Downhole tool for use in a drill string

• US 9,404,326 B2
• Filed: 03/14/2013
• Issued: 08/02/2016
• Est. Priority Date: 04/13/2012
• 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): Thompson, Kenneth L
• Application Number:
  US13/828,244
• Publication Number:
  US 20130269928A1
• Time in Patent Office: 1,237 Days
• Field of Search: 166/242.6, 166/374, 166/319, 166/321, 166/332.1, 166/334.4
• US Class Current: 1/1
• CPC Class Codes: E21B 17/06 Releasing-joints, e.g. safety joints
• CPC Class Codes: E21B 21/003 Means for stopping loss of drilling fluid plastering the borehole wall E21B33/138
• CPC Class Codes: E21B 21/08 Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure valve arrangements therefor E21B21/10
• 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

Abstract

A downhole tool in a drill string for mitigating hazards of a blockage in an annulus of the drill string. The downhole tool can sense blockages and selectively recirculate flow from within the annulus back to surface. Further, the downhole tool is made up of segments that are selectively detachable from one another, so that the segments above the point of detachment are removable from a wellbore. The bypass assembly includes a sleeve in the downhole tool with openings in its side; when the annulus reaches a set pressure, the sleeve slides to a position so the openings register with ports formed through a side of the tool to allow bypass flow. A processor in the downhole tool senses movement of the string, and when the string is axially stationary more than a designated period of time, the processor emits signals to detach the segments.

Claims

1. A downhole sub that is selectively coupled in series with a drill string comprising:

a bypass sub having a housing with an outer surface;

a bore axially disposed in the housing;

a relief valve assembly in a side wall of the housing that is selectively moveable from a closed position with the outer surface isolated from the bore to an open position with the fluid communication between the bore and outer surface; and

a passage in the side wall of the housing having an end in communication with the bore and a distal end in communication with the relief valve assembly that terminates within the housing and that is isolated from the outer surface of the housing, the passage selectively routing fluid from the bore to the relief valve assembly, so that when the fluid in the bore is at a designated pressure, the fluid in communication with the relief valve assembly exerts a force onto the relief valve assembly to move the relief valve assembly into the open position.

2. The downhole sub of claim 1, wherein the relief valve assembly comprises an annular space formed axially in the side wall of the housing, a sleeve axially moveable in an annular space formed axially in the side wall of the housing, an opening radially formed through a side wall of the sleeve, and a port formed radially through the housing that registers with the opening when the valve assembly is in the open position.

3. The downhole sub of claim 2, further comprising a poppet valve in the passage that is selectively moveable to an open position when pressure in the bore exceeds a designated value.

4. The downhole sub of claim 2, further comprising a piston head on an end of the sleeve that has a high pressure side in pressure communication with the passage, and a spring on a side of the piston distal from the high pressure side to bias the piston and sleeve into the closed position.

5. The downhole sub of claim 1, wherein the bore has diameter with a magnitude that remains substantially the same along a length of the bore.

6. The downhole sub of claim 1, further comprising a disconnect sub having upper and lower members that are selectively coupled by a latch assembly that selectively operates in response to when the sub is stationary for a designated period of time.

7. The downhole sub of claim 6, further comprising a motion detector and a controller for actuating the latch assembly.

8. The downhole sub of claim 7, further comprising a piston movable in a cylinder that is axially formed within the disconnect sub and having a low pressure side in communication with the latch assembly, a pressure vent in communication with fluid ambient to the sub system and having an end intersecting a high pressure end of the cylinder, a control valve for controlling flow through the pressure vent, and a controller for controlling operation of the control valve and that is in communication with the motion detector, so that when the motion detector detects a period of time that the sub system is motionless which exceeds a designated period of time, the controller directs the control valve to open, which pressurizes the cylinder and actuates the latch assembly.

9. The downhole sub of claim 8, wherein the latch assembly comprises a latch rod that selectively moves from within interfering contact between the upper and lower members into a one of the upper or lower members.

10. The downhole sub of claim 9, wherein the lower member comprises elongated clutch members that project axially into slots on the upper segment and wherein the latch rod extends from within a chamber in each of the clutch members and into a chamber in each of the slots when the upper and lower members are connected to one another, and where the latch rod is withdrawn from one of the chambers when the upper and lower members are separable.

11. The downhole sub of claim 1, wherein the relief valve assembly is moveable to the open position in response to a pressure in the bore being at a designated value.

12. A downhole sub that is selectively coupled in series with a drill string comprising:

a bypass sub having a housing with an outer surface;

a bore axially disposed in the housing;

a relief valve assembly in a side wall of the housing that is selectively moveable from a closed position with the outer surface isolated from the bore to an open position with the fluid communication between the bore and outer surface;

a disconnect sub having upper and lower members selectively coupled by a latch assembly;

an actuation system in communication with the latch assembly and in communication with fluid ambient to the downhole sub;

a motion detector; and

a controller in communication with the motion detector and the actuation system, so that when the motion detector senses that the downhole sub has been motionless for at least a designated period of time, the actuation system is directed to disconnect the upper and lower members.

13. The downhole sub of claim 12, wherein a bit is mounted on a lower terminal end of the drill string, and a downhole tool is between the downhole sub and the bit.

14. The downhole sub of claim 12, wherein a downhole tool is mounted in a portion of the drill string between the downhole sub and an opening of a wellbore in which the drill string is inserted.