US-12618292-B2 - On demand flow pulsing system

Abstract

Embodiments disclosed herein are directed to a flow pulsing system including a rotor, a stator, a dart which is configured to releasably couple with the rotor, and a nozzle releasably coupled to the rotor which is configured to control a fluid flow through the rotor. In some embodiments, the system uses a screen disposed therein which includes an inner bore in fluid communication with a plurality of lobe cavities along the rotor. In some embodiments, the system uses a stationary valve and an oscillating valve having a plurality of oscillating valve ports which are in fluid communication with the plurality of lobe cavities.

Inventors

• Khoi Trinh
• Steve Bhagwandin
• Yufang Xia
• Ian Forster

Assignees

• NATIONAL OILWELL VARCO, L.P.

Dates

Publication Date

20260505

Application Date

20200721

Claims (17)

1. 1 . A flow pulsing system comprising: a housing having a central axis, a first end, a second end opposite the first end, and a bore extending along the central axis from the first end to the second end; a stator disposed within the bore of the housing having a plurality of lobe cavities; a rotor disposed within the stator, the rotor comprising: an axis offset from the central axis; a plurality of lobes that mate with the plurality of lobe cavities; and a thru bore extending along the axis; and a valve section comprising: a stationary valve coupled to the second end of the housing, the stationary valve comprising a first face, a stationary central port aligned with the central axis, and a plurality of stationary valve ports; an oscillating valve coupled to the rotor, the oscillating valve comprising a second face abutting the first face, an oscillating central port aligned with the axis of the rotor and in fluid communication with the thru bore of the rotor, and a plurality of oscillating valve ports in fluid communication with the plurality of lobe cavities.
2. 2 . The flow pulsing system of claim 1 , wherein the position of the oscillating valve relative to the stationary valve creates: a central port overlap between the central port of the stationary valve and the central port of the oscillating valve; and a first port overlap between one of the plurality of stationary valve ports and one of the plurality of oscillating valve ports, wherein the motion of the rotor varies the first port overlap between a fully open position and a fully closed position.
3. 3 . The flow pulsing system of claim 2 , further including a second port overlap between another one of the plurality of stationary valve ports and another one of the plurality of oscillating valve ports, wherein the first port overlap and second port overlap have different areas at an intermediate position of the rotor, the intermediate position occurring between the fully open and the fully closed position.
4. 4 . The flow pulsing system of claim 1 , wherein the rotor is moveable to move the oscillating valve relative to the stationary valve.
5. 5 . The flow pulsing system of claim 4 , wherein rotor motion causes a nutating motion of the oscillating valve relative to the stationary valve.
6. 6 . The flow pulsing system of claim 4 , wherein rotor motion causes an eccentric motion of the oscillating valve relative to the stationary valve.
7. 7 . The flow pulsing system of claim 6 , wherein the oscillating central port and the oscillating valve ports rotate eccentrically relative to the stationary central port and the stationary valve ports.
8. 8 . A flow pulsing system comprising: a housing having a central axis, a first end, a second end opposite the first end, and a bore extending along the central axis from the first end to the second end; a stator disposed within the bore of the housing having a plurality of lobe cavities; a rotor disposed within the stator, the rotor comprising: an axis offset from the central axis; a plurality of lobes that mate with the plurality of lobe cavities; and a thru bore extending along the axis; a valve section comprising: a stationary valve coupled to the second end of the housing, the stationary valve comprising a first face, a stationary central port, and a plurality of stationary valve ports; and an oscillating valve coupled to the rotor, the oscillating valve comprising a second face abutting the first face, an oscillating central port in fluid communication with the thru bore of the rotor, and a plurality of oscillating valve ports in fluid communication with the plurality of lobe cavities; a releasable nozzle coupled to the rotor and configured to control a first fluid flow through the thru bore of the rotor; and a dart configured to releasably couple with a seat within the thru bore of the rotor, the dart including an inner coupling surface along an inner bore which threadably couples with the releasable nozzle coupled to the rotor; wherein the releasable nozzle is configured to control a second fluid flow along a path between the plurality of lobe cavities of the stator and the plurality of lobes along the rotor.
9. 9 . A flow pulsing system comprising: a housing having a central axis, a first end, a second end opposite the first end, and a bore extending along the central axis from the first end to the second end; a stator disposed within the bore of the housing having a plurality of lobe cavities; a rotor disposed within the stator, the rotor comprising: an axis offset from the central axis; a plurality of lobes that mate with the plurality of lobe cavities; and a thru bore extending along the axis; and a valve section comprising: a stationary valve coupled to the second end of the housing, the stationary valve comprising a first face, a stationary central port, and a plurality of stationary valve ports; an adapter comprising a body and an outer surface; an oscillating valve coupled to the rotor by the adapter disposed between the oscillating valve and the rotor, the oscillating valve comprising a body with a radially outer surface, a second face abutting the first face, an oscillating central port in fluid communication with the thru bore of the rotor, and a plurality of oscillating valve ports in fluid communication with the plurality of lobe cavities through an inlet disposed in the radially outer surface of the oscillating valve body.
10. 10 . The flow pulsing system of claim 9 , wherein a position of the oscillating valve relative to the stationary valve creates: a central port overlap between the central port of the stationary valve and the central port of the oscillating valve; and a first port overlap between one of the plurality of stationary valve ports and one of the plurality of oscillating valve ports, wherein motion of the rotor varies the first port overlap between a fully open position and a fully closed position.
11. 11 . The flow pulsing system of claim 10 , further including a second port overlap between another one of the plurality of stationary valve ports and another one of the plurality of oscillating valve ports, wherein the first port overlap and second port overlap have different areas at an intermediate position of the rotor, the intermediate position occurring between the fully open and the fully closed position.
12. 12 . The flow pulsing system of claim 9 , wherein the rotor is moveable to move the oscillating valve relative to the stationary valve.
13. 13 . The flow pulsing system of claim 12 , wherein rotor motion causes a nutating motion of the oscillating valve relative to the stationary valve.
14. 14 . The flow pulsing system of claim 12 , wherein rotor motion causes an eccentric motion of the oscillating valve relative to the stationary valve.
15. 15 . The flow pulsing system of claim 14 , wherein the oscillating central port and the oscillating valve ports rotate eccentrically relative to the stationary central port and the stationary valve ports.
16. 16 . The flow pulsing system of claim 9 , further comprising a releasable nozzle coupled to the rotor and configured to control a first fluid flow through the thru bore of the rotor.
17. 17 . The flow pulsing system of claim 16 , further comprising a dart which is configured to releasably couple with a seat within the thru bore of the rotor, the dart including an inner coupling surface along an inner bore which threadably couples with the releasable nozzle; wherein the releasable nozzle is further configured to control a second fluid flow along a path between the plurality of lobe cavities of the stator and the plurality of lobes along the rotor.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a 35 U.S.C. § 371 national stage application of PCT/US2020/042943 filed Jul. 21, 2020, and entitled “On Demand Flow Pulsing System”, which claims benefit of U.S. provisional patent application Ser. No. 62/877,168 filed Jul. 22, 2019 and entitled “On Demand Flow Pulsing System,” both of which are hereby incorporated herein by reference in their entirety. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not applicable. BACKGROUND The disclosure relates generally to downhole apparatus. More particularly, the disclosure relates to drilling apparatus and drilling methods which include an agitator or flow pulsing apparatus in a drill string. Among other benefits, a flow pulsing apparatus may be used to oscillate a drill string to reduce friction with a borehole, to enhance tool face control, to extend borehole lengths, and to improve drilling efficiency. The flow pulsing apparatus may be used in other downhole work strings as well. BRIEF SUMMARY Some embodiments disclosed herein are directed to a flow pulsing system. In an embodiment, the flow pulsing system includes a housing having a central axis, a first end, a second end opposite the first end, and a bore extending along the central axis from the first end to the second end. Additionally, some embodiments may include a stator disposed within the bore of the housing having a plurality of lobe cavities and a rotor disposed within the stator. The rotor includes an axis offset from the central axis, a plurality of lobes that mate with the plurality of lobe cavities, and a thru bore extending along the axis. Additionally, some embodiments may include a dart configured to releasably couple with the thru bore of the rotor, the dart including a first radially outer guide section, a second radially outer guide section, a tip, an inner bore, and a releasable nozzle configured to control a first fluid flow through the inner bore and the thru bore. Other embodiments disclosed herein are directed to a flow pulsing system including a housing having a central axis, a first end, a second end opposite the first end, and a bore extending along the central axis from the first end to the second end. Additionally, some embodiments may include a stator disposed within the bore of the housing having a plurality of lobe cavities and a rotor disposed within the stator. The rotor includes an axis offset from the central axis, a plurality of lobes that correspond with the plurality of lobe cavities, a thru bore extending along the axis. Additionally, some embodiments may include a screen disposed within the bore of the housing, the screen including a body and a coupling surface at a first end of the body, the coupling surface configured to couple to the housing. Additionally, some embodiments may include a screen housing extending to a second end of the body and an inner bore to fluidly communicate with the thru bore. Still other embodiments disclosed herein are directed to a flow pulsing system including a housing having a central axis, a first end, a second end opposite the first end, and a bore extending along the central axis from the first end to the second end. Additionally, some embodiments may include a stator disposed within the bore of the housing having a plurality of lobe cavities and a rotor disposed within the stator. The rotor includes an axis offset from the central axis, a plurality of lobes that mate with the plurality of lobe cavities, and a thru bore extending along the axis. Additionally, 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 central port, and a plurality of stationary valve ports. Additionally, some embodiments may include an oscillating valve coupled to the rotor, the oscillating valve including a second face abutting the first face, an oscillating central port in fluid communication with the thru bore of the rotor, and a plurality of oscillating valve ports in fluid communication with the plurality of lobe cavities. Embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical characteristics of the disclosed embodiments in order that the detailed description that follows may be better understood. The various characteristics and features described above, as well as others, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as the disclosed embodiments. It should also be reali