Valves for actuating downhole shock tools in connection with concentric drive systems

A system for generating pressure pulses in drilling fluid includes a concentric drive power section. The power section includes a stator and a rotor rotatably disposed in the stator. The rotor is coaxially aligned with the stator. The system also includes a valve. The valve includes a first valve member coupled to the stator and a second valve member coupled to the rotor. The second valve member is configured to rotate with the rotor relative to the first valve member and the stator. The rotation of the second valve member relative to the first valve member is configured to generate pressure pulses in drilling fluid flowing through the concentric drive power section.

Not applicable.

BACKGROUND

The disclosure relates generally to downhole tools. More particularly, the disclosure relates to downhole systems for inducing axial oscillations in drill strings during drilling operations. Still more particularly, the disclosure relates to valves used in connection with concentric drive systems to generate pressure pulses in drilling fluid that actuate shock tools that produce axial oscillations.

Drilling operations are performed to locate and recover hydrocarbons from subterranean reservoirs. Typically, an earth-boring drill bit is typically mounted on the lower end of a drill string and is rotated by rotating the drill string at the surface or by actuation of downhole motors or turbines, or by both methods. With weight applied to the drill string, the rotating drill bit engages the earthen formation and proceeds to form a borehole along a predetermined path toward a target zone.

During drilling, the drillstring may rub against the sidewall of the borehole. Frictional engagement of the drillstring and the surrounding formation can reduce the rate of penetration (ROP) of the drill bit, increase the necessary weight-on-bit (WOB), and lead to stick slip. Accordingly, various downhole tools that induce vibration and/or axial reciprocation may be included in the drillstring to reduce friction between the drillstring and the surrounding formation, as well as increase ROP. One such tool is an axial reciprocation tool that includes a valve that generates pressure pulses in drilling fluid and a shock tool that converts the pressure pulses in the drilling fluid into axial reciprocation.

The valve is operated by a downhole power section (rotor and stator assembly), and is usually positioned between the rotor of the power section and a bottom sub. In addition, the valve is typically made of two carbide plates with flow ports (holes or slots) therethrough. One of the plates, referred to as the oscillating valve plate, is connected to and rotates with the rotor of the power section, and the other plate, referred to as a stationary valve plate, is connected to and static relative to the bottom sub. Accordingly, flow exiting the power section passes through the valve and onward through the drill string or bottom hole assembly (BHA) therebelow.

Most conventional power sections include Moineau type mud motors in which the rotor rotates eccentrically within the stator as drilling fluid flows therethrough. The eccentric rotary motion of the rotor causes the alignment between the flow ports of the oscillating valve plate and the stationary valve plate to vary in a cyclical fashion. This, in turn, cyclically varies the flow area through the valve, which causes pressure fluctuations or pulses in the drilling fluid flowing therethrough.

As noted above, the shock tool induces axial oscillations in the drillstring in response to pressure pulses generated by the valve. The shock tool is typically a spring-loaded stroking tool. The pressure pulses act on the pump open area of the shock tool, causing the shock tool to reciprocate axially, which imparts cyclical axial vibrations to the drillstring.

BRIEF SUMMARY OF THE DISCLOSURE

Embodiments of systems for generating pressure pulses in drilling fluid are disclosed herein. In one embodiment, a system comprises a concentric drive power section including a stator and a rotor rotatably disposed in the stator. The rotor is coaxially aligned with the stator. In addition, the system comprises a valve including a first valve member coupled to the stator and a second valve member coupled to the rotor. The second valve member is configured to rotate with the rotor relative to the first valve member and the stator. The rotation of the second valve member relative to the first valve member is configured to generate pressure pulses in drilling fluid flowing through the concentric drive power section.

In another embodiment, a system for generating pressure pulses in drilling fluid comprises a concentric drive power section including a central axis, a stator, and a rotor rotatably disposed in the stator. The rotor and the stator are coaxially aligned with the central axis. The rotor includes a throughbore, a fluid inlet port extending radially from the throughbore to a radially outer surface of the rotor, and a fluid outlet port extending radially from the throughbore to the radially outer surface of the rotor. The fluid inlet port is axially spaced from the fluid outlet port. In addition, the system comprises a valve including an outer housing and a body rotatably disposed in the outer housing. The outer housing is coupled to an upper end of the stator and the body is coupled to an upper end of the rotor. The body has an upper end, a lower end, a throughbore extending axially from the upper end to the lower end, and a port extending radially from the throughbore to a radially outer surface of the body. Further, the system comprises an annulus radially positioned between the outer housing and the body. The body is configured to rotate with the rotor about the central axis relative to the outer housing and the stator. The body has a first rotational position with the annulus and the throughbore in fluid communication through the port and a second rotational position with fluid communication through the port between the annulus and the throughbore blocked.

Embodiments of methods for generating pressure pulses in drilling fluid to operate a downhole shock tool are disclosed herein. In one embodiment, a method comprises (a) flowing drilling fluid down a drillstring to a concentric rotary drive power section. The concentric rotary drive power section includes a rotor rotatably disposed in a stator. The rotor and the stator are coaxially aligned with a central axis of the concentric rotary drive power section. In addition, the method comprises (b) selectively directing at least a portion of the drilling fluid into an annulus radially positioned between the rotor and the stator to drive the rotation of the rotor about the central axis relative to the stator. Further, the method comprises (c) rotating a first valve member with the rotor relative to a second valve member in response to (b). Still further, the method comprises (d) selectively directing at least a portion of the drilling fluid through a port of the first valve member. Moreover, the method comprises (e) cyclically opening and closing the port of the first valve member with the second valve member to cyclically block the flow of drilling fluid through the port. The method also comprises (f) generating pressure pulses in the drilling fluid during (e).

Embodiments described herein comprise a combination of features and advantages intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical advantages of the invention in order that the detailed description of the invention that follows may be better understood. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices, components, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis. Any reference to up or down in the description and the claims will be made for purposes of clarity, with “up”, “upper”, “upwardly” or “upstream” meaning toward the surface of the borehole and with “down”, “lower”, “downwardly” or “downstream” meaning toward the terminal end of the borehole, regardless of the borehole orientation.

As described above, the valves used to generate pressure pulses in drilling fluid to actuate downhole shock tools are typically used in connection with Moineau type mud motors. Such motors include a stator having a helical internal bore and a helical rotor rotatably disposed within the stator bore. The inner surface of the stator is typically made of an elastomeric material that provides a surface having some resilience to facilitate the interference fit between the stator and the rotor. Conventional rotors often comprise a steel tube or rod having a helical-shaped outer surface, which may be chrome-plated or coated for wear and corrosion resistance. When the rotor and stator are assembled, the rotor and stator lobes intermesh to form a series of cavities. More specifically, an interference fit between the helical outer surface of the rotor and the helical inner surface of the stator results in a plurality of circumferentially spaced hollow cavities in which fluid can travel. During rotation of the rotor, these hollow cavities advance from one end of the stator towards the other end of the stator. Each cavity is sealed from adjacent cavities by seals formed along contact lines between the rotor and the stator. Pressure differentials across adjacent cavities exert forces on the rotor that causes the rotor to rotate within the stator. The centerline of the rotor is typically offset from the center of the stator so that the rotor rotates within the stator on an eccentric orbit.

The eccentricity of conventional Moineau type mud motors limits the maximum speed, limits the ability to run bearings easily without driveshafts or flexshafts, and limits the ability to employ concentrically rotating assemblies above and below the power section within relatively short lengths. The eccentricity also limits the size of the passage through the rotor also limits and/or prevents fish through capability. Consequently, many conventional pressure pulse generating devices are not run above nuclear source tools due to the inability to run fishing tools to retrieve sources in the event the string being stuck.

Relatively high downhole temperatures can reduce the strength of the stator elastomeric material along the inside of the stator and/or result in excessive thermal expansion of the stator elastomeric material. To avoid premature deterioration or damage to the elastomeric material, the maximum pressure drop across the mud motor is usually reduced. Consequently, the primary limitation in running axial reciprocation tools in relatively high temperature downhole environments is the mud motor.

Due to the eccentric rotation of the rotor and the flow ports in the oscillating valve plate being radially offset from the mud motor centerline, most conventional pressure pulse generating valves for actuating downhole shock tools are operated continuously. In other words, they cannot be selectively actuated. Due to the continuous operation of conventional pressure pulse generating devices, they are typically not positioned directly adjacent measurement-while-drilling (MWD) devices as MWD interference problems can arise. In particular, the pressure pulses being continuously generated can disrupt the proper decoding of mud pulse MWD tools on surface, thereby potentially leading to errors or misinterpretations of surveys. In embodiments described herein that allow for selective actuation, offer the potential for a large percentage of the borehole to be drilled without generating any pressure pulses, and then on an as needed basis (e.g., when the drill string becomes hard to progress in an extended lateral section of the borehole), the pressure pulse generating device can be actuated or turned on. This option may significantly minimize MWD interference issues by allowing surveys to take place during periods of no pressure pulse generation. In this same manner, the size of the pressure pulse being generated towards the end of the borehole would also help to limit damage until the larger effect is needed.

Referring now toFIG. 1, a schematic view of an embodiment of a drilling system10is shown. Drilling system10includes a derrick11having a floor12supporting a rotary table14and a drilling assembly90for drilling a borehole26from derrick11. Rotary table14is rotated by a prime mover such as an electric motor (not shown) at a desired rotational speed and controlled by a motor controller (not shown). In other embodiments, the rotary table (e.g., rotary table14) may be augmented or replaced by a top drive suspended in the derrick (e.g., derrick11) and connected to the drillstring (e.g., drillstring20).

Drilling assembly90includes a drillstring20and a drill bit21coupled to the lower end of drillstring20. Drillstring20is made of a plurality of pipe joints22connected end-to-end, and extends downward from the rotary table14through a pressure control device15, such as a blowout preventer (BOP), into the borehole26. Drill bit21is rotated with weight-on-bit (WOB) applied to drill the borehole26through the earthen formation. Drillstring20is coupled to a drawworks30via a kelly joint21, swivel28, and line29through a pulley. During drilling operations, drawworks30is operated to control the WOB, which impacts the rate-of-penetration of drill bit21through the formation. In addition, drill bit21can be rotated from the surface by drillstring20via rotary table14and/or a top drive, rotated by a power section100disposed along drillstring20proximal bit21, or combinations thereof (e.g., rotated by both rotary table14via drillstring20and power section100, rotated by a top drive and the power section100, etc.). For example, rotation via downhole power section100may be employed to supplement the rotational power of rotary table14, if required, and/or to effect changes in the drilling process. In either case, the rate-of-penetration (ROP) of the drill bit21into the borehole26for a given formation and a drilling assembly largely depends upon the WOB and the rotational speed of bit21.

During drilling operations a suitable drilling fluid31is pumped under pressure from a mud tank32through the drillstring20by a mud pump34. Drilling fluid31passes from the mud pump34into the drillstring20via a desurger36, fluid line38, and the kelly joint21. The drilling fluid31pumped down drillstring20flows through power section100and is discharged at the borehole bottom through nozzles in face of drill bit21, circulates to the surface through an annulus27radially positioned between drillstring20and the sidewall of borehole26, and then returns to mud tank32via a solids control system36and a return line35. Solids control system36may include any suitable solids control equipment known in the art including, without limitation, shale shakers, centrifuges, and automated chemical additive systems. Control system36may include sensors and automated controls for monitoring and controlling, respectively, various operating parameters such as centrifuge rpm. It should be appreciated that much of the surface equipment for handling the drilling fluid is application specific and may vary on a case-by-case basis.

While drilling, one or more portions of drillstring20may contact and slide along the sidewall of borehole26. To reduce friction between drillstring20and the sidewall of borehole26, in this embodiment, an axial reciprocation system91is provided along drillstring20proximal bit21. Axial reciprocation system91includes power section100and a shock tool92coupled to power section100. As will be described in more detail below, a valve (not visible inFIG. 1) coupled to power section100generates cyclical pressure pulses in the drilling fluid flowing down drillstring20through shock tool92and power section100. The pressure pulses cyclically and axially extend and retract shock tool92. With bit21disposed on the hole bottom, the axial extension and retraction of shock tool92induces axial reciprocation in the portion of drillstring22above power section100, which reduces friction between drillstring20and the sidewall of borehole26.

In general, shock tool92can be any shock tool known in the art that is actuated to reciprocally and axially extend and retract in response to pressure pulses in drilling mud generated by the valve disposed in power section100. Examples of shock tools that can be used as shock tool92are disclosed in U.S. Pat. Nos. 2,240,519 and 3,949,150, each of which is hereby incorporated herein by reference in its entirety.

Referring now toFIG. 2, power section100is shown. Unlike conventional Moineau type mud motors that include a rotor that rotates eccentrically within a stator, in this embodiment, power section100is a concentric rotary drive system. Namely, power section100includes an outer stator and a rotor that is coaxially disposed within and rotates concentrically relative to the stator.

Power section100has a first or upper end100acoupled to shock tool92, a second or lower end100bcoupled to a bearing assembly150, and a central or longitudinal axis105. As shown inFIG. 2, power section100includes two stages—a first or upper stage101and a second or lower stage102coupled to stage101. Stages101,102are serially arranged and connected end-to-end—first stage101extends from upper end100ato second stage102, and second stage102extends from lower end100bto upper stage101. Although power section100includes two stages101,102in this embodiment, in other embodiments, the power section (e.g., power section100) may include only one stage (e.g., stage101) or more than two stages.

Referring now toFIGS. 2-4, both stages101,102have the same structure and function, and thus, first stage101will be described, it being understood that second stage102is the same. Stage101of power section100includes a tubular central shaft or rotor110rotatably disposed within a tubular housing or stator120. Rotor110is coaxially aligned with and concentrically disposed within stator120. In particular, rotor110and stator120have central axes coaxially aligned with axis105of power section100. An annulus or working fluid space130is radially positioned between rotor110and stator120. The upper and lower boundaries of working fluid space130are defined by upper and lower shoulders131,132fixed within stator120. Shoulders131,132also constrain the axial position of rotor110relative to stator120(i.e., prevent rotor110from moving axially relative to stator120).

As best shown inFIGS. 2 and 3, rotor110has a first or upper end110a, a second or lower end110b, and a central throughbore111extending axially between ends110a,110b. In addition, rotor110includes a plurality of fluid inlet ports116proximal upper end110a, a plurality of fluid outlet ports117proximal lower end110b, and a flow restrictor113disposed within bore111axially between ports116,117. Ports116,117are in fluid communication with working fluid space130and throughbore111. Flow restrictor113divides throughbore111into a first or upstream region111aextending axially from upper end110ato restrictor113and a second or downstream region111bextending axially from restrictor113to downstream end110b. In general, flow restrictor113allows axial flow directly between regions111a,111b, but restricts and limits the fluid flow through bore111and between regions111a,111b, thereby forcing at least some of the fluid flowing through upstream region111aof bore111to pass through ports116into working fluid space130. The fluid flowing into and through working space130passes back into downstream region111bof bore111via ports117. Accordingly, stage101may be described as defining a fluid path between a fluid intake zone in an upstream region111aof bore111, through inlet ports116into working fluid space130, and out of working fluid space130through outlet ports117into a fluid exit zone in a downstream region111bof bore proximal lower end110b, from which zone fluid flow can continue to second stage102.

Stator120has a first or upper end120a, a second or lower end120b, and a central throughbore121extending axially between ends120a,120b. Throughbore121is defined by a generally cylindrical radially inner surface122of stator120. As shown inFIG. 2, lower end110bof rotor110of first stage101is coupled to upper end110aof rotor110of second stage102with throughbores111of rotors110in fluid communication, and lower end120bof stator120of first stage101is coupled to upper end120aof stator120of second stage102.

As best shown inFIG. 4, the radially outer surface of rotor110includes a plurality of uniformly circumferentially-spaced longitudinal rotor lobes114. A plurality of axially extending, uniformly circumferentially-spaced elongate gates140are disposed along inner surface122of stator120and are pivotally mounted to stator120within respective elongate gate-receiving pockets123in inner surface122of stator120. As rotor110rotates within stator120, lobes114sequentially engage gates140and deflect gates140into corresponding gate pockets123in stator120so that rotor lobes114can pass by. Thus, each gate140pivots between a first or extended position in contact with or closely adjacent to rotor110when positioned circumferentially between adjacent rotor lobes114, and a second or deflected position when displaced into its corresponding gate pocket123by a passing rotor lobe114.

Gates140are biased into substantially fluid-tight contact with rotor110. As a result, working fluid space130between rotor110and stator120is divided into longitudinal chambers133between rotor lobes114and adjacent gates140. Longitudinal chambers133are bound at either end by shoulders131,132. In operation, a pressurized working fluid (e.g., drilling mud) is pumped from the surface into region111aof throughbore111. The working fluid then passes through inlet ports116, thereby pressurizing (at any given time) one or more longitudinal chambers133and inducing rotation of rotor110relative to stator120. Opposite the high pressure side of each lobe114, the fluid is directed through fluid outlet ports117and onward to region111aof second stage102.

The number of rotor lobes114and the number of gates140can vary. Preferably, however, there will always be at least one fluid inlet port116and at least one fluid outlet port117located between adjacent rotor lobes114at any given time, and at least one gate140sealing between adjacent fluid inlet and outlet ports116,117at any given time. Torque and speed outputs of each stage101,102are dependent on the length and radial height (i.e., gate lift) of chambers133. For a given stage length, a smaller gate lift produces higher rotational speed and lower torque. Conversely, a larger gate lift produces higher torque and lower rotational speed. In this embodiment, each stage101,102is substantially the same as an embodiment of a concentric rotary drive system disclosed in U.S. Pat. No. 9,574,401. However, in general, each stage (e.g., stage101,102) can comprise any suitable concentric rotary drive system known in the art. Examples of concentric rotary drive systems that can be used in connection with embodiments described herein are disclosed in U.S. Pat. Nos. 6,976,832 and 9,574,401, and European Patent Application Nos. EP 20130780628 EP2013078062850 of which are hereby incorporated herein by reference in their entirety.

Referring again toFIG. 2, bearing assembly150includes an elongate tubular mandrel160coaxially and rotatably disposed within a generally cylindrical outer housing170. Mandrel160has a central axis165coaxially aligned with axis105, a first or upper end160acoupled to lower end110bof rotor110of second stage102, a second or lower end160bcoupled to drill bit21, and a throughbore161extending axially from upper end160ato lower end160b. Throughbore161is in fluid communication with throughbores111of rotors110such that drilling fluid passes through bore161to bit21coupled to lower end160bof mandrel160. In this embodiment, lower end110bof rotor110of second stage102is concentrically coupled to upper end160aof mandrel160by a splined connection. In other embodiments, a threaded connection may be used to concentrically couple lower end110bof rotor110of second stage102to upper end160aof mandrel160. Housing170has a central axis175coaxially aligned with axes105,165, a first or upper end170adirectly coupled to lower end120bof stator120of second stage102, and a second or lower end170bdistal power section100. Mandrel160extends axially through lower end170bof housing170.

Bearing assembly150comprises multiple bearings for transferring the various axial and radial loads between mandrel160and housing170that occur during the drilling process. Thrust bearings transfer on-bottom and off-bottom operating loads, while radial bearings transfers radial loads between mandrel160and housing170. In preferred embodiments, the thrust bearings and radial bearings are mud-lubricated PDC (polycrystalline diamond compact) insert bearings, and a small portion of the drilling fluid is diverted through the bearings to provide lubrication and cooling. In other embodiments, other types of mud-lubricated bearings may be used, or one or more of the bearings may be oil-sealed. Notwithstanding the foregoing discussion of thrust bearings and radial bearings in downhole bearing assembly150, it is to be noted that any suitable type and arrangement bearings known in the art can be used.

Referring still toFIG. 2, in this embodiment, second stage102of power section100includes an optional relief or bypass valve180seated in throughbore111of rotor110of second stage102. More specifically, bypass valve180is axially positioned between inlet ports116and outlet ports117of rotor110of second stage102. Thus, similar to flow restrictor113of first stage101, bypass valve180of second stage102divides throughbore111of the corresponding rotor110(of second stage102) into a first or upstream region111aextending axially from upper end110aof the corresponding rotor110to bypass valve180and a second or downstream region111bextending axially from bypass valve180to downstream end110bof the corresponding rotor110. Valve180has a closed position preventing axial flow between regions111a,111bof throughbore111of the corresponding rotor110and an open position allowing axial flow between regions111a,111b. In particular, valve180can open to varying degrees to allow an adjustable volumetric flow of axial flow between regions111a,111b—the more valve180is open, the greater the volumetric flow of axial flow between regions111a,111b.

In this embodiment, bypass valve180is transitioned from the closed position to the open position at a predetermined or threshold pressure differential across second stage102(e.g., fluid pressure differential between regions111a,111bon opposite sides of valve180) and is transitioned between varying degrees of openness as the pressure differential across second stage102varies above the predetermined pressure differential—once above the predetermined pressure differential, the greater the pressure differential across second stage102the more open valve180and the lesser the pressure differential across second stage, the less open valve180. In other embodiments, the bypass valve in the second stage (e.g., bypass valve180of second stage102) actuates in response to the flow rate of fluid through the upstream region of the corresponding rotor (e.g., upstream region111aof throughbore111of rotor110of second stage102). In general, bypass valve180can be any valve known in the art that can be selectively opened to varying degrees in response to a pressure differential or flow rate. Examples of such suitable valves are disclosed in PCT patent application no. PCT/US2013/038446 (WO 2013/163565), which is hereby incorporated herein by reference in its entirety for all purposes.

When valve180is closed, axial flow between regions111a,111bis prevented, and thus, all the flow through region111aof the corresponding rotor110is forced to pass through ports116into working fluid space130of second stage102, and then from working fluid space130of second stage into downstream region111bof bore111via ports117. However, when valve180is open, a portion of the flow through region111aof the corresponding rotor110is allowed to flow axially from region111ainto region111b, thereby bypassing inlet ports116, outlet ports117, and working fluid space130of second stage102. Thus, any axial flow directly between regions111a,111b, as permitted by bypass valve180, bypasses inlets116, outlets117, and working fluid space130of second stage102. In general, the more open valve180, the greater the portion of fluid flowing through region111athat is allowed to flow axially into region111band bypass working fluid space130of second stage; and the less open valve, the smaller the portion of fluid flowing through region111athat is allowed to flow axially into region111band bypass working fluid space of second stage102. Accordingly, second stage102may also be described as defining a fluid path between a fluid intake zone in an upstream region111aof bore111of the corresponding rotor110, through inlet ports116into working fluid space130, and out of working fluid space130through outlet ports117into a fluid exit zone in a downstream region111bof bore111of the corresponding rotor110proximal lower end110b, from which zone fluid flow can continue to throughbore161of mandrel160.

As previously described, in operation, the pressurized working fluid (e.g., drilling mud) flowing into and through working fluid spaces130of stages101,102of power section100drives the rotation of rotors110relative to stators120of stages101,102. The opening of bypass valve180increases the relative quantity of drilling fluid that bypasses working fluid space130of second stage102, and hence, decreases the relative quantity of drilling fluid flowing through working fluid space130of second stage102, thereby decreasing the rotational speed of rotors110of stages101,102. Similarly, the more open bypass valve180(once valve180is open), the greater the relative quantity of drilling fluid that bypasses working fluid space130of second stage102, and hence, the lesser the relative quantity of drilling fluid flowing through working fluid space130of second stage102, thereby decreasing the rotational speed of rotors110of stages101,102. Likewise, the less open bypass valve180(and closing of valve180), the lesser the relative quantity of drilling fluid that bypasses working fluid space130of second stage102, and hence, the greater the relative quantity of drilling fluid flowing through working fluid space130of second stage102, thereby increasing the rotational speed of rotors110of stages101,102. As previously described, in this embodiment, bypass valve180is transitioned from the closed position to the open position at a threshold pressure differential across second stage102, and is transitioned between varying degrees of openness as the pressure differential across second stage102varies (once the threshold pressure differential is achieved). Thus, in this embodiment, by controlling the pressure of drilling fluid flowing through power section100(and rotors101), and hence the pressure differential across second stage102, the rotational speed of rotors110can be controlled and adjusted.

Referring again toFIG. 3, an oscillating or rotary valve200is coupled to upper end100aof power section100. Consequently, valve200, as well as other embodiments of valves disclosed herein that are coupled to the upper end of a power section and/or positioned upstream of the power section, may also be referred to as a “top mount” valve. Top mount valves offer several potential benefits. For example, top mount valves enable the ability to bypass a substantial volume of drilling fluid around the power section (e.g., via directing more flow through the rotor as opposed to the working fluid space) since the pressure pulses are generated above the power section. In addition, in embodiments of top mount valves including variable bypass nozzles, the speed of the downstream power section can be altered without damping or killing the pressure pulse generated uphole of the power section. In addition, top mount valves allow the frequency of pressure pulses to be more easily tuned independent of flowrate. Still further, top mount valves can more easily be modified for selective actuation or deactivation, in combination with the ability to be fished through for retrieval of components (e.g., nuclear sources) downhole of the top mount valve and power section.

In general, oscillating valve200is operated by the rotation of rotor110to selectively generate pressure pulses in the drilling fluid upstream of power section100. The pressure pulses generated by valve200drive the axial reciprocation of shock tool92(FIG. 1). As best shown inFIGS. 3, 5, and 6, in this embodiment, valve200includes a first valve member or outer housing210and a second valve member or body220rotatably disposed within housing210. Body220is concentrically disposed within housing210, and further, body220and housing210are coaxially aligned with each rotor110and stator120of power section100. In other words, body220and housing210have central axes that are coaxially aligned with axis105.

Referring now toFIGS. 3 and 6, housing210has a first or upper end210acoupled to drillstring22, a second or lower end210bdirectly coupled to upper end120aof stator120, and a radially inner surface211extending axially from upper end210ato lower end210b. Inner surface211defines a central throughbore212extending axially between ends210a,210b. Body220extends through central throughbore212. In this embodiment, upper end210ais a box end that threadably receives a mating pin end of a sub that couples housing210and power section100to drillstring22, while lower end210bis a pin end that threadably couples housing210to a mating box end disposed at upper end120aof stator120. Thus, housing210is static or fixed relative to stator120and drillstring22.

The inner radius of housing210measured radially from axis105to inner surface211varies moving axially along inner surface211. In particular, moving axially from upper end210ato lower end210b, inner surface211includes an internally threaded first cylindrical surface211aextending axially from upper end210aand defining a box end, a second cylindrical surface211b, a third cylindrical surface211c, and a fourth cylindrical surface211d. The radii of each pair of axially adjacent cylindrical surfaces211a,211b,211c,211dare different, and thus, an annular shoulder extends radially between each pair of axially adjacent cylindrical surfaces211a,211b,211c,211d. In this embodiment, surface211ahas a radius that is greater than the radius of surface211b, surface211bhas a radius that is greater than the radius of surface211c, and surface211chas a radius that is less than the radius of surface211d. Thus, in this embodiment, the radius of cylindrical surface211cdefines the smallest inner radius of housing210. As best shown inFIGS. 3 and 6, a raised lug213is disposed on surface211band extends radially inward relative to surface211b. Lug213extends circumferentially along a portion of surface211b(e.g., about 30° measured about axis105) and has a radially inner cylindrical surface214. As will be described in more detail below, surfaces211c,214directly contact and slidingly engage body220.

Referring now toFIGS. 3 and 5, body220is rotatably disposed within housing210and has a first or upper end220a, a second or lower end220b, a radially outer surface221extending axially between ends220a,220b, and a radially inner surface222extending axially between ends220a,220b. Lower end220bis fixably coupled to upper end110aof rotor110such that body220rotates with rotor110relative to housing210and stator120.

Inner surface222defines a central passage223extending axially between ends220a,220b. In addition, body220includes a port224axially positioned between ends220a,220band extending radially from outer surface221to inner surface222. In this embodiment, lower end220bis a box end that threadably receives a mating pin end at upper end110aof rotor110.

Referring still toFIGS. 3 and 5, in this embodiment, inner surface222includes a receptacle222aat upper end220a, a reduced inner radius section222baxially adjacent receptacle222a, and a cylindrical surface222cextending axially between section222band end220b. Reduced inner radius section222bdefine a flow restriction along passage223.

As best shown inFIG. 3, in this embodiment, a plug seat225is coupled to upper end220aand a nozzle226is removably threaded into receptacle222a. Seat225defines a receptacle immediately above end220aand nozzle226sized and positioned to receive a plug230. In this embodiment, seat225is an annular sleeve threadably mounted to upper end220aand plug230is a ball sized to be slidingly received by seat225when dropped from the surface down drillstring22to valve200. When plug230is disposed in seat225as shown inFIG. 3, it blocks the flow of drilling fluid through nozzle226and passage223of body220, thereby forcing the drilling fluid to bypass passage223and flow between body220and housing210. However, when plug230is not disposed in seat225, drilling fluid can flow through seat225, nozzle226, and passage223. As used herein, the term “block(s)” means to obstruct fluid flow, and hence restrict the fluid flow in a particular direction or along a particular path. In general, a structure or device that “blocks” fluid flow may partially restrict the fluid flow or completely restrict (i.e., prevent) the fluid flow in a particular direction or along a particular path.

In general, the size of the orifice in nozzle226influences the amount of drilling fluid that flows through bore223relative to the amount of drilling fluid that bypasses or flows around passage223between body220and housing210when plug230is not disposed in seat225. In particular, a smaller orifice in nozzle226allows less drilling fluid into passage223(resulting in more drilling fluid bypassing passage223) and a larger orifice in nozzle allows more drilling fluid into passage223(result in less drilling fluid bypassing passage223). Thus, different nozzles226having different sized orifices can be used to alter the relative quantity of drilling fluid flowing through bore223versus bypassing bore223, which in turn affects the amplitude of each pressure pulse generated by valve200.

Referring again toFIG. 3, body220is disposed in housing210with port224axially aligned with lug213and cylindrical surface221aof body220radially opposed cylindrical surfaces211b,211cof housing210. Cylindrical surface211bof housing210is radially spaced from cylindrical surface221aof body220, thereby resulting in an annular space or annulus227radially disposed between surfaces221a,211b. Surface221ais disposed at substantially the same radius as surfaces211c,214of housing210, and thus, surface221adirectly contacts and slidingly engages surfaces211c,214. Port224has a circumferential width that is less than the circumferential width of lug213and corresponding surface214, and further, port224has an axial height that is less than the axial height of lug213and corresponding surface214. Thus, when port224is circumferentially aligned with lug213, port224is closed (or substantially closed) by lug213and fluid communication between annulus227and passage223via port224is substantially restricted and/or prevented. However, when port224is not circumferentially aligned with lug213, port224is open and allowed fluid communication between annulus227and passage223. Although valve200is shown and described as including one port224and one lug213, in general, the valve (e.g., valve200) can have one or more ports (e.g., ports224) and one or more lugs (e.g., lug213).

Referring still toFIG. 3, during drilling operations, drilling fluid is pumped down drillstring22to power section100. At least initially, plug230is not disposed in seat225, and thus, a portion of the drilling fluid flows through nozzle226and a portion of the drilling fluid flows into annulus227. The drilling fluid that passes through nozzle226enters passage223of body220. The drilling fluid that passes through annulus227also enters passage223, but it does so via port224. The drilling fluid flowing into and through bore223(via nozzle226and port224) flows downstream into rotor110of first stage101and drives the rotation of rotors110of stages101,102as previously described. Body220is fixably coupled to rotors110, and thus, body220rotates with rotors110relative to housing210. Rotation of body220results in the cyclically opening and closing of port224with lug213—as port224rotates into circumferential alignment with lug213, port224is temporarily closed, and when port224rotates out of circumferential alignment with lug213, port224is opened. The cyclical opening and closing of port224generates pressure pulses in the drilling fluid upstream of valve200—when port224is closed, the pressure of drilling fluid immediately upstream of valve200increases, and when port224is open, the pressure of the drilling fluid immediately upstream of valve decreases. In this manner, the rotation of rotors110drive the rotation of body220relative to housing210, which in turn generates cyclical pressure pulses in the drilling fluid that drive the axial reciprocation of shock tool92.

The drilling fluid passing through port224flows radially inward from annulus227through port224into passage223. Accordingly, valve200, as well as other embodiments of valves disclosed herein that cyclically vary the radial flow of drilling fluid (e.g., flow generally perpendicular to the central axis of the valve and the power section) to generate pressure pulses for operating a shock tool (e.g., shock tool92) may also be referred to herein as “radial” valves. In contrast, embodiments of valves disclosed herein that cyclically vary the axial flow of drilling fluid to generate pressure pulses for operating a shock tool (e.g., shock tool92) may also be referred to herein as “axial” valves.

As previously described, bypass valve180can be used to controllably adjust the rotational speed of rotors110of stages101,102—the more drilling fluid that bypasses working fluid space130of second stage102, the lower the rotational speed of rotors110, and the less drilling fluid that bypasses working fluid space130of second stage102, the greater the rotational speed of rotors110. Body220is fixably coupled to rotors110, and thus, rotates at the same rotational speed as rotors110. The greater the rotational speed of body220, the greater the frequency of the pressure pulses generated by valve200, and the lower the rotational speed of body220, the lower the frequency of the pressure pulses generated by valve200. In this manner, bypass valve180can be used to selectively decrease or increase the frequency of pressure pulses generated by valve200.

As previously described, the size of the orifice in nozzle226determines the relative amounts of drilling fluid that pass through nozzle226and annulus227. Without being limited by this or any particular theory, the greater the relative amount of drilling fluid that passes into annulus227(and less relative amount of drilling fluid that passes through nozzle226), the greater the amplitude or height of each pressure pulse generated by valve200. Thus, by using nozzles226having different sized orifices, the amplitude and pulse height of the pressure pulses generated by valve200can be adjusted.

Plug seat225and corresponding plug230enable the selective ability to increase the amplitude and pulse height of the pressure pulses generated by valve200downhole without retrieving valve200to the surface to change nozzle226. In particular, when plug230is seated in plug seat225, nozzle226is blocked and drilling fluid is restricted and/or prevented from flowing therethrough, thereby increasing the relative quantity of drilling fluid directed into annulus227and port224(when nozzle226is blocked, essentially all of the drilling fluid is directed into annulus227and port224). In other words, when plug230is seated in plug seat225, none of the drilling fluid can bypass port224via nozzle226.

Although this embodiment of valve200includes plug seat225sized and positioned to receive plug230, in other embodiments, no plug seat (e.g., plug seat225) is provided. For example,FIG. 7illustrates an oscillating valve200′ that is substantially the same as valve200previously described with the exception that valve200′ does not include a plug seat (e.g., plug seat225) for receiving a plug from the surface. Thus, in this embodiment of valve200′, the ability to selectively increase the amplitude and pulse height of the pressure pulses generated by the valve by dropping a plug (e.g. plug230) from the surface may not be possible.

As previously described, valve200includes nozzle226, which can be changed to adjust the size of the orifice and relative amounts of drilling fluid that flow through nozzle226and annulus227. In that embodiment of valve200, nozzle226is threaded into mating receptacle222aat upper end220aof body220, and thus, is generally fixed in position once valve200is disposed downhole. Although nozzle226enables the ability to adjust the amplitude and height of the pressure pulses generated by valve200, the presence of nozzle226may limit the ability to fish through valve200(e.g., nozzle226limits axial access to passage223). Accordingly, in other embodiments, no nozzle (e.g., nozzle226) is provided to enable fish through capability. For example, referring now toFIG. 8, an embodiment of an oscillating valve300without a nozzle is shown.

As shown inFIG. 8, valve300is coupled to a power section100′ that is substantially the same as power section100previously described with the exception that flow restrictor113is replaced with a plug seat113′ disposed within bore111axially between ports116,117. In this embodiment, plug seat113′ has a central throughbore118and an annular uphole facing shoulder or seat119disposed along throughbore118. Seat119is sized to sealingly engage a plug230′, which is a ball in this embodiment. Throughbore118is coaxially aligned with central axis105of power section100′ and is substantially “full bore,” meaning the diameter of throughbore118is greater than the diameter of throughbore111of rotor110within which plug seat113′ is disposed, substantially the same as the diameter of throughbore111of rotor110within which plug seat113′ is disposed, or only slightly less than (e.g., within 10%) the diameter of throughbore111of rotor110within which plug seat113′ is disposed. The relatively large diameter of throughbore118and coaxial alignment of throughbore118with power section100′ enables fish through capability when plug230′ is not seated therein.

Plug seat113′ also allows for the selective actuation of stage101of power section100′. In particular, when plug230′ is not seated in plug seat113′, drilling fluid is free to flow through plug seat113′ with little to no restriction due to throughbore118having a full bore diameter. As a result, the drilling fluid flowing through bore111and plug seat113′ bypasses working fluid space130of stage101—all or substantially all of the drilling fluid flows through throughbore111and little to none of the drilling fluid flows through working fluid space130of stage101. Consequently, the drilling fluid does not drive the rotation of rotor110of stage101. However, when plug230′ is dropped from the surface and lands in plug seat113′, throughbore118is closed and drilling fluid is prevented from flowing therethrough. Consequently, all of the drilling fluid flowing down upstream region111aof throughbore111is forced into working fluid space130, thereby driving the rotation of rotor110of stage101. Although only one stage101is shown inFIG. 8, it should be appreciated that power section100′ may include additional stages (e.g., second stage102) that are the same as stage101shown inFIG. 8.

Referring still toFIG. 8, valve300is substantially the same as valve200previously described. In particular, valve300is operated by the rotation of rotor110to selectively generate pressure pulses in the drilling fluid upstream power section100′, which drive the axial reciprocation of shock tool92(FIG. 1). In this embodiment, valve300includes a first valve member or outer housing210and a second valve member or body220′ rotatably disposed within housing210. Body220′ is concentrically disposed within housing210, and further, body220′ and housing210are coaxially aligned with rotor110and stator120of power section100′. In other words, body220′ and housing210have central axes that are coaxially aligned with axis105.

Housing210is as previously described with respect to valve200. Body220′ is substantially the same as body220previously described with the exception that no nozzle (e.g., nozzle226) is provided in body220′ and the central passage223′ of body220′ has a full bore diameter (e.g., within 10% of the diameter of throughbore111of rotor110) between its upper and lower ends220a,220b. An annular uphole facing shoulder or seat226′ is disposed along passage223′ and sized to sealingly engage a plug230, which is a ball in this embodiment. Passage223′ is coaxially aligned with central axis105of power section100′. The relatively large diameter of passage223′ and coaxial alignment of passage223′ with power section100′ enables fish through capability.

Plug seat226′ also allows for the selective actuation, or at least selective increase in the amplitude and height of the pressure pulses generated by valve300. In particular, when plug230is not seated in plug seat226′, drilling fluid is free to flow through passage223′ with little to no restriction due to passage223′ having a full bore diameter. As a result, most or substantially all of the drilling fluid flowing down drillstring22bypasses annulus227and port224—all or substantially all of the drilling fluid flows through passage223′ and little to none of the drilling fluid flows through annulus227and port224. Consequently, amplitude and height of the pressure pulses generated by valve300, if any, is relatively small, and hence, induces little to no axial reciprocation of shock tool92. However, when plug230is dropped from the surface and lands in plug seat226′, passage223′ is closed at upper end220aand drilling fluid is prevented from flowing into passage223′ at upper end220a. Consequently, all of the drilling fluid flowing down drillstring22is forced into annulus227and port224, thereby “turning on” or at least increasing the amplitude and height of the pressure pulses generated by valve300.

In the embodiment of valve300and power section100′ shown inFIG. 8and described above, stage101of power section100′ can be fished through prior to both (1) actuation of stage101via seating of plug230′ in plug seat113′, and (2) actuation of valve300via seating of plug230in plug seat226′; and valve300can be fished through prior to actuation of valve300via seating of plug230in plug seat226′. However, since each plug230,230′ is a ball that is generally not retrievable, once plug230′ and/or plug230are seated in the corresponding seats113′,226′ respectively, the ability to fish through stage101is limited and/or prevented; and once plug230is seated in seat226′, the ability to fish through valve300is limited and/or prevented. However, in other embodiments, the plugs used to actuate stage101and valve300are specifically designed to be retrievable, thereby allowing fish through capability before actuation of stage101and valve300, as well as fish through capability after actuation of stage101and valve300via retrieval of the associated plugs. For example,FIG. 9illustrates valve300and power section100′, each as previously described, in connection with embodiments of retrievable plugs.

Referring now toFIG. 9, plug230′ is replaced with a plug230″, and plug230is replaced with a plug330. Unlike plugs230,230′ previously described, which were both free floating and independent balls, in this embodiment, plug330is a dart and plug230″ is a ball coupled to plug330. In particular, plug330is an elongate dart having a central or longitudinal axis335, a first or upper end330a, a second or lower end330b, an elongate counterbore or recess331extending axially from upper end330a, and a throughbore332extending axially from recess331to lower end330b. Upper end330aincludes a fishing-neck334configured to be engaged and grasped by a retrieval tool lowered down drillstring22from the surface. In this embodiment, fishing-neck334includes an annular downward facing shoulder proximal upper end330a. The radially outer surface of plug330includes an annular downward facing shoulder336sized and positioned to seat against mating seat226′ of valve300with fishing-neck334axially positioned above valve300and lower end330bdisposed within passage223′ of body220′.

In this embodiment, plug230″ is a ball, but is hung or suspended from plug330with an elongate connection member337. In particular, connection member337has a first or upper end337adisposed in recess331and a second or lower end337bfixably secured to plug230″. Upper end337acan move axially within recess331, but has an outer diameter greater than the diameter of throughbore332, which prevents upper end337afrom passing through bore332. In this embodiment, connection member337is a rigid rod, however, in other embodiments; the connection member (e.g., connection member337) can be a flexible cable.

Referring still toFIG. 9, plug seat113′ allows for the selective actuation of stage101of power section100′ in the same manner as previously described. Namely, when plug230″ is not seated in plug seat113′, drilling fluid is free to flow through plug seat113′ with little to no restriction due to throughbore118having a full bore diameter. As a result, the drilling fluid flowing through bore111and plug seat113′ bypasses working fluid space130of stage101and does not drive the rotation of rotor110of stage101. However, when plug230″ is seated in plug seat113′, throughbore118is closed and drilling fluid is prevented from flowing therethrough. As a result, all of the drilling fluid flowing down upstream region111aof throughbore111is forced into working fluid space130, thereby driving the rotation of rotor110of stage101.

Plug seat226′ allows for the selective actuation, or at least selective increase in the amplitude and height of the pressure pulses generated by valve300in the same manner as previously described. Namely, when plug330is not seated in plug seat226′, drilling fluid is free to flow through passage223′ with little to no restriction due to passage223′ having a full bore diameter. As a result, most or substantially all of the drilling fluid flowing down drillstring22bypasses annulus227and port224. Consequently, amplitude and height of the pressure pulses generated by valve300, if any, is relatively small, and hence, induces little to no axial reciprocation of shock tool92. However, when plug330is seated in plug seat226′, passage223′ is closed at upper end220aand all of the drilling fluid flowing down drillstring22is forced into annulus227and port224, thereby “turning on” or at least increasing the amplitude and height of the pressure pulses generated by valve300.

In the embodiment shown inFIG. 9, plugs230″,330are coupled via connection member337, and thus, are dropped from the surface down drillstring22together, with plug230″ hung from plug330as previously described. Connection member337has a length selected such that both plugs230″,330are seated in corresponding seats113′,226′ at the same time.

As previously described, plugs230″,330can be retrieved from the surface to allow fish through capability for both valve300and stage101after actuation of valve300and stage101. To retrieve plugs230″,330, a fishing tool is lowered from the surface through drillstring22to plug330, the fishing tool engages mating fishing-neck334at upper end330a, and then the fishing tool is pulled back to the surface. Due to the positive engagement of the fishing tool and fishing-neck334, plug330is pulled from seat226′ and retrieved to the surface with the fishing tool; and since upper end337aof connection member337cannot be pulled through bore332, plug230″ is pulled from seat113′ and retrieved to the surface with the fishing tool and plug330. In general, the fishing tool used to retrieve plugs230″,330can be any fishing tool known in the art. Once plugs230″,330are retrieved to the surface, valve300and stage101can be fished through. Following the fish through operation, plugs230″,330can be dropped down drillstring22form the surface and reseated in corresponding seats113′,226′.

Valves200,200′,300previously described are top mount valves because each is coupled to the upper end of a corresponding power section and/or positioned upstream of the corresponding power section. Although top mount oscillating valves may offer the potential for some advantages, embodiments of oscillating valves for use in connection with concentric drive systems to generate pressure pulses can also be “bottom mount.” As used herein, the term “bottom mount” may be used to describe an oscillating valve that is coupled to the lower end of a power section and/or positioned downstream of the power section.

Referring now toFIG. 10, an embodiment of a bottom mount oscillating or rotary valve400is shown in connection with a power section500, which can be used in place of power section100previously described. In this embodiment, power section500is substantially the same as power section100′ previously described with the exception that power section500includes only a single stage and valve400is axially positioned between power section500and bearing assembly150. In particular, power section500is a concentric rotary drive system having a first or upper end500a, a second or lower end500b, and a central or longitudinal axis505. Lower end500bis coupled to valve400. When power section500is disposed along drillstring22, upper end500ais coupled to shock tool92. As noted above, power section500includes one stage that is similar to stage101previously described. Although power section500includes one stage in this embodiment, in other embodiments, the power section (e.g., power section500) may include more than one stage.

Referring still toFIG. 10, power section500includes a tubular central shaft or rotor110rotatably disposed within a tubular housing or stator120. Rotor110and stator120are each as previously described (e.g., rotor110is coaxially aligned with and concentrically disposed within stator120). A plug seat113′ as previously described is disposed within bore111of rotor110axially between ports116,117. Plug seat113′ is sized to sealingly engage a plug230′, which is a ball in this embodiment. Plug seat113′ also allows for the selective actuation power section500in the same manner as previously described. In particular, when plug230′ is not seated in plug seat113′, drilling fluid is free to flow through plug seat113′ with little to no restriction, thereby bypassing working fluid space130; and when plug230′ is seated in plug seat113′, throughbore118is closed and drilling fluid is prevented from flowing therethrough, thereby forcing all of the drilling fluid flowing down upstream region111aof throughbore111into working fluid space130and driving the rotation of rotor110.

Referring now toFIGS. 11-13, oscillating valve400is operated by the rotation of rotor110of power section500to selectively generate pressure pulses in the drilling fluid upstream of valve400. The pressure pulses generated by valve400are transferred upstream through the drilling fluid in power section500to shock tool92, and drive the axial reciprocation of shock tool92(FIG. 1). In this embodiment, valve400includes a first valve member or outer housing410and a second valve member or body420rotatably disposed within housing410. Body420is concentrically disposed within housing410, and further, body420and housing410are coaxially aligned with rotor110and stator120of power section500. In other words, body420and housing410have central axes that are coaxially aligned with axes105,505.

Referring now toFIGS. 11 and 13, housing410has a first or upper end410adirectly coupled to lower end120bof stator120, a second or lower end410bcoupled to upper end170aof housing170of bearing assembly150, and a radially inner surface411extending axially from upper end410ato lower end410b. Inner surface411defines a central throughbore412extending axially between ends410a,410b. Body420extends through central throughbore412. In this embodiment, upper end410ais a pin end threadably received by a mating box end at lower end120bof stator120while lower end410bis a box end that threadably receives a mating pin end at upper end170aof housing170. Thus, housing410is static or fixed relative to stator120and drillstring22.

In this embodiment, inner surface411is a cylindrical surface disposed at a uniform and constant radius moving axially along inner surface411between the pin and box ends disposed at upper and lower ends410a,410b, respectively. A raised lug413is disposed on surface411between ends410a,410b, and extends radially inward relative to surface411. Lug413extends circumferentially along a portion of surface411b(e.g., about 30° measured about axis105) and has a radially inner cylindrical surface414. As will be described in more detail below, surface414directly contacts and slidingly engages body420.

Referring now toFIGS. 11 and 12, body420is rotatably disposed within housing410and has a first or upper end420a, a second or lower end420b, a radially outer surface421extending axially between ends420a,420b, a first cylindrical flow passage422extending axially from upper end420a, and a second cylindrical flow passage423extending axially from lower end420b. Flow passage422is in fluid communication with downstream region111bof throughbore111of rotor110and flow passage423is in fluid communication with throughbore161of mandrel160. However, in this embodiment, flow passages422,423are not connected and are not in direct fluid communication—the lower end of flow passage422is axially positioned above the upper end of flow passage423. Both flow passages422,423are coaxially aligned with rotor110and stator120. Upper end420ais fixably coupled to lower end110bof rotor110and lower end420bis fixably coupled to upper end160aof mandrel160such that body420rotates with rotor110and mandrel160relative to housing410and stator120. In this embodiment, upper end420acomprises a pin end that is threadably disposed in a mating box end disposed at lower end110bof rotor110and lower end420bcomprises a box end that receives a mating pin end disposed at upper end160aof mandrel160.

A plurality of circumferentially-spaced outlet ports424extend radially from the lower end of flow passage422to outer surface421and an inlet port425extends radially from outer surface421to the upper end of flow passage423. Port425is axially positioned below ports424.

Outer surface421of body420includes a plurality of axially adjacent cylindrical surfaces positioned between ends420a,420b. In particular, outer surface421include a first cylindrical surface421aproximal upper end420aand a second cylindrical surface421baxially positioned between surface421aand lower end420b. Ports424extend to surface421aand port425extends to surface421b.

Referring again toFIG. 11, body420is disposed in housing410with ports424axially positioned above lug413and port425axially aligned with lug413. Outer surface421of body420is radially spaced from inner surface411of housing410, thereby resulting in an annular space or annulus427radially disposed between surfaces411,421. As shown inFIG. 10, the upper and lower ends of annulus427are closed off and sealed (or substantially restricted) within lower end120bof stator120and axially upper end170aof housing170, respectively.

Inner surface414of lug413is disposed at substantially the same radius as cylindrical surface421bof valve member421, and thus, surface421bdirectly contacts and slidingly engages surface414. Port425has a circumferential width that is less than the circumferential width of lug413and corresponding surface414, and further, port425has an axial height that is less than the axial height of lug413and corresponding surface414. Thus, when port425is circumferentially aligned with lug413, port425is closed (or substantially closed) by lug413and fluid communication between annulus427and throughbore423via port425is substantially restricted and/or prevented. However, when port425is not circumferentially aligned with lug413, port425is open and allowed fluid communication between annulus427and passage423. Although valve400is shown and described as including one port425and one lug413, in general, the valve (e.g., valve400) can have one or more ports (e.g., ports425) and one or more lugs (e.g., lug413).

Referring still toFIG. 11, during drilling operations, pressured drilling fluid is pumped down drillstring22to power section500. With plug230′ disposed in plug seat113′, drilling fluid flows through upstream region111aof throughbore111and inlet ports130into working fluid space130, and then from working fluid space130through outlet ports117into downstream region of throughbore111, thereby driving the rotation of rotor110relative to stator120. Body420is coupled to rotor110, and thus, rotates with rotor110relative to stator120and housing410coupled thereto. The drilling fluid in downstream region111bflows into passage422and out ports424into annulus427, and then flows from annulus427through port425into passage423. The drilling fluid in passage423then flows into throughbore161of mandrel160.

Rotation of body420results in the cyclically opening and closing of port425with lug413—as port425rotates into circumferential alignment with lug413, port425is temporarily closed, and when port425rotates out of circumferential alignment with lug413, port425is opened. The cyclical opening and closing of port425generates pressure pulses in the drilling fluid upstream of valve400. The pressure pulses travel through the drilling fluid in power section500to shock tool92. In this manner, the rotation of rotors110drive the rotation of body420relative to housing410, which in turn generates cyclical pressure pulses in the drilling fluid that drive the axial reciprocation of shock tool92.

The drilling fluid passing through port425flows radially inward from annulus427through port425into passage423. Accordingly, valve400may also be described as a radial valve.

Referring now toFIG. 14, another embodiment of a bottom mount, oscillating or rotating radial valve400′ is shown coupled to power section500previously described. Valve400′ is substantially the same as valve400previously described with the exception that a throughbore extends axially between flow passages422,423and a plug can be used to selectively block flow between passages422,423. Thus, valve400′ includes a first valve member or outer housing410and a second valve member or body420′ rotatably disposed within housing410. Body420′ is concentrically disposed within housing410, and further, body420′ and housing410are coaxially aligned with rotor110and stator120of power section500. In other words, body420′ and housing410have central axes that are coaxially aligned with axis105. Housing410is as previously described. Body420′ is substantially the same as body420previously described with the exception that a throughbore426extends axially between flow passages422,423. A plug230can be used to selectively block flow between passages422,423via throughbore426. In particular, the lower end of flow passage422defines a seat428for plug230, which is a ball in this embodiment. Seat428is positioned axially below the inlets to ports424from flow passage422.

Throughbore426and plug230can be used to selectively increase the amplitude and height of the pressure pulses generated by valve400′. In particular, when plug230is not seated in flow passage422against seat428, drilling fluid flowing through passage422is free through bore426directly into passage423or through ports424into annulus427. Thus, the drilling fluid flowing through passage422is divided into a first portion that flows through ports424into annulus427and a second portion that flows from passage422directly into passage423via throughbore426. The drilling fluid in annulus427flows through port425, which is cyclically opened and closed with lug413by rotation of rotation of body420as previously described to generate pressure pulses. However, the drilling fluid flowing from passage422directly into passage423via throughbore426bypasses port425, and thus, does not contribute to the generation of pressure pulses. It should be appreciated that the diameter of throughbore426can be adjusted (e.g., with nozzles having different sized orifices) to adjust the relative quantity of drilling fluid drilling fluid flowing through annulus427and port425versus bypassing port425via throughbore426. However, when plug230is seated in flow passage422against seat428, throughbore426is blocked and drilling fluid is restricted and/or prevented from flowing therethrough, thereby increasing the relative quantity of drilling fluid directed into annulus427and port425(when throughbore426is blocked, essentially all of the drilling fluid is directed into annulus427and port425). In other words, when plug230is seated in against seat428, none of the drilling fluid can bypass port425via throughbore426.

In the embodiment of power section500previously described and shown inFIGS. 10 and 11, central throughbore118of plug seat113′ is substantially full bore, meaning the diameter of throughbore118is substantially the same or only slightly less than (e.g., within 10%) the diameter of throughbore111of rotor110within which plug seat113′ is disposed. Thus, when plug230′ is not seated in plug seat113′, substantially all of the drilling fluid flowing through rotor110flows directly from upstream region111ainto downstream region111bvia throughbore118. However, in other embodiments, the plug seat disposed in throughbore111of rotor110may comprise a flow restricting orifice that limits the quantity of drilling fluid that bypasses working fluid space130. For example, inFIG. 15, plug seat113′ having a full bore throughbore118is replaced with a plug seat113″ having a restricted throughbore118′. As a result, when plug230′ is not seated in plug seat113″, the restrictive throughbore118′ forces a portion of the drilling fluid flowing down upstream region111ainto working fluid chamber130, thereby driving the rotation of rotor110. When plug230′ is seated in plug seat113″, throughbore118′ is closed and drilling fluid is prevented from flowing therethrough, thereby forcing all of the drilling fluid flowing down upstream region111aof throughbore111into working fluid space130, thereby driving the rotation of rotor110. Thus, with or without plug230′ seated in seat113″, drilling fluid is supplied to working fluid space130to drive rotation of rotor110. However, the seating of plug230′ in seat113″ increases the relative quantity of drilling fluid flowing through working fluid space130, thereby increasing the rotational speed of rotor110. Without being limited by this or any particular theory, the increased rotational speed of rotor110generates increased power and increased frequency of pressure pulses generated. In this manner, plug230′ can be used to selectively increase the rotational speed of rotor110, increase the power output of power section500, and increase the frequency of pressure pulses generated by valve400′.

In the embodiment of valve400′ and power section500shown inFIG. 14and described above, power section500can be fished through prior to actuation via seating of plug230′ in plug seat113′. Although throughbore426is coaxially aligned with throughbore111and passages422,423, it may be challenging to fish through valve400′ because throughbore426does not have a full bore diameter (e.g., the diameter of throughbore426is substantially less than the diameter of passages422,423extending axially therefrom). Moreover, since each plug230,230′ is a ball that is generally not retrievable, once plug230′ is seated in the corresponding seat113′, the ability to fish through power section500is limited and/or prevented; and once plug230is seated in seat428, the ability to fish through valve400′ is limited and/or prevented. However, in other embodiments, the plugs used to actuate power section500and the bottom mount valve coupled thereto (e.g., valve400′) are specifically designed to be retrievable, thereby allowing fish through capability prior to and after actuation of power section500and the bottom mount valve coupled thereto. For example,FIG. 16illustrates power section500as previously described and a bottom mount valve400″ in connection with retrievable plugs230″,330(and associated connection member337) as previously described.

In this embodiment, reduced diameter throughbore426is replaced with a full bore diameter passage. In particular, plug seat428is positioned along flow passage422below ports424, however, a throughbore426′ with a full diameter bore extends axially from seat428and flow passage422to flow passage423. In this embodiment, and as previously described, plug330is a dart and plug230″ is a ball hung or suspended from plug330with elongate connection member337.

Referring still toFIG. 16, plug seat113′ allows for the selective actuation of power section500in the same manner as previously described. Namely, when plug230″ is not seated in plug seat113′, drilling fluid is free to flow through plug seat113′ with little to no restriction due to throughbore118having a full bore diameter. As a result, the drilling fluid flowing through bore111and plug seat113′ bypasses working fluid space130of power section500and does not drive the rotation of rotor110. However, when plug230″ is seated in plug seat113′, throughbore118is closed and drilling fluid is prevented from flowing therethrough. As a result, all of the drilling fluid flowing down upstream region111aof throughbore111is forced into working fluid space130, thereby driving the rotation of rotor110of power section500.

Plug seat428allows for the selective actuation or at least selective increase in the amplitude and height of the pressure pulses generated by valve400″. In particular, when plug330is not seated in plug seat428, drilling fluid is free to flow through throughbore426′ with little to no restriction due to throughbore426′ having a full bore diameter. In other words, the drilling fluid can flow directly from passage422into passage423via throughbore426′. As a result, most or substantially all of the drilling fluid flowing down drillstring22bypasses annulus427and port425. Consequently, amplitude and height of the pressure pulses generated by valve400″, if any, is relatively small, and hence, induces little to no axial reciprocation of shock tool92. However, when plug330is seated in plug seat428, throughbore426′ is closed and direct fluid communication between passages422,423is prevented. As a result, all of the drilling fluid flowing down drillstring22is forced into annulus427and port425, thereby “turning on” or at least increasing the amplitude and height of the pressure pulses generated by valve400″.

In the embodiment shown inFIG. 16, plugs230″,330are coupled via connection member337, and thus, are dropped from the surface down drillstring22together, with plug230″ hung from plug330as previously described. Connection member337has a length selected such that both plugs230″,330are seated in corresponding seats113′,428at the same time. Plugs230″,330can be retrieved from the surface to allow fish through capability for both valve400″ and power section500after actuation of valve400″ and stage power section500. As previously described, to retrieve plugs230″,330, a fishing tool is lowered from the surface through drillstring22to plug330, the fishing tool engages mating fishing-neck334at upper end330a, and then the fishing tool is pulled back to the surface. Due to the positive engagement of the fishing tool and fishing-neck334, plug330is pulled from seat113′ and retrieved to the surface with the fishing tool; and since upper end337aof connection member337cannot be pulled through bore332, plug230″ is pulled from seat428and retrieved to the surface with the fishing tool and plug330. In general, the fishing tool used to retrieve plugs230″,330can be any fishing tool known in the art. Once plugs230″,330are retrieved to the surface, valve400″ and power section500can be fished through. Following the fish through operation, plugs230″,330can be dropped down drillstring22form the surface and reseated in corresponding seats113′,428.

Embodiments of valves200,200′,300,400,400′,400″ used in connection with concentric rotary drive systems described herein are radial valves that cyclically vary the radial flow of drilling fluid to generate pressure pulses for operating a shock tool (e.g., shock tool92). However, in other embodiments, axial valves can be used in connection with concentric rotary drive systems. As described above, axial valves cyclically vary the axial flow of drilling fluid (e.g., flow generally parallel to the central axis of the valve and the power section) to generate pressure pulses for operating a shock tool (e.g., shock tool92).

Referring now toFIG. 17, an embodiment of an oscillating or rotary axial valve600is shown coupled to a power section100″. Power section100″ is substantially the same as power section100previously described with the exception that rotor110of first stage101includes an annular plug seat126and a plurality of circumferentially-spaced ports127. Seat126is axially positioned proximal upper end110aand is sized and arranged to receive a plug230, which in this embodiment is a ball. Ports127extend radially through rotor110from the outer surface of rotor110to upstream region111aof central throughbore111. In addition, ports127are axially adjacent and below seat126.

In this embodiment, valve600is coupled to upper end100aof power section100″, and thus, valve600is a top mount valve. In general, valve600is operated by the rotation of rotor110to selectively generate pressure pulses in the drilling fluid upstream of power section100″. The pressure pulses generated by valve600drive the axial reciprocation of shock tool92(FIG. 1). In this embodiment, valve600includes a first or upper valve member610fixably coupled to stator120and a second or lower valve member620fixably coupled to upper end110aof rotor110. Although valve member610and stator120are fixably coupled in this embodiment, in other embodiments, the upper valve member (e.g., valve member610) and the stator (e.g., stator120) are coupled via a splined connection that allows relative axial movement but not relative rotational movement. As previously described, rotor110rotates relative to stator120, and thus, lower valve member620rotates with rotor110relative to upper valve member610. Accordingly, upper valve member610may also be referred to as a static or stationary valve member and lower valve member620may also be referred to as a rotating or oscillating valve member.

Upper valve member610has a central or longitudinal axis615, a first or upper end610a, a second or lower end610b, and a central throughbore611extending axially between ends610a,610b. In addition, upper valve member610includes an annular flange or valve plate612at lower end610band a tubular sleeve613extending axially from plate612to upper end610a. Throughbore611extends through both sleeve613and plate612. Upper end610aincludes external threads that threadably engaging mating internal threads in the bottom of a sub630fixably coupled to stator120. Sleeve613includes plurality of circumferentially-spaced ports614extending radially from the radially outer surface of sleeve613to throughbore611. As best shown inFIGS. 17-19, annular plate612includes a plurality of circumferentially-spaced flow ports616extending axially therethrough. In this embodiment, two flow ports616spaced 180° apart are provided, and further, each flow port616is an elongate throughbore having terminal ends616a,616bthat are angularly-spaced about 100° apart.

Referring again toFIG. 17, lower valve member620has a central or longitudinal axis625, a first or upper end620a, a second or lower end620b, and a central throughbore621extending axially between ends620a,620b. In this embodiment, axis625of lower valve member620is parallel to but radially offset from axis615of upper valve member610to further choke flow. However, in other embodiments, the central axes of the upper and lower valve members (e.g., axes615,625of valve members610,620) are coaxially aligned. In addition, lower valve member620includes an annular flange or valve plate622at upper end620aand a tubular sleeve623extending axially from plate622to lower end620a. Throughbore621extends through both sleeve623and plate622. Lower end620bincludes external threads that threadably engaging mating internal threads in upper end110aof rotor110. As best shown inFIGS. 17-19, annular plate622includes a plurality of circumferentially-spaced flow ports626extending axially therethrough. In this embodiment, two flow ports626spaced 180° apart are provided, and further, each flow port626is an elongate throughbore having terminal ends626a,626bthat are angularly-spaced about 100° apart.

As best shown inFIG. 17, ends610b,620aand corresponding plates612,622are axially biased into engagement with each other. In addition, annular plate612extends radially outward from sleeve613and slidingly engages inner surface122of stator120. In particular, the radially outer cylindrical surface of sleeve613is disposed at substantially the same radius as inner surface122. A first or upper annulus631is radially positioned between sleeve613and stator120axially above plate612, and a second or lower annulus632is radially positioned between stator120and sleeve623. Annulus632extends axially downward between upper end110aof rotor110and stator120. As best shown inFIGS. 18 and 19, ports616,626are disposed at substantially the same radii. Accordingly, as rotor110and lower valve member620coupled thereto rotate relative to stator120and upper valve member610coupled thereto, ports626rotate into and out of circumferential alignment with ports616.

Referring again toFIG. 17, during drilling operations, drilling fluid is pumped down drillstring22to power section100″. At least initially, plug230is not disposed in plug seat126, and thus, drilling fluid is free to flow axially through bores611,621and directly into throughbore111of rotor110. It should be appreciated that in this embodiment, throughbores611,621have substantially full bore diameters (e.g., each has a diameter within 10% of diameter of throughbore111), and thus, when plug230is not seated in plug seat126, there is little resistance to the axial flow of drilling fluid through bores611,621,111. Consequently, substantially all or all of the drilling fluid flows axially from throughbores611,621into and through bore111, and little to none of the drilling fluid passes annuli631,632. Thus, the drilling fluid effectively bypasses valve600. The drilling fluid flowing downstream into rotor110drives the rotation of rotors110of stages101,102as previously described. The drilling fluid bypassing valve600does not contribute to the generation of pressure pulses for driving the axial reciprocating of shock tool92.

Plug seat126and corresponding plug230enable the selective ability to actuate valve600to generate pressure pulses. In particular, when plug230is seated in plug seat126, throughbore111is blocked at upper end110aand drilling fluid is restricted and/or prevented from flowing axially from bores611,621into throughbore111of rotor110. As a result, the drilling fluid flowing through bore611flows radially outward through ports614of upper valve member610into upper annulus631, then flow axially from upper annulus631to lower annulus632via ports616,626, and then flows radially from lower annulus632into throughbore111via ports127. This increases the quantity of drilling fluid directed into annuli631,632and ports616,626(when throughbore111is blocked at upper end110aof rotor110, essentially all of the drilling fluid is directed into annuli631,632and ports616,626). In other words, when plug230is seated in plug seat126, none of the drilling fluid can bypass valve600. The drilling fluid entering throughbore111below plug230flows downstream through rotor110drives the rotation of rotors110of stages101,102as previously described.

As previously described, valve member620is fixably coupled to rotors110, and thus, valve member620rotates with rotors110relative to valve member610. Rotation of valve member620results in the cyclically opening and closing of ports616—when ports626rotate into alignment with ports616, ports616are opened and fluid can flow through aligned ports616,626, and when ports626rotate out of alignment with ports616, ports616are closed and fluid is restricted and/or prevented from flowing through ports616. Thus, when drilling fluid is flowing through annuli631,632and ports616,626(e.g., when plug230is seated in plug seat126), the cyclical opening and closing of ports616generates pressure pulses in the drilling fluid upstream of valve600—when ports616are closed, the pressure of drilling fluid immediately upstream of valve600increases, and when ports616are open, the pressure of the drilling fluid immediately upstream of valve600decreases. In this manner, the rotation of rotors110drive the rotation of valve member620relative to valve member610, which in turn generates cyclical pressure pulses in the drilling fluid that drive the axial reciprocation of shock tool92.

It should be appreciated that the full bore diameters of throughbores611,621and coaxial alignment of throughbores611,621with power section100″ enables fish through capability prior to actuation of valve600with plug230. Although plug230is a ball in this embodiment, in other embodiments, the plug used to actuate valve600is a dart (e.g., plug330) that can be retrieved to the surface following actuation of valve600to enable fish through capability.

Although axial valve600is configured as a top mount valve inFIG. 17, in other embodiments, axial valves (e.g., valve600) used in connection with concentric rotary drive systems are arranged as bottom mount valves.

In select embodiments of rotary valves described herein, the valve can be actuated or “turned on” to generate pressure pulses that induce axial reciprocation of a shock tool (e.g., shock tool92). In such embodiments, the valve is actuated with a plug to selectively induce axial reciprocation of the shock tool when desired (e.g., valve600is actuated by seating plug230in plug seat126). However, in other embodiments, the valve is actuated by mechanisms or means other than a plug. For example, referring now toFIGS. 20 and 21, an embodiment of a valve700that is actuated by axial movement is shown. Valve700is shown coupled to a power section100″. Power section100′″ is substantially the same as power section100previously described with the exception that rotor110of first stage101includes a plurality of circumferentially-spaced ports127proximal upper end110a. Ports127extend radially through rotor110from the outer surface of rotor110to upstream region111aof central throughbore111.

Referring still toFIGS. 20 and 21, valve700is substantially the same as valve600previously described with the exception that the throughbore of the lower valve member is closed at its upper end and valve700is actuated by relative axial movement of the upper and lower valve members. More specifically, valve700includes a first or upper valve member610as previously described and second or lower valve member720. Upper valve member610is fixably coupled to a connection member730that is axially movable relative to stator120. Thus, upper valve member610can be moved axially relative to stator120and lower valve member720. In general, connection member730and upper valve member610can be moved axially by any suitable means known in the art. Exemplary devices that can be used to selectively move connection member730and upper valve member610relative to lower valve member720and stator120are disclosed in U.S. Pat. Nos. 8,863,852 and 8,844,634, each of which is hereby incorporated herein by reference in its entirety.

Lower valve member720has a central or longitudinal axis725, a first or upper end720a, and a second or lower end720b. In addition, lower valve member720includes a cylindrical valve plate722at upper end720aand a tubular sleeve723extending axially from plate722to lower end720b. Lower end720bincludes external threads that threadably engaging mating internal threads in upper end110aof rotor110. Annular plate722includes a plurality of circumferentially-spaced flow ports626as previously described extending axially therethrough. In this embodiment, two flow ports626spaced 180° apart are provided, and further, each flow port626is an elongate throughbore having terminal ends that are angularly-spaced about 100° apart.

A first or upper annulus731is radially positioned between sleeve613and stator120axially above plate612, and a second or lower annulus732is radially positioned between stator120and sleeve723. Annulus732extends axially downward between upper end110aof rotor110and stator120.

Valve700is coupled to upper end100aof power section100′″, and thus, valve700is a top mount valve. In general, valve700is selectively actuated or “turned on” to generate pressure pulses in the drilling fluid upstream of power section100″ by moving plates612,722axially together as shown inFIG. 20, and is selectively de-actuated or “turned off” by moving plates612,722axially apart as shown inFIG. 21. More specifically, with plates612,722in axial engagement (FIG. 20), drilling fluid pumped down drillstring to power section100′″ flows through bore611but cannot flow axially into sleeve723of lower valve member720as plate722blocks flow into sleeve723. As a result, the drilling fluid flowing through bore611flows radially outward through ports614of upper valve member610into upper annulus731, then flow axially from upper annulus731to lower annulus732via ports616,626, and then flows radially from lower annulus732into throughbore111via ports127. The drilling fluid entering throughbore111flows downstream through rotor110drives the rotation of rotors110of stages101,102as previously described. Valve member720is fixably coupled to rotors110, and thus, valve member720rotates with rotors110relative to valve member610. Rotation of valve member720results in the cyclically opening and closing of ports616as previously described. Thus, when plates612,722are in axial engagement, drilling fluid flowing through annuli731,732and ports616,626generates pressure pulses in the drilling fluid upstream of valve700, which in turn generates cyclical pressure pulses in the drilling fluid that drive the axial reciprocation of shock tool92.

With plates612,722axially spaced apart (FIG. 21), the drilling fluid can flow through bore611or through ports614,616into the axial gap or space740between plates612,722, and then across gap740and through ports722,127into throughbore111of rotor110. Due to the presence of gap740, ports616are effectively always opened as lower member720rotates. Thus, the drilling fluid effectively bypasses valve700when plates612,722are axially spaced apart. The drilling fluid flowing downstream into rotor110drives the rotation of rotors110of stages101,102as previously described. The drilling fluid bypassing valve700does not contribute to the generation of pressure pulses for driving the axial reciprocating of shock tool92.

Referring now toFIGS. 22 and 23, another embodiment of a top mount radial valve800that is selectively actuated by axial movement is shown. Valve800is coupled to the upper end of a power section100′ (not shown) as previously described. In this embodiment, valve800is substantially the same as valve300previously described. In particular, valve800includes a first valve member or outer housing210coupled to the upper end120aof stator120(not shown) and a second valve member or body220″ coupled to upper end110aof rotor110(not shown). Thus, valve member220″ is rotatably disposed within housing210. Body220″ is concentrically disposed within housing210, and further, body220″ and housing210are coaxially aligned with rotor110and stator120of power section100′. In other words, body220″ and housing210have central axes that are coaxially aligned with axis105. Housing210is as previously described with respect to valve200. Body220″ is substantially the same as valve member220′ previously described with the exception that no plug seat (e.g., plug seat226) is provided along passage223′, and further, an uphole facing, planar annular sealing surface228is disposed at upper end220a.

An axial actuation device850for selectively actuating valve800is coupled to upper end210aof outer housing210. As will be described in more detail below, actuation device850allows for the selective actuation, or at least selective increase in the amplitude and height of the pressure pulses generated by valve800. In this embodiment, actuation device850includes an outer housing851, a mandrel860moveably disposed in housing851, and an indexing mechanism870positioned between mandrel860and housing851. Mandrel860and housing851are coaxially aligned with valve800and power section100′. Housing851has a lower end851bthreadably coupled to upper end210aof outer housing210and an upper end (not shown) coupled to shock tool92and drill string22. Mandrel860has a first or upper end860a, a second or lower end860b, and a central throughbore861extending axially therethrough. As will be described in more detail below, indexing mechanism870allows mandrel860to actuate or move axially relative to housing851in response to the flow rate and associated pressures of drilling fluid flowing through mandrel860.

Referring still toFIGS. 22 and 23, a ported piston880is fixably attached to mandrel860, and thus, moves axially with mandrel860. Ported piston880has a first or upper end880athreadably coupled to lower end860bof mandrel860, a second or lower end880bdistal mandrel860, a central throughbore881extending axially from upper end880ato lower end880b, and a plurality of circumferentially-spaced ports882extending radially from throughbore881to an outer surface of piston880. An annular plug seat883is disposed along throughbore881axially below ports882. In addition, piston880has an upper portion884awith an enlarged outer diameter and a lower portion884bwith a reduced outer diameter. Upper portion884aslidingly and engages housing851. Lower portion884bof piston880extends from lower end880bto upper portion884aand is radially spaced from housing210. As a result, an annulus885is radially positioned between lower portion884band housing851, and extends axially from lower end880bto upper portion884. Ports882extend from throughbore881to annulus885. In this embodiment, lower end880bcomprises a downhole facing, planar annular sealing surface886.

Device850is actuated to move mandrel860and piston880axially up and down relative to housing851and body220″ to bring sealing faces886,228into and out of engagement. In this embodiment, indexing mechanism870allows mandrel860to move axially in response to the flow rate and associated pressures of drilling fluid flowing therethrough. More specifically, plug seat883is sized and positioned to receive a plug230. When plug230is not disposed in seat883, drilling fluid can flow axially through throughbores861,881with little resistance and mandrel860is maintained in a position with surfaces228,886axially spaced apart. However, when plug230is dropped from the surface and seats in seat883, it blocks free flow through throughbore881, chokes the flow rate through mandrel860, and generates a pressure differential across mandrel860that moves mandrel860axially downward, thereby bringing surfaces228,886into engagement. Indexing mechanism870can be reset to lift mandrel860upward and bring surfaces228,886out of engagement by temporarily reducing the flow rate of drilling fluid down the drill string22and through device850, thereby decreasing the pressure differential across mandrel860. Examples of indexing mechanisms that can be used in device850to facilitate the axial movement of mandrel860in response to the flow rate and associated pressures of drilling fluid flowing through mandrel860are disclosed in U.S. Pat. Nos. 8,863,852 and 8,844,634, each of which is hereby incorporated herein by reference in its entirety.

As previously described, device850is actuated to bring sealing face886into and out of engagement with mating sealing face228disposed at upper end220a. This allows device850to controllably open and close the open upper end220aof valve member220″ to selectively distribute drilling fluid between passage223′ and annulus227. When plug230is not disposed in seat883, drilling fluid can flow through throughbores861,881, across any gap between ends220a,860b, and directly into passage223′ at upper end220a. Due to passage223′ having a full bore diameter, the drilling fluid is free to flow through passage223′ with little to no restriction, thereby bypassing annulus227and port224. Consequently, the amplitude and height of the pressure pulses generated by valve800, if any, is relatively small, and hence, induces little to no axial reciprocation of shock tool92. When plug230is disposed in seat883but surfaces228,886are axially spaced apart (e.g., prior to actuation of mandrel860or upon reset of indexing mechanism870), drilling fluid can flow through throughbore861and into throughbore881, then out ports882into annulus885, through annulus885and any gap between ends220a,860b, and into passage223′ at upper end220a. Due to passage223′ having a full bore diameter, the drilling fluid is free to flow through passage223′ with little to no restriction, thereby bypassing annulus227and port224. Consequently, the amplitude and height of the pressure pulses generated by valve800, if any, is relatively small, and hence, induces little to no axial reciprocation of shock tool92. However, when plug230is seated in seat883and mandrel860is actuated to bring surfaces228,886into engagement, the drilling fluid flows through throughbore861and into throughbore881, and then out ports882into annulus885. Engagement of surfaces228,886prevents or substantially restricts the drilling fluid in annulus885from passing into passage223′ at upper end220a. Consequently, all of the drilling fluid flowing down drillstring22is forced from annulus885into annulus227and port224, thereby “turning on” or at least increasing the amplitude and height of the pressure pulses generated by valve800. The pressure pulses generated by valve800actuate shock tool92.

Referring now toFIGS. 24 and 25, another embodiment of a top mount axial valve900that is selectively actuated by axial movement is shown. Valve900is coupled to the upper end of a power section100′ as previously described. An axial actuation device850for selectively actuating valve900is coupled to upper end120aof stator120. Device850is as previously described and shown inFIGS. 22 and 23. As will be described in more detail below, actuation device850allows for the selective actuation, or at least selective increase in the amplitude and height of the pressure pulses generated by valve900.

In this embodiment, valve900includes a first or upper valve member910fixably coupled to lower end860bof mandrel860and a second or lower valve member920fixably coupled to upper end110aof rotor110. Thus, lower valve member920is rotatable relative to upper valve member910. Valve members910,920are concentrically disposed within stator120, and further, valve members910,920are coaxially aligned with rotor110and stator120of power section100′. In other words, valve members910,920have central axes that are coaxially aligned with axis105. In addition, each valve member910,920includes a throughbore or port911,921, respectively, extending axially therethrough. Ports911,921are sized and positioned such that they come into and out of alignment as lower valve member920rotates relative to upper valve member910. For example, each port911,921can have an oval shape. Thus, when valve members910,920are spaced apart as shown inFIG. 24, drilling fluid can flow through the full, maximum cross-sectional flow area of both ports911,921. However, when valve members910,920are brought together with their opposed planar faces slidingly engaging, drilling fluid can only flow through the passage defined by the portions of ports911,921that are aligned and in direct fluid communication. The cross-sectional flow area of that passage will cyclically increase and decrease as lower valve member920rotates relative to upper valve member910, thereby generating pressure pulses in the drilling fluid flowing therethrough. Examples of valve members that can be used as valve members910,920are disclosed in US Patent Application Publication No. 20010054515, which is hereby incorporated herein by reference in its entirety.

Referring still toFIGS. 24 and 25, a ported piston980is fixably attached to mandrel860, and thus, moves axially with mandrel860. Ported piston980has a first or upper end980athreadably coupled to lower end860bof mandrel860, a second or lower end980bdistal mandrel860, a central throughbore981extending axially from upper end980ato lower end980b, a first plurality of circumferentially-spaced ports982extending radially from throughbore981to an outer surface of piston980, and a second set of circumferentially-spaced ports983extending radially from throughbore981to the outer surface of piston980. Ports983are axially positioned below ports982. An annular plug seat984is disposed along throughbore981axially between ports982,983. In addition, piston980has an upper portion985awith an enlarged outer diameter and a lower portion985bwith a reduced outer diameter. Upper portion985aslidingly and sealingly engages housing851. Lower portion985bof piston980extends from lower end980bto upper portion985aand is radially spaced from housing210. As a result, an annulus986is radially positioned between lower portion985band housing851, and extends axially from lower end980bto upper portion985a. Ports982,983extend from throughbore981to annulus986. Upper valve member910is threadably attached to lower end980b, and thus, moves axially with piston980and mandrel860.

Device850is actuated to move mandrel860and piston980axially up and down relative to housing851and power section100′ to bring the opposed planar faces of valve members910,910into and out of engagement. In a similar manner as previously described, indexing mechanism870allows mandrel860to move axially in response to the flow rate and associated pressures of drilling fluid flowing therethrough. More specifically, plug seat984is sized and positioned to receive a plug230. When plug230is not disposed in seat984, drilling fluid can flow axially through throughbores861,981and port911with little resistance and mandrel860is maintained in a position with valve members910,920axially spaced apart. However, when plug230is dropped from the surface and seats in seat984, it blocks free flow through throughbores881and port911, chokes the flow rate through mandrel860, and generates a pressure differential across mandrel860that moves mandrel860axially downward, thereby bringing the opposed planar faces of valve members910,920into engagement. Indexing mechanism870can be reset to lift mandrel860upward and bring valve members910,920out of engagement by temporarily reducing the flow rate of drilling fluid down the drill string22and through device850, thereby decreasing the pressure differential across mandrel860.

As previously described, device850is actuated to bring upper valve member910into and out of engagement with lower valve member920. This allows device850to controllably and selectively force the flow of drilling fluid through both ports911,921. When plug230is not disposed in seat984, drilling fluid can flow through throughbores861,981, and port911, across any gap between valve members910,920, through port921of valve member920, and directly into throughbore111of rotor110. Due to the spacing of valve members910,920, the drilling fluid is free to flow through the full, maximum cross-sectional area of each port911,921with little to no restriction, thereby effectively bypassing valve900. Consequently, the amplitude and height of the pressure pulses generated by valve900, if any, is relatively small, and hence, induces little to no axial reciprocation of shock tool92. When plug230is disposed in seat984but valve members910,920are axially spaced apart (e.g., prior to actuation of mandrel860or upon reset of indexing mechanism870), drilling fluid can flow through throughbore861and into throughbore981, then out ports982into annulus986, through annulus986and any gap between valve members910,920(or from annulus986back into throughbore981and out port911across the any gap between valve members910,920), and through port921into rotor110. Due to the spacing of valve members910,920, the drilling fluid is free to flow through the full, maximum cross-sectional area of each port911,921with little to no restriction, thereby effectively bypassing valve900. Consequently, the amplitude and height of the pressure pulses generated by valve900, if any, is relatively small, and hence, induces little to no axial reciprocation of shock tool92. However, when plug230is seated in seat984and mandrel860is actuated to bring valve members910,920into engagement, the drilling fluid flows through throughbore861and into throughbore981, and then out ports982into annulus885. Engagement of the opposed planar surfaces of valve members910,920prevents or substantially restricts the drilling fluid in annulus986from passing directly into port921. Consequently, all of the drilling fluid flowing down drillstring22is forced from annulus986back into throughbore981below plug230via ports983, and then through ports911,921. As previously described, when valve members910,920slidingly engage, the cross-sectional flow area of the passage through valve members910,920through which the drilling fluid can flow will cyclically increase and decrease as lower valve member920rotates relative to upper valve member910, thereby generating pressure pulses in the drilling fluid flowing therethrough. Thus, moving valve member910axially into engagement with valve member920“turns on” or at least increases the amplitude and height of the pressure pulses generated by valve900. The pressure pulses generated by valve900actuate shock tool92.

As previously described, top mount radial valve200shown inFIG. 3includes nozzle226, which enables the ability to adjust the amplitude and height of the pressure pulses generated by valve200. In addition, plug230can be deployed during drilling operations to block nozzle226and restrict and/or prevent drilling fluid from flowing therethrough, thereby enabling the selective ability to increase the amplitude and pulse height of the pressure pulses generated by valve200downhole without retrieving valve200to the surface to change nozzle226. Thus, during drilling operations, valve200allows for the one-time selective ability to increase the amplitude and pulse height of the pressure pulses it generates. However, in other embodiments, a plurality of plugs can be sequentially deployed to selectively and progressively increase the amplitude and pulse height of the pressure pulses. For example,FIGS. 26 and 27illustrate a power section100as previously described and a top mount, oscillating or rotating radial valve200″ that can selectively and progressively increase the amplitude and pulse height of the pressure pulses via the sequential and selective deployment of a plurality of plugs230as previously described.

Referring now toFIGS. 26 and 27, valve200″ is similar valve200previously described. In particular, valve200″ is operated by the rotation of rotor110to selectively generate pressure pulses in the drilling fluid upstream power section100, which drive the axial reciprocation of shock tool92(FIG. 1). In this embodiment, valve200″ includes a first valve member or outer housing210and a second valve member or body320rotatably disposed within housing210. Body320is concentrically disposed within housing210, and further, body320and housing210are coaxially aligned with rotor110and stator120of power section100. In other words, body320and housing210have central axes that are coaxially aligned with axis105.

Housing210is as previously described with respect to valve200. Thus, upper end210aof housing210is coupled to drillstring22and lower end210bof housing210is directly coupled to upper end120aof stator120. Body320extends through central throughbore212of housing210.

Body320is similar to body220previously described. More specifically, body320has a first or upper end320a, a second or lower end320b, a radially outer surface321extending axially between ends320a,320b, and a radially inner surface322extending axially between ends320a,320b. Lower end320bis fixably coupled to upper end110aof rotor110such that body320rotates with rotor110relative to housing210and stator120.

Inner surface322defines a central passage323extending axially between ends320a,320b. In addition, body320includes a port324axially positioned between ends320a,320band extending radially from outer surface321to inner surface322. In this embodiment, lower end320bis a box end that threadably receives a mating pin end at upper end110aof rotor110.

In this embodiment, inner surface322includes a first or stepped receptacle322aat upper end320a, a second receptacle322bextending axially from first receptacle322a, a reduced inner radius section322cextending axially from second receptacle322b, and a cylindrical surface322dextending axially from section322cto the box end disposed at lower end320b. A nozzle226as previously described is removably threaded into receptacle322b. Reduced inner radius section322cdefines a flow restriction along passage323immediately downstream of nozzle226. As will be described in more detail below, first receptacle322ais sized and positioned to receive a plurality of plugs230as previously described to selectively and progressively increase the amplitude and pulse height of the pressure pulses generated by valve200″.

Referring now toFIG. 26-28, in this embodiment, inner surface322includes a plurality of axially spaced annular uphole facing shoulders or seats along first receptacle322a. In particular, inner surface322includes first or lower annular uphole facing shoulder or seat326aaxially positioned proximal second receptacle322b(and nozzle226when disposed in receptacle322b) and a second or upper annular uphole facing shoulder or seat326baxially positioned between upper end320aand seat326a. Cylindrical surfaces extend between receptacle322band seat326a, between seats326a,326b, and between seat326band upper end320a. Each seat326a,326bis sized to sealingly engage one corresponding plug230. In this embodiment, each plug230is a spherical ball.

The inner diameter of passage323defined by seats326a,326bgenerally increases moving axially uphole from nozzle226to end320a—the minimum inner diameter defined by lower seat326ais less than the minimum diameter defined by intermediate seat326b. Accordingly, the diameter of plug230sized to sealingly engage lower seat326ais less than the diameter of plug230sized to sealingly engage upper seat326b. For purposes of clarity and further explanation, the plug230that engages lower seat326awill also be referred to herein as first or lower plug230and the plug230that engages upper seat326bwill also be referred to herein as second or upper plug230.

Referring still toFIGS. 26-28, one or more bypass slots327are disposed along inner surface322and extend axially from each seat326a,326b. In this embodiment, a plurality of uniformly circumferentially spaced bypass slots327extend axially from lower seat326aalong inner surface322in first receptacle322a, and one bypass slot327extends axially from upper seat326balong inner surface322in first receptacle322a. Thus, the number of bypass slots327associated with seats326a,326bdecreases moving axially uphole from lower seat326ato upper seat326b. As will be described in more detail below, bypass slots327allow the restricted flow of drilling through passage323and around the plug230seated against the corresponding seat326a,326b. For example, when lower plug230sealingly engages lower seat326a, drilling fluid can flow through passage323and around lower plug230via slots327in seat326a, and similarly, when upper plug230sealingly engages upper seat326b, drilling fluid can flow through passage323and around upper plug230via slot327in upper seat326b. Thus, in this embodiment, plugs230restrict the flow of drilling fluid through passage323and nozzle226, but do not completely prevent or stop the flow of drilling fluid through passage323.

Although each bypass slot327is a recess disposed along inner surface322and extending axially from a corresponding seat326a,326bin this embodiment, in other embodiments, bypass slots327may be replaced with bores or holes extending from the corresponding seat326a,326bto inner surface322below the corresponding seat326a,326b. In this embodiment, a plurality of bypass slots327extend from lower seat326aand one bypass slot327extends from upper seat326b. However, in other embodiments, the number of bypass slots (e.g., bypass slots327) in each seat (e.g., seat326a,326b) may vary with the understanding that the number of bypass slots associated with the seats preferably decreases moving axially uphole from one seat to the next. For example, in another embodiment, one or more bypass slots327extend axially from lower seat326aand no bypass slots327extend from upper seat326b. In that embodiment, when plug230is seated against upper seat326b, all of the drilling fluid bypasses nozzle226and flows into annulus328and through port324.

In general, the size of the orifice in nozzle226influences the amount of drilling fluid that flows through passage323relative to the amount of drilling fluid that bypasses or flows around passage323between body320and housing210when plugs230are not disposed in seats326a,326b. As previously described, a smaller orifice in nozzle226allows less drilling fluid into passage323(resulting in more drilling fluid bypassing passage323) and a larger orifice in nozzle allows more drilling fluid into passage323(result in less drilling fluid bypassing passage223). Thus, different nozzles226having different sized orifices can be used to alter the relative quantity of drilling fluid flowing through passage323versus bypassing passage323, which in turn affects the amplitude of each pressure pulse generated by valve200″.

Body320is disposed in housing210with port324axially aligned with lug213and cylindrical surface321aof body320radially opposed cylindrical surfaces211b,211cof housing210. Cylindrical surface211bof housing210is radially spaced from cylindrical surface321aof body320, thereby resulting in an annular space or annulus328radially disposed between surfaces321a,211b. Surface321ais disposed at substantially the same radius as surfaces211c,214of housing210, and thus, surface321adirectly contacts and slidingly engages surfaces211c,214. Port324has a circumferential width that is less than the circumferential width of lug213and corresponding surface214, and further, port324has an axial height that is less than the axial height of lug213and corresponding surface214. Thus, when port324is circumferentially aligned with lug213, port324is closed (or substantially closed) by lug213and fluid communication between annulus328and passage323via port324is substantially restricted and/or prevented. However, when port324is not circumferentially aligned with lug213, port324is open and allowed fluid communication between annulus328and passage323. Although valve200″ is shown and described as including one port324and one lug213, in general, the valve (e.g., valve200″) can have one or more ports (e.g., ports324) and one or more lugs (e.g., lug213).

Referring now toFIG. 29, an embodiment of a method340for selectively and progressively increasing the amplitude and height of the pressure pulses in drilling fluid during drilling operations with a top mount, oscillating or rotating radial valve is shown. For purposes of clarity and further explanation, method340will be described with respect to the operation of valve200″ described above and shown inFIGS. 26 and 27.

Beginning in block341, drilling fluid is pumped down drillstring22to power section100. Moving now to block342, a portion of the drilling fluid flows axially through passage323of body320, and a portion of the drilling fluid flows into annulus328and then radially through port324into passage323. More specifically, at least initially, no plugs230are disposed in seats326a,326b, and thus, a portion of the drilling fluid flows through nozzle226and a portion of the drilling fluid flows into annulus328. The drilling fluid that passes through nozzle226enters passage323of body320. The drilling fluid that passes through annulus328also enters passage323, but it does so via port324. Next, in block343, the drilling fluid flowing into and through passage323of body320(via nozzle226and port324) drives the rotation of body320relative to housing210. In particular, the drilling fluid exits passage323and flows downstream into rotor110of first stage101and drives the rotation of rotors110of stages101,102as previously described. Body320is fixably coupled to rotors110, and thus, body320rotates with rotors110relative to housing210.

Moving now to block344, rotation of body320relative to housing210generates pressure pulses in the drilling fluid upstream of the valve200″. More specifically, rotation of body320results in the cyclically opening and closing of port324with lug213—as port324rotates into circumferential alignment with lug213, port324is temporarily closed, and when port324rotates out of circumferential alignment with lug213, port324is opened. The cyclical opening and closing of port324generates pressure pulses in the drilling fluid upstream of valve200″—when port324is closed, the pressure of drilling fluid immediately upstream of valve200″ increases, and when port324is open, the pressure of the drilling fluid immediately upstream of valve200″ decreases. In this manner, the rotation of rotors110drive the rotation of body320relative to housing210, which in turn generates cyclical pressure pulses in the drilling fluid that drive the axial reciprocation of shock tool92. As previously described, the size of the orifice in nozzle226determines the relative amounts of drilling fluid that pass through nozzle226and annulus328. Without being limited by this or any particular theory, the greater the relative amount of drilling fluid that passes into annulus328(and less relative amount of drilling fluid that passes through nozzle226), the greater the amplitude or height of each pressure pulse generated by valve200″. Thus, by using nozzles226having different sized orifices, the amplitude and pulse height of the pressure pulses generated by valve200″ can be adjusted.

Plug seats326a,326band corresponding plugs230enable the selective ability to progressively increase the amplitude and pulse height of the pressure pulses generated by valve200″ downhole without retrieving valve200″ to the surface to change nozzle226. In particular, to increase in the amplitude and pulse height of the pressure pulses generated by valve200″ when desired, lower plug230is dropped from the surface and seats in lower seat326aaccording to block345. As a result, flow through nozzle226is partially restricted from flowing therethrough, thereby increasing the relative quantity of drilling fluid directed into annulus328and port324, which increases in the amplitude or height of each pressure pulse generated by valve200″. When yet a further increase in the amplitude and pulse height of the pressure pulses generated by valve200″ is desired, upper plug230is dropped from the surface and seats in upper seat326baccording to block346. As a result, flow through nozzle226is further restricted from flowing therethrough, thereby further increasing the relative quantity of drilling fluid directed into annulus328and port324, which further increases in the amplitude or height of each pressure pulse generated by valve200″. It should be appreciated that in this embodiment, neither lower plug230nor upper plug230completely prevents flow through nozzle226as ports327in seats326a,326ballow some drilling fluid to flow around the corresponding plugs230and through nozzle226. However, since upper seat326bincludes fewer bypass slots327than lower seat326a, the restriction of flow through nozzle226is further restricted by upper plug230as compared to lower plug230alone.

In the manner described, valve200″ allows for the selective and progressive increase in the amplitude and height of the pressure pulses generated by valve200″. In this embodiment, valve200″ can be used to progressively increase the amplitude and height of the pressure pulses twice by dropping lower plug230and seating it against lower seat326a, and then by dropping upper plug230and seating it against upper seat326b. However, in other embodiments, the valve (e.g., valve200″) may be designed for more than two progressive increases in the amplitude and height of the pressure pulses by increasing the number of seats (e.g., seats326a,326b) disposed along the inner surface of the body (e.g., inner surface322of320) upstream of the nozzle (e.g., nozzle226) with each seat having fewer bypass slots. In this embodiment, each slot327along inner surface322of body320of valve200″ has the same geometry and size, and the number of slots327extending from each seat326a,326bis varied to adjust the degree of bypass of the corresponding plug230, in other embodiments, the size of the slots (e.g., cross-sectional area of slots327) extending from each seat (e.g., seat326a,326b) can be varied to adjust the degree of bypass of the corresponding plug (e.g., plug230).

In some drilling operations, it may be desirable to limit the maximum amplitude and height of the pressure pulses generated by the oscillating or rotary valve used to drive the shock tool (e.g., shock tool92). For example, it may be desirable to limit the use of relatively high amplitude pressure pulses to select situations when a large portion of the drillstring is engaging the borehole wall as continuous use of high amplitude pressure pulses can increase the likelihood of premature fatigue and failure of components along the drillstring.FIG. 30illustrates a power section100as previously described and a top mount, oscillating or rotating radial valve1000that can selectively and progressively increase the amplitude and pulse height of the pressure pulses via the sequential and selective deployment of a plurality of plugs230, while simultaneously limiting the maximum amplitude and height of the pressure pulses. Valve1000is substantially the same as valve200″ previously described with the exception that valve1000does not include nozzle226and valve1000includes a pressure relief valve1010.

Referring now toFIG. 30, valve1000is similar valve200previously described. In particular, valve1000is operated by the rotation of rotor110to selectively generate pressure pulses in the drilling fluid upstream power section100, which drive the axial reciprocation of shock tool92(FIG. 1). In this embodiment, valve1000includes a first valve member or outer housing210and a second valve member or body320′ rotatably disposed within housing210. Body320′ is concentrically disposed within housing210, and further, body320′ and housing210are coaxially aligned with rotor110and stator120of power section100. In other words, body320′ and housing210have central axes that are coaxially aligned with axis105.

Housing210is as previously described with respect to valve200. Thus, upper end210aof housing210is coupled to drillstring22and lower end210bof housing210is directly coupled to upper end120aof stator120. Body320′ extends through central throughbore212of housing210.

Body320′ is substantially the same as body320previously described. More specifically, body320′ has a first or upper end320a, a second or lower end320b, a radially outer surface321extending axially between ends320a,320b, and a radially inner surface322extending axially between ends320a,320b. Lower end320bis fixably coupled to upper end110aof rotor110such that body320rotates with rotor110relative to housing210and stator120. Inner surface322defines a central passage323extending axially between ends320a,320b. In addition, body320includes a port324axially positioned between ends320a,320band extending radially from outer surface321to inner surface322. In this embodiment, lower end320bis a box end that threadably receives a mating pin end at upper end110aof rotor110.

In this embodiment, inner surface322includes a first or stepped receptacle322aas previously described at upper end320a, a reduced inner radius section322c, and a cylindrical surface322dextending axially from section322cto the box end disposed at lower end320b. However, in this embodiment, reduced inner radius section322cextends axially from receptacle322a. In other words, in this embodiment, inner surface322does not include receptacle322bor associated nozzle226between receptacle322aand reduced inner radius section322c. An annular downhole facing frustoconical shoulder326cextends radially between sections322cand surface322d.

Referring still toFIG. 30, outer surface321of body320′ includes a cylindrical surface321aextending from lower end320band a cylindrical surface321bextending from upper end320a. Port324extends radially from surface321ato surface322d. However, unlike body320previously described, in this embodiment body320′ also includes a relief port325extending radially from surface321bto section322c.

Body320′ is disposed in housing210with port324axially aligned with lug213and cylindrical surface321aof body320′ radially opposed cylindrical surfaces211b,211cof housing210. Cylindrical surface211bof housing210is radially spaced from cylindrical surface321aof body320′, thereby resulting in an annular space or annulus328radially disposed between surfaces321a,211b. Surface321ais disposed at substantially the same radius as surfaces211c,214of housing210, and thus, surface321adirectly contacts and slidingly engages surfaces211c,214. Port324has a circumferential width that is less than the circumferential width of lug213and corresponding surface214, and further, port324has an axial height that is less than the axial height of lug213and corresponding surface214. Thus, when port324is circumferentially aligned with lug213, port324is closed (or substantially closed) by lug213and fluid communication between annulus328and passage323via port324is substantially restricted and/or prevented. However, when port324is not circumferentially aligned with lug213, port324is open and allowed fluid communication between annulus328and passage323. Although valve1000is shown and described as including one port324and one lug213, in general, the valve (e.g., valve1000) can have one or more ports (e.g., ports324) and one or more lugs (e.g., lug213).

Referring still toFIG. 30, relief valve1010is disposed in passage323and axially positioned between receptacle322aand port324. In this embodiment, relief valve1010includes a valve body1011movably disposed in passage323and a biasing member1020radially positioned between body1011and surface322d. Valve body1011has a first or upper end1011a, a second or lower end1011b, a radially outer surface1012extending axially between ends1011a,1011b, and a radially inner surface1013extending axially between ends1011a,1011b. Inner surface1013defines a central passage1014extending axially between ends1011a,1011b.

Outer surface1012includes a reduced outer radius cylindrical surface1012aextending from upper end1011a, a cylindrical surface1012bextending axially from lower end1011b, and an increased outer radius cylindrical surface1012caxially positioned between surfaces1012a,1012b. An annular upward facing frustoconical shoulder1012dextends radially between surfaces1012a,1012cand an annular downward facing planar shoulder1012eextends radially between surfaces1012b,1012c. Cylindrical surface1012aslidingly engages inner surface323along section322cand cylindrical surface1012cslidingly engages inner surface322d. Surfaces1012b,322dare radially spaced, thereby defining an annulus between valve body1010and body320′ within which biasing member1020is disposed. More specifically, biasing member1020is axially compressed between shoulder1012eand a snap ring1021seated in a mating recess along cylindrical surface322d. A plurality of uniformly circumferentially spaced ports1015extend from shoulder1012dto passage1014.

Referring still toFIG. 30, valve body1011can move axially relative to body320′ and housing210between a first or closed position preventing the flow of drilling fluid through relief port325and a second or open position allowing the flow of drilling fluid through relief port325. In the closed position shown inFIG. 30, upper end1011aof valve body1011is fully seated within section322cand extends completely across relief port325, and shoulder1012dengages mating shoulder326c. As a result, drilling fluid is blocked and restricted and/or prevented from flowing from annulus328through port325and passage1014into passage323of body320′. In the open position, upper end1011aof valve body1011is at least partially withdrawn from section322cand does not extend completely across, and shoulder1012dis axially spaced from shoulder326c. As a result, drilling fluid is allowed to flow from annulus328through port325and passage1014(via open upper end1011aand/or ports1015) into passage323of body320′. It should be appreciated that port325is disposed axially below receptacle322aand any plugs230disposed therein, and further, drilling fluid that flows through port325from annulus328into passage323of body320′ does not flow through port324. Thus, drilling fluid that flows through port325into passage323of body320′ bypasses plugs230and port324.

In this embodiment, biasing member1020is a spring that axially biases valve body1011to the closed position. However, when the pressure differential across relief valve1010(e.g., the pressure differential between the drilling fluid in annulus328and the drilling fluid in passage323axially below relief valve1010) exceeds the biasing force of biasing member1020, valve body1011moves axially downward relative to body320′ from the closed position to the open position, thereby allowing drilling fluid radially positioned between body320′ and housing210to bypass port324.

Referring now toFIG. 31, an embodiment of a method440for selectively and progressively increasing the amplitude and height of the pressure pulses in drilling fluid during drilling operations with a top mount, oscillating or rotating radial valve while simultaneously limiting the maximum amplitude and height of the pressure pulses is shown. For purposes of clarity and further explanation, method440will be described with respect to the operation of valve1000described above and shown inFIG. 30.

Valve1000operates in substantially the same manner as valve200″ previously described with the exception that relief valve1010opens to allow drilling fluid to bypass plugs320and port324at a sufficient pressure differential. Accordingly, method440includes blocks341-346as previously described. For example, in block341, drilling fluid is pumped down drillstring22to power section100. In block342, a portion of the drilling fluid flows axially through passage323of body320′, and a portion of the drilling fluid flows into annulus328and then radially through port324into passage323. More specifically, at least initially, no plugs230are disposed in seats326a,326b, and thus, a portion of the drilling fluid flows through passage323and reduced inner radius section322c, and a portion of the drilling fluid flows into annulus328and then radially inward through port324. Next, in block343, the drilling fluid flowing into and through passage323of body320′ (via section322cand port324) drives the rotation of body320′ relative to housing210. In particular, the drilling fluid flowing into and through passage323(via section322cand port324) flows downstream into rotor110of first stage101and drives the rotation of rotors110of stages101,102as previously described. Body320′ is fixably coupled to rotors110, and thus, body320′ rotates with rotors110relative to housing210.

Moving now to block344, rotation of body320′ relative to housing210generates pressure pulses in the drilling fluid upstream of the valve1000. In particular, rotation of body320′ results in the cyclically opening and closing of port324with lug213as previously described. The cyclical opening and closing of port324generates pressure pulses in the drilling fluid upstream of valve1000. In this manner, the rotation of rotors110drive the rotation of body320′ relative to housing210, which in turn generates cyclical pressure pulses in the drilling fluid that drive the axial reciprocation of shock tool92. As previously described, the diameter of section322cdetermines the relative amounts of drilling fluid that pass through section322cand annulus328. Without being limited by this or any particular theory, the greater the relative amount of drilling fluid that passes into annulus328(and less relative amount of drilling fluid that passes through section322c), the greater the amplitude or height of each pressure pulse generated by valve1000.

Similar to valve200″, plug seats326a,326band corresponding plugs230enable the selective ability to progressively increase the amplitude and pulse height of the pressure pulses generated by valve1000downhole without retrieving valve1000. In particular, to increase in the amplitude and pulse height of the pressure pulses generated by valve1000when desired, lower plug230is dropped from the surface and seats in lower seat326aaccording to block345. As a result, flow through nozzle226is is restricted from flowing therethrough, thereby increasing the relative quantity of drilling fluid directed into annulus328and port324, which increases in the amplitude or height of each pressure pulse generated by valve1000. When yet a further increase in the amplitude and pulse height of the pressure pulses generated by valve1000is desired, upper plug230is dropped from the surface and seats in upper seat326baccording to block346. As a result, flow through section322cis further restricted from flowing therethrough, thereby further increasing the relative quantity of drilling fluid directed into annulus328and port324, which further increases in the amplitude or height of each pressure pulse generated by valve1000. It should be appreciated that in this embodiment, neither lower plug230nor upper plug230completely prevents flow through section322cas ports327in seats326a,326ballow some drilling fluid to flow around the corresponding plugs230and through section322c. However, since upper seat326bincludes fewer bypass slots327than lower seat326a, the restriction of flow through nozzle226is further restricted by upper plug230as compared to lower plug230alone.

Although each bypass slot327is a recess disposed along inner surface322and extending axially from a corresponding seat326a,326bin this embodiment, in other embodiments, bypass slots327may be replaced with bores or holes extending from the corresponding seat326a,326bto inner surface322below the corresponding seat326a,326b. In this embodiment, a plurality of bypass slots327extend from lower seat326aand one bypass slot327extends from upper seat326b. However, in other embodiments, the number of bypass slots (e.g., bypass slots327) in each seat (e.g., seat326a,326b) may vary with the understanding that the number of bypass slots associated with the seats preferably decreases moving axially uphole from one seat to the next. For example, in another embodiment, one or more bypass slots327extend axially from lower seat326aand no bypass slots327extend from upper seat326b. In that embodiment, when plug230is seated against upper seat326b, all of the drilling fluid flows into annulus328and through port324.

Typically, valve body1011remains in the closed position, and thus, all the drilling fluid directed into annulus328flows through port324to generate pressure pulses in the same manner as valve200″ previously described. However, in this embodiment, valve1000includes relief valve1010, which opens to relieve pressure in annulus328. Accordingly, method440includes an additional block347at which relief valve1010opens in response to a sufficient pressure differential to relieve pressure in annulus328, thereby limiting the maximum amplitude and height of the pressure pulses generated by valve1000. In particular, at the sufficient pressure differential across relief valve1010between drilling fluid in annulus328and drilling fluid in passage323downstream of valve1010, valve body1011transitions to the open position to relieve pressure in annulus328by allowing some drilling fluid in annulus328to bypass plugs230and port324. Reduction of the pressure of drilling fluid in annulus328limits the maximum amplitude and height of the pressure pulses generated by valve1000.

In the embodiments of valves200″,1000described above, successively dropped plugs230enable the selective and progressive increase in the amplitude and height of the pressure pulses generated by valves200″,1000. In those embodiments, plugs230are not retrievable, and thus, once plugs230are seated in corresponding seats326a,326b, it may not be possible to decrease the amplitude and height of the pressure pulses generated by valves200″,1000. However, in relatively long lateral sections of a borehole, relatively large amplitude pressure pulses may not be necessary or desirable while tripping out of the borehole. In such situations, it may be desirable to decrease the amplitude and height of the pressure pulses, and further to maintain the deceased amplitude and height of the pressure pulses while tripping.FIGS. 32-34illustrates a power section100as previously described and a top mount, oscillating or rotating radial valve1100that can selectively increase the amplitude and pulse height of the pressure pulses generated by valve1100via deployment of a plug230, and subsequently, selectively decrease the amplitude and pulse height of the pressure pulses generated by valve1100.

Referring now toFIGS. 32-34, valve1100is operated by the rotation of rotor110to selectively generate pressure pulses in the drilling fluid upstream power section100, which drive the axial reciprocation of shock tool92(FIG. 1). In this embodiment, valve1100includes a first valve member or outer housing210, a second valve member or body1120rotatably disposed within housing210, and an actuator1130slidably disposed in body1120. Body1120is concentrically disposed within housing210and actuator1130is concentrically disposed in body1120. In addition, housing210, body1120, and actuator1130are coaxially aligned with rotor110and stator120of power section100. In other words, housing210, body1120, and actuator1130have central axes that are coaxially aligned with axis105.

Housing210is as previously described with respect to valve200. Thus, upper end210aof housing210is coupled to drillstring22and lower end210bof housing210is directly coupled to upper end120aof stator120. Body1120extends through central throughbore212of housing210.

Body1120has a first or upper end1120a, a second or lower end1120b, a radially outer surface1121extending axially between ends1120a,1120b, and a radially inner surface1122extending axially between ends1120a,1120b. Inner surface1122defines a central passage1123extending axially between ends1120a,1120b. In addition, body1120includes a port1124axially positioned between ends1120a,1120b(proximal lower end1120b), a plurality of uniformly circumferentially-spaced outlet ports1125axially positioned proximal upper end1120a, and a bypass port1126axially positioned between port1124and ports1125. Each port1124,1125,1126extends radially from outer surface1121to inner surface1122. Lower end1120bof body1120is fixably coupled to upper end110aof rotor110such that body1120rotates with rotor110relative to housing210and stator120. In this embodiment, lower end1120bis a box end that threadably receives a mating pin end at upper end110aof rotor110.

In this embodiment, outer surface1121includes a cylindrical surface1121aextending axially from upper end1120aand a cylindrical surface1121bextending axially from lower end1120b. A downward facing annular shoulder1121cextends radially between surfaces1121a,1121b. Surface1121ais disposed at a diameter greater than surface1121b, thereby defining an enlarged head1121dat upper end1120a. Head1121dand corresponding surface1121aslidingly engages a mating cylindrical portion of inner surface211of housing210. Sliding engagement of head1121dand housing210restricts the flow of drilling fluid therebetween but does not define a seal therebetween or prevent the flow of drilling fluid therebetween. Cylindrical surface1121bis radially spaced from inner surface211of housing210with the exception of lug213and corresponding surface214, which slidingly engages surface1121b.

In this embodiment, inner surface1122includes a first cylindrical surface1122aextending axially from upper end1120a, a second cylindrical surface1122bextending axially from the box end at lower end1120b, and a third cylindrical surface1122caxially positioned between surfaces1122a,1122b. An annular uphole facing planar shoulder1123aextends radially inward from surface1122ato surface1122c, and an annular uphole facing planar shoulder1123bextends radially inward from surface1122cto surface1122b. Thus, surface1122ais disposed at a diameter greater than surface1122c, and surface1122cis disposed at a dimeter greater than surface1122b. Port1124extends radially from surface1121bto surface1122b, ports1125extend from surface1121ato surface1122bat shoulder1122c, and port1126extends radially from surface1121bto surface1122c.

Referring still toFIGS. 32-34, body1120is disposed in housing210with port1124axially aligned with lug213and cylindrical surface1121bof body1120radially opposed cylindrical surfaces211b,211cof housing210. Cylindrical surface211bof housing210is radially spaced from cylindrical surface1121bof body1120, thereby resulting in an annular space or annulus1128radially disposed between surfaces1121b,211b. Surface1121bis disposed at substantially the same radius as surfaces211c,214of housing210, and thus, surface1121bdirectly contacts and slidingly engages surfaces211c,214. Port1124has a circumferential width that is less than the circumferential width of lug213and corresponding surface214, and further, port1124has an axial height that is less than the axial height of lug213and corresponding surface214. Thus, when port1124is circumferentially aligned with lug213, port1124is closed (or substantially closed) by lug213and fluid communication between annulus1128and passage1123via port1124is substantially restricted and/or prevented. However, when port1124is not circumferentially aligned with lug213, port1124is open and allowed fluid communication between annulus1128and passage1123. Although valve1100is shown and described as including one port1124and one lug213, in general, the valve (e.g., valve1100) can have one or more ports (e.g., ports1124) and one or more lugs (e.g., lug213).

Actuator1130includes a first or upper end1130a, a second or lower end1130b, a radially outer surface1131extending axially between ends1130a,1130b, and a radially inner surface1132extending axially between ends1130a,1130b. Inner surface1132defines a central passage1133extending axially between ends1130a,1130b. In addition, actuator1130includes a plurality of uniformly circumferentially-spaced outlet ports1134axially positioned proximal upper end1130aand a plurality of uniformly circumferentially-spaced bypass ports1135axially positioned between outlet ports1134and lower end1130b. Each port1134,1135extends radially from outer surface1131to inner surface1132.

In this embodiment, inner surface1132includes a stepped receptacle1132aat upper end1130aand a reduced inner radius section1132bdefined by a cylindrical surface extending axially from receptacle1132ato lower end1130b. A plurality of axially spaced annular uphole facing shoulders or seats are disposed along inner surface1132within receptacle1132a. In particular, inner surface1132includes first or lower annular uphole facing shoulder or seat1136aaxially positioned proximal section1132band a second or upper annular uphole facing shoulder or seat1136baxially positioned between upper end1130aand seat1136a. Cylindrical surfaces extend between section1132band seat1136a, between seats1136a,1136b, and between seat1136band upper end1130a. Each seat1136a,1136bis sized to sealingly engage one corresponding plug230. In this embodiment, each plug230is a spherical ball. A plurality of bypass slots327as previously described extend axially along inner surface1132from seat1136aand a bypass slot327as previously described extends axially along inner surface1132from seat1136b. Slots327allow restricted flow of drilling fluid around the corresponding plug230disposed in the corresponding seat1136a,1136b.

Although each bypass slot327is a recess disposed along inner surface1132and extending axially from a corresponding seat1136a,1136bin this embodiment, in other embodiments, bypass slots327may be replaced with bores or holes extending from the corresponding seat1136a,1136bto inner surface1132below the corresponding seat1136a,1136b. In this embodiment, a plurality of bypass slots327extend from lower seat1136aand one bypass slot327extends from upper seat1136b. However, in other embodiments, the number of bypass slots (e.g., bypass slots327) in each seat (e.g., seat1136a,1136b) may vary with the understanding that the number of bypass slots associated with the seats preferably decreases moving axially uphole from one seat to the next. For example, in another embodiment, one or more bypass slots327extend axially from lower seat1136aand no bypass slots327extend from upper seat1136b. In that embodiment, when plug230is seated against upper seat1136b, all of the drilling fluid flows into annulus1128and through port1124.

The inner diameter of passage1133defined by seats1136a,1136bgenerally increases moving axially uphole from section1132bto end1130a—the minimum inner diameter defined by seat1136ais less than the minimum diameter defined by seat1136b. Accordingly, the diameter of plug230sized to sealingly engage lower seat1136ais less than the diameter of plug230sized to sealingly engage upper seat1136b. For purposes of clarity and further explanation, the plug230that engages lower seat1136awill also be referred to herein as first or lower plug230and the plug230that engages upper seat1136bwill also be referred to herein as second or upper plug230.

Outlet ports1134are axially positioned between seats1136a,1136b, while bypass ports1135are axially positioned below both seats1136a,1136b. Each seat1136a,1136bis sized to engage one corresponding plug230. In this embodiment, each plug230is a spherical ball.

Referring still toFIGS. 32-34, actuator1130can be selectively moved axially downward relative to body1120and housing210between a first or deactivated position (FIGS. 32 and 33) preventing the flow of drilling fluid through bypass ports1126,1135and a second or activated position (FIG. 34) allowing the flow of drilling fluid through bypass ports1126,1135. In the deactivated position, shown inFIGS. 32 and 33, outlet ports1125,1134are axially and circumferentially aligned, bypass ports1126,1135are axially misaligned, cylindrical surface1131bof actuator1130extends completely across bypass port1126, and shoulders1131c,1123aare axially spaced apart. As shown inFIG. 32(without a plug230seated against seat1136band actuator1130in the deactivated position, receptacle1132aand annulus1128are in fluid communication via outlet ports1125,1134, thereby allowing drilling fluid to flow between receptacle1132aand annulus1128; however, bypass ports1126,1135are not in fluid communication, thereby restricting and/or preventing the flow of drilling fluid through bypass port1126. In the activated position shown inFIG. 34, outlet ports1125,1134are axially misaligned, bypass ports1126,1135are axially aligned, cylindrical surface1122aextends completely across outlet ports1135, cylindrical surface1131bof actuator1130is axially positioned below bypass port1126(e.g., surface1131bdoes not extend across bypass port1126), and shoulders1131c,1123aaxially abut. As a result, passage1133and annulus1128are in fluid communication via bypass ports1126,1135, thereby allowing drilling fluid to flow between annulus1128and passage1133. It should be appreciated that bypass ports1126,1135are disposed axially below receptacle1132aand any plugs230disposed therein, and further, drilling fluid that flows through ports1126,1135from annulus1128into passage1133of actuator1130does not flow through port1124. Thus, drilling fluid that flows through bypass ports1126,1135into passage1133of actuator1130bypasses plugs230and port1124. In this embodiment, actuator1130is generally held and maintained in the deactivated position during drilling operations by a shear pin1140extending between body1120and actuator1130. However, when the pressure differential across actuator1130(e.g., the pressure differential between the drilling fluid above actuator1130and the drilling fluid in passages1123,1133axially below actuator1130exceed the shear strength of pin1140, actuator1130shifts axially downward from the deactivated position to the activated position by shearing pin1140, thereby allowing drilling fluid in annulus1128to bypass port1124.

Although actuator1130is transitioned from the deactivated position to the activated position by shearing the pin1140in this embodiment, in other embodiments, shear pin1140may be replaced with a shear ring or a spring that allows actuator1130to transition from the deactivated position to the activated position in response to a sufficient pressure differential.

Referring now toFIG. 35, an embodiment of a method540for selectively increasing the amplitude and height of the pressure pulses in drilling fluid during drilling operations with a top mount, oscillating or rotating radial valve and subsequently reducing the amplitude and height of the pressure pulses is shown. For purposes of clarity and further explanation, method540will be described with respect to the operation of valve1100described above and shown inFIGS. 32-34.

Valve1100is deployed with actuator1130in the deactivated position with shear pin1140intact and maintaining actuator1130in the deactivated position. During drilling operations, valve1100operates in substantially the same manner as valve200″ previously described with the exception that actuator1130can be transitioned to the activated position to decrease the amplitude or height of each pressure pulse generated by valve1100. Accordingly, method540includes blocks341-345as previously described. For example, in block341, drilling fluid is pumped down drillstring22to power section100. In block342, a portion of the drilling fluid flows axially through passage1133of body1120, and a portion of the drilling fluid flows into annulus1128and then radially through port1124into passage1133. More specifically, at least initially, no plugs230are disposed in seats1136a,1136b, and thus, a portion of the drilling fluid flows through passage1133and reduced inner radius section1132b, and a portion of the drilling fluid flows into annulus1128and then radially inward through port1124.

Next, in block343, the drilling fluid flowing into and through passage1133of body1120(via section1132band port1124) drives the rotation of body1120relative to housing210. In particular, the drilling fluid flowing into and through passage1133(via section1132band port1124) flows downstream into rotor110of first stage101and drives the rotation of rotors110of stages101,102as previously described. Body1120is fixably coupled to rotors110and actuator1130is fixably coupled to body1120via shear pin1140, and thus, body1120and actuator1130disposed therein rotate with rotors110relative to housing210.

Moving now to block344, rotation of body1120relative to housing210generates pressure pulses in the drilling fluid upstream of the valve1100. In particular, rotation of body1120results in the cyclically opening and closing of port1124with lug213as previously described. The cyclical opening and closing of port1124generates pressure pulses in the drilling fluid upstream of valve1100. In this manner, the rotation of rotors110drive the rotation of body1120relative to housing210, which in turn generates cyclical pressure pulses in the drilling fluid that drive the axial reciprocation of shock tool92. As previously described, the diameter of section1132bdetermines the relative amounts of drilling fluid that pass through section1132band annulus1128. Without being limited by this or any particular theory, the greater the relative amount of drilling fluid that passes into annulus1128(and less relative amount of drilling fluid that passes through section1132b), the greater the amplitude or height of each pressure pulse generated by valve1100.

Similar to valve200″, plug seat1136aand the corresponding lower plug230enables the selective ability to increase the amplitude and pulse height of the pressure pulses generated by valve1100downhole without retrieving valve1100. In particular, to increase the amplitude and pulse height of the pressure pulses generated by valve1100when desired, lower plug230is dropped from the surface and seats in lower seat1136aaccording to block345. As a result, flow from receptacle1132ainto section1132bis restricted and the relative quantity of drilling fluid directed from receptacle1132ainto annulus1128via aligned outlet ports1125,1134is increased. It should also be appreciated that any drilling fluid passing between enlarged head1121dof body1120and housing210also flows into annulus1128and then through port1124. Thus, the seating of lower plug230against seat1136aincreases the relative quantity of drilling fluid directed into annulus1128and port1124, which increases in the amplitude or height of each pressure pulse generated by valve1100.

Typically, actuator1130remains in the deactivated position, and thus, all the drilling fluid directed into annulus1128flows through port1124to generate pressure pulses in the same manner as valve200″ previously described. However, in this embodiment, actuator1130can be selectively transitioned to the activated position to decrease the amplitude and pulse height of the pressure pulses generated by valve1100. Accordingly, method540includes an additional block546at which actuator1130is transitioned to the activated position to decrease the amplitude and pulse height of the pressure pulses generated by valve1100. In particular, when it is desirable to decrease the amplitude and pulse height of the pressure pulses generated by valve1100, upper plug230is dropped from the surface and seats in upper seat1136b. As a result, flow into receptacle1132aat upper end1130ais restricted at seat1136b. As previously described, enlarged head1121drestricts the flow of drilling fluid between housing210and head1121d, and thus, fluid pressure within housing210upstream of valve1100increases until the pressure differential across actuator1130is sufficient to shear or break pin1140. Once pin1140is sheared, the pressure differential across actuator1130transitions actuator1130from the deactivated position (FIG. 32) to the activated position (FIG. 34). In the activated position, upper plug230seated against upper seat1136bis axially positioned below outlet ports1125, thereby allowing flow of drilling fluid around upper plug230and enlarged head1121dthrough outlet ports1125. As previously described, in the activated position (FIG. 34), passage1133and annulus1128are in fluid communication via bypass ports1126,1135, thereby allowing drilling fluid to flow between annulus1128and passage1133. Drilling fluid that flows through ports1126,1135from annulus1128into passage1133of actuator1130does not flow through port1124, thereby bypassing port1124and decreasing the relative quantity of drilling fluid directed through port1124, which decreases the amplitude or height of each pressure pulse generated by valve1100.

In the embodiment of top mount, oscillating or rotating radial valve1100shown inFIGS. 32-34and described above, deployment of lower plug230can be used to selectively increase the amplitude and pulse height of the pressure pulses generated by valve1100, and then the subsequent deployment of upper plug230can be used to selectively decrease the amplitude and pulse height of the pressure pulses generated by valve1100. Thus, in that embodiment, valve1100allows for the selective increase and then decrease in the amplitude and pulse height of the pressure pulses generated by valve1100. However, in some drilling operations, it may be desirable to tailor or adjust the change in the amplitude and pulse height of the pressure pulses upon deployment of the lower plug230and then upon deployment of upper plug230.FIGS. 36-38illustrates a power section100as previously described and a top mount, oscillating or rotating radial valve1100′ that allows for adjustment of the selective change in the amplitude and pulse height of the pressure pulses generated by valve1100′ via deployment of a lower plug230and then an upper plug230.

Referring now toFIGS. 36-38, valve1100′ is the same as valve1100previously described and shown inFIGS. 32-34with the exception that valve1100′ includes a plurality of nozzles1150,1151,1152that can be adjusted (e.g., by removal and replacement) to generate pressure pulses having different and distinct amplitudes and pulse heights at each of three sequential stages: (1) prior to deployment of plugs230(no plugs230disposed in stepped receptacle1121a) (FIG. 36); (2) after deployment of lower plug230(lower plug230seated against seat1136abut no plug230seated against seat1136b) (FIG. 37); and (3) after deployment of both lower plug230and upper plug230(lower plug230seated against seat1136aand upper plug230seated against seat1136b) and transition of body1120to the activated position (FIG. 38). More specifically, nozzle1150is removably threaded into a bore1127extending radially through body1120axially below shoulder1123band offset (axially and/or circumferentially) from lug213and corresponding surface214. Nozzle1151is removably threaded into the upper end of section1132band axially positioned between receptacle1132aand ports1135. Nozzle1152is removably threaded into the lower end of section1132bat end1130band axially positioned below ports1135.

Prior to deployment of plugs230as shown inFIG. 36(stage one), drilling fluid flows through receptacle1132a, nozzle1151, section1132b, and nozzle1152into passage1123, and drilling fluid flows from receptacle1132athrough aligned outlet ports1125,1134, annulus1128, and both port1124and nozzle1150into passage1123. Thus, in stage one, the drilling fluid flows through all three nozzles1150,1151,1152. After deployment of lower plug230as shown inFIG. 37(stage two), drilling fluid flows from receptacle1132athrough aligned ports1125,1134, annulus1128, and both port1124and nozzle1150into passage1123. Thus, in stage two, drilling fluid flows through nozzle1150but does not flow through nozzles1151,1152. After deployment of both plugs230and transition of body1120to the activated position as shown inFIG. 38(stage three), drilling fluid flows from receptacle1132athrough port1125, annulus1128, aligned ports1126,1135, section1132b, and nozzle1152into passage1132, and drilling fluid flows from receptacle1132athrough port1125, annulus1128, and both port1124and nozzle1150into passage1132. Thus, in stage three (FIG. 38), drilling fluid flows through nozzles1150,1152but does not flow through nozzle1151. In general, the drilling fluid that flows through any nozzle1150,1151,1152during any of the stages bypasses port1124.

In general, the size of the orifices in each nozzle1150,1151,1152influences the amount of drilling fluid that flows therethrough. As previously described, the drilling fluid flowing through any of the nozzles1150,1151,1152bypasses port1124. In addition, as previously described, in stage one (FIG. 36), drilling fluid flows through nozzles1150and1151(before flowing through nozzle1152); in stage two (FIG. 37), drilling fluid flows through nozzle1150; and in stage three (FIG. 38), drilling fluid flows through nozzles1150,1152. Thus, in stages one, two, and three, a smaller orifice in nozzle1150results in more drilling fluid flowing through port1124and a larger orifice in nozzle1150results in less drilling fluid flowing through port1124; in stage one, a smaller orifice in nozzle1151results in more drilling fluid flowing through port1124and a larger orifice in nozzle1151results in less drilling fluid flowing through port1124; and in stage two, a smaller orifice in nozzle1152results in more drilling fluid flowing through port1124and a larger orifice in nozzle1152results in less drilling fluid flowing through port1124. Thus, different nozzles1150,1151,1152having different sized orifices can be used to alter the relative quantity of drilling fluid flowing through port1124versus bypassing port1124in each stage one, two, and three, which in turn affects the amplitude of each pressure pulse generated by valve1100′ in each stage one, two, and three.

Valve1100′ generally operates in the same manner as valve1100previously described and shown inFIG. 35. In particular, valve1100′ is deployed with actuator1130in the deactivated position with shear pin1140intact and maintaining actuator1130in the deactivated position (stage one). At least initially, no plugs230are disposed in seats1136a,1136b, and thus, a portion of the drilling fluid flows through passage1133and reduced inner radius section1132b, and a portion of the drilling fluid flows into annulus1128and then radially inward through port1124. Nozzles1150,1151generally control the amplitude and pulse height of pressure pulses during stage one. When it is desirable to change the amplitude and pulse height of the pressure pulses generated by valve1100′, lower plug230is dropped from the surface and seats in lower seat1136a(stage two). Nozzle1150generally controls the amplitude and pulse height of pressure pulses during stage two. When yet a further change in the amplitude and pulse height of the pressure pulses generated by valve1100′ is desired, upper plug230is dropped from the surface and seats in upper seat1136b, thereby transitioning actuator1130to the activated position (stage three). Nozzles1150,1152generally control the amplitude and pulse height of pressure pulses during stage three. For some drilling operations, nozzles1150,1151,1152are selected (e.g., the sizes of the orifices of nozzles1150,1151,1152are selected) such that the sequence of pressure pulse amplitudes are as follows: in stage one (FIG. 36), the pressure pulses have medium amplitudes and pulse heights while running into the borehole and during the early parts of drilling operations; in stage two (FIG. 37), the pressure pulses have large amplitudes and pulse heights when maximum axial oscillation of shock tool92is desired during the later stages of drilling; and in stage three (FIG. 38), the pressure pulses have small amplitudes and pulse heights when tripping out of the borehole. In such operations, the amplitudes of the pressure pulses in stage two are greater than the amplitudes of the pressure pulses in stage one, and the amplitudes of the pressure pulses in stage one are greater than the amplitudes of the pressure pulses in stage three. This approach offers the potential to induce high amplitude pressure pulses only when needed, thereby saving the drillstring22from unnecessary high amplitude cycles during other stages of drilling and reducing the overall fatigue experienced by the drillstring22during drilling operations.

In embodiments described herein, the oscillating or rotary valves (e.g., valves200,200′,200″,300,400,400′,400″,600,1000,1100,1100′) are generally shown and described as being disposed below a shock tool (e.g., shock tool92) in the same string, and thus, generate pressure pulses that travel uphole to the shock tool and actuate the shock tool. However, in other embodiments, the valves may be positioned above the shock tool such that pressure pulses generated by the valve travel downhole to the shock tool and actuate the shock tool. Such embodiments may provide benefits to excitation depending on the particular application.