Three-way flow sub for continuous circulation

Patent metadata

Field	Value
Publication number	US-9353587-B2
Application number	US-201213596987-A
Country	US
Kind code	B2
Filing date	Aug 28, 2012
Priority date	Sep 21, 2011
Publication date	May 31, 2016
Grant date	May 31, 2016

Abstract

A flow sub for use with a drill string includes: a tubular housing having a longitudinal bore formed therethrough and a flow port formed through a wall thereof; a bore valve operable between an open position and a closed position, wherein the bore valve allows free passage through the bore in the open position and isolates an upper portion of the bore from a lower portion of the bore in the closed position; and a sleeve disposed in the housing and movable between an open position where the flow port is exposed to the bore and a closed position where a wall of the sleeve is disposed between the flow port and the bore; and a bore valve actuator operably coupling the sleeve and the bore valve such that opening the sleeve closes the bore valve and closing the sleeve opens the bore valve.

First claim

The invention claimed is:

1. A flow sub for use with a drill string, comprising:
a tubular housing having a longitudinal bore formed therethrough and a flow port formed through a wall thereof;
a bore valve operable between an open position and a closed position, wherein the bore valve isolates an upper portion of the bore from a lower portion of the bore in the closed position;
a sleeve disposed in the housing and movable between an open position where the flow port is exposed to the bore and a closed position where a wall of the sleeve isolates the flow port and the bore; and
a bore valve actuator operably coupling the sleeve and the bore valve such that opening the sleeve closes the bore valve and closing the sleeve opens the bore valve,
wherein the bore valve actuator is operable to close the bore valve after the sleeve is at least partially open and to open the bore valve before the sleeve is fully closed, and the sleeve is free from the bore valve actuator when the sleeve is in the closed position.

2. The flow sub of claim 1 , wherein:
the bore valve comprises a ball, and
the bore valve actuator further comprises:
a cam operably connected to the ball; and
a linkage and toggle operably connecting the sleeve and the cam.

3. A system, further comprising:
the flow sub of claim 1 ;
a clamp comprising an inlet for injecting fluid into the flow port and operable to engage the sleeve and seal against a surface of the housing adjacent to the flow port; and
an automated port valve actuator operable to move the sleeve.

4. The system of claim 3 , wherein:
the clamp comprises a body, a band, and the port valve actuator connected to the body,
the housing further has a window formed through the wall thereof and exposing an outer surface of the sleeve, and
the port valve actuator engages the sleeve through the window as the body and band engage the housing.

5. The system of claim 3 , wherein:
the port valve actuator comprises a piston formed with or connected to the sleeve,
the housing further has a hydraulic port formed therethrough and
the clamp is further operable to seal against the housing adjacent to the hydraulic port and conduct hydraulic fluid between the hydraulic port and a hydraulic manifold.

6. The flow sub of claim 1 , further comprising an automated port valve actuator operable to move the sleeve.

7. The flow sub of claim 6 , wherein:
the port valve actuator comprises a piston formed with or connected to the sleeve and in fluid communication with the flow port, and
the sleeve is moved to the open position in response to injection of drilling fluid into the port.

8. A method for drilling a wellbore using the flow sub of claim 1 , comprising:
drilling the wellbore by injecting drilling fluid into a top of a tubular string disposed in the wellbore at a first flow rate and rotating a drill bit, wherein:
the tubular string comprises:
the drill bit disposed at a bottom thereof,
tubular joints connected together, each joint having a longitudinal bore formed therethrough, and
the flow sub,

the drilling fluid exits the drill bit and carries cuttings from the drill bit, and
the cuttings and drilling fluid (returns) flow from the drill bit via an annulus defined between the tubular string and the wellbore;

moving the sleeve to engage and close the bore valve which isolates the top of the tubular string from the flow port;
freeing the sleeve from the bore valve and further opening the sleeve; and
injecting the drilling fluid into the flow port at a second flow rate while adding a stand to the tubular string,
wherein injection of drilling fluid into the tubular string is continuously maintained between drilling and adding the stand to the tubular string.

9. The method of claim 8 , further comprising:
closing the sleeve after adding the stand to the tubular string, thereby also automatically opening the bore valve; and
resuming drilling of the wellbore after closing the sleeve.

10. The method of claim 9 , wherein the sleeve is opened and closed by operating an automated actuator.

11. The method of claim 10 , further comprising:
engaging the tubular string with a clamp before opening the sleeve; and
disengaging the clamp from the tubular string after closing the sleeve,
wherein the drilling fluid is injected into the flow port via an inlet of the clamp.

12. The method of claim 11 , wherein:
the sleeve is accessible from an exterior of the tubular string,
the clamp comprises a body and the actuator, and
the actuator engages the sleeve as the body engages the tubular string.

13. The method of claim 10 , wherein the tubular string comprises the actuator.

14. The method of claim 13 , further comprising:
engaging the tubular string with a clamp before opening the sleeve; and
disengaging the clamp from the tubular string after closing the sleeve,
wherein the clamp powers the actuator.

15. The method of claim 13 , wherein:
the actuator is in fluid communication with the flow port, and
the actuator opens the sleeve in response to injection of drilling fluid into the flow port.

16. The method of claim 8 , further comprising:
measuring the first flow rate while drilling the wellbore;
measuring the second flow rate while injecting the drilling fluid into the port;
measuring a flow rate of the returns while drilling and while injecting the drilling fluid into the port; and
comparing the returns flow rate to the first flow rate while drilling the wellbore and to the second flow rate while injecting drilling fluid into the port to ensure control of an exposed formation adjacent to the wellbore.

17. A system, comprising:
a flow sub for use with a drill string, comprising:
a tubular housing having a longitudinal bore formed therethrough and a flow port formed through a wall thereof;
a bore valve operable between an open position and a closed position, wherein the bore valve isolates an upper portion of the bore from a lower portion of the bore in the closed position;
a sleeve disposed in the housing and movable between an open position where the flow port is exposed to the bore and a closed position where a wall of the sleeve isolates the flow port and the bore; and
a bore valve actuator operably coupling the sleeve and the bore valve such that opening the sleeve closes the bore valve and closing the sleeve opens the bore valve,
wherein the bore valve actuator is operable to close the bore valve after the sleeve is at least partially open and to open the bore valve before the sleeve is fully closed;

a clamp comprising an inlet for injecting fluid into the flow port and operable to engage the sleeve and seal against a surface of the housing adjacent to the flow port; and
an automated port valve actuator operable to move the sleeve,
wherein the clamp comprises a body, a band, and the port valve actuator connected to the body, the housing further has a window formed through the wall thereof and exposing an outer surface of the sleeve, and the port valve actuator engages the sleeve through the window as the body and band engage the housing, and wherein:
the sleeve has a lug formed in an outer surface thereof,
the port valve actuator comprises:
a yoke for engaging the lug and having a nut portion engaged with a lead screw;
a hydraulic motor; and
a gear train operably coupling the lead screw to the hydraulic motor.

18. The system of claim 17 , wherein:
the clamp further comprises a latch operable to fasten the band to the body, and
an automated band actuator operable to tens

Assignees

• Bansal Ram K
• Noske Joe
• Mihalj Miroslav
• Menard Bill
• Bailey Thomas F
• Pavel David
• Buchanan Gerald Wes Don
• George Geoff
• Vieraitis David
• Weatherford Technology Holdings Llc

Inventors

• Bansal Ram K
• Noske Joe
• Mihalj Miroslav
• Menard Bill
• Bailey Thomas F
• Pavel David
• Buchanan Gerald Wes Don
• George Geoff
• Vieraitis David

Classifications

• E21B34/12

  operated by movement of casings or tubings · CPC title

• E21B21/10 Primary

  Valve arrangements in drilling-fluid circulation systems · CPC title

• E21B21/08 Primary

  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 title

• E21B21/019

  Arrangements for maintaining circulation of drilling fluid while connecting or disconnecting tubular joints · CPC title