This invention pertains to downhole equipment for oil and gas wells. More particularly, it pertains to a mechanically activated bypass valve apparatus for use on a wellbore pipe string such as a coiled tubing string or pipe string and, more particularly, this invention relates to an apparatus for bypassing flow around a downhole tool string.
During the drilling, work over, or plug and abandonment of oil and gas producing wellbores, a variety of down hole tools may be attached to a pipe or coiled tubing string and utilized to perform various functions within the wellbore. Circumstances arise making it desirable to bypass flow around the downhole tool string within the wellbore. The toolstring is often referred to as a bottom hole assembly (BHA). These may consist of a variety of tools. Most frequently it will contain a downhole mud motor. These mud motors have a maximum flow rate rating which must not be exceeded otherwise damage to the mud motor will occur. Thus, if a flow rate is required by an operator which is in excess of the mud motor rating, a portion of the fluid being circulated must be bypassed or diverted to the wellbore. Other circumstances can include lost circulation where lost circulation material (LCM) must be pumped, well control issues, and others of the like which require the flow of fluid within the pipestring to be bypassed around the toolstring or BHA.
In many wells being drilled today, hydraulic fracturing is being utilized to maximize the output of the wells. Hydraulic fracturing, known as fracking, requires multiple stages to be perforated and fractured with a composite bridge plug set between each stage. These composite bridge plugs must be subsequently drilled out using a mud motor and drill bit. These mud motors have flow rate limitations which are oftentimes not high enough to properly clean the drilled debris (bridge plug parts) out of the wellbore. Thus a bypass valve apparatus must be utilized above the mud motor to divert a portion of the fluid being circulated directly into the wellbore and therefore avoiding exceeding the mud motor's flow rating.
There are currently two common types of bypass valves on the market. The first is known as a dual circulation sub (DCS) and can only be activated once with no means to deactivate. The DCS contains a piston which blocks fluid exit ports and is held in place via shear screws. A steel ball must be pumped from surface which lands and seals upon the piston. Pressure is then applied until the shear screws fail and the piston shifts downward, revealing the fluid exit ports. At this point, all fluid being circulated is directed into the wellbore. There is no means to reclose the fluid exit ports.
A second bypass valve device, (known as a PBL® Multiple Activation Bypass System), employs a deformable ball to activate the bypass valve, allowing fluid to travel into the wellbore and around the tool string. A second, metal ball(s) is employed to close the bypass valve off and allow circulation to continue through the tool string. This device allows the operator to perform this function several times while the device is in the wellbore. There are two main disadvantages to this process. The first is that the balls that are pumped down are captured in a “basket”, thus preventing further balls to be circulated to devices below this bypass device. This is very important as many downhole tools require ball activation. If two ball activated devices are run simultaneously, the uppermost device must utilize a larger ball for activation than the lower device. In this case, the PBL® disallows balls to continue through it once the first ball has been captured. The second disadvantage is that pumping a ball through a pipe or coiled tubing string is a very time consuming, and thus costly process, especially through a coiled tubing string where the ball must travel through the entire spool of coiled tubing before it even reaches the vertical column within the wellbore, and eventually land in the intended device.
Consequently, there is a need for a mechanically activated bypass valve apparatus which does not utilize any balls to either activate or deactivate and also has the ability for balls to be circulated through this device to activate other tools run lower in the toolstring.
The present invention is for a new mechanically activated bypass valve apparatus to satisfy the aforementioned needs. The mechanically activated bypass valve apparatus, hereafter referred to as “MABV apparatus” or simply “apparatus” is comprised of a top sub, a tubular housing, a mandrel, a mandrel nut, and a spring. The tubular housing is threadedly attached to the top sub, with the mandrel slidably engaged with the central bore of both the top sub and the tubular housing; the mandrel is prevented from rotating about its longitudinal axis by means of a spline(s) on its outer surface, which mates with a corresponding slot(s) in the tubular housing, or vice versa. Other means to prevent relative rotation between the mandrel and the tubular housing may include pins engaged with slots, balls engaged with slots, keyways, flats or other shapes such hexagonal, etc. These are merely a few of the possibilities for eliminating relative rotation, stated as examples only. The tubular housing includes a port(s) which allows fluid to circulate from the central bore of the mandrel to the outside of the tool string and into the wellbore. Also included are threaded holes for shear screws to be engaged through the wall of the housing and into the mandrel, preventing axial motion until a predetermined amount of weight-on-bit (WOB) is applied. The spring is concentric to the central bore of the housing and is placed between the top sub and the mandrel nut, which is threadedly engaged with the mandrel.
During normal drilling or workover operations, fluid, which can be a liquid, gas, or a combination thereof, is circulated through a downhole tool string. In the event that operators need to bypass the tool string downhole of the MABV apparatus, WOB must be applied to shear the shear screws, and allow the mandrel to move axially relative to the housing. The operator will then lift up on the pipe string, whereby the mandrel will then shift away from the tubular housing, so that the port(s) in the mandrel aligns with the port(s) in the tubular housing, allowing fluid to flow out of the MABV apparatus. The port(s) will remain aligned thus bypassing fluid to the wellbore until the operator sets down WOB upon the toolstring. At this point the mandrel moves towards the tubular housing thus closing the bypass ports.
In the event that the mud motor begins to stall during a drilling operation, this invention will allow an operator to relieve the stall without having to shut down the pump, or risking backlash which might compromise (back off or loosen) the threaded connections between tools downhole of the apparatus, as is currently common. If a stall occurs, the toolstring can be lifted slowly, thereby slowly opening the bypass ports, and allowing fluid to flow out of the tool string without entering the motor, dissipating pressure and relieving the stall. The operator is then free to again set down WOB upon the toolstring, closing the ports, and normal drilling will resume.
This invention can also be used as a downhole shock absorber, if such tools as vibrators or perforating (TCP) guns are included in the tool string and vibrator and or impact absorption is required. Once the shear screws have been sheared, the mandrel is free to travel axially with respect to the tubular housing, and any axial force occurring in the tool string will be absorbed by the spring and the sealed air chamber of the apparatus, thus dissipating impact or vibrational loads thereby eliminating damage or fatigue to tools in the BHA.
Another unique advantage of this apparatus is that during drilling operations, with WOB being applied, the MABV apparatus applies a constant downward force upon the mud motor and thus the object or formation being drilled. Generally, drilling toolstrings are very rigid. So, when an operator sets down WOB and the drill bit removes a portion of the object being drilled and fluid washes it uphole, the WOB decreases (called drilling off) because the pipe has not moved. Thus to maintain the WOB, the operator must again lower the pipe into the wellbore thereby setting down more WOB. This process must be repeated constantly to maintain a consistent (or consistent as possible) WOB. The MABV apparatus however has several inches of travel, with the mandrel being preloaded by both a spring and compressed air (or other compressible fluid) chamber. So, the MABV apparatus always applies a downward force (WOB) within the stroke limitations of the MABV apparatus. For example, if an operator sets down enough WOB to completely close the MABV apparatus (where the shoulder of the mandrel encounters the end of the tubular housing), the operator can keep the pipestring in the same location as the MABV apparatus applies a WOB to the mud motor for several inches. This allows the operator to keep the pipe in one place for much longer periods of time while the MABV apparatus applies the WOB. For example with 2⅞″ OD tools, this WOB can range from 500 lbs. to 2500 lbs. The operator can however set down as much WOB as he desires (within pipe or coil tubing limitations) without detrimentally affecting the MABV apparatus. These values will range dramatically from the smaller 1 11/16″ mud motors to the larger 12″ mud motors. This MABV apparatus provides a much more consistent and efficient drilling process while requiring far less operator efforts.
Yet another use for the MABV apparatus is the deposition of acid across perforations in a wellbore during production or workover operations. In order to accomplish this, it is necessary to seal off the upper toolstring from the mud motor on the lower end, as acid destroys the elastomer lining of the motor, usually by means of a circulated ball. Currently, this process is performed using two methods. One is the use of a dual circulating sub, which has ports that open under a preset pressure, but can only be activated once with no means to deactivate and therefore must be pulled out of the wellbore and reset after each deposition of acid. The second method is the use of the aforementioned PBL®, which can be activated several times, but requires a second set of balls to deactivate between uses. Use of the MABV apparatus, with an attached acid sub, would greatly reduce the time required for this process. When ready to deposit acid, operators will pump a ball down, which will seal against a deformable plastic seat inside the acid sub, thus sealing off the apparatus from the motor. Then, operators need only lift off WOB, and open the bypass ports, flooding the wellbore with acid. When acid placement is complete, operators will again reapply WOB, closing the bypass ports. Pressure is then applied against the ball, forcing it through the deformable plastic seat and into the basket below it, clearing the apparatus for normal use.
In the configurations shown in
A second embodiment of the MABV apparatus of
While exiting or “tripping out” of the wellbore, the toolstring and or drill bit may become lodged, with the MABV apparatus (5) is in the bypass position. When this occurs, the operator may desire to again utilize the mud motor to backream or drill the object preventing him from exiting the wellbore. But at this time, the spring (30) is forcing the mandrel (25) to be fully extended, thereby aligning bypass ports (70) and (75), allowing fluid to flow out of the MABV apparatus (5), and thus not activating the mud motor below it. In order to close bypass ports (70), the operator can apply upwards axial force far in excess of normal operating axial forces to shear the retaining pin(s) (50). This allows the mandrel (25) to move downwards relative to the tubular housing (20) thereby closing off bypass port(s) (70) and thus re-establishing circulation through the mud motor to drill away the obstruction.
A third embodiment of apparatus (5) of
A possible addition to apparatus (5) is acid sub apparatus (250) of
A second embodiment of apparatus (250), shown in
A second embodiment of the MABV apparatus (5) is shown in
Yet a third embodiment of the MABV apparatus (5) is illustrated in
While the preceding description gives a number of details regarding several embodiments of the apparatus (and methods of its use), embodying the principles of the present invention, it is to be understood that same are offered by way of example, and not limitation. For example, dimensions and materials may be varied to suit particular settings; the apparatus may be used in various operational settings in addition to those described herein, etc.
Therefore, the scope of the invention is not to be limited by the examples given above, but by the appended claims and the legal equivalents thereof.
This non-provisional United States patent application claims priority to U.S. provisional patent application Ser. No. 62/027,411, filed Jul. 22, 2014 and 62/116,794, filed Feb. 16, 2015, for all purposes. The disclosures of those provisional patent applications are incorporated herein by reference, to the extent not inconsistent with this disclosure.
Number | Date | Country | |
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62027411 | Jul 2014 | US | |
62116794 | Feb 2015 | US |