DESCRIPTION

The present invention relates to a device as defined in the preamble of claim 1 , for ensuring continuous circulation in well drilling, particularly during insertion or removal of a drill string in wells for hydrocarbon exploration and production.

For simplicity, the present disclosure will be made without limitation with particular reference to the step of insertion of a new drill string, the same considerations being also applicable to the step of removal of drill strings, when the drilling bit must be removed from the well, e.g. for replacement.

When drilling a hydrocarbon well, the process of insertion of a drill string is required for increasing the well drilling depth.

During insertion of a new string, continuous circulation of drilling mud must be ensured throughout the process until a complete pipe is obtained and the whole hydraulic circuit is restored. Indeed, pressure drops or variations in mud circulation have been found to cause considerable structural stresses in the well being drilled, which involve collapse in uncased structures of the well being drilled.

In order to ensure such continuous circulation of drilling mud throughout the drilling process, and hence also during the steps of insertion of new drill strings or removal of existing strings, devices have been long provided, for ensuring steady circulation of drilling mud even during insertion or removal of a drill string.

A device of the aforementioned type is disclosed in the prior art document US 3298385. Particularly, this prior art document shows the possibility of using a flapper valve having a single shut-off member for selectively regulating the passage of the drilling mud through the central axial conduit of the valve or, alternatively, through a lateral passage interposed between opposite ends of the valve.

The technical solution of using a single shut-off member to provide the aforementioned selective regulation of the passage of the drilling mud through the central axial conduit of the valve or, alternatively, through the lateral passage, is preferred over the use of two distinct shut-off members, as disclosed, for instance, in the prior art document US 7845433, amongst other things due to the fact that there is no uncertainty about the closing position assumed by the single shut-off member.

Nevertheless, it shall be noted that, while the use of a single shut-off member to alternatively close either the central axial conduct of the valve or the aforementioned lateral passage interposed between the opposite ends of the valve provides advantages in terms of operation, it poses serious problems concerning proper positioning and centering of the body of the shut-off member within the central axial conduit of the valve. This is because the single shut-off member must be able to ensure a tight sealing effect, both in a first angular position, with the seat of the shut-off member oriented transverse to the axis of the valve, and in a second angular position, with the seat of the shut-off member longitudinally extending along the axis of the valve. Therefore, even a minor angular or axial positioning error with respect to the valve body may cause an imperfect sealing action of the shut-off member in at least one of the two seats of the shut-off member, which is not compatible with the high pressures of the drilling mud.

Particularly proper axial positioning of the body of the shut-off member and the point at which it is hinged to the valve body is problematic. In an attempt to tackle this problem, the valve body and the parts that form the moving shut-off assembly should be formed with very strict processing tolerances but sometimes this has not been practically found to be sufficient. During assembly of the valve and the moving shut-off member therein, the processing tolerances of the various parts may sum up and sometimes cause imperfect closure of the shut-off member in both seats of the shut-off member.

For the aforementioned reasons, these valves comprising a single shut-off member have not gained success in this field heretofore.

Therefore, there is an unfulfilled need of ensuring proper closing operation of the shut-off member in both closing positions, irrespective of any particular critical condition that may be encountered during assembly due to the summation of the tolerances of the various connections that have been made.

The present invention is based on the problem of conceiving a device for ensuring continuous circulation in well drilling, particularly during insertion or removal of a drill string into and out of wells for hydrocarbon exploration and production, that has such stmctural and functional characteristics as to fulfill the above need, without being affected by the aforementioned prior art problems.

This problem is solved by a device for ensuring continuous circulation in well drilling as defined in claim 1.

Further characteristics and advantages of the device of the present invention for ensuring continuous circulation in well drilling will be apparent from the following description of a few preferred embodiments thereof, which are given by way of illustration and without limitation with reference to the accompanying figures, in which:

- Figure 1 shows a simplified plane longitudinal sectional view of the device of the invention, with the lateral conduit closed by the shut-off member in a longitudinal position;

- Figure 2 shows a longitudinal sectional view of the device of Figure 1 , with the axial conduit closed by the shut-off member in a transverse position;

- Figures 3 and 4 show two respective perspective longitudinal sectional views of the device of Figure 2 as taken along two different planes;

- Figure 5 shows an enlarged detail of Figure 4;

- Figure 6 shows an exploded perspective view of the device of Figure 1 ;

- Figure 7 shows an exploded plane view of the device of Figure 1 ;

- Figure 8 only shows a longitudinal sectional plane view detail of the tubular body of the device of Figure 1 ;

- Figure 9 shows a longitudinal sectional plane view of the device of Figure 1 with the locking guide and its Seeger ring removed, and

- Figure 10 shows a sectional view taken along line X - X of Figure 9.

Referring to the accompanying figures, numeral 1 generally designates an inventive device for ensuring continuous circulation in well drilling, namely a device for ensuring continuous circulation in well drilling particularly during insertion or removal of a drill string into or out of wells for hydrocarbon exploration and production.

The device 1 comprises: - a substantially tubular body 2 extending in a preset axial direction X-X from an upstream end 2a to a downstream end 2b, the tubular body 2 being shown as having a circular cylindrical section;

- an axial conduit extending from the upstream end 2a to the downstream end 2b, for drilling mud to flow therethrough in the device 1 ;

- first threaded connection means at the upstream end 2a for connection of the downstream end 2b of the device 1 to one end of a drill string;

- second threaded connection means at the downstream end 2b for connection of the downstream end 2b of the device 1 to one end of a drill string;

- a lateral opening 3 located in the tubular- body 2 between the upstream end 2a and the downstream end 2b to define a lateral conduit in the device 1, in fluid communication with the aforementioned axial conduit, the axial conduit having an axis Y-Y which is preferably perpendicular to the axis X-X of the axial conduit;

- a plug 5 removably fitted into the lateral opening 3 in a pressure -tight manner by a threaded nut-screw engagement;

- valve means 6 located in the axial conduit to block the drilling mud and stop its flow from the upstream end 2a to the downstream end 2b;

wherein:

- the aforementioned valve means comprise a shut-off member 6 that is movably supported in the axial conduit to move from a position transverse to the axial conduit (see

Figures 1 , 9), in which the shut-off member 6 extends transverse to the axis of the axial conduit to stop fluid continuity between the upstream end 2a and the downstream end 2b in the axial conduit, and a longitudinal position relative to the axial conduit (see Figures 2, 4, 5), in which the shut-off member 6 substantially extends along the axis of the axial conduit and is located close to a side wall portion within the tubular body 2;

- in such transverse position (see Figures 1, 9) the shut-off member 6 is located between the lateral conduit and the upstream end 2a of the tubular body 2 to be placed upstream from the aforementioned lateral opening 3, relative to the flow of the drilling mud in the axial conduit from the upstream end 2a to the downstream end 2b and

- in such longitudinal position (see Figures 2, 4, 5) the shut-off member 6 closes in a pressure-tight manner the lateral opening 3 to stop fluid continuity between the lateral conduit and the axial channel of the tubular body.

Concerning drill strings, it shall be noted that, according to an applicable industry standard, these have a male threaded lower end and an opposed nut threaded upper end, which is designed for nut-screw engagement with the lower end of another drill string. According to this standard, in the device 1 the first screw connection means of the upstream end 2a consist of a nut screw, and the second screw connection means of the downstream end 2b consist of male screw threads, said nut screw and said male screw threads being equal to said nut threads and said male screw threads provided at the upper and lower ends respectively of each drill string.

At the lateral opening 3, the tubular body 2 of the device 1 has a seat for the shut- off member which is designed for pressure-tight engagement by the shut-off member 6, when such shut-off member is in the aforementioned longitudinal position (see Figures 2, 4, 5), such seat for the shut-off member allowing the lateral opening 3 and the lateral channel defined thereby to be closed in a pressure-tight manner, as mentioned above.

Preferably, such seat for the shut-off member is an inserted seat 7, and is associated in integral and pressure-tight fashion with the tubular body 2. In accordance with the illustrated embodiments, the inserted seat 7 for the shut-off member is defined by a threaded ring nut, having:

- an outer portion with male screw threads, for pressure-tight nut-screw engagement with corresponding nut threads provided at the lateral opening 3, and

- an inner portion with nut threads, for pressure-tight screw engagement with the male screw threads of the plug 5.

Alternatively, the above-mentioned inserted seat for the shut-off member may be formed as a one-piece with the tubular body 2, and an inserted seat for the shut-off member welded to the tubular body or secured thereto in a manner other than the above described screw connection, may be also used.

Similarly, it shall be noted that the screw engagement between the plug 55 and the inserted seat 7 for the shut-off member is a preferred embodiment, although different removable pressure-tight connection arrangements may be provided. In any case, the inserted seat 7 and the plug 5 should have small dimensions, and be at the most flush with the footprint of the outer wall of the tubular body 2, to prevent any radially projecting portion of the tubular body 2 of the device from creating interferences in the well being drilled.

Preferably, the shut-off member 6 comprises a convex, preferably a partially spherical portion/wall, whose convexity faces the lateral opening 3. This spherical portion/wall engages such inserted seat 7 for the shut-off member in a pressure-tight manner, when the shut-off member 6 is in the aforementioned longitudinal position (see Figures 2, 4, 5).

Preferably, the above-mentioned valve means consist of a flapper valve having a diaphragm shut-off member 6, which is connected by hinge connection means, at a peripheral portion thereof, to an axis of rotation 8, said diapliragm 6 moving from such longitudinal position (see Figures 2, 4, 5) to said transverse position (see Figures 1, 9), and vice versa, by rotating about said axis of rotation 8. Such axis of rotation 8:

- extends transverse, preferably perpendicular, to the longitudinal axis X-X of said axial conduit;

- is placed close to the inner wall of said tubular body 2;

- is circumferentially placed to be substantially located at said lateral opening 3 and

- is located substantially proximate to said lateral opening 3 in the portion of the tubular body 2 located between said lateral opening 3 and the upstream end 2a of the tubular body 2,

As a result, when the tubular body 2 is placed with the longitudinal axis substantially in a vertical orientation, with the upstream end 2a located at a higher level than the downstream end 2b:

- the aforementioned hinge connection means and the axis of rotation 8 are placed above the through opening 3 and,

- due to its weight force the shut-off member 6 tends to move to the aforementioned longitudinal position (see Figures 2, 4, 5) in which it seals the lateral opening 3. According to both embodiments of the figures, the shut-off member 6 and the hinge connection means are supported by a tubular support 9 for the shut-off member, which is concentrically fitted in a pressure-tight mariner into the tubular conduit defined in the tubular body 2 from the upstream end 2a to an axial limit-stop position as defined by an inner annular shoulder 34 of the tubular body 2.

The device 1 is also equipped with positioning and centering means 1 1 , which are adapted to ensure proper axial and angular positioning of the tubular support 9 within the tubular body 2 by abutment against the aforementioned inner annular shoulder 34.

The positioning and centering means may be formed in accordance with different possible functionally and/or structurally equivalent embodiments. Thus, for example, according to the illustrated embodiment, the above positioning and centering means 11 comprise:

- a through hole 31 provided in the wall of the tubular body 2 perpendicular to the axis X-X,

- a blind hole 32 provided in the outer wall of the tubular support 9 perpendicular to the axis X-X and

- a pin 33 adapted to fit into the through hole 31 of the tubular body 2 to engagement of the blind hole 32 of the tubular support.

The through hole 31 and the blind hole 32 are placed in such positions relative to the tubular body 2 and the tubular support 9, as to be exactly aligned when the tubular support 9 is properly angularly rotated about the axis X-X of the axial conduit such that, in the aforementioned longitudinal position (see Figures 2, 4, 5), the shut-off member 6 is located over said lateral opening 3 (namely in pressure-tight engagement relationship with the seat 7 for the shut-off member) for pressure-tight closure thereof.

Therefore, the engagement of the pin 33 in the through hole 31 and the blind hole

32 confirms proper positioning of the tubular support 9 in the tubular conduit 2. It shall be noted that the proper depth of insertion of the tubular support 9 in the axial channel of the tubular body 2 is ensured by abutment of the head end 9b of the tubular support 9 against an inner annular shoulder 34 of the tubular body 2.

The aforementioned pin 33 is carried by a support plate 35, which is mounted to the tubular body 2 from the outside by means of fastening screws. For this purpose, a seat 37 is provided in the outer wall of the tubular body 2 for receiving the support plate 35, the insertion of the support plate 35 in the receiving seat 37 confimiing that the pin 33 is also inserted in the blind hole 32 of the tubular support 9 and hence that the tubular support 9 is properly positioned (both axially and angularly) within the tubular body 2.

Preferably, the aforementioned support plate 35 axially extends to engagement of an outer seat for the removable plug 5, thereby also acting as a safety feature to prevent rotation and hence loosening of the removable plug 5.

As shown in the figures, seal means 24 are provided between the tubular support 9 and the inner tubular wall of the tubular body, to afford pressure tightness. For this purpose, an annular seat is provided in the exterior of the tubular support 9, in which the seal means 24 are housed in outwardly projecting arrangement for interference with the inner tubular wall of the tubular body 2.

The device 1 further comprises retainer means 13 for maintaining the tubular support 9 inserted in the axial conduit, in the aforementioned limit stop axial position.

These retainer means 13 comprise:

- a plurality of retainer elements 14, placed in said tubular conduit in a circumferentially offset position and close to the head end 9a of the tubular support 9 facing the upstream end 2a of the tubular body 2, said retamer elements 14 acting as retainer means to prevent the tubular support 9 from axially moving toward the upstream end 2a of the tubular body 2;

- an inner seat 15 provided in the inner tubular wall of said tubular body 2, which only houses a first portion 14a of the retainer elements 14, a second portion 14b of the retainer elements 14 projecting out of the inner tubular wall of the tubular body 2 into the axial channel and

- a locking guide 16 for maintaining said first portion of the retainer elements within the inner seat 15.

According to the illustrated embodiment, the retainer elements 14 comprise circumferential sectors having a substantially L-shaped cross section, wherein

- a first branch of the L shape defines the aforementioned first portion 14a inserted in said groove 15, whereas

- the second branch of the L shape defines said second portion 14b that defines the inner shoulder, acted upon by the adjustment pressing/pushing member 50.

Preferably, the aforementioned circumferential sectors 14 are oriented such that the aforementioned second branch 14b of the L shape will extend from the first branch 14a of the L shape toward the upstream end 2a of the tubular body 2.

Advantageously, the device 1 comprises an adjustment pressing/pushing member 50, wherein:

- said adjustment pressmg/pushing member 50 is coaxially associated in kinematic nut-screw engagement with the tubular support 9, such that a relative rotation of said adjustment pressing/pushing member 50 in a first direction or in the opposite direction with respect to said tubular support 9 corresponds to a relative displacement of said adjustment pressing/pushing member 50 along the axis X-X, in a first direction or in the opposite direction with respect to the tubular support 9;

- following a relative rotation of the adjustment pressing/pushing member 50 with respect to the tubular support 9, the adjustment pressing/pushing member 50 reversibly moves along the axis X-X, from a more retracted position relative to the upstream end 2a toward a more advanced position with respect to said upstream end 2a of the tubular body, and vice-versa;

- when the adjustment pressing/pushing member 50 is in the aforementioned more retracted position it does not interfere with the retainer elements 14, as it is at a longer distance from the upstream end 2a of the tubular body 2 than the retainer elements 14;

- the aforementioned inner shoulder defined in the tubular conduit 2 by the retainer elements 14 defines a limit-stop abutment against the movement of the adjustment pressing/pushing member 50 toward the aforementioned more advanced position.

In view of the above, when the device 1 is properly mounted, the adjustment pressing/pushing member 50 is rotated relative to the tubular member 9 for the adjustment pressing/pushing member 50 to be moved closer to the upstream end 2a of the tubular body 2. This movement stops before the adjustment pressmg/pushing member 50 reaches the aforementioned more advanced position. Namely, this movement stops when the adjustment pressing/pushing member 50 abuts and is forced against the aforementioned inner shoulder defined in the tubular conduit 2. Due to such abutment:

- the retainer elements 14 can be forced into the inner seat 15 toward the upstream end 2a of the tubular body and, at the same time,

- the tubular support 9 can be forced into the axial limit-stop position against said positioning and centering means 1 1.

This will afford effective recovery of the clearances in positioning the tubular support 9 and the means 6 supported thereby inside the tubular body 2.

According to a preferred embodiment:

- the aforementioned adjustment pressing/pushing member 50 is a threaded ring nut and

- the aforementioned head end 9a of the tubular support 9 facing toward said upstream end 2a of the tubular body 2 has threads for coupling with said threaded ring nut by nut-screw engagement.

Preferably, the device 1 comprises stop means which act upon the

adjustment pressing/pushing member 50 to reversibly lock the angular position of said adjustment pressing/pushing member 50 with respect to the tubular element 9, to thereby prevent rotation and consequent axial displacement of the adjustment pressmg/pushing member 50 with respect to the tubular body 9.

According to the illustrated embodiment, the aforementioned stop means comprise a locking pin 51 which is inserted in a through opening 52 formed in the tubular wall of the tubular body 2 level with the adjustment pressing pushing member 4 and transverse, preferably perpendicular to the axis X-X of the tubular element 2. Such locking pin 41 abuts with a predetermined pre-load against the outer cylindrical wall of the adjustment pressing/pushing member 50 to prevent rotation thereof about the axis (X-X). In the illustrated example, the locking pin 51 is force-fitted into said through opening 52, although other coupling forms may be provided, such as a threaded nut-screw engagement.

According to a preferred embodiment, the outer cylindrical wall of the adjustment pressing/pushing member 50 has a plurality of grooves (not shown for simplicity) which extend parallel to the axis and, accordingly, the free end of the locking pin 51 which is designed to contact the adjustment pressing/pushing member 50 also has a corresponding series of grooves (not shown). The coupling between the aforementioned grooves of the outer cylindrical wall of the adjustment pressmg/pushing member 50 and the free end of the locking pin 51 helps to prevent any rotation of the adjustment pressing/pushing member 50 about the axis X-X.

According to an embodiment that is not shown, the retainer elements 14 may be other than the above described circumferential sectors. Thus, for example, there may be a great number of (at least ten) retainer elements in the form of spherical elements, elements with spherical-surface portions or rollers with their axes parallel to the longitudinal axis X-X of the tubular body 2. These retainer elements are also at a convenient distance, i.e. spaced, from each other in the circumferential direction, and define together the aforementioned annular retainer element whose inside diameter is smaller than the inside diameter of the lateral opening 3. It shall be noted that, also in this case, the aforementioned plurality of retainer elements can accomplish as a whole an effective and uniform retaining action for the aforementioned adjustment pressing/pushing member 50.

Preferably, the aforementioned inner seat 15 comprises a profile that matches the profile of the first portion of the retainer elements inserted therein.

Preferably, a circumferential groove is provided in the aforementioned inner annular seat 15, for receiving magnets, preferably in the form of annular sectors or an open ring, whereby the retainer elements 14 can be held in position in the inner annular seat 15 during assembly of the device 1 , namely prior to positioning of the locking guide 16.

Instead of or in addition to the provision of the aforementioned magnets in the inner annular seat 15, the retainer elements 14 may be provided themselves in the form of magnetic elements. This may be achieved by magnetizing the retainer elements 14 or associating magnets therewith.

Concerning the aforementioned locking guide 16 for locking the retainer elements 14, it will be appreciated that it may be conveniently held in position within the tubular conduit 2, against the inner wall of the tubular conduit 2, using a Seeger ring 19, which partially engages an inner circumferential groove 20 provided in the inner tubular wall of the tubular body 2.

The outer tubular wall of the locking guide 16 comprises a circumferential groove (not shown), in which an O-ring is housed with a portion projecting outwards. This O-ring provides pressure-tightness between the outer annular wall of the locking guide 16 and the inner wall of the tubular conduit 2.

Preferably, the device 1 comprises magnetic means 22 for exerting an attractive force on the shut-off member 6 in the longitudinal position (see Figures 2, 4, 5), or in a position proximate thereto, and/or for holding it in said longitudinal position with a preset force, such that only when a force that can exceed such magnetic attractive force is exerted on the shut-off member 6, such shut-off member 6 may be moved toward the aforementioned transverse position (see Figures 1, 9).

Preferably, these magnetic means 22 have a ring shape, although magnets having the shape of annular sectors, disks or others may be used and placed on/in the plug 5.

According to the illustrated embodiments, these magnetic means are carried by the plug 5, preferably by the inner side of the plug 5, i.e. the side of the plug 5 that faces the aforementioned axial channel when the plug 5 is applied to close the lateral opening 3 in a pressure-tight manner.

According to an embodiment that is not shown in the figures, the aforementioned magnetic means may comprise one or more magnets carried by the shut-off member at the side of the shut-off member 6 that faces the lateral opening 3 when the shut-off member 6 is in the aforementioned longitudinal position, whereby such magnets may interact with the inner wall of the tubular body 2, with the seat 7 for the shut-off member and/or preferably with a portion of the plug 5. These magnetic means may also preferably have a ring shape and are applied to the side of the shut-off member 6 that faces the lateral opening 3 when the shut-off member 6 is in the longitudinal position. This is particularly advantageous when the shut-off member 6 has a substantially circular shape, because the magnetic ring may be applied to the shut-off member 6 in concentric arrangement.

Possibly, the aforementioned magnetic means 22 may be arranged to be carried both by the plug 5 and by the shut-off member 6, in the latter case the magnets of the plug and the shut-off member should be arranged in substantially facing positions, for mutual magnetic attraction when the shut-off member 6 is in the aforementioned longitudinal position (see Figures 2, 4, 5).

Concerning the attractive force that attracts the shut-off member 6 toward the plug, it will be appreciated that such attractive force is useful during the transient steps in which the shut-off member 6 is carried from the aforementioned transverse position to the longitudinal position. Indeed, when the drilling mud flows along the axial channel from the end 2a to the end 2b, the mud flow itself pushes the shut-off member and holds it in the aforementioned longitudinal position. Therefore, the magnets 22 help the shut- off member 6 to adhere against the inserted seat 7 prior to the action of the inner pressure of the drilling mud.

Once the adapter has been mounted and the mud flow has been deflected from the axial to the radial direction, the flow will open the shut-off member without having to overcome any magnetic attraction, as magnets have already been removed with the plug (as they were joined to the plug).

Preferably there is no direct contact between the plug 5 and the shut-off member 6, a minimum distance being always ensured therebetween, to avoid that any residual mud might prevent the shut-off member from reaching the aforementioned longitudinal position (see Figures 2, 4, 5), and hence to ensure tight sealing of the lateral opening.

As a result, when the shut-off member 6 is in the aforementioned longitudinal position (see Figures 2, 4,5), a closed chamber is defined between the shut-off member 6 and the plug 5. In order to provide depressurization of such chamber, according to a preferred embodiment the plug 5 comprises a small axial through opening 29 at which a closed screw cap 28 is located, which is adapted to be actuated into a pressure-tight closed state and an open state, for respectively obstmcting and allowing the passage of fluid through the aforementioned through opening, in the latter case allowing the passage of the drilling mud. Hence the axial through opening together with the screw cap 28 constitute a discharge valve.

Therefore, by opening the aforementioned discharge valve, any drilling mud retained thereby may be evacuated, which will improve the stability of the shut-off member in the longitudinal position (see Figures 2, 4, 5), and will ensure pressure-tight closure of the lateral passage.

Preferably, the aforementioned magnetic means 22 are applied to the plug 5 in such a manner as to circumscribe the aforementioned through opening that has the discharge valve located thereat.

As clearly shown in the above description, the device 1 of the present invention fulfills the aforementioned need and also obviates prior art drawbacks as set out in the introduction of this disclosure. The possibility of acting upon the adjustment pressing/pushing member to press and force the tubular support into the limit-stop position against the aforementioned positioning and centering means affords recovery of clearances due to processing tolerances, and allows the tubular support to assume a given well-precise axial position in the tubular body of the device, whereby the axial position of the shut-off member is also well-defined, and the shut-off member is optimally positioned relative to its respective shut-off member seats.

Advantageously, the provision of magnetic means housed in the inner annular seat of the tubular body allows the retainer elements to be held in position in the inner annular seat during assembly of the device, namely prior to positioning of the locking guide.

Those skilled in the ail will obviously appreciate that a number of changes and variants may be made to the above described device, still within the scopeof the invention, as defined in the following claims.