Patent Application
20240418041
In the process of drilling and maintaining a wellbore, drilling fluid is pumped through drilling motors, such as positive displacement motors, and other drilling and completion equipment, such as friction reduction tools, percussion hammers, turbines, and MWDs. Most drilling fluids contain solid particles (e.g., weighting material such as barite and hematite, low gravity solids such as clay and silt, fractured rock, and cuttings). Certain portions of the drilling and completion equipment are sensitive to the solid particles within the drilling fluid. For example, certain drilling motors include only metal components, which are not able to deform when drilling fluids containing solid particles flow between the metal components (in contrast to drilling motors with elastomeric stators). Instead, the solid particles often become wedged between two metal components, which causes the drilling motors to prematurely wear out or to stop rotating, thereby disabling the metal-to-metal drilling motor.
Accordingly, metal-to-metal drilling motors are not usually used in applications in which the drilling fluid contains solid particles. Instead, these tools are typically only used when the drilling fluid contains no solids, which is not favorable in most drilling applications. In applications involving solid particles in drilling fluid, drilling motors with power sections including elastomeric components are typically used. The elastomeric materials flex to enable solid particles to flow through the drilling motor. However, certain elastomer materials begin to degrade or fail at high temperatures, such as temperatures over 320° F., to which drilling tools are exposed within particular zones (i.e., high temperatures zones) of certain subterranean wellbores. In wellbores through high temperature zones, metal-to-metal drilling machines are the only option.
There is a need for a drilling system that enables the effective use of solid particles within drilling fluids, even when the drilling system is exposed to high temperatures.
Disclosed herein is a drilling assembly including a metal-to-metal positive displacement motor and a particle adjusting mechanism configured to adjust a solid particle condition of a media flowing therethrough before the media flows into the metal-to-metal positive displacement motor. The particle adjusting mechanism may be configured to remove, reduce a size or dimension of, change a shape of, deform, dissolve, or chemically react at least a portion of any solid particles contained in the media.
Referring to
Particle adjusting mechanism 12 is configured to adjust a solid particle condition of a media flowing therethrough to a treated condition in which any remaining solid particles will travel through the motor gap of metal-to-metal positive displacement motor 14 without widening the motor gap to a failure gap size. The failure gap size may be a size of the motor gap that causes the metal rotor to slow down to a reduced rotational rate (i.e., a reduced RPM) which renders drilling inefficient or to stop rotating within the metal stator altogether. In certain embodiments, the failure gap size may be greater than 0.020 inches.
For example, the solid particle condition may be an amount of solid particles, which particle adjusting mechanism 12 may be configured to adjust to a treated condition by removing and/or collecting a portion of any solid particles contained within the media. In this way, particle adjusting mechanism 12 may be configured to reduce a concentration or amount of solid particles contained within the media. Alternatively, the solid particle condition may be a size, a dimension, or a shape of any solid particles contained in the media, which particle adjusting mechanism 12 may be configured to adjust to a treated condition by reducing a size of, reducing at least one dimension of, deforming, or adjusting a shape of a portion of any solid particles contained within the media. In other embodiments, the solid particle condition may be a chemical condition of any solid particles contained in the media, which particle adjusting mechanism 12 may be configured to adjust to a treated condition by dissolving or chemically reacting a portion of any solid particles in the media. In certain embodiments, the media in the treated condition may include no remaining solid particles. In other embodiments, any remaining solid particles in the media in the treated condition may fit through the motor gap of positive displacement motor 14. In still other embodiments, the metal rotor and the metal stator of the positive displacement motor 14 may be configured to crush any remaining solid particles in the treated condition into a size or a shape that fits through the motor gap.
Alternatively, filter screen 22 may include a closed upstream end and an open downstream end. The closed upstream end may be closed or blocked by a seal or any other separate component secured thereto or by an integrated lateral portion of the filter screen 22. The open downstream end may provide a fluid passage out of central filter cavity 30. In these embodiments, a filter flow path includes annular space 32, openings 24, central filter cavity 30, and the open downstream end of filter screen 22. In these embodiments, a media flowing into particle adjusting mechanism 18 may be directed through annular space 32. As the media flows through openings 24 into central filter cavity 30, at least a portion of any solid particles contained within the media are retained within annular space 32. In this way, annular space 32 provides a collection cavity in this embodiment. Accordingly, the media containing a reduced amount or concentration of the solid particles may flow into central filter cavity 30 and flow downstream from particle adjusting mechanism 18 into a metal-to-metal positive displacement motor disposed downstream, such as motor 14 shown in
Solid particles collected in each embodiment of particle adjusting mechanism 18 may build up over time until the plurality of openings 24 become blocked. In some embodiments, the collected solid particles may be cleaned out by removing particle adjusting mechanism 18 from a downhole string in which it is secured and disassembling particle adjusting mechanism 18. In other embodiments, such as the embodiment illustrated in
In still other embodiments, the particle adjusting mechanism may include a first set of filter openings configured to retain a larger size range of solid particles and a second set of filter openings configured to retain a smaller size range of solid particles. The first and second set of filter openings may be disposed on the same filter screen. Alternatively, multiple filter screens may be employed to provide a graduated filtering effect.
Referring to
In certain embodiments, central cavity 36 is defined within inner sleeve 47 and annular cavity 38 is defined between inner sleeve 47 and housing 48. The one or more vanes 40 may be integrally formed with inner sleeve 47. Alternatively, the one or more vanes 40 may be provided by one or more separate components that are operatively connected to inner sleeve 47, housing 48, or both. Closed upstream end 43 may be closed by a separate component, by housing 48, by an integrally formed portion of inner sleeve 47, or by any combination thereof. Closed downstream end 46 may be closed by a separate component, by housing 48, by inner sleeve 47, or by any combination thereof. Housing 48 may be formed of multiple housing segments as illustrated or a single continuous housing segment.
A media containing solid particles flowing into the upstream end of particle adjusting mechanism 34 may flow through open upstream end 45 of annular cavity 38 and the centrifugal flow path. The centrifugal force generated by the media's flow in the helical direction between the one or more vanes 40 in the annular cavity 38 forces solid particles radially in an outward direction away from the one or more lateral openings 42 into central cavity 38. Accordingly, at least a portion of the solid particles contained in the media remains in annular cavity 38 while the remainder of the media flows through lateral openings 42 into central cavity 38. The removed solid particles remain in annular cavity 38 and are retained and collected by closed downstream end 46 of annular cavity 38. Additionally, the size of the one or more lateral openings 42 may function to prevent larger solid particles from flowing into the central cavity 36. The vanes 40 and the lateral openings 42 may be configured to cause annular cavity 38 to retain any solid particles that do not fit through a motor gap between the metal rotor and a lobe of the metal stator in the downstream positive displacement motor. The media containing a reduced amount or concentration, or no solid particles, continues flowing through the downstream outlet of particle adjusting mechanism 34 into a metal-to-metal positive displacement motor disposed downstream, such as motor 14 shown in
Solid particles collected in annular cavity 38 may build up over time until the one or more lateral openings 42 become blocked. In some embodiments, the collected solid particles may be cleaned out of annular cavity 38 by removing particle adjusting mechanism 34 from a downhole string in which it is secured and disassembling particle adjusting mechanism 34. In other embodiments, such as the embodiment illustrated in
In still other embodiments, the particle adjusting mechanism may include a first cyclone configured to retain a larger size range of solid particles and a second cyclone configured to retain a smaller size range of solid particles. In these embodiments, multiple cyclones may be employed to provide a graduated separation effect.
With reference now to
First and second crushing surfaces 62 and 64 are configured for relative rotation there between while maintaining the same crushing space or at least a minimal predetermined crushing space. For example, first crushing surface 62 may move relative to second crushing surface 64 while maintaining crushing space 66 therebetween. Alternatively, second crushing surface 64 may move relative to first crushing surface 62 while maintaining crushing space 66 therebetween. The relative movement may be in any direction that causes first and second crushing surfaces 62 and 64 to impart crushing or grinding forces, such as, but not limited to, frictional and compressive forces. For example, the relative movement may be rotation, axial movement, eradicate movement, or any combination thereof, of one crushing surface relative to the other crushing surface. In the illustrated embodiment, first crushing surface 62 may be configured to rotate relative to second crushing surface 64. The crushing forces reduce the size or a dimension of at least a portion of any solid particles disposed in crushing space 66.
In some embodiments, such as the embodiment illustrated in
In certain embodiments, particle adjusting mechanism 60 may include additional crushing surfaces, such as crushing surface 74 and crushing surface 76 with crushing space 78 disposed therebetween in the illustrated embodiment. Relative movement between the additional crushing surfaces 74, 76 and/or between one of the additional crushing surfaces and first or second crushing surfaces 62, 64 may also impart crushing forces on any solid particles disposed within crushing space 78 therebetween.
In other embodiments, the particle adjusting mechanism may include a first crusher portion configured to crush a larger size range of solid particles and a second crusher portion configured to crush a smaller size range of solid particles. In these embodiments, multiple crushers may be employed to provide a graduated crushing effect.
With reference to
One or more cavities 86 are defined between metal rotor 82 and metal stator 84. Media flow through cavity 86 may cause rotor 82 to rotate, thereby rotating mandrel 68. In this way, rotor 82 may provide the rotational movement of first crushing surface 62 on mandrel 68 relative to second crushing surface 64 on housing 70, thereby imparting crushing forces on any solid particles disposed within crushing space 66.
As described above, a media containing solid particles flowing through particle adjusting mechanism 60 may flow into crushing space 66. The crushing forces caused by the rotation of first crushing surface 62 on mandrel 68 relative to second crushing surface 64 within housing 70 may grind, deform, and/or crush a portion of any solid particles contained in the media in order to reduce the size or at least one dimension of the solid particles. For example, the solid particles may be deformed by changing the shape of at least a portion of the solid particles, such as by making solid particles flatter (i.e., reducing at least the thickness of the solid particles). The media containing smaller solid particles may then continue flowing downstream through annular space 72 and into cavity 86. Media flow through cavity 86 causes rotor 82 and mandrel 68 to rotate relative to stator 84 and housing 70, respectively. The media flowing through cavity 86 downstream of particle adjusting mechanism 60 contains smaller solid particles, which reduces or eliminates the possibility that any solid particles will become stuck within motor gap 88 between the sealing line of the metal rotor 82 and the lobes of metal stator 84. Crushing space 66 may be configured to reduce the size of, at least one dimension of, or a shape of solid particles to less than a size of motor gap 88. In some embodiments, motor gap 88 may have a default size of 0.005 inches to 0.020 inches. Particle adjusting mechanism 60 may be configured to adjust a solid particle condition of the media into a treated condition in which any remaining solid particles will travel through motor gap 88 without widening the motor gap to a failure gap size. The failure gap size may be a size of motor gap 88 that causes metal rotor 82 to lock up within metal stator 84 or to slow down to a reduced rotational rate that renders drilling inefficient. In certain embodiments, the failure gap size of motor gap 88 may be greater than 0.020 inches. In some embodiments, the remaining solid particles, if any, in the treated condition of the media flowing downstream from particle adjusting mechanism 60 are dimensioned to fit through motor gap 88, thereby allowing the solid particles to flow through power section 80 of the positive displacement motor without becoming wedged in motor gap 88 between metal rotor 82 and metal stator 84. Alternatively, metal rotor 82 and metal stator 84 may crush any remaining solid particles in the treated condition of the media flowing downstream from particle adjusting mechanism 60 into a size and/or a shape that fits through motor gap 88.
Referring to
In other embodiments, the treatment substance may be configured to chemically react with at least a portion of any solid particles contained in a media as the media flows through treatment chamber 92 in order to form one or more liquid reaction products, one or more gas reaction products, or one or more solid reaction products with smaller sizes, or at least one smaller dimension, than the solid particles entering particle adjusting mechanism 90. For example, the treatment material may be hydrochloric acid, which may chemically react with at least a portion of any chalk contained in a media flowing through treatment chamber 92. Many other embodiments of treatment media configured to dissolve solid particles will be clear to skilled artisans. The media containing the reaction products continues flowing through the downstream outlet of particle adjusting mechanism 90 into a metal-to-metal positive displacement motor disposed downstream, such as motor 14 shown in
In other embodiments, the particle adjusting mechanism may include a first treatment substance contained in a first treatment chamber of the particle adjusting mechanism and a second treatment substance contained in a second treatment chamber of the particle adjusting mechanism. A first chemical subset of the solid particles in the media may be dissolved or chemically reacted with the first treatment substance, and a second chemical subset of the solid particles in the media may be dissolved or chemically reacted with the second treatment substance. In these embodiments, multiple treatment chambers may be employed to provide a sequenced solid particle adjusting effect.
With reference to
A drilling media may be pumped through downhole string 100. As the drilling media flows through particle adjusting mechanism 12, a solid particle condition of the drilling media may be adjusted to a treated condition in which any remaining solid particles fit through a motor gap of positive displacement motor 14. For example, all or a portion of the solid particles within the drilling media may be removed or modified in order to change at least one dimension by crushing, grinding, deforming, dissolving, or chemically reacting as described above. The drilling media (i.e., the remaining liquid or gas components, along with any remaining original or modified solid particles) flows downstream through metal-to-metal positive displacement motor 14 and drill bit 104. Metal-to-metal positive displacement motor 14 is capable of withstanding the high temperatures within wellbore 102 and configured to allow use of drilling media containing solid particles within downhole string 100, all while preventing or minimizing any abrasive damage or blockages within motor 14 by adjusting the solid particles to fit within the motor gap between the metal rotor and the metal stator before the drilling media and solid particles (if any) flow through motor 14.
Particle adjusting mechanism 12 disclosed herein, including all disclosed embodiments, may be secured within any portion of downhole string 100 in order to adjust a solid particle condition contained in the drilling media before it flows through any tool in the downhole string 100, such as but not limited to drilling motors, percussion assemblies, vibration assemblies, or any other tool including a metal rotor and a metal stator. In some embodiments, multiple particle adjusting mechanisms 12 may be used within a single downhole string 100.
As used herein, “solid particles” means any solid materials contained within a media, including but not limited to clay, sand, barite, hematite, cuttings, rock fragments, or metal fragments from the equipment. As used herein, “solid particle condition” means a condition of all of the solid particles contained in a media, including but not limited to an amount, a dimension, a shape, or a chemical condition. As used herein, “media” or “drilling media” means any liquid or compressible gas, which may include solid particles. As used herein, “treated condition” means a condition of the drilling media or a condition of any solid particles contained in the drilling media after adjustment of a solid particle condition by the particle adjusting mechanism. As used herein, “adjust” in reference to solid particles or solid particle condition means to reduce an amount or concentration of, reduce a size, reduce at least one dimension, deform, change a shape, dissolve, or chemically react to produce one or more reaction products, which may include one or more gas substances, liquid substances, or solid particles having a reduced size or at least one reduced dimension relative to the initial solid particle reactants, or any combination thereof. As used herein, “crusher” means any device configured to break up, change the shape of, or deform solid particles by pressing the particles between two surfaces or by applying frictional forces to the particles in multiple directions. As used herein, “downhole string” shall include a series of drill string or pipe segments and a coiled tubing line, along with any components secured thereto. As used herein, “plurality” means two or more. As used herein, “above” and “below” shall each be construed to mean upstream and downstream, such that the directional orientation of the device is not limited to a vertical arrangement.
Except as otherwise described or illustrated, each of the components in this device may have a generally cylindrical shape and may be formed of steel or another metal. Portions of drilling system 10 may be formed of a wear resistant material, such as tungsten carbide, ceramics, or ceramic coated steel.
Each device described in this disclosure may include any combination of the described components, features, and/or functions of each of the individual device embodiments. Each method described in this disclosure may include any combination of the described steps in any order, including the absence of certain described steps and combinations of steps used in separate embodiments. For example, the drilling assembly may include any combination of one or more sets of filters, one or more sets of cyclones, one or more sets of crushers, and one or more sets of treatment chambers. Any of these combinations may be configured to adjust a solid particle condition progressively and/or in a graduated manner (e.g., progressively smaller remaining solid particles in the treated condition of the media. Any range of numeric values disclosed herein includes any subrange therein.
While preferred embodiments have been described, it is to be understood that the embodiments are illustrative only and that the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalents, many variations and modifications naturally occurring to those skilled in the art from a review hereof.
