line 3006 due to several factors such as, for example, the pressure drop associated with the flow of the impactor slurry through one or more components such as, for example, the valve 3034 and the orifice 3036. Notwithstanding this pressure drop, the pump 3004 continues to maintain a pressurized flow of drilling fluid into the injector vessel 3024 via the line 3006, the line portion 3030b, the valve 3028, the line portion 3030a and the line 3032. Due to the pressurized flow of tilling fluid, and the pressure drop across the orifice 3010, the pressure in the line 3035 is still greater than the pressure in the line portion 3012b of the line 3012. As a result, the impactor slurry having the desired and relatively high volume of solid material impactors 100 is injected into the line portion 3012b of the line 3012, and therefore to the pipe string 55, at a relatively high pressure.
In an exemplary embodiment, it is understood that gravity may be employed to assist in the flow of the slurry from the injector vessel 3024 to the line portion 3012b via the line 3035 and the orifice 3036. In an exemplary embodiment, it is understood that the flow of impactor slurry delivered to the pipe string 55 via the line portion 3012b of the line 3012 may be accelerated and discharged to remove a portion of the formation 52 (
After the impactor slurry has been completely discharged from the injector vessel 3024, the valves 3028 and 3034 are closed, thereby preventing any flow of drilling fluid from the tank 3002, through the pump 3004, the line 3006, the line portion 3030b, the line portion 3030a, the line 3032, the injector vessel 3024, the valve 3034, the orifice 3036 and the line 3035, and to the line portion 3012b of the line 3012. The cylinder 3026 is then operated so that the hydraulic cylinder fluid in the chamber 3026d is discharged therefrom. During this discharge, the pressurized drilling fluid still present in the line 3032, the line portion 3030a and the injector vessel 3024 applies pressure against the piston 3026a. As a result, the pressure in the line 3032, the line portion 3030a and the injector vessel 3024 is reduced, and may be reduced to atmospheric pressure. The valve 3037 is opened, thereby permitting a volume of the pressurized drilling fluid that may still be present in the injector vessel 3024 to be displaced, thereby causing additional drilling fluid to flow from the line 3038 to the tank 3040. As a result, the pressure in the injector vessel 3024 may be vented, thereby facilitating its return to atmospheric pressure.
At this point, the injector vessel 3024 is again in its initial condition, with the injector vessel full of drilling fluid and the valve 3037 open, and the valves 3022, 3048, 3072, 3028, 3054, 3066, 3008, 3088, 3034, 3060 and 3082 closed. The pump 3004 continues to cause drilling fluid to flow from the mud tank 3002, through the line 3006, the line portion 3012a, the orifice 3010 and the line portion 3012b, and to the pipe string 55.
In an exemplary embodiment, the above-described operation of the injector vessel 3024 may be repeated by again opening the valve 3022 to again charge the injector vessel 3024, that is, to again permit introduction of the solid material impactors 100 into the injector vessel 3024, as discussed above.
The individual operation of the injector vessel 3050 will be described. In an exemplary embodiment, the individual operation of the injector vessel 3050 is substantially similar to the operation of the injector vessel 3024, with the conduit 3046, the valve 3048, the injector vessel 3050, the cylinder 3052, the piston 3052a, the housing 3052b, the chamber 3052c, the chamber 3052d, the valve 3054, the line 3056, the line portion 3056a, the line portion 3056b, the line 3058, the valve 3060, the orifice 3062, the line 3064 and the valve 3066 operating in a manner substantially similar to the above-described operation of the conduit 3020, the valve 3022, the injector vessel 3024, the cylinder 3026, the piston 3026a, the housing 3026b, the chamber 3026c, the chamber 3026d, the valve 3028, the line 3030, the line portion 3030a, the line portion 3030b, the line 3032, the valve 3034, the orifice 3036, the line 3035 and the valve 3037, respectively. The line 3068 operates in a manner similar to the line 3038, except that both the line 3068 and the line 3038 are used to vent the injector vessel 3050 during its operation.
More particularly, the injector vessel 3050 is initially full of drilling fluid and the valve 3066 is open, while the valves 3022, 3048, 3072, 3028, 3054, 3037, 3008, 3088, 3034, 3060 and 3082 remain closed. As a result of the valve 3066 being open, the pressure in the injector vessel 3050 is substantially equal to atmospheric pressure. The pump 3004 continues to cause drilling fluid to flow from the mud tank 3002, through the line 3006, the line portion 3012a, the orifice 3010 and the line portion 3012b, and to the pipe string 55.
To operate the injector vessel 3050, the valve 3048 is opened and the conveyor 3016 transports solid material impactors 100 from the reservoir 3014 to the tank 3018. Solid material impactors 100 are also transported from the tank 3018 and into the injector vessel 3050 via the conduit 3046 and the valve 3048, thereby charging the injector vessel with the solid material impactors. In an exemplary embodiment, the solid material impactors 100 may be fed into the injector vessel 3050 with drilling fluid, in a solution or slurry form, and/or may be gravity fed into the injector vessel 3050 via the conduit 3046 and the valve 3048. The solid material impactors 100 and the drilling fluid present in the injector vessel 3050 mix to form a suspension of liquid in the form of drilling fluid and the solid material impactors 100, that is, to form an impactor slurry.
As a result of the introduction of the solid material impactors 100 into the injector vessel 3050, drilling fluid present in the injector vessel is displaced and the volume of the displaced drilling fluid flows to the tank 3040 via the lines 3068 and 3038 and the valve 3066. It is understood that the pump 3042 may be operated to cause at least a portion of the displaced drilling fluid in the tank 3040 to flow into the tank 3018 via the line 3044.
After the injector vessel 3050 has been charged, that is, after the desired and relatively high volume of the solid material impactors 100 has been introduced into the injector vessel, the valve 3046 is closed to prevent further introduction of solid material impactors 100 into the injector vessel, and the valve 3066 is closed to prevent any further flow of drilling fluid to the tank 3040. The cylinder 3052 is then operated so that hydraulic cylinder fluid is introduced into the chamber 3052d and, in response, the piston 3052a applies pressure to the drilling fluid in the line 3056, thereby pressurizing the line 3056, the line 3058 and the injector vessel 3050. The cylinder 3052 pressurizes the line portion 3056a, the line 3058 and the injector vessel 3050 until the pressure in the line portion 3056a, the line 3058 and the injector vessel 3050 is greater than the pressure in the line portion 3012b, and is less than, substantially or nearly equal to, or greater than, the pressure in the line 3006 and the line portion 3012a which, in turn and as noted above, is substantially equal to the supply pressure of the pump 3004.
The valve 3054 is opened and, in response, a portion of the drilling fluid in the line portion 3056b may flow through the valve 3054 and into the line portion 3056a so that the respective pressures in the line portions 3012a, 3056a and 3056b, the line 3058 and the injector vessel 3050 further equalize to a pressure that still remains greater than the pressure in the line portion 3012b.
The valve 3060 is opened, thereby permitting the impactor slurry to flow through the line 3064 and the orifice 3062, and to the line portion 3012b. It is understood that the pressure in the line 3064 may be less than the pressure in the line 3006 due to several factors such as, for example, the pressure drop associated with the flow of the impactor slurry through one or more components such as, for example, the valve 3060 and the orifice 3062. Notwithstanding this pressure drop, the pump 3004 continues to maintain a pressurized flow of drilling fluid into the injector vessel 3050 via the line 3006, the line portion 3056b, the valve 3054, the line portion 3056a and the line 3058. Due to the pressurized flow of drilling fluid, and the pressure drop across the orifice 3010, the pressure in the line 3064 is still greater than the pressure in the line portion 3012b of the line 3012. As a result, the impactor slurry having the desired and relatively high volume of solid material impactors 100 is injected into the line portion 3012b of the line 3012, and therefore to the pipe string 55, at a relatively high pressure.
In an exemplary embodiment, it is understood that gravity may be employed to assist in the flow of the slurry from the injector vessel 3050 to the line portion 3012b via the line 3064 and the orifice 3062. In an exemplary embodiment, it is understood that the flow of impactor slurry delivered to the pipe string 55 via the line portion 3012b of the line 3012 may be accelerated and discharged to remove a portion of the formation 52 (
After the impactor slurry has been completely discharged from the injector vessel 3050, the valves 3054 and 3060 are closed, thereby preventing any flow of drilling fluid from the tank 3002, through the pump 3004, the line 3006, the line portion 3056b, the line 3058, the injector vessel 3050, the valve 3060, the orifice 3062 and the line 3064, and to the line portion 3012b of the line 3012. The cylinder 3052 is then operated so that the hydraulic cylinder fluid in the chamber 3052d is discharged therefrom. During this discharge, the pressurized drilling fluid still present in the line 3058, the line portion 3056a and the injector vessel 3050 applies pressure against the piston 3052a. As a result, the pressure in the line 3058, the line portion 3056a and the injector vessel 3050 is reduced, and may be reduced to atmospheric pressure. The valve 3066 is opened, thereby permitting a volume of the pressurized drilling fluid that may still be present in the injector vessel 3050 to be displaced via the line 3068, thereby causing additional drilling fluid to flow from the line 3038 to the tank 3040. As a result, the pressure in the injector vessel 3050 may be vented, thereby facilitating its return to atmospheric pressure.
At this point, the injector vessel 3050 is again in its initial condition, with the injector vessel full of drilling fluid and the valve 3066 open, and the valves 3022, 3048, 3072, 3028, 3054, 3037, 3008, 3088, 3034, 3060 and 3082 closed. The pump 3004 continues to cause drilling fluid to flow from the mud tank 3002, through the line 3006, the line portion 3012a, the orifice 3010 and the line portion 3012b, and to the pipe string 55.
In an exemplary embodiment, the above-described operation of the injector vessel 3050 may be repeated by again opening the valve 3048 to again charge the injector vessel 3050, that is, to again permit introduction of the solid material impactors 100 into the injector vessel 3050, as discussed above.
The individual operation of the injector vessel 3074 will be described. In an exemplary embodiment, the individual operation of the injector vessel 3074 is substantially similar to the operation of the injector vessel 3024, with the conduit 3070, the valve 3072, the injector vessel 3074, the cylinder 3076, the piston 3076a, the housing 3076b, the chamber 3076c, the chamber 3076d, the valve 3008, the line 3078, the line 3080, the valve 3082, the orifice 3084, the line 3086 and the valve 3088 operating in a manner substantially similar to the above-described operation of the conduit 3020, the valve 3022, the injector vessel 3024, the cylinder 3026, the piston 3026a, the housing 3026b, the chamber 3026c, the chamber 3026d, the valve 3028, the line portion 3030a, the line 3032, the valve 3034, the orifice 3036, the line 3035 and the valve 3037, respectively. The line 3090 operates in a manner similar to the line 30308, except that both the line 3090 and the line 3038 are used to vent the injector vessel 3074 during its operation.
More particularly, the injector vessel 3074 is initially full of drilling fluid and the valve 3088 is open, while the valves 3022, 3048, 3072, 3028, 3054, 3066, 3008, 3037, 3034, 3060 and 3082 remain closed. As a result of the valve 3088 being open, the pressure in the injector vessel 3074 is substantially equal to atmospheric pressure. The pump 3004 continues to cause drilling fluid to flow from the mud tank 3002, through the line 3006, the line portion 3012a, the orifice 3010 and the line portion 3012b, and to the pipe string 55.
To operate the injector vessel 3074, the valve 3072 is opened and the conveyor 3016 transports solid material impactors 100 from the reservoir 3014 to the tank 3018. Solid material impactors 100 are also transported from the tank 3018 and into the injector vessel 3074 via the conduit 3070 and the valve 3072, thereby charging the injector vessel with the solid material impactors In an exemplary embodiment, the solid material impactors 100 may be fed into the injector vessel 3074 with drilling fluid, in a solution or slurry form, and/or may be gravity fed into the injector vessel 3074 via the conduit 3070 and the valve 3072. The solid material impactors 100 and the drilling fluid present in the injector vessel 3074 mix to form a suspension of liquid in the form of drilling fluid and the solid material impactors 100, that is, to form an impactor slurry.
As a result of the introduction of the solid material impactors 100 into the injector vessel 3074, drilling fluid present in the injector vessel is displaced and the volume of the displaced drilling fluid flows to the tank 3040 via the lines 3090 and 3038 and the valve 3037. It is understood that the pump 3042 may be operated to cause at least a portion of the displaced drilling fluid in the tank 3040 to flow into the tank 3018 via the line 3044.
After the injector vessel 3074 has been charged, that is, after the desired and relatively high volume of the solid material impactors 100 has been introduced into the injector vessel, the valve 3072 is closed to prevent further introduction of solid material impactors 100 into the injector vessel, and the valve 3088 is closed to prevent any further flow of drilling fluid to the tank 3040. The cylinder 3076 is then operated so that hydraulic cylinder fluid is introduced into the chamber 3076d and, in response, the piston 3076a applies pressure to the drilling fluid in the line 3078, thereby pressurizing the line 3078, the line 3080 and the injector vessel 3074. The cylinder 3076 pressurizes the line 3078, the line 3080 and the injector vessel 3074 until the pressure in the line 3078, the line 3080 and the injector vessel 3074 is greater than the pressure in the line portion 3012b, and is less than, substantially or nearly equal to, or greater than, the pressure in the line 3006 and the line portion 3012a which, in turn and as noted above, is substantially equal to the supply pressure of the pump 3004.
The valve 3008 is opened and, in response, a portion of the drilling fluid in the line portion 3006 may flow through the valve 3008 and into the line 3078 so that the respective pressures in the line portion 3012a, the lines 3078 and 3080 and the injector vessel 3074 further equalize to a pressure that still remains greater than the pressure in the line portion 3012b.
The valve 3082 is opened, thereby permitting the impactor slurry to flow through the line 3086 and the orifice 3084, and to the line portion 3012b. It is understood that the pressure in the line 3086 may be less than the pressure in the line 3006 due to several factors such as, for example, the pressure drop associated with the flow of the impactor slurry through one or more components such as, for example, the valve 3082 and the orifice 3084. Notwithstanding this pressure drop, the pump 3004 continues to maintain a pressurized flow of drilling fluid into the injector vessel 3074 via the line 3006, the valve 3008, the line 3078 and the line 3080. Due to the pressurized flow of drilling fluid, and the pressure drop across the orifice 3010, the pressure in the line 3086 is still greater than the pressure in the line portion 3012b of the line 3012. As a result, the impactor slurry having the desired and relatively high volume of solid material impactors 100 is injected into the line portion 3012b of the line 3012, and therefore to the pipe string 55, at a relatively high pressure.
In an exemplary embodiment, it is understood that gravity may be employed to assist in the flow of the slurry from the injector vessel 3074 to the line portion 3012b via the line 3086 and the orifice 3084. In an exemplary embodiment, it is understood that the flow of impactor slurry delivered to the pipe string 55 via the line portion 3012b of the line 3012 may be accelerated and discharged to remove a portion of the formation 52 (
After the impactor slurry has been completely discharged from the injector vessel 3074, the valves 3008 and 3082 are closed, thereby preventing any flow of drilling fluid from the tank 3002, through the pump 3004, the line 3006, the line 3078, the line 3080, the injector vessel 3074, the valve 3082, the orifice 3084 and the line 3086, and to the line portion 3012b of the line 3012. The cylinder 3076 is then operated so that the hydraulic cylinder fluid in the chamber 3076d is discharged therefrom. During this discharge, the pressurized drilling fluid still present in the line 3080, the line 3078 and the injector vessel 3074 applies pressure against the piston 3076a. As a result, the pressure in the line 3080, the line 3078 and the injector vessel 3074 is reduced, and may be reduced to atmospheric pressure. The valve 3088 is opened, thereby permitting a volume of the pressurized drilling fluid that may still be present in the injector vessel 3074 to be displaced via the line 3090, thereby causing additional drilling fluid to flow from the line 3038 to the tank 3040. As a result, the pressure in the injector vessel 3074 is vented, thereby facilitating its return to atmospheric pressure.
At this point, the injector vessel 3074 is again in its initial condition, with the injector vessel full of drilling fluid and the valve 3088 open, and the valves 3022, 3048, 3072, 3028, 3054, 3066, 3008, 3037, 3034, 3060 and 3082 closed. The pump 3004 continues to cause drilling fluid to flow from the mud tank 3002, through the line 3006, the line portion 3012a, the orifice 3010 and the line portion 3012b, and to the pipe string 55.
In an exemplary embodiment, the above-described operation of the injector vessel 3074 may be repeated by again opening the valve 3072 to again charge the injector vessel 3074, that is, to again permit introduction of the solid material impactors 100 into the injector vessel 3074, as discussed above.
In an exemplary embodiment, it is understood that the injector vessels 3024, 3050 and 3074 of the injection system 3000 may be operated in a manner similar to the operation of the injector vessels 324, 350 and 374 of the injection system 300 described above in connection with
It is understood that the above-described clamping rings forming the above-described connections may be conventional and may form pressure-tight and fluid-tight connections.
It is understood that additional variations may be made in the foregoing without departing from the scope of the disclosure. For example, in addition to, and/or instead of the valve embodiments described above in connection with
Moreover, it is understood that the injection system 300, the injection system 3000 and/or components thereof may be combined in whole or in part with the excavation system 1. For example, the injection system 300 may be added to the system 1 and the tank 94 may be replaced by the tank 318, and/or the tank 82 may be replaced by the tank 314. For another example, instead of or in addition to the slurrification tank 98, one or more of the injector vessels 324, 350 and 374 may be used in the system 1. In an exemplary embodiment, the injection system 300 may be added to the system 1 and the slurry line 88 in the system 1 may be replaced by the line portion 312b. In an exemplary embodiment, the injection system 300 may be employed without any removal of any of the components of the system 1. In an exemplary embodiment, the injection system 300 may be employed with the removal of one or more components of the system 1 such as, for example, one or more of the tank 94, the tank 82, the tank 98, the line 88, the impactor introducer 96, the tank 6, the pump 10 and/or any combination thereof.
In an exemplary embodiment, in addition to, or instead of the conveyor 16, it is understood that the solid material impactors 100 may be transported to the tank 318 using a wide variety of techniques such as, for example, chutes, conduits, trucks and/or any combination thereof.
In an exemplary embodiment, in addition to, or instead of the valve 334, it is understood that one or more of the above-described closings of the other valves may result in a contact line being defined by the engagement between the plug element of the valve and the corresponding plug seat, and that the contact line may be 15 degrees from an imaginary vertical axis. In an exemplary embodiment, the contact lines defined by the engagement between the plug element of the valve and the corresponding plug seat, corresponding to two 180-degree-circumferentially-spaced locations on the plug element, may define a 30-degree angle therebetween. It is understood that the angle defined by the contact lines defined by the engagement between any one of the above-described plug seats and the corresponding plug element of the corresponding valve may vary widely.
In an exemplary embodiment, and in addition to, or instead of injecting an impactor slurry into a flow region defined by the line portion 312b and to the pipe string 55 to remove a portion of the formation 52 (
In an exemplary embodiment, in addition to, or instead of the solid material impactors 100 and/or drilling fluid, it is understood that the impactor slurry may be a suspension of any type of impactors and/or any type of liquids. The impactors may include and/or be composed of any type of solid material in a wide variety of forms such as, for example, any type of solid pellets, shot or particles. It is understood that the type of liquid or fluid and/or the type of impactor used to form the suspension and therefore the impactor slurry may be dictated by the application for which the injection system 300 and/or the injection system 3000 is to be used.
In an exemplary embodiment, the line 327 may be used as a bleeder line, or a portion of a bleeder line, to bleed air and/or other fluids from the passage 324fa, the passage 324ea and/or the chamber 324aa. One or more valves may be connected to the line 327 and operated so that air and/or other fluids present in the passage 324fa, the passage 324ea and/or the chamber 324aa bleed out through at least a portion of the line 327. The air and/or other fluids may bleed out to, for example, the tank 340. In an exemplary embodiment, the air and/or other fluids may be bleed through at least a portion of the line 327 and be vented to atmosphere. The bleeding of air and/or other fluids from the passage 324fa, the passage 324ea and/or the chamber 324aa, via the line 327 or at least a portion thereof, may occur before, during and/or after one or more of the operational steps described above. For example, bleeding may occur upon start-up operation of the injector vessel 324 and/or after maintenance thereof. In an exemplary embodiment, it is understood that the lines 353 and/or 378 may also be used as bleeder lines.
In an exemplary embodiment, it is understood that, in addition to, or instead of the cylinders 326, 352 and/or 376, a wide variety of other pressurizing means, equipment and/or systems may be employed to pressurize the injector vessels 324, 350 and/or 374, and/or a wide variety of modifications may be made to the cylinders 326, 352 and/or 376. The quantity of cylinders may be increased or decreased, and/or plunger mechanisms, piston mechanisms and/or other actuating mechanisms may be connected to, or used instead of, one or more of the cylinders 326, 352 and/or 376, to pressurize the injector vessels 324, 350 and/or 374. Also, one or more pumps may be used, in addition to, or instead of one or more of the cylinders 326, 352 and/or 376. Moreover, one or more of the cylinders 326, 352 and/or 376 may be removed from the injection system 300 and a pump such as, for example, the pump 304, may be used to pressurize one or more of the injector vessels 324, 350 and/or 374. It is understood that one or more additional valves, lines and/or other components and/or systems may be added to the injection system 300 to effect any modification.
In an exemplary embodiment, any hydraulic fluid or other fluid described above and present in the injection system 300 and/or 3000, and/or present in one or more components thereof such as, for example, one or more of the cylinders 326, 352 and/or 376, may be in a wide variety of fluidic forms such as, for example, oil, drilling fluid or mud, air and/or any combination thereof and/or any type of conventional hydraulic fluid, and/or any other type of fluid, including any type of liquid or gas.
Any foregoing spatial references such as, for example, “upper,” “lower,” “above,” “below,” “rear,” “between,” “vertical,” “angular,” etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.
In several exemplary embodiments, it is understood that one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. It is further understood that one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.
The PDC (Polycrystalline Diamond Compact) bit is a relatively fast conventional drilling bit in soft-to-medium formations but has a tendency to break or wear when encountering harder formations. The Roller Cone is a conventional bit involving two or more revolving cones having cutting elements embedded on each of the cones.
The overall graph of
Note that the PDTI bit performance in this area was significantly better than that of the other two bits—the PDTI bit took only 0.42 hours to drill the 30 feet where the PDC bit took 1 hour and the roller cone took about 1.5 hours. The total time to drill the approximately 800 foot interval took a little over 7 hours with the PDTI bit, whereas the Roller cone bit took 7.5 hours and the PDC bit took almost 10 hours.
The graph demonstrates that the PDTI system has the ability to not only drill the very hard formations at higher rates, but can drill faster that the conventional bits through a wide variety of rock types.
The table below shows actual drilling data points that make up the PDTI bit drilling curve of
While specific embodiments have been shown and described, modifications can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments as described are exemplary only and are not limiting. Many variations and modifications are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
This application is a continuation of co-pending application Ser. No. 11/205,006, which is a continuation-in-part of application Ser. No. 10/897,196, filed Jul. 22, 2004 which, in turn, is a continuation-in-part of application Ser. No. 10/825,338, filed Apr. 15, 2004, which, in turn, claims the benefit of 35 U.S.C. 111(b) provisional application Ser. No. 60/463,903, filed Apr. 16, 2003, the disclosures of which are incorporated herein by reference, the disclosures of which are incorporated herein by reference.
Number | Name | Date | Kind |
---|---|---|---|
1459147 | Dings | Jun 1923 | A |
2626779 | Armentrout | Jan 1953 | A |
2724574 | Ledgerwood, Jr. | Nov 1955 | A |
2727727 | Williams | Dec 1955 | A |
2728557 | McNatt | Dec 1955 | A |
2761651 | Ledgerwood, Jr. | Sep 1956 | A |
2779571 | Ortloff | Jan 1957 | A |
2807442 | Ledgerwood, Jr. | Sep 1957 | A |
2809013 | Ledgerwood, Jr. et al. | Oct 1957 | A |
2815931 | Williams | Dec 1957 | A |
2841365 | Ramsey et al. | Jul 1958 | A |
2868509 | Williams | Jan 1959 | A |
2954122 | Colburn | Sep 1960 | A |
3001652 | Schroeder et al. | Sep 1961 | A |
3055442 | Yie | Sep 1962 | A |
3084752 | Tiraspolsky | Apr 1963 | A |
3093420 | Levene et al. | Jun 1963 | A |
3112800 | Bobo | Dec 1963 | A |
3132852 | Dolbear | May 1964 | A |
3261463 | Eveson et al. | Jul 1966 | A |
3322214 | Buck | May 1967 | A |
3374341 | Klotz | Mar 1968 | A |
3385386 | Goodwin et al. | May 1968 | A |
3389759 | Mori et al. | Jun 1968 | A |
3416614 | Goodwin et al. | Dec 1968 | A |
3424255 | Mori et al. | Jan 1969 | A |
3469642 | Goodwin et al. | Sep 1969 | A |
3542142 | Hasiba et al. | Nov 1970 | A |
3548959 | Hasiba et al. | Dec 1970 | A |
3576221 | Hasiba | Apr 1971 | A |
3645346 | Miller et al. | Feb 1972 | A |
3684090 | Kilbride | Aug 1972 | A |
3688852 | Gaylord et al. | Sep 1972 | A |
3688859 | Maurer | Sep 1972 | A |
3704966 | Beck, Jr. | Dec 1972 | A |
3838742 | Juvkam-Wold | Oct 1974 | A |
3852200 | Meyer | Dec 1974 | A |
3865202 | Takahashi et al. | Feb 1975 | A |
3924698 | Juvkam-Wold | Dec 1975 | A |
4042048 | Schwabe | Aug 1977 | A |
4067617 | Bunnelle | Jan 1978 | A |
4141592 | Lavon | Feb 1979 | A |
4260477 | Corrans | Apr 1981 | A |
4269279 | House | May 1981 | A |
4304609 | Morris | Dec 1981 | A |
4391339 | Johnson, Jr. et al. | Jul 1983 | A |
4420390 | Carr | Dec 1983 | A |
4444277 | Lewis | Apr 1984 | A |
4476027 | Fox | Oct 1984 | A |
4490078 | Armstrong | Dec 1984 | A |
4492276 | Kamp | Jan 1985 | A |
4497598 | Blanton | Feb 1985 | A |
4534427 | Wang et al. | Aug 1985 | A |
4624327 | Reichman | Nov 1986 | A |
4627502 | Dismukes | Dec 1986 | A |
4681264 | Johnson | Jul 1987 | A |
4699548 | Bergstrom | Oct 1987 | A |
4768709 | Yie | Sep 1988 | A |
4809791 | Hayatdavoudi | Mar 1989 | A |
4825963 | Ruhle | May 1989 | A |
5090498 | Hamill | Feb 1992 | A |
5199512 | Curlett | Apr 1993 | A |
5291957 | Curlett | Mar 1994 | A |
5355967 | Mueller et al. | Oct 1994 | A |
5421420 | Malone et al. | Jun 1995 | A |
5542486 | Curlett | Aug 1996 | A |
5718298 | Rusnak | Feb 1998 | A |
5862871 | Curlett | Jan 1999 | A |
5881830 | Cooley | Mar 1999 | A |
5897062 | Enomoto et al. | Apr 1999 | A |
5944123 | Johnson | Aug 1999 | A |
5944195 | Huang et al. | Aug 1999 | A |
6003623 | Miess | Dec 1999 | A |
6142248 | Thigpen et al. | Nov 2000 | A |
6152356 | Minden | Nov 2000 | A |
6264842 | Boehm | Jul 2001 | B1 |
6345672 | Dietzen | Feb 2002 | B1 |
6347675 | Kolle | Feb 2002 | B1 |
6386300 | Curlett et al. | May 2002 | B1 |
6474418 | Miramon | Nov 2002 | B2 |
6506310 | Kulbeth | Jan 2003 | B2 |
6530437 | Maurer et al. | Mar 2003 | B2 |
6533946 | Pullman | Mar 2003 | B2 |
6571700 | Nakamura et al. | Jun 2003 | B2 |
6581700 | Curlett et al. | Jun 2003 | B2 |
6651822 | Alanis | Nov 2003 | B2 |
6904982 | Judge et al. | Jun 2005 | B2 |
7090017 | Justus et al. | Aug 2006 | B2 |
7172038 | Terry et al. | Feb 2007 | B2 |
7258176 | Tibbitts et al. | Aug 2007 | B2 |
7343987 | Tibbitts | Mar 2008 | B2 |
7383896 | Tibbitts | Jun 2008 | B2 |
7398838 | Harder et al. | Jul 2008 | B2 |
7398839 | Harder et al. | Jul 2008 | B2 |
7503407 | Tibbitts | Mar 2009 | B2 |
20020011338 | Maurer et al. | Jan 2002 | A1 |
20020134550 | Leeson et al. | Sep 2002 | A1 |
20060011386 | Tibbitts | Jan 2006 | A1 |
20060016622 | Tibbitts | Jan 2006 | A1 |
20060016624 | Tibbitts | Jan 2006 | A1 |
20060021798 | Tibbitts | Feb 2006 | A1 |
20060027398 | Tibbitts | Feb 2006 | A1 |
20060180350 | Harder | Aug 2006 | A1 |
20060191717 | Harder et al. | Aug 2006 | A1 |
20060191718 | Harder et al. | Aug 2006 | A1 |
20080017417 | Tibbits | Jan 2008 | A1 |
20080156545 | Tibbitts | Jul 2008 | A1 |
20080196944 | Tibbitts | Aug 2008 | A1 |
20080210472 | Tibbitts | Sep 2008 | A1 |
20080230275 | Harder | Sep 2008 | A1 |
20090038856 | Vuyk | Feb 2009 | A1 |
20090090557 | Vuyk, Jr. et al. | Apr 2009 | A1 |
20090126994 | Tibbitts et al. | May 2009 | A1 |
20090200080 | Tibbitts | Aug 2009 | A1 |
20090200084 | Vuyk | Aug 2009 | A1 |
20090205871 | Tibbitts | Aug 2009 | A1 |
20090218098 | Tibbitts et al. | Sep 2009 | A1 |
20090223718 | Tibbitts | Sep 2009 | A1 |
Number | Date | Country |
---|---|---|
2522568 | Nov 2004 | CA |
2588170 | May 2007 | CA |
0192016 | Aug 1986 | EP |
2385346 | Aug 2003 | GB |
2385346 | Sep 2004 | GB |
20055376 | Nov 2005 | IQ |
0225053 | Mar 2002 | WO |
0234653 | May 2002 | WO |
0292956 | Nov 2002 | WO |
2004094734 | Nov 2004 | WO |
2004106693 | Dec 2004 | WO |
2006001997 | Feb 2006 | WO |
2009009792 | Jan 2009 | WO |
Number | Date | Country | |
---|---|---|---|
20080230275 A1 | Sep 2008 | US |
Number | Date | Country | |
---|---|---|---|
60463903 | Apr 2003 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 11205006 | Aug 2005 | US |
Child | 12122374 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 10897196 | Jul 2004 | US |
Child | 11205006 | US | |
Parent | 10825338 | Apr 2004 | US |
Child | 10897196 | US |