Patent Application
20190153798
See Application Data Sheet.
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The present invention relates to downhole tools in the oil and gas industry. More particularly, the present invention relates to a tool assembly to generate vibration on a casing string or drill string. The present invention also relates to controlling fluid flow oscillations.
Fluidic components, such as vortex chambers, fluidic switches and feedback loops, are already known to set the flow path through a variable resistance device of a downhole tool. A fluidic agitator generates vibration along a drill string or casing string, so that the respective string can pass bends and angles in the wellbore. The string can pass through tight turns instead of getting stuck on the edge of a rock formation. A fluidic oscillator can pulse the delivery of fluid so that control screens can be cleaned, scale can be removed from casing, and other chemical treatments can be effectively delivered to the downhole location by a pressure pulse. There has always been a need to control fluid flow through the wellbore.
U.S. Pat. No. 8,931,566, issued on 13 Jan. 2015 to Dykstra et al. describes a fluid agitator with curved fluid chamber having a fluid diode as a switch between two ports for generating vibration from the tubular housing of a downhole tool.
U.S. Pat. No. 8,944,160, issued on 3 Feb. 2015 to Surjaatmadja et al. discloses a fluidic agitator with pulsed fluid discharge for the vibration of the tubular string through the wellbore. The flow control relates to discharging fluid in a selected direction for the vibration of the tubular string along the wellbore. U.S. Pat. No. 9,328,587, issued on 3 May 2016 to Surjaatmadja et al. addresses the physical fluid chamber component of the fluidic agitator.
U.S. Pat. No. 9,260,952, issued on 16 Feb. 2016 to Fripp et al. discloses controlling fluid flow with a switch in a fluidic oscillator also. The device delivers fluids downhole as selected for various characteristics and conditions downhole. The fluid chamber relies on physical shapes and structures to split, switch, and shape fluid flow so that the output can be regulated autonomously.
U.S. Pat. No. 9,546,536, issued on 17 Jan. 2017 to Schultz et al., U.S. Pat. No. 9,316,065, issued on 19 Apr. 2016 to Schultz et al., and U.S. Pat. No. 9,212,522, issued on 15 Dec. 2015 to Schultz et al., all show the wide range of shapes and pathways for a fluid chamber. The different vortex chambers and numbers of vortex chambers, feedback loops and flow paths of feedback loops are shown. The tangential and radial connections, and the placement of outlets can also set the sequence of the flow path through the components to affect fluid flow.
It is an object of the present invention to control fluid flow in a downhole tool.
It is an object of the present invention to provide a tool assembly for vibrations in a wellbore.
It is an object of the present invention to provide a fluidic agitator for vibrating a tubular string through a wellbore.
It is an object of the present invention to provide a fluidic oscillator for regulating fluid flow and fluid pressure in a wellbore.
It is another object of the present invention to provide a tool assembly for vibrations with an insert having a feedback chamber.
It is another object of the present invention to provide a tool assembly for vibrations with an asymmetric flow path.
It is still another object of the present invention to provide a tool assembly for vibrations with asymmetric flow path through an input chamber, a switch, a vortex chamber, and a feedback chamber.
It is still another object of the present invention to provide a tool assembly for vibrations with asymmetric flow path between a vortex chamber and a feedback chamber of an insert of the tool assembly.
It is still another object of the present invention to provide a tool assembly for vibrations with asymmetric flow path through an input chamber, a switch, a vortex chamber, and a feedback chamber.
It is yet another object of the present invention to provide a tool assembly for vibrations with one channel between a vortex chamber and a feedback chamber larger than another channel between the vortex chamber and the feedback chamber.
These and other objectives and advantages of the present invention will become apparent from a reading of the attached specifications and appended claims.
The tool assembly of the present invention is a fluidic agitator used in a downhole tool to vibrate the drill string so that the drill string can pass by curves and bends in the borehole. The vibrations reduce friction as the drill string rubs against the bend in a rock formation. The strength and frequency of the vibrations affect the efficiency and effectiveness of the fluidic agitator. The tool assembly has a pressure profile with multiple levels, such as a lower level, a middle level, and a higher level. Thus, the range of strength of the pressure pulses is greater than conventional fluidic agitators. Furthermore, the range of frequency of the higher level allows for lower frequency vibrations than conventional fluidic agitators. In the present invention, the range of frequency is achieved without increasing the distance from the inlet chamber and vortex chamber. The tool assembly includes a housing having an inlet and an outlet, a insert mounted in the housing, and a cover fitted over the insert in the housing. The cover seals the insert within the housing for installation in a casing string or drill string. The tool assembly may also be used as a fluidic oscillator for more general fluid flow control for delivery of fluids downhole under the resulting pressure profile of the insert.
Embodiments of the tool assembly include an insert comprising an inlet chamber, a vortex chamber, and a feedback chamber. The inlet chamber is in fluid connection with the inlet of the housing, and the vortex chamber has an output in fluid connection to the outlet of the housing. The fluid flow through the inlet at the input chamber, vortex chamber, and feedback chamber has a pressure profile with a plurality of levels, corresponding to the number of feedback chamber. Additionally, the pressure profile has a frequency determined by the feedback chamber when the input chamber maintains a constant position and fluid connection to the vortex chamber. In some embodiments, the input chamber, vortex chamber and feedback chamber are in an asymmetric flow path. The insert includes a first input channel connecting the inlet chamber to one side of the vortex chamber, and a second input channel connecting the inlet chamber to an opposite side of the vortex chamber. There is a switch means in the input chamber based on the Coanda effect for the flow path alternating between the first input channel and the second input channel.
Some embodiments include a first transition channel connecting the vortex chamber to one side of the feedback chamber, and a second transition channel connecting the vortex chamber to an opposite side of the feedback chamber. The second transition channel is larger than the first transition channel so that the asymmetry is in this position in the flow path. This asymmetric flow path comprises a first fluid flow from the input chamber to the first input channel and to the vortex chamber is in a first direction around the vortex chamber, and a second fluid flow from the input chamber to the second input channel and to the vortex chamber is in a second direction around the vortex chamber. The second direction is opposite the first direction.
The first fluid flow can continue from the vortex chamber to the feedback chamber by the first transition channel and is in a first circulation direction around the feedback chamber. The second fluid flow can continue from the vortex chamber to the feedback chamber by the second transition channel and is in a second circulation direction around the feedback chamber. The second circulation direction is opposite the first circulation direction. The embodiments of the tool assembly include both the second transition channel having a larger width dimension than the first transitional channel and the second transition channel having a smaller width dimension than the first transitional channel. The transition channels are different for the asymmetry in this embodiment.
There can also be a first flowback channel extending from the feedback chamber to the input chamber, and a second flowback channel extending from the feedback chamber to the input chamber. These flowback or feedback channels return fluid back to the input chamber.
Embodiments of the present invention include the method of vibrating a casing string or drill string in a wellbore. The method includes assembling the tool with the insert having the feedback chamber and asymmetric flow path, installing the tool on the casing string or drill string, flowing a fluid through the insert with a pressure profile with multiple levels, and generating vibrations in the tool according to the pressure profile and feedback chamber. The method includes the step of flowing the fluid through the insert with alternating the flow path between the first input channel and the second input channel for the first fluid flow path and the second fluid flow path of the asymmetric flow path.
The step of flowing the fluid through the insert includes flowing the fluid between the vortex chamber and the feedback chamber, according to the step of alternating between the first fluid flow path and the second fluid flow path. In embodiments of the tool assembly with flowback channels or feedback channels, the method can further include the step of flowing the fluid between the feedback chamber and the input chamber.
Fluid control in a wellbore is important for more than one reason. A fluidic agitator can be used in a downhole tool to vibrate a tubular string, such as a drill string or casing string, so that the tubular string can pass by curves and bends in the borehole. A fluidic oscillator can be used to pulse fluid treatment chemicals to downhole locations in the wellbore. A pressure pulse of a fluid treatment can be used to clean components in the remote downhole locations. The strength and frequency of the vibrations or pressure pulses affect the efficiency and effectiveness of the fluid control tool assembly. There is limited space in a downhole tool, and there is a need for the control without enlarging the agitator.
Referring to
As shown in
Additionally, the pressure profile has a frequency determined by the feedback chamber 36 of the insert 30. With the feedback chamber 36 in fluid connection between the vortex chamber 34 and the input chamber 32, the input chamber 32 can be placed in a constant position and in fluid connection to the vortex chamber 34. Thus, the inlet 22 and the outlet 24 are matched with the input chamber 32 and vortex chamber 34. In some embodiments, the input chamber 32 and the vortex chamber 34 can be placed close together, just as the inlet 22 would be placed near the outlet 24. The feedback chamber 36 in the insert is positioned to regulate frequency as a buffer to delay feedback flow. The sizes of the inlet 22 and outlet 24 are no longer expanded or narrowed to control frequency, and the distance between the inlet 22 and input chamber 32 to the outlet 24 and the vortex chamber 34 are no longer extended or retracted to control frequency. The structure, size and arrangement of the insert 30 achieve the pressure profile with a plurality of levels with ranges of strength and frequency required for downhole activity.
Embodiments of the tool assembly 10 include an insert 30 comprising an inlet chamber 32, a vortex chamber 34, and a feedback chamber 36 in fluid connection between the vortex chamber 34 and the inlet chamber 32. The inlet chamber 32 is fluid connection with the vortex chamber 34 directly and through the feedback chamber 36, as shown in
The insert 30 also includes a first transition channel 46 connecting the vortex chamber 34 to one side of the feedback chamber 36, and a second transition channel 48 connecting the vortex chamber 34 to an opposite side of the feedback chamber 36. The feedback chamber 36 is in fluid connection to the vortex chamber 34. The first and second transition channels 46, 48 are mirror images of each other, being symmetrical in position along the longitudinal axis orientation or center line of the insert 30.
Embodiments of the present invention include the inlet chamber 32, the vortex chamber 34, and the feedback chamber 36 in an asymmetric flow path 66.
The first fluid flow path 54 continues from the vortex chamber 34 to the feedback chamber 36 by the first transition channel 46 and is in a first circulation direction 62 around the feedback chamber 36. The second fluid flow path 58 continues from the vortex chamber 34 to the feedback chamber 36 by the second transition channel 48 and is in a second circulation direction 64 around the feedback chamber 36. The second circulation direction 64 is opposite the first circulation direction 62. In
Embodiments of the present invention include the method for fluid control in a wellbore, which can be used for vibrating a casing string or drill string in the wellbore. The method includes assembling the tool 10 with the insert 30 having the feedback chamber 36 between the vortex chamber 34 and the input chamber 32 with the input chamber 32 in fluid connection with the vortex chamber 34 directly and through the feedback chamber 36, installing the tool 10 on a tubular string, such as a casing string or drill string, flowing a fluid through the insert 30 with a pressure profile with a plurality of levels, such as lower 72, middle 74 and higher 76 levels, and generating vibrations in the tool 10 according to the pressure profile. The feedback chamber 36 is a generally round cavity in the insert 30 without an output. Fluid can flow around in the feedback chamber 36, similar to a vortex chamber, except that there is no output for the fluid to leave the feedback chamber in the center of the feedback chamber. In some embodiments, the feedback chamber 36 is a circulation chamber positioned on the feedback side of the vortex chamber 34. The placement of the feedback chamber 36 creates a buffer to delay feedback flow to the input chamber. Previously, the feedback channels were lengthened or double backed to the input chamber, but there was no flow or circulation arrangement of the feedback chamber 36. The fluid must exit through the transition channel or flowback channel, which are tangent to the feedback chamber in
When the insert 30 is comprised of a switch 44, the first input channel 40 and the second input channel 42 in fluid connection between the inlet chamber 32 and the vortex chamber 34, the step of flowing the fluid includes alternating the flow between the first input channel 40 and the second input channel 42 for the first fluid flow path 54 and the second fluid flow path 58 of the asymmetric flow path 66. In the vortex chamber 34, the first fluid flow path 54 is in a first direction 56 around the vortex chamber 34, while the second fluid flow path 58 can be in a second direction 60 around the vortex chamber 34 in the opposite direction. The connections to the vortex chamber 34 are on opposite sides for symmetrical positions along the center line of the insert 30.
The step of flowing the fluid through the insert 30 can further include flowing the fluid between the vortex chamber 34 and the feedback chamber 36. FIGS. 2-4 show the first transition channel 46 and the second transition channel 48 for this step of flowing. The flowing between the vortex chamber 34 and the feedback chamber 36 corresponds to the step of alternating the flow path, so that the flow through the larger second transition channel 48 is different than the flow through the smaller first transition channel 46. This flow path is an asymmetric flow path 66 due to the first and second transition channels 46, 48. The connections to the vortex chamber 34 and the feedback chamber 36 are also tangent connections on opposite sides for symmetrical positions along the center line. However, the first and second transition channels 46, 48 are different so that the flow path remains asymmetric, despite the symmetry in the positions around the vortex chamber 34 and the feedback chamber 36.
Since the step of flowing between the vortex chamber 34 and the feedback chamber 36 corresponds to the step of alternating, the first fluid flow path 54 and the second fluid flow path 56 are similarly related in the feedback chamber 36. In the feedback chamber 36, the first fluid flow path 54 is in a first circulation direction 62 around the feedback chamber 36, while the second fluid flow path 58 can be in a second circulation direction 64 around the feedback chamber 36 in the opposite direction to the first circulation direction 62. The connections to the vortex chamber 34 and the feedback chamber 36 are on opposite sides for symmetrical positions along the center line of the insert 30 and tangent to both the vortex chamber 34 and the feedback chamber 36.
Alternate embodiments further include the step of flowing the fluid from the feedback chamber 36 to the inlet chamber 32. When the insert 30 has a first flowback channel 50 and a second flowback channel 52, the step of flowing includes recycling fluid from the feedback chamber 36 back to the inlet chamber 32 through the flowback channels, 50, 52 according to the step of alternating at the switch 44. Since the step of flowing between the feedback chamber 36 and the inlet chamber 32 corresponds to the step of alternating, the step of flowing of the method includes alternating between the first flowback channel 50 and the second flowback channel 52. The connections to the feedback chamber 36 are on opposite sides for symmetrical positions along the center line of the insert 30 and tangent to the feedback chamber 36. The method controls fluid flow by the variable resistance in the insert. The asymmetric flow path 66 relative to the feedback chamber 36 creates the pressure profile with a plurality of levels, such as a lower level 72, a middle level 74, and a higher level 76. Alternate embodiments may include more feedback chambers, larger or smaller feedback chambers, etc., which corresponds to more than three levels. There may also be other portions of the flow path 66 with asymmetry. The method can vary the strength of the pressure pulse and frequency of the pressure pulse to vibrate a tubular string for the required conditions in the wellbore. The present invention can be adjusted for stronger vibrations and lower frequency to pass a particularly severe bend in the rock formation or for weaker vibrations and higher frequency for different wellbore conditions.
The present invention can control fluid flow in a downhole tool for fluidic agitators and fluidic oscillators. The tool assembly of the present invention is typically used for a fluidic agitator to generate vibrations in a wellbore. The vibration of a tubular string, such as a drill string or casing string, allows the tubular string to pass through the rock formations in the wellbore more easily and with less risk of damage to the string. The tool assembly includes an insert with a feedback chamber in a particular relationship to an inlet chamber, switch, vortex chamber, and flowback channels.
In particular, the prior art required changing the area of the inlet to change the frequency of the pressure profile. The change of the area of the inlet resulted in a corresponding change to inlet flow speed and change to strength of the pressure pulse for the oscillation or vibration. There was no system to achieve the lower frequencies, while maintaining strength. Some tools have added multiple vortex chambers or circulation chambers between the input chamber and the vortex chamber to affect frequency and multiple level pressure profiles. However, the inlet and outlets must change on the housing, and there may not be sufficient space to include as many circulation chambers as needed. Other prior art relied on changing the length of the feedback and inlet channels. However, the change was not efficient, and there could only be small effects on frequency within the lengthening in the limited space on the insert. The present invention includes the feedback chamber as an additional feedback control. The size, number, and connection to the transition channels now determines frequency and strength of the pressure profile. The length of feedback channels, area of the inlet and the position of the inlet relative to the outlet no longer need to be modified in order to maintain control of frequency and strength. The feedback chamber of the present invention allows for compact arrangement of the inlet and outlet, without reducing the ability to regulate the greater range of frequencies and to maintain a sufficiently strong pressure pulse.
Embodiments further includes a particular asymmetry in the transitional channels between the feedback chamber and the vortex chamber. The asymmetry can be a result of different dimensions, such as width of the second transition channel being larger than the width of the first transition channel. In the present invention, the asymmetry does not rely on the type of connection being tangent or radial. The benefit in easier fabrication and durability of the insert with this type of asymmetry is an improvement and advantage over known fluidic agitators. The wear on different surfaces is not as unbalanced, so the working life and control of the present invention is a better flow control with more reliable and precise vibrations.
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.
