Patent Grant
11028669
See Application Data Sheet.
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The present invention relates to a downhole tool for the oil and gas industry. Particularly, the present invention relates to a multiple use flow diverter tool assembly. Even more particularly, the present invention relates to a pressure activated proportional flow bypass.
A bottom hole assembly (BHA) used in drilling and wellbore clean out or hole cleaning applications utilize a positive displacement motor (PDM) for well directional control and/or to rotate the drill bit of the BHA. These PDM motors are typically referred to as mud motors. Fluid pumped through the rotor/stator portion of the motor, generally called the PDM power section, results in bit rotation. Bit rotation, in revolutions per minute (rpm), is directly proportional to the flow rate pumped though the power section.
PDM power sections have a maximum flow rate specification due to their construction and selection of elastomer materials required to enable their functionality. The power section maximum flow rate value is the limiting factor in the BHA when higher flow rates are considered. It is important to avoid exceeding the power section maximum flow rate value, as stator failure will likely occur, resulting in non-productive time due to an unnecessary trip out of the hole to replace damaged equipment.
However, it is advantageous to increase the flow rate through the BHA above the power section maximum flow rate value for other activities, besides rotating the drill bit for drilling. For example, the increased flow rate can be used for hole cleaning purposes. Hole cleaning is a term used to describe removal of drill bit cuttings and other debris from the wellbore during drilling and/or clean out operations in cased wellbores. Hole cleaning results are improved, if the fluid in the annular space between the wellbore or casing inside diameter and the BHA and other tubulars outside diameters, is being pumped to surface in a turbulent flow regime. Turbulent flow better entrains solid particles in the flow stream allowing these solids to be pumped to surface, removing them from the wellbore. Fluid velocity (feet per minute) in the annular space, referred to as annular velocity, is the key independent variable in achieving turbulence as defined by the Reynold's number calculation.
Where: Re=Reynold's number, dimensionless
Annular velocity is related to flow rate (gallons per minute) by equation (2) below.
Where: AV=annular velocity (ft/min.)
For a given set of tubulars, annular velocity is directly proportional to flow rate. One should be aware that the BHA outside diameter is greater than the pipe or coiled tubing outside diameter that conveyed the BHA to the bottom of the well. Annular velocity values are calculated around the BHA and around the pipe or tubing. The annular velocity value around the pipe or tubing is of greater interest since it is a lower value due to increased annular flow area. This results in a reduced Reynolds number and more difficulty in achieving turbulent flow.
The Reynold's number is directly proportional to annular velocity for given tubular and fluid conditions and annular velocity is directly proportional to flow rate under the same conditions. A greater flow rate is required to increase the Reynolds's number such that a turbulent flow regime is achieved.
Downhole tools, that allow for increased flow rates without damaging a PDM power section, currently exist. These tools can be operated one time, for instance when a pressure relief disc is used or a limited amount of times when using tools activated by dropping a ball or dart down the inside diameter of the pipe. These style tools are inefficient, bypass 100% of the flow to the annulus and provide limited capability to respond to unplanned events.
More recently tools have been developed that attempt to divide flow to the annulus and through the BHA. These tools have experienced erosion and failure to return to a fully closed position due to foreign matter becoming enmeshed in the internal mechanism of the tool. When a tool fails to close fully, the flow rate to the PDM may be insufficient for it to operate in its proper range. These operational shortcomings cause extra time to be expended to retrieve and replace a non-functioning tool and then return a new tool to the same measured depth as the failed tool. Daily operating costs can be $50,000.00 per day or greater. The cost of replacing a failed tool can be a significant and unnecessary additional cost in the operator's total well cost.
Various patents and patent applications have been published in the field of these prior art bypass and control valve systems. References include U.S. Pat. No. 9,260,938, issued to Holderman et al on 16 Feb. 2016, U.S. Pat. No. 6,675,897, issued to McGarian et al on 13 Jan. 2004, U.S. Pat. No. 9,903,180, issued to Boutin et al on 27 Feb. 2018, U.S. Pat. No. 8,534,369, issued to deBoer on 17 Sep. 2013, U.S. Pat. No. 6,293,342, issued to McGarian et al on 25 Sep. 2001, U.S. Pat. No. 7,334,597, issued to Hughes et al on 26 Feb. 2008, U.S. Pat. No. 7,299,880, issued to LoGuidice et al on 27 Nov. 2007, U.S. Pat. No. 9,708,872, issued to O'Neal et al on 18 Jul. 2017, U.S. patent Ser. No. 10/100,605, issued to Gay et al on 16 Oct. 2018, U.S. Pat. No. 9,890,601, issued to Baudoin on 13 Feb. 2018, U.S. Pat. No. 9,404,326, issued to Zhou on 2 Aug. 2016, U.S. patent Ser. No. 10/107,073, issued to Cramer et al on 23 Oct. 2018, U.S. Pat. No. 9,494,014, issued to Manke et al on 15 Nov. 2016, U.S. Pat. No. 8,393,403, issued to de Boer on 12 Mar. 2013, and U.S. Pat. No. 7,891,428, issued to Martin et al on 22 Feb. 2011.
It is an object of the present invention to provide a tool assembly for fluid bypass.
It is an object of the present invention to provide a tool assembly that allows increased flow rate without damaging or limiting the flow rate limited tools on the drill string.
It is another object of the present invention to position a flow bypass tool assembly above the flow rate limited tools.
It is an object of the present invention to provide a tool assembly that is pressure activated for multiple repeated fluid bypasses.
It is an object of the present invention to provide a tool assembly for proportional flow split through the tool assembly and through the bypass assembly to the annulus.
These and other objectives and advantages of the present invention will become apparent from a reading of the attached specifications and appended claims.
Embodiments of the tool assembly of the present invention can be used in both the drilling and completion phases of a well. In coordination with other downhole tools, such as a bottom hole assembly (BHA), the tool assembly allows flow rates to increase, without exceeding surface pressure limits and without flow related damage to flow rate restricted tools, such as the BHA. The tool assembly includes a main body and a bypass assembly removably attached to the main body.
The main body includes an off-set through bore and a cavity with a cavity surface. The cavity surface includes components to engage the bypass assembly. There can be a cavity attachment means, a channel surface centered over the off-set through bore, a first fluid bypass port, a second fluid bypass port, and a pressure inlet port aligned with the fluid bypass ports and placed between the fluid bypass ports and the second cavity end.
Embodiments of the present invention also include a flow restrictor means in fluid connection with the pressure inlet port. The flow restrictor means is placed within the off-set through bore. The flow restrictor means can be a nozzle, venturi, bluff body or other known components to control fluid flow to build a pressure differential across the flow restrictor means. The present invention includes a bluff body port and bluff body and a pressure inlet insert as the flow restrictor means.
The bypass assembly fits within the cavity of the main body, and there are respective components to component on the cavity surface of the main body. The bypass assembly includes a bypass housing, a pressure chamber, a piston, and a spring assembly. The bypass housing has a first fluid bypass hole and a second fluid bypass hole, which both align with the first fluid bypass port and the second fluid bypass port on the main body. Similarly, there is a pressure inlet hole on the bypass housing to align with the pressure inlet port of the main body. In the present invention, the pressure inlet hole is in fluid connection with the pressure chamber. Thus, the pressure differential across the flow restrictor means increases pressure in the pressure chamber. The piston abuts the pressure chamber so that the piston and the spring assembly exert pressure against each other.
Embodiments of the present invention further include a method of using the tool assembly. The method for controlling flow includes deploying the tool assembly into a wellbore, with the piston starting in a first piston position. Fluid is pumped from a surface location through or by the flow restrictor means within the bypass housing so as to create a pressure differential across the flow restrictor means and in the pressure chamber. The piston actuates from the first piston position to the second piston position with the pressure differential. Now, a portion of the fluid from the surface location flows through the tool assembly and another portion of the fluid from the surface location flows through the first fluid bypass hole and the second fluid bypass hole to the wellbore.
The first fluid bypass hole and the second fluid bypass hole allow flow through the bypass assembly to the annulus concurrent with a flow through main body when a predetermined flow rate is achieved at the flow restrictor. There is now bypass flow through a sidewall of the tool assembly and through the tool assembly. The bypass flow can be set so that proportional flow is developed through the bypass assembly and through the main body to other downhole tools, such as a BHA, below the tool assembly.
Referring to
Embodiments of the tool assembly 10 include a main body 20 having a proximal end 22 with a proximal opening 24 and a distal end 26 opposite the proximal end with a distal opening 28, and a bypass assembly 100 removably attached to the main body and having an inner side 102 and an outer side 104 opposite the inner side, as shown in
The ports 50, 51, 52 are in fluid connection with the off-set through bore 30. The first fluid bypass port 50 is positioned a set distance 99 from the second fluid bypass port 51. The first fluid bypass port 50 is in fluid connection with the off-set through bore 30. The second fluid bypass port 51 is also in fluid connection with the off-set through bore 30, separate from the first fluid bypass port 50. The pressure inlet port 52 is also in fluid connection with the off-set through bore 30, separate from both the first fluid bypass port 50 and the second fluid bypass port 51.
The cavity attachment means 46 refers to structures, such as bolts, screws and threads.
There is also a flow restrictor means 186 in fluid connection with the pressure inlet port 52, as shown in
Embodiments of the tool assembly 10 include the bypass assembly 100 removably attached to the main body 20 within the cavity 48 and having an inner side 102 and an outer side 104 opposite the inner side 102.
The bypass attachment means 120 also refers to structures, such as bolts, screws and threads.
The pressure chamber 122 has a distal end cap 124 and a pressure stop 126. The distal end cap 124 is set against the distal bypass end 114, and the pressure stop 126 extends from the distal end cap 124 toward the proximal bypass end 112. The second piston end 134 faces the pressure chamber 122 at the pressure stop 126.
The piston 130 has a first piston position and a second piston position. In
Embodiments of the piston 130 are shown in
One embodiment of the first piston end 132 is shown in
The first fluid bypass hole 160 and the second fluid bypass hole 162 are between the proximal bypass end 112 and the distal bypass end 114. The first fluid bypass hole 160 is also positioned the set distance 99 from the second fluid bypass hole 162. Again, it is the same set distance 99 between the first fluid bypass port 50 and the second fluid bypass port 51 and between the first piston flow hole 146 and the second piston flow hole 148. As shown in
Still another embodiment of the bypass assembly 100 is shown in
There are also alternative embodiments with variations in both the main body 20 and the bypass assembly 100. These alternative embodiments have analogous structures between the main body 20 and the bypass assembly 100.
For the different flow restrictor means 186,
The present invention further includes some alternate embodiments of the piston 130 as shown in
Embodiments of the present invention further include a method of using the tool assembly 10. The method for controlling flow includes deploying the tool assembly 10 into a wellbore, with the piston 130 starting in the first piston position. Then, fluid is pumped from a surface location through the flow restrictor means 186 within the bypass housing 110 so as to create a pressure differential across the flow restrictor means 186 with the off-set through bore 30. The pressure chamber 122 and a portion the off-set through bore 30 between the surface location and the flow restrictor means 186 are one side of the flow restrictor means 186. Another portion of the off-set through bore 30 between the flow restrictor means 186 and the proximal bypass end 112 are on another side of the flow restrictor means 186. The pressure differential increases as the pressure on the one side with the pressure chamber 122 can be increased with increased flow rate from the surface. The piston 130 actuates from the first piston position to the second piston position with the pressure differential. Now, a portion of the fluid from the surface location flows through the tool assembly 10 and another portion of the fluid from the surface location flows through the first fluid bypass hole 160 and the second fluid bypass hole 162 to the wellbore.
In the embodiments of the method, the portion of the fluid through the tool assembly 10 and the another portion of the fluid through the first fluid bypass hole 160 and the second fluid bypass hole 162 are proportional according to a hole diameter of the off set through bore 30, a first bypass hole diameter of the first fluid bypass hole 160, and a second bypass hole diameter of the second fluid bypass hole 162. Furthermore, the portion of the fluid through the tool assembly 10 and the another portion of the fluid through the first fluid bypass hole 160 and the second fluid bypass hole 162 are proportional according to a hole area of the off set through bore 30, a first bypass hole area of the first fluid bypass hole 160, and a second bypass hole area of the second fluid bypass hole 162. The selection of physical dimensions can determine the range of flow rates and proportional flow that can be achieved with the tool assembly 10.
Additionally, the flow restrictor means 186 can still be a bluff body 180 or even a nozzle or venturi, in the method of the using the invention. The flow restrictor means 186 is the boundary between the pressure differential. The fluid can flow through or by the flow restrictor means. In some embodiments, the spring member 144 has a spring rate corresponding to a predetermined flow rate of the fluid from the surface location and the pressure differential. Selecting the spring member 144 can also determine the range of flow rates and proportional flow that can be achieved with the tool assembly 10.
The method of using the present invention is not a single use flow diverter. The method can include reducing pumping the fluid from the surface location and actuating the piston 130 from the second piston position to the first piston position. In that first piston position, fluid flows from the surface location through the tool assembly 10. The first piston position closes the first fluid bypass hole 160 and the second fluid bypass hole 162. However, the first fluid bypass hole 160 and the second fluid bypass hole 162 can be re-opened by changing flow rates again. There is no shut down or complicated removal of a ball that triggered a pressure seat valve.
In the present invention, a pressure differential is created by passing the fluid pumped from surface through a flow restrictor in the inside diameter of the tool, in particular, in the off-set through bore. This invention can use a nozzle or venturi or bluff body or pressure inlet insert to develop the pressure differential.
For a nozzle the pressure drop can be calculated from the following equation (3).
Where: P is nozzle prressure loss (psi)
Using values of interest and assumming Cd=1 and MW=8.2 ppg, pressure loss can be calculated at certain flow rates. The top end of the open/close slide piston in the flow self-contained bypass assembly experiences these pressure values.
For a venturi the pressure loss can be calculated from the following equation (4)
Where: ΔP is pressure loss (psi)
Using values of interest and assuming tool inner diameter (ID)=1″ and MW=8.2 ppg, pressure loss can be calculated at certain flow rates
Pressure values developed with a nozzle or venturi flow restriction implementation are experienced at the top end of the open/close slide piston in the self-contained bypass assembly. The cross-sectional area (int) of the open/close slide piston top times the pressure value (psi) developed by the nozzle or venturi creates a force that can overcome the spring rate and friction that keeps the open/close slide in the closed position.
The spring member can have a spring rate that keeps the open/close slide in the closed position blocking flow from the inner diameter (ID) of the tool to the annulus until a predetermined flow rate and pressure drop (as described above) creates an opposing force that overcomes the spring rate and any friction. When this occurs the open/close slide moves approximately 0.75″, aligning flow holes in the self-contained bypass assembly with the lower two ports in the main body. Flow is then established from the ID of the tool to the annulus
The tool assembly achieves a proportional flow through the bottom of the tool and through the self-contained bypass assembly. The sizing of the relative flow areas (holes and ports) appropriately can determine the proportional flow. Using the example of a 1″ internal diameter tool and two exit ports with a diameter of 0.438″ each, the following data can be generated.
In this example we keep the flow self-contained bypass assembly in the closed position until a flow rate of 190 gpm is established. At flow rates above 190 gpm, the pressure drop through the internal flow restriction is sufficient to move the open/close slide to the open position. Flow is then divided proportionally through the tool and through the self-contained bypass assembly based on the ratio of their flow areas to the total flow area. Approximately 28% of the flow will exit through the self-contained bypass assembly and 72% of the flow will exit through the bottom end of the tool.
The internal diameter of the lower port insert can be a greater or smaller dimension than 0.438″ used in this example in order to adjust the percent of flow that passes through the tool and through the self-contained bypass assembly.
The embodiments of the present invention further provide a linear dynamic seal on the open/close slide piston rectangular section or plate member to control fluid flow through the bypass housing the fluid bypass holes transitions from closed to open and back to closed. The sealing system consists of elastomer seals. Four seals can be rectangular seals on the sliding plate member of the piston. These seals are present on both sides of the slide piston.
The lower port face seal prohibits bypass flow from the off set through bore to the annulus, when the piston is in the closed position by sealing against the solid portion of the plate member. In the opened position of the piston, the open area or bypass fluid holes of the bypass housing align with the open area or piston flow holes of the slide. The seal is positioned in a concentric fashion around these open areas allowing flow to pass through the plate member to the annulus. The embodiments as rectangular seals on both sides of the plate member or slide prevent fluid leakage as the plate member or slide transitions between the first and second piston positions.
The present invention provides a tool assembly for fluid bypass. The tool assembly enables increased flow rates above the conventional flow rates limited by certain downhole tools. Flow rate limited tools, such as the bottom hole assembly (BHA) previously limited flow rates. These flow rate limited tools have high risk of damage at the higher flow rates. Those prior art systems required drilling with the BHA to stop in order to remove debris, like cuttings. Performing the hole cleaning at the higher flow rates was not possible concurrent with drilling. These stoppages were usually achieved with single use bypass and control valves, triggered by balls or darts dropped into the wellbore. These balls and darts had to be removed in order to restart the drilling after the hole cleaning. These delays cost significant money. The present invention eliminates these stoppages.
The tool assembly of the present invention is positioned above the flow rate limited tools. The turbulent flow regime can be achieved with the bypass flow through the bypass assembly of the present invention. The flow at the safe flow rates for the flow rate limited tools can still be passed through the tool assembly of the present invention.
The tool assembly of the present invention has the pressure chamber and the spring member to control the proportional split of the flow. The flow restrictor means controls the pressure in the pressure chamber, which can act against the spring member. The desired proportional flow through the tool assembly to the other downhole tools and through the bypass assembly of the tool assembly for the turbulent flow in the annulus can be set by choosing the strength and other characteristics of the spring member and selecting the dimensions of the holes and ports in the tool assembly. The spring member and the pressure chamber can push back and forth, so the tool assembly is not a single use system. Fluid bypass holes can be opened and closed and opened and closed repeatedly without stopping the tool assembly. There are fewer delays and more efficient operations in the wellbore.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated structures, construction and method can be made without departing from the true spirit of the invention.
| Number | Name | Date | Kind |
|---|---|---|---|
| 6293342 | McGarian et al. | Sep 2001 | B1 |
| 6675897 | McGarian et al. | Jan 2004 | B1 |
| 7299880 | LoGuidice et al. | Nov 2007 | B2 |
| 7334597 | Hughes et al. | Feb 2008 | B1 |
| 7891428 | Martin et al. | Feb 2011 | B2 |
| 8393403 | de Boer | Mar 2013 | B2 |
| 8534369 | deBoer | Sep 2013 | B2 |
| 9260938 | Holderman et al. | Feb 2016 | B2 |
| 9404326 | Zhou | Aug 2016 | B2 |
| 9494014 | Manke et al. | Nov 2016 | B1 |
| 9708872 | O'Neal et al. | Jul 2017 | B2 |
| 9890601 | Baudoin | Feb 2018 | B2 |
| 9903180 | Boutin et al. | Feb 2018 | B2 |
| 10100605 | Gay et al. | Oct 2018 | B2 |
| 10107073 | Cramer et al. | Oct 2018 | B2 |
| 20050269134 | Strazhgorodskiy | Dec 2005 | A1 |
| 20150159466 | Themig | Jun 2015 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 20200123877 A1 | Apr 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62766431 | Oct 2018 | US |
