Hydraulically driven hole cleaning apparatus

Abstract

An apparatus includes a tool body having a bore that is aligned with a lengthwise axis and a rotating assembly coupled to the tool body. The rotating assembly includes a turbine wheel that is disposed adjacent to an inner surface of the wall and exposed to the bore. The rotating assembly includes an impeller that is disposed adjacent to an outer surface of the wall in a position corresponding to the turbine wheel. Each of the turbine wheel and impeller has a respective axis of rotation that is transverse to the lengthwise axis. The rotating assembly includes a link rod that couples the turbine wheel to the impeller and is used to transfer mechanical energy generated by the turbine wheel to the impeller. The apparatus is operable by fluid flow through a drill string to increase pressure in a wellbore annulus and enhance transportation of formation cuttings up the annulus.

Claims

1. An apparatus comprising: a tool body having a wall and a lengthwise axis, the wall defining a bore that is aligned with the lengthwise axis; one or more rotating assemblies coupled to the tool body, each of the rotating assemblies comprising: a turbine wheel disposed adjacent to an inner surface of the wall and exposed to the bore, the turbine wheel having an axis of rotation transverse to the lengthwise axis; an impeller disposed adjacent to an outer surface of the wall in a position corresponding to the turbine wheel, the impeller having an axis of rotation transverse to the lengthwise axis; and a link rod operatively coupling the turbine wheel to the impeller, the link rod to transfer mechanical energy generated by the turbine wheel to the impeller.

2. The apparatus of claim 1, wherein the link rod passes through a portion of the wall of the tool body between the turbine wheel and the impeller and is rotatably supported by a bearing mounted in the portion of the wall of the tool body.

3. The apparatus of claim 1, wherein the turbine wheel has a higher hydrodynamic drag in comparison to the impeller when the turbine wheel and the impeller are immersed in a fluid.

4. The apparatus of claim 1, wherein the impeller is an open impeller or a semi-open impeller.

5. The apparatus of claim 4, wherein the impeller is a radial impeller.

6. The apparatus of claim 1, further comprising an impeller casing mounted around the impeller to provide a chamber around the impeller that guides flow from the impeller, the impeller casing having an opening forming an outlet port that is fluidly connected to the chamber.

7. The apparatus of claim 6, wherein the chamber is a volute chamber.

8. The apparatus of claim 6, further comprising an external shield disposed around the tool body with a space between the external shield and the tool body to accommodate the impeller casing and the impeller, wherein the external shield includes an opening forming an inlet port that is fluidly connected to the chamber.

9. The apparatus of claim 1, wherein a plurality of the rotating assemblies are coupled to the tool body, and wherein the plurality of the rotating assemblies are uniformly distributed along a circumference of the tool body.

10. A drill string comprising: a drill bit; one or more drill pipes forming a conduit that is fluidly connected to the drill bit; and one or more hole cleaning apparatuses disposed along the conduit, each of the hole cleaning apparatuses comprising: a tool body having a wall and a lengthwise axis, the wall defining a bore that is aligned with the lengthwise axis and fluidly connected to the conduit; one or more rotating assemblies coupled to the tool body, each of the rotating assemblies comprising: a turbine wheel disposed adjacent to an inner surface of the wall and exposed to the bore, the turbine wheel having an axis of rotation transverse to the lengthwise axis; an impeller disposed adjacent to an outer surface of the wall in a position corresponding to the turbine wheel, the impeller having an axis of rotation transverse to the lengthwise axis; and a link rod operatively coupling the turbine wheel to the impeller, the link rod to transfer mechanical energy generated by the turbine wheel to the impeller.

11. The drill string of claim 10, wherein the turbine wheel of each of the one or more rotating assemblies has a higher hydrodynamic drag in comparison to the corresponding impeller when the turbine wheel and the corresponding impeller are immersed in a fluid.

12. The drill string of claim 11, wherein the impeller is an open impeller or a semi-open impeller.

13. The drill string of claim 11, wherein the impeller is a radial impeller.

14. The drill string of claim 10, further comprising an impeller casing mounted around each impeller to provide a chamber around the impeller that guides flow from the impeller, each impeller casing having an opening forming an outlet port that is fluidly connected to the chamber.

15. The drill string of claim 14, wherein the chamber is a volute chamber.

16. The drill string of claim 14, further comprising an external shield disposed around the tool body with a space between the external shield and tool body to accommodate each impeller casing and corresponding impeller, wherein the external shield includes an opening forming an inlet port that is fluidly connected to the chamber.

17. The drill string of claim 16, wherein each impeller casing is connected to the external shield.

18. The drill string of claim 10, wherein a plurality of the rotating assemblies are coupled to the tool body of each hole cleaning apparatus, and wherein the plurality of the rotating assemblies are uniformly distributed along a circumference of the tool body.

19. A method comprising: disposing a drill string including at least one hole cleaning apparatus in a wellbore; pumping a fluid into the drill string while operating the drill string to cut into a subsurface formation around the wellbore; returning the fluid pumped into the drill string and cuttings from the subsurface formation to a surface through an annulus between the drill string and the wellbore; during pumping of the fluid into the drill string, rotating at least one turbine wheel disposed inside a tool body of the hole cleaning apparatus by the fluid passing through the drill string; rotating at least one impeller disposed outside the tool body of the hole cleaning apparatus in response to rotation of the at least one turbine wheel; and increasing a pressure of the fluid in the annulus at a location of the at least one impeller by the rotation of the at least one impeller; wherein rotating the at least one impeller comprises rotating the at least one impeller about an axis of rotation that is transverse to a lengthwise axis of the tool body of the hole cleaning apparatus.

20. A method comprising: disposing a drill string including at least one hole cleaning apparatus in a wellbore; pumping a fluid into the drill string while operating the drill string to cut into a subsurface formation around the wellbore; returning the fluid pumped into the drill string and cuttings from the subsurface formation to a surface through an annulus between the drill string and the wellbore; during pumping of the fluid into the drill string, rotating at least one turbine wheel disposed inside a tool body of the hole cleaning apparatus by the fluid passing through the drill string; rotating at least one impeller disposed outside the tool body of the hole cleaning apparatus in response to rotation of the at least one turbine wheel; and increasing a pressure of the fluid in the annulus at a location of the at least one impeller by the rotation of the at least one impeller; wherein rotating the at least turbine wheel comprises rotating the at least one turbine wheel about an axis of rotation that is transverse to a lengthwise axis of the tool body of the hole cleaning apparatus, and wherein rotating the at least one impeller comprises rotating the at least one impeller about an axis of rotation that is transverse to the lengthwise axis of the tool body of the hole cleaning apparatus.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) The following is a description of the figures in the accompanying drawings. In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn are not necessarily intended to convey any information regarding the actual shape of the particular elements and have been solely selected for ease of recognition in the drawing.

(2) FIG. 1 is a cross-sectional view of a rotating assembly for use in a hole cleaning apparatus.

(3) FIG. 2 is a front elevation view of a turbine wheel of the rotating assembly of FIG. 1.

(4) FIG. 3 is a front elevation view of an impeller of the rotating assembly of FIG. 1.

(5) FIG. 4 is a cross-sectional view of a hole cleaning apparatus.

(6) FIG. 5 is a cross-sectional view of the hole cleaning apparatus of FIG. 4 along line 5-5.

(7) FIG. 6 is a cross-sectional view of a hole cleaning apparatus with impeller casings.

(8) FIG. 7 is a cross-sectional view of FIG. 6 along line 7-7.

(9) FIG. 8 is a partial cross-sectional view of the hole cleaning apparatus shown in FIGS. 6 and 7.

(10) FIG. 9 is a side elevation view of the hole cleaning apparatus shown in FIGS. 6-8.

(11) FIG. 10 is a schematic diagram of a drilling system incorporating one or more hole cleaning apparatuses in a drill string.

(12) FIG. 11 is a schematic diagram showing flow patterns in a portion of a wellbore containing a hole cleaning apparatus with impeller casings.

(13) FIG. 12 is a schematic diagram showing flow patterns in a portion of a wellbore containing a hole cleaning apparatus without impeller casings.

DETAILED DESCRIPTION

(14) In the following detailed description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations and embodiments. However, one skilled in the relevant art will recognize that implementations and embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, and so forth. In other instances, related well known features or processes have not been shown or described in detail to avoid unnecessarily obscuring the implementations and embodiments. For the sake of continuity, and in the interest of conciseness, same or similar reference characters may be used for same or similar objects in multiple figures.

(15) A hole cleaning apparatus that may be installed in a drill string is described herein. The hole cleaning apparatus includes one or more rotating assemblies that operate to increase the pressure in the annulus of a wellbore while the drill string is used in the wellbore. The extra pressure will assist in transporting formation cuttings up the annulus. Advantageously, the hole cleaning apparatus will reduce the need for hole sweeps to ensure proper hole cleaning.

(16) FIG. 1 shows one illustrative implementation of a rotating assembly 100 that may be included in a hole cleaning apparatus for the purpose of enhancing hole cleaning while drilling. Rotating assembly 100 includes a turbine wheel 104 and an impeller 108, which are positioned in spaced apart relation along a main axis 110. The axes of rotation of turbine wheel 104 and impeller 108 are parallel to main axis 110. In the illustrated example, the axes of rotation of turbine wheel 104 and impeller 108 are coincident with each other and main axis 110. However, it is possible that the axes of rotation of turbine wheel 104 and impeller 108 could be offset from each other while remaining parallel to main axis 110. In use, turbine wheel 104 extracts hydraulic energy from a first fluid stream and converts the hydraulic energy to mechanical energy, and impeller 108 converts the mechanical energy from turbine wheel 104 to pressure energy in a second fluid stream. Turbine wheel 104 and impeller 108 are coupled together by a link rod (or linkage) 112 such that the mechanical energy generated by turbine wheel 104 can be transferred to impeller 104 through link rod 112.

(17) In one example, as illustrated in FIGS. 1 and 2, turbine wheel 104 includes a disc wheel 120 having a central opening 124 to receive an end portion of link rod 112. Central opening 124 may include any suitable features to attach the end portion of link rod 112 to disc wheel 120, such as, but not limited to, threads. Blades 116 are attached to disc wheel 120 and arranged around central opening 124. Although six blades are shown in FIG. 2, the number of blades may be variable, for example, in a range from 6 to 12. Blades 116 are shown as spiral curved blades in FIG. 2. However, blades 116 could have other types of curved shapes. In alternative examples, blades 116 could be straight or flat blades. In some cases, an open wheel, i.e., a wheel in the form of a ring, may be used instead of disc wheel 120. Other turbine wheel designs known in the art may be used.

(18) Returning to FIG. 1, impeller 108 may be a radial impeller. A radial impeller is an impeller that causes fluid to move in a radial direction relative to an axis of rotation of the impeller. In one example, as illustrated in FIGS. 1 and 3, impeller 108 includes blades 128 disposed around a central hub 132 and a shroud 136 disposed on one side of blades 128. The presence of shroud 136 on one side of blades 128 implies a semi-open impeller design. Shroud 136 may be omitted for an open impeller design. Blades 128 are shown as spiral curved blades. However, blades 128 could have other types of curved shapes as well as straight shapes. Blades 128 may be attached to central hub 132 in some cases. For the semi-open impeller design, shroud 136 may be attached to or integrally formed with central hub 132, and blades 128 may be attached to either or both of central hub 132 and shroud 136. Central hub 132 has an opening 134 (in FIG. 1) to receive an end portion of link rod 112. Opening 134 may include any suitable features to attach the end portion of link rod 112 to central hub 132, such as, but not limited to, threads. Other impeller designs known in the art, particularly the art of pumps, may be used.

(19) Returning to FIG. 1, turbine wheel 104 and impeller 108 are preferably designed such that when turbine wheel 104 and impeller 108 are immersed in fluid, the hydrodynamic drag exerted on turbine wheel 104 will be greater than the hydrodynamic drag exerted on impeller 108. The relative hydrodynamic drag exerted on turbine wheel 104 and impeller 108 may be achieved by controlling the relative size and/or shape of the turbine wheel and impeller. For example, turbine wheel 104 may have a larger diameter compared to impeller 108. Designing the hydrodynamic drag exerted on turbine wheel 104 to be greater than the hydrodynamic drag exerted on impeller 108 will ensure that turbine wheel 104 consumes energy from the fluid and transfers the energy to impeller 108 through link rod 112. In use, turbine wheel 104 may be positioned to be exposed to fluid flow in a drill string, and impeller 108 may be positioned to be exposed to fluid flow in an annulus of a wellbore. Rotation of turbine wheel 104 by fluid flow through the drill string will generate mechanical energy that is transferred to impeller 108 through link rod 112. In turn, the rotation of impeller 108 will create an additional pressure gradient in the annulus that can enhance hole cleaning.

(20) FIGS. 4 and 5 show a hole cleaning apparatus 200 including two rotating assemblies 100. Although two rotating assemblies are shown, hole cleaning apparatus 200 may generally include one or more rotating assemblies. In one implementation, hole cleaning apparatus 200 includes a tool body 204 to which rotating assemblies 100 are mounted. When hole cleaning apparatus 200 includes multiple rotating assemblies 100, the rotating assemblies may be uniformly distributed along a circumference of tool body 204. Tool body 204 has a lengthwise axis 206 (in FIG. 4). End connections 202, 203 may be provided at ends of tool body 204. End connections 202, 203 may have inner threaded surfaces 202a, 203a for engaging other components, such as drill string components. In some cases, threads may be provided on outer surfaces of either or both connections 202, 203. Tool body 204 includes a wall 205 having an inner wall surface 208 defining a bore 210, which extends along lengthwise axis 206. Flat wall recesses 212 are formed in inner wall surface 208 to accommodate turbine wheels 104 of rotating assemblies 100. In general, the number of recesses 212 will correspond to the number of turbine wheels 104 to be disposed inside tool body 204. In one example, when multiple recesses 212 are provided in inner wall surface 208 to accommodate multiple turbine wheels, the recesses may be uniformly distributed along inner wall surface 208. Recesses 212 are open to bore 210. Consequently, when turbine wheels 104 are mounted within recesses 212, turbine wheels 104 are exposed to bore 210.

(21) Impellers 108 are disposed adjacent to an outer wall surface 216 of wall 205 and in positions corresponding to turbine wheels 104 in recesses 212. In the portion of wall 205 disposed between each corresponding turbine wheel 104 and impeller 108, a hole 220 is formed. Link rod 112 passes through hole 220 and operatively connects corresponding turbine wheel 104 and impeller 108. A bearing 224 may be mounted in hole 220 to support rotation of link rod 112. When each rotating assembly 100 is assembled to tool body 204 as shown in FIGS. 4 and 5, an axis of rotation of each of turbine wheel 104 and impeller 108 is transverse to lengthwise axis 206.

(22) In one implementation, an external shield 248 is disposed around tool body 204 and impellers 108. External shield 248 may be a tubular wall and may be attached to tool body 204, as shown in FIG. 5, using any suitable method. Impellers 108 are located in channels 249 formed between an inner wall surface 250 of external shield 248 and outer wall surface 216 of tool body 204. Fluid can enter into and leave channels 249 through the open bottom and top ends of external shield 248.

(23) Impeller casings that guide impeller flow up hole cleaning apparatus 200 may be provided. As shown in FIGS. 6 and 7, an alternative external shield 248′ carrying impeller casings 232 may be disposed around tool body 204 and impellers 108. Each impeller casing 232 includes an inner surface 234 that defines a chamber 236. A respective impeller 108 is received in chamber 236. As illustrated in FIG. 8, chamber 236 may be a volute chamber, i.e., a chamber having a curved funnel shape. An opening at a top end of impeller casing 232 provides an outlet port 238 that is fluidly connected with chamber 236. Returning to FIGS. 6 and 7, impeller casing 232 is disposed in a channel 249′ formed between an inner wall surface 250′ of external shield 248′ and outer wall surface 216 of tool body 204. Impeller casing 232 may be attached to inner wall surface 250′. A portion of external shield 248′ covering one side of chamber 236 includes an opening forming an inlet port 240 (see FIG. 9) that is fluidly connected to chamber 236. The positioning of external shield 248′ may be such that inlet port 240 is aligned with the eye of impeller 108. The eye of an impeller is the point at which fluid enters the impeller and from which fluid spreads between the impeller blades. The eye is located at the center of the impeller and on the axis of rotation of the impeller.

(24) Returning to FIGS. 6 and 7, fluid flowing outside hole cleaning apparatus 200 can enter the eye of impeller 108 through inlet port 240. The fluid will flow into spaces between blades 128 of impeller 108 to the circumference of impeller 108. As impeller 108 is driven by the respective turbine wheel 104, the rotational motion of impeller 108 will accelerate the flow passing between impeller blades 128 to inner surface 234 of impeller casing 232, which will then act to guide the flow to outlet port 238.

(25) FIG. 10 illustrates an exemplary drilling environment in which hole cleaning apparatus 200 may be deployed. A drill string 300 is suspended in a wellbore 304 from a derrick 308 at a surface. Drill string 300 includes one or more drill pipes 312 connected to form a conduit and a drill bit 316 at the end of the conduit. At least one hole cleaning apparatus 200 is installed along drill string 300, for example, by making up connections between ends of the hole cleaning apparatus and other drill string components. In some cases, multiple hole cleaning apparatus 200 may be distributed along the length of drill string 300 to enhance hole cleaning at various points along the length of drill string 300. The installation of each hole cleaning apparatus 200 is such that the bore of the tool body of the hole cleaning apparatus is fluidly connected with the conduit formed by drill pipes 312. Besides drill pipe(s) 312, hole cleaning apparatus 200, and drill bit 316, drill string 300 may include several other tools known in the art of drilling.

(26) Wellbore 304 is drilled by operating drill bit 316 to cut into surrounding subsurface formation 320. Typically, this involves rotating drill string 300 from the surface using a top drive 324 (or a rotary table in other examples). During drilling, a surface pump 328 is operated to pump drilling fluid (also known as mud) into drill string 300. The fluid pumped into drill string 300 will exit through nozzles in drill bit 316 into the bottom of wellbore 304 and then move up an annulus 332 between wellbore 304 and drill string 300 towards the surface, carrying along cuttings of the subsurface formation. At the surface, the fluid is diverted into a mud treatment system, cleaned up, and pumped back into the drill string.

(27) FIG. 11 illustrates the flow pattern in wellbore 304 at the location of each hole cleaning apparatus for the implementation of hole cleaning apparatus 200 with impeller casings. The fluid pumped down drill string 300 is indicated by arrow 336. As fluid is pumped down the drill string, the fluid passes through bore 210 of hole cleaning apparatus 200. Turbine wheels 104 are exposed to the full flow pumped down drill string and passing through bore 210. The fluid passing through bore 210 will exert force on turbine wheels 104, causing turbine wheels 104 to rotate and drive impellers 108 through link rods 112. As fluid moves up annulus 332, as indicated by arrows 340, at least a portion of the fluid will enter the eyes of impellers 108, as indicated by arrows 342, and pass into the spaces between the impeller blades 128 to the circumference of the impellers. The rotating impellers 108 will accelerate the fluid radially towards the impeller casings 232, which will guide the fluid to outlet ports 238 and in a direction uphole, as shown by arrows 344.

(28) Movement of fluid in annulus 332 is slightly different for the hole cleaning apparatus with impeller casings. As shown in FIG. 12, for the hole cleaning apparatus without impeller casings, fluid moving uphole in annulus 332 enters into channels 249 containing impellers 108 from the bottom of external shield 248, as shown by arrows 346. Impellers 108 will increase the velocity of the fluid passing through channels 249, and the fluid with the increased velocity head will exit channels 249 as shown by arrows 348.

(29) In both flow patterns shown in FIGS. 11 and 12, the rotation of impellers 108 increases the pressure gradient in annulus 332. This increased pressure gradient enhances mixing of the fluid and formation cuttings in the annulus and forces the cuttings to move up the annulus and exit the wellbore.

(30) The detailed description along with the summary and abstract are not intended to be exhaustive or to limit the embodiments to the precise forms described. Although specific embodiments, implementations, and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the relevant art.