INTELLIGENT CIRCULATION SYSTEM

Description

FIELD OF THE INVENTION

Embodiments of the present invention generally relate to advancements in circulation systems, focusing on enhanced efficiency, control, and safety mechanisms. Specifically, this invention pertains to the field of oil and gas drilling technology, encompassing a novel wellbore drilling tool that integrates sophisticated operational control systems, improved fluid management, and safety features. The invention is particularly applicable to the area of downhole tools and equipment used in drilling operations for oil and gas extraction, offering significant improvements over existing technologies in terms of operational efficiency, precise control of drilling functions, and enhanced safety measures.

BACKGROUND OF THE INVENTION

The present invention relates to improvements in circulation systems, particularly addressing the limitations and inefficiencies found in traditional drilling systems used in the oil and gas industry. Traditional drilling systems have utilized conventional methods for operating tools, primarily relying on the use of balls of different sizes to activate and deactivate valves. While these systems have been standard in the industry, they exhibit several drawbacks that can significantly impact drilling operations, especially in critical situations where every minute counts.

Drawbacks of Traditional Systems:

Time-Consuming Operations: The use of two different ball sizes for activation and deactivation of tools in traditional systems results in extended operational times. Each ball can take up to 30 minutes to reach its seat, and in emergency situations, this delay can exacerbate the problem.

Lack of Adjustable Shear Pressure: Traditional systems use standard-sized balls, which do not allow for adjustable shear pressure based on varying well conditions. This inflexibility often leads to situations where the tools do not activate appropriately due to mismatched conditions.

Absence of Mechanical Stop: In traditional systems, the absence of a mechanical stop for the balls can lead to situations where the balls bypass the intended seat without activating the necessary tools, often due to a misunderstanding of well conditions.

Weak Spring Mechanism: The reliance on weak springs with low preload force makes traditional tools less effective in retracting to their original position after deactivation.

Dependence on Drilling Fluid Weight: Traditional systems require different types of balls depending on the weight of the drilling fluid, adding complexity and limiting adaptability.

Limited Access for Other Tools: Conventional ball catcher designs in traditional systems do not allow other tools to pass through, regardless of their size, limiting operational flexibility in emergency situations.

Inefficient Utilization of Drilling Fluids: The use of multiple balls for a single cycle of operation leads to increased consumption of drilling fluids, which is both economically and environmentally undesirable.

Therefore, accordingly, there remains a need in the art for a well bore clean-out apparatus that can overcome the aforementioned problems. Therefore, there is a need for an intelligent circulation system.

SUMMARY OF THE INVENTION

According to an aspect of the present invention, there is provided an intelligent circulation system, the system comprises a main tool body, housing a main shaft, with three ports and a nozzle for fluid circulation, featuring a PIN and BOX connection for attachment to a drill string connected with a tool; a cam mechanism with an index pin, configured for controlled movement between open and closed positions of the tool; a wave spring on the main shaft, providing a retraction mechanism after tool operation; one or more ball bearings above and below the cam mechanism for smooth operation; a bullet mechanism, including a shear pin and a mechanical stop for activating and deactivating the tool using one or more bullets; a bullet catcher, disposed alongside the main tool body, having a specific profile for diverting the one or more bullets without obstructing operations of the tool; an internal seal system with inner and outer O-ring seals to maintain pressure inside a deflector; an intelligent communicator valve configured to control fluid flow and communicate with the surface equipment to adjust operational parameters dynamically.

In accordance with an embodiment of the present invention, the main tool body's three ports are designed for optimized fluid flow and debris removal during drilling operations.

In accordance with an embodiment of the present invention, the cam mechanism's index pin allows for precise positioning and stability of the tool in varying operational states.

In accordance with an embodiment of the present invention, the wave spring aids in maintaining the tool in an open position during drilling, enhancing operational efficiency.

In accordance with an embodiment of the present invention, the placement of ball bearings ensures reduced friction and wear during the tool's opening and closing movements.

In accordance with an embodiment of the present invention, the bullet catcher's special profile facilitates the safe and efficient diversion of bullets, maintaining unobstructed drilling pathways.

In accordance with an embodiment of the present invention, the bullet mechanism's shear pin and mechanical stop enable rapid activation or deactivation of the tool in response to drilling conditions.

In accordance with an embodiment of the present invention, the system featuring an internal seal system with robust O-ring seals to withstand high-pressure environments and prevent fluid leakage.

In accordance with an embodiment of the present invention, the nozzle in the main tool body is configured to optimize drilling fluid flow, contributing to the system's 50% efficiency improvement.

In accordance with an embodiment of the present invention, the nozzle fitted inside the main tool body is designed to enhance the directional flow of drilling fluids, improving cleaning efficiency.

In accordance with an embodiment of the present invention, the PIN and BOX connection of the main tool body facilitates quick and secure attachment to varying types of drill strings.

In accordance with an embodiment of the present invention, the cam mechanism is designed to facilitate easy transition between different operational modes under varying wellbore conditions.

In accordance with an embodiment of the present invention, the index pin of the cam mechanism is configured for enhanced durability and precise operational control.

In accordance with an embodiment of the present invention, the wave spring is designed for longevity and consistent performance under high-pressure drilling conditions.

In accordance with an embodiment of the present invention, the ball bearings are made of materials suited for high-stress and high-temperature drilling environments.

In accordance with an embodiment of the present invention, the bullet catcher includes an adjustable angle mechanism to handle varying sizes and types of bullets.

In accordance with an embodiment of the present invention, the bullet mechanism's shear pin is designed for quick release under predetermined pressure conditions.

In accordance with an embodiment of the present invention, the mechanical stop in the bullet mechanism is adjustable for varying operational requirements.

In accordance with an embodiment of the present invention, the system featuring a dual-layer O-ring seal system for enhanced sealing capability under extreme wellbore pressures.

In accordance with an embodiment of the present invention, the intelligent communicator valve is integrated for real-time monitoring and adjustment of drilling parameters.

In accordance with an embodiment of the present invention, the three ports of the main tool body are configured to allow for simultaneous multiple drilling operations.

In accordance with an embodiment of the present invention, the bullet catcher's special profile is adaptable to different drilling fluids and debris types.

In accordance with an embodiment of the present invention, the bullet mechanism includes an anti-jamming feature to ensure reliable operation in various drilling scenarios.

In accordance with an embodiment of the present invention, the nozzle is designed to be easily replaceable for maintenance and adaptability to different drilling requirements.

In accordance with an embodiment of the present invention, the main tool body is constructed from materials selected for their resistance to corrosion and wear.

In accordance with an embodiment of the present invention, the system featuring a modular design of the cam mechanism for easy maintenance and replacement.

In accordance with an embodiment of the present invention, the wave spring is adjustable to accommodate different drilling forces.

In accordance with an embodiment of the present invention, the ball bearings are sealed to prevent contamination from drilling fluids and debris.

In accordance with an embodiment of the present invention, the system incorporating a failsafe mechanism in the bullet catcher to prevent unintended release of bullets.

In accordance with an embodiment of the present invention, the internal seal system is designed for easy replacement to minimize downtime during drilling operations.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments. These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:

FIG. 1 illustrates an intelligent circulation system, in accordance with an embodiment of the present invention;

FIG. 2 illustrates a main tool body, in accordance with an embodiment of the present invention;

FIG. 3 illustrates a cam mechanism, in accordance with an embodiment of the present invention;

FIGS. 4A and 4B illustrate working of the cam mechanism having an index pin, in accordance with an embodiment of the present invention;

FIG. 5 illustrates a wave spring, in accordance with the present invention;

FIGS. 6A and 6B illustrate a bullet catcher, in accordance with the present invention;

FIG. 7A illustrates a bullet mechanism, in accordance with the present invention;

FIGS. 7B and 7C illustrate working of the bullet mechanism, in accordance with the present invention; and

FIGS. 8A and 8B illustrate a working example of the system, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description.

While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for case of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this description, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense, (i.e., meaning must). Further, the words “a” or “an” mean “at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as “including,” “comprising,” “having,” “containing,” or “involving,” and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term “comprising” is considered synonymous with the terms “including” or “containing” for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the like are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.

This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.

FIG. 1 illustrates an intelligent circulation system (100), in accordance with an embodiment of the present invention. As shown in FIG. 1, the intelligent circulation system (100) comprises a main tool body (103), a cam mechanism (106), a wave spring (110), one or more ball bearings (1040, 1041), a bullet mechanism (not shown in FIG. 1), a Bullet Catcher (200) (not shown in FIG. 1), an internal seal system (100) with inner and outer O-ring seals, (not shown in FIG. 1) and an intelligent communicator valve (not shown in FIG. 1).

FIG. 2 illustrates a main tool body, in accordance with an embodiment of the present invention. As shown in FIG. 2, the Main tool body (103) is the central structure of the system (100) with three ports (1030, 1031) and a nozzle for fluid circulation, which connects to the drill string via a PIN and BOX connection. In alternative embodiments, the main tool body (103) could have varying shapes and dimensions to accommodate different borehole sizes. The nozzle for fluid circulation could feature an adjustable design, where the flow pattern or size could be altered according to the drilling requirements. This could be achieved through mechanical adjustments or by using fluid dynamics control system. It could also feature modular sections for customizable assembly based on specific drilling tasks. The main tool body (103) houses other components and provides the primary pathway for fluid flow. The main tool body (103) acts as the chassis for the entire assembly. It physically houses the cam mechanism (106), wave spring (110), ball bearings (1040, 1041), and bullet mechanism. Its three ports (1030, 1031) are critical for the entry and exit of fluids, with the nozzle directing the flow as needed.

FIG. 3 illustrates a cam mechanism, in accordance with an embodiment of the present invention. Cam mechanism (106) with Index pin (108): The cam mechanism (106) is a mechanical linkage within the main tool body (103), and the index pin (108) is a component of this Cam mechanism (106) that engages with the cam to control its position. The cam mechanism (106) could be designed with multiple index pin (108) s for added stability, or it could incorporate electronic or hydraulic controls for remote operation. An alternative embodiment might replace the mechanical cam with a programmable servo-motor system (100) for automated position changes. FIGS. 4A and 4B illustrate working of the cam mechanism having an index pin, in accordance with an embodiment of the present invention. The cam mechanism (106) is designed to move between open and closed positions within the tool (112). The cam mechanism (106) with an index pin (108) is mounted inside the main tool body (103). As shown in FIGS. 4A and 4B, the index pin (108) interacts with grooves or notches on the cam mechanism (106), holding it in place or allowing it to move as required to change the tool's (112) position from open to closed.

FIG. 5 illustrates a wave spring, in accordance with the present invention. Wave spring (110): Located on the main shaft (102), as shown in FIG. 1, the wave spring (110) functions as a retraction mechanism. Instead of a wave spring (110), alternative embodiments might use a gas-charged accumulator to provide the necessary retraction force, which could be adjustable for different drilling pressures. This would allow for more precise control of the return force applied to the tool (112). After the tool (112) is operated, the wave spring (110) aids in returning it to its original position. The wave spring (110) surrounds the main shaft (102) and is compressed or expanded as the cam mechanism (106) moves. This spring action aids in returning the tool (112) to its starting position after the operation.

Coming back to FIG. 1, the Main shaft (102) is the core axial component around which the internal parts of the tool (112) are arranged. The main shaft (102) could be constructed from various high-strength, corrosion-resistant materials like titanium or non-metallic composites to reduce weight or enhance durability. Additionally, the shaft could have an expandable design allowing it to extend or retract to fit different tool lengths. The wave spring (110), cam mechanism (106), and other components are mounted on or interact with the main shaft (102). The main shaft (102) is the central axis of the tool (112), providing structural support for the cam mechanism (106) and the wave spring (110). It ensures the alignment of the internal components for proper functioning.

As shown in FIG. 1, the Ball Bearings (1040, 1041) are Positioned above and below the cam mechanism (106), these bearings (1040, 1041) allow for the smooth movement of the cam mechanism (106) and reduce friction during its operation. In other embodiments, ball bearings (1040, 1041) could be coated with advanced materials like diamond-like carbon to reduce wear, or they could be replaced with magnetic levitation bearings that reduce friction and maintenance requirements. Ball bearings (1040, 1041) are situated around the main shaft (102), above and below the cam mechanism (106). They facilitate the smooth rotation or movement of the cam mechanism (106), reducing wear and tear due to friction.

FIGS. 6A and 6B illustrate a bullet collector, in accordance with the present invention the bullet catcher (200) with a Special Profile: The Bullet Catcher (200) is designed to divert bullets (202) from the main flow path to a side pathway. The Bullet Catcher (200) could be designed with a variable-angle profile that can be adjusted in real-time to accommodate different types of bullets (202) or operational scenarios, using actuators or smart material that changes shape in response to electrical or thermal inputs. Its special profile is tailored to ensure that the bullets (202) do not obstruct operational functions. The Bullet Catcher (200) with a special profile is integrated into the main tool body (103). Its design allows it to catch and divert bullets (202) used in the operation without disrupting the flow of fluids or the functioning of other components.

Special Angle: The defining feature of the bullet catcher (200) is its special angle. This unique design aspect is crucial for its functionality. The angle is likely calculated to precisely control the path of the bullet (202), ensuring efficient and reliable operation.

Functionality: The primary role of the bullet catcher (200) is to divert the bullet (202) from the main pathway to a side pathway within the tool (112). This diversion is critical for maintaining the integrity and functionality of the system (100).

Operational Flexibility: A significant aspect of the bullet catcher's (200) design is that it allows for other operations to be carried out even when a bullet (202) is activated inside the catcher. This means that the bullet catcher's (200) operation does not hinder the overall functionality of the system (100) but rather complements it, ensuring smooth continuation of operations without interruption.

Unique Design, for example:

Shape: The bullet catcher (200) is conically shaped, differing from traditional cylindrical designs. This shape aids in smoothly guiding the bullet (202) away from the main flow path.

Material: It's made of a wear-resistant alloy that can withstand high pressures and abrasive materials common in drilling operations.

Mechanism: Inside the cone, there are spiral grooves that help in redirecting the bullet (202), adding a rotational motion to its path, which further aids in the diversion process.

Special Angle, for example:

Conical Angle: The cone's angle is specifically calculated to optimize the bullet (202)'s trajectory. For example, may be, but not limited to, a 45-degree angle might be chosen to balance between efficiently diverting the bullet (202) and maintaining fluid flow.

Groove Angles: The spiral grooves inside the cone have their angles calculated to impart just the right amount of spin to the bullet (202), ensuring it moves into the side pathway without clogging or damaging the tool (112).

Further, FIG. 7A illustrates a bullet mechanism, and FIGS. 7B and 7C illustrate working of the bullet mechanism, in accordance with the present invention. The bullet mechanism with Shear pin (2022) and Mechanical stop (2020): This mechanism is involved in activating and deactivating the tool (112). The bullet mechanism could feature electronic or magnetic release system (100) s for the bullets (202), which would allow for more precise control and reusability. An alternative mechanism might include a reusable locking system (100) that can be reset without replacing the shear pin (2022).

The Bullet mechanism with Shear pin (2022) and Mechanical stop (2020) is a uniquely designed system (100) that serves to activate and deactivate the drilling tool as needed. Here are the details:

Bullet (202): This component is part of the activation/deactivation mechanism within the drilling tool. It is designed to move into place to initiate a change in the tool's (112) operation, such as opening or closing a valve or switching the tool (112) from one mode to another.

Shear pin (2022): The shear pin (2022) is an integral part of the bullet mechanism. It is designed to hold the bullet (202) in place under normal operations. The shear pin (2022) will break under specific conditions—typically a predetermined level of force or pressure—to allow the bullet (202) to move and activate or deactivate the tool (112).

Mechanical stop (2020): Once the shear pin (2022) shears and the bullet (202) moves, the mechanical stop (2020) comes into play. This component such, as movable balls, or stoppers, sets the profile for the bullet (202)'s movement, preventing it from traveling beyond a certain point. This ensures precise control over the bullet (202)'s position, which is critical for the correct activation or deactivation of the tool (112).

O-Ring Seal and Pressure: The O-ring seal is involved in creating a pressure boundary within the tool (112). When the tool (112) needs to be activated or deactivated, the pressure against the O-ring seal may change, which could be part of the mechanism that determines when the shear pin (2022) breaks.

Spring and Cam mechanism (106): The components include a spring and cam mechanism (106) that are affected by the bullet (202)'s movement. The spring (110) likely provides the force needed to move the bullet mechanism, while the cam mechanism (106) would facilitate the shift from one position to another within the tool (112).

The bullet mechanism with the shear pin (2022) and mechanical stop (2020) is a critical safety and operational feature within the drilling tool, allowing for controlled activation and deactivation based on the specific pressures and forces encountered during drilling

The shear pin (2022) holds the bullet (202) in place under normal conditions, and the mechanical stop (2020) limits the bullet (202)'s movement during operation. The bullet mechanism with shear pin (2022) and mechanical stop (2020) interacts directly with the main tool body (103) and the bullet catcher (200). When the shear pin (2022) breaks, the bullet (202) is released, triggering the tool (112) to change states. The mechanical stop (2020) ensures that the bullet (202) only travels as far as necessary to activate or deactivate the tool (112).

Internal Seal System with Inner and Outer O-Ring Seals: This seal system ensures that the internal pressure is maintained and that fluid does not leak out of the main tool body (103). Alternative sealing systems may include magnetic fluid seals that provide a non-contact seal, reducing wear and eliminating leakage. Another embodiment could use shape-memory materials that self-adjust to maintain a perfect seal under varying pressure and temperature conditions. The internal seal system with inner and outer O-ring seals ensures the integrity of the fluid flow within the main tool body (103), preventing leaks and maintaining the pressure necessary for the tool's (112) operation.

Inner O-Ring Seal: This seal is likely positioned within the internal components of the system (100). Its primary function is to create a tight seal around the moving or stationary parts inside the tool (112), preventing internal fluid leakage and ensuring that the internal mechanisms operate efficiently and effectively.

Outer O-Ring Seal: The outer seal functions similarly to the inner seal but is located on the exterior interfaces of the system (100) components. This seal is crucial for preventing external contaminants from entering the tool (112) and for preventing the loss of drilling fluids or other materials from the tool (112) to the external environment.

The intelligent communicator valve: typically incorporates sensors and electronic controls. As an individual component, it is not simply a mechanical valve but a smart device capable of receiving, processing, and responding to data. As a standalone unit, this valve would likely include sensors to monitor various operational parameters such as pressure, temperature, and flow rate; actuators to adjust the valve's position and control the flow based on the received data; electronic Circuitry, to process signals from the sensors and execute commands based on pre-set algorithms or remote instructions; and communication Hardware, to facilitate data transmission to and from surface equipment. In terms of its connection with other components in the system (100), the intelligent communicator valve would be physically installed within the main tool body (103), typically in-line with the fluid flow path. It might be electronically connected to the cam mechanism (106) if the valve's operation is synchronized with the position of the cam. It could be associated with the internal seal system (100) since maintaining or adjusting pressure could be part of its function. The valve's actuation could be powered by the same power source that operates the wave spring (110) or other electronically controlled components. It may receive signals related to the position of the bullet mechanism to adjust fluid flow when the tool (112) is activated or deactivated. The valve's connectivity to these components involves physical placement and electronic integration but does not extend to their interrelated functions or operations. Components of the system (100) could be designed for easy interchangeability, allowing for rapid replacement or upgrading of parts such as the cam mechanism (106), Bullet Catcher (200), or nozzles without the need to disassemble the entire tool.

The invention works in following manner:

The working of the circulation system (100), as described in the independent and dependent claims, can be explained chronologically:

Connection and Initial Fluid Entry: The system (100) begins with the main tool body (103) attached to a drill string/tool via a PIN and BOX connection, suitable for various drill string types. Working fluid enters through the three ports (1030, 1031), designed for optimized fluid flow and debris removal. Here's a detailed explanation of this process:

Connection to the Drill String: The main tool body (103) of the circulation system (100) is designed to connect to the drill string. This connection is facilitated by a PIN and BOX mechanism. The PIN and BOX connection is a reliable method used in drilling operations. The ‘PIN’ refers to a male end (externally threaded), and the ‘BOX’ refers to a female end (internally threaded). This type of connection provides a robust and secure linkage that can withstand the stresses and strains of drilling operations. The design of this connection may be versatile, allowing compatibility with various types of drill strings. This versatility is crucial because drill strings can vary based on the specific requirements of each drilling operation, such as depth, borehole size, and the geological environment.

Initial Fluid Entry: Once the main tool body (103) is securely connected to the drill string, the working fluid begins its entry into the system (100). The working fluid (typically a drilling fluid or mud) enters through three ports (1030, 1031) located on the main tool body (103). These ports (1030, 1031) are strategically designed to optimize the flow of fluid into and through the system (100). The design of these ports (1030, 1031) focuses on maximizing fluid flow efficiency and facilitating the removal of debris. This is essential in drilling operations for several reasons:

Efficient fluid flow ensures that the drilling fluid can carry out its multiple roles effectively, such as cooling the drill bit, lubricating the drill string, and carrying drill cuttings out of the borehole.

Debris removal is critical to maintain the integrity of the drilling operation. The drilling fluid helps transport the cuttings and debris produced during drilling back to the surface. Efficient removal of this debris is crucial to prevent blockages, reduce wear on the equipment, and maintain the stability of the borehole.

The connection of the main tool body (103) to the drill string via a PIN and BOX connection and the subsequent entry of the working fluid through the optimized ports (1030, 1031) mark the commencement of the system's (100) s operation. This stage sets the foundation for the efficient functioning of the entire system (100), ensuring that the fluid can circulate effectively to support the drilling process.

Fluid Circulation and Direction: The fluid circulates through the tool (112), guided by a nozzle optimized for flow and cleaning efficiency.

Fluid circulation through the tool (112): Once the working fluid enters the system (100) through the three ports (1030, 1031) in the main tool body (103), it circulates throughout the tool (112). This circulation is crucial for several key drilling processes, including lubricating the drill bit, cooling the equipment, removing cuttings from the drill face, and stabilizing the wellbore walls. The efficiency and effectiveness of these processes depend heavily on how well the fluid is circulated within the tool (112) and the borehole.

Role of the Nozzle: An integral component in managing this fluid circulation is the nozzle that is part of the main tool body (103). The nozzle is not just a simple opening but a carefully designed feature optimized for specific flow characteristics. The design of the nozzle focuses on maximizing the fluid's directional flow, which is critical for ensuring that the drilling fluid reaches all necessary areas within the borehole and the tool (112). Proper directional flow aids in efficiently clearing debris and cuttings from the drill face and transporting them to the surface.

Contribution to Efficiency: The design and functionality of the nozzle contribute significantly to the overall efficiency of the system (100). By enhancing the directional flow of the drilling fluids and improving cleaning efficiency, the nozzle plays a key role in reducing operational time and the amount of drilling fluid required. This improvement in efficiency, as claimed, can lead to a 50% reduction in operational time and drilling fluid requirements compared to traditional systems. This level of efficiency is particularly valuable in drilling operations, where time and resource management are critical for economic and environmental reasons. The process of fluid circulation and direction in the circulation system (100), guided by an optimized nozzle, is a vital component that significantly enhances the system (100)'s overall efficiency.

Tool Operation Control: The cam mechanism (106), with an index pin (108), controls the tool's (112) movement between open and closed positions, ensuring precise positioning and stability.

Cam mechanism (106) Functionality: The cam mechanism (106) is a key component in the wellbore drilling tool, designed to control the movement of various parts of the tool (112), typically transitioning between open and closed positions. In drilling tools, these positions could refer to the activation or deactivation of certain functions like fluid flow control, cutting mechanisms, or other operational features. The cam mechanism (106) works by converting rotational movement into linear movement, which is a fundamental mechanical process to create controlled, precise motion in the tool (112).

Role of the Index pin (108): As shown in FIG. 3, an integral part of the cam mechanism (106) is the index pin (108). This component is crucial for ensuring the precise positioning of the cam, which in turn dictates the tool's (112) operational state. As shown in FIGS. 4A and 4B, the index pin (108) interacts with specifically designed grooves or notches on the cam. As the cam rotates, the index pin (108) follows these pathways, locking the cam into specific positions at the required times. This interaction is critical for the stability of the tool's (112) operational states, preventing unintentional shifts that could lead to operational failures or inefficiencies.

Transition Between Operational Modes: The system (100) is designed to operate under varying wellbore conditions, which could range from different pressures and temperatures to various geological formations. The cam mechanism (106), with its precise and durable design, allows for smooth transitions between different operational modes of the tool (112), adapting to these varying conditions. Such transitions might include adjusting the flow of drilling fluid, changing the pressure applied to the wellbore, or activating/deactivating specific cutting or cleaning functions.

Durability and Precision: The durability of the cam mechanism (106) is a critical feature, especially considering the harsh environments encountered in drilling operations. This durability ensures the system (100) remains reliable over extended periods and under challenging conditions. Precision in the control mechanisms of the cam mechanism (106) is essential for the tool's (112) effectiveness. Precise control allows for accurate adjustments to the tool's (112) functions, crucial for optimizing drilling operations and responding to real-time feedback from the drilling environment.

The tool (112) Operation Control stage of the circulation system (100), involving the cam mechanism (106) and index pin (108), is fundamental for the precise and stable operation of the tool (112). This system (100) enables the tool (112) to adapt seamlessly to varying operational needs, ensuring effective drilling under diverse wellbore conditions. The design's durability and precision are key to maintaining operational efficiency and safety throughout the drilling process. The system (100) can transition smoothly between different operational modes under varying wellbore conditions, thanks to its durable and precise control mechanisms.

Wave spring (110) Functionality: The wave spring (110) as shown in FIG. 1, on the main shaft (102) helps maintain the tool (112) in an open position during drilling and retracts it post-operation. The wave spring (110) is mounted on the main shaft (102) of the tool (112). This central location is strategic for the spring's (110) function. Its primary role is to maintain the tool (112) in an open position during drilling operations. The “open position” typically refers to a state where the tool's (112) internal mechanisms, such as valves or cutters, are active or engaged, allowing for effective drilling. Post-operation, which refers to the period after a specific drilling task is completed or when the tool (112) needs to be moved or adjusted, the wave spring (110) facilitates the retraction of the tool (112). This retraction might involve disengaging the active parts of the tool (112), moving them back to a neutral or closed position.

The design of the wave spring (110) as shown in FIG. 1 and FIG. 5, is key to its functionality. The wave springs (110) are known for their ability to provide a significant force in a compact space, which is particularly beneficial in the confined environment of a drilling tool. The spring's (110) material and construction are chosen to ensure longevity. This means that the spring (110) can withstand the wear and tear of repeated use, particularly under the high-stress conditions typical in drilling operations. Durability is crucial because any failure in the spring (110) could lead to operational downtime or even cause damage to the tool (112) or the wellbore.

Drilling operations can involve a wide range of pressures, depending on the depth, geological formations, and other factors. The wave spring (110) is designed to perform consistently across these varying pressures. Consistent performance is important for ensuring that the tool (112) operates as expected, regardless of the external pressure conditions. This consistency helps to prevent malfunctions that could arise from pressure fluctuations.

The wave spring's (110) adjustability is another critical feature. Different drilling scenarios may require different forces for the tool (112) to operate effectively. Being able to adjust the wave spring (110) means that the tool (112) can be adapted to different drilling conditions without needing to replace the spring (110) or make significant modifications to the tool (112). This adjustability enhances the versatility of the drilling tool, making it suitable for a wider range of drilling operations.

The wave spring's (110) functionality in the circulation system (100) is integral to the tool's (112) operation. Its ability to maintain the tool (112) in an open position during drilling and facilitate retraction post-operation, combined with its longevity, consistent performance, and adjustability, makes it a vital component in ensuring the tool's (112) efficiency, reliability, and adaptability in various drilling environments.

Ball Bearings (1040, 1041) and Movement Efficiency: The Ball bearings (1040, 1041) placed strategically around the cam mechanism (106) as shown in FIG. 1, reduce friction and wear, allowing smooth operation. Ball bearings (1040, 1041) are strategically positioned around the cam mechanism (106) in the drilling tool. The cam mechanism (106), responsible for controlling the tool's (112) movement, requires precise and smooth operation to function correctly. The placement of these bearings (1040, 1041) is critical in reducing friction between moving parts of the cam mechanism (106). By minimizing friction, the bearings (1040, 1041) enable the cam mechanism (106) to transition smoothly between different positions or states, essential for various drilling operations. The primary function of the ball bearings (1040, 1041) is to facilitate smooth movement by significantly reducing friction. This reduction in friction is crucial for several reasons such as It enhances the overall efficiency of the tool (112) by allowing mechanical components to move freely without unnecessary resistance. It reduces wear on the parts of the cam mechanism (106). Over time, friction can lead to the deterioration of mechanical components, which can cause malfunctions or the need for more frequent maintenance.

The materials used for these ball bearings (1040, 1041) are selected for their ability to withstand high-stress and high-temperature environments. Such environments are typical in drilling operations, where equipment is subjected to intense pressures and heat. High-stress resistance ensures that the bearings (1040, 1041) can withstand the physical forces exerted on them during drilling operations without deforming or breaking. High-temperature resistance is critical to maintaining the integrity of the bearings (1040, 1041) in the heated environment of deep wellbore drilling, where temperatures can rise significantly.

In addition to being made from robust materials, the ball bearings (1040, 1041) are sealed. This sealing is an important design feature for several reasons, such as, it protects the bearings (1040, 1041) from contamination by drilling fluids and debris. Contaminants can interfere with the smooth operation of the bearings (1040, 1041) and lead to premature wear or failure. The sealing also helps in maintaining the lubrication of the bearings (1040, 1041), essential for their smooth operation. Without proper lubrication, the bearings (1040, 1041) could seize up, leading to operational issues.

The ball bearings (1040, 1041) in the circulation system (100) play a crucial role in ensuring the smooth and efficient operation of the cam mechanism (106). Their strategic placement, design to reduce friction and wear, composition for high-stress and high-temperature environments, and sealing against contamination collectively contribute to the tool's (112) operational efficiency, reliability, and longevity. This careful design consideration is key to maintaining the performance of the drilling tool in the challenging conditions encountered during drilling operations.

Bullet mechanism and Activation: As shown in FIG. 6A, in accordance with the present invention, the bullet catcher (200), with a special profile, safely diverts bullets (202) without obstructing operations, adjustable for different fluid and debris types. The bullet mechanism, including a shear pin (2022) and mechanical stop (2020), activates or deactivates the tool (112) in response to drilling conditions. This mechanism is designed for quick release under specific pressures and includes an anti-jamming feature for reliable operation. The Bullet Catcher (200) is an integral part of the system (100) designed to interact with bullets (202)—small, specialized objects used to trigger certain operations within the tool (112). It features a “special profile,” which is a unique design aspect tailored to effectively guide and divert bullets (202) within the tool (112). This profile is critical for ensuring that the bullets (202) are directed to the correct location without obstructing the overall operation of the tool (112). The catcher's design allows it to adapt to different types of fluids and debris encountered in drilling operations. This adaptability is important because the presence of various fluids and debris can affect how bullets (202) move within the tool (112).

Bullet mechanism Functionality: FIG. 7A illustrates a bullet mechanism and FIGS. 7B and 7C illustrate working of the bullet mechanism, in accordance with the present invention. The bullet mechanism is a central component of the tool's (112) operation control system (100). It includes a shear pin (2022) and a mechanical stop (2020). As shown in FIG. 7B, the shear pin (2022) is a designed weak point in the mechanism. It holds the bullet (202) in place under normal conditions but is engineered to break under specific pressures. As shown in FIG. 7C when the appropriate pressure is reached, the pin shears, releasing the bullet (202) and thereby activating a particular function of the tool (112), such as changing the flow path of drilling fluids or engaging a cutting operation. The bullet (202) travels in the bullet (202) deflector (204) to a ball catcher inner sleeve as shown in FIGS. 6A and 6B. This way, the bullet (202) is moved from the main pathway to side pathway to allow any other operations. Other operation may include, but not limited to, operation of the cam mechanism (106) including changing of the position of the index pin (108) from the open position to close position and vice versa. The mechanical stop (2020) is a feature that controls how far the bullet (202) moves once the shear pin (2022) is broken. This ensures that the bullet (202) travels only the necessary distance to activate the tool's (112) function and no further, providing precision in the tool's (112) operation.

The system (100) uses a bullet (202) to change the tool's (112) flow path and toggle between closed and open positions. This mechanism is a key feature of the system (100), particularly in managing lost circulation issues in drilling operations. Let's break down the explanation:

Bullet (202) to Change Flow Path:

The system (100) employs a bullet mechanism to alter the internal flow path. The bullet (202) is a physical component that is dropped through the system (100). When the bullet (202) is in place, it changes the direction or path of the fluid flow within the tool.

Changing Tool from Closed to Open Position:

The initial position of the tool (100) is closed, where the ports are sealed, and no fluid flows through them.

Upon applying pressure (after dropping the bullet), the tool (112) shifts to the open position. This is facilitated by a cam mechanism (106) that responds to the pressure change. In the open position, the ports are unsealed, allowing fluid to flow through them.

Apply Pressure then Bleed Off Pressure to Shift Positions: Applying pressure is the action needed to move the tool from the closed to the open position. Once the necessary operation (like spotting heavy fluid) is completed, the pressure is bled off, or reduced, which triggers the tool to shift back to the closed position.

Bullet Shuts Off Flow Path to Operate Tools: The bullet (202), when initially dropped into the tool, serves to shut off the standard flow path, which is part of operating the tool. This closure forces the fluid to be diverted to a different path, enabling the opening of the tool.

Diver Fluid to Big Port for Spotting Heavy Fluid: The ‘big port’ refers to the high flow rate TFA (throat or flow area) of the system (100), which is larger than that of the standard drilling bit. When the tool is in the open position, the fluid is diverted to this big port. This diversion is critical for ‘spotting’ heavy fluid, particularly lost circulation material (LCM), which is used to address lost circulation issues during drilling.

In essence, this mechanism allows the system (100) to function as a contingency valve. The bullet, pressure application, and bleeding off pressure are integral to the tool's operation, enabling it to switch between closed and open states. This functionality is vital for managing lost circulation by allowing the controlled spotting of heavy fluids through the larger port when necessary.

Quick Release and Anti-Jamming Features: The bullet mechanism is designed for quick release under predetermined pressure conditions. This responsiveness is vital for timely activation or deactivation of tool functions in response to changing drilling conditions. An anti-jamming feature is incorporated to ensure the reliable operation of the mechanism. In the challenging environment of drilling operations, where various forces and materials are at play, the potential for jamming is a significant concern. The anti-jamming design mitigates this risk, ensuring that bullets (202) move as intended without getting stuck or causing malfunctions.

Failsafe Mechanism: A failsafe mechanism is incorporated into the bullet catcher (200) to prevent unintended release of bullets (202). This safety feature is critical to avoid accidental activation of the tool's (112) functions, which could lead to operational issues or safety hazards.

The bullet mechanism and catcher in the circulation system (100) represent an innovative approach to controlling the tool's (112) functions. The mechanism's ability to activate or deactivate based on specific conditions, combined with the catcher's specialized design for safely and effectively handling bullets (202), ensures precise operational control. These features, along with the quick-release, anti-jamming, and failsafe mechanisms, make the system (100) reliable and adaptable to various drilling scenarios.

Sealing and Pressure Maintenance: Internal seals, comprising inner and outer O-ring seals, maintain pressure and prevent fluid leakage, even under extreme pressures. The dual-layer seal system (100) is robust and designed for easy replacement to minimize operational downtime.

Internal Seals Composition: The drilling tool incorporates a system of internal seals, consisting of both inner and outer O-ring seals. These seals are crucial for creating airtight and fluid-tight barriers within the tool (112).

O-ring seals are simple yet highly effective sealing mechanisms. They are usually made from elastomeric materials, which allow them to maintain their shape and sealing capabilities under pressure and temperature fluctuations. The choice of material for these O-rings is critical. It must be resistant to the chemicals in drilling fluids and durable enough to withstand the wear and tear of drilling operations.

Pressure Maintenance: One of the primary functions of these seals is to maintain pressure within the tool (112). In drilling operations, maintaining the correct pressure is crucial for the tool's (112) effectiveness and the safety of the operation. Proper pressure maintenance ensures that the tool (112) functions as expected, whether it's for drilling, fluid circulation, or any other operation that requires precise pressure control.

Prevention of Fluid Leakage: Another crucial function of these seals is to prevent the leakage of fluids. This includes both the prevention of drilling fluids leaking out of the tool (112) and the prevention of external fluids (like groundwater) from entering the tool (112). This sealing capability is particularly important to protect the internal components of the tool (112) from contamination and to prevent environmental contamination by the drilling fluids.

Dual-Layer Seal System (100): The seal system (100) employs a dual-layer configuration, enhancing its effectiveness. This might involve two sets of O-ring seals arranged in such a way to provide redundant sealing protection, thereby increasing the reliability of the system (100). The dual-layer system (100) ensures that even if one layer fails or degrades, the second layer can continue to provide the necessary sealing, maintaining the tool's (112) operational integrity.

The sealing and pressure maintenance system (100) in the wellbore drilling tool plays a vital role in ensuring the tool's (112) operational efficiency and safety. The internal seals, especially the inner and outer O-ring seals, are designed to withstand extreme pressures and prevent fluid leakage. The dual-layer arrangement of these seals provides an added layer of protection and reliability.

Intelligent Communication and Adjustment: The intelligent communicator valve controls the flow of the working fluid and communicates with surface equipment. This valve dynamically adjusts operational parameters based on real-time monitoring, enhancing efficiency. This component is a key innovation in the system (100). The intelligent communicator valve serves two primary functions:

Control of Working Fluid Flow: The valve regulates the flow of the drilling fluid (or working fluid) through the tool (112). This regulation is crucial for various operations such as cooling the drill bit, removing cuttings from the wellbore, and maintaining pressure.

Communication with Surface Equipment: Besides fluid control, the valve is equipped with communication capabilities that allow it to send and receive data to and from surface equipment. This communication is vital for real-time monitoring and adjustment of drilling operations.

Dynamic Adjustment of Operational Parameters: The valve's ability to dynamically adjust operational parameters based on real-time monitoring is a significant advancement. It can alter the flow rate, pressure, and other critical parameters in response to changing conditions in the wellbore or based on instructions from the surface.

This dynamic adjustment leads to enhanced efficiency. For instance, it can optimize fluid flow for maximum cutting removal or adjust pressure to prevent wellbore collapse, thereby improving the overall efficiency and safety of the drilling process.

Multiple Operations and Fluid Flow: The main tool body (103)'s ports (1030, 1031) allow for simultaneous multiple drilling operations, maximizing utility and productivity. The main tool body (103) is equipped with multiple ports (1030, 1031), which are integral to the system (100)'s functionality.

Simultaneous Multiple Drilling Operations: These ports (1030, 1031) allow for the execution of simultaneous multiple drilling operations. This means that various functions such as drilling, fluid circulation, and measurement can occur concurrently. The ability to perform multiple operations simultaneously greatly enhances the utility and productivity of the tool (112). It reduces the time needed to complete various tasks, as these can be done in parallel rather than sequentially.

Maximizing Utility and Productivity: The combined effect of these ports (1030, 1031) is a significant increase in the system's (100) efficiency. By enabling multiple processes to occur at the same time, the tool (112) maximizes its utility and productivity, leading to more efficient drilling operations. This feature is particularly beneficial in complex drilling operations where time is a critical factor, and multiple tasks need to be managed concurrently.

Failsafe Mechanisms: The Bullet Catcher (200) incorporates a failsafe mechanism to prevent unintended release of bullets (202), adding a layer of safety and reliability to the system (100).

Bullet Catcher (200) Functionality: The Bullet Catcher (200) is a component within the drilling tool that interacts with bullets (202), which are small devices used to trigger certain operations or changes within the tool (112). The primary function of the bullet catcher (200) is to guide and control the movement of these bullets (202) to ensure they activate the tool's (112) functions at the correct time and in the correct manner.

The failsafe mechanism involves a secondary locking or restraining system (100) within the bullet catcher (200). This failsafe mechanism is designed to hold the bullet (202) securely in place under normal conditions. The mechanism would only allow the release of the bullet (202) when specific, intentional conditions are met. These conditions could be related to the pressure, temperature, or other parameters that are precisely controlled during drilling operations. In the event of a malfunction or abnormal operation within the tool (112), the failsafe mechanism ensures that the bullets (202) remain securely held, preventing any unintended activation of the tool's (112) functions.

For example, the drilling operation encounters sudden pressure changes due to unexpected geological formations. The primary system (100) might mistakenly interpret this as the cue to release the bullet (202). However, the failsafe mechanism recognizes that other conditions (like the correct temperature or tool orientation) are not met and thus overrides the primary cue, keeping the bullet (202) secured and preventing unintended activation of the tool's (112) function. As a result, despite the irregular pressure fluctuation, the tool (112) continues to operate safely without prematurely changing its operational state. The drilling operation can then be adjusted or halted as necessary to assess and respond to the unexpected change in conditions.

Working example: FIGS. 8A and 8B illustrate a working example of the system (100), in accordance with an embodiment of the present invention. provides information about the working of the Intelligent Circulation System (ICS) as a contingency valve in drilling and milling operations, specifically focusing on its operation in both open and closed states. Let's break down the working of this invention by referring to the images illustrating the closed and open port configurations.

The system in Closed Configuration, FIG. 8A illustrates the system in closed configuration.

Closed State Functionality: When the system (100) is in the closed state, the tool (112) functions as part of the drilling or milling bottom hole assembly. In this state, the tool maintains a closed port, preventing the flow of fluids through it. Flow of the fluid is shown in FIG. 8A using arrows.

High Flow Rate TFA: The tool (112) is designed with a high flow rate through the throat or flow area (TFA), but this high flow rate is not utilized in the closed state.

Contingency Valve Role: As a contingency valve, the system (100) remains closed during normal drilling operations until a specific need arises, such as dealing with lost circulation.

The system (100) in Open Configuration, FIG. 8B illustrates the system (100) in open configuration.

Opening Mechanism: To transition from the closed to the open state, a bullet is dropped through the tool, and pressure is applied. This action engages a cam mechanism (106) that opens the port of the tool (112).

Dealing with Lost Circulation: Once the port is open, the high flow rate TFA becomes functional. This is crucial for spotting lost circulation material (LCM) in the formation when loss of circulation occurs.

Spotting LCM: With the port open, the operator can spot LCM to secure the losses. The doubled TFA compared to the drilling bit facilitates efficient spotting and securing of LCM. Flow of the fluid is shown in FIG. 8B using arrows.

Closing and Resuming Drilling: After the lost circulation issue is managed, the port is closed again using the cam mechanism (106). This allows for the resumption of normal drilling operations.

The tool's (112) functionality revolves around its ability to switch between open and closed states. In the closed state, it is part of the regular drilling assembly, while in the open state, it actively combats lost circulation issues by allowing for the efficient spotting and securing of LCM. This transition is facilitated by a bullet and cam mechanism (106), emphasizing the tool's role as a contingency valve that can adapt to changing drilling conditions. The images in the document likely illustrate these two states, showing the mechanical changes in the tool as it switches between closed and open configurations.

The invention has various advantages.

Enhanced Efficiency and Resource Utilization: The system's (100) design, especially with the optimized nozzle and fluid control mechanisms, significantly improves the efficiency of drilling operations. By enhancing the directional flow of drilling fluids and improving cleaning efficiency, the system (100) reduces the operational time and drilling fluid requirements by up to 50% compared to traditional systems. This improvement in efficiency means less waste of resources, reduced operational costs, and a smaller environmental footprint.

Precise Operational Control: The incorporation of a cam mechanism (106) with an index pin (108) allows for precise control over the tool's (112) operation, enabling smooth transitions between different operational modes under varying wellbore conditions. This precision leads to more effective drilling and the ability to handle complex drilling scenarios that prior art may not manage as efficiently.

Improved Safety and Reliability: The Bullet Catcher (200) with its special profile and the bullet mechanism with a shear pin (2022) and mechanical stop (2020) add a significant layer of safety and reliability. The failsafe mechanism in the bullet catcher (200) prevents unintended release of bullets (202), reducing the risk of operational errors or accidents.

The robust internal seal system (100) with dual-layer O-ring seals ensures that the tool (112) maintains integrity under high-pressure environments, preventing fluid leakage and potential equipment failure.

Adaptability and Versatility: The system's (100) ability to perform multiple operations simultaneously, as enabled by the main tool body (103)'s multiple ports (1030, 1031), offers greater versatility and utility. This feature allows for a more productive drilling operation, as different processes can be conducted concurrently. The intelligent communicator valve's capacity to dynamically adjust operational parameters based on real-time data makes the system (100) adaptable to a wide range of drilling conditions and scenarios.

Durability and Easy Maintenance: The wave spring (110), ball bearings (1040, 1041), and other critical components are designed for longevity and consistent performance, even under the demanding conditions of drilling operations. This durability translates to fewer maintenance requirements and longer operational life. The modular design of key components like the cam mechanism (106) and the nozzle, along with easily replaceable seals, ensures that maintenance, when required, is straightforward and minimizes operational downtime.

Environmental Impact: By reducing the amount of drilling fluid required and optimizing operational time, the system (100) minimizes environmental impact. Efficient use of resources and reduced waste are critical considerations in modern drilling operations, making this system (100) more environmentally friendly compared to traditional methods. The described circulation system (100) offers a comprehensive set of technical advancements that enhance efficiency, safety, control, and adaptability. These improvements position the system (100) as a significant advancement over existing prior arts in drilling technology.

Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.