Abstract: A compact gas turbine motor and a speed reduction transmission capable of providing the speed and torque required for drilling with center discharge bits. The transmission includes two sun gears of different pitch diameters, keyed to the turbine shaft. Upper planet gears, whose carrier is fixed in place, drive an outer ring gear, which engages lower planet gears having a different pitch diameter. The lower planet gears engage the lower sun gear. Due to the different pitch diameters of the sun gears and planet gears, the gear carrier for the lower planet gears rotates in the same direction as the turbine shaft, but at a much slower rate. Exhaust gas from the turbine can be directed through one or more flow restriction elements to increase gas density in the turbine, further reducing turbine speed. The flow restriction element can comprise a venturi, to provide a vacuum assist to remove cuttings.

Abstract: Hydraulic pulses are produced each time that a pulse valve interrupts the flow of a pressurized fluid through a conduit. The pulse valve includes an elongate housing having an inlet configured to couple to the conduit to receive the pressurized fluid, and an outlet configured to couple to one or more tools. In the housing, a valve assembly includes a poppet reciprocating between open and closed positions, and a poppet seat, in which the poppet closes to at least partially block the flow of pressurized fluid through the valve. A pilot within the poppet moves between disparate positions to modify fluid paths within the valve. When the valve is open, a relatively lower pressure is produced by a Venturi effect as the fluid flows through a throat in the poppet seat, to provide a differential pressure used to move the pilot and poppet. An optional bypass reduces the pulse amplitude.

Abstract: A self-actuated cyclical flow interruption valve on a deployment tool is positioned at a proximal end of a well completion assembly. Fluid is pumped though the self-actuated cyclical flow interruption valve and vented immediately distal of the valve, to return to surface of the well. A water hammer pulse is generated each time the self-actuated cyclical flow interruption valve closes, thereby generating an impact force that acts to push the completion equipment distally into the well. The continuous cyclic force of the impact facilitates placement of the completion equipment where desired in the well, including within a horizontal extension of the well. Fluid discharged through the self-actuated cyclical flow interruption valve circulates up to the surface through a vertical and inclined section of the well.

Abstract: A gas turbodrill with an adjustable bent housing for use in a spur lateral drilling application. The gas turbodrill includes a high-speed gas turbine, a gearbox assembly, a pivoting shaft connection point, a gimbal assembly comprising a hollow ball and socket joint, a bearing assembly and drill bit assembly. The gas turbodrill gimbal assembly enabling a bend through an angle of up to 5 degrees while drilling. Springs and the application of pressure will lock the bend in place once drilling commences to facilitate lateral drilling of the spur.

Abstract: A bottom hole assembly is configured with a drill bit section connected to a pulse generation section. The pulse generation section includes a relatively long external housing, the particular housing length being selected for the particular drilling location. The long external housing is positioned closely adjacent to the borehole sidewalls to thereby create a high speed flow course between the external walls of the housing and the borehole sidewalls. The long external housing includes a valve cartridge assembly and optionally a shock sub decoupler. While in operation, the valve cartridge assembly continuously cycles and uses downhole pressure to thereby generate seismic signal pulses that propagate to geophones or other similar sensors on the surface. The amount of bypass allowed through the valve assembly is selectable in combination with the long external housing length and width to achieve the desired pulse characteristics.

Abstract: A flexible milling assembly for milling an orifice through a well casing. One embodiment includes a drive yoke, and a plurality of straight and split yoke assemblies—all linked together and to a cutter head with universal blocks that enable the components to pivot relative to each other. A string of joint tubing connected to a prime mover on the surface is used to lower the milling assembly into a well and supply the driving torque. A split shoe coupled to a guide tube is positioned within the well casing where the orifice is to be milled. The milling assembly is guided through a curved passage within the split shoe to bring the cutter head into contact with the well casing. A protector assembly can be provided to enclose and protect the milling assembly when it is tripping into and out of the well casing.

Abstract: A jet drill coupled to a distal end of a flexible jet lance is lowered into a well casing and advanced through a curved passage formed in a deflection shoe oriented to direct the jet drill through an orifice milled in the well casing. The jet drill is actuated with a pressurized fluid produced by a pump on the surface that is conveyed through a high pressure hose that runs through the flexible jet lance. Force transmitted through a thrust liner of the jet lance advances the jet drill while the lateral bore is being drilled. The thrust liner comprises helical coils of steel wire providing a high elastic modulus and buckling resistance, even while passing through the curved passage. Tension cables in the jet lance maintain tension on the thrust liner and enable the assembly to be pulled from the lateral bore and well.

Abstract: A compact gas turbine motor and a speed reduction transmission capable of providing the speed and torque required for drilling with center discharge bits. The transmission includes two sun gears of different pitch diameters, keyed to the turbine shaft. Upper planet gears, whose carrier is fixed in place, drive an outer ring gear, which engages lower planet gears having a different pitch diameter. The lower planet gears engage the lower sun gear. Due to the different pitch diameters of the sun gears and planet gears, the gear carrier for the lower planet gears rotates in the same direction as the turbine shaft, but at a much slower rate. Exhaust gas from the turbine can be directed through one or more flow restriction elements to increase gas density in the turbine, further reducing turbine speed. The flow restriction element can comprise a venturi, to provide a vacuum assist to remove cuttings.

Abstract: A combination liquid and gas separator and jetting tool includes a housing containing a rotatable drum, a stator in the inlet end of the housing for swirling a liquid/gas mixture, a rotor attached to the drum for rotation by the mixture; whereby the gas and liquid are separated. The liquid and gas are discharged through separate restricted orifices downstream of the drum. Orifices can be located in a rotating head for cleaning, cutting or other downhole operations.

Abstract: A combination liquid and gas separator and jetting tool includes a housing containing a rotatable drum, a stator in the inlet end of the housing for swirling a liquid/gas mixture, a rotor attached to the drum for rotation by the mixture; whereby the gas and liquid are separated. The liquid and gas are discharged through separate restricted orifices downstream of the drum. Orifices can be located in a rotating head for cleaning, cutting or other downhole operations.

Abstract: A sleeved hose assembly for lateral jet drilling through an ultra-short radius curve. The sleeved hose assembly includes a wire-wound high-pressure hose inserted inside a reinforcing sleeve. In general, wire-wound high-pressure hoses exhibit transverse moduli that are insufficient to resist buckling forces encountered during lateral drilling. A sleeve is selected to encompass a wire-wound high-pressure hose and to exhibit a transverse stiffness sufficient to prevent the combination of the wire-wound high-pressure hose and the sleeve (i.e., a “sleeved hose assembly”) from buckling during lateral drilling. Also disclosed are a method for drilling a lateral borehole using such a sleeved hose assembly, and a method for drilling an ultra-short radius curve using such a sleeved hose assembly. In a particularly preferred exemplary embodiment, the sleeve includes a fiber reinforced epoxy composite having a transverse modulus of about 10 GPa.

Abstract: A method for governing the speed of a fluid turbine by establishing a circulating flow and a rotational flow with a rotor, and interrupting the rotational flow with an opposing stator. A related braking apparatus includes a housing, a rotatable shaft, a rotor configured to rotatingly engage the shaft and engage a fluid in the housing with a plurality of radial vanes, and a non-rotating stator comprising a plurality of fluid pockets. The stator is disposed such that the radial vanes of the rotor and the fluid pockets of the stator are oriented in a facing relationship. When the shaft is rotated, the fluid in the housing experiences both a circulating flow and a rotational flow. Thus, the rotational flow is present proximate the radial vanes, but not in the fluid pockets, and the fluid imparts a braking torque on the rotating shaft via the rotor's radial vanes.

Abstract: Rotary jetting tool including a rotor with axially-opposed pressure-balanced mechanical face seals. Vented upper mechanical face seal enables the rotor to be operated with the relativity low starting torque achievable using reaction forces from offset jets energized with a pressurized fluid. When rotor is displaced axially due to set-down conditions, a pressure chamber exerts a pressure imbalance on the rotor, forcing the rotor to return to a normal operating position. Alternate structure to achieve low starting torque includes a volume disposed adjacent to a lower mechanical face seal, the volume being coupled in fluid communication with the pressurized fluid. Mechanical face seal surfaces are fabricated from ultra-hard materials, such as tungsten carbide, silicon carbide, and diamond. A gage ring designed to ensure the jets remove all of the material from the gage of the protective housing before the tool can advance can be incorporated.

Abstract: A rotary jetting tool including a pressure-balanced rotor, which is achieved using a vented volume. Axial movement of the rotor relative to the housing caused by pressure imbalances acting on the rotor selectively uncovers or opens a vent that places the volume in fluid communication with an ambient volume, enabling the rotor to achieve a pressure balanced condition. A plurality of radial clearance seals between the rotor and the housing are used to provide hydrodynamic bearings to reduce friction between the rotor and housing. The diameters of the seals are manipulated to facilitate pressure balancing of the rotor. In one embodiment, the rotor includes a centrifugal brake configured to control a maximum rotational speed of the rotor. Pressurized fluid is introduced into the rotor in an axial direction, enabling a relatively large upstream settling chamber to be incorporated into the rotor, thereby reducing inlet turbulence and improving jet quality.

Abstract: This invention discloses a valve that generates a hydraulic negative pressure pulse and a frequency modulator for the creation of a powerful, broadband swept impulse seismic signal at the drill bit during drilling operations. The signal can be received at monitoring points on the surface or underground locations using geophones. The time required for the seismic signal to travel from the source to the receiver directly and via reflections is used to calculate seismic velocity and other formation properties near the source and between the source and receiver. This information can be used for vertical seismic profiling of formations drilled, to check the location of the bit, or to detect the presence of abnormal pore pressure ahead of the bit. The hydraulic negative pressure pulse can also be used to enhance drilling and production of wells.

Abstract: A method for increasing the efficiency of drilling operations by using a drilling fluid material that exists as supercritical fluid or a dense gas at temperature and pressure conditions existing at a drill site. The material can be used to reduce mechanical drilling forces, to remove cuttings, or to jet erode a substrate. In one embodiment, carbon dioxide (CO2) is used as the material for drilling within wells in the earth, where the normal temperature and pressure conditions cause CO2 to exist as a supercritical fluid. Supercritical carbon dioxide (SC—CO2) is preferably used with coiled tube (CT) drilling equipment. The very low viscosity SC—CO2 provides efficient cooling of the drill head, and efficient cuttings removal. Further, the diffusivity of SC—CO2 within the pores of petroleum formations is significantly higher than that of water, making jet erosion using SC—CO2 much more effective than water jet erosion.

Abstract: Methods and apparatus employing an ultra high-pressure fluid pulse to perform metal working operations, including joining and cold working. In one application, an ultra high-pressure fluid pulse is directed into a hollow rivet that is seated within an orifice formed in two metal sheets, causing the fastener to expand outwardly, in an interference fit with the orifice that joins the metal sheets together. The ultra high-pressure fluid pulse can alternatively be applied to the metal sheets to plastically deform them into a cavity to form a clinch fastener joint. Further, the ultra high-pressure fluid pulse is usable to plastically deform the interface between stacked metal sheets or other components into surface features that are provided on one of the sheets, to form a mechanical interlock.

Abstract: Suction pressure pulses are generated within a borehole by closing a valve that interrupts the flow of a drilling fluid (e.g., drilling mud) circulating through one or more high velocity flow courses within the borehole. In one embodiment in which the suction pressure pulses are applied to improve the efficiency of a drilling bit, the valve interrupts the flow of drilling mud directed through the bit and thus through high velocity flow course(s) disposed downstream of the bit. Arresting flow of the drilling mud through the high velocity flow course(s) generates suction pressure pulses of substantial magnitude over a face of the drill bit. The suction pressure pulses provide a sufficient differential pressure that weakens the rock through which the drill bit is advancing and also increase the force with which the drill bit is being advanced toward the rock at the bottom of the borehole.

Abstract: An inlet chamber receives fluid from a small high pressure pump, such fluid flowing through a flow restrictor and one-way valve into an accumulator, until very high pressure is established in the accumulator. At the same time, a sealed poppet is pushed against a poppet seat by the high pressure within the inlet chamber to prevent fluid flow into an output chamber coupled to a bore hole. When the high pressure fluid in the accumulator is to be discharged into the output chamber, the inlet chamber is vented to the atmosphere to rapidly separate the poppet from the poppet seat. The poppet has an end portion having an area greater than the sealing area occupied by the poppet seat which permits the fluid under high pressure within the accumulator to rapidly separate the poppet from the valve seat so that a very large fraction of the energy in the accumulator is discharged through the outlet portion of the apparatus, to be injected into a bore hole for the purpose of fragmenting rock or the like.

Abstract: Providing a fluid pressure pulse generator having a fluid inlet chamber communicating with an accumulator via a movable ball positioned within the inlet chamber, a narrow fluid passageway bypassing the ball, an outlet chamber coupled to a valve seat for preventing communication between the outlet chamber and the accumulator when the movable ball assumes a first position against the valve seat and for permitting the outlet chamber to communicate with the accumulator when the ball is separated from the valve seat in a second position, introducing fluid within the fluid inlet chamber causing the ball to assume the first position and for causing the fluid to flow through the passageway into the accumulator until fluid pressure is very high; and thereafter rapidly reducing fluid pressure within the inlet chamber to cause the ball to assume the second position for in turn causing high impulse ejection of fluid from the accumulator into the outlet chamber.