Intelligent Circulation System

Embodiments of the present invention generally relate to advancements in circulation systems, focusing on enhanced efficiency, control, and safety mechanisms. Specifically, this invention pertains to the field of oil and gas drilling technology, encompassing a novel wellbore drilling tool that integrates sophisticated operational control systems, improved fluid management, and safety features. The invention is particularly applicable to the area of downhole tools and equipment used in drilling operations for oil and gas extraction, offering significant improvements over existing technologies in terms of operational efficiency, precise control of drilling functions, and enhanced safety measures.

The present invention relates to improvements in circulation systems, particularly addressing the limitations and inefficiencies found in traditional drilling systems used in the oil and gas industry. Traditional drilling systems have utilized conventional methods for operating tools, primarily relying on the use of balls of different sizes to activate and deactivate valves. While these systems have been standard in the industry, they exhibit several drawbacks that can significantly impact drilling operations, especially in critical situations where every minute counts.

Time-Consuming Operations: The use of two different ball sizes for activation and deactivation of tools in traditional systems results in extended operational times. Each ball can take up to 30 minutes to reach its seat, and in emergency situations, this delay can exacerbate the problem.

Lack of Adjustable Shear Pressure: Traditional systems use standard-sized balls, which do not allow for adjustable shear pressure based on varying well conditions. This inflexibility often leads to situations where the tools do not activate appropriately due to mismatched conditions.

Absence of Mechanical Stop: In traditional systems, the absence of a mechanical stop for the balls can lead to situations where the balls bypass the intended seat without activating the necessary tools, often due to a misunderstanding of well conditions.

Weak Spring Mechanism: The reliance on weak springs with low preload force makes traditional tools less effective in retracting to their original position after deactivation.

Dependence on Drilling Fluid Weight: Traditional systems require different types of balls depending on the weight of the drilling fluid, adding complexity and limiting adaptability.

Limited Access for Other Tools: Conventional ball catcher designs in traditional systems do not allow other tools to pass through, regardless of their size, limiting operational flexibility in emergency situations.

Inefficient Utilization of Drilling Fluids: The use of multiple balls for a single cycle of operation leads to increased consumption of drilling fluids, which is both economically and environmentally undesirable.

Therefore, accordingly, there remains a need in the art for a well bore clean-out apparatus that can overcome the aforementioned problems. Therefore, there is a need for an intelligent circulation system.

According to an aspect of the present invention, there is provided an intelligent circulation system, the system comprises a main tool body, housing a main shaft, with three ports and a nozzle for fluid circulation, featuring a PIN and BOX connection for attachment to a drill string connected with a tool; a cam mechanism with an index pin, configured for controlled movement between open and closed positions of the tool; a wave spring on the main shaft, providing a retraction mechanism after tool operation; one or more ball bearings above and below the cam mechanism for smooth operation; a bullet mechanism, including a shear pin and a mechanical stop for activating and deactivating the tool using one or more bullets; a bullet catcher, disposed alongside the main tool body, having a specific profile for diverting the one or more bullets without obstructing operations of the tool; an internal seal system with inner and outer O-ring seals to maintain pressure inside a deflector; an intelligent communicator valve configured to control fluid flow and communicate with the surface equipment to adjust operational parameters dynamically.

In accordance with an embodiment of the present invention, the main tool body's three ports are designed for optimized fluid flow and debris removal during drilling operations.

In accordance with an embodiment of the present invention, the cam mechanism's index pin allows for precise positioning and stability of the tool in varying operational states.

In accordance with an embodiment of the present invention, the wave spring aids in maintaining the tool in an open position during drilling, enhancing operational efficiency.

In accordance with an embodiment of the present invention, the placement of ball bearings ensures reduced friction and wear during the tool's opening and closing movements.

In accordance with an embodiment of the present invention, the bullet catcher's special profile facilitates the safe and efficient diversion of bullets, maintaining unobstructed drilling pathways.

In accordance with an embodiment of the present invention, the bullet mechanism's shear pin and mechanical stop enable rapid activation or deactivation of the tool in response to drilling conditions.

In accordance with an embodiment of the present invention, the system featuring an internal seal system with robust O-ring seals to withstand high-pressure environments and prevent fluid leakage.

In accordance with an embodiment of the present invention, the nozzle in the main tool body is configured to optimize drilling fluid flow, contributing to the system's 50% efficiency improvement.

In accordance with an embodiment of the present invention, the nozzle fitted inside the main tool body is designed to enhance the directional flow of drilling fluids, improving cleaning efficiency.

In accordance with an embodiment of the present invention, the PIN and BOX connection of the main tool body facilitates quick and secure attachment to varying types of drill strings.

In accordance with an embodiment of the present invention, the cam mechanism is designed to facilitate easy transition between different operational modes under varying wellbore conditions.

In accordance with an embodiment of the present invention, the index pin of the cam mechanism is configured for enhanced durability and precise operational control.

In accordance with an embodiment of the present invention, the wave spring is designed for longevity and consistent performance under high-pressure drilling conditions.

In accordance with an embodiment of the present invention, the ball bearings are made of materials suited for high-stress and high-temperature drilling environments.

In accordance with an embodiment of the present invention, the bullet catcher includes an adjustable angle mechanism to handle varying sizes and types of bullets.

In accordance with an embodiment of the present invention, the bullet mechanism's shear pin is designed for quick release under predetermined pressure conditions.

In accordance with an embodiment of the present invention, the mechanical stop in the bullet mechanism is adjustable for varying operational requirements.

In accordance with an embodiment of the present invention, the system featuring a dual-layer O-ring seal system for enhanced sealing capability under extreme wellbore pressures.

In accordance with an embodiment of the present invention, the intelligent communicator valve is integrated for real-time monitoring and adjustment of drilling parameters.

In accordance with an embodiment of the present invention, the three ports of the main tool body are configured to allow for simultaneous multiple drilling operations.

In accordance with an embodiment of the present invention, the bullet catcher's special profile is adaptable to different drilling fluids and debris types.

In accordance with an embodiment of the present invention, the bullet mechanism includes an anti-jamming feature to ensure reliable operation in various drilling scenarios.

In accordance with an embodiment of the present invention, the nozzle is designed to be easily replaceable for maintenance and adaptability to different drilling requirements.

In accordance with an embodiment of the present invention, the main tool body is constructed from materials selected for their resistance to corrosion and wear.

In accordance with an embodiment of the present invention, the system featuring a modular design of the cam mechanism for easy maintenance and replacement.

In accordance with an embodiment of the present invention, the wave spring is adjustable to accommodate different drilling forces.

In accordance with an embodiment of the present invention, the ball bearings are sealed to prevent contamination from drilling fluids and debris.

In accordance with an embodiment of the present invention, the system incorporating a failsafe mechanism in the bullet catcher to prevent unintended release of bullets.

In accordance with an embodiment of the present invention, the internal seal system is designed for easy replacement to minimize downtime during drilling operations.

The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description.

While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for case of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this description, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense, (i.e., meaning must). Further, the words “a” or “an” mean “at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as “including,” “comprising,” “having,” “containing,” or “involving,” and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term “comprising” is considered synonymous with the terms “including” or “containing” for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the like are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.

This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.

illustrates an intelligent circulation system (), in accordance with an embodiment of the present invention. As shown in, the intelligent circulation system () comprises a main tool body (), a cam mechanism (), a wave spring (), one or more ball bearings (,), a bullet mechanism (not shown in), a Bullet Catcher () (not shown in), an internal seal system () with inner and outer O-ring seals, (not shown in) and an intelligent communicator valve (not shown in).

illustrates a main tool body, in accordance with an embodiment of the present invention. As shown in, the Main tool body () is the central structure of the system () with three ports (,) and a nozzle for fluid circulation, which connects to the drill string via a PIN and BOX connection. In alternative embodiments, the main tool body () could have varying shapes and dimensions to accommodate different borehole sizes. The nozzle for fluid circulation could feature an adjustable design, where the flow pattern or size could be altered according to the drilling requirements. This could be achieved through mechanical adjustments or by using fluid dynamics control system. It could also feature modular sections for customizable assembly based on specific drilling tasks. The main tool body () houses other components and provides the primary pathway for fluid flow. The main tool body () acts as the chassis for the entire assembly. It physically houses the cam mechanism (), wave spring (), ball bearings (,), and bullet mechanism. Its three ports (,) are critical for the entry and exit of fluids, with the nozzle directing the flow as needed.

illustrates a cam mechanism, in accordance with an embodiment of the present invention. Cam mechanism () with Index pin (): The cam mechanism () is a mechanical linkage within the main tool body (), and the index pin () is a component of this Cam mechanism () that engages with the cam to control its position. The cam mechanism () could be designed with multiple index pin () s for added stability, or it could incorporate electronic or hydraulic controls for remote operation. An alternative embodiment might replace the mechanical cam with a programmable servo-motor system () for automated position changes.illustrate working of the cam mechanism having an index pin, in accordance with an embodiment of the present invention. The cam mechanism () is designed to move between open and closed positions within the tool (). The cam mechanism () with an index pin () is mounted inside the main tool body (). As shown in, the index pin () interacts with grooves or notches on the cam mechanism (), holding it in place or allowing it to move as required to change the tool's () position from open to closed.

illustrates a wave spring, in accordance with the present invention. Wave spring (): Located on the main shaft (), as shown in, the wave spring () functions as a retraction mechanism. Instead of a wave spring (), alternative embodiments might use a gas-charged accumulator to provide the necessary retraction force, which could be adjustable for different drilling pressures. This would allow for more precise control of the return force applied to the tool (). After the tool () is operated, the wave spring () aids in returning it to its original position. The wave spring () surrounds the main shaft () and is compressed or expanded as the cam mechanism () moves. This spring action aids in returning the tool () to its starting position after the operation.

Coming back to, the Main shaft () is the core axial component around which the internal parts of the tool () are arranged. The main shaft () could be constructed from various high-strength, corrosion-resistant materials like titanium or non-metallic composites to reduce weight or enhance durability. Additionally, the shaft could have an expandable design allowing it to extend or retract to fit different tool lengths. The wave spring (), cam mechanism (), and other components are mounted on or interact with the main shaft (). The main shaft () is the central axis of the tool (), providing structural support for the cam mechanism () and the wave spring (). It ensures the alignment of the internal components for proper functioning.

As shown in, the Ball Bearings (,) are Positioned above and below the cam mechanism (), these bearings (,) allow for the smooth movement of the cam mechanism () and reduce friction during its operation. In other embodiments, ball bearings (,) could be coated with advanced materials like diamond-like carbon to reduce wear, or they could be replaced with magnetic levitation bearings that reduce friction and maintenance requirements. Ball bearings (,) are situated around the main shaft (), above and below the cam mechanism (). They facilitate the smooth rotation or movement of the cam mechanism (), reducing wear and tear due to friction.

illustrate a bullet collector, in accordance with the present invention the bullet catcher () with a Special Profile: The Bullet Catcher () is designed to divert bullets () from the main flow path to a side pathway. The Bullet Catcher () could be designed with a variable-angle profile that can be adjusted in real-time to accommodate different types of bullets () or operational scenarios, using actuators or smart material that changes shape in response to electrical or thermal inputs. Its special profile is tailored to ensure that the bullets () do not obstruct operational functions. The Bullet Catcher () with a special profile is integrated into the main tool body (). Its design allows it to catch and divert bullets () used in the operation without disrupting the flow of fluids or the functioning of other components.