Abstract: A drilling assembly includes a particle adjusting mechanism upstream of a positive displacement motor. The motor includes a metal stator, a metal rotor at least partially disposed within the metal stator, and a motor gap defined between the sealing line of the metal rotor and the lobes of the metal stator. The particle adjusting mechanism adjusts a solid particle condition of a media flowing therethrough into a treated condition in which any remaining solid particles will travel through the motor gap without widening the motor gap to a failure gap size that causes the metal rotor to lock up or to rotate inefficiently slow. The particle adjusting mechanism adjusts the solid particle condition by removing, reducing a size, reducing a dimension, deforming, modifying a shape, dissolving, or chemically reacting at least a portion of any solid particles contained in the media. The drilling assembly is suited for high temperature wellbores.

Abstract: A sealing system for fluidly sealing a portion of a wellbore including a housing, a rupture disc disposed within a housing inner bore, and a plug disposed within the housing inner bore. The rupture disc includes a base and a central portion, which extends across the housing inner bore to fluidly seal the housing inner bore in a sealed state. The plug fluidly seals the housing inner bore in the sealed state. The plug is disposed an axial distance from the rupture disc in the sealed state. In some embodiments, a sleeve is disposed within the housing inner bore. A central bore of the sleeve retains the plug in the sealed state. Upon a release event, the plug is released from the sleeve. The release of the plug triggers a rupture event, which fractures the rupture disc. The plug clears rupture disc fragments.

Abstract: A sealing system for fluidly sealing a portion of a wellbore including a housing, a rupture disc disposed within a housing inner bore, and a plug disposed within the housing inner bore. The rupture disc includes a base and a central portion, which extends across the housing inner bore to fluidly seal the housing inner bore in a sealed state. The plug fluidly seals the housing inner bore in the sealed state. The plug is disposed an axial distance from the rupture disc in the sealed state. In some embodiments, a sleeve is disposed within the housing inner bore. A central bore of the sleeve retains the plug in the sealed state. Upon a release event, the plug is released from the sleeve. The release of the plug triggers a rupture event, which fractures the rupture disc. The plug clears rupture disc fragments.

Abstract: A downhole separation system for use upstream of any tool through which a media flows. The separation system filters at least a portion of any solids from the media flowing through a filter flow path. The separation system flushes at least a portion of the filtered solids through a flush flow path, through a flush outlet on an outer surface of a housing, and into a space surrounding the housing. A screen and an activation mechanism are disposed within a housing inner bore. The filter flow path extends through a plurality of openings in the screen. The activation mechanism is configured to move between a default position in which it directs fluid through the filter flow path and an activated position in which it directs fluid through the flush flow path. Optionally, a spring within the housing inner bore is configured to bias the activation mechanism toward the default position.

Abstract: A plug used in the hydraulic fracking of hydrocarbon wells. The plug, known as a frac or bridge plug, contains one or more containers housing a chemical substance such as a solid, liquid, or gel composition. The composition may constitute or include a cleaning agent, friction reducer, suspending agent, or other wellbore additive. For example, the composition may constitute or include epoxy components, resins, thermoplastics, dry add friction reducers, dry add gel, dry add pipe on pipe, similar agents, or any combination thereof. The containers can include the same chemical substance or a variety of chemical substances. During drill out of the plug, the containers rupture and release the chemical substance into the wellbore. The released chemical substance, if a cleaning agent, assists in the cleaning of the milled-plug pieces from the wellbore.

Abstract: A downhole separation system for use upstream of any tool through which a media flows. The separation system filters at least a portion of any solids from the media flowing through a filter flow path. The separation system flushes at least a portion of the filtered solids through a flush flow path, through a flush outlet on an outer surface of a housing, and into a space surrounding the housing. A screen and an activation mechanism are disposed within a housing inner bore. The filter flow path extends through a plurality of openings in the screen. The activation mechanism is configured to move between a default position in which it directs fluid through the filter flow path and an activated position in which it directs fluid through the flush flow path. Optionally, a spring within the housing inner bore is configured to bias the activation mechanism toward the default position.

Abstract: A downhole separation system for use upstream of any tool through which a media flows. The separation system filters at least a portion of any solids from the media flowing through a filter flow path. The separation system flushes at least a portion of the filtered solids through a flush flow path, through a flush outlet on an outer surface of a housing, and into a space surrounding the housing. A screen and an activation mechanism are disposed within a housing inner bore. The filter flow path extends through a plurality of openings in the screen. The activation mechanism is configured to move between a default position in which it directs fluid through the filter flow path and an activated position in which it directs fluid through the flush flow path. Optionally, a spring within the housing inner bore is configured to bias the activation mechanism toward the default position.

Abstract: A rupture disc configured to fluidly seal a passageway. The rupture disc includes a base extending from a distal surface to a proximal end, and a central portion extending across the proximal end of the base. The central portion traverses a central axis defined by the base. At least one surface of the central portion, such as an outer surface or inner surface, includes a plurality of facets defined by a plurality of seams. The facets may include one or more flat surfaces and/or one or more conical surfaces. A rupture disc system for fluidly sealing a portion of a wellbore includes the rupture disc disposed within and extending across a housing central bore of a housing, with one or more sealing members engaging the rupture disc and an inner surface of the housing central bore to fluidly seal the housing central bore.

Abstract: A drilling system for use in drilling a wellbore including a driving mechanism and a separation device disposed upstream of the driving mechanism. The separation device filters at least a portion of any solids from drilling media flowing through a filter flow path of the separation device. The separation device flushes at least a portion of the filtered solids through a flush flow path, through a flush outlet on an outer surface of the separation device, and into an annulus between the outer surface of the separation device and the wellbore. Optionally, the drilling system includes a second driving mechanism and a second separation device disposed above the second driving mechanism.

Abstract: A drilling system for use in drilling a wellbore including a driving mechanism and a separation device disposed upstream of the driving mechanism. The separation device filters at least a portion of any solids from drilling media flowing through a filter flow path of the separation device. The separation device flushes at least a portion of the filtered solids through a flush flow path, through a flush outlet on an outer surface of the separation device, and into an annulus between the outer surface of the separation device and the wellbore. Optionally, the drilling system includes a second driving mechanism and a second separation device disposed above the second driving mechanism.

Abstract: Tools for sealing a tubing in a downhole environment. The tools feature top and bottom slip assemblies and a monolithic sealing element. The monolithic sealing element includes a portion that is disposed between the top and bottom slip assemblies as well as portions that encapsulate the slip assemblies. When the tool is actuated from a run-in configuration to a set configuration, the slips move toward each other squeezing the sealing element so that it forms a fluid-tight seal with the tubing. Teeth of the slip assemblies penetrate the portions of the sealing element disposed thereon and bite into the tubing.

Abstract: An integrated milling and production device. The device includes a production housing, a connector, a motor, and a milling bit. The production housing has a central bore with at least one flapper valve pivotally disposed therein and an actuator. Upon completion of milling operations, the connector may be disengaged from the production housing. The production housing may be repositioned in the well. Activation of the actuator permanently opens the flapper valve to permit the flow of production up the production housing to the well surface. The actuator may be a piston.

Abstract: A bit saver assembly having an inner valve sleeve that actuates upon the weight-on-bit (WOB) of the drill bit exceeding a threshold value to overcome the countervailing force provided by a spring contained within the bit saver assembly and the internal flow pressure of the drilling fluid at the area of the inner valve sleeve. Actuation of the inner valve sleeve opens a fluid passage to the wellbore annulus resulting in a reduction of drilling fluid flow pressure and the stretch of the drill string thereby reducing WOB of the drill bit without operator assistance.

Abstract: Degradable downhole tools, tool components, and balls are formed from a processed polyvinyl alcohol (PVA) compound that is degradable in a high-salinity environment. The PVA compound exhibits strength and elasticity properties that are comparable to existing degradable downhole polymers and further exhibits degradability properties that are superior to existing degradable downhole polymers, particularly in high-salinity fluids. For different components, the PVA compound may include a reinforcing material such as fiberglass. The PVA compound also includes a loading of degradable metal, such as a degradable magnesium alloy, rendering the material degradable at high salinity. Usage of tools, tool components, and balls formed from the disclosed materials eliminates the requirement that such equipment be drilled out after use as the PVA compound quickly degrades in high-salinity downhole fluids.

Abstract: A flow rate control system includes a housing and a valve assembly slidingly disposed within a housing inner bore. The housing includes bypass openings. The valve assembly includes a valve and an orifice disposed in a valve inner bore. The valve includes a plurality of valve bypass bores extending axially through a valve collar. The valve assembly slides between closed and fully open positions. A spring biases the valve assembly toward the closed position in which the valve closes the housing bypass openings. In the open position, a bypass fluid path is formed including the valve bypass bores and the housing bypass openings. The valve assembly is flow rate controlled in the closed position and pressure controlled in the open position. The valve assembly may slide within a sleeve assembly including sleeve bypass openings, which connect the valve bypass bores and housing bypass openings in the bypass fluid path.

Abstract: Methods and systems for diverting the flow of fluids within a wellbore are disclosed. The methods and systems use a flow conveyed diverter pack, which includes a package portion and a wing portion. The package portion may contain a ball (a.k.a. a diverter ball) and may contain additional components. The diverter pack may be formed by sandwiching a diverter ball between films of a flexible material, for example, films of a dissolvable polymer. The diverter pack may be deployed in a wellbore, whereby the pack is conveyed by fluid flow to an opening to be sealed. The diverter pack seats upon the opening, thereby diverting flow from the opening.

Abstract: Dissolvable thread sealants are useful for forming a pressure-tight seal between dissolvable threaded components, particularly in downhole tools. A film of the dissolvable thread sealant can be formed on the threads of dissolvable threaded components. As the dissolvable threaded components are exposed to fluid under the appropriate conditions and begin to dissolve, the thread sealant becomes exposed to the fluid and, likewise, dissolves. Embodiments of the dissolvable thread sealants are made using polyvinyl alcohol (PVA).

Abstract: A flow rate control system includes a housing and a valve assembly slidingly disposed within a housing inner bore. The housing includes bypass openings. The valve assembly includes a valve and an orifice disposed in a valve inner bore. The valve includes a plurality of valve bypass bores extending axially through a valve collar. The valve assembly slides between closed and fully open positions. A spring biases the valve assembly toward the closed position in which the valve closes the housing bypass openings. In the open position, a bypass fluid path is formed including the valve bypass bores and the housing bypass openings. The valve assembly is flow rate controlled in the closed position and pressure controlled in the open position. The valve assembly may slide within a sleeve assembly including sleeve bypass openings, which connect the valve bypass bores and housing bypass openings in the bypass fluid path.

Abstract: A flow rate control system includes a housing and a valve assembly slidingly disposed within a housing inner bore. The housing includes bypass openings. The valve assembly includes a valve and an orifice disposed in a valve inner bore. The valve includes a plurality of valve bypass bores extending axially through a valve collar. The valve assembly slides between closed and fully open positions. A spring biases the valve assembly toward the closed position in which the valve closes the housing bypass openings. In the open position, a bypass fluid path is formed including the valve bypass bores and the housing bypass openings. The valve assembly is flow rate controlled in the closed position and pressure controlled in the open position. The valve assembly may slide within a sleeve assembly including sleeve bypass openings, which connect the valve bypass bores and housing bypass openings in the bypass fluid path.

Abstract: A bit saver assembly having an inner valve sleeve that actuates upon the weight-on-bit (WOB) of the drill bit exceeding a threshold value to overcome the countervailing force provided by a spring contained within the bit saver assembly and the internal flow pressure of the drilling fluid at the area of the inner valve sleeve. Actuation of the inner valve sleeve opens a fluid passage to the wellbore annulus resulting in a reduction of drilling fluid flow pressure and the stretch of the drill string thereby reducing WOB of the drill bit without operator assistance.