ALIGNMENT SUB WITH CLAMP LOCK MECHANISM

An alignment sub (100) includes first and second sections (200, 300) that are rotatably coupled to one another. The first and second sections are configured to respectively couple to a first wellbore tool (20) and a second wellbore tool (30). The alignment sub further includes a clamp (400) configured to selectively, rotationally lock the first and second sections to one another.

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Description
CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/487,969 filed Mar. 2, 2023 and U.S. Provisional Patent Application No. 63/386,026 filed Dec. 5, 2022, the entire contents of each of which being incorporated by reference herein.

BACKGROUND OF THE DISCLOSURE

Wellbore tools used in oil and gas operations, including perforating guns housing shaped charges, or similar operating explosive or mechanical devices, are often sent down a wellbore in tool strings connected together to reduce time and costs associated with the operation. Sub-assemblies connect adjacent wellbore tools to one another to form the tool string.

Some downhole operations require a certain alignment of a wellbore tool section of an adjacent wellbore tool. An example of this would be hydraulic fracturing procedures that achieve best results when perforations are oriented in the direction of maximum principal stress or the preferred fracture plane. Perforations oriented in the direction of the preferred fracturing plane create more stable perforation tunnels, and fractures can extend far into the hydraulically fractured geological formation. If fractures are not oriented in the direction of maximum stress, tortuous, non-transverse fractures may result, creating a complex near-wellbore flow path that can affect the connectivity of the fracture network, increase the chance of premature screen-out, and impede hydrocarbon flow. A wellbore tool string including perforating guns typically rests on a lower horizontal surface of a wellbore casing. This positioning may result in larger perforations being formed by shaped charges oriented toward the nearby horizontal surface, and smaller perforations being formed by shaped charges oriented away from the nearby horizontal surface. Another example would be the perforating in a horizontal section of a conventional oil and gas reservoir, where perforating in a certain direction can reduce a possible, unintended sand production from the reservoir.

Accordingly, there is a need for an alignment sub that allows alignment of wellbore tools, like shaped charge carrying perforating guns, in two or more adjacent wellbore tools connected to each other in a wellbore tool string. Further, there is a need for an alignment sub that is not limited in the alignment degree and inclination of two wellbore tools relative to each other and also not limited to a pure electrical connection but instead be able to feed through a ballistic transfer from a first to a second wellbore tool.

BRIEF DESCRIPTION

According to aspects of the present disclosure, the exemplary embodiments include an alignment sub including a first section, a second section, and a clamp. The first section has a first end portion configured to couple to a first wellbore tool, and a second end portion. The second section has a first end portion configured to couple to a second wellbore tool, and a second end portion defining a cavity therein configured for receipt of the second end portion of the first section. The first section and the second section are configured to rotatably couple to one another. The clamp is configured to selectively lock the first and second sections to one another to prevent rotation of the first and second sections relative to one another.

According to further aspects, the exemplary embodiments include an alignment sub for aligning a first wellbore tool with a second wellbore tool. The alignment sub includes a first body portion and a second body portion each having a first end portion and a second end portion. The first end portion of the first body portion is configured to couple to a first wellbore tool and the first end portion of the second body portion is configured to couple to a second wellbore tool. The second end portion of the second body portion defines a cavity therein configured for receipt of the second end portion of the first body portion. The second end portion of the second body portion has a threaded inner surface configured to threadedly couple to a threaded outer surface of the second end portion of the first body portion. The second body portion includes a clamp configured to selectively lock the first and second body portions to one another to prevent rotation of the first and second body portions relative to one another.

According to further aspects, the exemplary embodiments include an alignment sub including a first section, a second section, a clamp, and a retainer. The first section has a first end portion and second end portion, and the second section has a first end portion and a second end portion. The first end portion of the first section is configured to couple to a first wellbore tool and the first end portion of the second section is configured to couple to a second wellbore tool. The second end portion of the second section defines a cavity therein configured for receipt of the second end portion of the first section. The second end portion of the first section and the second end portion of the second section are configured to rotatably couple to one another. The clamp is configured to selectively lock the first section and the second section to one another to prevent rotation of the first section and the second section relative to one another. The retainer is configured to be positioned concentrically between the first section and the second section and is configured to axially fix the first section and the second section to one another.

According to further aspects, the exemplary embodiments include a perforating gun string including a first perforating gun, a second perforating gun, and an alignment sub. The alignment sub includes a first section, a second section, and a clamp. The first section has a first end portion configured to couple to the first perforating gun, and the second section has a first end portion configured to couple to the second perforating gun. The second section has a second end portion configured to rotatably connect to a second end portion of the first section. The clamp is configured to selectively lock a rotational orientation of the first section relative to the second section.

According to further aspects, the exemplary embodiments include a method of locking first and second wellbore tools to one another. The method includes inserting a first section of an alignment sub into a cavity defined in a second section of the alignment sub; rotating at least one of the first or second sections relative to one another; and moving a clamp into locking engagement with the first section, whereby the clamp resists rotational movement of the first section and the second sections relative to one another.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description will be rendered by reference to exemplary embodiments that are illustrated in the accompanying figures. Understanding that these drawings depict exemplary embodiments and do not limit the scope of this disclosure, the exemplary embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 is a perspective view of an exemplary embodiment of a perforating gun string or system including an alignment sub coupling first and second perforating guns to one another;

FIG. 2 is a side view of the alignment sub of FIG. 1;

FIG. 3 is a perspective view of the alignment sub of FIG. 2 including first and second sections and a locking mechanism;

FIG. 4A is a side view of the alignment sub of FIG. 2, with the second section shown in phantom;

FIG. 4B is a side view of the alignment sub of FIG. 2, with the first section shown in phantom;

FIG. 5 is a perspective view illustrating the second section of the alignment sub of FIG. 2;

FIG. 6 is a longitudinal cross-sectional view of the alignment sub of FIG. 3;

FIG. 7A is a cross-sectional view of the alignment sub of FIG. 6, showing a cross-section that is marked as 7A in FIG. 6;

FIG. 7B is a cross-sectional view of the alignment sub of FIG. 6, showing the cross-section that is marked as 7B in FIG. 6;

FIG. 8 illustrates a flow chart of the attachment and alignment of two wellbore tools by using the exemplary embodiment of the alignment sub;

FIG. 9 is a perspective view of an exemplary embodiment of an alignment sub;

FIG. 10 is a longitudinal cross-sectional view of the alignment sub of FIG. 9;

FIG. 11 is a side view of an exemplary embodiment of an alignment sub;

FIG. 12 is a longitudinal cross-sectional view of the alignment sub of FIG. 11;

FIG. 13 is a longitudinal cross-sectional view of another exemplary embodiment of an alignment sub;

FIG. 14 is a longitudinal cross-sectional view of yet another exemplary embodiment of an alignment sub.

FIG. 15 is a top plan view of an exemplary embodiment of an alignment sub; and

FIG. 16 is a transverse cross-sectional view of the alignment sub of FIG. 15.

Various features, aspects, and advantages of the exemplary embodiments will become more apparent from the following detailed description, along with the accompanying drawings in which like numerals represent like components throughout the figures and detailed description. The various described features are not necessarily drawn to scale in the drawings but are drawn to emphasize specific features relevant to some embodiments.

The headings used herein are for organizational purposes only and are not meant to limit the scope of the disclosure or the claims. To facilitate understanding, reference numerals have been used, where possible, to designate like elements common to the figures.

DETAILED DESCRIPTION

Reference will now be made in detail to various embodiments. Each example is provided by way of explanation and is not meant as a limitation and does not constitute a definition of all possible embodiments.

For purpose of this disclosure, “sub” may include a sub assembly having two or more assembled parts.

Embodiments described herein relate generally to wellbore tools and perforating guns for use in a wellbore environment. For purposes of this disclosure, the phrases “devices,” “systems,” and “methods” may be used either individually or in any combination referring without limitation to disclosed components, grouping, arrangements, steps, functions, or processes.

For purposes of illustrating features of the embodiments, an exemplary embodiment will now be introduced and referenced throughout the disclosure. This example is illustrative and not limiting and is provided for illustrating the exemplary features of an alignment sub as described throughout this disclosure.

Turning now to FIGS. 1-7B, the present disclosure provides an exemplary embodiment of a perforating gun string or system 10 including an alignment sub 100 for coupling first and second wellbore tools, such as, for example, a first perforating gun 20 and a second perforating gun 30. The alignment sub 100 may be an assembly that includes a first body portion or first section 200, a second body portion or second section 300 (FIGS. 4A and 6), and a locking mechanism including a clamp 400 and a fastener 404 that together rotationally secure the first section 200 and the second section 300 to one another.

Each of the first section 200 and the second section 300 may be a generally cylindrically-shaped body. The first section 200 includes a first end portion 200a and a second end portion 200b, and the second section 200 includes a first end portion 300a and a second end portion 300b. The first end portion 200a of the first section 200 has a first connector 220, and the first end portion 300a of the second section 300 has a second connector 320. The first connector 220 and the second connector 320 are configured to connect to the first perforating gun 20 and a second perforating gun 30, respectively. For example, the first connector 220 and the second connector 320 may be threaded outer surfaces configured to be threadedly coupled to a corresponding threaded inner surface (not explicitly shown) of the first perforating gun 20 and the second perforating gun 30.

To maintain a fluid-tight seal against wellbore fluid or gas, the first section 200 may include a seal 110a and the second section 300 may include a seal 110b. The seal 110a of the first section 200 may include first and second seals, and the second seal 110b of the second section 300 may include first and second seals. In aspects, the seals 110a, 110b may be O-rings. Other types of seals are also contemplated. The seal 110a is positioned adjacent the first connector 220 of the first section 200 and the seal 110b is positioned adjacent the second connector 320 of the second section 300. The seals 110a, 110b are configured to engage an annular inner surface (not explicitly shown) of the first perforating gun 20 and the second perforating gun 30, respectively, to form a fluid-tight seal therebetween. In aspects, the seals 110a, 110b may each include only a single seal or more than two seals.

The first section 200 defines a central bore 202 (FIGS. 3 and 6) therethrough, and the second section 300 defines a central bore 302 (FIGS. 5 and 6) therethrough, such that when the first and second sections 200, 300 are assembled, the central bore 202 and the central bore 302 cooperatively define a single, continuous central bore 202/302 through the alignment sub 100. The single, continuous bore 202/302 may extend on a central longitudinal axis “X” of the alignment sub 100 and allows for a signal transfer, like an electrical feedthrough or a ballistic transfer, through the alignment sub 100. The ballistic transfer may be an explosive booster or a detonating cord, or a combination of both, to transfer the ballistic signal received from the first perforating gun 20 to the second perforating gun 30. In aspects, the feedthrough hosted within the central bore 202/302 may be a conductive bulkhead that maintains sealing between the interiors of the first perforating gun 20 and the second perforating gun 30.

With reference to FIGS. 2, 3, 4A and 6, the first section 200 of the alignment sub 100 further includes an annular middle portion 200c positioned between and formed with the first end portion 200a and the second end portion 200b. The annular middle portion 200c may define a plurality of circumferentially spaced holes 114 configured for receipt of a tool used for manually rotating the first section 200 relative to the second section 300. The middle portion 200c has an outer surface 214 and an end face 216 (FIG. 6) extending radially inward from the outer surface 214.

The second end portion 200b of the first section 200 extends axially from the end face 216 of the middle portion 200c of the first section 200. The second end portion 200b includes a first cylindrical body 206 having a reduced diameter relative to the annular middle portion 200c, and a second cylindrical body 208 extending axially from the first cylindrical body 206 and having a reduced diameter relative to the first cylindrical body 206. The first cylindrical body 206 has a threaded outer surface 204 (e.g., a screw thread) along its length, whereas the second cylindrical body 208 may be devoid of threading. The second cylindrical section 208 may define one or more annular depressions having an internal seal 210 (e.g., one or more O-rings) received therein. The seal 210 prevents the transfer of fluids from an environment external to the alignment sub 100 into the central bore 202/302.

With reference to FIGS. 4A, 4B, 5, and 6, the second end portion 300b of the second section 300 defines the cavity 303 therein that is contiguous with and in communication with the central bore 302 of the second section 300. The cavity 303 of the second section 300 may be a counterbore that includes a first bore 303a having a first diameter, and a second bore 303b extending from the first bore 303a and having a second diameter smaller than the first diameter of the first bore 303a. The first bore 303a of the second section 300 is sized and configured for receipt of the first cylindrical body 206 of the first section 200, and the second bore 303b of the second section 300 is sized and configured for receipt of the second cylindrical body 208 of the first section 200.

As best shown in FIG. 6, the second end portion 300b of the second section 300 includes a threaded first inner surface 304 defining the first bore 303a, and an unthreaded second inner surface 306 extending axially from the threaded inner surface and defining the second bore 303b. As such, the first section 200 and the second section 300 of the alignment sub 100 are connected to one another with an internal threaded connection between the threaded outer surface 204 of the first cylindrical portion 206 of the first section 200 and the threaded first inner surface 304 of the second section 300. In some aspects, the first inner surface 304 and the second inner surface 306 may be threaded or unthreaded.

With continued reference to FIGS. 1-7B, the locking mechanism of the alignment sub 100 includes the clamp 400 and the fastener 404, such as, for example, a screw, for tightening the clamp 400 around the first section 200. It is contemplated that the clamp 400 may be part of the second section 300 of the sub 100 (e.g., integrally formed therewith). The clamp 400 may be formed from the second section 300 by cutting an annular or circumferential gap 402a and a transverse gap 402b into the second section 300. The annular gap 402a and the transverse gap 402b may be formed by, for example, but not limited to, chipping, mechanical cutting, plasma cutting, electrical discharge machining, or laser cutting. The annular gap 402a extends partially around the circumference of the alignment sub 100, and the transverse gap 402b extends perpendicularly from an end of the annular gap 402a. In other aspects, the clamp 400 may be a separate component that is secured or otherwise coupled to an end face of the second end portion 300b of the second section 300, for example, via adhesives, soldering, or the like.

The clamp 400 may include a first circumferential portion 406 fixed relative to (e.g., formed with) the second end portion 300b of the second section 300, and a second circumferential portion 408 that is movable (e.g., flexible) relative to the first circumferential portion 406 and the second end portion 300b of the second section 300. In other aspects, the clamp 400 may be hingedly coupled to the second end portion 300b of the second section 300. It is contemplated that the second circumferential portion 408 extends circumferentially about the alignment sub 100 at an angle “α” radians, as shown in FIG. 7A. For example, the first circumferential portion 406 and the second circumferential portion 408 may each extend circumferentially about the alignment sub 100 at an angle of 1 radian (i.e., 180°). In aspects, the first circumferential portion 406 and the second circumferential portion 408 may extend circumferentially about the alignment sub 100 to a different extent from one another. For example, the first circumferential portion 406 may extend circumferentially about the alignment sub 100 at an angle from about between 90° to about 270° and the second circumferential portion 408 may extend circumferentially about the alignment sub 100 from about 90° to about 270°.

The first circumferential portion 406 of the clamp 400 has an end 410, and the second circumferential portion 408 of the clamp 400 has an end 414 juxtaposing the first end 410 and spaced from the first end 410 by the transverse gap 402b. The end 410 of the first circumferential portion 406 defines a first threaded hole 412 (FIG. 7B) which threadedly engages the screw 404, and the end 414 of the second circumferential portion 408 a defines a round hole 414 therethrough configured for passage of the screw 404. As such, rotation of the screw 404 drives the end 414 of the second circumferential portion 408 toward the end 410 of the first circumferential portion 406 to contract the transverse gap 402b and constrict the second circumferential portion 408 about the first section 200, as will be described in further detail below.

The clamp 400, as part of the second section 300, sits on the threaded outer surface 204 of the first section 200 and may have a solid connection to the second section 300. The clamp 400 includes an inner-facing surface 420 (FIG. 6) that may have a plurality of teeth or threading configured to meshingly engage the threaded outer surface 204 of the first section 200. In aspects, the threading of the inner-facing surface 420 of the clamp 400 and the threading of the threaded inner surface 304 of the second section 300 may be uninterrupted. In aspects, the inner-facing surface 420 of the clamp 400 may be smooth.

FIGS. 15-16 show another exemplary embodiment of an alignment sub 900. The alignment sub 900 may include a first section 902, a second section 904, and a clamp 906. The clamp 906 may be formed or machined as a separate piece from the second section 904, i.e., not integrally connected to the second section 904 at an end. The clamp 906 may be cut or machined from the second section 904, or may be formed as separately from a different piece of material. The clamp 906 may be secured to the second section 904 via screws 908 positioned at either end of the clamp 906.

In FIG. 8, a method of assembling and setting a rotational orientation of the first perforating gun 20 and the second perforating gun 30 utilizing the alignment sub 100 of the present disclosure is illustrated. In step 101, the alignment sub 100 is assembled by axially inserting the second end portion 200b of the first section 200 into the cavity 303 defined in the second end portion 300b of the second section 300 and rotating the first section 200 and the second section 300 relative to one another. Rotation of the first section 200 and the second section 300 relative to one another axially approximate the first section 200 and the second section 300 due to the threaded connection between the threaded outer surface 204 of the first section 200 and the threaded inner surface 304 of the second section 300.

With the first section 200 and the second section 300 threadedly coupled to one another, in step 103, an electrical or ballistic transfer assembly (not explicitly shown) is passed through the central bore 202, 302 of the alignment sub 100. In step 105, the first wellbore tool 20 may be attached to the first end portion 200a of the first section 200 of the alignment sub 100 by axially inserting the first end portion 200a of the first section 200 of the alignment sub 100 into the first perforating gun 20 and rotating the first perforating gun 20 relative to the alignment sub 100. In step 107, the second perforating gun 30 may be attached to the first end portion 300a of the second section 300 of the alignment sub 100 by axially inserting the first end portion 300a of the second section 300 of the alignment sub 100 into the second perforating gun 30 and rotating the second perforating gun 30 relative to the alignment sub 100.

In step 109, with the first perforating gun 20 and the second perforating gun 30 secured to the alignment sub 100, the first section 200 and the second section 300 of the alignment sub 100 may be rotated relative to one another until a desired rotational alignment between the first perforating gun 20 and the second perforating gun 30 is achieved. The first section 200 and the second section 300 may be rotated directly by hand or by inserting one or more tools (not explicitly shown) into the alignment holes 114 (FIG. 3) of the first section 200 and the second section 300 to gain leverage. The second section 300, with the second perforating gun 30 attached thereto, may be rotated to slightly increase an axial gap 117 (FIG. 6) between the end face 216 of the middle portion 200c of the first section 200 and an end face 418 of the clamp 400.

With the first perforating gun 20 and the second perforating gun 30 being set at a desired rotational orientation relative to one another, in step 111, the screw 404 of the locking mechanism is rotated within the first hole 412 and the second hole 416 of the clamp 400, whereby a head of the screw 404 exerts a force, in a direction indicated by arrow “e” in FIG. 7B, on the end 414 of the second circumferential portion 408 of the clamp 400 to contract the transverse gap 402b and reduce an inner diameter of the first circumferential portion 408. It is contemplated that the second circumferential portion 408 of the clamp 400 may pivot or flex about a pivot or inflection point “P” (FIG. 7B) to close or contract the transverse gap 402b between the end 410 and the end 414. In other aspects, a hinge may be provided at the inflection point “P.” With this movement, the inner-facing surface 420 of the clamp 400 is moved towards the outer threaded surface 204 of the first section 200 whereby the clamp 400 exerts a force “f” (FIG. 7B) radially inward on the threaded outer surface 204 of the first section 200. Stated differently, the threaded outer surface 204 of the first section 200 is captured between the first circumferential portion 406 and the second circumferential portion 408 of the clamp 400. Rotation of the screw 404 is continued until the force “f” is determined sufficient to resist and/or prevent relative rotational movement between the first section 200 and the second section 300 and therefore between the first perforating gun 20 and the second perforating gun 30.

With reference to FIGS. 9 and 10, another embodiment of an alignment sub 500 is shown. The alignment sub 500 has multiple features in common with the alignment sub 100. Accordingly, only selected features of the alignment sub 500 will be described in detail hereinbelow. The alignment sub 500 generally includes a first section 502, different from the first section 200, and the second section 300 configured to receive and threadedly couple to the first section 502. The first section 502 defines a central bore 508 therethrough. The first section 502 has a first end portion 502a configured for coupling to a first wellbore tool (not explicitly shown), and a second end portion 502b configured for receipt in the second end portion 300b of the second section 300.

The first end portion 502a of the first section 502 may have a smaller outer diameter than that of the first end portion 300a of the second section 300 such that the first section 502 may be configured to couple to a different type of wellbore tool or a different sized perforating gun than that of the second section 300. It is contemplated that a plurality of first sections may be provided with each being configured to couple to the second section 300 and each having a distinct connector for connecting to a discrete wellbore tool.

With reference to FIGS. 11 and 12, another embodiment of an alignment sub 600 is shown. The alignment sub 600 has multiple features in common with the alignment sub 100. Accordingly, only selected features of the alignment sub 600 will be described in detail hereinbelow. The alignment sub 600 generally includes a first section 602 and a second section 604 configured to receive and rotatably couple to the first section 602. The first section 602 has a first end portion 602a configured to be coupled to a first wellbore tool (e.g., first perforating gun 20, FIG. 1) and a second end portion 602b, and the second section 604 has a first end portion 604a configured to be coupled to a second wellbore tool (e.g., second perforating gun 30, FIG. 1) and a second end portion 604b. The second end portion 604b of the second section 604 includes a clamp 608, similar to the clamp 400, configured to selectively, rotationally lock the second section 604 to the first section 602. The second section 604 may have an annular inner surface 610 configured to engage an annular outer surface 612 of the first section 602. In aspects, the annular inner surface 610 and the annular outer surface 612 may be free of threading such that the first section 602 and the second section 604 are freely rotatable relative to one another without resulting in relative axial movement.

The first section 602 includes an outer radial projection 614, and the second section 604 includes an inner radial projection 616 configured to abut the outer radial projection 614 when the first section 602 and the second section 604 are coupled to one another to prevent the first section 602 and the second section 604 from sliding past one another. The second end portion 602b of the first section 602 includes a threaded outer surface 618. An annular gap 620 is defined concentrically between the threaded outer surface 618 and the first end portion 604a of the second section 604.

The alignment sub 600 further includes a retainer 622, such as, for example, a nut, configured for axial receipt in the annular gap 620 defined concentrically between the second end portion 602b of the first section 602 and the first end portion 604a of the second section 604. The retainer 622 may be disc-shaped or cylindrically-shaped and defines a passageway 626 therethrough. The retainer 622 has a threaded inner surface 624 configured to threadedly engage the threaded outer surface 618 of the second end portion 602b of the first section 602. When the retainer 622 is fully inserted in the annular gap 620, the inner radial projection 616 of the second section 604 is axially restrained or captured between the outer radial projection 614 of the first section 602 and the retainer 622, such that the first section 602 and the second section 604 are prevented from moving axially relative to one another while continuing to be rotatable relative to one another about a central longitudinal axis of the alignment sub 600.

The retainer 622 may define a threaded hole 628 axially therethrough configured for receipt of a fastener, such as, for example, a retainer screw 630. The retainer screw 630, when inserted in the threaded hole 628, engages the threaded outer surface 618 of the second end portion 602b of the first section 602 to secure the retainer 622 to the first section 602 and prevent the retainer 622 from backing out of the annular gap 620. With the retainer 622 secured to the first section 602, the first section 602 and the second section 602 remain rotatable relative to one another. Upon rotating the first section 602 and the second section 604 to one another to a desired relative rotational orientation, a clamp screw 632 (FIG. 11) may be used to constrict the clamp 608 of the second section 604 about the outer radial projection 614 of the first section 602 to selectively lock the relative rotational orientation of the first section 602 and the second section 604.

With reference to FIG. 13, another embodiment of an alignment sub 700 is shown. The alignment sub 700 has multiple features in common with the alignment sub 100. Accordingly, only selected features of the alignment sub 700 will be described in detail hereinbelow. The alignment sub 700 generally includes a first section 702 and a second section 704 configured to receive and rotatably couple to the first section 702. The first section 702 has a first end portion 702a configured to be coupled to a first wellbore tool (e.g., first perforating gun 20, FIG. 1) and a second end portion 702b, and the second section 704 has a first end portion 704a configured to be coupled to a second wellbore tool (e.g., second perforating gun 30, FIG. 1), and a second end portion 704b. The second end portion 704b of the second section 704 includes a clamp 708, similar to the clamp 400, configured to selectively, rotationally lock the second section 704 to the first section 702. The first end portion 702a of the first section 702 has a pair of seals 710 (e.g., O-ring seals) positioned thereabout, and the first end portion 704a of the second section 704 has a pair of seals 712 (e.g., O-ring seals) positioned thereabout.

The second end portion 702b of the first section 702 includes a first cylindrical body 706 having a reduced diameter relative to the first end portion 702a, and a second cylindrical body 714 extending axially from the first cylindrical body 706 and having a reduced diameter relative to the first cylindrical body 706. The first cylindrical body 706 has an outer surface along its length that includes a non-threaded (e.g., smooth) proximal section 716a positioned concentrically within the clamp 708, and a threaded distal section 716b. The second cylindrical body 714 may have an outer surface devoid of threading. The second cylindrical body 714 may define one or more annular depressions having a pair of seals 718 (e.g., one or more O-rings) received therein.

The second section 704 defines a counterbore therein that includes a first bore 720a having a first diameter, and a second bore 720b extending from the first bore 720a and having a second diameter smaller than the first diameter of the first bore 720a. The first bore 720a of the second section 704 is sized and configured for receipt of the first cylindrical body 706 of the first section 702, and the second bore 720b of the second section 704 is sized and configured for receipt of the second cylindrical body 714 of the first section 702.

The second end portion 704b of the second section 704 includes a threaded first inner surface 722a partially defining the first bore 720a, and a non-threaded second inner surface 722b extending axially from the threaded first inner surface 722a and defining the second bore 720b. As such, the first section 702 and the second section 704 of the alignment sub 700 are connected to one another with an internal threaded connection between the threaded distal section 716b of the first section 702 and the threaded first inner surface 722a of the second section 704. The clamp 708 has a non-threaded (e.g., smooth) inner surface 724 configured to contact and conform to the non-threaded proximal section 716a of the outer surface of the first cylindrical body 706.

With reference to FIG. 14, another embodiment of an alignment sub 800 is shown. The alignment sub 800 has multiple features in common with the alignment sub 100. Accordingly, only selected features of the alignment sub 800 will be described in detail hereinbelow. The alignment sub 800 generally includes a first section 802 and a second section 804 configured to receive and rotatably couple to the first section 802. The first section 802 has a first end portion 802a configured to be coupled to a first wellbore tool (e.g., first perforating gun 20, FIG. 1), and a second end portion 802b, and the second section 804 has a first end portion 804a configured to be coupled to a second wellbore tool (e.g., second perforating gun 30, FIG. 1), and a second end portion 804b. The second end portion 804b of the second section 804 includes a clamp 808, similar to the clamp 400, configured to selectively, rotationally lock the second section 804 to the first section 802.

The second end portion 802b of the first section 802 has an outer surface along its length that includes a non-threaded (e.g., smooth) proximal section 810a positioned concentrically within the clamp 808, a threaded distal section 810b, and a non-threaded intermediate section 810c positioned between the proximal section 810a and the distal section 810b. The intermediate section 810c may define one or more annular depressions having a pair of seals 812 (e.g., one or more O-rings) received therein. The second end portion 804b of the second section 804 includes a non-threaded proximal inner surface 814a configured to be positioned in contact with the intermediate section 810c of the outer surface of the first section 802, and a threaded distal inner surface 814b configured to threadedly couple to the threaded distal section 810b of the outer surface of the first section 802. As such, the first section 802 and the second section 804 of the alignment sub 800 are connected to one another with an internal threaded connection between the threaded distal section 810b of the first section 802 and the threaded distal inner surface 814b of the second section 804. The clamp 808 has a non-threaded (e.g., smooth) inner surface 820 configured to contact and conform to the non-threaded proximal section 810a of the outer surface of the first section 802.

This disclosure, in various embodiments, configurations and aspects, includes components, methods, processes, systems, and/or apparatuses as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. This disclosure contemplates, in various embodiments, configurations and aspects, the actual or optional use or inclusion of, e.g., components or processes as may be well-known or understood in the art and consistent with this disclosure though not depicted and/or described herein.

The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

In this specification and the claims that follow, reference will be made to a number of terms that have the following meanings. The terms “a” (or “an”) and “the” refer to one or more of that entity, thereby including plural referents unless the context clearly dictates otherwise. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. Furthermore, references to “one embodiment”, “some embodiments”, “an embodiment” and the like are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as “about” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Terms such as “first,” “second,” “upper,” “lower” etc. are used to identify one element from another, and unless otherwise specified are not meant to refer to a particular order or number of elements.

As used herein, the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur-this distinction is captured by the terms “may” and “may be.”

As used in the claims, the word “comprises” and its grammatical variants logically also subtend and include phrases of varying and differing extent such as for example, but not limited thereto, “consisting essentially of” and “consisting of.” Where necessary, ranges have been supplied, and those ranges are inclusive of all sub-ranges therebetween. It is to be expected that the appended claims should cover variations in the ranges except where this disclosure makes clear the use of a particular range in certain embodiments.

This disclosure is presented for purposes of illustration and description. This disclosure is not limited to the form or forms disclosed herein. In the Detailed Description of this disclosure, for example, various features of some exemplary embodiments are grouped together to representatively describe those and other contemplated embodiments, configurations, and aspects, to the extent that including in this disclosure a description of every potential embodiment, variant, and combination of features is not feasible. Thus, the features of the disclosed embodiments, configurations, and aspects may be combined in alternate embodiments, configurations, and aspects not expressly discussed above. For example, the features recited in the following claims lie in less than all features of a single disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this disclosure.

Advances in science and technology may provide variations that are not necessarily express in the terminology of this disclosure although the claims would not necessarily exclude these variations.

Claims

1. An alignment sub, comprising:

a first section having a first end portion configured to couple to a first wellbore tool, and a second end portion;
a second section having a first end portion configured to couple to a second wellbore tool, and a second end portion defining a cavity therein configured for receipt of the second end portion of the first section, wherein the first section and the second section are configured to rotatably couple to one another; and
a clamp configured to selectively lock the first and second sections to one another to prevent rotation of the first and second sections relative to one another.

2. The alignment sub of claim 1, wherein the first section defines a first central channel therethrough and the second section defines a second central channel therethrough, the first and second central channels collectively defining a single continuous channel through the alignment sub when the first and second sections are coupled to one another.

3. The alignment sub of claim 1, further comprising a screw configured to adjust a clamping force exerted by the clamp on the first section.

4. The alignment sub of claim 1, wherein the clamp is fixed to the second end portion of the second section and extends around an outer surface of the first section, the clamp being configured to frictionally retain the first section to the second section.

5. The alignment sub of claim 4, wherein the clamp and the second end portion of the second section define an annular gap extending axially therebetween, the annular gap extending only partially around a circumference of the alignment sub.

6. The alignment sub of claim 1, wherein the clamp includes:

a first circumferential portion fixed relative to the second end portion of the second section; and
a second circumferential portion movable relative to the first circumferential portion and the second end portion of the second section.

7. The alignment sub of claim 6, wherein the first circumferential portion and the second circumferential portion define a transverse gap therebetween.

8. The alignment sub of claim 7, wherein the first circumferential portion has an end defining a threaded first hole, and the second circumferential portion has an end that defines a second hole therethrough.

9. The alignment sub of claim 8, further comprising a screw configured for receipt in the second hole and configured to threadedly engage the threaded first hole such that rotation of the screw drives the end of the second circumferential portion toward the end of the first circumferential portion to contract the transverse gap.

10. The alignment sub of claim 1, wherein the cavity of the second section includes:

a first bore having a first diameter; and
a second bore extending from the first bore and having a second diameter smaller than the first diameter.

11. The alignment sub of claim 10, wherein the second end portion of the first section includes:

a first cylindrical body configured for receipt in the first bore, the first cylindrical body having a threaded outer surface configured to threadedly couple to a threaded inner surface of the second end portion of the second section; and
a second cylindrical body extending from the first cylindrical body and configured for receipt in the second bore.

12. The alignment sub of claim 1, further comprising a seal positioned radially between the second end portion of the first section and the second end portion of the second section.

13. The alignment sub of claim 1, wherein:

the first end portion of the first section has a threaded outer surface configured to threadedly couple to the first wellbore tool, and
the first end portion of the second section has a threaded outer surface configured to threadedly couple to the second wellbore tool.

14. The alignment sub of claim 1, wherein the clamp is integrally formed with the second end portion of the second section or attached to the second end portion of the second section.

15. The alignment sub of claim 1, further comprising a retainer configured for receipt in the first end portion of the second section, wherein the retainer is configured to threadedly couple to the second end portion of the first section to axially fix the first and second sections to one another.

16. An alignment sub for aligning a first wellbore tool with a second wellbore tool, the alignment sub comprising;

a first body portion having a first end portion configured to couple to a first wellbore tool, and a second end portion having a threaded outer surface; and
a second body portion having a first end portion configured to couple to a second wellbore tool, and a second end portion defining a cavity therein configured for receipt of the second end portion of the first body portion, the second end portion of the second body portion having a threaded inner surface configured to threadedly couple to the threaded outer surface of the second end portion of the first body portion, wherein the second body portion includes a clamp configured to selectively lock the first and second body portions to one another to prevent rotation of the first and second body portions relative to one another.

17. The alignment sub of claim 16, further comprising a screw configured to constrict the clamp about the second end portion of the first body portion.

18. The alignment sub of claim 17, wherein the screw is positioned radially outward of the second end portion of the first body portion.

19. The alignment sub of claim 17, wherein the clamp includes:

a first portion secured to the second end portion of the second body portion; and
a second portion positioned about the threaded outer surface of the first body portion, wherein the second portion of the clamp is configured to flex relative to the first portion and engage the threaded outer surface of the first body portion in response to the screw being fastened to the clamp.

20. The alignment sub of claim 16, wherein: the clamp has a threaded inner surface configured to engage the threaded outer surface of the second end portion of the first body portion.

the clamp is integrally formed with or coupled to the second end portion of the second body portion; and
Patent History
Publication number: 20260201781
Type: Application
Filed: Nov 30, 2023
Publication Date: Jul 16, 2026
Inventors: Stefan VOLBERG (Troisdorf), Benedikt FARTMANN (Sieburg)
Application Number: 19/136,124
Classifications
International Classification: E21B 43/119 (20060101); E21B 17/043 (20060101); E21B 43/116 (20060101);