On-demand flow pulse system

Abstract

The embodiments disclosed herein relate to a flow pulse system including a rotor, a stator, an ejector configured for releasable coupling to the rotor, and a nozzle releasablely coupled to the rotor, the nozzle being configured to control fluid flow through the rotor. In some embodiments, the system uses a screen disposed therein, the screen including an inner aperture in fluid communication with a plurality of lobe-shaped cavities along the rotor. In some embodiments, the system uses a fixed valve and an oscillating valve having a plurality of oscillating valve ports in fluid communication with the plurality of lobe-shaped cavities.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 877,168, filed July 22, 2019, entitled “On Demand Flowfulsing System,” the entire contents of which are incorporated herein by reference for all purposes.

[0003] Statement regarding federally funded research or development

[0004] not applicable. Background Technology

[0005] This disclosure generally relates to downhole equipment. More specifically, this disclosure relates to drilling equipment and drilling methods that include a stirrer or a flow pulse device in the drill string. Among other benefits, the flow pulse device can be used to oscillate the drill string to reduce friction with the wellbore, enhance tool face control, extend wellbore length, and improve drilling efficiency. The flow pulse device can also be used with other downhole work strings. Summary of the Invention

[0006] Some embodiments disclosed herein relate to a flow pulse system. In one embodiment, the flow pulse system includes a housing having a central axis, a first end, a second end opposite to the first end, and an aperture extending along the central axis from the first end to the second end. Furthermore, some embodiments may include a stator and a rotor, the stator being disposed within the aperture of the housing, the stator having a plurality of lobe-shaped cavities, and the rotor being disposed within the stator. The rotor includes an axis offset from the central axis, a plurality of lobes cooperating with the plurality of lobe-shaped cavities, and a through-hole extending along the axis. Additionally, some embodiments may include a dart configured to releasably engage with the through-hole of the rotor, the dart including a first radially outward guide section, a second radially outward guide section, a tip, an inner bore, and a releasable nozzle configured to control a first fluid flow through the inner bore and the through-hole.

[0007] Other embodiments disclosed herein relate to a flow pulse system including a housing having a central axis, a first end, a second end opposite to the first end, and an aperture extending from the first end to the second end along the central axis. Furthermore, some embodiments may include a stator and a rotor, the stator being disposed within the aperture of the housing, the stator having a plurality of lobe-shaped cavities, and the rotor being disposed within the stator. The rotor includes an axis offset from the central axis, a plurality of convex blades corresponding to the plurality of lobe-shaped cavities, and a through-hole extending along the axis. Furthermore, some embodiments may include a screen disposed within the aperture of the housing, the screen including a body and a connecting surface at a first end of the body, the connecting surface being configured to connect to the housing. Furthermore, some embodiments may include a screen housing and an inner aperture extending to a second end of the body, the inner aperture being in fluid communication with the through-hole.

[0008] Other embodiments disclosed herein relate to a flow pulse system including a housing having a central axis, a first end, a second end opposite to the first end, and an aperture extending along the central axis from the first end to the second end. Furthermore, some embodiments may include a stator and a rotor, the stator being disposed within the aperture of the housing, the stator having a plurality of lobe cavities, and the rotor being disposed within the stator. The rotor includes an axis offset from the central axis, a plurality of lobes cooperating with the plurality of lobe cavities, and a through-hole extending along the axis. Furthermore, some embodiments may include a valve section including a stationary valve coupled to the second end of the housing, the stationary valve including a first face, a stationary center port, and a plurality of stationary valve ports. Furthermore, some embodiments may include an oscillating valve coupled to the rotor, the oscillating valve including a second face adjacent to the first face, an oscillating center port in fluid communication with the through-hole of the rotor, and a plurality of oscillating valve ports in fluid communication with the plurality of lobe cavities.

[0009] The embodiments described herein include combinations of features and characteristics designed to address various drawbacks associated with certain existing apparatuses, systems, and methods. The features and technical characteristics of the disclosed embodiments have been outlined rather broadly above to facilitate a better understanding of the detailed implementation described below. Those skilled in the art will readily understand the various features and characteristics described above, as well as others, by reading the following detailed description and referring to the accompanying drawings. It should be understood that the disclosed concepts and specific embodiments can be readily used as the basis for modifications or the design of other structures for performing the same purposes as the disclosed embodiments. It should also be recognized that such equivalent structures do not depart from the spirit and scope of the principles disclosed herein. Attached Figure Description

[0010] To describe the various exemplary embodiments in detail, reference will now be made to the accompanying drawings, in which:

[0011] Figure 1 This is a cross-sectional view of a flow pulse device according to some embodiments;

[0012] Figure 2 yes Figure 1 A cross-sectional view of the activation section and a partial cross-sectional view of the rotor section of the flow pulse device;

[0013] Figure 3 yes Figure 1 A cross-sectional view of the rotor section of the flow pulse device;

[0014] Figure 4 yes Figure 1 A cross-sectional view of the valve section of a flow pulse device;

[0015] Figure 5 Is Figure 2 A three-dimensional view of the screen used in the activation section;

[0016] Figure 6 yes Figure 5 A cross-sectional view of the sieve;

[0017] Figure 7 Is Figure 2 A three-dimensional view of the ejectors and nozzles used in the activation section;

[0018] Figure 8 yes Figure 7 A cross-sectional view of the ejector and nozzle;

[0019] Figure 9 These are cross-sectional views of the active section and partial cross-sectional views of the rotor section in the deactivated state.

[0020] Figure 10 Is Figure 4 A three-dimensional view of the oscillating valve used in the valve section;

[0021] Figure 11 Is Figure 4 A three-dimensional view of the fixed valves used in the valve section;

[0022] Figure 12 yes Figure 10 and Figure 11 Cross-sectional views of the oscillating valve and the stationary valve;

[0023] Figure 13 These are cross-sectional views of the active section and partial cross-sectional views of the rotor section, showing the fluid flow in the deactivated state.

[0024] Figure 14 These are cross-sectional views of the active section and partial cross-sectional views of the rotor section, showing the fluid flow through them in the active state;

[0025] Figure 15 yes Figure 4 A cross-sectional view of the valve section, showing the fluid flow through it;

[0026] Figure 16 This is a schematic axial view of the interface between the oscillating valve and the stationary valve, showing the overlap of the ports in the open state;

[0027] Figure 17 This is another schematic axial view of the oscillating valve and stationary valve interface, showing the overlap of the ports in the partially open state; and

[0028] Figure 18 This is another schematic axial view of the oscillating valve and stationary valve interface, showing the overlap of the ports in the closed state. Detailed Implementation

[0029] The following discussion pertains to various exemplary embodiments. However, those skilled in the art will understand that the examples disclosed herein have broad applications, and that the discussion of any embodiment is merely meant to be an example of that embodiment and is not intended to imply that the scope of this disclosure (including the claims) is limited to that embodiment.

[0030] The accompanying drawings are not necessarily drawn to scale. Some features and components may be shown at an enlarged scale or in a schematic form, and for the purposes of clarity and brevity, some details of conventional components may not be shown.

[0031] In the following discussion and claims, the terms “comprising” and “including” are used in an open-ended manner and should therefore be interpreted as meaning “including, but not limited to…”. Furthermore, the terms “connected” or “linked to” are intended to indicate either an indirect or direct connection. Thus, if a first device is connected to a second device, the connection can be a direct connection between the two devices or an indirect connection established via other devices, components, nodes, and connectors. Additionally, as used herein, the terms “axial” and “axially” generally refer to along or parallel to a given axis (e.g., the central axis of a body or port), while the terms “radial” and “radially” generally refer to perpendicular to a given axis. For example, axial distance refers to a distance measured along or parallel to the axis, while radial distance refers to a distance measured perpendicular to the axis.

[0032] As described above, a flow pulse system (also referred to herein as a stirrer) can be used along the drill string to introduce pressure pulses or pressure waves within the drill string. Flow pulse systems can be used alone or in conjunction with other components to provide drilling benefits, including enhanced tool face control, improved drilling efficiency, and can be used to introduce oscillations in the drill string. More specifically, one such additional component used with a flow pulse system can be a percussion tool that utilizes pressure pulses from the flow pulse system to induce oscillations along the longitudinal axis of the drill string. In some applications, such drill string oscillations can provide reduced friction within the wellbore and can allow for extended drill string lengths. To operate a flow pulse system, pumping pressure from the drilling rig is required to overcome the pressure drop across the flow pulse system; therefore, it may be desirable to provide a flow pulse system that can be selectively activated only when the drill string encounters the desired downhole conditions. Furthermore, it may be desirable to operate the flow pulse system with adjustable frequency and amplitude, which in turn allows for a smaller overall pressure drop. In addition, it may be desirable to have a flow pulse system that can be deactivated when no longer needed, or deactivated and reconfigured to provide an improved pressure pulse for another section of well drilling. Besides the drill string, this flow pulse device can also be used for other downhole operations or tubing.

[0033] Therefore, the embodiments disclosed herein include systems and methods for using a fluid pulse system that can be selectively engaged after drilling has commenced and while the drill string is positioned within the wellbore. Furthermore, the embodiments disclosed herein include systems and methods for selectively adjusting the frequency and amplitude of the fluid pulse system, and for selectively disengaging and / or reconfiguring its frequency and amplitude after use within the wellbore. Additionally, the systems and methods disclosed herein provide valve ports operable between fully open, partially open, and fully closed positions, which can provide improved pressure pulse response. Furthermore, the systems and methods disclosed herein prevent clogging of the fluid pulse system when materials (e.g., plugging materials) are introduced into the wellbore.

[0034] refer to Figure 1The flow pulse system 10 is shown coupled to a first sub-section 20 and a second sub-section 40, both aligned along axis 15. The flow pulse system 10 includes a housing 30 and includes an activation section 100, a rotor section 200, and a valve section 300. Generally, the flow pulse system 10 is a tubular assembly that can be installed along any segment of the drill string within the wellbore (not shown). An exemplary connection is shown along the first end 21 of the first sub-section 20 and the second end 42 of the second sub-section 40, both of which can be modified as needed to fit a particular drill string. Similarly, the second end 22 of the first sub-section 20 (… Figure 9 ) and the first end 41 of the second short section 40 ( Figure 4 It can also be modified as needed to suit the housing 30 and the flow pulse system 10.

[0035] refer to Figure 2 The activation section 100, which can be used within the flow pulse system 10, is shown in more detail. The activation section 100 includes an axis 115 generally aligned with the axis 15 of the flow pulse system 10, an axis 215 offset from the axis 115, a screen 110, and a nozzle 140 mounted within the ejector 160. More specifically, the housing 30 has a first end 31 and a second end 32 opposite to the first end 31 (e.g., ...). Figure 4 (As shown) and a hole 33 concentric with the housing 30, both extending along axis 115 between ends 31 and 32. The screen 110 is positioned along axis 115 near the first end 31, while the nozzle 140 and ejector 160 are positioned along axis 215 between the screen 110 and the second end 32.

[0036] refer to Figure 2 and Figure 3The rotor section 200 is shown in more detail, comprising a rotor 210 aligned with axis 215 and a stator 230 aligned with axis 115. Typically, the rotor 210 and stator 230 are tubular members housed within a bore 33, wherein the rotor 210 is at least partially positioned within the stator 230. More specifically, the stator 230 includes a first end 232 and a second end 234 opposite to the first end 232, and includes a radially inner surface 236 extending between the ends 232 and 234. The stator 230 is coupled to the housing 30 within the bore 33 at a position between the ends 31 and 32, and includes a plurality of leaf-shaped cavities 240 axially spaced along the radially inner surface 236. The plurality of leaf-shaped cavities 240 cause the diameter of the inner surface 236 to sequentially increase and decrease along the length of the stator 230. The rotor 210 is also a tubular member, comprising a first end 212, a second end 214 opposite to the first end 212, a body 216, and a bore 218. Both the body 216 and the bore 218 are aligned with the axis 215 and extend between the ends 212 and 214. The rotor 210 also includes a vane 224 extending radially outward from the body 216, wherein the vane 224 is arranged in a generally helical manner along the axis 215 and extends between the ends 212 and 214. When in... Figure 2 and Figure 3 When viewed in the cross-section shown, the pitch is chosen such that a full 360-degree rotation of the convex blade 224 around axis 215 aligns with the distance between the blade cavities 240. As described, a single continuous convex blade 224 is shown in this embodiment; however, other embodiments may use multiple convex blades arranged helically, or multiple separate convex blades not forming a helix. In some embodiments, the number of convex blades 224 of rotor 210 may be one less than the number of blade cavities 240 along stator 230. In all cases, when considered as a simplified representation for discussing the geometry of rotor 210 in the cross-sectional view, convex blade 224 may be referred to as a single convex blade. For example, in Figure 3 In this rotor 210, there are 11 convex blades 224. The relative dimensions of the radial inner surface 236, the blade-shaped cavity 240, and the convex blades 224 are selected such that the rotor 210 can be rotatably arranged within the stator 230. The radial clearance between the convex blades 224 and the blade-shaped cavity 238 defines the cavity 238.

[0037] refer to Figure 4The valve section 300 is shown in more detail, comprising a component aligned with axis 215 of rotor 210 and a component aligned with axis 315, which is generally aligned with axis 15 of flow pulse system 10. Typically, the component aligned with axis 215 is coupled to rotor 210 and thus moves with rotor 210 within housing 30, while the component aligned with axis 315 remains stationary relative to housing 30 and the second stub 40. More specifically, the valve section 300 component aligned with axis 215 includes an oscillating valve adapter 310 and an oscillating valve port section 340. Furthermore, the valve section 300 component aligned with axis 315 includes a fixed valve port section 360 and a fixed valve adapter 380.

[0038] refer to Figure 5 and Figure 6 The screen 110 is shown in more detail, and the screen 110 includes an axis 115, a first end 112, and a second end 114 opposite to the first end 112. Furthermore, the screen 110 includes a connecting surface 116 extending from the first end 112 along the axis 115, a screen housing 120 extending from the second end 114 along the axis 115, and a body 118 extending between the connecting surface 116 and the screen housing 120. In some embodiments, the connecting surface 116 includes threads and has a smaller diameter than the body 118, and an annular shoulder 132 creates a radial transition between the connecting surface 116 and the body 118. Moreover, a flat portion 119 may be provided along the body 118 to allow torque to be applied to the threads of the connecting surface 116. A hole 122 extends from the first end 112, passes through the interior of the connecting surface 116 and the body 118, while an inner surface 123 extends from the second end 114 and passes through the interior of the screen housing 120, intersecting the hole 122. A chamfer 130 transitions between the inner surface 123 and the hole 122, while a chamfer 128 is included along the hole 122 at the first end 112. The screen housing 120 and the inner surface 123 are generally truncated conical in shape, with an inlet diameter 124 near the first end 112 larger than an outlet diameter 126 at the second end 114. Furthermore, the screen housing 120 includes a screen element or slot 134 passing through it. In this embodiment, the screen element 134 includes a plurality of elongated channels circumferentially distributed around an axis 115, each having a long axis aligned with the axis 115. However, other embodiments may include channels of different shapes arranged differently within the screen element 134 (e.g., a plurality of circular channels extending radially relative to the axis 115).

[0039] refer to Figure 7 and Figure 8The ejector 160 is shown in more detail, and is generally symmetrical with respect to axis 215. More specifically, the ejector 160 includes a first end 162, a second end 164 opposite to the first end 162, and a plurality of features extending axially along axis 215 (including a head 166 extending from the first end 162, a neck 168 extending from the head 166, a first radially outward guiding section 174 near the neck 168, a second radially outward guiding section 182 near the second end 164, and a truncated conical tip 184 that narrows toward the second end 164). In this embodiment, the head 166 has a larger diameter than the neck 168, and thus forms a shoulder 170 between the head 166 and the neck 168. Furthermore, the first radially outward guiding section 174 and the second radially outward guiding section 182 have larger diameters than the nearby sections of the ejector 160, and thus include various diameter transitions. More specifically, in this embodiment, a chamfered transition section is used and includes transition sections 172, 176, and 180. For reasons that will become more apparent in the following description, a first radially outward guide section 174 and a second radially outward guide section 182 are spaced apart along axis 215, and a pressure-reducing section 178 with a reduced diameter is provided between them. Furthermore, the first radially outward guide section 174 also includes a groove 186 arranged along the outer cylindrical surface of the first radially outward guide section 174 and receiving a ring 187 (e.g., an O-ring) within the groove 186.

[0040] Regarding the inner surface of the ejector 160, the ejector 160 also includes a hole 188 extending from the second end 164 into the neck 168, an inner connecting surface 190 extending from the first end 162, and a second hole 192 extending between the hole 188 and the inner connecting surface 190. In this embodiment, the inner connecting surface 190 is threaded and has a larger diameter than the second hole 192, thus forming a shoulder 194 between the inner connecting surface 190 and the second hole 192.

[0041] Still referencing Figure 7 and Figure 8Nozzle 140 is shown mounted within a first end 162 of ejector 160. More specifically, nozzle 140 is axially symmetrical about axis 215 and includes a first end 142, a second end 144 opposite to the first end, and an outer connecting surface 146 extending between ends 142 and 144. Nozzle 140 also includes a driver 154 extending from the first end 142 and an inner nozzle profile 150 extending between ends 142 and 144. More specifically, inner nozzle profile 150 includes an inlet 148 at the first end 142 and an outlet 152 at the second end 144. In this embodiment, inlet 148 has a smaller diameter than outlet 152 and can therefore be considered a diffusion nozzle, wherein fluid traveling from inlet 148 to outlet 152 will experience a decrease in flow rate and an associated increase in pressure. However, in other embodiments, inlet 148 may have a diameter equal to or greater than that of outlet 152. The diameter of the inlet 148, the diameter of the outlet 152, and the shape of the inner nozzle profile 150 will be provided in various combinations and sizes, as the fluid flow through the nozzle 140 will affect the flow along the various sections within the flow pulse system 10, as will be discussed more fully below.

[0042] When nozzle 140 is mounted within ejector 160, the outer engagement surface 146 of nozzle 140 engages with the inner engagement surface 190 of ejector 160. A driver 154 can be used to apply torque to thread multiple segments together until the second end 144 of nozzle 140 abuts against the shoulder 194 of ejector 160. A seal 196 (e.g., an O-ring seal) can be provided along the second end 144 to prevent fluid leakage around the outer periphery of nozzle 140, and / or alternative seals 196 (not shown) can be provided as needed along other sections of nozzle 140 (e.g., near the first end 142 of nozzle 140).

[0043] refer to Figure 9The active section 100 is shown in a deactivated state or position, in which the ejector 160 is not positioned within the rotor 210. A first short section 20 is shown coupled to a housing 30 and a screen 110, both aligned along axis 115. More specifically, the first short section 20 includes an outer coupling surface 24 extending from a second end 22, which engages with an inner coupling surface 34 of the housing 30. A shoulder 26 on the first short section 20 abuts against a first end 31 of the housing 30 to limit axial position between them, while a seal 29 provides a hole seal therebetween. The first short section 20 also includes an inner coupling surface 28 extending from the second end 22 within the first short section 20. When the connecting surface 116 engages the inner connecting surface 28, the screen 110 is connected to the first short section 20, and the axial position between the screen 110 and the first short section 20 is established as the annular shoulder 132 of the screen 110 abuts the second end 22 of the first short section 20. As previously described, the stator 230 is connected in a fixed position within the hole 33 of the housing 30, while the rotor 210 is housed within the stator 230. The first end 212 of the rotor 210 is positioned near and in some cases abuts the second end 114 of the screen 110.

[0044] refer to Figure 10 and Figure 12 An oscillating valve 311 is shown, which includes an oscillating valve adapter 310 and an oscillating valve port section 340. Generally, the oscillating valve port section 340 mates within the oscillating valve adapter 310 to form the oscillating valve 311. More specifically, the oscillating valve adapter 310 includes a first end 312, a second end 314 opposite to the first end 312 along an axis 215, a connecting surface 316 extending from the first end 312, a body 318 extending from the second end 314, and an outer shoulder 320 extending radially between the connecting surface 316 and the body 318. In some embodiments, the connecting surface 316 may include threads. Furthermore, a through hole 322 extends from the first end 312 along the axis 215 to meet a second hole 324 extending from the second end 314 along the axis 215. The second hole 324 is a blind hole that terminates within the body 318 to form an inner shoulder 326.

[0045] The oscillating valve port section 340 includes a first end 342, a second end 344 opposite to the first end 342 along an axis 215, and a body 346 extending between the ends 342 and 344. More specifically, the body 346 extends from the first end 342 along a first region with a constant diameter, and then widens to an increasing diameter near the second end 344. The oscillating valve port section 340 also includes a hole 348 extending from the first end 342 along an axis 215, which meets a central port 350 extending from the second end 344 along an axis 215. A transition portion 352 is disposed between the hole 348 and the central port 350, and in this embodiment is formed in a frustum conical shape, the diameter of which decreases near the second end 344. An orifice 354 is formed as a through hole in the body 346, extending at an angle relative to the axis 215 into the hole 348. In some embodiments, the orifice 354 is angled toward the second end 344 (e.g., the radially inward portion is positioned closer to the second end 344), wherein a portion of the orifice 354 extends along the transition portion 352. An oscillating valve port 358 extends from the second end 344 and includes an inlet 356 that extends to the radially outer surface of the body 346. In some embodiments, the oscillating valve port 358 extends axially relative to axis 215, while the inlet 356 extends at an angle toward the second end 344 (e.g., the radially inward portion is positioned closer to the second end 344). Figure 10 As best shown, a plurality of oscillating valve ports 358 and a plurality of inlets 356 may be arranged along the second end 344 and may be distributed circumferentially relative to axis 215. For example, in this embodiment, four oscillating valve ports 358 and four inlets 356 are distributed at ninety-degree intervals.

[0046] To form the oscillating valve 311, the oscillating valve port section 340 is coupled to the oscillating valve adapter 310. More specifically, the body 346 of the oscillating valve port section 340 is fitted within a second hole 324 of the oscillating valve adapter 310, wherein a first end 342 of the oscillating valve port section 340 abuts an inner shoulder 326 of the oscillating valve adapter 310. In some embodiments, the fit between the second hole 324 and the body 346 may be a press fit, which requires relative heating between the surfaces during assembly.

[0047] refer to Figure 11 and Figure 12A fixed valve 361 is shown, which includes a fixed valve port section 360 and a fixed valve adapter 380. Generally, the fixed valve port section 360 mates within the fixed valve adapter 380 to form the fixed valve 361. More specifically, the fixed valve port section 360 includes a first end 362, a second end 364 opposite to the first end 362 along an axis 315, and a body 366 extending between the ends 362 and 364. In the illustrated embodiment, the body 366 has a constant diameter portion near the second end 364, and then an increasing diameter along the first end 362. Furthermore, a central port 368 extends within the body 366 from the first end 362 and meets a tapered portion 370 extending from the second end 364. More specifically, the tapered portion 370 has a truncated conical profile, the diameter of which increases axially away from the second end 364. Fixed valve ports 372 are positioned offset from axis 315 along the first end 362, and these fixed valve ports 372 are circumferentially distributed relative to axis 315 (e.g., Figure 11 (Best shown) and extends into the body 366 to meet the inner cavity formed by the tapered portion 370. In this embodiment, four fixed valve ports 372 are provided and they are distributed at ninety-degree intervals. The fixed valve ports 372 may extend into the body 366 in a direction parallel to the axis 315 or may extend at an angle. For example, the fixed valve ports 372 may converge toward the axis 315 at a position near the second end 364.

[0048] The fixed valve adapter 380 includes a first end 382, ​​a second end 384 opposite to the first end 382 along an axis 315, a body 386 extending from the first end 382, ​​a seal receiving portion 394 extending from the second end 384, and a connecting surface 398 extending between the body 386 and the seal receiving portion 394. More specifically, the body 386, the connecting surface 398, and the seal receiving portion 394 are generally cylindrical features symmetrical about the axis 315, connected to radially oriented shoulders. A shoulder 400 is formed between the body 386 and the connecting surface 398, while a shoulder 396 is formed between the connecting surface 398 and the seal receiving portion 394. An annular groove 401 (receiving seal 402) is formed in the seal receiving portion 394 near the second end 384 and axially spaced along the axis 315. In some embodiments, the connecting surface 398 may include threads. Furthermore, the first hole 388 extends from the first end 382 along the axis 315 and terminates within the body 386 to form an inner shoulder 390, while the second hole 392 extends from the second end 384 along the axis 315 to intersect with the first hole 388.

[0049] To form a fixed valve 361, a fixed valve port section 360 is coupled to a fixed valve adapter 380. More specifically, the body 366 of the fixed valve port section 360 is fitted within a first hole 388 of the fixed valve adapter 380, wherein a second end 364 of the fixed valve port section 360 abuts an inner shoulder 390 of the fixed valve adapter 380. In some embodiments, the fit between the first hole 388 and the body 366 may be a press fit, which requires relative heating between the surfaces during assembly.

[0050] refer to Figure 4 and Figure 12 Valve section 300 houses an oscillating valve 311 and a fixed valve 361 within a bore 33 of housing 30. As previously described, valve section 300 includes an axis 215 coinciding with the movable rotor 210 and a fixed axis 315 concentric with housing 30 and second stub 40. More specifically, oscillating valve 311 is aligned with axis 215 when it is coupled to rotor 210, while fixed valve 361 is aligned with axis 315 when it is coupled to second stub 40. In this way, the offset of axis 215 from axis 315, as well as any other offset axis, can be referred to as “eccentricity,” and such terminology also applies to components such as oscillating valve 311 and fixed valve 361 that are axially offset relative to each other. When the second end 214 of rotor 210 abuts against the outer shoulder 320 of oscillating valve 311, the coupling surface 316 of oscillating valve 311 engages with the oscillating valve coupling surface 228 of rotor 210.

[0051] The fixed valve 361 partially fits within the second short section 40 near the first end 41. More specifically, when the fixed valve 361 and the second short section 40 engage along surfaces 47, 398 and abut along the first end 41 and shoulder 400, the seal 402 of the fixed valve 361 seals along the hole 48 of the second short section 40.

[0052] During operation, when the rotor 210 applies thrust along axis 215, the flat surfaces of the second end 344 of the oscillating valve 311 and the first end 362 of the stationary valve 361 abut and are generally sealed. Furthermore, as the rotor 210 rotates within the stator 230, it also undergoes nutating motion, in which axis 215 moves relative to axis 315 in an elliptical or orbital pattern based on the eccentricity of the rotor 210 and the interacting convex blades 224 with the blade-shaped cavity 240. Considering this combination of thrust applied by the rotor 210 and nutating motion, slippage occurs at the flat abutting surfaces of valves 311 and 361 because the oscillating valve 311 also nutates relative to the stationary valve 361. As a shorthand term herein, the nutating motion of components within the flow pulse system 10 may alternatively be referred to as “rotation.” Furthermore, those skilled in the art will understand that the nutating motion can be modified (e.g., by changing the dimensions of the rotor 210 and stator 230) without departing from the operating principles disclosed herein. In some embodiments, as the rotor 210 rotates within the stator 230, the path of the axis 215 will form an incycloid.

[0053] refer to Figure 13 The active section 100 is shown as being in a deactivated state or position, wherein the emitter 160 is not installed within the rotor 210. Generally, in the deactivated state, the rotor 210 rotates only slowly within the stator 230, and as a result, the flow pulse system 10 may only generate a small amount of pulsating flow.

[0054] During drilling operations, drilling mud can be introduced into the orifice or annulus of the drill string (not shown), imparting an upstream flow 500 extending from the first short section 20 into the active section 100. The upstream flow 500 generally flows along axis 115 and thus tends to continue in this direction through screen 110 and primarily as orifice flow 502 into the orifices 218 within rotor 210. Due to the restricted flow downstream of orifice flow 502, a relatively small back pressure occurs that impedes it, and typically, this inactivity state may result in a pressure loss of only 20 to 80 psi throughout the flow pulse system 10. Under certain flow conditions, back pressure may occur within the orifices 218 of rotor 210, which will cause some annular flow 504 to deflect through screen element 134 of screen 110. The annular flow 504 then moves downstream between rotor 210 and stator 230, resulting in some rotation of rotor 210, even in the inactivity state. For clarity, the gap between screen 110 and rotor 210 is exaggerated and can be shown in near-adjacent contact during application, so that any annular flow 504 will pass through screen element 134. This configuration can help prevent particle clogging between rotor 210 and stator 230. For example, plugging material in upstream flow 500 will tend to be guided into orifice 218 and away from the relatively small channel between rotor 210 and stator 230. Furthermore, the tapered shape of screen housing 120 can tend to prevent clogging of screen element 134 and can be “self-cleaning” in effect. Moreover, the tight positioning of screen 110 can provide additional operational benefits to rotor section 200, as rotor 210 may be constrained by axial movement when the second end 114 of screen 110 abuts the first end 212 of rotor 210. During some flow conditions, even when the screen 110 is configured to maintain the gap between the ends 114, 212, the rotor 210 may tend to "kick back" and thus exert a thrust on the screen 110.

[0055] refer to Figure 14The activation section 100 is shown in an activated state or position, wherein the ejector 160 is mounted within the rotor 210. In the activated state, an additional upstream flow 500 is directed to the annular flow 504 to increase the rotation of the rotor 210, which causes the flow pulse system 10 to generate an increased pulse flow. The pulse frequency and amplitude are related to the flow velocity of the annular flow 504, which can be partially controlled by selecting a specific nozzle 140 for the ejector 160. More specifically, when the ejector 160 engages along the seat 222 of the rotor 210, the ring 187 can seal along the second hole 220 of the rotor 210, and substantially all of the flow 502 through the hole of the rotor 210 will pass through the nozzle 140, and the back pressure (e.g., pressure head loss or pressure drop through the nozzle 140) will then drive a larger annular flow 504, causing the rotor 210 to rotate at a higher frequency. By providing various nozzle 140 configurations, once the drill string is in place within the partially drilled wellbore, the user of the flow pulse system 10 can select a flow pulse frequency and amplitude suitable for a specific downhole condition. Because the total pressure loss through the flow pulse system 10 tends to increase with increasing annular flow 504, the user of the flow pulse system 10 can select a nozzle with an inner nozzle profile 150 (e.g., Figure 8 The nozzle 140 (shown) optimizes the flow pulse frequency and amplitude while balancing the overall pressure drop across the flow pulse system 10. Additionally, the orifice 354 (shown) can also be modified. Figure 12 The diameter of the flow pulse system 10 and the properties of the drilling mud (e.g., weight and viscosity) influence the pulse frequency and amplitude. This ability to balance the performance of the flow pulse system 10 against the relevant pressure drop can be advantageous during operation, as the precise flow pulse frequency and amplitude required may not be known or can not be predicted before drilling operations. Furthermore, even if the user does know in advance what frequency and amplitude will be needed, this on / off selectivity allows the user to engage the flow pulse system 10 only when needed, thus preserving the pumping pressure requirements of the surface equipment on the drilling rig.

[0056] In addition, such as Figure 13As shown, the active section 100 can return to the deactivated state because the ejector 160 can be selectively disengaged from the seat 222 of the rotor 210. More specifically, a separate tool (e.g., a cable tool or puller, not shown) can be used to grip the ejector 160 along the shoulder 170 and / or neck 168 and apply a pull force to retract the ejector 160. In some embodiments, close proximity between the first end 212 of the rotor 210 and the second end 114 of the screen 110 can be advantageous because the abutment contact between them can compressively resist the pull force applied to the ejector 160. After the ejector 160 is retracted, drilling operations can continue without operating the flow pulse system 10, thus reducing the total pressure drop on the flow pulse system 10, or the nozzle 140 of the ejector 160 can be reconfigured to select a flow pulse frequency or amplitude different from the initially used flow pulse frequency or amplitude. This sequential retraction and reconfiguration of the ejector 160 can be repeated as needed during drilling operations.

[0057] refer to Figure 15 Valve section 300 is shown in a deactivated state, where ejector 160 is not installed within rotor 210. As previously described, in the deactivated state, orifice flow 502 is greater than annular flow 504; therefore, a large portion of the total upstream flow 500 is directed between center ports 350, 368, which can be configured to generate only small pulsed flows. More specifically, center port flow 508 is defined between center ports 350, 368 of oscillating valve port section 340 and stationary valve port section 360, respectively. Valve port flow 510 is defined between oscillating valve port 358 and stationary valve port 372. Downstream flow 512 is defined as the flow exiting stationary valve adapter 380 and entering the second stub 40 and includes the sum of flows 508 and 510. Flow 506 is also shown passing through orifice 354, which, in some flow configurations, provides a flow path between orifice flow 502 and annular flow 504. For example, as will be discussed more fully below, when nozzle 140 directs flow to annular flow 504 and there is a blockage between ports 358 and 372 that restricts or completely blocks valve port flow 510.

[0058] refer to Figures 16 to 18An axial view aligned with axis 315 is shown to illustrate the relative positions of the oscillating valve port segment 340 and the fixed valve port segment 360. More specifically, each figure shows the port positions along the adjacent surfaces of segments 340, 360 to show the valve overlap as the rotor 210 nutates relative to the fixed position of the oscillating valve port segment 340. Furthermore, point P indicates the position where segments 340, 360 contact or are closest to contact at each oscillating valve port segment 340 location. A central port overlap 520 is defined as an open passage between central ports 350, 368, while a first port overlap 522, a second port overlap 524, a third port overlap 526, and a fourth port overlap 528 are defined between the plurality of oscillating valve ports 358 and the fixed valve port 372. Figure 16 As shown, in some arrangements of ports 358 and 372, the areas of the overlapping ports 522, 524, 526, and 528 may not be equal, and the relative sizes of the areas of the overlapping ports 522, 524, 526, and 528 can vary depending on the position of the oscillating valve port section 340, for example... Figure 17 As shown. Overall, the sum of the areas of the overlapping ports 522, 524, 526, and 528 affects the valve port flow 510 (as shown). Figure 15 As shown), the area of ​​the overlapping portion 520 at the center port affects the flow 508 at the center port (as shown). Figure 15 (As shown). The changes in the position (e.g., relative to time) of the port overlaps 522, 524, 526, 528 and the center port overlap 520 relative to the rotor 1210 together generate periodic flow pressure pulses in the downstream flow 512. Figure 16 The locations of the port overlaps 522, 524, 526, and 528 with the largest total area are shown, which may alternatively be referred to as the “fully open position” of valve section 300. Figure 17 The “partially open position” of valve section 300 is shown, wherein the total area of ​​the port overlaps 522, 524, 526, and 528 is less than the maximum total area of ​​the fully open position. Figure 18 The “fully closed position” of valve section 300 is shown, in which there are no port overlaps 522, 524, 526, 528.

[0059] refer to Figures 15 to 18In the deactivated state, where the ejector 160 is not installed within the rotor 210, the orifice flow 502 is greater than the annular flow 504. Therefore, the center port flow 508 through the center port overlap 520 is greater than the valve port flow 510 through the port overlaps 522, 524, 526, and 528. Although in some embodiments the flow areas of the center port flow 508 and the valve port flow 510 through the valve section 300 are comparable, in the deactivated state, the center port flow 508 will still be greater than the valve port flow 510 because the pressure drop of the annular flow 504 along the rotor section 200 is higher than that of the orifice flow 502. The small annular flow 504 causes the rotor 210 to rotate only slightly, the center port overlap 520 to change only slightly, and therefore only slight pressure pulses in the downstream flow 512. Furthermore, in some embodiments, even if the rotor 210 rotates, the center port overlap can be configured to have a small or no area change relative to the rotor position. Flow 506 can also flow out of orifice 348 and contribute to valve port flow 510; however, this flow will still not generate flow pulses because the “bypass” flow will not cause rotor 210 to rotate, and therefore will not change port overlaps 522, 524, 526, 528.

[0060] Still referencing Figures 15 to 18 After the activation section 100 is activated, with the injector 160 installed within the rotor 210, the annular flow 504 increases relative to the deactivated state. As the area of ​​the port overlaps 522, 524, 526, and 528 decreases, the annular flow 504 causes the valve port flow 510 and intermittently redirects to flow 506. The diameter of orifice 354 can be adjusted to provide a suitable "bypass" flow, and in some embodiments, orifice 354 can be omitted entirely. As previously mentioned, the size of the orifice flow 502 depends on the selection of nozzle 140 and may still be relatively large compared to the annular flow 504 in some configurations, thus the center port flow 508 will also be relatively large. In such a configuration, the center port overlap 520 may or may not contribute to the pressure pulse, depending on the relative size and position of the center ports 350 and 368.

[0061] As described herein, the embodiments disclosed include systems and methods for using a flow pulse system that can be selectively engaged after wellbore drilling has commenced while the drill string remains positioned within the wellbore. Furthermore, the systems and methods disclosed herein allow for selective adjustment of the frequency and amplitude of the flow pulse system, as well as systems and methods for selectively disengaging and / or reconfiguring this frequency and amplitude while the flow pulse system remains positioned within the wellbore. In this way, the total pressure loss through the flow pulse system 10 can be selectively controlled. Additionally, the systems and methods disclosed herein provide valve ports operable between fully open, partially open, and fully closed positions, which can provide improved pressure pulse response. As valve port sections 340, 360 cycle through the open, partially open, and closed positions, the oscillating valve port section 340 nutates relative to the fixed valve port section 360. Furthermore, the systems and methods disclosed herein prevent clogging of the flow pulse system when material (e.g., plugging material or a diverter) is introduced into the wellbore.

[0062] Although exemplary embodiments have been shown and described, modifications can be made to them by those skilled in the art without departing from the scope or teachings herein. For example, it is contemplated that the screen 110 may have a different non-conical shape along the screen housing 120. Furthermore, the screen element 134 may be modified to include a plurality of through holes, such as radially oriented circular through holes. It is also contemplated that the ejector 160 may be sealed to the rotor 210 with different combinations of hole sealing rings (e.g., ring 187), or that face sealing rings may be used between adjacent annular shoulders. Such adjacent shoulders may also be included to prevent or control the degree of tapered locking between the tip 184 and the seat 222. Furthermore, it is contemplated that the flow pulse system 10 may be configured in a constant activation state, wherein the ejector 160 and the nozzle 140 cannot be removed from the hole 218 of the rotor 210. For example, such embodiments may be produced by welding the ejector 160 to the rotor 210 or alternatively by omitting the ejector 160 and directly coupling the nozzle 140 to the rotor 210. Therefore, nozzle 140 can also be non-removably coupled to rotor 210 (e.g., welded) or can be manufactured as part of rotor 210. Alternative shapes and arrangements of the ports within oscillating valve 311 and stationary valve 361 are conceivable, as the diameter of orifice 354 and the overlaps (e.g., center port overlap 520 and overlaps 522, 524, 526, 528) will control the “shape” of the pressure pulses generated on the amplitude verses time plot. For example, port overlaps with a large rate of change relative to time can produce a pressure pulse shape close to a square wave, also with a large rate of change relative to time, while port overlaps with a slower rate of change can produce a pressure pulse shape with a slower rate of change. Thus, these pressure pulse shapes can be adjusted to maximize the performance of the impact tool while also optimizing the stresses applied to the mechanical components within the pumping equipment and drill string. Furthermore, for example, if a convex blade-shaped outer profile is used, the ports within oscillating valve 311 and / or stationary valve 361 can be omitted, since the space between the convex blades can be used as ports. Therefore, the embodiments described herein are exemplary and not restrictive. Many modifications and variations of the systems, devices, and processes described herein are possible and are within the scope of this disclosure. Therefore, the scope of protection is not limited to the embodiments described herein, but is limited only by the appended claims, the scope of which should include all equivalent forms of the subject matter of each claim. Unless otherwise expressly stated, the steps in the method claims may be performed in any order. Identifiers referenced before the steps in the method claims (e.g., (a), (b), (c) or (1), (2), (3), etc.) are not intended to specify, nor do they specify, a particular order of these steps, but are used to simplify subsequent references to such steps.

Claims

1. A flow pulse system, comprising: A housing having a central axis, a first end, a second end opposite to the first end, and a hole extending along the central axis from the first end to the second end; A stator, the stator being disposed within the hole in the housing, the stator having a plurality of leaf-shaped cavities; Rotor, the rotor being arranged within the stator, the rotor comprising: An axis that is offset from the central axis; Multiple convex blades, wherein the multiple convex blades mate with the multiple blade-shaped cavities; and Through hole, the through hole extending along the axis; and An ejector configured to releasably engage with the through-hole of the rotor, the ejector comprising: First radially outward guiding section; Second radial outward guiding section; Tip; Inner hole; and A releasable nozzle configured to control a first fluid flow through the inner bore and the through-hole.

2. The flow pulsing system of claim 1, wherein, The rotor also includes a seat within the through hole, wherein the seat is configured to engage with the tip of the ejector.

3. The flow pulsing system of claim 1, wherein, The nozzle is connected to the ejector along the inner connecting surface of the ejector.

4. The flow pulse system according to claim 3, wherein, The nozzle is configured to direct the first fluid flow to the path between the plurality of leaf-shaped cavities of the stator and the plurality of convex blades along the rotor, and to divert the second fluid flow to the through-hole of the rotor.

5. The flow pulse system according to claim 4, further comprising: In the first position, the ejector is located at the surface of the well; And a second position, in which the ejector is releasably connected to the rotor at a downhole location.

6. The flow pulse system according to claim 2, wherein, A cable or puller tool is used to disengage the tip of the ejector from the seat of the rotor to increase the flow of the first fluid into the through-hole of the rotor.

7. A flow pulse system, comprising: A housing having a central axis, a first end, a second end opposite to the first end, and a hole extending along the central axis from the first end to the second end; A stator, the stator being disposed within the hole in the housing, the stator having a plurality of leaf-shaped cavities; Rotor, the rotor being arranged within the stator, the rotor comprising: An axis that is offset from the central axis; Multiple convex blades, wherein the multiple convex blades correspond to the multiple blade-shaped cavities; and Through hole, the through hole extending along the axis; and A screen, the screen being disposed within the holes of the housing, the screen comprising: ontology; A connecting surface located at a first end of the body, the connecting surface being configured to connect to the housing; Screen housing, the screen housing extending to a second end of the body; and An inner hole, which is in fluid communication with the through hole.

8. The flow pulse system according to claim 7, wherein, The screen housing has a truncated conical shape and includes screen elements formed with slots aligned with the central axis of the housing.

9. The flow pulse system according to claim 7, wherein, The second end of the screen is configured to intermittently contact the rotor, thereby restricting the movement of the rotor toward the first end of the housing.

10. The flow pulse system according to claim 7, wherein, The inner holes of the screen are configured as receivers.

11. The flow pulse system according to claim 10, wherein, The ejector can be installed inside the rotor.

12. The flow pulse system according to claim 11, wherein, When the ejector is placed inside the rotor, one end of the ejector is arranged in the inner hole of the screen.

13. The flow pulse system according to claim 11, wherein, When the ejector is placed inside the rotor, the hole in the housing, the inner hole of the screen, the screen housing, the inner hole of the ejector, and the through hole of the rotor are in fluid communication.

14. A flow pulse system, comprising: A housing having a central axis, a first end, a second end opposite to the first end, and a hole extending along the central axis from the first end to the second end; A stator, the stator being disposed within the hole in the housing, the stator having a plurality of leaf-shaped cavities; Rotor, the rotor being arranged within the stator, the rotor comprising: An axis that is offset from the central axis; Multiple convex blades, wherein the multiple convex blades mate with the multiple blade-shaped cavities; and Through hole, the through hole extending along the axis; and Valve section, the valve section comprising: A fixed valve is connected to the second end of the housing, the fixed valve including a first surface, a fixed center port aligned with the central axis, and a plurality of fixed valve ports; An oscillating valve is connected to the rotor, the oscillating valve including a second surface adjacent to the first surface, an oscillating center port aligned with the axis of the rotor and in fluid communication with the through hole of the rotor, and a plurality of oscillating valve ports in fluid communication with the plurality of leaf-shaped cavities.

15. The flow pulse system according to claim 14, wherein, The position of the oscillating valve relative to the fixed valve is generated as follows: The overlap between the center ports of the fixed valve and the oscillating valve; and A first port overlap portion between one of the plurality of fixed valve ports and one of the plurality of oscillating valve ports, wherein the movement of the rotor changes the first port overlap portion between a fully open position and a fully closed position.

16. The flow pulse system of claim 15, further comprising a second port overlap between another fixed valve port of the plurality of fixed valve ports and another oscillating valve port of the plurality of oscillating valve ports, wherein, The first port overlap and the second port overlap have different areas at the middle position of the rotor, which is located between the fully open position and the fully closed position.

17. The flow pulse system according to claim 14, wherein, The rotor is movable so that the oscillating valve can move relative to the fixed valve.

18. The flow pulse system according to claim 17, wherein, The rotor motion causes the oscillating valve to nutate relative to the stationary valve.

19. The flow pulse system according to claim 17, wherein, The rotor motion causes the oscillating valve to move eccentrically relative to the stationary valve.

20. The flow pulse system according to claim 19, wherein, The oscillation center port and the oscillation valve port rotate eccentrically relative to the fixed center port and the fixed valve port.

21. The flow pulse system of claim 14, further comprising a releasable nozzle coupled to the rotor and configured to control a first fluid flow through the through-hole of the rotor.

22. The flow pulse system of claim 21, further comprising an ejector configured to be releasably coupled to a seat within the through-hole of the rotor, the ejector including an inner coupling surface along the inner bore, the inner coupling surface being threadedly coupled to the releasable nozzle; and in, The releasable nozzle is also configured to control a second fluid flow along a path between the plurality of leaf-shaped cavities in the stator and the plurality of convex blades along the rotor.

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