Reverse circulation well tool

• US 10,428,607 B2
• Filed: 01/29/2016
• Issued: 10/01/2019
• Est. Priority Date: 01/29/2016
• Status: Active Grant

• Current Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Original Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Inventors: Zhou, Shaohua
• Primary Examiner(s): Buck, Matthew R
• Assistant Examiner(s): Wood, Douglas S
• Application Number:
  US15/010,364
• Publication Number:
  US 20170218710A1
• Time in Patent Office: 1,341 Days
• Field of Search: None
• CPC Class Codes: E21B 21/103 Down-hole by-pass valve arrangements, i.e. between the inside of the drill string and the annulus valves specifically for maintaining circulation of drilling fluid while connecting or disconnecting tubular joints E21B21/019
• CPC Class Codes: E21B 2200/06 Sleeve valves
• CPC Class Codes: E21B 33/12 Packers; Plugs used for cementing E21B33/134, E21B33/16
• CPC Class Codes: E21B 33/127 with inflatable sleeve E21B33/122, E21B33/124 take precedence
• CPC Class Codes: E21B 33/129 with mechanical slips for hooking into the casing E21B33/122, E21B33/124 take precedence
• CPC Class Codes: E21B 34/06 in wells
• CPC Class Codes: E21B 43/08 Screens or liners expandable screens or liners E21B43/108

Abstract

A crossover sub includes a tubular housing connected to a drill string in a wellbore, a sealing structure to seal against a wellbore wall, and a sleeve valve disposed within the housing and movable between a closed position and an open position in response to a fluid pressure in a first flow chamber or second, separate flow chamber of the housing. The first flow chamber fluidly connects an upper annulus of the wellbore to a central bore of the drill string downhole of the crossover sub. The second flow chamber fluidly connects a central bore of the drill string uphole of the sealing structure to a lower annulus of the wellbore. The sleeve valve closes the second flow chamber in response to the sleeve valve being in the closed position, and opens the second flow chamber in response to the sleeve valve being in the open position.

Claims

1. A well flow crossover sub comprising:

a substantially tubular housing configured to be part of a drill string and disposed in a wellbore, the substantially tubular housing comprising a first flow chamber and a second, separate flow chamber;

a sealing structure circumscribing a portion of the substantially tubular housing and comprising a sealing element, the sealing element configured to seal against a wellbore wall of the wellbore; and

a sleeve valve disposed within the substantially tubular housing and selectively movable between a first, closed position and a second, open position in response to a fluid pressure in the first flow chamber or second flow chamber;

wherein the first flow chamber fluidly connects an annulus of the wellbore uphole of the sealing structure to a central bore of the drill string downhole of the well flow crossover sub, the first flow chamber extending between a first radial port opening at the annulus of the wellbore uphole of the sealing structure proximate a first longitudinal end of the substantially tubular housing and a downhole central bore in the substantially tubular housing at a second, opposite longitudinal end of the substantially tubular housing; and

wherein the second flow chamber fluidly connects a central bore of the drill string uphole of the sealing structure to the annulus of the wellbore downhole of the sealing structure, the second flow chamber extending between an uphole central bore in the substantially tubular housing at the first longitudinal end and a second radial port opening at the annulus of the wellbore downhole of the sealing structure proximate the second longitudinal end of the substantially tubular housing; and

the sleeve valve configured to close the second radial port opening in response to the sleeve valve being in the first, closed position and to open the second radial port opening in response to the sleeve valve being in the second, open position.

2. The well flow crossover sub of claim 1, wherein the sleeve valve comprises a passage through a wall of the sleeve valve, and wherein the passage is alignable with the second radial port opening when the sleeve valve is in the second, open position.

3. The well flow crossover sub of claim 1, wherein the tubular housing comprises a fluid pressure chamber fluidly coupled to the first flow chamber by a flow port, and the sleeve valve contacts a fluid in an interior of the fluid pressure chamber, the sleeve valve configured to move in response to hydraulic pressure of the fluid in the fluid pressure chamber acting on the sleeve valve.

4. The well flow crossover sub of claim 3, further comprising a biasing element between the sleeve valve and the tubular housing to bias the sleeve valve toward the first, closed position;

and

wherein the sleeve valve is configured to move toward the second, open position in response to a hydraulic pressure of the fluid in the fluid pressure chamber greater than a threshold hydraulic pressure, the threshold hydraulic pressure corresponding to a biasing force acting on the sleeve valve from the biasing element.

5. The well flow crossover sub of claim 3, wherein the flow port comprises at least one of a sandscreen or filter.

6. The well flow crossover sub of claim 3, further comprising a piston assembly disposed within a piston chamber of the tubular housing, the piston assembly comprising a piston and a piston pin extending toward the sleeve valve;

wherein a fluid inlet port fluidly couples the piston chamber to the uphole central bore at the first longitudinal end of the tubular housing; and

wherein the piston assembly is configured to contact and move the sleeve valve toward the second, open position in response to hydraulic pressure of fluid in the piston chamber acting on the piston assembly.

7. The well flow crossover sub of claim 6, wherein the piston pin contacts the sleeve valve to move the sleeve valve to the second, open position in response to hydraulic pressure of fluid in the piston chamber acting on a surface of the piston.

8. The well flow crossover sub of claim 6, further comprising a biasing element between a surface of the housing and the piston assembly to bias the piston assembly in a direction opposite the hydraulic pressure of fluid in the piston chamber acting on the piston assembly.

9. The well flow crossover sub of claim 6, further comprising a pressure-activated disk valve disposed in the fluid inlet port, the disk valve configured to selectively open the fluid inlet port in response to a hydraulic pressure in the uphole central bore at the first longitudinal end of the tubular housing greater than a threshold hydraulic pressure.

10. The well flow crossover sub of claim 3, wherein the sealing element comprises an inflatable packer, and wherein the sealing structure comprises an activation chamber fluidly connected to the fluid pressure chamber by an activation flow port;

and

wherein the sleeve valve is configured to close the activation flow port in response to the sleeve valve being in the first, closed position and to open the activation flow port to the fluid pressure chamber in response to the sleeve valve being in the second, open position.

11. The well flow crossover sub of claim 1, wherein the sealing structure couples to the substantially tubular housing with a ball bearing.

12. The well flow crossover sub of claim 1, wherein the sealing element comprises a packer element.

13. The well flow crossover sub of claim 12, wherein the packer element comprises at least one of a mechanical packer or an inflatable packer.