Electro-Hydraulic Tubing Punch

The present invention relates generally to making a punch. More specifically, the present invention is a tubing punch for piercing holes in tubing of oil and gas wells.

The field of oil and gas extraction has long been a cornerstone of the energy sector, with continual advancements in technology being crucial for maintaining and enhancing efficiency, safety, and environmental compliance. A significant operation in this field involves creating perforations in well tubing and casing. Historically, several methods have been employed to achieve this perforation, each with its unique mechanisms and associated challenges.

Traditionally, explosively charged punches have been extensively used for creating perforations. These devices rely on controlled explosive charges to puncture the well tube, creating pathways to communicate tubing and annulus. While effective in creating perforations, the explosive method presents significant safety risks due to the handling and deployment of explosives. Moreover, the use of explosives can compromise the structural integrity of the well tubing over time, potentially leading to costly repairs and environmental hazards.

Mechanical punches represent another method, employing a physical force to create holes in the well tubing. Although safer than explosive charges, mechanical punches require considerable manual effort or mechanical complexity to generate sufficient force. This can lead to operational inefficiencies and limitations in the precision and consistency of the perforations. Additionally, the mechanical wear and tear on these devices necessitate frequent maintenance and replacement, adding to the operational costs.

Devices utilizing plasma for perforation have also been developed, offering a high degree of precision in creating perforations. However, plasma-based methods require significant energy inputs and sophisticated equipment to generate and control the plasma, complicating their use in the variable and harsh conditions commonly encountered in oil and gas wells. Moreover, the complexity and cost of plasma systems can be prohibitive for widespread adoption in the industry.

In light of these challenges, the present invention seeks to provide a solution to the pitfalls of the prior art. The present invention addresses such pitfalls by providing an electric hydraulic punch for creating perforations in oil and gas well tubing. Unlike the prior art, this device leverages electrically powered hydraulics to generate force, offering a safer, more reliable, and environmentally friendly alternative to explosive charges. Furthermore, the electric hydraulic punch provides greater control and consistency over the perforation process compared to mechanical punches, without the complexity and operational challenges associated with plasma-based methods.

An electro-hydraulic tubing punch having an electronic section, a hydraulic power section, an oriented centralizer, and a hydraulic punch head. The oriented centralizer is a mechanism that self-centers the punch perpendicular to the tubing wall.

All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art that the present disclosure has broad utility and application. As should be understood, any embodiment may incorporate only one or a plurality of the above-disclosed aspects of the disclosure and may further incorporate only one or a plurality of the above-disclosed features. Furthermore, any embodiment discussed and identified as being “preferred” is considered to be part of a best mode contemplated for carrying out the embodiments of the present disclosure. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present disclosure.

Accordingly, while embodiments are described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the present disclosure, and are made merely for the purposes of providing a full and enabling disclosure. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.

Additionally, it is important to note that each term used herein refers to that which an ordinary artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used herein-as understood by the ordinary artisan based on the contextual use of such term-differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the ordinary artisan should prevail.

Furthermore, it is important to note that, as used herein, “a” and “an” each generally denotes “at least one,” but does not exclude a plurality unless the contextual use dictates otherwise. When used herein to join a list of items, “or” denotes “at least one of the items,” but does not exclude a plurality of items of the list. Finally, when used herein to join a list of items, “and” denotes “all of the items of the list.”

The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While many embodiments of the disclosure may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the disclosure. Instead, the proper scope of the disclosure is defined by the appended claims. The present disclosure contains headers. It should be understood that these headers are used as references and are not to be construed as limiting upon the subjected matter disclosed under the header.

Other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description. It should be understood at the outset that, although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described below.

Unless otherwise indicated, the drawings are intended to be read together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up”, “down” and the like, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, “radially”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly,” “outwardly” and “radially” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.

The present disclosure includes many aspects and features. Moreover, while many aspects and features relate to, and are described in the context of an electro-hydraulic tubing punch, embodiments of the present disclosure are not limited to use only in this context.

As shown inand, the present invention is an electro-hydraulic tubing punchcomprising an electronic section, a hydraulic chamber, a punch head, and an oriented centralizer. In the context of the present invention, as shown inand, the electronic sectionis coupled adjacent the hydraulic chamber; the hydraulic chamberis further coupled adjacent to the punch head; and the oriented centralizeris coupled adjacent to the punch head. In the preferred embodiment of the present invention, the electronic sectionis threadedly coupled to the hydraulic chamber; the punch headis threadedly coupled to the hydraulic chamber; and the oriented centralizeris threadedly coupled to the punch head.

As shown inand, the electronic sectioncomprises a tubular housingand a connection port. Within the context of the present invention, the connection portis positioned at a distal end of the tubular housing. Additionally, in the context of the present invention, the connection portfacilitates the communication of electrical signals and electrical power to the hydraulic chamber, the punch head, and the oriented centralizer. Furthermore, within the preferred embodiment of the present invention, the electronic sectionfurther comprises an electronic boardand a processor, wherein said electrical boardand processorare contained within the housingof the electrical section. In the context of the present invention, the electronic boardcomprises electrical connections such that the processor, a device understood to facilitate computer executable methods, receives and transmits signals through the electrical board.

Furthermore, as shown in,, and, in the context of the present invention, the hydraulic chamberis a tubular member comprising a first endand a second end, wherein said first endand second endare opposing distal ends of the hydraulic chamber. In the preferred embodiment of the present invention, the first distal endis coupled to the punch headand the second distal endis coupled to the electronic member. Furthermore, in the preferred embodiment of the present invention, the hydraulic chambercomprises a tubular housingwherein said tubular housingcontains hydraulic fluid, a motor, and a pump. In the preferred embodiment of the present invention, hydraulic oil is used as hydraulic fluid. Additionally, within the preferred embodiment of the present invention, the motoris a direct current (DC) motor wherein the pumpis driven by said motor. In the preferred embodiment of the present invention, the pumpis a piston pump wherein the motordrives said piston pump, thereby moving hydraulic fluidthrough hydraulic chamber.

In regard to,, and, the punch headcomprises a piercing punch, a main body, and an engagement panel. In the preferred embodiment of the present invention, the engagement panelextends and retracts from the main body. Furthermore, in the preferred embodiment of the present invention, the piercing punchextends and retracts with respect to the engagement panel. In the preferred embodiment of the present invention, the electro-hydraulic tubing punchcomprises a retracted configuration, as shown in; a partially extended configuration, as shown in; and a fully extended configuration, as shown in. In the context of the present invention, while in the retracted configuration, the engagement panelis set into the main body. Furthermore, in the context of the present invention, while in the partially extended configuration, the engagement panelis extended outwardly from the main body. Moreover, in the preferred embodiment of the present invention, in the fully extended configuration, the engagement panelis extended outwardly from the main bodyand at least a portion of the piercing punchprojects outwardly from the engagement panel.

As shown inand, in the preferred embodiment of the present invention, the punch headfurther comprises a fluid channel, a spring, a fluid cavity, and a punch piston. In the preferred embodiment of the present invention, the springis interposed between the engagement paneland the punch pistonwithin the main bodywherein the springis circumferentially positioned around the piercing punch. Additionally, in the preferred embodiment of the present invention, the fluid cavityis a cylindrical recess within the main bodywherein the punch pistonis laterally displaced during operation. Furthermore, in some embodiments of the present invention, the main bodyfurther comprises an at least one pistonwherein said at least one pistonis contained within the main bodysuch that said at least one pistondisplaces the engagement panel. Furthermore, in the preferred embodiment of the present invention, the fluid channeltraverses through a portion of the main bodyto the fluid cavity, thus communicating hydraulic fluidinto said fluid cavity, causing the linear displacement of the punch pistonand thereby the piercing punch. In the preferred embodiment of the present invention, the springassists in the retraction of the piercing punchafter the hydraulic fluidescapes the fluid channel.

Within the context of the present invention, as shown inand, the engagement panelcomprises a hole, an exterior surface, and an at least one rodsuch that the holeis a through hole extending through the engagement panelfrom the exterior surface, inwardly. Furthermore, within the context of the present invention, the exterior surfaceis the outwardly facing surface of the engagement panel. In the preferred embodiment of the present invention, the at least one rod, is a shaft connected to the engagement panel, aligned within the at least one pistonsuch that a force applied to the at least one rodby the at least one pistoncauses a linear displacement of the engagement panel. Additionally, in the preferred embodiment of the present invention, the at least one pistoncomprises a fluid chamber, a piston head, a stem, and a springwherein the piston headis coupled to the stem; the springis circumferentially positioned around the stem; and the piston headtraverses laterally within the cylindrically shaped fluid chamber. In the preferred embodiment of the present invention, the piecing punchtraverses the holeof the engagement panel.

As further shown in, in the preferred embodiment of the present invention, the piercing punchcomprises a tip, a neck, a body, and a stem. In the context of the present invention, the piercing punchis an elongated member wherein the stemis threadedly coupled to the punch piston; the tipis the distal portion of the piercing punch, opposite the stem; and the neckand bodyare interposed between the tipand the stemof the piercing punch. In the preferred embodiment of the present invention, the neckis interposed between the tipand bodyof the piercing punch. Additionally, within the preferred embodiment of the present invention, the neckcomprises a truncated-hyperboloid shape (i.e. a bell shape) wherein the portion with the greatest diameter is adjacent to the bodyand the portion with the smallest diameter is adjacent to the tip. Moreover, in the preferred embodiment of the present invention, the piercing punchcomprises a channelwherein said channelis a cylindrical recess that traverses the stemsuch that the channelextends inwardly along a central axis of the stem. In the preferred embodiment of the present invention, in the event that the piercing punchbecomes stuck and unable to be retracted, the bodyof the piercing punchmay be broken off, thus exposing the channeland pouring hydraulic fluidinto the system. In the context of the present invention “the system” is defined as the environment in which the electro-hydraulic tubing punchis being utilized (i.e. a section of tubing).

Within the context of the present invention, the oriented centralizeris a device that positions the electro-hydraulic tubing punch, specifically the piercing punch, in a user-desired position, thus ensuring the correct placement of the hole produced by the piercing punch. Within the preferred embodiment of the present invention, as shown in, the oriented centralizercomprises an elongated member, a plurality of collars, a plurality of arms, a spring, and a head. As shown, the headis disposed at one end of the elongated member. Furthermore, the plurality of collarsis positioned circumferentially about the elongated membersuch that the plurality of collars, including a first collarand a second collar, are offset from each other, and the springis interposed between the second collarand the head. Additionally, as shown, the plurality of armsare hingedly coupled to the plurality of collarssuch that the plurality of arms, including a first armand a second arm, are angularly offset from each other. Further, in the preferred embodiment of the present invention, each arm of the plurality of armscomprises a first member,, a second member,, and an elbow,, wherein the first member,and the second member,are connected at the elbow,; the elbow,being a hinged connection between the first,and second member,of the respective arms. In the preferred embodiment of the present invention, the first collaris fixed to the elongated memberand the second collaris slidably coupled to the elongated membersuch that the second collarslides freely along the elongated member. In the preferred embodiment of the present invention, upon an inwardly directed (i.e. an axially aligned) force being applied to the head, the second collardisplaces along the elongated member, thus causing the plurality of armsto bend outwardly. In the preferred embodiment of the present invention, the outward bend of the plurality of armsabout the elbows,provide stabilization points which engage with an interior wall of a pipe.

As shown in, in the preferred embodiment of the present invention, the electro-hydraulic tubing punchfurther comprises a controllerwherein said controllerfacilitates the operation of the electro-hydraulic tubing punch. In the preferred embodiment of the present invention, the controlleris connected to the connection portof the electronic sectionsuch that the controllerenables a user to transmit electrical signals to the electro-hydraulic tubing punch, through the controller. As shown in, in the preferred embodiment of the present invention, the controlleris a user interface device comprising a housingwherein said housingcontains a power button, a power input, a punch actuator, a display, a mode selector, a voltage selector, and a voltage knob. In the context of the present invention, the punch actuatorand the mode selectorreceives an input from the user and converts said input into an electrical signal which extends and retracts the piercing punch.

With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of an embodiment enabled by the disclosure, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by an embodiment of the disclosure.

Therefore, the foregoing is considered as illustrative only of the principles of the disclosure. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure. In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be only one of the elements.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention.