Downhole tool and actuation element

Abstract

A downhole circulation tool includes: a housing having an axially extending delivery bore for conveying a drilling mud flow therethrough, the housing having a circulation port for discharging drilling mud; and a valve member rotatably disposed within the housing, the valve member comprising a through-flow channel and a circulation channel. The valve member is rotatable between a through-flow position in which the through-flow channel is arranged to convey drilling mud flow from an upstream portion of the delivery bore to the downstream portion of the delivery bore, and a circulation position in which the circulation channel is arranged to convey drilling mud from the upstream portion of the delivery bore to the circulation port to discharge drilling mud from the housing. There is also disclosed a downhole tool comprising a unidirectional drive mechanism, an actuation element for a downhole tool, and a method of operating a downhole tool.

Claims

1. A downhole circulation tool comprising: a housing having an axially extending delivery bore for conveying a drilling mud flow therethrough, the housing having a circulation port for discharging drilling mud; and a valve member rotatably disposed within the housing, the valve member comprising a through-flow channel and a circulation channel; wherein the valve member is rotatable between a through-flow position in which the through-flow channel is arranged to convey drilling mud flow from an upstream portion of the delivery bore to the downstream portion of the delivery bore, and a circulation position in which the circulation channel is arranged to convey drilling mud from the upstream portion of the delivery bore to the circulation port to discharge drilling mud from the housing; wherein the circulation channel and through-flow channel of the valve member do not intersect one another.

2. A downhole circulation tool according to claim 1, wherein the valve member is a ball valve member.

3. A downhole circulation tool according to claim 1, wherein the valve member is configured to prevent drilling mud flow to the downstream portion of the delivery bore.

4. A downhole circulation tool according to claim 1, wherein there are a plurality of circulation channels, each arranged to deliver drilling mud to a respective circulation port in the housing when the valve member is in the circulation position.

5. A downhole circulation tool according to claim 1, wherein the or each circulation channel is arranged to turn the drilling mud flow flowing therethrough such that, in use, drilling mud is discharged to the respective circulation port along a circulation channel discharge direction having an axial component parallel and opposite to the direction of flow in the axially extending delivery bore.

6. A downhole circulation tool according to claim 1, wherein the or each circulation channel is configured so that, in use in the circulation position, drilling mud is discharged to the respective circulation port along a circulation channel discharge direction having a tangential component.

7. A downhole circulation tool according to claim 1, wherein the or each circulation channel is curved along its length.

8. A downhole circulation tool according to claim 1, wherein an opening of the through-flow channel and the or each circulation inlet are angularly spaced apart by substantially 90 with respect to a rotational axis of the valve member.

9. A downhole circulation tool according to claim 1, wherein there is a first circulation channel and a second circulation channel each having respective circulation inlets, wherein the first and second circulation channels do not intersect one another, and wherein the circulation inlet of the second circulation channel is antipodal with respect to the circulation inlet of the first circulation channel.

10. A downhole circulation tool according to claim 1, wherein the valve member comprises a plurality of circulation channels and wherein there are a corresponding plurality of circulation ports in the housing.

11. A downhole circulation tool according to claim 1, wherein the or each circulation port is configured to turn a drilling mud flow flowing therethrough.

12. A downhole circulation tool according to claim 1, wherein the or each circulation port is configured to discharge drilling mud along a port discharge direction having a tangential component and an axial component parallel and opposite to the direction of flow in the axially extending delivery bore.

13. A downhole circulation tool according to claim 1, wherein a component defining an upstream portion of the delivery bore adjacent to the valve member and/or a component defining a downstream portion of the delivery bore adjacent to the valve member is configured to seal with the valve member.

14. A downhole circulation tool according to claim 1, wherein the circulation channel is further defined as two circulation channels, the circulation channels sharing a common inlet and having separate outlets.

15. A downhole circulation tool according to claim 1, wherein the delivery bore has a diameter at the valve member, the through-flow channel has an inlet having the same diameter as the delivery bore at the valve member, and the circulation channel has an inlet having the same diameter as the delivery bore at the valve member.

Description

(1) The disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:

(2) FIG. 1 shows a cross-sectional view of a bore hole with a drill string installed for drilling, including a circulation tool;

(3) FIG. 2a shows a side view of a circulation tool according to the disclosure;

(4) FIG. 2b shows a cross-sectional side view of the circulation tool in the through flow configuration (section along A-A of FIG. 2a);

(5) FIG. 2c shows a cross-sectional side view of the circulation tool in the through flow configuration (section along B-B of FIG. 2b);

(6) FIG. 3 shows an exploded isometric view of a unidirectional drive for rotating the valve member of the circulation tool;

(7) FIG. 4 shows a perspective view showing internal channels of the valve member of the circulation tool;

(8) FIG. 5 shows a cross-sectional side view of the circulation tool in the through flow configuration (section along A-A of FIG. 2a), with the tubular actuating piston member in the depressed configuration;

(9) FIG. 6a shows a cross-sectional side view of the circulation tool in the circulation position (section along A-A of FIG. 2a), with the tubular actuating piston member in the resting configuration;

(10) FIG. 6b shows a cross-sectional side view of the circulation tool in the circulation position taken along a staggered cross-section line which cuts through the circulation channels of the valve member;

(11) FIG. 7 shows a cross-sectional side view of the upper section of an electromagnetically actuated circulation tool;

(12) FIG. 8 shows a cross-sectional side view of the upper section of an annulus pressure actuated circulation tool; and

(13) FIG. 9 shows a cross-sectional view of the disintegratable actuation element.

(14) In the following description the terms up, down, upper, lower, above, below, upwards, downwards, top and bottom et cetera are relative to the orientation of the bore hole 110 and drill string 114 as shown in FIG. 1. It should be noted that a bore hole 110 may be drilled at any angle through the Earth's crust 112 and in some cases may be horizontal. Accordingly, the above relative terms can be interpreted with relation to the longitudinal axis of the drill string 114 and/or the downhole circulation tool, irrespective of its orientation, in which drilling mud 118 is delivered along the axis of the drill string 114 from a proximal, upstream or upper position to a distal, downstream or lower position. For example, the drill bit 116 can be described as at a distal or downstream position, and the downhole circulation tool receives drilling mud from a proximal or upstream position. Correspondingly, axial and radial orientations relate to the longitudinal axis of the circulation tool within the bore hole 110.

(15) FIG. 2a shows a side view of a circulation tool 128 comprising a substantially tubular housing in which a plurality of fixed and movable internal components are disposed. The tubular housing itself is made up of three coupled tubular housing members including an upper housing member 210, a central housing member 212, and a lower housing member 214.

(16) Three axially-spaced pairs of opposing retaining pins 216 (retaining pins 216a-216c are visible in FIG. 2a) extend through the central housing member 212 on a common plane extending through the longitudinal axis of the circulation tool 128 (i.e. the axis lies in the plane). The retaining pins 216 serve to retain a number of the internal components within the central housing member 212, as will be described in detail below.

(17) Four hollow flow port inserts 218 (flow port inserts 218a, 218b visible in FIG. 2a) extend radially through the wall of the central housing member 212 at an axial position between the lower two pairs of retaining pins (216b, 216c), the flow port inserts 218 being angularly spaced apart at intervals of 90. Each flow port insert 218 has a curved flow port passageway 220 shaped to direct drilling mud flowing therethrough upwards and outwards (tangentially and radially) in a swirling helical motion into the bore hole annulus. Drilling mud is only provided to flow through the flow ports 218 when the circulation tool 128 is set in a circulation position, as will be described in detail below. The flow port inserts 218 are typically composed of a hard erosion-resistant material, such as a suitable metal, alloy, ceramic or cermet.

(18) FIGS. 2b and 2c show cross-sectional views of the circulation tool 128 in a through-flow mode, with the internal components of the circulation tool 128 defining an axial delivery bore 222 for delivering drilling mud to a lower part of a drill string 114 in which the circulation tool 128 is disposed in use (not shown), such as a drill bit 116. The delivery bore 222 allows the unhindered passage of drilling mud axially through the circulation tool 128 in the through-flow position.

(19) The upper and lower housing members 210, 214 are threadedly connected with respective upper and lower ends of the central housing member 212 using high strength threaded connectors 224a, 224b. Drilling mud is prevented from leaking through a clearance gap between the upper and lower housing members 210, 214 and central housing member 212 by O-ring seals 226a, 226b. The O-ring seals 226a, 226b may be composed of any suitable seal material, such as an elastomer, for example a Fluoroelastomer (FKM) or Perfluoroelastomer (FFKM). The O-ring seals 226a, 226b are prevented from being extruded through the clearance gap between the upper and lower housing members 210, 214 and the central housing member 212 by backup rings 228a, 228b. The backup rings 228a, 228b may be composed of any suitable material, such as a plastic, for example Polytetrafluoroethylene (PTFE) or Polyetheretherketone (PEEK).

(20) An upper piston seal housing 230 is axially secured within the central housing member 212 by retaining pins 216a, 216d. The retaining pins 216a, 216d are retained within the upper piston seal housing 230 by socket cap screws 232a, 232b which extend axially through the upper piston seal housing 230, threading into the retaining pins 216a, 216d, at right angles to the axes of the retaining pins 216a, 216d. The upper piston seal housing 230 has an outer groove which is fitted with an O-ring seal 226c and backup rings 228c, 228d as described above with respect to the connections between the upper, lower and central housings 210, 214, 212. The O-ring seal 226c forms a pressure-tight seal between the upper piston seal housing 230 and the central housing member 212.

(21) A counterbore is provided in the lower end of the upper piston seal housing 230, and is fitted with a scrapper seal 234a, T-seal 236a and wear rings 238a, 238b for receiving a tubular actuating piston member 240 which slidably extends therethrough and is axially displaceable relative to the upper piston seal housing 230. The scrapper seal 234a is configured to ensure the tubular actuating piston member 240 is kept clean and prevents debris from being forced past the T-seal 236a and wear rings 238a, 238b to prevent damage by debris. The wear rings 238a, 238b are configured to centralise the tubular actuating piston member 240, thereby allowing it to move smoothly. The scrapper seal 234a and wear rings 238a, 238b may be composed of plastic, such as PTFE or PEEK. The T-seal 236a provides a pressure tight seal between the upper piston seal housing 230 and the tubular actuating piston member 240. The T-seal 236a may be composed of an elastomer, such as FKM or FFKM. The scrapper seal 234a, T-seal 236a and wear rings 238a, 238b are retained in the upper piston seal housing 230 by retaining rings 242a, 242b.

(22) The tubular actuating piston member 240 has an internal bore extending therethrough, and a frustoconical seat 244 at its upper end for catching and arresting the movement of an actuation element travelling down through the drill string in use. The seat 244 is in the form of a frustoconical inner wall (tapering downwardly) at the upper end of the internal bore of the tubular actuating piston member 240 which is configured to receive an actuation element sized to block the bore therethrough. Accordingly, in use when an actuation element is received on the seat 244, a flow of drilling mud through the tubular actuating piston member 240 is blocked, such that the tubular actuating piston member 240 and actuating element together form a piston.

(23) The longitudinally displaceable tubular actuating piston member 240 is biased upwardly to a resting configuration in which it is stopped, as will be described below. The tubular actuating piston member 240 is biased by a compression spring disposed between a piston collar 250 mounted around and constrained to move with the tubular actuating piston member 240 towards its upper end and a spring seat 252 mounted within and constrained to move with the central housing member 212. The biasing force produced by the compressed spring 246 is transferred to the tubular actuating piston member 240 via a thrust bearing 248 within the piston collar 250, which itself is coupled to the tubular actuating piston member 240 via a retaining ring 242c received in an outer annular groove located towards the upper end of the tubular actuating piston member 240.

(24) The lower end of the tubular actuating piston member 240 passes through internal bores of (in downward order) the spring seat 252, a shim plate 254 and a lower piston seal housing 256. The spring seat 252 and shim plate 254 are secured to the lower piston seal housing 256 by socket cap screws 232c, 232d, which thread into the lower piston seal housing 256. The spring seat 252 supports the biasing spring 246. The internal bore of the spring seat 252 has an internal groove fitted with a wear ring 238c. The wear ring 238c centralises the tubular actuating piston member 240, allowing it to slide smoothly in an axial direction in use. The wear ring 238c may be composed of plastic such as PTFE or PEEK.

(25) The axial travel of the tubular actuating piston member 240 from the resting configuration is constrained by the depth of a counterbore in the lower end of the spring seat 252, which provides a space above the shim plate 254 in which a retaining ring 242d fitted within an external groove towards the lower end of the tubular actuating piston member 240 can ride. In the resting configuration, the retaining ring 242d abuts an upper shoulder of the counterbore in the lower end of the spring seat 252, whereas in a depressed configuration corresponding to the maximum axial travel of the tubular actuating piston member 240, the retaining ring 242d abuts the upper surface of the shim plate 254. The shim plate 254 therefore provides a lower stop, and the upper shoulder of the counterbore in the lower end of the spring seat 252 provides an upper stop for the travel of the tubular actuating piston member 240.

(26) The lower piston seal housing 256 has a counterbore in its upper end for receiving the lower end of the tubular actuating piston member 240 and accommodating its axial travel. The counterbore is fitted with a scrapper seal 234b, a T-seal 236b axially above the scrapper seal 234b, and wear rings 238d, 238e axially either side of the T-seal 236b. The tubular actuating piston member 240 passes through the scrapper seal 234b, T-seal 236b and wear rings 238d, 238e, and penetrates into the counterbore in the lower piston seal housing 256. The scrapper seal 234b ensures the tubular actuating piston member 240 is kept clean and prevents debris from being forced past the T-seal 236b and wear rings 238d, 238e and causing damage in use. The wear rings 238d, 238e are configured to centralise the tubular actuating piston member 240, thereby allowing it to move smoothly in use. The scrapper seal 234b and wear rings 238d, 238e may be composed of any suitable material, such as a plastic, for example PTFE or PEEK. The T-seal 236b provides a pressure tight seal between the lower piston seal housing 256 and the tubular actuating piston member 240. The T-seal 236b may be composed of any suitable seal material, such as an elastomer, for example FKM or FFKM. The scrapper seal 234b, T-seal 236b and wear rings 238d, 238e are retained in the lower piston seal housing 256 by the retaining rings 242e, 242f.

(27) Axially below the lower piston seal housing 256 and within the central housing member 212 there is provided a valve assembly comprising a ball valve member 268, upper and lower insert housings 258, 274 carrying upper and lower seal carrier piston members 260a, 260b respectively, as will be described in detail below.

(28) The lower piston seal housing 256 forms a spigot connection with the upper insert housing 258. A counterbore at the upper end of the upper insert housing 258 has an internal groove which is fitted with an O-ring seal 226d, which forms a pressure tight seal between the lower piston seal housing 256 and the upper insert housing 258 at the spigot connection. The O-ring seal 226d may be composed of any suitable seal material, such as an elastomer, for example FKM or FFKM. To prevent the O-ring seal 226d being extruded through the spigot connection clearance gap, backup rings 228e, 228f are provided axially either side of the O-ring seal 226d, which may be composed of any suitable material, such as a plastic, for example PTFE or PEEK.

(29) The upper insert housing 258 is axially secured within the central housing member 212 by retaining pins 216b, 216e extending through the central housing member 212 and received in corresponding recesses in the upper insert housing 258. The retaining pins 216b, 216e are retained within the upper insert housing 258 by socket cap screws 232e, 232f which extend axially through the upper insert housing 258, threading into retaining pins 216b, 216e along a direction perpendicular to the respective axes of the pins.

(30) There is a double counterbore at the lower end of the upper insert housing 258 which receives a hollow seal carrier piston member 260a, biasing spring 262a, O-ring seal 226e and backup rings 228g, 228h. The seal carrier piston member 260a has an outer profile comprising two outer shoulders corresponding to the double counterbore in the lower end of the upper insert housing 258, so as to form a spigot connection therewith. The O-ring seal 226e and backup rings 228g, 228h are fitted above the upper shoulder of the seal carrier piston member 260a. The O-ring seal 226e forms a pressure tight seal between the upper insert housing 258 and the seal carrier piston member 260a. The O-ring seal 226e may be composed of any suitable seal material, such as an elastomer, for example FKM or FFKM. To prevent the O-ring seal 226e being extruded through the spigot connection clearance gap, backup rings 228g, 228h are provided, which may be composed of any suitable material, such as a plastic, for example PTFE or PEEK. The biasing spring 262a is a compression spring disposed between the lower lateral counterbore face (or shoulder) of the upper insert housing 258 and the lower shoulder on the seal carrier piston member 260a so as to urge the seal carrier piston member 260a against the ball valve member 268 to form a seal therewith.

(31) The lower end of the seal carrier piston member 260a is fitted with a double seal arrangement comprising a primary seal 264a and a secondary resilient seal 266a. The primary seal 264a may be composed of metal, plastic or composite material whilst the secondary resilient seal 266a may be composed of an elastomer, such as FKM or FFKM. The primary seal 264a and the secondary resilient seal 266a are urged into contact with the ball valve member 268 under the biasing force of the biasing spring 262a. The biasing spring 262a ensures that a low pressure seal is maintained between the secondary resilient seal 266a and the ball valve member 268 when low pressure drilling mud flows through the circulation tool 128.

(32) An area difference is created between the exposed upper end of seal carrier piston member 260a and the secondary seal 266a. This creates what is known to those skilled in the art as Double Piston member Effect (DPE) sealing. The drilling mud pressure acting over the area difference in use results in a pressure force acting downwardly on the seal carrier piston member 260a, thereby forming a high pressure seal between the primary seal 264a and the ball valve member 268.

(33) As shown in FIG. 2c, in this embodiment trunnion pins 270a, 270b extend through the central housing member 212 on a common plane passing through the longitudinal axis of the circulation tool 128 (i.e. the longitudinal axis lies in the plane) and perpendicular to the plane on which the retaining pins 216a-216f are positioned. The trunnion pins 270a, 270b define a rotational axis for the ball valve member 268 and support the ball valve member 268 within the central housing member 212. The ball valve member is also supported by the upper and lower seal carrier pistons 260a, 260b. The trunnion pins 270a, 270b are retained in the central housing member 212 by sliders 272a, 272b. The trunnion pins 270a, 270b engage with overrunning clutch assemblies 282a, 282b fitted within cylindrical clutch pockets 284a, 284b on either side of the ball valve member 268, as will be described in detail below with reference to FIG. 3. In other embodiments, the ball valve member 268 may be supported by the seal carrier pistons 260a, 260b alone, and there may be no trunnion pins. Accordingly, the axis of the ball carrier valve 268 is defined by the position of the ball valve member 268 and the connection with the overrunning clutch assemblies 282a, 282b.

(34) Referring back to FIG. 2b, the lower insert housing 274 and lower seal carrier piston member 260b are disposed below the ball valve member 268 and arranged in a corresponding but inverted manner as the upper insert housing 258 and upper carrier piston member 260a to support and seal with the ball valve member 268 from below.

(35) The lower insert housing 274 is axially secured within the central housing member 212 by retaining pins 216c, 216f below the ball valve member 268. The retaining pins 216c, 216f are retained within the lower insert housing 274 by socket cap screws 232g, 232h which extend axially through the lower insert housing 274, threading into retaining pins 216c, 216f, at right angles to their respective axes. A double counterbore at the upper end of the lower insert housing 274 is fitted with a seal carrier piston member 260b, biasing spring 262b, O-ring seal 226f and backup rings 228i, 228j, as described above with respect to the upper insert housing 258 and upper seal carrier piston member 260a, albeit inversely oriented. Accordingly, the lower seal carrier piston member 260b is biased to form a pressure tight seal with the underside of the ball valve member 268 in the same manner as described above.

(36) Referring again to FIG. 2c, the piston collar 250 (which is mounted to the tubular actuating piston member 240) is connected via axially extending push rods 276a, 276b to the sliders 272a, 272b disposed on either side of the ball valve member 268. The push rods 276a, 276b are secured to the piston collar 250 by threaded studs 278a, 278b. The threaded studs 278a, 278b are locked in position by a locking collar 280 disposed above and secured to the piston collar 250 by socket cap screws 232i, 232j (as shown in FIG. 2b). Accordingly, axial motion of the tubular actuating piston member 240 on reception of an actuation element is transmitted to the sliders 272a, 272b via the piston collar 250 and push rods 276a, 276b, as will be described in detail below.

(37) FIG. 3 shows an exploded view of a unidirectional drive mechanism for rotating the ball valve member 268, comprising overrunning clutch assemblies 282a, 282b fitted within cylindrical clutch pockets 284 on either side of the ball valve member 268 to provide a unidirectional drive (or ratchet, or overrunning clutch mechanism).

(38) In this embodiment, the clutch pockets 284 are integrally formed in the ball valve member 268, but in other embodiments the clutch pockets 284 may comprise an insert received in or mounted to the ball valve member 268. The clutch pockets 284 have a circumferentially extending saw tooth profile which provides four ratchet positions angularly spaced at 90 intervals around the rotational axis of the ball valve member 268 defined by the trunnion pins 270a, 270b. The saw tooth profile within the opposing clutch pockets 284 are aligned with each other (so they have the same overrunning direction).

(39) The first overrunning clutch assembly 282a comprises a pawl carrier 310a, pawls 312a, 312b, pawl springs 314a, 314b, an inner pawl carrier seal 316a, and an outer pawl carrier seal 318a. The second overrunning clutch assembly 282b comprises a pawl carrier 310b, pawls 312c, 312d, pawl springs 314c, 314d, inner pawl carrier seal 316b and outer pawl carrier seal 318b. The overrunning clutch assemblies 282a, 282b will be described in detail with respect to the second overrunning clutch assembly 282b, the components of which are more clearly visible in FIG. 3 than the first overrunning clutch assembly 282a.

(40) The trunnion pin 270b extends inwardly from the wall of the central housing member 212 through a slot in the slider 272b (as will be described below) and into the pawl carrier 310b, thereby supporting the overrunning clutch assembly 282b and the ball valve member 268 and defining the rotational axis of the ball valve member 268 and overrunning clutch assembly 282b. In other embodiments, there may be no trunnion pins, and the overrunning clutch assemblies 282a, 282b may be supported by virtue of their connection to the clutch pockets and the sliders 272a, 272b.

(41) The pawl carrier 310b comprises a disc coaxially aligned with the rotational axis of the ball valve member 268, having an inner opening for receiving an inner pawl carrier seal 316b and the trunnion pin 270b and an outer cylindrical surface carrying an outer pawl carrier seal 318b. On the side of the pawl carrier 310b towards the ball valve member 268, the pawl carrier 310b comprises pawl slots for receiving rotating parts of the pawls 312c, 312d, and pawl spring slots for receiving rotating parts of the pawl springs 314c, 314d.

(42) The inner pawl carrier seal 316b is configured to seal around the trunnion pin 270b to prevent debris from entering the overrunning clutch assembly 282b between the trunnion pin 270b and the pawl carrier 310b whilst allowing rotation. The inner pawl carrier seal 316b may comprise a labyrinth type seal. The outer pawl carrier seal 318b prevents debris from entering the overrunning clutch assembly 282b between the pawl carrier 310b and the ball valve member 268 whilst allowing rotation. The outer pawl carrier seal 318b may also be a labyrinth type seal.

(43) The pawls 312c, 312d are mounted within the respective pawl slots of the pawl carrier 310b and are urged by pawl springs 314c, 314d received within the corresponding pawl spring slots to engage the teeth of the respective clutch pocket 284.

(44) The clutch pocket 284 comprises four teeth, each having an angular extent of 90 of the saw-tooth profile, thereby providing four engagement features or tooth-edges against which a pawl may drive the clutch pocket 284 (and thereby the ball valve member 268) to rotate in an anticlockwise direction (viewed along the axis from trunnion pin 270b to 270a) as viewed in FIG. 3. Correspondingly, the pawl slots of the pawl carrier 310b and the pawls 312c, 312d are configured so that the distal end of each pawl extends in a generally anticlockwise direction, so as to be engageable with the tooth-edges of the clutch pocket 284.

(45) The overrunning clutch assembly 282b is therefore configured to overrun in the clockwise direction (viewed along the axis from trunnion pin 270b to 270a) within the clutch pocket 284. Rotation of the overrunning clutch assembly 282b in the anti-clockwise engaging direction (viewed along the axis from trunnion pin 270b to 270a) will therefore cause the spring loaded pawls 312c, 312d to engage with the tooth-edges of the saw tooth profile of the clutch pocket 284 in one of the four ratchet positions, which are angularly spaced at 90 intervals. Once engaged in a ratchet position, further anti-clockwise rotation of the overrunning clutch assembly 282b will cause the ball valve member 268 to rotate in an anti-clockwise direction (viewed along the axis from trunnion pin 270b to 270a).

(46) The first overrunning clutch assembly 282a and corresponding clutch pocket 284 is arranged in a corresponding but reflected manner as the second overrunning clutch assembly 282b and corresponding clutch pocket 284 described above, so that the overrunning clutch assembly 282a overruns in the clockwise direction of FIG. 3, and drives the ball valve member 268 to rotate in the anticlockwise direction when engaged in a ratchet position.

(47) The sliders 272a, 272b each have a vertical slot for receiving the respective trunnion pins 270a, 270b, and respective horizontal slider slots 320a, 320b which engage with pawl carrier pins 322 (322b shown only) fitted to the pawl carriers 310a, 310b respectively in an eccentric position with respect to the rotational axis of the pawl carriers and ball valve member 268. The horizontal slider slots 320a, 320b and the pawl carrier pins 322 are configured so that upward translation of the sliders 272a, 272b drives the respective pawl carriers 310a, 310b to rotate in the anti-clockwise direction (viewed along the axis from trunnion pin 270b to 270a), whereas downward translation of the sliders 272a, 272b drives the respective pawl carriers 310a, 310b to rotate in the clockwise direction.

(48) Slider locking pins 324a, 324b are fitted towards the lower end of the sliders 272a, 272b and configured to engage with corresponding locking pockets 326 of the ball valve member 268, angularly spaced from one another at 90 intervals. The slider locking pins 324a, 324b are configured to prevent the ball valve member 268 from rotating and overrunning in a clockwise direction (viewed along the axis from trunnion pin 270b to 270a) when the sliders 272a, 272b are positioned in an upper position corresponding to the resting configuration of the tubular actuating piston member 240.

(49) The ball valve member 268 has a through-flow channel 223 which extends axially through the centre of the ball valve member 268 (i.e. from pole to pole) between antipodal openings in a direction orthogonal to the rotational axis of the ball valve member 268. The through-flow channel 223 is arranged to allow drilling mud to pass from an upstream portion of the delivery bore 222 to a downstream portion of the delivery bore 222 when the ball valve member 268 is in a through-flow position in which the through-flow channel 223 is aligned with the delivery bore 222.

(50) Additionally, the ball valve member 268 has two circulation manifolds, each comprising four circulation channels (or circulation passageways) 328 which are unconnected to (i.e. do not intersect) the through-flow channel 223. Each circulation channel 328 of the respective manifold shares a common circulation inlet 330, and there are four separate circulation outlets or circulation ports 332 that exit the ball valve member 268.

(51) The common circulation inlets 330 oppose one another (i.e. are antipodal with respect to each other), and are angularly spaced from the antipodal openings of the through-flow channel 223 by 90 with respect to the rotational axis of the ball valve member 268. The circulation manifolds are configured so that, when the ball valve member 268 is positioned in a circulation position in which one of the common circulation inlets 330 is aligned with the delivery bore 222 of the downhole circulation tool 128 (i.e. the bore extending through the tubular actuating piston member 240, upper insert housing 258 and upper seal carrier piston member 260a), the circulation outlets 332 align with the respective curved flow port passageways 220 within the flow port inserts 218a-218d fitted in the central housing member 212, thereby allowing drilling mud to flow from the delivery bore 222 into the bore hole annulus. In the circulation position, the through-flow channel 223 extends laterally so that does not receive drilling mud flow. Accordingly, the flow of drilling mud to the downstream portion of the delivery bore 222 is prevented.

(52) FIG. 4 shows an internal view of the through-flow channel 223 and circulation channels 328 within the ball valve member 268. The clutch pockets 284 have been omitted from this view for clarity. As shown, the circulation manifolds each have four circulation channels 328 sharing a common circulation inlet 330, but having four separate circulation outlets 332 that exit the ball valve member 268. Each circulation channel 328 is curved along its length to prevent flow separation, minimise pressure drop and reduce component erosion by a drilling mud flow flowing therethrough. The circulation channels and circulation ports (flow port passageways) are configured to partially reverse the drilling mud flow, such that the drilling mud flow is discharged from the circulation ports 220 along respective discharge directions having a component parallel and opposite to the upstream to downstream axial direction of the tool (i.e. an upward direction when the tool is oriented vertically).

(53) In this embodiment, the actuation element or actuation ball 510 (as shown in FIG. 5) is a disintegratable spherical ball comprising a core or body surrounded by an outer protective coating for resisting damage and erosion during transit of the actuation element through the drill string 114. The disintegratable actuation element 510 is designed to have sufficient compressive strength to actuate the tubular actuating piston member 240 (as described below), but to subsequently disintegrate and break down within the drilling mud, so that it may pass through the downhole circulation tool 128, without the need for a ball-catcher.

(54) In this embodiment, the inner core or body of the disintegratable actuation element 510 comprises an ionic compound such as salt (e.g. sodium chloride (NaCl) and/or potassium chloride (KCl)) and bentonite clay, in particular, sodium bentonite (sodium montmorillonite clay). In other embodiments, calcium carbonate, calcium sulphide or graphite may be used (additionally or alternatively to sodium chloride and/or potassium chloride).

(55) The ionic surface of the phyllosilicate clay, bentonite, has the property of allowing the bentonite to bind to itself and to other pieces of bentonite (e.g. particles or aggregate form bentonite). This self-binding or self-sticky property of the bentonite allows the body or core of the disintegratable actuation element 510 to be formed under high-pressure compression within a die to form the hard disintegratable actuation element 510. This is in contrast to previously considered manufacturing methods for actuation balls, which typically rely on a binder material.

(56) The precise composition of the body of the disintegratable actuation element 510 may depend on the pressure force which the disintegratable actuation element 510 must withstand in order to displace the tubular actuating piston member 240 from the resting configuration to the depressed configuration. For example, the disintegratable actuation element 510 may comprise between 5% and 60% bentonite by volume. 10% to 30% of bentonite by volume has been shown to be effective, in terms of an adequate strength and suitable disintegration time.

(57) The self-binding or self-sticky property of the bentonite is activated in the presence of water, and typically requires hydration of at least 1% by weight for sufficient bonding strength. Sodium bentonite is considered by the applicant to provide the highest compressive strength of the various bentonite types (sodium, calcium and potassium bentonite), which may be because the sodium ions allow the montmorillonite flakes to separate and disperse, thereby giving uniform coating over individual particles.

(58) A high bentonite composition (i.e. greater than 60% by volume) may result in over-swelling of the material of the disintegratable actuation element 510 (e.g. between 5 and 15 times the dry volume), which could therefore present a blockage in the drill string 114 if the disintegratable actuation element 510 does not disintegrate (and thereby wash away). Accordingly, a bentonite composition of less than 60% is desirable. In normal operation, the disintegratable actuation element 510 used with an 80 mm outer diameter circulation tool 128 has a diameter of approximately 27 mm before insertion into the drilling mud flow.

(59) The disintegration of the disintegratable actuation element 510 can be controlled by adjusting the quantity of salt and filler material in the disintegratable actuation element 510, to moderate the self-stickiness of the bentonite. The filler material may be a powdered particulate, which may be non-abrasive, such as wood dust. When used with water based drilling muds, the salt dissolves in water and the filler material disperses and thereby allows the disintegratable actuation element 510 to break down. When used with oil-based drilling muds, the actuation element 510 may absorb the drilling mud, which may mechanically degrade the salt portions (comprising salt and filler material) and progress the disintegration of the actuation element 510.

(60) Since both bentonite and salt (brines) are commonly used during drilling operations, their effects are well understood by the drilling industry and therefore the introduction of these materials into the drill string 114 in a disintegratable fashion will not present operational problems. Both bentonite and the above-mentioned salts have high melting points and compressive strengths, which makes them well suited to the high temperature and pressure environments found within deep bore holes 110.

(61) FIG. 9 shows a cross-sectional view of the disintegratable actuation element 510 which in this embodiment comprises a core or body 511 surrounded by a protective outer coating 512. The protective outer coating 512 is resistant to high temperature (e.g. temperatures in excess 150 C.). Many different materials could be used for the protective outer coating 512, including temperature resistant resins (epoxides, glycidyl, oxirane groups, benzoxazines polyimides, bismaleimides and cyanate esters. Alternatively, the protective outer coating 512 may comprise a ceramic glaze material, such as silica-based coating. The protective outer coating 512 may be applied by dipping or spraying, for example.

(62) The disintegratable actuation element 510 is produced by press-forming, for example using a tablet press known to those skilled in the art, which compresses granulated powder into spherical pills of uniform size and weight. In the press-forming method, granulated powder is poured into a cavity formed by two punches and a die. The punches are then pressed together, causing the material to fuse together to form a spherical pill or ball. The granulated powder may be composed of calcium carbonate, sodium chloride, potassium chloride, sodium bentonite (powdered drilling mud) or a combination thereof. The spherical pill is then coated with a protective outer coating 512.

(63) A method of actuating the downhole circulation tool 128 will now be described, by way of example.

(64) FIGS. 2b and 2c show cross-sectional views of the downhole circulation tool 128 with the tubular actuating piston member 240 in the resting configuration and the ball valve member 268 in the through-flow position. Drilling mud is pumped down through the delivery bore 222 of the downhole circulation tool 128, and passes through the tubular actuating piston member 240 (including the seat 244), and the ball valve assembly including the through-flow channel 223 of the ball valve member 268. The drilling mud therefore reaches the BHA 132, and is ejected through the jetting nozzles 120 to wash the drilling cuttings 126 away from the drill bit 116.

(65) In order to actuate the ball valve member 268 to move to the circulation position, a disintegratable actuation element 510 is added to the drilling mud flow so that it is received on the seat 244 of the tubular actuating piston member 240, as shown in FIG. 5. As shown in FIG. 5, the downhole circulation tool 128 remains in the through-flow position as the tubular actuating piston member 240 begins to be displaced downwardly from the resting configuration under the pressure force acting on the disintegratable actuation element 510 and tubular actuating piston member 240 owing to the blocked bore.

(66) Since the sliders 272a, 272b are connected to the tubular actuating piston member 240 via the piston collar 250 and push rods 276a, 276b, the sliders 272a, 272b also move downwards with the tubular actuating piston member 240, thereby causing the pawl carrier pins 322a, 322b (as shown in FIG. 3) to move laterally in the horizontal slots 320a, 320b of the sliders 272a, 272b, such that the pawl carrier pins 322a, 322b and the pawl carriers 310a, 310b to which they are attached rotate in a clockwise direction. This rotation causes the pawls 312 to overrun the saw-tooth profile of the clutch pockets 284.

(67) The overrunning clutch assemblies 282 are configured to correspond to the axial travel of the tubular actuating piston member 240 so that the pawls 312 do not overrun a tooth-edge of the saw-tooth profile of the clutch pockets 284 until the tubular actuating piston member 240 has travelled at least a piston displacement threshold, which in this embodiment corresponds to approximately 90% of the full travel (as limited by the retaining ring 242d moving within the counterbore of the spring seat 252 up to the shim plate 254). In other embodiments, the threshold displacement may correspond to substantially 100% of the travel, such that it is not possible to depress the tubular actuating piston member 240 beyond the threshold piston displacement.

(68) Accordingly, as the drilling mud continues to be pumped, the pressure force rises to overcome the biasing force of the biasing spring 246 and associated friction forces, so that the tubular actuating piston member 240 is displaced to the piston displacement threshold, at which point the pawls 312 overrun the respective tooth-edges to arrive at a ratchet position in which the pawls 312 engage the respective tooth-edges. Accordingly, subsequent anticlockwise rotation of the pawls 312 drives the clutch pockets 284 and thereby the ball valve member in the anti-clockwise direction. It will be appreciated that in other embodiments the saw-tooth profiles may be configured so that, after overrunning a tooth-edge, a degree of rotation in the opposite direction is required before the pawls 312 engage the tooth-edge.

(69) Further pumping of the drilling mud causes the disintegratable actuation element 510 to become over-pressurised, thereby causing it to fracture or disintegrate. Partial fracture and/or of the actuation element results in rupture of the protective outer coating 512, which exposes the body of the actuation element and accelerates its disintegration.

(70) Once the disintegratable actuation element 510 has been fractured, it is pumped through the upstream portion of the delivery bore 222, including the through-flow channel 223 of the ball valve member 268, so that the delivery bore 222 is no longer blocked. The disintegrated parts of the disintegratable actuation element 510 are discharged through the jetting nozzles 120 in the drill bit 116.

(71) Consequently, the tubular actuating piston member 240 rises under the biasing force of the biasing spring 246 from the depressed configuration to the resting configuration, thereby causing corresponding movement of the sliders 272a, 272b. The upwards movement of the sliders causes the overrunning clutch assemblies 282a, 282b, now with pawls 312 engaged in respective ratchet positions, to rotate in the anticlockwise direction and drive corresponding rotation of the ball valve member 268 through 90 in an anti-clockwise direction (viewed along the axis from trunnion pin 270b to 270a), thereby positioning the ball valve member 268 in the circulation position. The ball valve member 268 is rotated through 90 because the tubular actuating piston member 240 is configured so that travel from the piston displacement threshold to the resting configuration when the clutch is engaged (i.e. the pawls 312 are engaged with the tooth-edges) corresponds to 90 of anticlockwise rotation. Even if the tubular actuating piston member 240 is displaced beyond the piston displacement threshold by an additional displacement amount, the additional displacement amount only corresponds to overrunning clockwise rotation of a pawl beyond a ratchet position, and so will not result in anti-clockwise rotation of the ball valve member 268 of more than 90, as the pawl 312 simply moves back to the ratchet (or engaged) position when the tubular actuating piston member 240 moves back over the additional displacement amount to the threshold piston displacement.

(72) As the sliders 272a, 272b return to their upper positions corresponding to the resting configuration of the tubular actuating piston member 240, the slider locking pins 324a, 324b engage with respective locking pockets 326 on either side of the ball valve member 268, thereby preventing the ball valve member 268 from rotating and overrunning in anti-clockwise direction (viewed along the axis from trunnion pin 270b to 270a).

(73) FIGS. 6a and 6b show the circulation tool 128 with the ball valve member 268 in the circulation position, and with the tubular actuating piston member 240 returned to the resting configuration. FIG. 6b shows a cross-sectional view of the circulation tool 128 taken along a section which cuts through the flow port passageways 220 within the flow port inserts 218a-218d. With the ball valve member 268 in the circulation position, the drilling mud from the upstream portion of the delivery bore 222 is smoothly redirected through the curved circulation channels 328 of the ball valve member 268 and subsequently through the curved flow port passageways 220 such that it is reversed from a downwards direction to an (at least partly) upwards direction, and so that both radial and tangential components are imparted on the flow to produce a helical flow within the bore hole annulus 122. The drilling mud therefore strikes the bore hole 110 at an oblique angle. This helical flow improves the removal and transportation of drilling cuttings 126 from the bore hole annulus 122 and helps maintain bore hole 110 stability.

(74) The gradual turning of the drilling mud through the circulation channels 328 of the ball valve member 268 ensures flow separation is minimised, reducing the likelihood of erosion or washing within the ball valve member 268 and flow port passageways 220. By avoiding separated flow, the pressure losses through the circulation tool 128 are minimized, thereby reducing the surface equipment pressure requirements, or alternatively allowing higher drilling mud flow rates to be achieved with the same pressure (when compared to existing circulation tools). The use of higher drilling mud flow rates may provide more effective removal of drilling cuttings 126 from the bore hole annulus 122.

(75) Unlimited actuation between the through-flow and circulation positions is achieved by dropping successive disintegratable actuation elements 510 into the drill string 114, which causes the ball valve member 268 to rotate anticlockwise through 90 with each actuation. Each successive 90 rotation causes a common circulation inlet 330 or an opening of the through-flow channel 223 to align with the upstream portion of the delivery bore 222.

(76) If the disintegratable actuation element 510 is pumped too fast or is damaged during transit, it will be blown through the seat 244 and delivery bore 222, and the tubular actuating piston member 240 will remain stationary in the resting configuration or will be displaced but not reach the piston displacement threshold, thereby ensuring that the circulation tool 128 remains un-actuated if the disintegratable actuation element 510 disintegrates too soon.

(77) The ball valve member 268 is configured so that, when it is in the through-flow position, the circulation outlets 332 do not align with the flow port passageways 220, thereby preventing debris from entering the circulation channels 328 and avoiding the likelihood of debris fouling the rotation of the ball valve member 268.

(78) The displacement of the tubular actuating piston member 240 is damped by a damping force acting on the piston collar 250 and locking collar 280 within the central housing member 212. The damping force is due to a damping medium, e.g. grease, oil, drilling mud or a similar fluid disposed within the central housing member 212. Damping the displacement of the tubular actuating piston member 240 causes the ball valve member 268 to rotate slowly between configurations, thereby giving the operator time to stop the drilling mud flow, and avoiding any potential water hammer effects and any potential for high velocity erosion of the ball valve member 268. The operator can determine when to stop the drilling mud flow based on pressure and flow rate monitoring, and knowledge of the time required for the ball valve member 268 to rotate, as determined by the (predetermined) damping of the displacement of the tubular actuation piston member 240. To ensure the pressure of the fluid in the central housing member 212 remains equal to pressure within the bore hole annulus 122 (i.e. a pressure differential is not set up), the central housing member 212 is vented to the bore hole annulus 122 via a floating pressure compensation piston (not shown).

(79) In a second embodiment of the downhole circulation tool 128, an upper section of the circulation tool 128 is provided with a means for electromagnetically actuating the circulation tool 128, as shown in FIG. 7.

(80) In the second embodiment, all components below the locking collar 280 remain unchanged from the first embodiment described above. However, the central housing member 212 is lengthened and the upper piston seal housing 230 is replaced by an upper seal insert 710, electromagnetic actuator assembly 712, thrust insert 714, battery pack 716 and control module 718. As in the first embodiment, there is a tubular actuating piston member 240 coupled to the piston collar 250, which allows the overrunning clutch assembly 282 to be driven by an actuation element, such as a disintegratable actuation element 510, as an alternative to electromagnetic actuation.

(81) The electromagnetic actuator assembly 712 is positioned above the upper seal insert 710. The electromagnetic actuator assembly 712 comprises a high torque electric motor which drives a hollow lead screw 720. The lower end of the hollow lead screw 720 is arranged to contact the upper end of the tubular actuating piston member 240.

(82) The thrust insert 714 is axially secured within the central housing member 212 by retaining pins 216a, 216d. The retaining pins 216a, 216d are retained within the thrust insert 714 by socket cap screws 232a, 232b which extend axially through the thrust insert 714, threading into the retaining pins 216a, 216d, at right angles to their respective axes. The thrust insert 714 provides a reaction to the thrust force produced by the electromagnetic actuator assembly 712.

(83) Above the thrust insert 714 there is disposed the battery pack 716 and control module 718. The battery pack 716 provides power to the control module 718 and electromagnetic actuator assembly 712. The control module 718 may contain actuation sensors, antennas, power regulators and microprocessors as needed to control the electromagnetic actuator assembly 712. The actuation sensors may include but not be limited to pressure sensors, wireless sensors, accelerometers and gyros.

(84) In use of the circulation tool 128 according to the second embodiment, an actuation command signal is received by the control module 718 and an actuation signal is sent to the electromagnetic actuator assembly 712 which causes the hollow lead screw 720 to actuate downwards. Since the lower end of the hollow lead screw 720 contacts the upper end of the tubular actuating piston member 240, the tubular actuating piston member 240 is depressed downwards. The electromagnetic actuator assembly 712 is subsequently controlled so that the hollow lead screw 720 is drawn upwards once more.

(85) Since the mechanical components below the upper seal insert 710 remain the same as the previously described embodiment, the actuation of the ball valve member 268 occurs in the same manner. Unlimited actuation between the through-flow and circulation positions is achieved by successive actuation of the electromagnetic actuator assembly 712, which causes the ball valve member 268 to rotate through 90 with each actuation.

(86) The actuation command signal may be sent after a pre-set time delay or sent to the control module 718 from the surface by an electrical command wire, mud pulse, drill string mechanical jarring or via an electronic actuation tag, which may be detected by respective sensors.

(87) The circulation tool 128 can also be actuated an unlimited number of times by dropping successive disintegratable actuation elements 510, as described above.

(88) In a third embodiment of the downhole circulation tool 128, the upper section of the circulation tool 128 is provided with a means for actuating the tool using mud pressure from the bore hole annulus 122, as shown in FIG. 8.

(89) In this third embodiment, all components below the locking collar 280 remain unchanged from the first embodiment. However, the central housing member 212 is lengthened and has the addition of two small pressure actuation ports 810 which vent to the bore hole annulus 122 Further, the upper piston seal housing 230 is replaced by a nitrogen actuation assembly 812.

(90) The nitrogen actuation assembly 812 comprises an upper seal insert 814 threaded into a lower nitrogen reservoir sleeve 816, both disposed around the tubular actuating piston member 240. Fitted within the nitrogen reservoir sleeve 816 and extending from the upper seal insert 814 there is an actuation plunger 818. O-ring gas seals 820 allow a gas tight annular nitrogen cavity 822 to be formed between the nitrogen reservoir sleeve 816 and the actuation plunger 818. The annular nitrogen cavity 822 is filled with pressurised nitrogen which biases the actuation plunger 818 upwardly, overcoming the hydrostatic pressure communicated through the pressure actuation ports 810 from the bore hole annulus 122, to which the upper end of the actuation plunger 818 is exposed. The nitrogen pressure within the annular nitrogen cavity 822 is set according to the required actuation depth of the circulation tool 128. The tubular actuating piston member 240 is configured to slide through the actuation plunger 818.

(91) The nitrogen actuation assembly 812 is axially secured within the central housing member 212 through the upper seal insert 814 using retaining pins 216a, 216d. The retaining pins 216a, 216d are retained within the upper seal insert 814 by socket cap screws 232a, 232b which extend axially through the upper seal insert 814, threading into the retaining pins 216a, 216d at right angles to their respective axes.

(92) In use, actuation between the though-flow and circulation positions is achieved by using mud pressure from the bore hole annulus 122.

(93) The circulation tool 128 is actuated by increasing the pressure in the bore hole annulus 122 from the surface. The increased pressure is communicated through the pressure actuation ports 810 and on to the upper end of the actuation plunger 818, which causes it to move downwards when the pressure overcomes the nitrogen pressure in the annular nitrogen cavity 822. The actuation plunger 818 is thereby brought into contact with the upper end of the locking collar 280, and further downward movement of the actuation plunger 818 causing the tubular actuating piston member 240 to be pushed downwards.

(94) Since the mechanical components below the upper seal insert 710 remain the same as the previously described embodiment, the actuation of the ball valve member 268 occurs in the same manner. Unlimited actuation between the through-flow and circulation positions is achieved by successive re-pressurisation of the drilling mud in the bore hole annulus 122, which causes the ball valve member 268 to rotate through 90 with each actuation as described above.

(95) As previously described, the circulation tool 128 can also be actuated an unlimited number of times by dropping successive disintegratable actuation elements 510.

(96) The circulation tool of the disclosure is more efficient and reliable than previously considered circulation tools, and can be used an unlimited number of times without penalty when drilling bore holes.

(97) It will be appreciated that while the above descriptions contain specific features relating to the configuration of the circulation tool and the specific components therein, these relate to particular embodiments. It will be appreciated that additional embodiments may use alternative means to affect actuation of the ball valve member within the circulation tool. These may include but not be limited to electromagnetic means, hydraulic means, mechanical means, pneumatic means, etc. The particular means of actuating the ball valve member does not impact other aspects of the disclosure.

(98) Although aspects of the disclosure relating to a downhole tool having a unidirectional drive mechanism and a movable tool device movable between multiple positions have been described in relation to the actuation of a ball valve member for a circulation tool, it will be appreciated that such aspects are applicable to other downhole tool devices. In particular, the unidirectional drive mechanism may be employed with respect to tool devices including hole openers/reamers, adjustable gauge stabilisers, rotary steerable systems, shut-off ball valves or blow out preventers, and disconnect tools.