US20200347676A1 - Wear resistant vibration assembly and method - Google Patents
Wear resistant vibration assembly and method Download PDFInfo
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- US20200347676A1 US20200347676A1 US16/401,594 US201916401594A US2020347676A1 US 20200347676 A1 US20200347676 A1 US 20200347676A1 US 201916401594 A US201916401594 A US 201916401594A US 2020347676 A1 US2020347676 A1 US 2020347676A1
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- rotor
- segment
- rotating valve
- sleeve
- vibration assembly
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Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B4/00—Drives for drilling, used in the borehole
- E21B4/02—Fluid rotary type drives
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/24—Drilling using vibrating or oscillating means, e.g. out-of-balance masses
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B1/00—Percussion drilling
- E21B1/12—Percussion drilling with a reciprocating impulse member
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B1/00—Percussion drilling
- E21B1/12—Percussion drilling with a reciprocating impulse member
- E21B1/24—Percussion drilling with a reciprocating impulse member the impulse member being a piston driven directly by fluid pressure
- E21B1/26—Percussion drilling with a reciprocating impulse member the impulse member being a piston driven directly by fluid pressure by liquid pressure
- E21B1/28—Percussion drilling with a reciprocating impulse member the impulse member being a piston driven directly by fluid pressure by liquid pressure working with pulses
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/10—Wear protectors; Centralising devices, e.g. stabilisers
- E21B17/1085—Wear protectors; Blast joints; Hard facing
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/10—Valve arrangements in drilling-fluid circulation systems
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B28/00—Vibration generating arrangements for boreholes or wells, e.g. for stimulating production
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B4/00—Drives for drilling, used in the borehole
- E21B4/06—Down-hole impacting means, e.g. hammers
- E21B4/14—Fluid operated hammers
Definitions
- a downhole drilling motor and a drill bit are attached to the end of a drill string.
- Most downhole drilling motors include a rotor rotating within a stator. The rotation of the rotor provides a vibration to the adjacent drill bit as it cuts through the subterranean formation to drill the wellbore.
- the drill string slides through the higher portions of the wellbore as the drill bit at the end of the drill string extends the wellbore deeper into the formation.
- a vibration tool is sometimes attached to the drill string a distance above the drill bit (e.g., 800-1,500 feet above the drill bit). The vibration tool provides vibration to the portions of the drill string above the vibration tool, thereby facilitating the movement of the drill string through the wellbore.
- Conventional vibration tools include a power section made of a rotor rotating within a stator and a valve positioned below the rotor. As the rotor rotates, the valve periodically restricts fluid flow through the vibration tool, which creates a pressure pulse or waterhammer that is transmitted through the power section and up through the portion of the drill string above the vibration tool.
- FIGS. 1A-1B are a cross-sectional view of a vibration assembly.
- FIG. 2 is a top view of a rotating valve segment of the vibration assembly.
- FIG. 3 is a top view of a stationary valve segment of the vibration assembly.
- FIGS. 4A-4C are another cross-sectional view of the vibration assembly.
- FIGS. 5A-5D are a cross-sectional view of the vibration assembly including a shock assembly.
- FIGS. 6A-6B are a cross-sectional view of an alternate embodiment of the vibration assembly.
- FIG. 7 is a top view of a stationary valve segment of the vibration assembly of FIGS. 6A-6B .
- FIG. 8 is a top view of a rotating valve segment of the vibration assembly of FIGS. 6A-6B .
- FIGS. 9A-9C are a cross-sectional view of a wear resistant vibration assembly.
- FIG. 10 is a detail cross-sectional view of the valve of the wear resistant vibration assembly in FIGS. 9A-9C .
- FIG. 11 is a detail cross-sectional view of an alternate valve of the wear resistant vibration assembly.
- FIG. 12 is a cross-sectional view of an inner sleeve and an outer sleeve of the valve in the wear resistant vibration assembly taken along line A-A in FIG. 10 .
- FIG. 13 is a cross-sectional view of an alternate inner sleeve and outer sleeve taken along line A-A in FIG. 10 .
- FIG. 14 is a cross-sectional view of a second alternate inner sleeve and outer sleeve taken along line A-A in FIG. 10 .
- FIG. 15 is a cross-sectional view of a third alternate inner sleeve and outer sleeve taken along line A-A in FIG. 10 .
- FIG. 16 is a detail cross-sectional view of a lower thrust bearing of the wear resistant vibration assembly.
- FIG. 17 is a detail cross-sectional view of an alternate lower thrust bearing.
- a vibration assembly of the present disclosure may be attached to a drill string and lowered into a wellbore.
- the vibration assembly may include a valve positioned above a power section.
- the power section may be a positive displacement power section, a turbine, or any other hydraulic motor mechanism for generating torque with a fluid flow.
- the power section is a positive displacement power section including a rotor disposed at least partially within a stator.
- the rotor is configured to rotate within the stator as a fluid flows through the vibration assembly.
- the valve may include a rotating valve segment and a stationary valve segment each including at least one fluid passage.
- the rotating valve segment is configured to rotate with rotation of the rotor, while the stationary valve segment remains fixed (i.e., does not rotate).
- the fluid passage of the rotating valve segment In an open position, the fluid passage of the rotating valve segment is aligned with the fluid passage of the stationary valve segment, and the fluid flows through these fluid passages of the valve.
- a restricted position the fluid passage of the rotating valve segment is not aligned with a fluid passage in the stationary valve segment (e.g., at least partially unaligned), thereby temporarily restricting the fluid flow through the valve.
- the flow restriction creates a pressure pulse or waterhammer that is transmitted upstream thereby stretching and retracting a drill string or coiled tubing line above the vibration assembly. Because the valve is positioned above the power section, the vibration assembly of the present disclosure transmits a pressure pulse to the drill string above more efficiently than conventional vibration tools.
- the vibration assembly may also include a shock assembly disposed at an upper end of the vibration assembly.
- the shock assembly facilitates relative axial movement of the drill string above the vibration assembly relative to the drill string below the vibration assembly thereby vibrating the drill string above the vibration assembly.
- a flex shaft or stiff cable may interconnect the valve and the power section.
- An upper end of the flex shaft or cable may be attached to the rotating valve segment, and a lower end of the flex shaft or cable may be attached to the rotor.
- the flex shaft or cable transmits torque from the rotor to the rotating valve segment to rotate the rotating valve segment with the rotation of the rotor.
- FIGS. 1A-1B illustrate one embodiment of the vibration assembly of the present disclosure.
- Vibration assembly 10 includes valve 12 , flex shaft 14 attached to a lower end of valve 12 , rotor 16 attached to a lower end of flex shaft 14 , and stator 18 disposed at least partially around rotor 16 .
- Valve 12 includes rotating valve segment 20 and stationary valve segment 22 .
- rotating valve segment 20 is positioned below stationary valve segment 22 , but other embodiments may include rotating valve segment 20 positioned above stationary valve segment 22 .
- Vibration assembly 10 may also include one or more tubular housing segments having an inner bore, with valve 12 , flex shaft 14 , rotor 16 , and stator 18 disposed within the inner bore.
- rotating valve segment 20 may be formed of a plate or disc including fluid passages 24 and 26 and central passage 28 .
- Stationary valve segment 22 may be formed of a plate or disc including fluid passages 30 and 32 and central passage 34 .
- passages 24 , 26 of rotating valve segment 20 are at least partially aligned with passages 30 , 32 of stationary valve segment 22 to allow a fluid to flow through valve 12 .
- the fluid flow may be temporarily restricted when passages 24 , 26 of rotating valve segment 20 are not aligned with passages 30 , 32 of stationary valve segment 22 . In this restricted position, the fluid flows through central passages 28 , 34 of rotating valve segment 20 and stationary valve segment 22 , respectively, to guarantee a minimum fluid flow to drive rotor 16 in stator 18 .
- rotating and stationary valve segments 20 , 22 include no central passages. Instead, the fluid passages of valve segments 20 , 22 are arranged such that at least one fluid passage of rotating valve segment 20 is partially aligned with a fluid passage of stationary valve segment 22 in the restricted position to guarantee a minimum fluid flow to drive rotor 16 in stator 18 .
- rotating valve segment 20 is secured to upper end 36 of flex shaft 14 such that rotating valve segment 20 rotates with flex shaft 14 .
- Central bore 38 of flex shaft 14 extends from upper end 36 to fluid passages 40 .
- Flex shaft 14 may include any number of fluid passages 40 to support the fluid flow through central bore 38 .
- the upper portion of flex shaft 14 surrounding central bore 38 may be formed of two or more segments, such as segments 42 , 44 .
- Thrust bearings 46 and radial bearings 48 may be disposed around segment 42 , and radial bearings 48 may abut an upper end of segment 44 .
- Stationary valve segment 22 is disposed between rotating valve segment 20 and nut 50 .
- Compression sleeve 52 may be disposed around stationary valve segment 22 and segment 42 of the upper portion of flex shaft 14 .
- An upper end of compression sleeve 52 may abut a lower end of nut 50 .
- Stationary valve segment 22 may be maintained in a non-rotating and stationary position by nut 50 .
- Radial bearings 48 may be maintained by compression sleeve 52 and nut 50 .
- flex shaft 14 may be formed of a rod or bar of sufficient length to provide flexibility for offsetting the eccentric motion of a multi-lobe rotor.
- Lower end 54 of flex shaft 14 may be secured to upper end 56 of rotor 16 .
- flex shaft 14 and rotor 16 may be threadedly connected. In this way, rotor 16 is suspended within stator 18 by flex shaft 14 .
- Housing 60 may include inner bore 61 .
- Housing 60 may be formed of housing segments 62 , 64 , 66 , and 68 , each including an inner bore.
- Nut 50 may be threadedly connected to the inner bore of housing segment 64 .
- Radial bearings 48 may engage a shoulder of housing segment 64 to support thrust bearings 46 , compression sleeve 52 , and stationary valve segment 22 , thereby operatively suspending flex shaft 14 and rotor 16 within inner bore 61 of housing 60 .
- Stator 18 may be secured within the inner bore of housing segment 66 .
- Housing segment 68 may include safety shoulder 70 designed to catch rotor 16 if rotor 16 is disconnected from flex shaft 14 or if flex shaft 14 is disconnected from housing segment 64 .
- Housing segment 68 may further include fluid bypass 72 to allow a fluid flow through inner bore 61 if rotor 16 engages safety shoulder 70 .
- vibration assembly 10 may be secured within a drill string by threadedly connecting housing segment 62 to a first drill string segment and connecting housing segment 68 to a second drill string segment.
- a fluid may be pumped through an inner bore of the first drill string segment and into inner bore 61 of housing 60 .
- valve 12 With valve 12 in the open position, the fluid may flow through fluid passages 30 , 32 of stationary valve segment 22 and fluid passages 24 , 26 of rotating valve segment 20 .
- the fluid flow may continue into central bore 38 of flex shaft 14 and out through fluid passages 40 of flex shaft 14 to return to inner bore 61 of housing 60 .
- the fluid may flow around flex shaft 14 in inner bore 61 of housing 60 and around upper end 56 of rotor 16 .
- Rotor 16 includes a number of lobes that correlate with a certain number of cavities of stator 18 .
- stator 18 When the fluid reaches stator 18 , the fluid flows through the cavities between stator 18 and rotor 16 . This fluid flow causes rotor 16 to rotate within stator 18 . In this way, rotor 16 and stator 18 form a positive displacement power section.
- the fluid flow exits at lower end 74 of stator 18 to return to inner bore 61 of housing 60 and continue flowing into an inner bore of the second drill string segment below vibration assembly 10 .
- stator 18 rotates rotor 16
- flex shaft 14 and rotating valve segment 20 are rotated as torque is transmitted to these elements.
- Rotating valve segment 20 rotates relative to stationary valve segment 22 , which cycles valve 12 between the open position and the restricted position in which fluid flow is limited to central passages 28 , 34 of rotating and stationary valve segments 20 , 22 .
- the fluid flow restriction generates a pressure pulse or waterhammer that is transmitted upstream to the drill string above vibration assembly 10 .
- the repeated pressure pulse generation causes a stretching and retracting in the drill string above vibration assembly 10 , thereby facilitating vibration and easing the movement of the drill string through a wellbore.
- the vibration may reduce friction between an outer surface of the drill string and an inner surface of the wellbore.
- the power section is formed of a turbine or any other hydraulic motor mechanism for generating torque with a fluid flow.
- the power section includes at least one rotor element configured to rotate with the fluid flow through the power section.
- the rotor element is operatively connected to the rotating valve segment, such that the rotating valve segment rotates with a rotation of the rotor.
- FIGS. 5A-5D illustrate another alternate embodiment of the vibration assembly of the present disclosure.
- Vibration assembly 80 includes the same features described above in connection with vibration assembly 10 , with the same reference numbers indicating the same structure and function described above.
- Vibration assembly 80 further includes an integrally formed shock assembly 82 designed to facilitate axial movement in the adjacent drill string with the pressure pulse transmitted by vibration assembly 80 .
- a separate shock assembly may be placed above the vibration assembly.
- the vibration assembly may function without a shock assembly, such as applications in which the vibration assembly is used with coiled tubing.
- shock assembly 82 may include first sub 84 and mandrel 86 at least partially slidingly disposed within inner bore 88 of first sub 84 .
- Upper end 90 of mandrel 86 extends above upper end 92 of first sub 84 .
- Shock assembly 82 may also include piston 98 and spring 100 .
- Piston 98 may be threadedly secured to lower end 106 of mandrel 86 .
- Spring 100 is disposed around mandrel 86 and within inner bore 88 of first sub 84 . Spring 100 is configured to be compressed with axial movement of mandrel 86 relative to first sub 84 in both directions.
- Shock assembly 82 may further include flex sub 118 .
- a lower end of flex sub 118 may be secured to the upper end of housing segment 62 above valve 12 . In this way, shock assembly 82 is disposed above housing 60 . An upper end of flex sub 118 may be secured to a lower end of first sub 84 of shock assembly 82 . An upper end 90 of mandrel 86 of shock assembly 82 may be secured to a drill string segment to position vibration assembly 80 in the drill string. A pressure pulse generated by valve 12 may cause mandrel 86 to move relative to first sub 84 in two directions along an axis (i.e., in both axial directions).
- FIGS. 6A-6B illustrate another alternate embodiment of the vibration assembly of the present disclosure, with the same reference numbers indicating the same structure and function described above.
- Vibration assembly 130 includes valve 132 disposed above rotor 16 and stator 18 all disposed within inner bore 61 of housing 60 , which includes housing segments 62 , 134 , 66 , and 68 .
- Vibration assembly 130 also includes adapter 136 and flex line 138 interconnecting valve 132 and rotor 16 .
- Lower end 140 of adapter 136 is secured to upper end 56 of rotor 16
- upper end 142 of adapter 136 is secured to lower end 144 of flex line 138 .
- Valve 132 may include rotating valve segment 146 and stationary valve segment 148 .
- Stationary valve segment 148 may engage and be supported by inner shoulder 149 of housing segment 134 .
- Rotating valve segment 146 may be positioned above stationary valve segment 148 and below nut 50 , which is threadedly connected to a surface of the inner bore of housing segment 134 .
- rotor 16 is suspended within inner bore 61 of housing 60 and within stator 18 by adapter 136 , flex line 138 , and rotating valve segment 146 .
- Outer surface 150 of rotating valve segment 146 is radially guided by radial sleeve 151 .
- radial sleeve 151 abuts a lower end of nut 50
- a lower end of radial sleeve 151 abuts an upper end of stationary valve segment 148 .
- Stationary valve segment 148 may be maintained in a non-rotating and stationary position by a compression force applied by nut 50 through radial sleeve 151 .
- stationary valve segment 148 may be formed of a plate or disc including fluid passages 152 and 153 and central aperture 154 .
- Rotating valve segment 146 may be formed of a plate or disc including fluid passage 156 and central aperture 158 .
- passage 156 of rotating valve segment 146 In an open position, passage 156 of rotating valve segment 146 is at least partially aligned with passage 152 or passage 153 of stationary valve segment 148 to allow a fluid to flow through valve 132 .
- passage 156 of rotating valve segment 146 In a restricted position, passage 156 of rotating valve segment 146 is unaligned (at least partially) with passages 152 , 153 of stationary valve segment 148 .
- flex line 138 is disposed through central aperture 154 of stationary valve segment 148 .
- Upper end 160 of flex line 138 is secured to central aperture 158 of rotating valve segment 146 . Due to the pressure drop generated by rotor 16 , flex line 138 is in tension and stationary valve segment 148 functions as a thrust bearing acting against rotating valve segment 146 .
- Flex line 138 may be formed of a cable, rope, rod, chain, or any other structure having a stiffness sufficient to transmit torque between adapter 136 and rotating valve segment 146 .
- flex line 138 may be formed of a steel rope or cable.
- Flex line 138 may be secured to central aperture 158 by clamping, braising, wedging, with fixed bolts, or any other suitable means. Rotation of rotor 16 may rotate adapter 136 , flex line 138 , and rotating valve segment 146 .
- the suspended arrangement of rotor 16 within inner bore 61 of housing 62 allows for the use of flex line 138 between shaft 16 and valve 132 (instead of a rigid flex shaft), which reduces the overall length and weight of vibration assembly 130 over conventional vibration tools.
- Vibration assembly 130 may be secured within a drill string by threadedly connecting housing segment 62 to a first drill string segment and connecting housing segment 68 to a second drill string segment.
- a fluid may be pumped through an inner bore of the first drill string segment and into inner bore 61 of housing 60 .
- valve 132 With valve 132 in the open position, the fluid may flow through fluid passage 156 of rotating valve segment 146 and fluid passage 152 or 153 of stationary valve segment 148 .
- the fluid flow may continue into inner bore 61 of housing 60 around flex line 138 , around adapter 135 , and around upper end 56 of rotor 16 .
- stator 18 As the fluid flow through stator 18 rotates rotor 16 (as described above), adapter 136 , flex line 138 , and rotating valve segment 146 are rotated as torque is transmitted to these elements.
- Rotating valve segment 146 rotates relative to stationary valve segment 148 , which cycles valve 132 between the open position and the restricted position in which fluid flow through valve 132 is restricted.
- the fluid flow restriction generates a pressure pulse or waterhammer that is transmitted upstream to the drill string above vibration assembly 130 .
- the repeated pressure pulse generation causes a stretching and retracting of the drill string initiating vibration in the drill string above vibration assembly 130 , thereby facilitating and easing the movement of the drill string through a wellbore.
- the vibration may reduce friction between an outer surface of the drill string and an inner surface of the wellbore.
- vibration assembly 130 further includes a shock assembly, such as shock assembly 82 .
- the shock assembly facilitates axial movement (in both directions) of the drill string above vibration assembly 130 relative to the drill string below vibration assembly 130 .
- a valve In conventional vibration tools, a valve is positioned below a positive displacement power section. A pressure pulse generated in the valve of conventional vibration tools must be transmitted through the positive displacement power section before being transmitted to the drill string above. Because power sections are designed to convert hydraulic energy into mechanical energy, the positive displacement power sections of conventional vibration tools use a portion of the hydraulic energy of the pressure pulse generated by the valve below by converting an amount of the hydraulic energy into mechanical energy to overcome friction between the rotor and the stator, which is defined by the mechanical efficiency of the positive displacement power section itself. Additionally, the rubber or other flexible material of the stator in conventional vibration tools is compressed when in contact with the rotor, which dampens the magnitude of the pressure pulse as the pressure pulse is forced to travel through the positive displacement power section before being transmitted to the drill string above.
- a valve is disposed above a power section.
- the pressure pulse generated by the valve is transmitted to the drill string above without traveling across the power section.
- the vibration assembly of the present disclosure transmits an unobstructed pressure pulse or waterhammer to the drill string or coiled tubing above. Accordingly, the vibration assembly of the present disclosure transmits the pressure pulse or waterhammer and vibration energy to the drill string above more efficiently than conventional vibration tools.
- a wear resistant vibration assembly may be designed to prevent separation between a rotating valve segment and a non-rotating valve segment.
- the wear resistant vibration assembly may include a lower thrust bearing at the lower end of the rotor. The lower thrust bearing may prevent axial movement of the rotor, flex shaft, and valve segments as portions of the thrust bearings are worn through use.
- the wear resistant vibration assembly may include a non-rotating valve segment positioned above a rotating valve segment, with the non-rotating valve segment configured to move axially within a predetermined range without rotating (i.e., an axially sliding non-rotating valve segment).
- the wear resistant vibration assembly includes both a lower thrust bearing and a non-rotating valve segment configured to move axially within a predetermined range without rotating.
- FIGS. 9A-9C illustrate wear resistant vibration assembly 200 .
- the components of wear resistant vibration assembly 200 include the same features described above in connection with the corresponding components of vibration assembly 10 .
- Vibration assembly 200 includes non-rotating valve segment 202 positioned above rotating valve segment 204 .
- Rotating valve segment 204 may be rotationally secured to upper end 206 of mandrel 234 .
- Mandrel 234 is connected to flex shaft 208 such that rotation of flex shaft 208 rotates mandrel 234 and rotating valve segment 204 .
- Mandrel 234 and flex shaft 208 may be threadedly secured to one another.
- Lower end 210 of flex shaft 208 may be secured to upper end 212 of rotor 214 , which may be at least partially disposed through stator 216 .
- Valve segments 202 and 204 , mandrel 234 , flex shaft 208 , rotor 214 , and stator 216 are each disposed within a central bore of a housing, which may be formed of housing segments.
- housing segment 218 may be disposed above valve segments 202 and 204 .
- Valve segments 202 and 204 , mandrel 234 , and flex shaft 208 may be disposed through central bore 220 of housing segment 222 .
- Lower end 210 of flex shaft 208 , rotor 214 , and stator 216 may be disposed within central bore 224 of housing segment 226 .
- Housing segment 228 may be disposed below lower end 230 of rotor 214 . Adjacent housing segments may be threadedly secured to one another.
- Central bore 231 of mandrel 234 extends from upper end 206 to central bore 233 of flex shaft 208 , which extends to fluid passages 232 of flex shaft 208 .
- Flex shaft 208 may include any number of fluid passages 232 to support fluid flow through central bores 231 and 233 of mandrel 234 and flex shaft 208 , respectively.
- the upper portion 236 of flex shaft 208 surrounding central bore 233 is connected to lower end of mandrel 234 .
- Thrust bearings 238 and radial bearings 240 , 242 may be disposed around mandrel 234 .
- Thrust bearings 238 may include inner races 244 , outer races 246 , and roller elements 248 disposed in partial cavities between inner and outer races 244 and 246 .
- Radial bearings 240 , 242 may abut an upper end of upper portion 236 of flex shaft 208 .
- flex shaft 208 may be formed of a rod or bar of sufficient length to provide flexibility for offsetting the eccentric motion of a multi-lobe rotor.
- Valve segments 202 and 204 may each be formed of a plate or disc including a central passage and one or more fluid passages.
- a fluid passage of valve segment 202 is at least partially aligned with a fluid passage of valve segment 204 to allow a fluid to flow through the valve assembly.
- the fluid flow may be temporarily restricted when rotating valve segment 204 rotates such that the fluid passage of valve segment 204 is not aligned with the fluid passage of valve segment 202 .
- a minimum amount of fluid may flow through the central apertures of valve segments 202 and 204 to drive rotor 214 in stator 216 .
- non-rotating valve segment 202 may be disposed above rotating valve segment 204 and upper end 206 of mandrel 234 .
- Inner sleeve 250 may be disposed around non-rotating valve 202
- outer sleeve 252 may be disposed around inner sleeve 250 .
- Inner sleeve 250 may include upper shoulder 254 configured to retain non-rotating valve segment 202 (i.e., to prevent non-rotating valve segment 202 from traveling through the upper end of the bore in inner sleeve 250 ).
- Nut 256 may be secured above non-rotating valve segment 202 within housing segment 222 .
- Nut 256 may be threadedly connected within housing segment 222 to secure outer sleeve 252 , compression sleeve 258 disposed around upper end 206 of mandrel 234 , thrust bearings 238 , and radial bearings 242 in place within housing segment 222 , as illustrated.
- non-rotating valve segment 202 may be maintained in a non-rotating position by nut 50 , outer sleeve 252 , and inner sleeve 250 . Fluid flowing through the central bore of nut 256 may exert a downstream force on shoulder 254 of inner sleeve 250 and non-rotating valve segment 202 such that non-rotating valve segment 202 remains in contact with rotating valve segment 204 .
- wear resistant vibration assembly 200 further includes one or more springs 260 disposed between a lower end of nut 256 and an upper surface of inner sleeve 250 .
- the one or more springs 260 bias inner sleeve 250 and non-rotating valve segment 202 in a downstream direction toward rotating valve segment 204 .
- vibration assembly 200 is configured to maintain contact between the two valve segments even if rotating valve segment 204 moves in a downstream direction within housing segment 222 due to wear of thrust bearings 238 .
- inner sleeve 250 and non-rotating valve segment 202 are configured to slide axially within outer sleeve 252 without rotation.
- Inner sleeve 250 and outer sleeve 252 each includes a cooperating alignment mechanism configured to allow relative axial sliding and to prevent relative rotation between inner sleeve 250 and outer sleeve 252 .
- the cooperating alignment mechanism of inner sleeve 250 and outer sleeve 252 includes axial grooves 264 in inner sleeve 250 and outer sleeve 252 .
- An elongated pin 266 is positioned within each set of the aligned axial grooves 264 .
- Axial grooves 264 of inner sleeve 250 may slide along elongated pin 266 to allow inner sleeve 250 to move axially relative to outer sleeve 252 without relative rotation between the sleeves.
- the cooperating alignment mechanism of inner sleeve 250 includes elongated recess 268
- the cooperating alignment mechanism of outer sleeve 252 includes pin 270 secured within aperture 272 .
- Inner sleeve 250 may slide axially within outer sleeve 252 , with pin 270 engaging elongated recess 268 to prevent relative rotation between inner sleeve 250 and outer sleeve 252 .
- the cooperating alignment mechanism of inner sleeve 250 includes flat outer surface 274
- the cooperating alignment mechanism of outer sleeve 252 includes reciprocal flat inner surface 276 configured to engage flat outer surface 274 of inner sleeve 250 .
- Inner sleeve 250 may slide axially within outer sleeve 252 with flat surfaces 274 , 276 preventing relative rotation between inner sleeve 250 and outer sleeve 252 .
- the cooperating alignment mechanism of inner sleeve 250 includes spline profile outer surface 278
- the cooperating alignment mechanism of outer sleeve 252 includes spline profile inner surface 280 that is reciprocal to and configured to engage spline profile outer surface 278 of inner sleeve 250
- Inner sleeve 250 may slide axially within outer sleeve 252 with spline profile surfaces 278 , 280 preventing relative rotation between inner sleeve 250 and outer sleeve 252 .
- wear resistant vibration assembly 200 may also include lower thrust bearing 282 at lower end 230 of rotor 214 .
- Lower thrust bearing 282 takes up an axial load to reduce wear of components within thrust bearings 238 , thereby preventing axial movements of rotor 214 , flex shaft 208 , mandrel 234 , and valve segment 204 .
- Lower thrust bearing 282 may be formed of a rotor bearing disposed above and in contact with a second bearing.
- the rotor bearing and the second bearing are each a thrust bearing.
- the rotor bearing may be housing within a cavity in lower end 230 of rotor 214 .
- a lower surface of lower end 230 may form the rotor bearing.
- the second bearing may be housed within a cavity in an upper end of plug 286 .
- an upper surface of plug 286 may form the second bearing.
- Plug 286 may include an upper surface above fluid passages 288 , which lead to central bore 290 .
- Plug 286 is disposed below rotor 214 with the lower end of plug 286 secured within housing segment 228 .
- Fluid passages 288 may be disposed above the upper end of housing segment 228 .
- Plug 286 may include any number of fluid passages 288 , such as between 1 and 10 fluid passages 288 , or any subrange therein.
- a diameter of central bore 290 of plug 286 is about equal to a diameter of central bore 292 of housing segment 228 .
- a fluid exiting the cavities between rotor 214 and stator 216 may flow around the upper end of plug 286 , flow through fluid passages 288 , flow through central bore 290 of plug 286 , and into central bore 292 of housing segment 228 .
- lower thrust bearing 282 includes rotor bearing 294 housed within a cavity in lower end 230 of rotor 214 and second bearing 296 housed within a cavity in the upper end of plug 286 .
- Rotor bearing 294 and second bearing 296 may be formed of blocks formed of an abrasion resistant metal, tungsten carbide, silicon carbide, polycrystalline diamond compact (PDC), grit hot-pressed inserts (GHI), or natural diamond.
- FIG. 17 illustrates another embodiment of lower thrust bearing 282 .
- Lower thrust bearing 282 may include rotor bearing 294 in a cavity in lower end 230 of rotor 214 , second bearing 296 within a cavity in the upper end of plug 286 , and spring 298 disposed below second bearing 296 in the cavity in the upper end of plug 286 .
- spring 298 biases second bearing 296 in a direction toward rotor bearing 294 to ensure continuous contact between second bearing 296 and rotor bearing 294 .
- Spring 298 may be formed of a coil spring, coned-disc spring, conical spring washer, disc spring, Belleville spring, or cupped spring washer.
- wear resistant vibration assembly 200 may include no plug 286 and lower thrust bearing 282 may include rotor bearing 294 in a cavity in lower end 230 of rotor 214 and second bearing 296 secured to housing segment 228 such that rotor bearing 294 and the second bearing 296 are in continuous contact.
- second bearing 296 may be secured to housing segment 228 in numerous ways (e.g., with bolts, pins, screws, brazed, welded, shrink-fit arrangement, or any other fastening device) and housing segment 228 may be modified to provide for fluid flow around second bearing 296 and into central bore 292 of housing segment 228 .
- lower thrust bearing 282 prevents axial movement of rotor 214 , flex shaft 208 , mandrel 234 , and valve segment 204 to prevent separation between valve segments 202 and 204 .
- wear resistant vibration assembly 200 includes an axially sliding non-rotating valve segment without lower thrust bearing 282 . In another alternate embodiment, wear resistant vibration assembly 200 includes lower thrust bearing 282 in addition to an axially sliding non-rotating valve segment.
- Wear resistant vibration assembly 200 may be secured within a drill string by threadedly connecting housing segment 218 to a first drill string segment and connecting housing segment 228 to a second drill string segment.
- a fluid may be pumped through an inner bore of the first drill string segment and into the inner bore of housing segment 218 . With the valve in the open position, the fluid may flow through the fluid passages of non-rotating valve segment 202 . The fluid flow may continue into inner bore 231 of mandrel 234 and inner bore 233 of flex shaft 208 , through fluid passages 232 of flex shaft 208 , into inner bore 220 of housing segment 222 , around the lower portion of flex shaft 208 , and around upper end 212 of rotor 214 .
- stator 216 rotates rotor 214 , which causes flex shaft 208 , mandrel 234 , and rotating valve segment 204 to rotate as torque is transmitted to these elements.
- Rotating valve segment 204 rotates relative to non-rotating valve segment 202 , which cycles the valve between the open position and the restricted position in which fluid flow through the valve is restricted.
- the fluid flow restriction generates a pressure pulse or waterhammer that is transmitted upstream to the drill string above wear resistant vibration assembly 200 .
- the repeated pressure pulse generation causes a stretching and retracting of the drill string initiating vibration in the drill string above assembly 200 , thereby facilitating and easing the movement of the drill string through a wellbore.
- the vibration may reduce friction between an outer surface of the drill string and an inner surface of the wellbore.
- Lower thrust bearing 282 reduces the axial load taken up by thrust bearings 238 . In this way, lower thrust bearing 282 reduces the wear on the components of thrust bearings 238 . Additionally, as the components of thrust bearings 238 are worn through extended use, the configuration of inner sleeve 250 and outer sleeve 252 surrounding non-rotating valve segment 202 allows non-rotating valve segment 202 to maintain contact with rotating valve segment 204 , thus continuing to create the pressure pulses as the fluid flow is temporarily restricted.
- drill string shall include a series of drill string segments and a coiled tubing line.
Abstract
Description
- In the drilling of oil and gas wells, a downhole drilling motor and a drill bit are attached to the end of a drill string. Most downhole drilling motors include a rotor rotating within a stator. The rotation of the rotor provides a vibration to the adjacent drill bit as it cuts through the subterranean formation to drill the wellbore. The drill string slides through the higher portions of the wellbore as the drill bit at the end of the drill string extends the wellbore deeper into the formation. A vibration tool is sometimes attached to the drill string a distance above the drill bit (e.g., 800-1,500 feet above the drill bit). The vibration tool provides vibration to the portions of the drill string above the vibration tool, thereby facilitating the movement of the drill string through the wellbore.
- Conventional vibration tools include a power section made of a rotor rotating within a stator and a valve positioned below the rotor. As the rotor rotates, the valve periodically restricts fluid flow through the vibration tool, which creates a pressure pulse or waterhammer that is transmitted through the power section and up through the portion of the drill string above the vibration tool.
-
FIGS. 1A-1B are a cross-sectional view of a vibration assembly. -
FIG. 2 is a top view of a rotating valve segment of the vibration assembly. -
FIG. 3 is a top view of a stationary valve segment of the vibration assembly. -
FIGS. 4A-4C are another cross-sectional view of the vibration assembly. -
FIGS. 5A-5D are a cross-sectional view of the vibration assembly including a shock assembly. -
FIGS. 6A-6B are a cross-sectional view of an alternate embodiment of the vibration assembly. -
FIG. 7 is a top view of a stationary valve segment of the vibration assembly ofFIGS. 6A-6B . -
FIG. 8 is a top view of a rotating valve segment of the vibration assembly ofFIGS. 6A-6B . -
FIGS. 9A-9C are a cross-sectional view of a wear resistant vibration assembly. -
FIG. 10 is a detail cross-sectional view of the valve of the wear resistant vibration assembly inFIGS. 9A-9C . -
FIG. 11 is a detail cross-sectional view of an alternate valve of the wear resistant vibration assembly. -
FIG. 12 is a cross-sectional view of an inner sleeve and an outer sleeve of the valve in the wear resistant vibration assembly taken along line A-A inFIG. 10 . -
FIG. 13 is a cross-sectional view of an alternate inner sleeve and outer sleeve taken along line A-A inFIG. 10 . -
FIG. 14 is a cross-sectional view of a second alternate inner sleeve and outer sleeve taken along line A-A inFIG. 10 . -
FIG. 15 is a cross-sectional view of a third alternate inner sleeve and outer sleeve taken along line A-A inFIG. 10 . -
FIG. 16 is a detail cross-sectional view of a lower thrust bearing of the wear resistant vibration assembly. -
FIG. 17 is a detail cross-sectional view of an alternate lower thrust bearing. - A vibration assembly of the present disclosure may be attached to a drill string and lowered into a wellbore. The vibration assembly may include a valve positioned above a power section. The power section may be a positive displacement power section, a turbine, or any other hydraulic motor mechanism for generating torque with a fluid flow. In one embodiment, the power section is a positive displacement power section including a rotor disposed at least partially within a stator. The rotor is configured to rotate within the stator as a fluid flows through the vibration assembly. The valve may include a rotating valve segment and a stationary valve segment each including at least one fluid passage. The rotating valve segment is configured to rotate with rotation of the rotor, while the stationary valve segment remains fixed (i.e., does not rotate). In an open position, the fluid passage of the rotating valve segment is aligned with the fluid passage of the stationary valve segment, and the fluid flows through these fluid passages of the valve. In a restricted position, the fluid passage of the rotating valve segment is not aligned with a fluid passage in the stationary valve segment (e.g., at least partially unaligned), thereby temporarily restricting the fluid flow through the valve. The flow restriction creates a pressure pulse or waterhammer that is transmitted upstream thereby stretching and retracting a drill string or coiled tubing line above the vibration assembly. Because the valve is positioned above the power section, the vibration assembly of the present disclosure transmits a pressure pulse to the drill string above more efficiently than conventional vibration tools. In certain embodiments, the vibration assembly may also include a shock assembly disposed at an upper end of the vibration assembly. When present, the shock assembly facilitates relative axial movement of the drill string above the vibration assembly relative to the drill string below the vibration assembly thereby vibrating the drill string above the vibration assembly.
- In some embodiments, a flex shaft or stiff cable may interconnect the valve and the power section. An upper end of the flex shaft or cable may be attached to the rotating valve segment, and a lower end of the flex shaft or cable may be attached to the rotor. In this way, the flex shaft or cable transmits torque from the rotor to the rotating valve segment to rotate the rotating valve segment with the rotation of the rotor.
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FIGS. 1A-1B illustrate one embodiment of the vibration assembly of the present disclosure.Vibration assembly 10 includesvalve 12,flex shaft 14 attached to a lower end ofvalve 12,rotor 16 attached to a lower end offlex shaft 14, andstator 18 disposed at least partially aroundrotor 16.Valve 12 includesrotating valve segment 20 andstationary valve segment 22. In this embodiment,rotating valve segment 20 is positioned belowstationary valve segment 22, but other embodiments may includerotating valve segment 20 positioned abovestationary valve segment 22.Vibration assembly 10 may also include one or more tubular housing segments having an inner bore, withvalve 12,flex shaft 14,rotor 16, andstator 18 disposed within the inner bore. - With reference to
FIGS. 2 and 3 ,rotating valve segment 20 may be formed of a plate or disc includingfluid passages central passage 28.Stationary valve segment 22 may be formed of a plate or disc includingfluid passages central passage 34. In an open position,passages rotating valve segment 20 are at least partially aligned withpassages stationary valve segment 22 to allow a fluid to flow throughvalve 12. The fluid flow may be temporarily restricted whenpassages rotating valve segment 20 are not aligned withpassages stationary valve segment 22. In this restricted position, the fluid flows throughcentral passages rotating valve segment 20 andstationary valve segment 22, respectively, to guarantee a minimum fluid flow to driverotor 16 instator 18. - In other embodiments, rotating and
stationary valve segments valve segments valve segment 20 is partially aligned with a fluid passage ofstationary valve segment 22 in the restricted position to guarantee a minimum fluid flow to driverotor 16 instator 18. - Referring now to
FIGS. 4A-4C ,rotating valve segment 20 is secured toupper end 36 offlex shaft 14 such thatrotating valve segment 20 rotates withflex shaft 14. Central bore 38 offlex shaft 14 extends fromupper end 36 tofluid passages 40.Flex shaft 14 may include any number offluid passages 40 to support the fluid flow throughcentral bore 38. The upper portion offlex shaft 14 surroundingcentral bore 38 may be formed of two or more segments, such assegments 42, 44.Thrust bearings 46 andradial bearings 48 may be disposed aroundsegment 42, andradial bearings 48 may abut an upper end of segment 44.Stationary valve segment 22 is disposed betweenrotating valve segment 20 andnut 50.Compression sleeve 52 may be disposed aroundstationary valve segment 22 andsegment 42 of the upper portion offlex shaft 14. An upper end ofcompression sleeve 52 may abut a lower end ofnut 50.Stationary valve segment 22 may be maintained in a non-rotating and stationary position bynut 50.Radial bearings 48 may be maintained bycompression sleeve 52 andnut 50. Belowfluid passages 40,flex shaft 14 may be formed of a rod or bar of sufficient length to provide flexibility for offsetting the eccentric motion of a multi-lobe rotor.Lower end 54 offlex shaft 14 may be secured toupper end 56 ofrotor 16. In one embodiment,flex shaft 14 androtor 16 may be threadedly connected. In this way,rotor 16 is suspended withinstator 18 byflex shaft 14. -
Housing 60 may includeinner bore 61.Housing 60 may be formed ofhousing segments Nut 50 may be threadedly connected to the inner bore ofhousing segment 64.Radial bearings 48 may engage a shoulder ofhousing segment 64 to supportthrust bearings 46,compression sleeve 52, andstationary valve segment 22, thereby operatively suspendingflex shaft 14 androtor 16 withininner bore 61 ofhousing 60.Stator 18 may be secured within the inner bore ofhousing segment 66.Housing segment 68 may includesafety shoulder 70 designed to catchrotor 16 ifrotor 16 is disconnected fromflex shaft 14 or ifflex shaft 14 is disconnected fromhousing segment 64.Housing segment 68 may further includefluid bypass 72 to allow a fluid flow throughinner bore 61 ifrotor 16 engagessafety shoulder 70. - Referring still to
FIGS. 4A-4C ,vibration assembly 10 may be secured within a drill string by threadedly connectinghousing segment 62 to a first drill string segment and connectinghousing segment 68 to a second drill string segment. A fluid may be pumped through an inner bore of the first drill string segment and intoinner bore 61 ofhousing 60. Withvalve 12 in the open position, the fluid may flow throughfluid passages stationary valve segment 22 andfluid passages rotating valve segment 20. The fluid flow may continue intocentral bore 38 offlex shaft 14 and out throughfluid passages 40 offlex shaft 14 to return toinner bore 61 ofhousing 60. The fluid may flow aroundflex shaft 14 ininner bore 61 ofhousing 60 and aroundupper end 56 ofrotor 16.Rotor 16 includes a number of lobes that correlate with a certain number of cavities ofstator 18. When the fluid reachesstator 18, the fluid flows through the cavities betweenstator 18 androtor 16. This fluid flow causesrotor 16 to rotate withinstator 18. In this way,rotor 16 andstator 18 form a positive displacement power section. The fluid flow exits atlower end 74 ofstator 18 to return toinner bore 61 ofhousing 60 and continue flowing into an inner bore of the second drill string segment belowvibration assembly 10. - As the fluid flow through
stator 18 rotatesrotor 16,flex shaft 14 androtating valve segment 20 are rotated as torque is transmitted to these elements. Rotatingvalve segment 20 rotates relative tostationary valve segment 22, which cyclesvalve 12 between the open position and the restricted position in which fluid flow is limited tocentral passages stationary valve segments vibration assembly 10. The repeated pressure pulse generation causes a stretching and retracting in the drill string abovevibration assembly 10, thereby facilitating vibration and easing the movement of the drill string through a wellbore. The vibration may reduce friction between an outer surface of the drill string and an inner surface of the wellbore. - In an alternate embodiment, the power section is formed of a turbine or any other hydraulic motor mechanism for generating torque with a fluid flow. The power section includes at least one rotor element configured to rotate with the fluid flow through the power section. The rotor element is operatively connected to the rotating valve segment, such that the rotating valve segment rotates with a rotation of the rotor.
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FIGS. 5A-5D illustrate another alternate embodiment of the vibration assembly of the present disclosure.Vibration assembly 80 includes the same features described above in connection withvibration assembly 10, with the same reference numbers indicating the same structure and function described above.Vibration assembly 80 further includes an integrally formedshock assembly 82 designed to facilitate axial movement in the adjacent drill string with the pressure pulse transmitted byvibration assembly 80. In other embodiments, a separate shock assembly may be placed above the vibration assembly. In still other embodiments (as illustrated inFIGS. 1A-4C ), the vibration assembly may function without a shock assembly, such as applications in which the vibration assembly is used with coiled tubing. - In the embodiment illustrated in
FIGS. 5A-5D ,shock assembly 82 may includefirst sub 84 andmandrel 86 at least partially slidingly disposed withininner bore 88 offirst sub 84.Upper end 90 ofmandrel 86 extends aboveupper end 92 offirst sub 84.Shock assembly 82 may also includepiston 98 andspring 100.Piston 98 may be threadedly secured tolower end 106 ofmandrel 86.Spring 100 is disposed aroundmandrel 86 and withininner bore 88 offirst sub 84.Spring 100 is configured to be compressed with axial movement ofmandrel 86 relative tofirst sub 84 in both directions.Shock assembly 82 may further includeflex sub 118. A lower end offlex sub 118 may be secured to the upper end ofhousing segment 62 abovevalve 12. In this way,shock assembly 82 is disposed abovehousing 60. An upper end offlex sub 118 may be secured to a lower end offirst sub 84 ofshock assembly 82. Anupper end 90 ofmandrel 86 ofshock assembly 82 may be secured to a drill string segment to positionvibration assembly 80 in the drill string. A pressure pulse generated byvalve 12 may causemandrel 86 to move relative tofirst sub 84 in two directions along an axis (i.e., in both axial directions). -
FIGS. 6A-6B illustrate another alternate embodiment of the vibration assembly of the present disclosure, with the same reference numbers indicating the same structure and function described above.Vibration assembly 130 includesvalve 132 disposed aboverotor 16 andstator 18 all disposed withininner bore 61 ofhousing 60, which includeshousing segments Vibration assembly 130 also includesadapter 136 andflex line 138interconnecting valve 132 androtor 16.Lower end 140 ofadapter 136 is secured toupper end 56 ofrotor 16, andupper end 142 ofadapter 136 is secured tolower end 144 offlex line 138.Valve 132 may includerotating valve segment 146 andstationary valve segment 148.Stationary valve segment 148 may engage and be supported byinner shoulder 149 ofhousing segment 134. Rotatingvalve segment 146 may be positioned abovestationary valve segment 148 and belownut 50, which is threadedly connected to a surface of the inner bore ofhousing segment 134. In this way,rotor 16 is suspended withininner bore 61 ofhousing 60 and withinstator 18 byadapter 136,flex line 138, androtating valve segment 146.Outer surface 150 ofrotating valve segment 146 is radially guided byradial sleeve 151. An upper end ofradial sleeve 151 abuts a lower end ofnut 50, and a lower end ofradial sleeve 151 abuts an upper end ofstationary valve segment 148.Stationary valve segment 148 may be maintained in a non-rotating and stationary position by a compression force applied bynut 50 throughradial sleeve 151. - Referring now to
FIGS. 7 and 8 ,stationary valve segment 148 may be formed of a plate or disc includingfluid passages central aperture 154. Rotatingvalve segment 146 may be formed of a plate or disc includingfluid passage 156 andcentral aperture 158. In an open position,passage 156 ofrotating valve segment 146 is at least partially aligned withpassage 152 orpassage 153 ofstationary valve segment 148 to allow a fluid to flow throughvalve 132. In a restricted position,passage 156 ofrotating valve segment 146 is unaligned (at least partially) withpassages stationary valve segment 148. - With reference again to
FIGS. 6A-6B ,flex line 138 is disposed throughcentral aperture 154 ofstationary valve segment 148.Upper end 160 offlex line 138 is secured tocentral aperture 158 ofrotating valve segment 146. Due to the pressure drop generated byrotor 16,flex line 138 is in tension andstationary valve segment 148 functions as a thrust bearing acting againstrotating valve segment 146.Flex line 138 may be formed of a cable, rope, rod, chain, or any other structure having a stiffness sufficient to transmit torque betweenadapter 136 androtating valve segment 146. For example,flex line 138 may be formed of a steel rope or cable.Flex line 138 may be secured tocentral aperture 158 by clamping, braising, wedging, with fixed bolts, or any other suitable means. Rotation ofrotor 16 may rotateadapter 136,flex line 138, androtating valve segment 146. The suspended arrangement ofrotor 16 withininner bore 61 ofhousing 62 allows for the use offlex line 138 betweenshaft 16 and valve 132 (instead of a rigid flex shaft), which reduces the overall length and weight ofvibration assembly 130 over conventional vibration tools. -
Vibration assembly 130 may be secured within a drill string by threadedly connectinghousing segment 62 to a first drill string segment and connectinghousing segment 68 to a second drill string segment. A fluid may be pumped through an inner bore of the first drill string segment and intoinner bore 61 ofhousing 60. Withvalve 132 in the open position, the fluid may flow throughfluid passage 156 ofrotating valve segment 146 andfluid passage stationary valve segment 148. The fluid flow may continue intoinner bore 61 ofhousing 60 aroundflex line 138, around adapter 135, and aroundupper end 56 ofrotor 16. As the fluid flow throughstator 18 rotates rotor 16 (as described above),adapter 136,flex line 138, androtating valve segment 146 are rotated as torque is transmitted to these elements. Rotatingvalve segment 146 rotates relative tostationary valve segment 148, which cyclesvalve 132 between the open position and the restricted position in which fluid flow throughvalve 132 is restricted. The fluid flow restriction generates a pressure pulse or waterhammer that is transmitted upstream to the drill string abovevibration assembly 130. The repeated pressure pulse generation causes a stretching and retracting of the drill string initiating vibration in the drill string abovevibration assembly 130, thereby facilitating and easing the movement of the drill string through a wellbore. The vibration may reduce friction between an outer surface of the drill string and an inner surface of the wellbore. - In one embodiment,
vibration assembly 130 further includes a shock assembly, such asshock assembly 82. The shock assembly facilitates axial movement (in both directions) of the drill string abovevibration assembly 130 relative to the drill string belowvibration assembly 130. - In conventional vibration tools, a valve is positioned below a positive displacement power section. A pressure pulse generated in the valve of conventional vibration tools must be transmitted through the positive displacement power section before being transmitted to the drill string above. Because power sections are designed to convert hydraulic energy into mechanical energy, the positive displacement power sections of conventional vibration tools use a portion of the hydraulic energy of the pressure pulse generated by the valve below by converting an amount of the hydraulic energy into mechanical energy to overcome friction between the rotor and the stator, which is defined by the mechanical efficiency of the positive displacement power section itself. Additionally, the rubber or other flexible material of the stator in conventional vibration tools is compressed when in contact with the rotor, which dampens the magnitude of the pressure pulse as the pressure pulse is forced to travel through the positive displacement power section before being transmitted to the drill string above.
- In the vibration assembly of the present disclosure, a valve is disposed above a power section. The pressure pulse generated by the valve is transmitted to the drill string above without traveling across the power section. In other words, the vibration assembly of the present disclosure transmits an unobstructed pressure pulse or waterhammer to the drill string or coiled tubing above. Accordingly, the vibration assembly of the present disclosure transmits the pressure pulse or waterhammer and vibration energy to the drill string above more efficiently than conventional vibration tools.
- In a further embodiment, a wear resistant vibration assembly may be designed to prevent separation between a rotating valve segment and a non-rotating valve segment. In one embodiment, the wear resistant vibration assembly may include a lower thrust bearing at the lower end of the rotor. The lower thrust bearing may prevent axial movement of the rotor, flex shaft, and valve segments as portions of the thrust bearings are worn through use. In another embodiment, the wear resistant vibration assembly may include a non-rotating valve segment positioned above a rotating valve segment, with the non-rotating valve segment configured to move axially within a predetermined range without rotating (i.e., an axially sliding non-rotating valve segment). In yet another embodiment, the wear resistant vibration assembly includes both a lower thrust bearing and a non-rotating valve segment configured to move axially within a predetermined range without rotating.
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FIGS. 9A-9C illustrate wearresistant vibration assembly 200. Except as otherwise described, the components of wearresistant vibration assembly 200 include the same features described above in connection with the corresponding components ofvibration assembly 10.Vibration assembly 200 includesnon-rotating valve segment 202 positioned above rotatingvalve segment 204. Rotatingvalve segment 204 may be rotationally secured toupper end 206 ofmandrel 234.Mandrel 234 is connected to flex shaft 208 such that rotation of flex shaft 208 rotatesmandrel 234 androtating valve segment 204.Mandrel 234 and flex shaft 208 may be threadedly secured to one another. Lower end 210 of flex shaft 208 may be secured to upper end 212 ofrotor 214, which may be at least partially disposed throughstator 216. -
Valve segments mandrel 234, flex shaft 208,rotor 214, andstator 216 are each disposed within a central bore of a housing, which may be formed of housing segments. For example, housing segment 218 may be disposed abovevalve segments Valve segments mandrel 234, and flex shaft 208 may be disposed throughcentral bore 220 ofhousing segment 222. Lower end 210 of flex shaft 208,rotor 214, andstator 216 may be disposed within central bore 224 of housing segment 226.Housing segment 228 may be disposed below lower end 230 ofrotor 214. Adjacent housing segments may be threadedly secured to one another. - Central bore 231 of
mandrel 234 extends fromupper end 206 to central bore 233 of flex shaft 208, which extends tofluid passages 232 of flex shaft 208. Flex shaft 208 may include any number offluid passages 232 to support fluid flow throughcentral bores 231 and 233 ofmandrel 234 and flex shaft 208, respectively. Theupper portion 236 of flex shaft 208 surrounding central bore 233 is connected to lower end ofmandrel 234.Thrust bearings 238 andradial bearings mandrel 234.Thrust bearings 238 may include inner races 244,outer races 246, androller elements 248 disposed in partial cavities between inner andouter races 244 and 246.Radial bearings upper portion 236 of flex shaft 208. Belowfluid passages 232, flex shaft 208 may be formed of a rod or bar of sufficient length to provide flexibility for offsetting the eccentric motion of a multi-lobe rotor. -
Valve segments valve segment 202 is at least partially aligned with a fluid passage ofvalve segment 204 to allow a fluid to flow through the valve assembly. The fluid flow may be temporarily restricted when rotatingvalve segment 204 rotates such that the fluid passage ofvalve segment 204 is not aligned with the fluid passage ofvalve segment 202. In this closed position, a minimum amount of fluid may flow through the central apertures ofvalve segments rotor 214 instator 216. - Referring to
FIGS. 9A and 10 ,non-rotating valve segment 202 may be disposed aboverotating valve segment 204 andupper end 206 ofmandrel 234.Inner sleeve 250 may be disposed aroundnon-rotating valve 202, andouter sleeve 252 may be disposed aroundinner sleeve 250.Inner sleeve 250 may includeupper shoulder 254 configured to retain non-rotating valve segment 202 (i.e., to preventnon-rotating valve segment 202 from traveling through the upper end of the bore in inner sleeve 250).Nut 256 may be secured abovenon-rotating valve segment 202 withinhousing segment 222.Nut 256 may be threadedly connected withinhousing segment 222 to secureouter sleeve 252,compression sleeve 258 disposed aroundupper end 206 ofmandrel 234, thrustbearings 238, andradial bearings 242 in place withinhousing segment 222, as illustrated. - With reference now to
FIG. 10 ,non-rotating valve segment 202 may be maintained in a non-rotating position bynut 50,outer sleeve 252, andinner sleeve 250. Fluid flowing through the central bore ofnut 256 may exert a downstream force onshoulder 254 ofinner sleeve 250 andnon-rotating valve segment 202 such thatnon-rotating valve segment 202 remains in contact withrotating valve segment 204. - As illustrated in
FIG. 11 , in one embodiment, wearresistant vibration assembly 200 further includes one ormore springs 260 disposed between a lower end ofnut 256 and an upper surface ofinner sleeve 250. The one ormore springs 260 biasinner sleeve 250 andnon-rotating valve segment 202 in a downstream direction towardrotating valve segment 204. In both embodiments,vibration assembly 200 is configured to maintain contact between the two valve segments even if rotatingvalve segment 204 moves in a downstream direction withinhousing segment 222 due to wear ofthrust bearings 238. - With reference to
FIGS. 12-15 ,inner sleeve 250 andnon-rotating valve segment 202 are configured to slide axially withinouter sleeve 252 without rotation.Inner sleeve 250 andouter sleeve 252 each includes a cooperating alignment mechanism configured to allow relative axial sliding and to prevent relative rotation betweeninner sleeve 250 andouter sleeve 252. In the embodiment illustrated inFIG. 12 , the cooperating alignment mechanism ofinner sleeve 250 andouter sleeve 252 includesaxial grooves 264 ininner sleeve 250 andouter sleeve 252. Anelongated pin 266 is positioned within each set of the alignedaxial grooves 264.Axial grooves 264 ofinner sleeve 250 may slide alongelongated pin 266 to allowinner sleeve 250 to move axially relative toouter sleeve 252 without relative rotation between the sleeves. In a second embodiment illustrated inFIG. 13 , the cooperating alignment mechanism ofinner sleeve 250 includes elongated recess 268, and the cooperating alignment mechanism ofouter sleeve 252 includespin 270 secured withinaperture 272.Inner sleeve 250 may slide axially withinouter sleeve 252, withpin 270 engaging elongated recess 268 to prevent relative rotation betweeninner sleeve 250 andouter sleeve 252. In a third embodiment illustrated inFIG. 14 , the cooperating alignment mechanism ofinner sleeve 250 includes flat outer surface 274, and the cooperating alignment mechanism ofouter sleeve 252 includes reciprocal flat inner surface 276 configured to engage flat outer surface 274 ofinner sleeve 250.Inner sleeve 250 may slide axially withinouter sleeve 252 with flat surfaces 274, 276 preventing relative rotation betweeninner sleeve 250 andouter sleeve 252. In a fourth embodiment illustrated inFIG. 15 , the cooperating alignment mechanism ofinner sleeve 250 includes spline profileouter surface 278, and the cooperating alignment mechanism ofouter sleeve 252 includes spline profileinner surface 280 that is reciprocal to and configured to engage spline profileouter surface 278 ofinner sleeve 250.Inner sleeve 250 may slide axially withinouter sleeve 252 with spline profile surfaces 278, 280 preventing relative rotation betweeninner sleeve 250 andouter sleeve 252. - With reference again to
FIG. 9C , wearresistant vibration assembly 200 may also include lower thrust bearing 282 at lower end 230 ofrotor 214. Lower thrust bearing 282 takes up an axial load to reduce wear of components withinthrust bearings 238, thereby preventing axial movements ofrotor 214, flex shaft 208,mandrel 234, andvalve segment 204. - Lower thrust bearing 282 may be formed of a rotor bearing disposed above and in contact with a second bearing. The rotor bearing and the second bearing are each a thrust bearing. The rotor bearing may be housing within a cavity in lower end 230 of
rotor 214. Alternatively, a lower surface of lower end 230 may form the rotor bearing. The second bearing may be housed within a cavity in an upper end ofplug 286. Alternatively, an upper surface ofplug 286 may form the second bearing. - Plug 286 may include an upper surface above
fluid passages 288, which lead tocentral bore 290.Plug 286 is disposed belowrotor 214 with the lower end ofplug 286 secured withinhousing segment 228.Fluid passages 288 may be disposed above the upper end ofhousing segment 228. Plug 286 may include any number offluid passages 288, such as between 1 and 10fluid passages 288, or any subrange therein. In one embodiment, a diameter ofcentral bore 290 ofplug 286 is about equal to a diameter ofcentral bore 292 ofhousing segment 228. A fluid exiting the cavities betweenrotor 214 andstator 216 may flow around the upper end ofplug 286, flow throughfluid passages 288, flow throughcentral bore 290 ofplug 286, and intocentral bore 292 ofhousing segment 228. - In the embodiment illustrated in
FIGS. 9C and 16 , lower thrust bearing 282 includes rotor bearing 294 housed within a cavity in lower end 230 ofrotor 214 andsecond bearing 296 housed within a cavity in the upper end ofplug 286.Rotor bearing 294 andsecond bearing 296 may be formed of blocks formed of an abrasion resistant metal, tungsten carbide, silicon carbide, polycrystalline diamond compact (PDC), grit hot-pressed inserts (GHI), or natural diamond. -
FIG. 17 illustrates another embodiment of lower thrust bearing 282. Lower thrust bearing 282 may include rotor bearing 294 in a cavity in lower end 230 ofrotor 214,second bearing 296 within a cavity in the upper end ofplug 286, andspring 298 disposed belowsecond bearing 296 in the cavity in the upper end ofplug 286. In this embodiment,spring 298 biasessecond bearing 296 in a direction toward rotor bearing 294 to ensure continuous contact betweensecond bearing 296 androtor bearing 294.Spring 298 may be formed of a coil spring, coned-disc spring, conical spring washer, disc spring, Belleville spring, or cupped spring washer. - Alternatively, wear
resistant vibration assembly 200 may include noplug 286 and lower thrust bearing 282 may include rotor bearing 294 in a cavity in lower end 230 ofrotor 214 andsecond bearing 296 secured tohousing segment 228 such that rotor bearing 294 and thesecond bearing 296 are in continuous contact. As readily understood by a skilled artisan,second bearing 296 may be secured tohousing segment 228 in numerous ways (e.g., with bolts, pins, screws, brazed, welded, shrink-fit arrangement, or any other fastening device) andhousing segment 228 may be modified to provide for fluid flow aroundsecond bearing 296 and intocentral bore 292 ofhousing segment 228. - In each embodiment, lower thrust bearing 282 prevents axial movement of
rotor 214, flex shaft 208,mandrel 234, andvalve segment 204 to prevent separation betweenvalve segments - In one alternate embodiment, wear
resistant vibration assembly 200 includes an axially sliding non-rotating valve segment without lower thrust bearing 282. In another alternate embodiment, wearresistant vibration assembly 200 includes lower thrust bearing 282 in addition to an axially sliding non-rotating valve segment. - Wear
resistant vibration assembly 200 may be secured within a drill string by threadedly connecting housing segment 218 to a first drill string segment and connectinghousing segment 228 to a second drill string segment. A fluid may be pumped through an inner bore of the first drill string segment and into the inner bore of housing segment 218. With the valve in the open position, the fluid may flow through the fluid passages ofnon-rotating valve segment 202. The fluid flow may continue intoinner bore 231 ofmandrel 234 and inner bore 233 of flex shaft 208, throughfluid passages 232 of flex shaft 208, intoinner bore 220 ofhousing segment 222, around the lower portion of flex shaft 208, and around upper end 212 ofrotor 214. The fluid flow throughstator 216 rotatesrotor 214, which causes flex shaft 208,mandrel 234, androtating valve segment 204 to rotate as torque is transmitted to these elements. Rotatingvalve segment 204 rotates relative tonon-rotating valve segment 202, which cycles the valve between the open position and the restricted position in which fluid flow through the valve is restricted. The fluid flow restriction generates a pressure pulse or waterhammer that is transmitted upstream to the drill string above wearresistant vibration assembly 200. The repeated pressure pulse generation causes a stretching and retracting of the drill string initiating vibration in the drill string aboveassembly 200, thereby facilitating and easing the movement of the drill string through a wellbore. The vibration may reduce friction between an outer surface of the drill string and an inner surface of the wellbore. - Lower thrust bearing 282 reduces the axial load taken up by
thrust bearings 238. In this way, lower thrust bearing 282 reduces the wear on the components ofthrust bearings 238. Additionally, as the components ofthrust bearings 238 are worn through extended use, the configuration ofinner sleeve 250 andouter sleeve 252 surroundingnon-rotating valve segment 202 allowsnon-rotating valve segment 202 to maintain contact withrotating valve segment 204, thus continuing to create the pressure pulses as the fluid flow is temporarily restricted. - As used herein, “above” and any other indication of a greater height or latitude shall also mean upstream, and “below” and any other indication of a lesser height or latitude shall also mean downstream. As used herein, “drill string” shall include a series of drill string segments and a coiled tubing line.
- While preferred embodiments have been described, it is to be understood that the embodiments are illustrative only and that the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalents, many variations and modifications naturally occurring to those skilled in the art from a review hereof.
Claims (21)
Priority Applications (6)
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US16/401,594 US10829993B1 (en) | 2019-05-02 | 2019-05-02 | Wear resistant vibration assembly and method |
PCT/US2020/018070 WO2020222890A1 (en) | 2019-05-02 | 2020-02-13 | Wear resistant vibration assembly and method |
CA3136798A CA3136798A1 (en) | 2019-05-02 | 2020-02-13 | Wear resistant vibration assembly and method |
GB2213288.0A GB2608061B (en) | 2019-05-02 | 2020-02-13 | Wear resistant vibration assembly and method |
GB2114940.6A GB2596766B (en) | 2019-05-02 | 2020-02-13 | Wear resistant vibration assembly and method |
CN202080033081.9A CN113767208B (en) | 2019-05-02 | 2020-02-13 | Wear resistant vibration assembly and method |
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US16/401,594 US10829993B1 (en) | 2019-05-02 | 2019-05-02 | Wear resistant vibration assembly and method |
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US20200347676A1 true US20200347676A1 (en) | 2020-11-05 |
US10829993B1 US10829993B1 (en) | 2020-11-10 |
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US (1) | US10829993B1 (en) |
CN (1) | CN113767208B (en) |
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2019
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2020
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CN113767208A (en) | 2021-12-07 |
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CN113767208B (en) | 2024-03-22 |
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GB202213288D0 (en) | 2022-10-26 |
GB2596766B (en) | 2022-12-21 |
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