Downhole tools used in the oil and gas industry can include wellbore downhole tools such as gravel pack tools to help avoid voids in a gravel pack. Some such tools include shunt tube systems which can include sand control screens and a gravel pack placed around the screens for controlling sand production. An incomplete gravel pack can be associated with the formation of sand bridges in the interval to be packed which in turn can prevent placement of sufficient sand along a screen on the opposite side of the bridge, resulting in excessive sand production, screen failure, or wellbore collapse.
Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
As part of the present disclosure, we recognized certain problems associated with the assembly and use of certain wellbore downhole tools, e.g., a gravel pack tool configured as, or including, a shunt tube system, and in particular, the mounting of a nozzle assembly in the shunt tube system. Nozzle assemblies are used in gravel packing where a slurry (e.g., a gravel slurry) exits the shunt tube system through one or more erosion resistant nozzles of the nozzle assembly onto or about a screen of the tool (e.g., one or more sand screens of the wellbore downhole tool).
Part of our process of assembling the tool can include brazing a nozzle into a stainless metal tube to form brazing joints, and then welding that brazed assembly of the nozzle and the metal tube onto a packing tube of the shunt tube system of the tool.
The term brazing as used herein refers to the process of joining metal materials (e.g., the metal material of nozzle and the metal material of the metal tube) by melting and flowing a filler metal (e.g., a braze metal alloy) into the joint between the two materials. The term welding as used herein refers to the process of joining metal materials by melting one or both of the metals to cause fusion between the metals.
The assembly process can present problems. The brazing process is an additional process step that requires specifications and quality control. When the brazed assembly of nozzle and metal tube is welded to the packing tube, the heat from welding can re-melt the braze with a consequent potential failure of braze joints. There is also an inherent problem with brazing a carbide nozzle to a stainless steel tube due to large differences in the thermal expansion coefficients of carbide versus stainless steel. For instance, the carbide nozzle can crack during a subsequent post-braze cooling process, and in some cases, a certain degree of cracking has to be tolerated as part of assembly and use of the tool.
To address these problems, we have developed a nozzle assembly, and method of assembly, where a nozzle is mechanically connected to a holding body without brazing. The braze-free nozzle assembly can be mounted via a holding body to a packing tube such that the nozzle is aligned with an exit hole in the packing tube. Additionally, the holding body helps to protect the packing tube exit hole from wear due to the passage of slurry there-through. The assembly of the wellbore downhole tool includes assembling the nozzle assembly and mounting to the packing tube with the elimination of a brazing step and thus avoid the problematic issues associated with welding on top of a brazed joint to reduce manufacturing costs.
One aspect of the disclosure is wellbore downhole tool 100 that includes a nozzle assembly.
Embodiment of the nozzle 102 can be or include a cylindrically-shaped tube 110 with a substantially uniform outer diameter 112 across substantially an entire height 114 of the nozzle, and having at least one retaining body opening 116 located in an outer wall 118 of the nozzle. Embodiments of the holding body 104 can include a conduit 120, the conduit sized to fit the nozzle there-through, and an alignment opening 122 extending from an outer surface 125 of the holding body to the conduit. Embodiments of the retaining body 106 can be sized to fit within the alignment opening of the holding body and to contact the retaining body opening 116 of the nozzle when the nozzle is inserted in the conduit (e.g.,
As noted, the cylindrically-shaped tube 110 has a substantially uniform outer diameter 112. For instance, in some such embodiments of the nozzle, other than portions of the nozzle having the retaining body opening, or openings, or threaded portions, the outer diameter of the cylindrically-shaped tube does not have a varying diameter (e.g., a percent variation of ±5, ±1±0.1 or ±0.01% or less in the diameter 112) across the entire height (e.g., at least 90, 95, or 99% of the height 114). That is, the cylindrically-shaped tube of the nozzle is free of shoulders, inserts or other structures that would substantially vary the outer diameter and thereby restrain the translational or rotational movement of the nozzle while being inserted and positioned in the conduit of the holding body.
Non-limiting example embodiments of the cylindrically-shaped tube 110 of the nozzle 102 include right (e.g.,
Embodiments of the nozzle can be composed of carbide, ceramic materials, cobalt metal alloys, a surface-hardened metals, or alloys or composites thereof, or other erosion resistant metal materials familiar to those skilled in the pertinent art. Embodiments of the holding body can be composed of metal or metal alloys (e.g., stainless steel).
The holding body 104 and retaining body 106, when connected to the nozzle 102, cooperate to prevent the nozzle's cylindrically-shaped tube 110 from either axial or rotational movement, e.g., to prevent the tube from getting pushed in or out of the conduit 120 due to slurry fluid pressure and to prevent the tube from rotating in the conduit. To facilitate axial and rotational adjustment and positioning of the tube 110 in the conduit, embodiments of the conduit 120 can be a cylindrically-shaped opening with a uniform inner diameter (e.g.,
In any such embodiments, the conduit 120 passing through the holding body 104 can have an acute angle relative to a mounting surface of the holding body (e.g.,
In some embodiments, the holding alignment opening 122 can form a substantially right angle relative to the holding body conduit angle 142 (e.g.,
Embodiments of the retaining body opening 116 of the nozzle can be a through-hole opening that breaks through to the interior space of the nozzle (e.g.,
When the nozzle tube 110 is inserted into the holding block conduit 120, the tube 110 can be axially and rotationally adjusted so that the opening 116 matches up with the alignment opening 122 of the holding body. After such adjustments the retaining body 106 can be placed in the alignment opening 122 and contacted to the retaining body opening 116 such that the nozzle cannot be further rotated or axially moved in or out of the conduit.
Embodiments of the retaining body 106 can be shaped and sized to fit in whole or in part in the alignment opening 122. For instance, the retaining body 106 can be a screw (e.g., set screw 106,
In some embodiments, the retaining body opening 116 can be a blind-hole opening shaped as a groove that traverses partly around a circumference of the outer wall 118 of the nozzle (e.g.,
For any embodiments of the retaining body 106 such as discussed in the context of
For any embodiments of the tube 110 and conduit 120 such as discussed in the context of
As illustrated in
As further illustrated, in some embodiments, the packing tube 130 includes one or more planar outer surfaces (e.g., surface 134) which can define a rectangle cross-section of the packing tube. In some such embodiments, the mounting surface 144 of the holding body 104 can also include one or more planar surfaces to facilitate mounting on one or more of the planar outer surfaces 167 of the packing tube. However, in other embodiments, the packing tube 130 can be cylindrically shaped and the mounting surface 144 of the holding body 104 can be a curved surface to facilitate mounting to such a cylindrically shaped packing tube 130.
For any of the embodiments of the holding body and the packing tube, such as discussed in the context of
As illustrated in
Another embodiment of the present disclosure is a method of assembling a wellbore downhole tool including any embodiments of the tool 100 disclosed in the context of
In some such embodiments, inserting the nozzle into the conduit (step 515) further includes rotating the cylindrically-shaped tube in the conduit to align the at least one retaining body opening with the alignment opening (step 525).
In some such embodiments, inserting the nozzle into the conduit (step 515) further includes threading the nozzle into the conduit such that threads on the outer wall of nozzle 162 engage with threads on an interior wall of the conduit (e.g. conduit threads 160).
In some such embodiments, inserting the retaining body into the alignment opening (step 520) includes threading the retaining body into the alignment opening such that threads on an outer wall of the retaining body (e.g., threads 124) engage with threads on an interior wall of the alignment opening (e.g., threads 123).
In some such embodiments, inserting the retaining body into the alignment opening (step 520) includes placing the retaining body having a partly-circular shape (e.g.,
Any such embodiments of the method 500 can further include mounting the nozzle assembly to a packer tube of a shunt tube system (step 530). Embodiments of the mounting (step 530) can include welding the holding body to the packer tube (e.g.,
Disclosure Statements.
Statement 1. a wellbore downhole tool, comprising a nozzle assembly, the nozzle assembly including: a nozzle, the nozzle including a cylindrically-shaped tube with a substantially uniform outer diameter across substantially an entire height of the nozzle, and having at least one retaining body opening located in an outer wall of the nozzle; a holding body, the holding body including: a conduit, the conduit sized to fit the nozzle there-through, an alignment opening extending from an outer surface of the holding body to the conduit; and a retaining body, the retaining body sized to fit within the alignment opening of the holding body and to contact the retaining body opening of the nozzle when the nozzle is inserted in the conduit such that the cylindrically-shaped tube of the nozzle cannot rotate or move further in or out of the conduit.
Statement 2. The tool of statement 1, wherein the conduit of the holding body is a cylindrically-shaped opening with a uniform inner diameter that is greater than the uniform outer diameter of the cylindrically-shaped tube of the nozzle.
Statement 3. The tool of statement 1, wherein the retaining body opening of the nozzle is a through-hole opening that breaks through to the interior space of the nozzle.
Statement 4. The tool of statement 1, wherein the retaining body opening of the nozzle is a blind-hole opening that does not break through to the interior space of the nozzle.
Statement 5. The tool of statement 1, wherein the retaining body opening of the nozzle is a blind-hole opening shaped as a slot and the retaining body is sized to fit within the alignment opening and contact the slot such the nozzle cannot rotated in or move further in or out of the conduit.
Statement 6. The tool of statement 1, wherein the alignment opening of the holding body is a tapered opening and the retaining body is a tapered body to fit into the tapered opening and contact the retaining body opening of the nozzle.
Statement 7. The tool of statement 1, wherein the alignment opening of the holding body is a threaded opening and the retaining body is a threaded body to engage with the threaded opening and contact the retaining body opening of the nozzle.
Statement 8. The tool of statement 1, wherein the retaining body opening of the nozzle is a blind-hole opening shaped as a grooved opening that traverses partly around a circumference of the outer wall of the nozzle.
Statement 9. The tool of statement 8, wherein the alignment opening of the holding body is a partly-circular alignment opening sized to align with the grooved opening of the nozzle.
Statement 10. The tool of statement 9, wherein the retaining body is shaped as a partly-circular body and sized to fit in the grooved opening and in the partly-circular alignment opening.
Statement 11. The tool of statement 10, wherein the partly-circular body is a snap ring or a snap wire.
Statement 12. The tool of statement 1, wherein the conduit of the holding body is threaded and at least a portion of the outer wall of the nozzle is threaded to engage with the threaded conduit of the holding body.
Statement 13. The tool of statement 1, further including a packing tube, the packing tube having an opening and the holding body mounted to the packing tube such that the nozzle is aligned with the opening in the packing tube.
Statement 14. The tool of statement 13, wherein the holding body mount to the packing tube include a weld or a mechanical connection.
Statement 15. The tool of statement 13, wherein the packing tube includes one or more planar outer surfaces and the mounting surface of the holding body includes one or more planar surfaces configured to rest on one or more of the planar outer surfaces of the packing tube.
Statement 16. The tool of statement 1, further including a shunt tube system that includes one or more of the nozzle assemblies, a transport tube, a packing tube and interconnecting conduit between the transport and packing tubes, wherein the holding body of each one of the nozzle assemblies is mounted to the packing tube such that the nozzle of each one of the nozzle assemblies is aligned with respective ones of the openings in the packing tube.
Statement 17. A method of assembling a wellbore downhole tool, comprising: assembling a nozzle assembly, including: providing a holding body, the holding body including a conduit and an alignment opening extending from an outer surface of the holding body to the conduit; inserting a nozzle into the conduit, the nozzle including a cylindrically-shaped tube with a uniform outer diameter across an entire height of the nozzle and having at least one retaining body opening located in an outer wall of the nozzle; and inserting a retaining body into the alignment opening of the holding body to contact the retaining body opening of the nozzle, such that the cylindrically-shaped tube of the nozzle cannot be rotated or moved further in or out of the conduit.
Statement 18. The method of statement 17, wherein inserting the nozzle into the conduit includes rotating the cylindrically-shaped tube in the conduit to align the at least one retaining body opening with the alignment opening.
Statement 19. The method of statement 17, wherein inserting the nozzle into the conduit includes threading the cylindrically-shaped tube of the nozzle into the conduit such that threads on the outer wall of cylindrically-shaped tube engage with threads on an interior wall of the conduit.
Statement 20. The method of statement 17, wherein inserting the retaining body into the alignment opening includes threading the retaining body into the alignment opening such that threads on an outer wall of the retaining body engage with threads on an interior wall of the alignment opening.
Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.