METHOD AND APPARATUS FOR REMOTELY CHANGING FLOW PROFILE IN CONDUIT AND DRILLING BIT

Abstract

The present invention relates to apparatus and methods for remotely adjusting the drill bit hydraulic horse power per square inch (HSI). Varying the nozzle geometry remotely without the need to pull the drill string outside the hole has obvious advantage. Changing the nozzle flow geometry results in changing the nozzle HSI, which is beneficial to optimize drilling a well having different rock formations. The drill bit nozzle geometry of the present invention can be varied by causing a change of at least one physical property of the environment. The variable geometry nozzle is not limited to drill bit, it can be placed within the inner flow passage or between the inner flow passage and annular flow passage for controlling flow profile within a wellbore, a tubular string or a flow conduit.

Description

RELATED APPLICATIONS

The present application is a continuation-in-part application of U.S. patent application Ser. No. 13/846,946, filed Mar. 18, 2013, for APPARATUS AND METHOD TO REMOTELY CONTROL FLUID FLOW IN TUBULAR STRINGS AND WELLBORE ANNULUS, by Ahmed M. Tahoun, Raed I. Kafafy, Karam J. Jawamir, Mohamed A. Aldheeb, Abdul M. Khalil, included by reference herein and for which benefit of the priority date is hereby claimed.

The present application is a continuation-in-part application of U.S. patent application Ser. No. 13/861,255, filed Apr. 11, 2013, for APPARATUS AND METHOD TO REMOTELY CONTROL FLUID FLOW IN TUBULAR STRINGS AND WELLBORE ANNULUS, by Ahmed M. Tahoun, Raed I. Kafafy, Karam J. Jawamir, Mohamed A. Aldheeb, and Abdul M. Khalil, included by reference herein and for which benefit of the priority date is hereby claimed.

The present application is a continuation-in-part application of U.S. provisional patent application Ser. No. 61/648,575, filed May 17, 2012, for METHOD AND APPARATUS TO REMOTELY CHANGE THE AREA OF DRILL BIT NOZZLES AND DRILL STRING FLOW RESTRICTORS, by Ahmed M. Tahoun, Raed I. Kafafy, Karam J. Jawamir, Mohamed A. Aldheeb, included by reference herein and for which benefit of the priority date is hereby claimed.

The present application is a continuation-in-part application of U.S. provisional patent application Ser. No. 61/622,572, filed Apr. 11, 2012, for METHOD AND APPARATUS OF CONTROL DRILLING FLUID LOSSES AND IMPROVED HOLE CLEANING IN OIL & GAS SUBTERRANEAN DRILLING OPERATIONS, by Ahmed M. Tahoun, Raed I. Kafafy, Karam J. Jawamir, Mohamed A. Aldheeb, included by reference herein and for which benefit of the priority date is hereby claimed.

The present application is a continuation-in-part application of U.S. provisional patent application Ser. No. 61/710,823, filed Oct. 19, 2012, for METHOD AND APPARATUS TO HARVEST ENERGY INSIDE WELLBORE FROM CHANGE OF FLUID FLOW RATE, by Ahmed M. Tahoun, Raed I. Kafafy, Karam J. Jawamir, Mohamed A. Aldheeb, included by reference herein and for which benefit of the priority date is hereby claimed.

The present application is a continuation-in-part application of U.S. provisional patent application Ser. No. 61/710,887, filed Oct. 8, 2012, for METHOD AND APPARATUS TO CONTROL THE MUD FLOW IN DRILL STRINGS AND WELLBORE ANNULUS, by Ahmed M. Tahoun, Raed I. Kafafy, Karam J. Jawamir, Mohamed A. Aldheeb, included by reference herein and for which benefit of the priority date is hereby claimed.

The present application is related to U.S. Pat. No. 6,227,316B1, issued Oct. 3, 1999, for JET WITH VARIABLE ORIFICE NOZZLE, by Bruce A. Rohde, included by reference herein.

The present application is related to U.S. Pat. No. 3,120,284, issued Aug. 17, 1959, for JET NOZZLE FOR DRILL BIT, by J. S. Goodwin, included by reference herein.

The present application is related to U.S. Pat. No. 3,137,354, issued Jan. 11, 1960, for DRILL BIT NOZZLES, by A. W. Crawfort et al., included by reference herein.

The present application is related to U.S. Pat. No. 4,533,005, issued Nov. 21, 1983, for ADJUSTABLE NOZZLE, by Wilford V. Morris, included by reference herein.

The present application is related to United States patent number US20100147594, issued Nov. 8, 2007, for REVERSE NOZZLE DRILL BIT, by Sadek Ben Lamin, included by reference herein.

The present application is related to United States patent number US20090020334, issued Jul. 16, 2008, for NOZZLES INCLUDING SECONDARY PASSAGE, DRILL ASSEMBLIES INCLUDING SAME AND ASSOCIATED METHOD, by David Gavia, included by reference herein.

The present application is related to United States patent number US20110000716, issued Dec. 15, 2009, for DRILL BIT WITH A FLOW INTERRUPTER, by Laurier E. Comeau, included by reference herein.

The present application is related to U.S. Pat. No. 8,342,266, issued Mar. 15, 2011, for TIMED STEERING NOZZLE ON A DOWNHOLE DRILL BIT, by David R. Hall, included by reference herein.

FIELD OF THE INVENTION

oil and gas drilling and completion

pipeline flow conduit

downhole drilling device and method

remotely changing the geometry of drill bit nozzle flow profile

control of fluid flow within a tubular string

control of fluid flow between a tubular string inner flow passage and its annular flow passage

selectively and remotely sending a command to an apparatus disposed within wellbore

BACKGROUND OF THE INVENTION

The concept of forming subterranean well is referred to; a drill string is typically used to drill a wellbore of a first depth into the formation.

While drilling, a drilling fluid (or mud fluid) is circulated down through the tubular string, then through perforation in a drill bit which is located at the end of the drill string. Then, the drilling fluid continues the circulation up through the annular flow passage between the outer perimeter of the tubular string and inner wall of the well.

The mud jets from the bit nozzles are normally directed toward the hole bottom and formation being drilled, with the velocities mostly of several hundred feet per second to create turbulence which serves to clean the bit, as well as carry away the cut chips. The drill bit nozzles are flow-restrictors which determine the total area of the drill bit outlet, and therefore the terminal velocity of the mud jet.

The majority of drilling systems used in current days include heavy tubular with bigger outer diameter above the drill bit among other equipment such as motors or logging while drilling equipment or directional drilling control systems, or any combination thereof that is frequently called Bottom Hole Assembly or BHA. Above BHA normally extend smaller drill pipes connecting the BHA to surface.

When drilling in Earth formations going through earth layers having variations in mechanical properties, the drill bit nozzle hydraulic horse power per square inch (HSI) can be too high for some formation layers which gets over drilled or too low which results in less efficient cuttings removal.

Conventionally, the drill bit nozzle lowered in the wellbore has a fixed flow geometry and total flow area (TFA) and it is not possible to change the nozzle geometry without pulling the tubular string out of the wellbore.

In another aspect, flow restrictors exist in other components of the tubular string used for drilling or in fluid conduits which are used in the oil and gas industry or other industries.

In many situations, the ability to change the geometry of such flow restrictors remotely is desirable. For example, it is desirable to change the geometry of the flow restrictor which is used within the mud motor of a tubular string during drilling without pulling the tubular string out of hole.

From Bernoulli's equation for incompressible flow, we can express the fluid properties at drill bit nozzle exit in terms of the fluid properties inside the drill bit cavity as

$P_2+\frac{1}{2}\rho V_2^2=P_1+\frac{1}{2}\rho V_1^2\approx P_1$

where P₁ and V₁ are the pressure and velocity inside the drill bit cavity, respectively; and P₂ and V₂ are the pressure and velocity at the nozzle exit, respectively. Neglecting the velocity of the flow inside the drill bit cavity with respect to the velocity of the jet at the nozzle exit, we can solve for the nozzle terminal velocity, V_n, in terms of the pressure drop across the drill bit, ΔP_bit, as

$V_n=\sqrt{2\frac{\Delta P_{\mathrm{bit}}}{\rho }}$

It has been shown, in the field, that velocity predicted by the above equation is off. So, it has been modified using discharge coefficient, C_d, to give

$V_n=C_d\sqrt{2\frac{\Delta P_{\mathrm{bit}}}{\rho }}$

For typical drill bit nozzles, the recommended value for C_d is 0.95. However, several studies have shown, experimentally, that the value of C_d must be increased up to 1.03.

If n nozzles are used in a drill bit, then the jet velocity of all nozzles will be equal, which is given as

$V_n=\frac{Q_1}{A_1}=\frac{Q_2}{A_2}=\dots$

Where Q_i and A_i are the flow rate and outlet orifice area of nozzle (i), respectively. The total flow rate through the whole drill bit can be calculated as

Q=Q₁+Q₂+Q₃+ . . . =V_n(A₁+A₂+A₃+ . . . )=V_n×TFA

The jet hydraulic horse power (HHP) can be calculated from the total flow rate and the pressure drop across the bit as

$\mathrm{HHP}=Q\times \Delta P_{\mathrm{bit}}=\frac{2\rho }{C_d^2}\frac{Q^3}{{\left(\mathrm{TFA}\right)}^2}$

The jet hydraulic horse power per square inch (HSI) is the jet hydraulic horse power per drill bit area, or

$\mathrm{HSI}=\frac{\mathrm{HHP}}{A_{\mathrm{bit}}}=4\frac{\mathrm{HHP}}{\pi D_{\mathrm{bit}}^2}=\frac{8\rho }{\pi C_d^2D_{\mathrm{bit}}^2}\frac{Q^3}{{\left(\mathrm{TFA}\right)}^2}$

The equation above shows clearly that in order to change the hydraulic horse power per square inch of a drill bit, we can either: (1) change the flow rate, or Q, through the drill bit; or (2) change the total flow area, or TFA, of the drill bit nozzles.

One way to change the drill bit nozzle HSI is to change the mud flow rate through the whole drilling string, i.e. change the mud circulation flow rate from the optimal flow rate. This may result in undesired annular flow velocity which causes deterioration in the hole cleaning efficiency through increase of suspended solids or cuttings within the wellbore or causing a washout when formation or other undesirable acts.

Another way to change the drill bit nozzle TFA is to pull the tubular string out of the wellbore and replace the drill bit nozzle with another giving the desired TFA. For example, adjustable geometry nozzle disclosed in the U.S. Pat. No. 4,533,005 requires the operator to pull the string out of the wellbore. Pulling out the tubular string from the wellbore to replace the nozzle with another of the desired TFA costs the operator significant time and money and increases the drilling risks.

In addition, drill bit nozzles are made of fixed size; therefore drill bit manufacturers provide different drill bit designs with alternative number of nozzles and sizes. A typical nozzle (shown in FIG. 3-A) is inserted into an aperture, and is held in place by any one of several means, such as a snap ring, screw threads, or a nail lock. The final outlet internal diameter of the nozzle is measured in increments of 1/32 of an inch. To adjust the flow, the nozzle has to be replaced with another nozzle which has a different outlet inner diameter. The size of nozzle needed cannot be determined in advance due to the many factors affecting the nozzle size. Therefore, drill bits are commonly shipped off-shore with several nozzles with different sizes for each aperture. At the drilling site, the correct-size nozzle is installed whereas unused nozzles are normally discarded or lost which increases the cost and time of drilling.

One aspect of the current invention is to introduce methods and apparatus to remotely change the geometry of a drill bit nozzle which allows adjusting the HSI of the drill bit nozzle while maintaining the mud flow rate at optimum.

Another aspect of the present invention is to introduce an apparatus and method for remotely and selectively changing the flow profile within the tubular string or between the tubular string inner flow passage and annular flow passage.

Maintenance of annular velocity and the introduction of adjustable TFA drill bit nozzles using the current invention will reduce the operating cost and the risks associated with suspended solids or cuttings as well as the risks associated with possible formation collapse.

In a more recent disclosed invention, the U.S. Pat. No. 6,227,316, a jet bit nozzle with variable outlet orifice is proposed (shown in FIG. 3-B). This design allows the same nozzle to deliver the mud at variable pressures. This is accomplished by the use of two thick plates, each having a shaped aperture therein. The degree to which the two apertures are overlapped determines the size of the outlet orifice. The movement of at least one of the plates, and thus the size of the outlet orifice, can be adjusted at the drill site, to give a desired pressure drop across the nozzle. However, adjusting size of the nozzle outlet orifice must be done before inserting the tubular string into the wellbore and changing the nozzle outlet orifice requires pulling the tubular string out of hole which involves time and cost.

SUMMARY OF THE INVENTION

In one example, disclosed is a nozzle adapted for use in a rotary drill bit for drilling Earth borehole based on changing the environment in the borehole, the nozzle including: a body configured to be secured within the rotary drill bit, at least one fluid passage of variable geometry through the said body for connecting a fluid through the said body, an outlet orifice disposed within the said body, in fluid communication with the at least one fluid passage and the borehole, a means for changing the geometry of the at least one fluid passage having at least one movable element, in fluid communication with the fluid passage and the outlet orifice, the said at least one movable element is movable from an initial position to at least one other predetermined position in response to intended changes in the borehole environment.

In one example, the said at least one moveable element is movable from an initial position to another predetermined position under normal fluid circulation (from the drill bit to the borehole), and the said at least one moveable element is movable from an initial position to a different predetermined position under reverse fluid circulation (from the borehole to the drill bit).

In one example, the said at least one moveable element is rotatable to a plurality of predetermined positions.

In one example, disclosed is an apparatus for remotely changing flow profile in conduit and rotary drill bit based on changing the environment in the borehole, the apparatus including: (a) a nozzle adapted for use in a rotary drill bit for drilling Earth borehole, the nozzle including: a body configured to be secured within the rotary drill bit, at least one fluid passage of variable geometry through the said body for connecting a fluid through the said body, an outlet orifice disposed within the said body, in fluid communication with the at least one fluid passage and the borehole, a means for changing the geometry of the at least one fluid passage having at least one movable element, in fluid communication with the fluid passage and the outlet orifice, the said at least one movable element is movable from an initial position to at least one other predetermined position in response to intended changes in the borehole environment; (b) at least one means for detecting a plurality of intended changes in at least one physical property of the borehole environment resulting in a detectable signal within the apparatus for processing the signal; (c) a means for actuating the means for changing the geometry of the at least one fluid passage; (d) a means for powering the means for actuating the at least movable element.

In one example, the at least one detecting means comprises a sensor.

In one example, the actuating means comprises an electric motor.

In one example, the actuating means comprises a movable rack, the rack mechanically engaged with the at least one movable element.

In one example, the powering means comprises an energy harvester.

In one example, the energy harvester is set to receive hydraulic energy from fluid flow in the tubular string and is configured to provide electrical energy to the means for actuating.

In one example, the energy harvester is set to receive hydraulic energy from a fluid pressure difference between the inner fluid passage and the wellbore fluid.

In one example, the energy harvester is set to receive thermal energy from a temperature difference between two points within the drill bit and is configured to provide electrical energy to the means for actuating.

In one example, the powering means comprises an energized resilient element.

In one example, the powering means comprises a battery.

In one set of examples, disclosed is a method for drilling Earth borehole based on changing the environment in the borehole, the method including: (a) disposing in a wellbore a drill bit attached to a tubular string, the drill bit including an apparatus, the apparatus comprising: a nozzle adapted for use in a rotary drill bit for drilling Earth borehole, the nozzle comprising: a body configured to be secured within the rotary drill bit, at least one fluid passage of variable geometry through the said body for connecting a fluid through the said body, an outlet orifice disposed within the said body, in fluid communication with the at least one fluid passage and the borehole, a means for changing the geometry of the at least one fluid passage having at least one movable element, in fluid communication with the fluid passage and the outlet orifice, the said at least one movable element is movable from an initial position to at least one other predetermined position in response to intended changes in the borehole environment; at least one means for detecting a plurality of intended changes in at least one physical property of the borehole environment resulting in a detectable signal within the apparatus for processing the signal; a means for actuating the means for changing the geometry of the at least one fluid passage; a means for powering the means for actuating the at least movable element. (b) causing a change in at least one physical property within the borehole environment in certain sequence within a specified period of time resulting in a detectable pattern at the at least one detecting means. (c) causing the actuating means to use the energy provided by the powering means to change the geometry of the at least one fluid passage within the nozzle.

In one example, the change in a physical property of the environment is a mechanical movement of the apparatus by means of moving the tubular string, causing the apparatus to move within the wellbore in at least one direction detectable by the said detecting means.

In one example, the change of physical property includes a change in one or more of the following fluid properties: pressure, temperature, flow rate, density, viscosity, color, and composition, detectable by the said detecting means.

In one example, the change in a physical property includes a change in one or more of the following physical properties: electromagnetic, electrostatic, and seismic, detectable by the said detecting means.

In one example, changing the geometry of the at least one fluid passage includes reducing the area of the nozzle outlet orifice to increase the velocity of the nozzle jet.

In one example, changing the geometry of the at least one fluid passage includes increasing the area of the nozzle outlet orifice to decrease the velocity of the nozzle jet.

In one example, the change of physical property includes a change in the direction of flow circulation.

In one example, changing the geometry of the at least one fluid passage includes moving the said at least one movable element from a first position to a second position when the flow is circulated in one direction and moving the said at least one movable element from the second position to the first position when the flow is circulated in the opposite direction.

In one example, the apparatus further includes a cam and a latch to hold the said at least one movable element in a position resulting in the desired change of the geometry of the at least one fluid passage and allowing the flow circulation to be changed.

In one example, the actuating means includes an actuator selected from at least one of a rack-type actuator, an electric motor, a solenoid, and a cam-type actuator.

In one example, the rack-type actuator includes at least one rack, and actuating the means for changing the geometry of the at least one fluid passage includes moving the rack between a first position and a second position.

In one example, the powering means includes a power source selected from at least one of a hydraulic power, an energized resilient element, a battery, a super capacitor, and an energy harvester.

In one example, the energy harvester is selected from at least one of an electromagnetic induction harvester, a piezoelectric harvester, and a thermoelectric harvester.

In one example, the hydraulic power includes creating a net pressure force on the surfaces of the said movable element exposed to the fluid passing through the said nozzle.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, in which:

FIG. 1 is a section view of a possible embodiment of a wellbore drilling system wherein a drill bit is disposed at the bottom of the drilling tubular string;

FIG. 2 is a bottom view of an example of drill bit comprises at least one nozzle port;

FIG. 3 is a section view of a drill bit of prior arts having a fixed nozzle in FIG. 3(a) and adjustable nozzle in FIG. 3(b);

FIG. 4 is a detailed section view of an example set of possible configurations of variable geometry nozzle showing movable a element in different positions;

FIG. 5 is a detailed section view of an example set of other possible configurations of variable geometry nozzle showing a movable element in different positions;

FIG. 6 is a detailed section view of an example set of other possible configurations of variable geometry nozzle showing a movable element in different positions;

FIG. 7 is a detailed section view of an example set of possible configurations of variable geometry nozzle showing a movable element having different shapes of movable element geometry outlet orifice in different positions;

FIG. 8 is a detail view of a possible configurations of variable geometry nozzle having one movable geometry element in different positions;

FIG. 9 is a detail view of a possible configurations of variable geometry nozzle having two movable geometry elements in different positions;

FIG. 10 is a detail view of a possible configurations of variable geometry nozzle having three movable geometry elements in different positions;

FIG. 11 is a detailed section view of an example set of other possible configurations of variable geometry nozzle showing movable element in different positions;

FIG. 12 is a partial cut out view of an example set of other possible configurations of variable geometry nozzle showing movable element in different positions;

FIG. 13 is a detailed section view of an example of a possible configuration of variable geometry nozzle showing movable element in different positions disposed within the nozzle body;

FIG. 14 is a section view of an example of variable geometry nozzle showing movable element in different positions under the effect of change of fluid flow direction;

FIG. 15 is a section view of an example of variable geometry nozzle using cam to change passage geometry through cycling movement;

FIG. 16 is a detail view of a possible disposition of variable geometry nozzle in a drilling bit or drilling tubular conduit; and

FIG. 17 is a diagram describing the steps of the method of remotely controlling the variable geometry nozzle.

For purposes of clarity and brevity, like elements and components will bear the same designations and numbering throughout the Figures.

DESCRIPTION OF THE PREFERRED EMBODIMENT

U.S. Provisional Application No. 61/710,887, filed Oct. 8, 2012 for METHOD AND APPARATUS TO CONTROL THE MUD FLOW IN DRILL STRINGS AND WELLBORE ANNULUS, by Ahmed TAHOUN, Raed Kafafy, Karam Jawamir, Mohamed Aldheeb, Abdul Mushawwir Mohamad Khalil is herein incorporated by reference in its entirety.

U.S. Provisional Application No. 61/622,572, filed Apr. 11, 2012 for METHOD AND APPARATUS OF CONTROL DRILLING FLUID LOSSES AND IMPROVED HOLE CLEANING IN OIL & GAS SUBTERRANEAN DRILLING OPERATIONS, by Ahmed Moustafa Tahoun is herein incorporated by reference in its entirety.

U.S. Provisional Application No. 61/710,823, filed Oct. 8, 2012 for METHOD AND APPARATUS TO HARVEST ENERGY INSIDE WELLBORE 100 FROM CHANGE OF FLUID FLOW RATE, by Ahmed M. Tahoun, Raed I. Kafafy, Karam Jawamir, Mohamed A. Aldheeb, Abdul M. Khalil is herein incorporated by reference in its entirety.

U.S. Provisional Application No. 61/648,575, filed May 17, 2012 for Method and Apparatus to remotely change the area of drill bit 120 nozzles and drill string flow restrictors, by Ahmed M. Tahoun, Raed I. Kafafy, Karam Jawamir, Mohamed A. Aldheeb is herein incorporated by reference in its entirety.

U.S. application Ser. No. 13/846,946, filed Mar. 18, 2013 for Apparatus and method to remotely control fluid flow in tubular strings and wellbore annulus, by Ahmed M. Tahoun, Raed I. Kafafy, Karam Jawamir, Mohamed A. Aldheeb, Abdul M. Khalil is herein incorporated by reference in its entirety.

U.S. application Ser. No. 13/861,255, filed Apr. 11, 2013 for Apparatus and method to remotely control fluid flow in tubular strings and wellbore annulus, by Ahmed M. Tahoun, Raed I. Kafafy, Karam Jawamir, Mohamed A. Aldheeb, Abdul M. Khalil is herein incorporated by reference in its entirety.

FIG. 1 is a section view of an example of a wellbore 100 drilling system wherein a plurality of the variable geometry nozzle 150 is disposed within drilling tubular string 110 during well forming operation. Majority of drilling systems used in current days include a tubular string 110 composed of a drill bit 120 having at least one perforation 125 located through the drill bit 120 to allow fluid flow there through. A heavy tubular with bigger outer diameter among other equipment such as mud motors or logging while drilling equipment or directional drilling control systems, or any combination thereof that is frequently called bottom hole assembly 130 connected to the drill bit 120 from one end. Bottom hole assembly 130 is normally connected by form of thread from the other end to a part of the tubular string 110 such as drill pipe 140 connecting the bottom hole assembly 130 to surface. The drill pipe 140 outer diameter is commonly known to be smaller when compared to the bottom hole assembly 130. Plurality of variable geometry nozzle 150 disposed within the wellbore 100 are connected to a portion of the tubular string 110 by a suitable means normally a form of thread. The wellbore 100 formed into the earth may have a deviated section where the wellbore 100 is not vertical. A cased hole section is the portion of the wellbore 100 having a tubular of large diameter called casing lining the inner side of the wellbore 100 to protect wellbore 100 from damage. While drilling a deeper section into earth formations an open hole section of the wellbore 100 is formed. A surface mud pump system 190 is disposed with most drilling operations and includes a drilling fluid tank to store drilling fluid and a pump 192 to force fluid into the inner flow passage 152 defined as the inner space within the tubular string 110. Cuttings generated from hole making are carried out through the annular flow passage 154. An annular flow passage 154 is defined as the space between the inner wall of the wellbore 100 and the outer wall of the tubular string 110. in this figure at least one variable geometry nozzle 150 is disposed inside perforation 125 or opening within the drill bit 120.

FIG. 2 is a bottom view of a typical drill bit 120 used in today's drilling activity. Drill bit 120 comprises a drill bit body 122, one or more bit cutter 835 disposed on bit outer surface and attached to at least one bit blade 840 suitably arranged to perform the cutting action when interact with earth formation during drilling operation. One or more perforation 125 is disposed on the bit body 200 in communication between the inner flow passage 152 and the annular flow passage 154. A flow restrictor, commonly known as bit nozzle is normally disposed within the bit perforation 125. In one example at least one variable geometry nozzle 150 is disposed in bit perforation 125.

FIG. 3-A is a section view of a drill bit 120 of prior art with conventional nozzle 135 disposed in one perforation 125 within the drill bit body 122 connecting inner flow passage 152 to the annular flow passage 154. The conventional nozzle 135 has fixed geometry and can be replaced only when brought out to surface.

FIG. 3-B is a section view of a drill bit 120 of prior art with adjustable nozzle 145 disposed in one perforation 125 within the drill bit body 122 connecting inner flow passage 152 to the annular flow passage 154. The adjustable nozzle 145 has adjustable geometry which can be changed only when brought out to surface.

FIG. 4 is a detailed section view of an example set of possible configurations of variable geometry nozzle 150 showing a movable element 400 in different positions.

FIG. 4-A-1 is a section view of one example of the variable geometry nozzle 150 comprising a body 200 having an inlet port 424 and an outlet orifice 425, a fluid passage 152 extending through the body 200, a movable element 400 disposed within the body 200 in one position where the flow geometry 440 is the geometry of the inner flow passage 152 at the area where the movable element 400 intersect with the inner flow passage 152. The flow geometry 440 is of a specific geometry when the movable element 400 is in one position and the flow geometry 440 is of a different geometry when the movable element is in a different position. The portion of the inner flow passage 152 between the movable element 400 and the outlet orifice 425 defines a downstream passage 800. The downstream passage 800 is the portion of the inner flow passage 152 within the variable geometry nozzle 150 where the movable element 400 interacts with inner flow passage 152 causing a change in the flow geometry 440 and causing the variable geometry nozzle 150 to have specific flow geometry 440 corresponding to the position of the movable element 400.

FIG. 4-A-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 4-A-1 where the movable element 400 is in a different position interacting with the inner flow passage 152 causing a change of the flow geometry 440 when compared to the flow geometry 440 of FIG. 4-A-1.

FIG. 4-B-1 is a section view of one example of the variable geometry nozzle 150 similar to the one described in FIG. 4-A-1. In this example a resilient element 405 is attached to the movable element 400 causing it to be biased in specific direction. The resilient element 405 further restrain the movement of the movable element 400 such that a greater force is required to move the movable element 400 to overcome the force induced by the resilient element 405

FIG. 4-B-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 4-B-1 where the movable element 400 is in a different position interacting with the inner flow passage 152 causing a change of the flow geometry 440 when compared to the flow geometry 440 of FIG. 4-B-1.

FIG. 4-C-1 is a section view of one example of the variable geometry nozzle 150 similar to the one described in FIG. 4-A-1. In this example a cam 420 similar to those explained in U.S. patent application Ser. Nos. 13/846,946 and 13/861,255 is attached to the movable element 400. A cam follower 415 disposed within the body 200 traverse the cam track 410 disposed on the cam 420 surface to control the movement of the movable element 400 and restrain the movable element movement to specific displacement and in specific direction.

FIG. 4-C-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 4-C-1 where the movable element 400 is in a different position interacting with the inner flow passage 152 causing a change of the flow geometry 440 when compared to the flow geometry 440 of FIG. 4-C-1.

FIG. 4-D-1 is a section view of one example of the variable geometry nozzle 150 similar to the one described in FIG. 4-A-1. In this example the variable geometry nozzle 150 further comprising a resilient element 405 similar to the one described in FIG. 4-B-1 attached to the movable element 400 and a cam 420 similar to the one described in FIG. 4-C-1 and attached to the movable element 400. A cam follower 415 disposed within the body 200 and a cam track 410 disposed on the cam 420 surface to restrain and control the movement of the movable element 400 to specific displacement and in specific direction.

FIG. 4-D-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 4-D-1 where the movable element 400 is in a different position interacting with the inner flow passage 152 causing a change of the flow geometry 440 when compared to the flow geometry 440 of FIG. 4-D-1.

FIG. 5 is a detailed section view of an example set of possible configurations of variable geometry nozzle 150 showing a movable element 400 in different positions. In this set of examples a communication duct 430 is disposed within the body 200 in fluid communication on one side with the movable element 400 and on another side in communication with the inner flow passage 152.

FIG. 5-A-1 is a section view of one example of the variable geometry nozzle 150 similar to the one described in FIG. 4-A-1. In this example a communication duct 430 is disposed within the body 200 in fluid communication on one side with the movable element 400 and on another side in communication with the inner flow passage 152.

FIG. 5-A-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 5-A-1 where the movable element 400 is in a different position interacting with the inner flow passage 152 causing a change of the flow geometry 440 when compared to the flow geometry 440 of FIG. 5-A-1.

FIG. 5-B-1 is a section view of one example of the variable geometry nozzle 150 similar to the one described in FIG. 4-B-1. In this example a communication duct 430 is disposed within the body 200 in fluid communication on one side with the movable element 400 and on another side in communication with the inner flow passage 152.

FIG. 5-B-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 5-B-1 where the movable element 400 is in a different position interacting with the inner flow passage 152 causing a change of the flow geometry 440 when compared to the flow geometry 440 of FIG. 5-B-1.

FIG. 5-C-1 is a section view of one example of the variable geometry nozzle 150 similar to the one described in FIG. 4-C-1. In this example a communication duct 430 is disposed within the body 200 in fluid communication on one side with the movable element 400 and on another side in communication with the inner flow passage 152.

FIG. 5-C-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 5-C-1 where the movable element 400 is in a different position interacting with the inner flow passage 152 causing a change of the flow geometry 440 when compared to the flow geometry 440 of FIG. 5-C-1.

FIG. 5-D-1 is a section view of one example of the variable geometry nozzle 150 similar to the one described in FIG. 4-D-1. In this example a communication duct 430 is disposed within the body 200 in fluid communication on one side with the movable element 400 and on another side in communication with the inner flow passage 152.

FIG. 5-D-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 5-D-1 where the movable element 400 is in a different position interacting with the inner flow passage 152 causing a change of the flow geometry 440 when compared to the flow geometry 440 of FIG. 5-D-1.

FIG. 6 is a detailed section view of an example set of possible configurations of variable geometry nozzle 150 having a movable element 400 comprising plurality of movable element geometry orifice 435 arranged in a form of a revolver. When the movable element 400 is in one position, one of the movable element geometry orifice 435 is aligned with the outlet orifice causing the flow geometry to follow that one of the movable element geometry orifice 435. When the movable element 400 is in a different position, a different movable element geometry orifice 435 will be aligned with the outlet orifice 425 resulting in the variable geometry nozzle 150 to have a different flow geometry 440.

FIG. 6-A-1 is an example of the variable geometry nozzle 150 comprising a body 200, a movable element 400 disposed within the body 200 having plurality of movable element geometry orifice 435 placed within the body 150 in an initial position; A cam follower 415 disposed within the body 200 traverse the cam track 410 disposed on the cam 420 surface to restrain and control the movement of the movable element 400 and restrict movement for specific displacement and in specific direction. In this example the movable element 400 is in specific position such that at least one movable element geometry orifice 435 is in fluid communication with the inner flow passage 152 from one side and aligned with the outlet orifice 425 on another side resulting in a specific flow geometry 440 of mostly rectangular geometry in this example of the downstream passage 800. Other movable element geometry orifice 435 are not aligned with the outlet orifice 425 and will have limited effect on the fluid flowing through the flow geometry 440.

FIG. 6-A-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 6-A-1 where the movable element 400 is in a different position such that a different movable element geometry orifice 435 of a mostly hexagonal geometry in this example is in communication with the inner flow passage 152 and aligned with the outlet orifice 425 causing a change of the flow geometry 440 when compared to the flow geometry 440 of FIG. 6-A-1.

FIG. 6-B-1 is an example of the variable geometry nozzle 150 similar to the one described in FIG. 6-A-1. In this example a resilient element 405 is attached to the movable element 400 causing it to be biased in specific direction to restrain the movement of the movable element 400. In another example, the resilient element 405 is arranged in connection with the movable element 400 such that at least one movable element geometry orifice 435 is restricted from communication with the inner flow passage 152.

FIG. 6-B-2 is a section view of one example of the variable geometry nozzle 150 explained in the description of FIG. 6-B-1 where the movable element 400 is in a different position interacting with the inner flow passage 152 such that a different movable element geometry orifice 435 is in communication with the inner flow passage 152 and aligned with the outlet orifice 425 causing a change of the flow geometry 440 of mostly hexagonal geometry in this example when compared to the flow geometry of FIG. 5-B-1.

FIG. 7 is a detailed section view of an example set of possible configurations of variable geometry nozzle 150 showing movable element 400 having different shapes of movable element geometry orifice 435 in different positions.

FIG. 7-A-1 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in one position shown in the cross section view described in FIG. 7-A-2.

FIG. 7-A-2 is a section view of an example set of possible configurations of variable geometry nozzle 150 comprising a movable element 400 having a movable element geometry orifice 435 in one position such that inner flow passage 152 is in free communication with the outlet orifice 425 through the downstream passage 800.

FIG. 7-A-3 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in a different position described in FIG. 7-A-4 showing a restricted downstream passage 800.

FIG. 7-A-4 is a section view of the variable geometry nozzle 150 described in FIG. 7-A-2 wherein the movable element 400 is in different position when compared to the position described in FIG. 7-A-2. In this figure the flow geometry 440 is obstructed and the downstream passage 800 is restricted due to the shape of the movable element 400 interacting and restricting flow from inner flow passage 152 to the outlet orifice 425 when the movable element 400 is in this position.

FIG. 7-B-1 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in one position shown in the cross section view described in FIG. 7-B-2.

FIG. 7-B-2 is a section view of an example set of possible configurations of variable geometry nozzle 150 comprising a movable element 400 having a movable element geometry orifice 435 in one position such that inner flow passage 152 is in free communication with the outlet orifice 425 through the downstream passage 800. The movable element geometry orifice 435 in this example is having a cavity of specific geometry comprising a curved surface.

FIG. 7-B-3 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in a different position described in FIG. 7-B-4 showing a restricted downstream passage 800.

FIG. 7-B-4 is a section view of the variable geometry nozzle 150 described in FIG. 7-B-2 wherein the movable element 400 is in different position when compared to the position described in FIG. 7-B-2. In this figure the downstream passage 800 is having a shape of two rounded openings wherein the movable element 400 flow geometry orifice 435 is in communication with the inner flow passage 152 on one side and to the outlet orifice 425 on the other side.

FIG. 7-C-1 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in one position shown in the cross section view described in FIG. 7-C-2.

FIG. 7-C-2 is a section view of an example of possible configurations of variable geometry nozzle 150 showing movable element 400 having a movable element geometry orifice 435 in one position such that inner flow passage 152 is in free communication with the outlet orifice 425 through the downstream passage 800. The movable element geometry orifice 435 in this example is having plurality of cavities with specific geometry.

FIG. 7-C-3 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in a different position described in FIG. 7-C-4 showing a restricted downstream passage 800.

FIG. 7-C-4 is a section view of the variable geometry nozzle 150 described in FIG. 7-C-2 wherein the movable element 400 is in different position when compared to the position described in FIG. 7-C-2. In this figure the flow geometry orifice 435 is having a shape of three rounded openings is in communication with the inner flow passage 152 on one side and to the outlet orifice 425 on the other side.

FIG. 7-D-1 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in one position shown in the cross section view described in FIG. 7-D-2.

FIG. 7-D-2 is a section view of an example of possible configurations of variable geometry nozzle 150 showing movable element 400 having a movable element geometry outlet orifice 435 in one position such that inner flow passage 152 is in free communication with the outlet orifice 425 through the downstream passage 800. The movable element geometry orifice 435 in this example is having another cavity with specific geometry comprising a curved surface.

FIG. 7-D-3 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in a different position described in FIG. 7-D-4 showing a restricted downstream passage 800.

FIG. 7-D-4 is a section view of the variable geometry nozzle 150 described in FIG. 7-D-2 wherein the movable element 400 is in different position when compared to the position described in FIG. 7-D-2. In this figure the flow geometry orifice 435 is having a shape of curved opening and is in fluid communication with the inner flow passage 152 on one side and to the outlet orifice 425 on the other side.

FIG. 7-E-1 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in one position shown in the cross section view described in FIG. 7-E-2.

FIG. 7-E-2 is a section view of an example of possible configurations of variable geometry nozzle 150 showing movable element 400 having a movable element geometry orifice 435 in one position such that inner flow passage 152 is in free communication with the outlet orifice 425 through the downstream passage 800. The movable element geometry orifice 435 in this example is having another cavity with specific geometry comprising an elongated surface.

FIG. 7-E-3 is a side view of the variable geometry nozzle 150 wherein the movable element 400 is in a different position described in FIG. 7-E-4 showing a restricted downstream passage 800.

FIG. 7-E-4 is a section view of the variable geometry nozzle 150 described in FIG. 7-E-2 wherein the movable element 400 is in different position when compared to the position described in FIG. 7-E-2. In this figure the flow geometry orifice 435 is having a shape of an opening having at least one straight side and is in fluid communication with the inner flow passage 152 on one side and to the outlet orifice 425 on the other side.

FIG. 8 is a detailed view of an example of the variable geometry nozzle 150 wherein the movable element 400 is having a curved surface and moves partially in rotation causing the change of downstream flow geometry 440. The movable element in this example is having a portion of a spherical shape having at least one cavity. An example the movable element is a portion of a mostly spherical shape such as a ball having a central cavity there through is presented in figure A-1, A2, A-3, B-1, B2, B-3, C-1, C2, C-3. The movable element in figure A-4, B-4, C-4 is an example of another portion of a mostly spherical shape such as a ball having a central cavity through

FIG. 8-A-1 is a front view of a partial cutaway example of the variable geometry nozzle 150 having one movable element 400 in one position such that the inner flow passage 152 is in communication with the outlet orifice 425 through the downstream passage 800 wherein the flow geometry 440 is an initial geometry generated by the movable element 400 interacting with the inner flow passage 152 when it is in this initial position.

FIG. 8-A-2 is a partial section view of the variable geometry nozzle 150 described in FIG. 8-A-1 wherein the movable element 400 is not cut away in view.

FIG. 8-A-3 is a partial section view from a tilted angle of the variable geometry nozzle 150 described in FIG. 8-A-1 wherein the movable element 400 is not cut away in view.

FIG. 8-A-4 is a section view of a variable geometry nozzle 150 similar to the one described in FIG. 8-A-1 wherein the movable element is a portion of a spherical shaped having one cavity there through extended from one end to another end.

FIG. 8-B-1 is a front view of a partial cutaway example of the variable geometry nozzle 150 described in FIG. 8-A-1 wherein the movable element is in a second position and the flow geometry 440 of the downstream passage 800 is of a second flow geometry 440 generated by the movable element 400 interacting with the inner flow passage 152 when it is in this second position.

FIG. 8-B-2 is a partial section view of the variable geometry nozzle 150 described in FIG. 8-B-1 wherein the movable element 400 is not cut away in view

FIG. 8-B-3 is a partial section view from a tilted angle of the variable geometry nozzle 150 described in FIG. 8-B-1 wherein the movable element 400 is not cut away in view.

FIG. 8-B-4 is a section view of the variable geometry nozzle 150 similar to the one described in FIG. 8-B-1 wherein the movable element is a portion of a spherical shaped having one cavity there through extended from one end to another end.

FIG. 8-C-1 is a front view of a partial cutaway example of the variable geometry nozzle 150 described in FIG. 8-A-1 wherein the movable element 400 is in another position and the flow geometry 440 of the downstream passage 800 is of another geometry generated by the movable element 400 interacting with the inner flow passage 152 when it is in this other position.

FIG. 8-C-2 is a partial section view of the variable geometry nozzle 150 described in FIG. 8-C-1 wherein the movable element 400 is not cut away in view.

FIG. 8-C-3 is a partial section view from a tilted angle of the variable geometry nozzle 150 described in FIG. 8-C-1 wherein the movable element 400 is not cut away in view.

FIG. 8-C-4 is a section view of the variable geometry nozzle 150 similar to the one described in FIG. 8-C-1 wherein the movable element is a portion of a spherical shaped having one cavity there through extended from one end to another end.

FIG. 9 is a detailed view of an example of the variable geometry nozzle 150 described in FIG. 8 wherein the nozzle comprising two movable element 400 disposed within the body 200 and are having a curved surface and move partially in rotation causing the change of downstream flow geometry 440. In this example two movable elements each is a portion of a mostly spherical shape element such as a ball having a cavity there through such that when the two elements are together in one position, the cavity between them is of an initial flow geometry 440, and when both movable elements are in another position the cavity between them is of different flow geometry 440. The geometry of the cavity between the elements decides the flow geometry 440 of the variable geometry nozzle.

FIG. 9-A-1 is a front view of a partial cutaway example of the variable geometry nozzle 150 described in FIG. 8-A-1 having two movable element 400 in an initial position such that the inner flow passage 152 is in communication with the outlet orifice 425 through the downstream passage 800 wherein the downstream passage 800 is of an initial flow geometry 440 generated by the movable element 400 in initial position and interacting with the inner flow passage 152 when it is in this initial position.

FIG. 9-A-2 is a partial section view of the variable geometry nozzle 150 described in FIG. 9-A-1 wherein the movable element 400 are not cut away in view.

FIG. 9-A-3 is a partial section view from a tilted angle of the variable geometry nozzle 150 described in FIG. 9-A-1 wherein the movable element 400 are not cut away in view

FIG. 9-A-4 is a section view of the variable geometry nozzle 150 described in FIG. 9-A-1.

FIG. 9-B-1 is a front view of a partial cutaway example of the variable geometry nozzle 150 described in FIG. 8-B-1 having two movable element 400 in a second position such that the inner flow passage 152 is in communication with the outlet orifice 425 through the downstream passage 800 wherein the downstream passage 800 is having a second flow geometry 440 generated by the movable element 400 interacting with the inner flow passage 152 when it is in this position.

FIG. 9-B-2 is a partial section view of the variable geometry nozzle 150 described in FIG. 9-B-1 wherein the movable element 400 are not cut away in view.

FIG. 9-B-3 is a partial section view from a tilted angle of the variable geometry nozzle 150 described in FIG. 9-B-1 wherein the movable element 400 are not cut away in view

FIG. 9-B-4 is a section view of the variable geometry nozzle 150 described in FIG. 9-B-1

FIG. 9-C-1 is a front view of a partial cutaway example of the variable geometry nozzle 150 described in FIG. 8-C-1 having two movable element 400 in another position such that the inner flow passage 152 is in communication with the outlet orifice 425 through the downstream passage 800 wherein the downstream passage 800 is of another flow geometry 440 generated by the movable element 400 interacting with the inner flow passage 152 when it is in this position.

FIG. 9-C-2 is a partial section view of the variable geometry nozzle 150 described in FIG. 9-C-1 wherein the movable element 400 is not cut away in view

FIG. 9-C-3 is a partial section view from a tilted angle of the variable geometry nozzle 150 described in FIG. 9-C-1 wherein the movable element 400 are not cut away in view

FIG. 9-C-4 is a section view of the variable geometry nozzle 150 described in FIG. 9-C-1

FIG. 10 is a detailed view of an example of the variable geometry nozzle 150 described in FIG. 8 wherein plurality of movable element 400 are disposed within the body 200 and are having a curved surface and move partially in rotation causing the change of downstream flow geometry 440. In this example three movable elements each is having at least one surface of a mostly spherical shape such as a portion of a ball and is having a cavity there through such that when the elements are together in one position, the cavity between them construct an initial flow geometry 440, and when the movable element are in another position the cavity between them is of different flow geometry 440. The geometry of the cavity between the elements decides downstream flow geometry 440 of the variable geometry nozzle 150

FIG. 10-A-1 is a front view of a partial cutaway example of the variable geometry nozzle 150 similar to the one described in FIG. 8-A-1. The variable geometry nozzle comprising a plurality movable element 400 in an initial position such that the inner flow passage 152 is in communication with the outlet orifice 425 through the downstream passage 800 wherein the downstream passage 800 geometry is of initial flow geometry 440 generated by the movable element 400 interacting with the inner flow passage 152 when it is in this position.

FIG. 10-A-2 is a partial section view of the variable geometry nozzle 150 described in FIG. 10-A-1 wherein the movable element 400 are not cut away in view

FIG. 10-A-3 is a partial section view from a tilted angle of the variable geometry nozzle 150 described in FIG. 10-A-1 wherein the movable element 400 are not cut away in view

FIG. 10-A-4 is a section view of the variable geometry nozzle 150 described in FIG. 10-A-1

FIG. 10-B-1 is a front view of a partial cutaway example of the variable geometry nozzle 150 described in FIG. 10-A-1 having the movable element 400 in a second position such that the inner flow passage 152 is in communication with the outlet orifice 425 through the downstream passage 800 wherein the downstream passage 800 geometry is of geometry second flow geometry 440 generated by the movable element 400 interacting with the inner flow passage 152 when it is in this position.

FIG. 10-B-2 is a partial section view of the variable geometry nozzle 150 described in FIG. 10-B-1 wherein the movable element 400 are not cut away in view.

FIG. 10-B-3 is a partial section view from a tilted angle of the variable geometry nozzle 150 described in FIG. 10-B-1 wherein the movable element 400 are not cut away in view.

FIG. 10-B-4 is a section view of the variable geometry nozzle 150 described in FIG. 10-B-1.

FIG. 10-C-1 is a front view of a partial cutaway example of the variable geometry nozzle 150 described in FIG. 10-A-1 having the movable element 400 in another position such that the inner flow passage 152 is in communication with the outlet orifice 425 through the downstream passage 800 wherein the downstream passage 800 is of another flow geometry 440 generated by the movable element 400 interacting with the inner flow passage 152 when it is in this position.

FIG. 10-C-2 is a partial section view of the variable geometry nozzle 150 described in FIG. 10-C-1 wherein the movable element 400 is not cut away in view.

FIG. 10-C-3 is a partial section view from a tilted angle of the variable geometry nozzle 150 described in FIG. 10-C-1 wherein the movable element 400 are not cut away in view.

FIG. 10-C-4 is a section view of the variable geometry nozzle 150 described in FIG. 10-C-1.

FIG. 11 is a detailed section view of an example of the variable geometry nozzle 150 where the movable element 400 is having at least one curved surface and is biased by a resilient element 405 in connection between the movable element 400 and the body 200. The movable element 400 is placed within the inner flow passage 152 such that when it is in an initial position, the flow geometry 440 is of an initial geometry and when the movable element 400 is in another position the downstream passage 800 is having a another flow geometry 440. FIG. 11-A-1 and FIG. 11-A-2 are showing the movable element 400 in two different positions with the downstream passage 800 in FIG. 11-A-1 is of initial flow geometry 440 and the movable element 400 is in initial position. In FIG. 11-A-2 the movable element 400 is in a different position and the downstream passage 800 is of more restricted flow geometry 440 when compared to the flow geometry 440 of the downstream passage 800 in FIG. 11-A-1.

FIG. 11-B-1 and FIG. 11-B-2 are similar to FIG. 11-A-1 and FIG. 11-A-2 except that the downstream passage 800 of FIG. 11-B-1 and 11-B-2 are of larger area caused by the placement of flow enlargement conduit 845 permanently in communication between the inner flow passage 152 and the outlet orifice 425.

FIG. 12 is a detailed view of an example of the variable geometry nozzle 150 wherein the means for changing the flow geometry comprising a movable element 400 in a form of a collet disposed within the body 200 and move mostly in the axial direction guided by guide surface 850 disposed within the body 200. The collet comprising at least one collet finger 880 connected to a collet base 888 through a finger flexing spring 881. A collet spring is a resilient element configured to bias the movable element in one direction and restrain the movable element movement until the force exerted on the movable element 400 is higher than the bias force of the resilient collet spring 887. The guide surface 850 is configured to be in contact with at least one of the collet finger 880 at least one time when the said movable element 400 traverse its travel pass. The guide surface 850 in this example is a mostly tapered shape such as a conical cavity, however can be configured in any other shape to achieve its objective of guiding the movable element 400 collet finger 880. The said guided movement causes the change of the flow geometry 440. When fluid flow through the inner flow passage in one direction, it exert a force on the collet base 888 in the same direction of the fluid movement for example the collet base 888 affected by the force exerted by fluid flowing through the variable geometry nozzle 150 from inlet port 424 through the inner flow passage 152 towards the outlet orifice 425 of normal circulation 825 or in opposite direction of reverse circulation 826. The force generated by the flowing fluid has to overcome the force exerted over the movable element by the collet spring 887 before it is initially moved.

FIG. 12-A is a partial cut away view of an example of the variable geometry nozzle 150 having a collet type movable element 400 in an initial position such that the inlet port 424 and inner flow passage 152 is in communication with the outlet orifice 425 through the downstream passage 800 wherein the downstream passage 800 is of a specific flow geometry 440 generated by arrangement of the collet finger 880 interacting with the inner flow passage 152 at this initial position and guided by the guide surface 850.

FIG. 12-B is a partial cut away view at a tilted angle of an example of the variable geometry nozzle described in FIG. 12-A wherein the movable element 400 position moved from initial position described in FIG. 12-A to a second position such that at least one collet finger 880 is in contact with the guide surface 850 such that the collet finger is displaced partially in a lateral direction towards the central major axis connecting between the inlet port and outlet orifice. downstream passage 800 is of a specific flow geometry 440 generated by the movable element 400 interacting with the inner flow passage 152 when it is in this second position and guided by the guide surface 850. The downstream passage 800 is having a flow geometry 440 of a less flow area in this position when compared to the flow area of the downstream passage 800 flow geometry 440 of FIG. 12-A as the collet finger 880 has moved inwardly reducing the total area of the flow geometry 440. It is worth noting that the guide surface 850 can be configured such that when the collet finger 880 is in this second position, the collet finger 880 displacement is lateral in outwardly direction causing the flow geometry 440 in this case to be of larger geometry when compared to FIG. 12-A.

FIG. 12-C is a partial cut away view of an example of the variable geometry nozzle 150 described in FIG. 12-A wherein the movable element 400 is in another position such that it is axially displaced further from the initial position when compared to the second position in FIG. 12-B. In this other position the collet finger 880 is further displaced inwardly as guided by the guide surface 850 causing a further reduction in the flow geometry 440. the downstream passage 800 geometry is of another flow geometry 440 generated by the movable element 400 interacting with the inner flow passage 152. The downstream passage 800 is having a flow geometry 440 of a less flow area in this position when compared to the flow area of the downstream passage 800 flow geometry 440 of FIG. 12-B and of FIG. 12-A.

FIG. 13 is a section view of an example of the variable geometry nozzle 150 explained in FIGS. 8, 9 and 10 having a means of movement restriction to prevent undesired or premature movement of the movable element 400. The means of movement restriction in this example is a form of a restriction pin 805 attached to the body 200. Enough force has to be exerted on the restriction pin 805 by the movable element 400 caused by a driving member to exert force to move the movable element 400 to a second position. The initial force exerted by the driving member 811 will have to be high enough to break the restriction pin 805 and allow for the movable element 400 to change position.

FIG. 13-A is a section view of one example of the variable geometry nozzle 150 having a driving member in a form of a threaded rack 810 engaged with a matching threaded pinion 815 disposed on the on the surface of the movable element 400 such that when the threaded rack 810 moves in certain direction it exerts a force on the pinion 815 in connection with the movable element 400. When this force exceeds a value set to break the restriction pin 805, then the said restriction pin 805 will break and the movable element 400 will move movable in this example will be movable partially in rotation in response to the movement of the threaded rack 810.

FIG. 13-B is a section view of one example of the variable geometry nozzle 150 described in FIG. 13-A wherein the movable element 400 is in a second position when compared to the position in FIG. 13-A and the downstream passage 800 is having a second flow geometry 440 that is different from the flow geometry 440 generated by the movable element 400 when in the initial position of FIG. 13-A.

FIG. 13-C is a section view of one example of the variable geometry nozzle 150 described in FIG. 13-A and FIG. 13-B wherein the movable element 400 is in different position when compared to the movable element 400 position in FIG. 13-B and the downstream passage 800 is having a flow geometry 440 that is different from the flow geometry 440 generated by the movable element 400 in FIG. 13-B and FIG. 13-A.

FIG. 14 is a detailed section view of an example of the variable geometry nozzle 150 described in FIG. 5 wherein the movable element movement direction is controlled by the circulation pattern under the effect of the fluid flow direction.

FIG. 14-A-1 showing the effect of fluid flow from the outlet orifice 425 towards the inner flow passage 152 in what is known in the industry as reverse circulation 826. This flow direction in this figure forces the movable element 400 away from the outlet orifice 425 and clears the inner flow passage 152 resulting in a downstream passage 800 of communicating flow geometry 440.

FIG. 14-A-2 is a section view of an example of the variable geometry nozzle 150 described in FIG. 14-A-1 wherein the fluid is flowing from the inner flow passage 152 in the direction towards the outlet orifice 425 in what is known in the art as normal circulation 825. Fluid force the movable element 400 to engage with the inner flow passage 152 and result in a downstream passage 800 having a different flow geometry 440 when compared to the flow geometry 440 in FIG. 14-A-1. In this example, the flow geometry 440 of FIG. 14-A-2 is having a smaller flow area when compared to the flow geometry 440 flow area of FIG. 14-A-1. It is worth to note that the movable element 400 can be arranged in a different example such that the flow geometry 440 of the downstream passage 800 in FIG. 14-A-1 is smaller than the downstream passage 800 geometry of FIG. 14-A-2.

FIG. 14-B-1 is a section view of an example of the variable geometry nozzle 150 similar to the one described in FIG. 5-B-1 under the effect fluid flow direction in reverse circulation 826 wherein a resilient element 405 as described in FIG. 5-B-1 insure that the movable element 400 is biased in certain direction such that its movable element 400 movement by effect of fluid flow is restrained and takes effect when the force exerted by the fluid flowing through the variable geometry nozzle 150 exceed the force imposed by the resilient element 405.

FIG. 14-B-2 is a section view of an example of the variable geometry nozzle 150 described in FIG. 14-B-1 wherein the movable element 400 is in a different position under the effect of fluid flow direction in normal circulation 825 when compared to FIG. 14-B-1 and resulting in a downstream passage 800 of a different flow geometry 440.

FIG. 15 is an example of the variable geometry nozzle 150 described in FIG. 5-C-1 and 5-C-2 wherein the movable element movement direction is controlled by the circulation pattern, and the movable element 400 position is controlled by the combination of the cam 420 and fluid flow direction. The movable element 400 position within the body 200 and interacting with the inner flow passage 152 determine the geometry and the total flow area of the flow geometry 440.

FIG. 15-A is an example of the variable geometry nozzle 150 described in FIG. 5-C-1 wherein the fluid flow direction is in normal circulation 825 from inlet port 424 through the inner flow passage 152 toward the outlet orifice 425 cause the movable element 400 to change position guided by the cam follower 415 traversing the cam track 410 in a determined displacement and direction.

FIG. 15-B is another view of the variable geometry nozzle 150 described in FIG. 15-A when fluid flow direction is reversed in what is known as reverse circulation 826 the fluid will flow from the outlet orifice 425 in a direction towards the inlet port 424 through the inner flow passage 152, then it will force the movable element 400 to change position guided by the cam flower 415 traversing the cam track 410 and resulting in the movable element 400 interacting with the inner flow passage 152 and causing the downstream passage 800 to have certain flow geometry 440 as seen in this FIG. 15-B. The cyclic movement of fluid flowing in normal circulation 825 or reverse circulation 826 will cause the movable element 400 to move within the body 200 of the variable geometry nozzle 150 as guided by the cam 420 and as a result the movable element 400 will engage with the inner flow passage 152 at different predetermined positions and stays in the same position until the fluid circulation direction is reversed.

This is a principal of the method disclosed herein after that is implemented to control the geometry of the of the variable geometry nozzle 150 apparatus and keep it at certain position during the desired operation.

FIG. 16 is an example of a possible placement of a preferred example of the variable geometry nozzle 150 apparatus within the tubular string 110.

FIG. 16-A is a section view of an example wherein the variable geometry nozzle 150 is placed in a drill bit perforation 125 and the result is a drill bit 120 having a remotely operated variable geometry nozzle 150.

FIG. 16-B is a section view of an example of the variable geometry nozzle 150 disposed within a tubular string 110 affecting the fluid flow profile flowing within the inner flow passage 152 of the tubular string 110 from one end to the other end through the inlet port 424 and the outlet orifice 425.

FIG. 16-C is a section view of an example of the variable geometry nozzle 150 disposed between the inner flow passage 152 and the annular flow passage 154 controlling the flow profile and flow pattern between the inner flow passage 152 and the annular flow passage 154 according to the downstream passage 800 flow geometry 440. This figure is a possible example of the variable geometry nozzle 150 wherein the body 200 is an integrated body 830 manufactured within the walls of a tool in the bottom hole assembly 130.

FIG. 17 is a flowchart diagram describing the method disclosed for remotely controlling the variable geometry nozzle 150. Step 1 855 is to dispose in a well bore a tubular string comprising a variable geometry nozzle 150 having a movable element 400 in initial position and a flow geometry 440 of initial geometry. Step 2 860 changing at least one physical property of the environment. Step 3 865 moving the movable element 400 from an initial position to a different predetermined position in response to the change of the at least one physical property of the environment. Step 4 866 causing a change of the flow geometry wherein the different predetermined position of the movable element 400 results in a change of the flow geometry 440 at the location within the inner flow passage 152 between the inlet port 424 and the outlet orifice 425.

In operation when drilling in Earth formations going through earth layers having variations in mechanical properties, the drill bit nozzle hydraulic horse power per square inch (HSI) can be too high for some formation layers which gets over drilled or too low which results in less efficient cuttings removal.

Conventionally, the drill bit nozzle lowered in the wellbore has a fixed flow geometry and total flow area (TFA) and it is not possible to change the nozzle geometry without pulling the tubular string out of the wellbore.

In another aspect, flow restrictors exist in other components of the tubular string used for drilling or in fluid conduits which are used in the oil and gas industry or other industries.

In many situations, the ability to change the geometry of such flow restrictors remotely is desirable. For example, it is desirable to change the geometry of the flow restrictor which is used within the mud motor of a tubular string during drilling without pulling the tubular string out of hole.

In another situation, it is desirable to provide a device that allow for fluid communication between the inner flow passage and the annular fluid passage. Such a device is common when running completion string for example during the process of placement of completion fluid. In other applications such as during drilling operation it is desirable to provide a device that allow operator to circulate fluid between inner fluid passage and annular fluid passage such as the case of stuck pipe.

Today, current technology does not allow for changing fluid flow restrictor particularly in drilling application and more specifically for drill bit nozzles without pulling the tubular string out to surface to make the necessary changes. This process is costly and involve extensive rig time and further introduces higher operating risks.

The current disclosed invention introduces a remotely operated variable geometry nozzle that can be placed within a drill bit as described in FIG. 16-A to allow operator to change the total flow area and nozzle flow geometry remotely and without pulling out of hole. Another aspect of the present invention introduces a remotely operated variable geometry nozzle that can be placed within a tubular string inner flow passage as described in FIG. 16-B such as in mud motor to control the pressure drop through the nozzle. In another aspect, the present invention introduces a remotely operated variable geometry nozzle that can be placed within the wall of a tubular string to change fluid flow profile between inner fluid passage and annular fluid passage.

It is further desirable to restrain undesired changes of the variable geometry nozzle in normal operation.

The present invention introduces a variable geometry nozzle that can be adopted to be placed in a drill bit, within a tubular string inner fluid passage or between the inner fluid passage and annular fluid passage.

A variable geometry nozzle having a movable element placed at a predetermined initial position is adopted to be mounted within a tubular string such as drill bit within the inner flow passage at an initial position. Change of flow restriction or flow geometry is achieved by changing the position of the movable element within the inner flow passage.

Different examples of a means for changing the nozzle flow geometry 440 is achieved by disposing different arrangement of a movable element 400 within the body that interact with the inner flow passage causing a change in flow geometry 440. Different examples of a movable element 400 are described in this disclosure of the present invention. A movable element 400 that moves axially within the body as in FIG. 7, 11, 12, a movable element 400 moving in rotation as in FIG. 8,9, 10, 13 or a movable element 400 moving in revolving motion as in FIG. 6 or a movable element 400 moving at an angle from fluid flow passage such as in FIGS. 4, 5, 14, 15. The movement examples explained herein are not exclusive and are for demonstration purposes. Other movement or movement combination are to achieve the same objective are an integral part of this disclosure.

A means for restraining movement of the movable element is explained in FIG. 13 in a form of a shear pin, and in a form of resilient element as in FIG. 4-B-1, 4-B-2, 5-B-1, 5-B-2, 14-B-1, 14-B-2, FIG. 11.

A means for controlling the movement of the movable element is in a form of cam is explained in FIG. 4-C-1, 4-C-2, 5-C-1, 5-C-2, 6-A-1, 6-A-2, or a combination of cam and resilient element as in FIGS. 4-D-1, 4-D-2, 5-D-1, 5-D-2, 6-B-1, 6-B-2, or in a form of rack and pinion as in FIGS. 8, 9, 10, 13.

A means for moving the movable element is explained in FIG. 12 as the collet base 888 affected by the force exerted by fluid flowing through the variable geometry nozzle 150 from inlet port 424 through the inner flow passage 152 towards the outlet orifice 425 of normal circulation 825 or in opposite direction of reverse circulation 826. The force generated by the flowing fluid has to overcome the force exerted over the movable element by the collet spring 887 before it is initially moved. Another means of moving the movable element is explained in FIGS. 5, 14 and 15 where flowing fluid exert force over the movable element through the communication duct 430. Another example of means of moving the movable element is explained in view of FIGS. 6 and 11 where the fluid flowing through the inner flow passage 152 exert a force on the movable element 400 in the same direction of flow. Another example of the means for moving the movable element is explained in view of FIGS. 4 & 7 where fluid flowing through the inner flow passage generate a turbulence at the downstream passage 800 the exert a force over the movable element such that when fluid flow in normal circulation 825 from the inlet port 424 to the outlet orifice 825, the turbulence will create a form of a lower pressure pulling the movable element from its initial position to a second position. When the fluid flow in reverse circulation 826, the force exerted on the movable element 400 will force it to move from the second position towards the initial position. Another example of the means for moving the movable element is explained in view of FIGS. 8, 9, 10, 13 wherein a rack ring 811 is disposed within the inner flow passage 152 between the inlet port 424 and outlet orifice 425 and rigidly connected to the threaded rack 810. Fluid flow through the inner flow passage 152 in normal circulation 824 will exert a force on the rack ring 811 in one direction causing the threaded rack 810 to move in the same direction and forcing the movable element 440 to move and change position by means of the threaded pinion 815 engaged with the threaded rack 810. It is understood that similar movement of the movable element 440 achieved through the interaction of the threaded rack 810 and threaded pinion 815 in this example can be achieved by magnetic coupling instead of threaded coupling or by friction coupling or other coupling that is commonly known in the art. Other means of moving the movable elements such as an energized resilient element or electric motors are explained in detail in the patent application Ser. No. 13/846,946 dated Mar. 18, 2013 and application Ser. No. 13/861,255 dated Apr. 11, 2013 by the current inventors and not repeated in this disclosure.

Each of the rack ring 811, collet base 888 are configured to have a surface area sufficient to be affected by change in fluid flow and accordingly act as a means for detecting fluid flow. When fluid flow through the inner flow passage 152 in one direction it exert certain force on the rack ring 811 or the collet base 888. In the examples explained previously, when the fluid flow increase in the same direction, the force exerted on the rack ring 811 or collet base 888 increase and vice versa. Geometry of the rack ring 811 or the collet base 888 can be configured and arranged to be affected by other change in the environment such as change in fluid viscosity as the force exerted on the rack ring 811 and the collet base 888 will be proportionally changing with the change of fluid viscosity, similarly when the density change as the said force is proportionally related to the mass flow rate. Other means for detecting change in environment such as pipe movement or having an electronic sensor are explained in more details in the patent application Ser. No. 13/846,946 dated Mar. 18, 2013 and application Ser. No. 13/861,255 dated Apr. 11, 2013 by the current inventors and not repeated in this disclosure.

The present invention discloses a method for changing a nozzle geometry disposed within a tubular string such as a drill bit by introducing in a tubular string A remotely controlled variable geometry nozzle comprising:

a body configured to be disposed within the tubular string, the body having an inlet port and an outlet orifice;

a fluid passage having a plurality of predetermined geometries and extending through the body, the fluid passage is in fluid communication with the inlet port and the outlet orifice; and

a means for changing the geometry of the fluid passage having a movable element disposed within the body, the movable element is configured to be movable to a plurality of predetermined positions in response to a change in a physical property of the environment, and wherein the geometry of the fluid passage is responsive to the position of the movable element within the body.

Causing a change in the environment such as changing fluid flow direction or changing fluid flow rate, or changing fluid mass flow rate by means of changing fluid density or movement of the tubular string. Such a change is detectable by a sensor means within the apparatus. This sensor means in one example is an electronic sensor and in another example is a simple geometry such as the collet base 888 or rack ring 811 explained above.

Changing the movable element position from an initial position to another position in response of the change of the environment such that the flow geometry changes form an initial flow geometry to another flow geometry. Examples of the means for moving the movable element from an initial position to a second position are explained above such as the collet base disposed 888 disposed within the flow passage and affected by fluid flow rate and fluid flow direction.

Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.

Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.

Claims

1. A remotely controlled variable geometry nozzle comprising:

a body configured to be disposed within the tubular string, the body having an inlet port and an outlet orifice;

a fluid passage having a plurality of predetermined geometries and extending through the body, the fluid passage is in fluid communication with the inlet port and the outlet orifice; and

a means for changing the geometry of the fluid passage having a movable element disposed within the body, the movable element is configured to be movable to a plurality of predetermined positions in response to a change in a physical property of the environment, and wherein the geometry of the fluid passage is responsive to the position of the movable element within the body.

2. The apparatus of claim 1, wherein the nozzle is adapted and configured for use in a drill bit.

3. The nozzle of claim 1, further comprising a means for controlling the movable element movement between the predetermined positions.

4. The nozzle of claim 1, further comprising a means for restraining the movement of the movable element.

5. The nozzle of claim 4, wherein the means for restraining the movement of the movable element comprises a resilient element configured and arranged for restraining undesired movement of the movable element.

6. The nozzle of claim 1, wherein the plurality of predetermined geometries comprises an initial geometry having an initial cross section area and having an initial cross section shape at a particular position within the fluid passage, and at least one predetermined geometry at a particular position within the fluid passage selected from the set of geometries including: a larger geometry having a larger cross section area, a smaller geometry having a smaller cross section area, and another geometry having a different cross section shape.

7. The nozzle of claim 1, wherein the movable element is movable to a predetermined position in response to fluid flow through the tubular string in one direction, and the movable element is movable to another predetermined position in response to fluid flow through the tubular string in another direction.

8. The nozzle of claim 1, wherein the change of a physical property of the environment comprises a change of a physical property selected form the set of: fluid flow rate, fluid flow direction, fluid flow pattern, fluid chemical composition, fluid viscosity, fluid electric property, fluid magnetic property, fluid pressure, fluid temperature, fluid density, fluid color, movement of the tubular string, movement of a part of the tubular string, introducing an object into the wellbore, and introducing an object into the inner passage of the tubular string; or any combination thereof.

9. A remotely controlled variable geometry nozzle comprising:

a body configured to be disposed within the tubular string, the body having an inlet port and an outlet orifice;

a fluid passage having a plurality of predetermined geometries and extending through the body wherein the fluid passage is in fluid communication with the inlet port and the outlet orifice;

a means for changing the geometry of the fluid passage having a movable element disposed within the body, the movable element is configured to be movable to a plurality of predetermined positions in response to a change in a physical property of the environment, and the geometry of the fluid passage is responsive to the movement of the movable element;

a means for detecting the change in a physical property of the environment generating a detectable signal; and

a means for actuating the means for changing the geometry of the fluid passage positioned and arranged within the body and configured to move the movable element in response to the detectable signal.

10. The nozzle of claim 9, wherein the means for detecting comprises a sensor positioned and arranged in the wellbore environment and configured to sense at least one physical property of the environment.

11. The nozzle of claim 9, wherein the means for actuating comprises an actuator selected from the a set of actuators that includes: an electric actuator, a mechanical actuator, a hydraulic actuator, an electric motor, a solenoid, a rack—being mechanically engaged with the movable element, a cam-type actuator, an energy harvester actuator set to receive an energy from a fluid pressure difference between two points within the well bore, and an energy harvester actuator set to receive an energy from a change of fluid flow property within the well bore.

12. The nozzle of claim 9, further comprising a means for restraining the movement of the movable element responsive to the change of a physical property of the environment.

13. A method for remotely changing the geometry of a fluid passage in a wellbore having a fluid comprising:

disposing in the wellbore a tubular string including a variable geometry nozzle comprising:

a body configured to be disposed within the tubular string, the body having an inlet port and an outlet orifice;

a fluid passage having a plurality of predetermined geometries and extending through the body, the fluid passage is in fluid communication with the inlet port and the outlet orifice; and

a means for changing the geometry of the fluid passage having a movable element disposed within the body, the movable element is configured to be movable to a plurality of predetermined positions in response to a change in a physical property of the environment, and the geometry of the fluid passage is responsive to the position of the movable element within the body.

Changing a physical property of the environment;

moving the movable element from an initial predetermined position to another predetermined position in response to the change in the physical property of the environment; and

changing the geometry of the fluid passage from an initial predetermined geometry to another predetermined geometry in response to the movement of the movable element from an initial predetermined position to another predetermined position

14. The method of claim 13, wherein the plurality of predetermined geometries comprises an initial geometry having an initial cross section area and having an initial cross section shape at a particular position within the fluid passage, and at least one predetermined geometry at a particular position within the fluid passage selected from the set of geometries including: a larger geometry having a larger cross section area, a smaller geometry having a smaller cross section area, and another geometry having a different cross section shape.

15. The method of claim 13, wherein the change of a physical property of the environment comprising a change of a physical property selected form the set of: fluid flow rate, fluid flow direction, fluid flow pattern, fluid chemical composition, fluid viscosity, fluid electric property, fluid magnetic property, fluid pressure, fluid temperature, fluid density, fluid color, movement of the tubular string, movement of a part of the tubular string, introducing an object into the wellbore, and introducing an object into the inner passage of the tubular string; or any combination thereof.