Source: https://patents.google.com/patent/US8844634
Timestamp: 2018-03-22 20:05:43
Document Index: 176127849

Matched Legal Cases: ['§371', 'Application No. 60', 'Application No. 2', 'Application No. 2', 'Application No. 2', 'Application No. 2']

US8844634B2 - Circulation sub with indexing mechanism - Google Patents
Circulation sub with indexing mechanism Download PDF
US8844634B2
US8844634B2 US12743670 US74367008A US8844634B2 US 8844634 B2 US8844634 B2 US 8844634B2 US 12743670 US12743670 US 12743670 US 74367008 A US74367008 A US 74367008A US 8844634 B2 US8844634 B2 US 8844634B2
US12743670
US20100252276A1 (en )
A downhole circulation sub or valve includes a tubular housing with an outer port and a valve piston slidably disposed in the housing. A primary fluid flow path extends through an inner flow bore of the housing and valve piston. In a first position, the valve piston isolates the outer port to prevent fluid communication between the inner flow bore and a well bore annulus. In a second position, the valve piston is moved to obstruct the inner flow bore and expose the outer port to the inner flow bore and allow fluid communication between the inner flow bore and the well bore annulus. An indexing mechanism is coupled between the housing and the valve piston to guide the valve piston between the first and second positions. The indexing mechanism may include a rotatable component.
This application is the U.S. National Stage Under 35 U.S.C.§371 of International Patent Application No. PCTUS2008/083986 filed Nov. 19, 2008, which claims the benefit of U.S. Provisional Patent Application No. 60/989,345, filed Nov. 20, 2007, titled “Circulation Sub With Indexing Slot.”
The present disclosure relates generally to an apparatus and method for selectively circulating fluid in a well bore. More particularly, the present disclosure relates to a selectively and continually actuatable circulation sub or valve and its method of use in well bore operations, including drilling, completion, workover, well clean out, fishing and packer setting.
When drilling an oil or gas well, a starter hole is first drilled, and the drilling rig then installed over the starter hole. Drill pipe is coupled to a bottom hole assembly, which typically includes a drill bit, drill collars, stabilizers, reamers and other assorted subs, to form a drill string. The drill string is coupled to a kelly joint and rotary table and then lowered into the starter hole. When the drill bit reaches the base of the starter hole, the rotary table is powered and drilling may commence. As drilling progresses, drilling fluid, or mud, is circulated down through the drill pipe to lubricate and cool the drill bit as well as to provide a vehicle for removal of drill cuttings from the borehole. The drilling fluid may also provide hydraulic power to a mud motor. After emerging from the drill bit, the drilling fluid flows up the borehole through the annulus formed by the drill string and the borehole, or the well bore annulus.
During drilling operations, it may be desirable to periodically interrupt the flow of drilling fluid to the bottom hole assembly and divert the drilling fluid from inside the drill string through a flow path to the annulus above the bottom hole assembly, thereby bypassing the bottom hole assembly. For example, the mud motor or drill bit in the bottom hole assembly tend to restrict allowable fluid circulation rates. Bypassing the bottom hole assembly allows a higher circulation rate to be established to the annulus. This is especially useful in applications where a higher circulation rate may be necessary to effect good cuttings transport and hole cleaning before the drill string is retrieved. After a period of time, the flow of drilling fluid to the bottom hole assembly may be reestablished. Redirecting the flow of drilling fluid in this manner is typically achieved by employing a circulation sub or valve, positioned on the drill string above the drill bit.
Thus, there remains a need for a cost effective apparatus and method for selectively circulating fluid within a well bore, including continual valve actuation and reduction of valve tripping.
A downhole circulation sub or valve includes a tubular housing with an outer port and a valve piston slidably disposed in the housing. A primary fluid flow path extends through an inner flow bore of the housing and valve piston. In a first position, the valve piston isolates the outer port to prevent fluid communication between the inner flow bore and a well bore annulus. In a second position, the valve piston is moved to obstruct the inner flow bore and expose the outer port to the inner flow bore and allow fluid communication between the inner flow bore and the well bore annulus. In some embodiments, the circulation sub is selectively configurable to include multiple flow paths, including a primary flow path through the sub, a secondary flow path around a seated ball and through the sub, and a bypass flow path wherein fluid is diverted to the well bore annulus.
In some embodiments, an indexing mechanism is coupled between the housing and the valve piston to move the valve piston between the first and second positions. In some embodiments, the indexing mechanism includes a rotatable component. In certain embodiments, the rotatable component of the indexing mechanism rotates independently of both the housing and the valve piston. In some embodiments, the indexing mechanism can be used to continually move the valve piston between the first and second positions in a single trip into a well bore. In some embodiments, the valve piston and indexing mechanism are powered by manipulating fluid pressures in the circulation sub.
FIG. 7 depicts the circulation sub of FIG. 1 in a run-in configuration;
FIG. 8 is a perspective view of an indexer of the circulation sub of FIG. 7 in a run-in configuration;
FIG. 9 depicts the circulation sub of FIG. 1 in a through-tool configuration;
FIG. 10 is a perspective view of the indexer of the circulation sub of FIG. 9 in a through-tool configuration;
FIG. 12 depicts the circulation sub of FIG. 1 in a bypass configuration; and
FIG. 13 is a perspective view of the indexer of the circulation sub of FIG. 12 in a bypass configuration.
FIG. 1 schematically depicts an exemplary drill string portion, one of many in which a circulation sub or valve and associated methods disclosed herein may be employed. Furthermore, other conveyances are contemplated by the present disclosure, such as those used in completion or workover operations. A drill string is used for ease in detailing the various embodiments disclosed herein. A drill string portion 100 includes a circulation sub 105 coupled to a top sub 110 at its upper end 115 and to a bottom sub 120 at its lower end 125. As will be described herein, the sub 105 is selectively and continually actuatable, thus can also be referred to as a multi-opening circulation sub, or MOCS. The MOCS 105 includes a flowbore 135. The coupling of top sub 110 and bottom sub 120 to MOCS 105 establishes a primary fluid flow path 130 that also fluidicly couples to the fluid flow path in the drill string 100.
As will be described in detail below, the MOCS 105 is selectively configurable to permit fluid flow along one of multiple paths. In a first or “run-in” configuration, fluid flows along the path 130 from the top sub 110 through the MOCS 105 via flowbore 135 to the bottom sub 120 and other components that may be positioned downhole of the bottom sub 120, such as a drill bit. Alternatively, when the MOCS 105 assumes a second or “through-tool” configuration, fluid flows along the path 130 in the top sub 110, around a ball 245 and through ports 260, and finally back to the flowbore 135 to rejoin the path 130 to the bottom sub 120 and other lower components. In a further alternative position, when the MOCS 105 assumes a third or “bypass” configuration, fluid is diverted from the path 130 through a flow path 132 in the MOCS 105 to the well bore annulus 145, located between the drill string portion 100 and the surrounding formation 147. In some embodiments, the diversion flow path through the MOCS 105 is achieved via one or more ports 140. Once in the well bore annulus 145, the fluid returns to the surface, bypassing the bottom sub 120 and other components which may be positioned downhole of the bottom sub 120. An indexing mechanism 165 guides the MOCS 105 between these various configurations or positions.
Returning to FIG. 1, the details of the MOCS 105 will be described with additional reference to enlarged views of the upper, middle and lower portions of the MOCS 105 as depicted in FIGS. 4, 5 and 6, respectively. Referring first to FIG. 1, the MOCS 105 includes a valve body or housing 150, a floater piston 155, a valve mandrel 160, an indexing mechanism 165 and a ported valve piston 170 slidably disposed in the housing 150. The valve body 150 of the MOCS 105 couples to the top sub 110 via threaded connection 112 and to bottom sub 120 via threaded connection 122, as described above in reference to FIGS. 2 and 3. Proceeding from the uphole end 115 to the downhole end 125 of the MOCS 105, the ported valve piston 170, the indexer 165 and the floater piston 155 are positioned concentrically within the valve body 150. The valve mandrel 160 is positioned concentrically within the ported valve piston 170, the indexer 165 and the floater piston 155 between the top sub 110 and the bottom sub 120. In some embodiments, the valve mandrel 160, the ported valve piston 170 and other similarly represented components in the figures are cylindrical, hollow members or sleeves.
The manner in which the components of the MOCS 105 move relative to each other is best understood by considering the various configurations that the MOCS 105 can assume. In the embodiments illustrated by FIGS. 1 through 13, there are multiple configurations that the MOCS 105 can assume to execute multiple flow paths: the run-in configuration, the through-tool configuration, and the bypass configuration. The run-in configuration refers to the configuration of the MOCS 105 as it is tripped downhole and allows drilling fluid to flow along the path 130, as illustrated by FIGS. 7 and 8. The through-tool configuration of the MOCS 105 allows drilling fluid to continue flowing along the path 130, with only a slight deviation around the obturating member 245 and through the ports 260. This flow path is illustrated in FIGS. 9 and 10. The bypass configuration of the MOCS 105 diverts drilling fluid from the path 130 in upper sub 110 to the well bore annulus 145 via the path 132 through the ports 140. The bypass configuration of the MOCS 105 is illustrated by FIGS. 12 and 13.
In the exemplary embodiments of the MOCS 105 illustrated in FIGS. 1 through 13, the MOCS 105 is configurable by the application of a pressure load from the drilling fluid. However, in other embodiments, the MOCS 105 may be configurable by mechanical means, including, for example, a wireline physically coupled to the ported valve piston 170 and configured to translate the ported valve piston 170 as needed. Alternatively, the valve piston may receive a heavy mechanical load, such as a heavy bar dropped onto the top of the valve piston. Other means for actuating the MOCS and indexer arrangement described herein are consistent with the various embodiments.
While preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims.
a tubular housing having an outer port;
a piston slidably disposed in the housing;
an inner flow bore extending through the housing including a primary fluid flow path extending substantially between an upstream end of the inner flow bore and a downstream end of the inner flow bore;
wherein the piston includes a first position isolating the outer port from the primary fluid flow path and a second position obstructing the primary fluid flow path and exposing the outer port to provide a bypass flow path extending substantially between the upstream end of the inner flow bore and a well bore annulus;
wherein the piston is configured to receive an obturating member to actuate the piston from the first position toward the second position; and
an indexing mechanism coupled between the housing and the piston to cycle the piston between the first and second positions.
2. The downhole tool of claim 1 wherein the indexing mechanism provides continual movement of the piston between the first and second positions during a single trip into the well bore.
3. The downhole tool of claim 1 wherein the piston is moveable between the first and second positions an unlimited number of times during a single trip into the well bore.
4. The downhole tool of claim 1 wherein the indexing mechanism further includes a fixed spline sleeve and a rotatable index ring.
5. The downhole tool of claim 4 wherein the spline sleeve is fixed to the housing.
6. The downhole tool of claim 4 wherein the fixed spline sleeve includes angled tabs and inner splines slidable into alternating long slots and short slots on the rotatable index ring.
7. The downhole tool of claim 6 wherein the piston includes slots aligned with the inner splines of the spline sleeve.
8. The downhole tool of claim 7 wherein:
the index ring is disposed between the piston slots and the spline sleeve;
the short slots of the index ring engage the tabs of the spline sleeve in the first position to prevent the piston slots from engaging the inner splines; and
the long slots of the index ring engage the tabs of the spline sleeve in the second position to allow the inner splines to pass over the index ring and into the piston slots.
9. The downhole tool of claim 4 wherein the indexing mechanism further includes an index teeth ring engaged with the index ring and the spline sleeve.
10. The downhole tool of claim 4 wherein the indexing mechanism further includes a biasing spring.
11. The downhole tool of claim 1 further comprising a mandrel disposed in the piston, the mandrel having an upper end disposed below an upper end of the piston in the first position, and the piston upper end including a ball seat and an inner port.
12. The downhole tool of claim 11, wherein the obturating member comprising a ball is disposed in the ball seat to obstruct the primary flow path and provide a secondary inner flow path through the inner port.
13. The downhole tool of claim 12 wherein the inner port is disposed below the mandrel upper end in the second position to obstruct the inner port and the secondary inner flow path, and expose the outer port and the bypass flow path.
14. The downhole tool of claim 11 further comprising a piston biasing spring disposed about the mandrel.
15. The downhole tool of claim 14 wherein the indexing mechanism and the piston biasing spring are disposed in a sealed oil chamber.
16. The downhole tool of claim 1, wherein the tool is configured so as to divert all or part of the fluid flow to the well bore annulus when the piston is in the second position.
17. A system for circulating fluid within a well bore comprising:
a housing coupled to the tubular string, the housing including a housing port;
a piston disposed in the housing and having a primary fluid flow path;
wherein the piston is configured to receive an obturating member to obstruct the primary fluid flow path while isolating the housing port;
wherein the piston includes a secondary flow path disposed in the housing and extending around the received obturating member;
wherein the piston is selectively moveable to isolate and expose the housing port to the inner flow bore; and
a rotatable indexer coupled to the piston, the rotatable indexer operable to move the piston an unlimited number of times during a single trip into the well bore;
wherein the piston includes an upper end having a seat and a piston port, the obturating member comprises a ball, wherein the seat receives the ball to obstruct the primary fluid flow path into the piston while the housing port is isolated, and wherein the piston port directs the secondary fluid flow path into the piston.
18. The system of claim 17 wherein the rotatable indexer includes:
an index ring having a set of short slots and a set of long slots; and
a spline sleeve having a set of inner splines;
wherein the set of inner splines is alternately disposable in the set of short slots and the set of long slots while moving the piston.
19. The system of claim 17 further comprising an inner mandrel to obstruct the fluid flow into the piston port while the housing port is exposed and the fluid flow is directed into a well bore annulus.
20. The system of claim 19, wherein the tool is configured so as to divert all or part of the fluid flow to the well bore annulus when the housing port is exposed.
21. A method for circulating fluid within a well bore comprising:
disposing a tubular string having a circulation sub in the well bore;
flowing a fluid through a primary fluid flow path of the circulation sub;
isolating an outer port in the circulation sub with an inner piston;
obstructing the primary fluid flow path in the circulation sub while exposing the outer port to a fluid flow from upstream of the obstruction;
moving the inner piston by rotating an indexer;
exposing a downstream end of an inner flow bore of the circulation sub to a fluid flow from upstream of the obstruction while isolating the outer port;
blocking an inlet of the inner piston with the obturating member; and
flowing the fluid around the obturating member and into a piston port.
blocking the piston port in response to moving the inner piston; and
thereby directing the fluid flow through the outer port.
23. The method of claim 21, wherein directing the fluid flow comprises diverting all or part of the fluid flow through the outer port.
24. A method for circulating fluid within a well bore comprising:
flowing a fluid through the tubular string and the circulation sub;
isolating a housing port in an outer housing of the circulation sub with an inner piston;
providing an obturating member in the inner piston to obstruct a primary fluid flow path while isolating the housing port;
exposing the housing port to a fluid flow from upstream of the obturating member while obstructing the primary fluid flow path;
moving the inner piston by rotating a portion of an indexer to re-isolate the housing port and expose a downstream end of an inner flow bore of the outer housing to a fluid flow from upstream of the obturating member;
obstructing the primary fluid flow path to actuate the inner piston and the indexer;
maintaining isolation of the housing port by preventing translation of the inner piston using the indexer;
decreasing the fluid flow to translate the piston and reset the indexer;
increasing the fluid flow to translate the piston and expose the housing port; and
repeating the decreasing and increasing the fluid flow steps to selectively isolate and expose the housing port any number of times during the single well bore trip.
25. The method of claim 24, wherein exposing the housing port to the fluid flow comprises exposing the housing port to all or part of the fluid flow.
26. The method of claim 24 wherein the fluid flow is increased to divert part of the fluid flow through the exposed port and part of the fluid flow through the circulation sub.
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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CLAUSEN, JEFFERY RONALD;MARCHAND, NICHOLAS RYAN;SIGNING DATES FROM 20100513 TO 20100517;REEL/FRAME:024409/0819