1. Field of the Invention
Embodiments of the present invention generally relate to a downhole circulating tool. In particular, the present invention relates to an apparatus and method for circulating fluid in a wellbore.
2. Description of the Related Art
In the drilling, completion, and production of oil and gas wells, it may be desirable to circulate fluid into the annulus of a wellbore. For example, fluid may be needed in the annulus to assist in wellbore cleanout operations, fluid may be needed in the annulus to provide additional fluid to carry drill cuttings up the annulus to the surface, or fluid may be needed in the annulus to help seal the surrounding formation. In these instances, a circulating tool may be used to provide fluid to a particular location. In addition, the circulating tool may be required to open and close multiple times.
There is a need, therefore, for a circulating tool that is reliable and able to be opened and closed multiple times.
Embodiments of the invention generally relate to an apparatus and method for circulating fluid in a wellbore. A circulating tool may include a bottom sub having a bottom sub port and a mandrel, wherein the mandrel substantially forms an inner bore of the circulating tool and includes a mandrel port. The circulating tool may also include an activation piston that is movable in a first direction and a port piston movable in a second direction when the activation piston moves in the first direction. The circulating tool may further include an inner sleeve coupled to the port piston and movable with the port piston, the inner sleeve having an inner sleeve port in selective communication with the mandrel port for controlling fluid flow through the bottom sub port.
In one embodiment, the circulating tool may include an inner portion having a bore therethrough and a first port. The circulating tool may also include a housing having a second port that is aligned with the first port. An activation piston may be disposed between the inner sleeve portion and the housing and may be actuatable in a first direction. The circulating tool may also include a port piston having a third port and configured to move in a second direction as a result of the activation piston being actuated. The circulating tool may also include an index sleeve for guiding axial movement of the port piston and the inner sleeve port, wherein when the index sleeve is in a predetermined position, the inner sleeve port is aligned with the first and second ports to allow fluid to flow out of the circulating tool.
A method for circulating fluid into a wellbore may comprise positioning a circulating tool adjacent to the wellbore, wherein the circulating tool includes a housing and a mandrel having a mandrel port. The method may also comprise supplying pressure to move an activation piston in a first direction and moving an inner sleeve in a second direction in response to moving the activation piston, wherein the inner sleeve includes an inner sleeve port. The method for circulating fluid into a wellbore may further include aligning the mandrel port and the inner sleeve port, thereby allowing fluid to flow out of the circulating tool.
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
Embodiments of the present invention relate to a circulating tool for circulating fluid within a wellbore and a method for using such tool.
In one embodiment, the circulating tool 5 may include a top sub assembly 10, a mandrel 35, an activation piston 46, a port piston 64, a housing 75, an index sleeve 80, an inner sleeve 90, a collet 110, and a bottom sub 130. The mandrel 35 is generally tubular, has a longitudinal bore formed therethrough, and substantially forms an inner bore 37 of the circulating tool 5. The mandrel 35 may be coupled to an inner portion of the top sub assembly 10 at an upper end of the circulating tool 5, and may be coupled to an inner portion of the bottom sub 130 at the lower end of the circulating tool 5. The top sub assembly 10 forms the upper end of the circulating tool 5, and is positioned above the activation piston 46. The port piston 64 is disposed below the activation piston 46 and may be, in part, surrounded by a flow sleeve 42 and the index sleeve 80. The port piston 64 may be coupled to the inner sleeve 90 at a lower end. The inner sleeve 90 is partially positioned within an inner portion of the bottom sub 130 and partially positioned within the housing 75. The collet 110 may be positioned within the bottom end of the inner sleeve 90. The housing 75 may surround and/or be coupled to exterior portions of the top sub assembly 10, the flow sleeve 42, the index sleeve 80, the inner sleeve 90 and the bottom sub 130. These components will be described more fully herein.
Turning to
A flow sleeve 42, which is generally tubular, may surround the activation piston 46, and be concentrically surrounded and supported by the housing 75. The flow sleeve 42 may extend from the top sub assembly 10 to the port piston 64. A sealing element 43 is placed between the flow sleeve 42 and the housing 75 to prevent fluid from leaking therebetween. The mandrel 35 may be positioned to substantially form a cylinder that the activation piston 46 moves along, and may include a ball seat 55. The mandrel includes a radial extension 53 that engages the flow sleeve 42. A sealing element 51 prevents fluid from leaking between the radial extension 53 and the flow sleeve 42. The area formed between the mandrel 35, radial extension 53, flow sleeve 42, and the top sub 15 houses the activation piston 46, which floats between a first chamber 44 and second chamber 48.
In one embodiment, the ball seat 55 may be deformable. The ball seat may be elastically deformable, or the ball seat may be mechanically deformable. One mechanically deformable ball seat includes a collet seat with pins including bulbous heads that are biased in an outwardly radial direction (not shown). The collet seat may be guided axially within a collet seat housing, which moves the pins in and out of the bore. The collet seat may alternatively include a collet sleeve that may be positioned to surround the collet seat and thus contract the pins, or the collet sleeve may be moved to allow the pins to expand. The collet seat or collet sleeve movement may be guided by a piston or other actuation method. Other deformable ball seats are also contemplated. Examples of suitable deformable ball seats are disclosed in U.S. Pat. Nos. 7,441,607 and 7,661,478, both of which are incorporated by reference herein in their entirety.
One or more openings 41 placed around the circumference of the mandrel 35 allow fluid communication between the bore 37 and the first chamber 44. Drilling fluid or mud may flow into the first chamber 44 through the openings 41 and pressurize the first chamber 44 to move the activation piston 46 towards the second chamber 48.
Hydraulic fluid (not shown), such as oil, may be placed within the second chamber 48. The second chamber 48 includes a chamber port 49 that connects the second chamber 48 to a channel 50. Through the chamber port 49, the channel 50 allows fluid communication between the second chamber 48 and the port piston chamber 62. The channel 50 may be formed through the flow sleeve 42, or between the flow sleeve 42 and the housing 75. The channel 50 may run along the outside portion of the flow sleeve 42 and terminate at the piston chamber 62, where the piston chamber 62 is also filled with hydraulic fluid.
To actuate the actuation piston 46, a ball 56, which may be deformable in one embodiment, may be sent down the circulating tool 5 through the inner bore 37. The ball 56 may seat itself on the ball seat 55 and block fluid flow through the mandrel 35. When the ball 56 is seated, mud or drilling fluid flows into the first chamber 44 and builds up pressure, which in turn, causes the activation piston 46 to move in a first direction towards the lower end of the circulating tool, thereby compressing the second chamber 48. As a result, the hydraulic fluid is forced out of the second chamber 48, through the channel 50, and into the piston chamber 62.
In one embodiment, the actuator piston 46 may be actuated by using a dart or other obturating member instead of the ball 56. In another embodiment, no ball, dart, or other obturating member needs to be used to actuate the actuator piston 46. Instead, as shown in
A port 52a may be positioned through the housing 75 and aligned with the channel 50 to allow hydraulic fluid to be injected into or drained out of the second chamber 48 and/or channel 50. A plug 52b may be placed within the port 52a to prohibit fluid transfer between the circulating tool 5 and the annulus.
A port piston 64 is positioned between the mandrel 35 and the actuation sleeve 42. A spring 54 is located in a spring chamber 57 between the mandrel extension 53 and the upper end of the port piston 64. When the port piston 64 is actuated, which occurs when hydraulic fluid moves from the second chamber 48 to the port piston chamber 62, the port piston 64 moves in a second direction towards the top end of the circulating tool 5 and compresses the spring 54.
The upper end of the inner sleeve 90 is coupled to the port piston 64 and is movable with the port piston 64. The inner sleeve 90 may contain an inner shoulder 102 at its top end which receives and couples to the lower end of the port piston 64 via pins, or other fastening mechanism, such as a threaded connection. The port piston chamber 62 is disposed between the inner sleeve 90 and the port piston 64. An optional port 89a and plug 89b may extend through the housing 75 to fill or drain the chamber 62. Hydraulic fluid may be injected into the port 89a to manually actuate the port piston 64 as well, such as for testing purposes.
A guide cylinder 92 may be coupled to the outer portion of the inner sleeve 90, and may be substantially tubular. One or more longitudinal grooves are placed on the outside of the guide cylinder 92. Alignment pins 97 located in the bottom sub 130 protrude into the grooves of the cylinder 92 to ensure that the inner sleeve does not rotate relative to the circulating tool 5 as the inner sleeve 90 moves axially. When the circulating tool 5 is in its un-actuated position, the cylinder 92 may be positioned against a second shoulder 104 of the bottom sub 130. Other suitable ways of aligning the inner sleeve 90 are also contemplated.
The inner sleeve 90 also includes an inner sleeve port 96. In one embodiment, the port 96 may be the same diameter as a bottom sub port 94 located through the bottom sub 130, and the same diameter as a mandrel port 98 through the mandrel 35. The inner sleeve port 96 may be positioned on the inner sleeve 90 such that when the index sleeve 80 is in a third position 84c (as will be discussed herein), the inner sleeve port 96 is aligned with the mandrel port 98 and the bottom sub port 94. When these three ports 94, 96, 98 are aligned, fluid may flow out of the circulating tool 5.
The index sleeve 80 may concentrically surround the port piston 64 and be located adjacent to the inner sleeve 90. The index sleeve 80, which may be cylindrical with a bore therethrough, is bounded on its exterior by the housing 75. A perspective view of the index sleeve 80 is shown in
Before the circulating tool 5 is actuated, the pin 86 is located in the first notch 84a within the index sleeve 80.
In one embodiment, the bottom end of the inner sleeve 90 may include a graduated shoulder 106 for engaging collet 110. The most narrow diameter point of the graduated shoulder is positioned at the end of the inner sleeve 90, and the diameter increases along the length of the shoulder. The graduated shoulder 106 may be substantially the same length as the collet 110. The inner sleeve 90 may be at least partially positioned within the bottom sub.
The collet 110 is shown in detail in
In the neutral, un-actuated position of the circulating tool 5, the collet 110 may be positioned so that the heads 118 of the arms 116 are aligned with the top end of the graduated shoulder 106 of the inner sleeve 90, where the graduated shoulder 106 is the widest. That position provides the widest diameter for fluid to pass through within the circulating tool 5. After the circulating tool 5 is actuated, the port piston 64 moves the inner sleeve 90 toward the top end of the circulating tool 5. The arms 116 of the collet 110 are compressed by the graduated shoulder 106 of the inner sleeve 90, wherein the heads 118 of the arms 116 are pushed radially through the mandrel 35 and into the bore 37 of the circulating tool 5. This arm 116 compression may be seen in
In operation, the circulating tool 5 may be used to circulate fluid in a wellbore. The circulating tool 5 may be actuated when the ball 56 is seated on the ball seat 55 of the mandrel 35, which causes drilling fluid to flow into the first chamber 44. Pressure build up in the first chamber 44 causes the activation piston 46 to move in the first direction towards the second chamber 48, thereby forcing hydraulic fluid through the channel 50 into the port piston chamber 62. Pressure builds within the piston chamber 62 and causes the port piston 64 to move in the second direction to compress the spring 54. Movement in the second direction causes the inner sleeve 90 to move in the second direction, which causes the index sleeve 80 to rotate as the pin 86 guides the index sleeve 80 from the first position 84a to the second position 84b. The movement of the port piston 46 and inner sleeve 90 in the second direction, also causes the arms 116 of the collet 110 to be compressed to form a collet catch (see
Eventually, enough pressure may build behind the ball 56 to cause the ball 56 to move past the ball seat 55 and land on the collet catch. Because the ball 56 is no longer causing pressure to build behind the activation piston 46, the pressure decreases in the first chamber 44 and in the port piston chamber 62. The spring 54 moves the port piston 64 in the first direction, which causes at least some hydraulic fluid to flow back into the second chamber 48 from the port piston chamber 62 (pressure equalization). Furthermore the inner sleeve 90 and index sleeve 80 also move in the first direction. The index sleeve 80 limits movement of these components in the first direction when the index sleeve 80 reaches the third position 84c, as shown in
To cease the drilling fluid from flowing out to the wellbore, a second ball (not shown) may be sent down the circulating tool 5. Once again, the second ball is seated at the ball seat 55. Pressure build up moves the activation piston 46 toward the second chamber 48, which forces hydraulic fluid into the port piston chamber 62. In turn, the port piston 64 moves in the second direction, which causes the index sleeve 80 to move into the fourth position 84d. The collet catch may still be activated when the index sleeve 80 is in the fourth position 84d. Pressure builds behind the second ball, and eventually causes the second ball to move past the ball seat 55. The release of the second ball causes the pressure in the first chamber 44 to decrease, which again, causes the spring to move the piston 64 in the first direction. Hydraulic fluid flows back into the second chamber 48 and urges the activation piston 46 to move in the second direction. Movement of the port piston 64 in the first direction returns the index sleeve to the first position 84a. When the index sleeve 80 moves back into the first position 84a, the inner sleeve 90 also moves in the first direction, which causes the bias arms 116 of the of the collet 110 to release both balls down the circulating tool 5. The movement of the inner sleeve 90 in the first direction also causes the inner sleeve port 96 to shift such that the bottom sub port 94, inner sleeve port 96 and mandrel port 98 are no longer in alignment, thereby ceasing the flow of drilling fluid out into the wellbore. After both balls are released from the collet 110, fluid is free to flow down the drill string once more.
Alternatively, the collet 110 may be omitted from the circulating tool 5, wherein each ball 56 is released down the circulating tool 5 after moving past the ball seat 55.
In another alternative embodiment, the use of the ball 56 and the ball seat 55 may be omitted and replaced with a restriction 210, such as a nozzle. In such embodiment, fluid is sent down the circulating tool 5 at a high flow rate, which naturally causes pressure to build in the first chamber 44 to actuate the activation piston 46.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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