CA2921572A1 - Mud valve apparatus - Google Patents

Abstract

A mud saver apparatus comprising a housing having a first end, a second end, and an interior surface defining a passage through the housing between the first end and the second end. A
shuttle is slidably disposed in the passage against the interior surface for movement in response to one or more fluid flow characteristics in the passage. At least one spring is positioned between the shuttle and a first shoulder defined in the surface to urge the shuttle away from the second end. A valve member is positioned between the seat and the shuttle, and abutting the shuttle distal from the second end. A seat is operationally positioned between the valve member and the second end, and slidably disposed in the passage against the interior surface for movement in response to the fluid flow characteristics, wherein the valve member shaped and configured to mate and seal with the seat.

Description

MUD VALVE APPARATUS
Field:
[1],This disclosure relates to a mud check apparatus for use in drilling operations.
Background:

[2].In the oil and gas industry, holes are drilled in the earth to obtain deposits of, for example, hydrocarbon-bearing formations. In known drilling operations, a drill bit is operationally affixed at one end of a grouping, or "string," of pipe segments.
The bit may in some oases be rotated from the surface, and in others, from a location closer to or adjacent the bit. Drilling fluid or, as known in the art, "mud," is generally pumped from the drilling site, through the string, to exit at or adjacent the operational drill bit.
Mud serves multiple purposes, including pressure control, prevention of unauthorized fluid entry into well bore, drill bit temperature control, and cuttings removal and suspension, as is well known in the art.

[3]. As mud returns to the surface, it typically includes cuttings that travel away from the bit.
Problems occur when gathered mud restricts the flow to the surface. Drilling rigs may include a square or hexagonal pipe, which may be referred to as a "Kelly,"
which is rotated to rotate the string. Between the Kelly and the pipe may be what is commonly referred to as a "mud saver," which includes a valve which functions to close when the drill string is unscrewed. This serves to stop the flow of mud (e.g., when adding pipe segments).

141. Mud valves are used in order to prevent the spilling of drilling mud when opening up a drill pipe string, operating in a manner generally analogous to placing a finger over the end of a fluid filled drinking straw. By stopping drilling mud from spilling out of the drill string, a mud valve not only saves valuable drilling mud, but drastically reduces the environmental impact of spilling drilling mud as well, and minimizes occurrences of safety issues associated with personnel having to work in slippery and/or caustic mud.
[5].Known varieties of mud valves include, as examples, plunger designs, flapper designs and hydraulically actuated models. Hydraulically actuated models, while comparatively effective, are complex. As such, repairs, service or replacement causes substantial downtime and lost productivity. Further, the complex nature of such devices results in an increased likelihood of malfunction, and necessitates a higher level of expertise to complete repairs or replacements. In addition, these more complex devices are more costly to fabricate and, accordingly, purchase. Further, such devices remain unreasonably prone to failure (e.g., blockage when flow is desired, flow when blockage is desired, or inability to safely purge surges in pressure).
[6].In a production focused environment, cost and reliability of equipment is extremely important as the losses incurred through downtime typically have a financial impact which far outweighs the cost of the equipment that failed.
[7].As such, there exists a need to provide an Unproved mud saver valve, thereby alleviating or eliminating one or more of the aforementioned problems with or shortcomings of the prior art.

SUMMarr [8], There is disclosed herein a mud saver apparatus comprising: a housing having a first end, a second end, and an interior surface defining a passage through the housing between the first end and the second end; a shuttle slidably disposed in the passage, against the interior surface for movement in response to one or more fluid flow characteristics in the passage; at least one spring positioned between the shuttle and a first shoulder defined in the surface to urge the shuttle away from the second end; a valve member positioned between the seat and the shuttle, and abutting the shuttle distal from the second end; a seat operationally positioned between the valve member and the first end, and slidably disposed in the passage against the interior surface for movement in response to the fluid flow characteristics, wherein the valve member shaped and configured to mate and seal with the seat; a second shoulder defined in the surface for stalling movement of the seat towards the first end; one or more stop members for stalling movement of the seat towards the second end.
[9].In another disclosed aspect, when the fluid flow characteristic is normal flow from the first end to the first end, and the seat is urged away from the second end to abut the stop members and the shuttle is urged against the spring to provide the passage in an open configuration.
[10]. In another disclosed aspect, when the fluid flow characteristic is substantially no flow from the first end to the first end, the seat is urged to mate and seal with the valve member to close the passage.

[11]. In another disclosed aspect, the apparatus further comprises a plurality of sealing members interposed between each of the seat, the shuttle arid the surface.
[12]. In another disclosed aspect, the shuttle has an inner surface defining and opening therethrough, and an outer surface having formed thereon a ridge for engagement with the spring.
[13]. In another disclosed aspect, the ridge is formed substantially adjacent a first end of the shuttle.
[14]. In another disclosed aspect, the ridge has formed therein one or more ports for positioning one or more of the sealing members.
[15]. In another disclosed aspect, the valve member is attached to the shuttle at the first end thereof.
[16]. In another disclosed aspect, the apparatus further comprises a shuttle sleeve interposed between the shuttle and the surface, wherein the stop members are formed in the shuttle sleeve.
[17]. In another disclosed aspect, the stop members are integral to the housing.
[18]. In another disclosed aspect, the seat and the shuttle are positioned and oriented for movement along a common axis.

4 Drawings:
[19]. Figure 1 is a perspective view of an apparatus as disclosed herein.
[20). Figure 2 is an exploded view of the apparatus of Figure 1.
[21]. Figure 3A is a sectional view along line A-A of Figure 1, with the apparatus in an open position.
[22]. Figure 3B is a sectional view along line A-A of Figure 1, with the apparatus in a closed position.
[23]. Figure 3C is a sectional view along line A-A of Figure 1, with the apparatus in a pressure protection position.
Detailed Description [24]. There is provided a mud saver apparatus 100 including a housing 101, as shown in Figure 1. The housing 101, which may be composed of various metals, and shaped as needed for the given application, has a first end 102 and a second end 104.
The housing 101 functions as its name suggests, as the exterior casing of the apparatus 100.
The ends 102, 104 of the housing 101 hub may be altered to or provided with various pipe threads (not shown) as may be required in a particular industry or application. In operation, the apparatus 100 is attached to a drill kelly (not shown, e.g., at the first end 102) and drilling pipe (not shown) at the other (i.e., the second end 104).

[25]. An interior surface 106 of the housing 101 defines a passage 108 through the housing 101, between the first end 102 and the second end 104. While shown in Figures 3A-3C as being substantially annular and having a cross-sectional area decreasing in stepped increments moving from the first end 102 to the second end 104, the passage 108 need not necessarily be so shaped.
[26]. A shuttle 110 is provided, as shown in Figure 2, and, as shown in Figures 3A-3C, is slidably disposed in the passage 108. Looking more specifically to Figures 3A-3C, the shuttle 110 slidably engages with the interior surface 106 of the housing 101.
The shuttle 110 may preferably be constructed by way of machining, and may, in some embodiments, include multiple pieces. The shuttle 110 is adapted. for reciprocal movement along the primary axis of the housing 101 (i.e., substantially parallel to arrow C in Figure 3B).
Gaskets 112 may be provided to facilitate such sliding engagement and limit wear of the shuttle 110 and the surface 106, Similar wipes, sealing members or gaskets 112 (which terms are used interchangeably) may be provided at other surface to surface interfaces, with similar goals (as shown in Figures 2, 3A-3C). For example, a plurality of gaskets 112 may be provided, interposed between each of the seat 120, the shuttle 110 and the surface 106.
As will be described in greater detail below, movement and positioning of the shuttle 110 is dictated by one or more fluid flow characteristics in the passage 108.
[27]. The shuttle 110 has an inner surface 115a defining an opening 113 therethrough, and an outer surface 115b having formed thereon a ridge 117 for engagement with a spring 114. The shaping of the ridge 117 may vary, and the ridge 117 may be formed integrally with or attached to the shuttle 110. In some embodiments, and as shown in Figures 3A-3C, the ridge 117 is formed substantially adjacent a first end 119 of the shuttle 110.
The ridge 117 has formed in it one or more ports 121 for positioning one or more gaskets 112.
[28]. The spring 114 is provided, as discussed generally above and, positioned between the shuttle 110 and a first shoulder 116 defined in the surface 106, so as to urge the shuttle 110 away from the second end 104 of the housing 101. The strength of the particular spring(s) 114 used will be dictated by constraints of the particular application.
[29]. A valve member 118 is provided, and operatively positioned between a seat 120 and the shuttle 110; more particularly, substantially abutting the shuttle 110 at a position distal from the second end 104 of the housing 101, [301 The seat 120 is operationally positioned between the valve member 118 and the first end 102 of the housing 101. The seat 120 is also sliclably disposed, in a manner similar to the shuttle 110, in the passage 108, against the interior surface 106. The seat 120 also moves and is positioned in response to the fluid flow characteristics, as will be discussed below in more detail. The valve member 118 is shaped and configured to mate and seal with the seat 120. Movement of the seat 120 towards the first end 102 of the housing 101 will be stopped by a second shoulder 122 defined in the surface 106, or as provided on a shuttle sleeve 124 positioned adjacent the surface 106. The valve member 118 may preferably be composed of tungsten carbide, This valve member 118 is readily replaceable, as such a component can be expected to wear out over time; it may be easily replaced in the field by, for example, loosening two fasteners 123 (see Figure 2) and installing a new or replacement valve member 118.

[31], The stop members 126 are provided on the surface 106 or on the sleeve 124 to stop movement of the seat 120 towards the second end 104. The second shoulder 122 and the , stop member 126 will be located in positions suitable to allow a specific amount of travel of the seat 120. The valve member 118 is attached to the shuttle 110 at the first end 119 thereof, to facilitate engagement with the seat 120, [32]. Each of the shoulder 122 and stop members 126 may, in some embodiments, be formed substantially annularly in shape and may extend along the entirety of the circumference of the passage 108, The shoulder 122 may be formed integrally with the housing 101 or may be affixed thereto. The seat 120 and the shuttle 110 are preferably positione1 and oriented for axial movement along a common axis.
[33]. In use, the apparatus 100 has three functional positions. Looking first to Figure 3A, operationally, when drilling mud (not shown; but a direction of pumping is indicated by arrow B) is being pumped into the production pipe (not shown), the apparatus 100 is in an "open" position so as to allow the mud to flow through, This may be characterized as when the fluid flow characteristics (which refers to fluid that may pass in either direction through, or be down stream, or upstream from, the apparatus 100), is normal flow, i.e., from the first end 102 to the second end 104 (again, per arrow B). The seat 120 is urged towards the second end 104 to abut the stop members 126, and the shuttle 110 is urged against the spring to provide the passage 106 in an open configuration. Mud flow effectively pushes the seat 120 against stops 126 on the sleeve 124, and mud flow pushes the shuttle 110 open against the spring 114 and towards the second end 104. This configuration, best shown in Figure 3A, may be characterized as the normal operation position wherein mud is pumped through the apparatus 110 and into the drilling string.
[34]. When drill pipe is being disconnected, the apparatus 100 is in a "closed" position, as shown in Figure 33, to prevent mud front syphoning out of the production pipe. When the fluid flow characteristics is substantially no flow from the first end 102 to the second end 104, the seat 120 is urged to mate and seal with the valve member 118 to close the passage 106, As best shown in Figure 3B, the syphon (represented by arrow C) pulls the seat 120 against the valve member 118 preventing mud spillage. The mud in the drill string (not shown) creates a vacuum which pulls the seat 120 against the valve member 118 while the spring 114 pushes the shuttle 110 against a stop on the sleeve, The drilling string is thereby sealed, preventing mud from exiting the bottom of the drill string, 1351 If in the closed position and a down-hole (i.e., downstream from the second end 104) pressure event occurs, a "pressure protection" position (see Figure 3C) allows what is referred to in the art as, for example, a "burp," to be released. When the fluid flow characteristic is from the second end 104 to the first end 102, the seat 120 is urged to abut the second shoulder 122. Gas pressure moves the seat 120 against the stop. The sleeve stops shuttle 110 movement. If such a down-hole pressure event occurs, the apparatus reactively and automatically positions its components to relieve the pressure.
The seat 120 is forced against the second shoulder 122, while shuttle 110 travel is limited by the sleeve 124.
In this position the apparatus is effectively open but for the purpose of gas freely flowing to relieve pressure, [361, The spring 114 functions to counteract the vacuum effectively applied by the weight of the downstream drilling mud (not shown) when the apparatus 100 is in the closed position. The apparatus 100 is configured such that the spring 114 does not come into contact with the mud, which is typically erosive I corrosive. The shuttle 110 functions to: a) open and close the valve 118 by moving up and down (i.e., in axial directions C or D), thus either forcing the valve member 118 against the seat 120 (i.e., the "closed"
position, best shown Figure 3B) or by moving the valve member 118 away from the seat 120 (e.g., the "open"
position, best shown in Figure 3A); and, b) to direct the drilling mud from the hub area into the middle of the shuttle (and, subsequently, into the production drill pipe).
[37]. The sleeve 124 serves to limit the travel of the shuttle 110 towards the first end 102, as shown in Figure 3C. This limitation of travel is of critical importance in allowing the apparatus 100 to serve to provide pressure protection. The sleeve 124 also limits the travel of the seat when the apparatus 100 is in the open position (as shown in Figure 3A).
[38]. Limitation of seat 120 travel is required to ensure that mud pressure can easily unset the valve member whilst ensuring pressure protection. In addition to these functions, as the area at which the sleeve is employed is one highly susceptible to wear, not placing the sleeve would increase frequency of service and replacement due to such wear, Instead, the sleeve 120 is suitable for simple, quick and inexpensive field repair, limiting production downtime.
[39]. The seat 120 is provided and transitions into its required position via interactions with other componentry based on the forces mud flow; vacuum) acting on the overall apparatus 100. This part is one that will wear over time but may be readily and easily field replaced. In some embodiments it may be provided with a tapered edge so as to facilitate direction and flow of fluids through it.
[401. The disclosed apparatus 100 exhibits the level of functionality required in mud valves but has, in essence, only two moving parts. This facilitates easy manufagture, repair and replacement, without sacrificing performance (i.e., switching to the various operating positions in a completely automatic and responsive manner).
[41]. Various components of the apparatus may be manufactured, for example, via machining and other known methods. The hub, for example, may be composed of a various materials, typically steel, with strength and corrosion resistance properties suitable for the given application.
(421, The valve member 118 can be manufactured of various steels and by most industrial machine shops, for example using known equipment and skills. The shuttle 110 can be manufactured via Computerized Numerical Control (CNC) machining equipment and the skills required to program and operate same, [43], Embodiments of the disclosed apparatus may be provided in various sizes (e.g., cross-sectional areas, lengths, and angles) depending on the needs of the particular application in which the apparatus is to be employed. This would allow for use in respect of different mud flow ranges and pipe size requirements.
[44 While various embodiments in accordance with the principles disclosed herein have been described above, it should be understood that they have been presented by way of example only, and are not limiting. Thus, the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents issuing from this disclosure.
Furthermore, the above advantages and features are provided in describecl embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages.
[45], It will be understood that the principal features of this disclosure can be employed in various embodiments without departing from the scope of the disclosure.
Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this disclosure and are covered by the claims, [46]. Additionally, the section headings herein are provided as organizational cues.
These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure, Specifically and by way of example, although the headings refer to a "Field," such claims should not be limited by the language under this heading to describe the so-called technical field. Further, a description of technology in the "Background"
section is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the "Summary" to be considered a characterization of the Invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to "invention" in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.
[47]. The use of the word "a" or "an" when used in conjunction with the term "comprising" in the claims and/or the specification may mean "one," but it is also consistent with the meaning of "one or more," "at least one," and "one or more than one."
The use of the term "or" in. the claims is used to mean "and/or" unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and "and/or," Throughout this application, the term "about" is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.
[48]. As used in this specification and claim(s), the words "comprising" (and any form , of comprising, such as "comprise" and "comprises"), "having" (and any form of having, such as "have" and "has"), 'including" (and any form of including, such as "includes" and "include") or "containing" (and any form of containing, such as "contains" and "contain") are inclusive or open-ended and do not exclude additional, un-recited elements or method steps.
[49], All of the apparatuses disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this disclosure have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and. scope of the disclosure. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the disclosure as defined by the appended claims.

Claims (12)

Claims:

1. A mud saver apparatus comprising:
a housing having a first end, a second end, and an interior surface defining a passage through the housing between the first end and the second end;
a shuttle slidably disposed in the passage against the interior surface for movement in response to one or more fluid flow characteristics in the passage;
at least one spring positioned between the shuttle and a first shoulder defined in the surface to urge the shuttle away from the second end;
a valve member positioned between the seat and the shuttle, and abutting the shuttle distal from the second end;
a seat operationally positioned between the valve member and the first end, and slidably disposed in the passage against the interior surface for movement in response to the fluid flow characteristics, wherein the valve member shaped and configured to mate and seal with the seat;
a second shoulder defined in the surface for stalling movement of the seat towards the first end;
one or more stop members for stalling movement of the seat towards the second end.

2. An apparatus according to claim 1, wherein when the fluid flow characteristics is normal flow from the first end to the second end, the seat is urged away from the second end to abut the stop members and the shuttle is urged against the spring to provide the passage in an open configuration.

3. An apparatus according to claim 1, wherein when the fluid flow characteristics is substantially no flow from the first end to the second end, the seat is urged to mate and seal with the valve member to close the passage.

4. An apparatus according to claim 1, wherein when the fluid flow characteristics is from the second end to the first end, the seat is urged to mate and seal with the valve member and the seat is urged to abut the second shoulder,

5. An apparatus according to any one of claims 1 to 4, further comprising a plurality of sealing members interposed between each of the seat, the shuttle and the surface.

6. An apparatus according to claim 1, wherein the shuttle has an inner surface defining and opening therethrough, and an outer surface having formed thereon a ridge for engagement with the spring.

7. An apparatus according to claim 6, wherein the ridge is formed substantially adjacent a first end of the shuttle.

8. An apparatus according to any one of claims 5 to 7, wherein the ridge has formed therein one or more ports for positioning one or more of the sealing members,

9. An apparatus according to any one of claims 6 to 8, wherein the valve member is attached to the shuttle at the first end thereof.

10. An apparatus according to claim 1, further comprising a shuttle sleeve interposed between the shuttle and the surface, wherein the stop members are formed in the shuttle sleeve.

11. An apparatus according to claim 1, wherein the stop members are integral to the housing,

12. An apparatus according to claim 1, wherein the seat and the shuttle are positioned and oriented for movement along a common axis.