Fluid pulse drilling tool

Abstract

A fluid pulse apparatus for down hole drilling having a turbine assembly actuated by a flow of drilling fluid. The apparatus has a narrowed fluid flow section that cooperates with a piston that moves between an open and a fluid flow restricting position. The apparatus has a turbine assembly that rotates in response to a flow of drilling fluid. The turbine apparatus has upper and lower cam surfaces that cooperate with fixed cam followers such that rotation of the turbine assembly and cam action between the cam surfaces and the fixed followers causes the turbine assembly to reciprocate axially. The piston is fixed to either of the upper or the lower cam surfaces such that as the turbine assembly reciprocates axially, the piston moves between the open and the flow restricting positions to create a pulsed fluid flow.

Claims

1. A fluid pulse apparatus for down hole drilling, comprising: a housing defining a fluid flow passage for a flow of drilling fluid from an upstream end towards a downstream end; a turbine assembly within the fluid flow passage, the turbine assembly having an upstream annular cam surface, a downstream annular cam surface and a longitudinal axis extending between the upstream annular cam surface and the downstream annular cam surface; at least one turbine member that is operatively connected to the upstream annular cam surface and the downstream annular cam surface and is actuated by the flow of drilling fluid so as to cause rotation of the turbine assembly; and a piston fixed to the upstream annular cam surface; the fluid flow passage having a narrowed fluid flow passage upstream of the turbine assembly such that the piston is receivable within the narrowed fluid flow passage; at least one upstream cam follower fixed to the housing for cooperation with the upstream annular cam surface and at least one downstream cam follower fixed to the housing for cooperation with the downstream annular cam surface; such that when the turbine assembly is caused to rotate, there is a cam action between the upstream cam follower(s) and the upstream annular cam surface and between the downstream cam follower(s) and the downstream annular cam surface that causes the turbine assembly to reciprocate axially along the longitudinal axis within the fluid flow passage such that the piston moves axially along the longitudinal axis between a flow restricting position within the narrowed fluid flow passage and an open position to effect periodic restriction of the flow of drilling fluid through the fluid flow passage.

2. The apparatus of claim 1, wherein there is a single turbine member that is an Archimedes screw.

3. The apparatus of claim 1, wherein the turbine assembly includes a turbine sleeve and outer edges of the at least one turbine blade member(s) are fixed to the turbine.

4. The apparatus of claim 3, wherein the turbine assembly does not include a central shaft.

5. The apparatus claim 1, wherein the turbine assembly includes a shaft and the respective cam surfaces are fixed to opposing ends of the shaft.

6. The apparatus of claim 1, wherein a symmetrical cam force is applied to the upstream annular cam surface by the at least one upstream follower and a symmetrical cam force is applied to the downstream annular cam surface by the at least one downstream follower.

7. The apparatus of claim 1, wherein the narrowed fluid flow passage includes a plate with an orifice.

8. The apparatus of claim 7, wherein the plate is adapted to be removed and replaced with a plate with an orifice of a different size.

9. The apparatus of claim 1, wherein the piston is adapted for replacement with a piston of different dimensions.

10. The apparatus of claim 1, wherein the piston has a tapered head.

11. A fluid pulse drilling tool for down hole drilling comprising the fluid pulse apparatus of claim 1.

12. An assembly for delivering a percussive effect in a down hole drill string, the assembly including the fluid pulse apparatus of claim 1 and a fluid actuated pressure pulse response device that is actuated in response to the fluid pulse generated by the fluid pulse apparatus.

13. The assembly of claim 12, wherein the fluid actuated pressure pulse responsive device is located upstream of the fluid pulse apparatus.

14. The assembly of claim 12, wherein the fluid actuated pressure pulse responsive device is located downstream of the fluid pulse apparatus.

15. A method of drilling comprising operatively connecting the assembly claim 12 to a drill string and operating said drill string in a down hole mode.

16. A method of drilling comprising operatively connecting the fluid pulse apparatus of claim 1 to a drill string and operating said drill string in a down hole mode.

17. A fluid pulse apparatus adapted to be connected to a pipe line, the apparatus comprising: a housing defining a fluid flow passage for a flow of fluid from an upstream end towards a downstream end; a turbine assembly within the fluid flow passage, the turbine assembly having an upstream annular cam surface, a downstream annular cam surface and a longitudinal axis extending between the upstream annular cam surface and the downstream annular cam surface; at least one turbine member that is operatively connected to the upstream annular cam surface and the downstream annular cam surface and that is actuated by a flow of drilling fluid in the fluid flow passage so as to cause rotation of the turbine assembly; and a piston fixed to the upstream annular cam surface or the downstream annular cam surface; the fluid flow passage having a narrowed fluid flow passage section located upstream of the turbine assembly when the piston is fixed to the upstream annular cam surface such that the piston is receivable within the narrowed fluid flow passage, or the narrowed fluid flow passage is located downstream of the turbine assembly when the piston is fixed to the upstream annular cam surface such that the piston is receivable within the narrowed fluid flow passage; at least one upstream cam follower fixed to the housing for cooperation with the upstream annular cam surface and at least one downstream cam follower fixed to the housing for cooperation with the downstream annular cam surface; such that when the turbine assembly is caused to rotate, there is a cam action between the upstream follower(s) and the upstream annular cam surface and between the downstream cam follower(s) and the downstream annular cam surface that causes the turbine assembly to reciprocate axially along the longitudinal axis within the fluid flow passage such that the piston moves between a flow restricting position within the narrowed fluid flow passage and an open position to effect periodic flow restriction of the flow of fluid through the fluid flow.

18. A turbine assembly configured to be mounted within the fluid flow passage of the fluid pulse apparatus of claim 17, the turbine assembly comprising; a turbine sleeve having an upstream end and a downstream end; an upper annular cam surface operatively connected to the upstream end and a lower annular cam surface operatively connected to the downstream end; and a turbine screw member fixed within the turbine sleeve such that rotation of the turbine screw member causes rotation of the turbine sleeve and also rotation of the upper cam surface and the lower cam surface.

19. The turbine assembly of claim 18, wherein the screw is an Archimedes screw.

20. The turbine assembly of claim 19, wherein the Archimedes screw does not have a shaft and the outer edges of the screw are fixed to the turbine sleeve.

21. The turbine assembly of claim 20, wherein the upper cam surface is defined by the upstream end of the turbine sleeve and the lower cam surface is defined by the downstream end of the turbine sleeve.

22. The turbine assembly of claim 18 further comprising a piston fixed to the upper cam surface.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1 is a schematic view of the lower end of a drill string;

(2) FIG. 2 is a schematic cross sectional view of an apparatus of one aspect;

(3) FIG. 3 is a schematic cross section of the upper section of the aspect shown in FIG. 2;

(4) FIG. 4 is a schematic cross section of the lower section of the aspect shown in FIG. 2

(5) FIG. 5a is a schematic of the piston in the closed position;

(6) FIG. 5b is a schematic view of the piston in the open position;

(7) FIG. 6 is a schematic cross section of the lower section of the aspect shown in FIG. 2;

(8) FIG. 7 is a schematic cross sectional view of an apparatus of another aspect;

(9) FIG. 8 is a schematic cross sectional view of an apparatus of a further aspect;

(10) FIG. 9 is a graph showing pulse pressure as a function of time as generated by an apparatus of the present disclosure; and

(11) FIG. 10 is a further graph showing pulse pressure as a function of time generated by an alternate configuration of an apparatus of the present disclosure.

DETAILED DESCRIPTION

(12) In describing embodiments of the invention discussed herein, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to any specific terms used herein, and it is to be understood that each specific term includes all technical equivalents, which operate in a similar manner to accomplish a similar purpose.

(13) FIG. 1 is a schematic view of the lower end of a drill string 10 that includes a fluid pulse apparatus 12 of the present invention. The drill string 10 includes a conventional drill string component 14 that may be a drill collar, a drill pipe, a down hole mud motor or a measurement while drilling tool or a shock tool.

(14) The fluid pulse apparatus 12 comprises a housing with an upper sub 16 connected to a lower main body sub 18. The housing defines a fluid flow passage for a flow of drilling fluid from an upstream end towards a downstream end 7.

(15) The main body sub 18 is connected to a lower drill string component 20 that can also be any conventional down hole drilling component such as that may be a drill collar, a drill pipe, a down hole mud motor, shock tool or a measurement while drilling tool but not limited to.

(16) FIG. 2 shows a schematic cross section of the fluid pulse apparatus 12, with FIGS. 3 and 4 showing details of the upper and lower sections respectively.

(17) The upper sub 16 is connected to the lower main sub 18 through threaded connection 22. The upper sub 16 has a bore 24 defining a fluid flow passage. A bore restriction or narrowed fluid flow section 28 is located at the downstream end of the bore 24.

(18) An orifice plate 26 inserted into the downstream end of the connection 22 downstream of the bore restriction 28.

(19) FIGS. 2 and 3 show that the flow from the bore restriction 28 through the orifice 26a of the orifice plate 26 is restricted by the head 30 of a piston 32. The piston 32 is moveable between an open position (shown in detail in FIG. 5b) in which there is no fluid flow restriction through the bore restriction 28 and a fluid restricting position (shown in detail in FIG. 5a). As can be seen in FIG. 5a, the fluid flow is not restricted completely as this will cause the turbine to stall, as will be discussed further below.

(20) The orifice plate 26 can be readily replaced with a plate having a different sized orifice. In this way, the apparatus can be adapted for different flow rates, fluid types and mud types.

(21) The head 30 of the piston 32 piston is designed to have a taper so as to reduce the downward hydraulic force exerted on the piston 30 so as to reduce the torque required for rotation of the turbine.

(22) The tapered shape of the piston also reduces turbulent flow across the piston so as to achieve a stable and predictable pulse.

(23) The main body sub 18 has a radial bushing 40 pressed into the inner diameter. A shaft less helical screw or Archimedes screw 42 is mounted within the main body sub 18 for rotation.

(24) Archimedes screws are known to be able to operate under very low heads, are simple in construction, reliable and can tolerate debris. They can also tolerate low fluid levels. This means that an Archimedes screw may still be able to rotate under fluid flows where other types of turbine may stall. This means that the tolerance of the flow restriction may be as small as possible. The smallest possible clearance is desirable so as to maximize the water hammer effect. However, if the clearance restricts the flow completely or too much, the turbine can stall.

(25) The turbine can be adjusted in pitch of the turbine blades so that RPM of the turbine can be tailored to the amount of fluid pumped through it. In one example, a fluid flow of 400 gallons per minute will produce 1100 RPM but with the turbine pitch adjusted, 250 gallons per minute will produce 1100 RPM but not limited to. The RPM of the turbine is directly related to the frequency of pulse required.

(26) The outer edges of the screw 42 are fixed to a turbine sleeve 44. The turbine sleeve 44 is fitted into the bushing 40 with a clearance.

(27) The upstream and downstream ends of the turbine sleeve 44 are defined by respective cam surfaces 45, 47. The cam surfaces 45, 47 have orifices/apertures defining fluid inlets and outlets into the screw 42.

(28) Opposed pairs of cam pin followers 48, 50; 52, 54 are threaded through the outer walls of the main body and project inwardly into the main body sub 18.

(29) The upper and lower cam surfaces 45, 47 are in contact with the cam follower pins 48, 50; 52, 54 and the sleeve 44 is thereby supported by the lower cam follower pins 52, 54.

(30) In use the fluid flows into the main sub body 18 and causes the screw 42 to rotate as per conventional pulse tools. However, contrary to conventional tools, the present apparatus includes upper and lower cam surfaces that rotate with the turbine.

(31) The cam action of the rotating cam surfaces 45, 47 on the fixed followers causes 48, 50; 52, 54 the screw 42 and turbine sleeve 44 to reciprocate axially and the whole turbine assembly is alternatively positively pushed upwards by the lower cam action and positively pushed downwards by the upper cam action.

(32) Such positive action in both directions imparts a high degree of axial stability to the reciprocating movement. The result is an increase in reliability and tolerance to working angles, varying fluid flows and the like.

(33) The cam profiles can be adjusted so as to adjust the overall axial movement of the piston. This could be from 1 mm movement through to 50 mm movement but not limited to. This adjustment can then be used to tune the apparatus so as to achieve a fluid pulse under different conditions.

(34) FIG. 6 shows a schematic view of an alternative main body sub 60. The same features are those discussed above are identified by the same reference numerals. The main body sub 60 has upstream and downstream Kaplan turbines 62, 64.

(35) Each turbine 62, 64 has a shaft 66, 68 upon which helical blades 70 are mounted. The blades are fixed to a turbine sleeve 44.

(36) Each shaft 66, 68 is mounted to a cam surface 45, 47. The upper shaft 66 is fixed to a piston 32.

(37) In use, the fluid passes from the upstream end to the downstream end, the turbines 62, 64 are caused to rotate in response to the fluid flow, thereby causing rotation of the turbine sleeve and cams 45, 47 in the same manner as discussed above with respect to FIGS. 1-5.

(38) FIG. 7 shows a further aspect of a main sub body 80. The body 80 is similar to that describe above with respect to FIGS. 1 to 5 in having an Archimedes screw 42 attached to a turbine sleeve 44. Upstream and downstream cams 45, 47 are attached to the turbine sleeve 44. In this case, the screw 40 has a shaft 82.

(39) FIG. 8 shows a still further aspect of the main body sub 90. The main body sub is similar to that shown in FIG. 8 except that there is no turbine sleeve. The shaft is fixed to the cam surfaces 45, 47 and the cam surfaces are caused to rotate by rotation of the shaft rather than a turbine sleeve.

(40) FIG. 9 is a graph showing pulses per second at 700 psi that are created over one second by a fluid pulsing apparatus of the invention pumping 300 gallons per minute. There are 18 revolutions of the turbine apparatus per second and 18 pulses, representing one pulse per revolution.

(41) FIG. 10 is a graph of showing pulses per second at 400 psi that are created over one second by the same fluid pulsing apparatus as that used to generate the graph of FIG. 9, also pumping 300 gallons per minute. There are 9 revolutions of the turbine apparatus per second and 18 pulses, representing one pulse per revolution.

(42) The fluid pulses may be seen to be very consistent in frequency and pulse height. This makes the pulses that this tool creates very easy to filter out so that the pulses do not interfere with other tools such as directional tools and (measurement while drilling) MWD tools.

(43) As discussed above, the maximum fluid pressure is achieved when the piston is in the fluid restricting position. The narrower the restriction, the greater the increase in pressure. The graph of FIG. 10 was achieved with a piston of smaller diameter than that used to generate the graph in FIG. 9. It will be appreciated that by simply changing the piston and/or orifice diameter, the fluid pulse apparatus of the present invention can be easily tuned.

(44) Further adjustments may be made by adjusting the pitch of the turbine and size of the piston while using different fluid property and pumping different gallons per minute, it is possible to adjust the frequency of pulse over a second and to adjust the pulse height to create many different configurations tailored to match different conditions.

(45) The fluid pulse apparatus does not have any roller bearings or elastomers, such as those found in positive displacement motors that are used to drive valves to produce a pressure pulse as per known devices. The lack of roller bearings and elastomers can extend the life of the apparatus while being used in hot hole conditions and when there is abrasive matter being pumped through the apparatus.

(46) Still further without elastomers, non-aqueous chemical fluids can be pumped through the apparatus.

(47) Further, without elastomers or seals, the apparatus can tolerate higher pressures.

(48) As a result of the double cam action, the fluid pulses are very consistent in frequency and pulse height. It is believed that this consistency is as a result of the as a result of the double cam action. This makes the pulses that this tool creates very easy to filter out so that the pulses do not interfere with other tools such as directional tools and (measurement while drilling) MWD tools.

(49) Unlike other fluid pulse apparatus on the market, the flow control components of the present apparatus only move axially. This in turn means that there is no harmful and unwanted lateral vibration created. Those apparatus on the market that use mud motor technology do create lateral vibration that in turn causes damage to other components that make up and are included within the drill string.

(50) The present fluid pulse apparatus can be used with or without a shock tool. An advantage of the present apparatus is that the apparatus without a shock tool can induce a hammer effect on coil tubing which in turn creates axial movement of a drill string.

(51) When the fluid pulse apparatus is used with a shock tool the pulse will react on the pump open area of the shock tool. This will cause the shock tool to axially extend and retract with each pulse. The shock tool can be placed below the fluid pulse apparatus or above the fluid pulse apparatus. If the pump open area of the shock tool is increased, the pulse will have a larger area for the hydraulic force to act upon which in turn will increase the axial extend and retract the shock tool. If the pump open area of the shock tool is reduced, the pulse will have less area for the hydraulic force to act upon which in turn will reduce the axial extend and retract the shock tool. This is known as a hammer effect as described in U.S. Pat. No. 4,830,122.

(52) Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.

(53) It will also be appreciated that the various dependent claims and the features set forth therein can be combined in different ways than presented in the initial claims. It will also be appreciated that the features described in connection with individual embodiments may be shared with others of the described embodiments.