System for a downhole string with a downhole valve

• US 8,365,821 B2
• Filed: 10/29/2010
• Issued: 02/05/2013
• Est. Priority Date: 10/29/2010
• Status: Active Grant

• Current Assignee: Novatek IP, LLC
• Original Assignee: David R. Hall
• Inventors: Hall, David R., Marshall, Jonathan, Scott, Dahlgren
• Primary Examiner(s): Neuder, William P
• Application Number:
  US12/915,893
• Publication Number:
  US 20120103594A1
• Time in Patent Office: 830 Days
• Field of Search: 166/194, 166/330, 166/334.4, 175/231, 175/232, 175/317
• US Class Current: 166/194
• CPC Class Codes: E21B 34/06 in wells
• CPC Class Codes: F15B 13/0406 for rotary valves

Abstract

In one aspect of the present invention, a system for a downhole string comprises a fluid path defined by a bore formed within a tubular component. A reciprocating valve is located within a wall of the bore hydraulically connecting the bore with a fluid passage. The valve comprises a substantially cylindrical shaped housing. First and second ports are disposed on a circumference of the housing, and a fluid pathway is disposed intermediate the first and second ports. The valve comprises an axially slidable spool disposed within and coaxial with the housing and comprises a blocker. The blocker is configured to slide axially so to block and unblock the fluid pathway to control a flow from the bore to the fluid passage. The valve comprises a plurality of seals. Each seal is disposed opposite of the blocker causing pressure to be equally applied to the blocker and the plurality of seals.

Claims

1. A system for a downhole string, comprising:

a fluid path defined by a bore formed within a tubular component;

a rotary valve located within a wall of the bore and which hydraulically connects the bore with a fluid passage;

the valve comprising a substantially disc shaped rotor comprising a plurality of channels evenly spaced around a circumference of the rotor;

the valve also comprising a substantially toroidal shaped stator disposed around the rotor and comprising a plurality of ports evenly spaced around a circumference of the stator; and

the rotor is configured to rotate such that the plurality of channels and the plurality of ports align and misalign to control a flow from the bore to the fluid passage.

2. The system of claim 1, further comprising a fluid cavity disposed within the wall of the bore and the valve is disposed within the fluid cavity wherein the fluid cavity is configured to immerse the stator in fluid.

3. The system of claim 2, wherein the fluid cavity is in open communication with the bore.

4. The system of claim 1, wherein the plurality of ports force fluid to enter or exit the stator radially.

5. The system of claim 1, wherein the flow comprises drilling fluid.

6. The system of claim 1, wherein the tubular component is a downhole tool string component.

7. The system of claim 1, wherein the flow through the fluid passage actuates an expandable tool, piston, jar, vibrator, resistivity tool, geophone, motor, turbine, directional drilling device, sensors, and combinations thereof.

8. The system of claim 1, wherein the rotor comprises a plurality of peripheral surfaces each comprising a surface area greater than a cross-sectional area of one of the plurality of ports and wherein the plurality of peripheral surfaces disallow fluid to pass through the valve when the plurality of peripheral surfaces are aligned with the plurality of ports.

9. The system of claim 1, wherein outer surfaces of the rotor and stator comprise a superhard material to reduce erosion due to the flow.

10. The system of claim 1, wherein the evenly spaced plurality of channels and the evenly spaced plurality of ports cause pressure from the flow to be applied equally to the rotor and the stator in all directions causing the pressure to be balanced.

11. The system of claim 1, further comprising a covering disposed around the stator wherein the covering redirects drilling fluid flowing parallel to an axis of rotation of the rotor into the plurality of ports.

12. The system of claim 1, wherein the rotary valve is an entrance rotary valve hydraulically connecting the bore to a first fluid passage, and an exit rotary valve hydraulically connects a second fluid passage to an annulus of a wellbore.

13. The system of claim 1, further comprising a rotary actuator rigidly connected to the rotor and configured to rotate the rotor wherein the rotary actuator comprises a rotary solenoid, a mud motor, a hydraulic motor, or a limited angle torque.

14. The system of claim 13, wherein the rotary actuator is configured to rotate the rotor 360 degrees.

15. The system of claim 13, wherein the rotary actuator is in communication with a telemetry system or an electronic circuitry system.

16. The system of claim 15, further comprising a single armored coaxial wire connecting the rotary actuator and a plurality of other actuation devices wherein each actuation device comprises a unique electronic circuit.

17. The system of claim 16, further comprising a unique identifier signal sent through the signal armored coaxial wire to independently instruct an actuation device.

18. The system of claim 15, wherein the electronic circuitry system comprises a feedback circuitry configured to send an electrical signal through the armored coaxial wire indicating a position of the rotor by comprising;

a solenoid connected to a constant voltage source and comprising a first length and a core wherein the core comprises a permeability;

a plunger, controlled by the rotor, comprising a second length disposed coaxial with the solenoid wherein the plunger changes the permeability of the core by moving in and out of the solenoid;

a voltage feedback measuring the voltage decay of the solenoid to determine the position of the rotor.

19. The system of claim 18, wherein the plunger comprises a magnetic permeable material.

20. The system of claim 18, wherein the second length is substantially similar to or greater than the first length.