WORLD INTELLECTUAL PROPERTY ORGANIZATION
`Intemational Bureau
`
`
`
`INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)
`(51) International Patent Classification 6 :
`
`
`
`WO 97/44565
`
`(ll) International Publication Number:
`
`
`
`
`
`E21B 21/10, 4/02, 7/18, 7/24
`
`(43) International Publication Date:
`27 November 1997 (27.l 1.97)
`
`
`
` (21) International Application Number:
`PCT/GB97/01343
`(81) Designated State“ AL AM» AT’ AU— AZ» BA. BB, BG, BR,
`BY, CA, CH, CN, CU, CZ, DE, DK, EE, ES, PI, GB, GE,
`
`
`(22) International Filing Date:
`l6 May I997 (l6.05.97)
`
`GR, HU, IL, Is, JP, KE, KG, KP, KR, KZ, LC, LK, LR,
`Ls, LT, LU, LV, MD, MG, MK, MN, Mw, Mx, NO, NZ,
`
`PL, PT, R0, RU, SD. SE, SG, SI, SK, TJ, TM, TR, TT,
`
` (30) Priority Data:
`
`UA, UG, US, UZ, VN, YU, ARIPO patent (GH, KE, Ls,
`96l045l.8
`I8 May l996 (l8.05.96)
`GB
`
`
`Mw, SD, sz, UG), Eurasian patent (AM, AZ, BY, KG, KZ.
`
`
`96250964
`3 December 1996 (03.l2.96)
`GB
`MD, RU, TJ, TM), European patent (AT, BE, CH, DE, DK,
`
`ES, Fl, FR, GB, GR, IE, IT, LU, MC, NL. PT, SE), OAPI
`patent (BF, BJ, CF, CG, CI, CM, GA, GN, ML, MR, NE,
`SN, TD, TG).
`
`
`
`
`
`
`
`
`(71) Applicant (for all designated States except US): ANDER-
`GAUGE LIMITED [GB/GB]; Badentoy Industrial Park,
`
`Badentory Avenue, Aberdeen ABl 4YB (GB).
`Published
`With international search report.
`Before the expiration of the time limit for amending the
`claims and to be republished in the event of the receipt of
`amendments.
`
`
`
`
`
`
`
`(72) Inventors; and
`(75) Inventors/Applicants (for US only): EDDISON, Alan, Mar-
`tyn [GB/GB]; Stanley Cottage, Smiddy Road, Drumlithie,
`Stonehaven AB39 3YS (GB). HARDIE, Ronnie [GB/GB];
`48 Alder Drive, Portlethen, Aberdeen ABl 4WA (GB).
`
`
`
`
`
`
`(74) Agents: MCCALLUM, William, Potter et al.; Cruikshank &
`Fairweather, 19 Royal Exchange Square, Glasgow G1 3AE
`
`(GB).
`
`
`
`(54) Title: DOWNHOLE APPARATUS
`
`(57) Abstract
`
`
`
`CRC‘
`
`
`
`1‘
`
`
`
`
`
`
`_l.““§C‘53$?
`N‘
`13
`§ , ;l\
`
`16 fit
`§
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`
`
`
`Downhole flow pulsing apparatus comprises a housing (14) for location in a drillstring, the housing (14)
`defining a throughbore to permit passage of fluid through the housing. A valve (27, 30) is located in the bore
`and defines a flow passage (29, 31). The valve includes a valve member (27) which is movable to vary the area
`of the passage (29, 31) to provide a varying fluid flow therethrough. A fluid actuated positive displacement
`motor (15, 16) is associated with the valve member (27). In a preferred embodiment, the apparatus is provided
`in combination with a drill bit (5) and a pressure responsive device, such as a shock-sub (3), which expands
`or retracts in response to the varying drilling fluid pressure created by the varying flow passage area. The
`expansion or retraction of the shock-sub (3) provides a percussive effect at the drill bit.
`
`
`
` ._..'rp:!I1I
`
`
`
`NOV
`
`Exhibit 2011
`
` NOV
`Exhibit 2011
`
`

`
`
` FOR THE PURPOSES OF INFORMATION ONLY
`
`Codes used to identify States party to the PCT on the front pages of pamphlets publishing international applications under the PCT.
`
`LS
`LT
`LU
`LV
`MC
`MD
`MG
`MK
`
`ES
`Fl
`FR
`GA
`GB
`GE
`GH
`GN
`GR
`HU
`IE
`IL
`IS
`IT
`JP
`Kl-I
`KG
`KP
`
`
`
`Lesotho
`Spain
`Albania
`AL
`Lithuania
`Finland
`Armenia
`AM
`Luxembourg
`France
`Austria
`AT
`Latvia
`Gabon
`Australia
`AU
`Monaco
`United Kingdom
`Azerbaijan
`AZ
`Republic of Moldova
`Georgia
`Bosnia and Herzegovina
`BA
`Madagascar
`Ghana
`Barbados
`BB
`The former Yugoslav
`Guinea
`Belgium
`BE
`Republic of Macedonia
`Greece
`Burkina Faso
`BF
`Mali
`ML
`Hungary
`Bulgaria
`BG
`Mongolia
`MN
`Ireland
`Benin
`BJ
`Mauritania
`MR
`Israel
`Brazil
`BR
`Malawi
`MW
`Iceland
`Belarus
`BY
`Mexico
`MX
`ltaly
`Canada
`CA
`Niger
`NE
`Japan
`Central African Republic
`CF
`Netherlands
`NL
`Kenya
`Congo
`CG
`Norway
`N0
`Kyrgyzstan
`Switzerland
`CH
`New Zealnnd
`NZ
`Democratic People's
`Cote d‘lvoire
`Cl
`Poland
`Pl.
`Republic of Korea
`Cameroon
`CM
`Portugal
`PT
`Republic of Koren
`KR
`China
`CN
`Romania
`R0
`Kazakstan
`KZ
`Cuba
`CU
`Russian Federation
`RU
`Saint Lucia
`LC
`Czech Republic
`CZ
`Sudan
`SD
`Liechtenstein
`Ll
`Germany
`DE
`DK
`Denmark
`LK
`Sri Lanka
`SE
`Sweden
`
`EF.
`Estonia
`LR
`Liberia
`SG
`Singapore
`
`SI
`SK
`SN
`SZ
`TI)
`TG
`TJ
`TM
`TR
`1"!‘
`UA
`UG
`US
`UZ
`VN
`YU
`ZW
`
`Slovenia
`Slovakia
`Senegal
`Swaziland
`Chad
`Togo
`’l'ajikista.n
`Turkmenistan
`‘Turkey
`Trinidad and Tobago
`Ukraine
`Uganda
`United States of America
`Uzbekistan
`Viet Nam
`Yugoslavia
`Zimbabwe
`
`
`
`NOV
`
`Exhibit 2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCTIGB97/01343
`
`DOWNHOLE APPARATUS
`
`This
`
`invention relates to downhole apparatus.
`
`In
`
`particular, but not exclusively,
`
`the invention relates to
`
`drilling apparatus and a drilling method,
`
`and to a flow
`
`pulsing method and a flow pulsing apparatus for a drill
`
`string.
`
`In
`
`the oil
`
`and
`
`gas
`
`exploration and
`
`extraction
`
`industries it is well known that providing a percussive or
`
`hammer effect
`
`tends to increase the drilling rate that
`
`is
`
`achievable when drilling bores through hard rock.
`
`In such
`
`drilling operations drilling fluid or "mud" is pumped from
`
`the surface through the drill string to exit
`
`from nozzles
`
`provided on the drill bit.
`
`The
`
`flow of fluid from the
`
`nozzles assists in dislodging and clearing material
`
`from
`
`the cutting face and serves to carry the dislodged material
`
`through the drilled bore to the surface.
`
`It has been
`
`recognised that providing a pulsing fluid flow from the
`
`nozzles may also serve to increase the drilling rate.
`
`Apparatus utilising one or both of these principles is
`
`described in US Patents No 2,743,083 to Zublin,
`
`No
`
`2,780,4438 to Bielstein,
`
`and Nos 4,819,745, 4,830,122,
`
`4,979,577,
`
`5,009,272 and 5,190,114 all
`
`to Walter.
`
`A
`
`pulsing fluid flow is achieved by restricting the drilling
`
`fluid flow area through the apparatus,
`
`the restriction
`
`creating a pressure force which provides the percussive
`
`effect.
`
`The flow restriction may be achieved by a variety
`
`of means,
`
`including
`
`valves which
`
`rotate
`
`about
`
`the
`
`10
`
`15
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`EXNbfi2011
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`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`2
`
`longitudinal axis of the string, valves which rotate about
`
`a transverse axis, axially reciprocating valves and flap
`
`valves.
`
`The valves members are driven or
`
`reciprocated
`
`using drilling fluid driven turbines of various forms, or
`
`fluid pressure forces created by the movement of the valve
`
`member
`
`in the flow of drilling fluid.
`
`It is among the objectives of the present invention to
`
`provide an improved flow pulsing method and apparatus for
`
`a drill string.
`
`In accordance with one aspect of the present invention
`
`there is
`
`provided flow pulsing apparatus
`
`for
`
`a drill
`
`string,
`
`the apparatus comprising:
`
`a housing for location in a drill string above a drill
`
`bit,
`
`the housing defining a throughbore to permit passage
`
`of drilling fluid therethrough;
`
`a valve located in the bore and including first and
`
`second valve members each defining a respective axial flow
`
`opening and which openings are aligned to collectively
`
`10
`
`15
`
`define an open axial drilling fluid flow port
`
`through the
`
`20
`
`valve,
`
`the
`
`first
`
`member
`
`being
`
`rotatable
`
`about
`
`a
`
`longitudinal axis of the housing to vary the alignment of
`
`the openings and thus vary the open area of said port
`
`to,
`
`in use, provide a varying flow therethrough and variation
`
`of the drilling fluid pressure; and
`
`25
`
`drive means operatively associated with the valve for
`
`rotating the first member.
`
`According to another aspect of the present
`
`invention
`
`there is provided a flow pulsing drilling method comprising
`
`NOV
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`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`the steps:
`
`providing a valve in a drill string bore including
`
`first and second valve members each defining a respective
`
`axial
`
`flow opening and which openings collectively define
`
`an open axial flow port
`
`through the valve; and
`
`rotating the first member about a longitudinal axis to
`
`vary the alignment of the openings such that the open area
`
`of
`
`said axial
`
`flow port varies with said rotation to
`
`provide variable flow therethrough and thus produce varying
`
`fluid pressure in the drilling fluid.
`
`The provision of an open axial flow port minimises the
`
`possibility of the port becoming blocked by large particles
`
`or debris carried by the drilling fluid into the housing.
`
`Further,
`
`the use of first and second valve members which
`
`rotate relative to one another facilitates clearing of the
`
`port if any particles or debris should become lodged in the
`
`valve.
`
`The apparatus may
`
`form part of
`
`a
`
`rotary drilling
`
`string,
`
`that is a string that is rotated from surface, or
`
`may be incorporated in a downhole drilling motor and use
`
`the rotary drive of
`
`the motor
`
`to rotate the first valve
`
`member.
`
`Preferably also,
`
`the valve openings are of similar
`
`shape such that when the openings are aligned the maximum
`
`flow area of the axial flow port corresponds to the area of
`
`each opening:
`
`the axis of
`
`rotation of
`
`the first valve
`
`member may be offset
`
`from the second member
`
`such that
`
`rotation of
`
`the first member moves
`
`the openings out of
`
`l0
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`l5
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`NOV
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`EXNbfi2011
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` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`4
`
`alignment;
`
`or
`
`the
`
`axes
`
`of
`
`non—circular openings may
`
`coincide.
`
`In the preferred embodiment
`
`the valve openings
`
`are in the form of transverse slots on a common axis.
`
`Preferably also,
`
`the drive means is driven by passage
`
`5
`
`of drilling fluid therethrough. Most preferably,
`
`the drive
`
`means is in the form a positive displacement motor.
`
`Preferably also,
`
`the apparatus includes a pressure
`
`responsive device which will expand or retract in response
`
`to the varying drilling fluid pressure created by operation
`
`10
`
`of the apparatus; this expansion or retraction provides the
`
`desired percussive effect at
`
`the drill bit.
`
`The device,
`
`which may be in the form of a shock sub or tool, may be
`
`provided above or below the valve. Alternatively,
`
`the
`
`valve may form part of such a device.
`
`15
`
`In accordance with another aspect of
`
`the present
`
`invention
`
`there
`
`is
`
`provided
`
`downhole
`
`flow pulsing
`
`apparatus,
`
`the apparatus comprising:
`
`a housing for
`
`location in a
`
`string,
`
`the housing
`
`defining a
`
`throughbore
`
`to
`
`permit
`
`passage
`
`of
`
`fluid
`
`20
`
`therethrough;
`
`a valve located in the bore defining a flow passage
`
`and including a valve member,
`
`the valve member being
`
`movable to vary the area of
`
`the flow passage to,
`
`in use,
`
`provide a varying fluid flow therethrough; and
`
`25
`
`a
`
`fluid
`
`actuated
`
`positive
`
`displacement motor
`
`operatively associated with the valve for driving the valve
`
`member.
`
`The use of a positive displacement motor provides for
`
`NOV
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`EXNbfi2011
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`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`5
`
`close control of
`
`the rate at which the drive member
`
`is
`
`driven;
`
`typically,
`
`the speed of
`
`the motor
`
`is directly
`
`proportional
`
`to the rate of
`
`flow of
`
`fluid through the
`
`motor.
`
`Thus,
`
`the frequency of
`
`the changes in fluid flow
`
`may be subject to the same close control.
`
`Preferably,
`
`the positive displacement drive motor
`
`includes a
`
`rotor and the rotor
`
`is linked to the valve
`
`member. Most preferably,
`
`the rotor is utilised to rotate
`
`the valve member.
`
`The rotor may be linked to the valve
`
`member 1;;
`
`a universal
`
`joint which
`
`accommodates
`
`any
`
`transverse movement of the rotor. Alternatively,
`
`the rotor
`
`is
`
`linked to
`
`the
`
`valve member
`
`and
`
`communicate
`
`its
`
`transverse movement
`
`to
`
`the
`
`valve member.
`
`In
`
`this
`
`situation,
`
`the valve member may cooperate with a second
`
`valve member, each valve member defining a flow port,
`
`the
`
`alignment of
`
`the flow ports varying with the transverse
`
`movement of the first valve member.
`
`Preferably also,
`
`the positive displacement motor
`
`operates using the Moineau principle.
`
`Such motors include
`
`a
`
`lobed rotor which rotates within a
`
`lobed stator,
`
`the
`
`stator having one more rotor than the rotor.
`
`The preferred
`
`embodiment of the present
`
`invention includes a 1:2 Moineau
`
`motor,
`
`that
`
`is the rotor has one lobe and the stator has
`
`two lobes.
`
`These and other aspects of the present
`
`invention will
`
`now be described, by way of example, with reference to the
`
`accompanying drawings,
`
`in which:
`
`Figure 1 illustrates the lower end of a drill string
`
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`

`
`WO 97/44565
`
`PCT/GB97/0 1343
`
`6
`
`provided with flow pulsing apparatus in accordance with a
`
`first embodiment of the present
`
`invention;
`
`Figure 2 is a somewhat enlarged sectional view of the
`
`percussion sub of Figure 1;
`
`Figure 3 is an enlarged sectional view of the valve of
`
`the percussion sub of Figure 2;
`
`Figure 4
`
`is a plan ‘view of valve members of
`
`the
`
`percussion sub of Figure 2;
`
`Figure 5
`
`is a graph illustrating the fluid flow area
`
`through the valve of the percussion sub of Figure 2 versus
`
`the valve member relative rotation angle;
`
`Figure 6
`
`is a sectional View of the shock-sub of the
`
`apparatus of Figure 1;
`
`Figure 7
`
`is a sectional view of a percussion sub in
`
`accordance with
`
`another
`
`embodiment
`
`of
`
`the
`
`present
`
`invention;
`
`Figure 8
`
`is a sectional view of
`
`a downhole
`
`flow
`
`pulsing apparatus in accordance with a third aspect of the
`
`present invention; and
`
`Figure 9 is a an enlarged sectional view of area 8 of
`
`Figure 8.
`
`Referring first to Figure 1 of the drawings,
`
`the lower
`
`end of a drill string is shown and comprises a drill collar
`
`1 connected to a percussion sub 2,
`
`the percussion sub 2
`
`in
`
`turn being connected to a shock sub 3 which is attached to
`
`a connecting sub 4 which in turn is connected to a drill
`
`bit 5. All attachments are by way of conventional threaded
`
`connection. The string is shown located in a bore with the
`
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`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`7
`
`drill bit 5
`
`in contact with the cutting face.
`
`Reference is now also made to Figures 2 and 3 of the
`
`drawings which illustrates aspects of the percussion sub 2
`
`in greater detail.
`
`The sub 2 comprises a top section 10
`
`connected by a threaded joint 11 to a tubular main body 12.
`
`A flow insert 13
`
`is keyed into the main body 12 and flow
`
`nozzles 14 are screwed into the flow insert 13.
`
`The keyed
`
`flow insert
`
`13
`
`is attached to aa motor stator‘
`
`15 which
`
`contains a freely revolving rotor 16.
`
`The motor is of the
`
`positive displacement
`
`type, operating using the Moineau
`
`principle.
`
`The top section 10, keyed flow insert 13,
`
`flow
`
`nozzles 14, motor stator 15 and the main body 12 all allow
`
`drilling fluid to pass
`
`through the sub 2;
`
`in use, high
`
`velocity drilling fluid enters the top section 10.
`
`The
`
`flow is then channelled through the flow insert 13 and the
`
`flow nozzles 14.
`
`A balanced flow rate is achieved between
`
`the flow insert 13 and the flow nozzles 14 allowing the
`
`drilling fluid to rotate the rotor 16 at a defined speed in
`
`relation to the drilling fluid flow rate.
`
`The
`
`lower end of
`
`the motor stator 15
`
`is supported
`
`within a tubular insert 19 which has a threaded connection
`
`at its lower end 21 and has fluid passageways 20 to allow
`
`fluid to flow from the flow nozzles 14 over
`
`the motor
`
`stator 15 and into a chamber 22 defined by the insert 19.
`
`The rotor 16 is connected at its lower end to a shaft
`
`23 which in turn is connected to a tubular centre shaft 24.
`
`The shaft 24 extends into an intermediate outer body 17
`
`connected to the main
`
`body
`
`12
`
`by way of
`
`a
`
`threaded
`
`10
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`

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`WO 97/44565
`
`PCT/GB97/01343
`
`8
`
`connection.
`
`The connecting shaft 23 is located at either
`
`end by a universal
`
`joint 25 and 26.
`
`The rotor torque is
`
`thus directly translated through the connecting shaft 23
`
`and universal joints 25 and 26 to the centre shaft 24.
`
`A first valve plate 27 is attached to the lower end of
`
`the centre shaft
`
`24 via a
`
`threaded connection 28.
`
`The
`
`valve plate 27 defines a slot opening 29,
`
`as
`
`shown in
`
`Figure 4 of the drawings, which provides a fluid passageway
`
`for drilling fluid to flow onto the fixed second valve
`
`plate 30 which also defines a slot 31;
`
`the slots 29,
`
`31
`
`thus define an open axial
`
`flow passage.
`
`The fixed valve
`
`plate 30 is attached to an end body 44 by way of threaded
`
`connection 46.
`
`Drilling fluid is channelled through radial slots 32
`
`in the upper end of the centre shaft 24 into the centre of
`
`the shaft 24 whilst the shaft rotates. Fluid then travels
`
`through the first slot 29 and as the two slots 29 and 31
`
`rotate into and out of alignment with each other fluid flow
`
`is restricted periodically, causing a series of pressure
`
`pulses, as illustrated in Figure 5 of the drawings. These
`
`pressure pulses are used to provide a percussive action
`
`along the axis of
`
`the equipment
`
`to the drill bit 5, as
`
`described below.
`
`This percussive action increases
`
`the
`
`drill bit penetration rate in hard rock.
`
`It also causes a
`
`fluctuation in the drilling fluid flow rate at
`
`the bit
`
`which also provides more effective means to clean cuttings
`
`away from the bit during drilling.
`
`Radial bearings 33 in two positions are used to locate
`
`10
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`15
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`20
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`25
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`NOV
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`EXNbfi2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`9
`
`the revolving centre shaft 24.
`
`A spacer 34
`
`is located
`
`between the bearings 33 to distance them. Thrust bearings
`
`35,
`
`36 are utilised to support and restrict
`
`longitudinal
`
`movement of
`
`the shaft.
`
`An oil compensation sleeve 37,
`
`seals 38, 39, and oil filler assembly 41 are used to retain
`
`an oil supply at a balanced pressure to supply the bearings
`
`and seals with lubrication. Circlips 42 and 43 are used as
`
`assembly retention devices.
`
`The intermediate outer body 17 is connected to the end
`
`body 44 gig threaded connection at 45 and the gap between
`
`the fixed valve plate 30 and the valve plate 27 is kept
`
`to
`
`a minimum using shims 47.
`
`Reference is now made
`
`to Figure 6 of
`
`the drawings,
`
`which illustrates a
`
`shock sub arrangement
`
`3
`
`in greater
`
`detail; it should be noted that the illustrated arrangement
`
`is merely one example of a shock sub suitable for use with
`
`the invention.
`
`The sub 3
`
`includes an upper body 50 which
`
`is connected to the valve end body 44 1;;
`
`a
`
`threaded
`
`connection 52.
`
`The upper body 50 is threaded to a lower
`
`body 54 and collectively the upper and lower bodies 50 and
`
`54 define a housing 55 which slidably receives a mandrel 56
`
`which is splined to the lower body 54.
`
`A hollow piston 58
`
`is threaded to the upper end of the mandrel 56 such that a
`
`positive pressure differential between the drilling fluid
`
`in the sub and the drilling fluid in the bore annulus
`
`externally of
`
`the sub will
`
`tend to extend the mandrel 56
`
`from the housing 55.
`
`A compression spring in the form of
`
`a stack of Belleville washers
`
`60
`
`is provided between a
`
`10
`
`15
`
`20
`
`25
`
`NOV
`
`EXNbfi2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/414565
`
`PCT/GB97/01343
`
`10
`
`shoulder on the mandrel 56 and a lip on the upper body 50.
`
`The spring is also retained between the thread end on the
`
`lower body 54 and the hollow piston 58,
`
`thus the washer
`
`stack provides
`
`a
`
`resistive spring force in both axial
`
`directions.
`
`The lower end of
`
`the mandrel S6
`
`is attached to the
`
`connecting sub 4 and thus is linked to the drill bit 5. As
`
`drilling fluid passes through the percussion sub 2,
`
`the
`
`first valve plate 27 rotates and the valve slots 29 and 31
`
`rotate into alignment: at this point the fluid available to
`
`the shock sub 3
`
`is increased forcing the hollow piston 58
`
`and the mandrel S6 downwards onto the drill bit 5 producing
`
`the required intermittent force for the percussive action.
`
`At
`
`the
`
`same
`
`time maximum drilling
`
`fluid pressure
`
`differential is available across the bit ensuring a surge
`
`of drilling fluid at
`
`the bit at
`
`the same
`
`instance the
`
`percussive impact
`
`takes place.
`
`Reference is now made
`
`to Figure 7 of
`
`the drawings
`
`which shows part of
`
`an alternative embodiment of
`
`the
`
`invention in which a larger positive displacement motor is
`
`‘ used.
`
`with this configuration the total
`
`flow passes
`
`through the motor
`
`and none of
`
`the drilling fluid is
`
`diverted past
`
`the power section containing the stator 15a
`
`and rotor 16a. This arrangement provides greater control
`
`of percussion frequency because
`
`the frequency will be
`
`directly proportional to the drilling fluid flow rate.
`
`Reference
`
`is now made
`
`to Figures
`
`8
`
`and 9 of
`
`the
`
`drawings which illustrate flow pulsing apparatus
`
`70
`
`in
`
`l0
`
`l5
`
`20
`
`25
`
`NOV
`
`EXNbfi2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`ll
`
`accordance with
`
`a
`
`third embodiment
`
`of
`
`the
`
`present
`
`invention.
`
`As with the first described embodiment,
`
`the
`
`apparatus 70 is intended for location on the lower end of
`
`a drill string above a drill bit.
`
`As will be described,
`
`the apparatus may be used in conjunction with a shock sub
`
`or other apparatus to provide a percussive or hammer action
`
`or may be used solely to provide a pulsed flow of fluid to
`
`the drill bit.
`
`The apparatus 70
`
`includes an elongate tubular body
`
`having an upper motor section 72 and a lower valve section
`
`74.
`
`The motor section 72 accommodates a Moineau principle
`
`motor having a two lobe elastomeric stator 76 and a single
`
`lobe rotor 78.
`
`The valve section 74 accommodates first and
`
`second valve plates 80, 82, each defining a flow port 84,
`
`86.
`
`The first valve plate 80 is directly mounted on the
`
`lower
`
`end of
`
`the rotor
`
`78
`
`y;§_
`
`a ported connector
`
`88
`
`defining flow passages 90 which provide fluid communication
`
`between the variable geometry annulus defined between the
`
`stator 76 and the rotor 78 and the flow port 84.
`
`The
`
`second valve plate 82 is mounted on the valve section body
`
`74 directly below the first valve plate 80 such that
`
`the
`
`respective flow ports 84,
`
`86 coincide.
`
`As
`
`the rotor 78
`
`rotates it oscillates from side—to~side and this movement
`
`is transferred directly to the valve plate 80 to provide a
`
`cyclic variation in the flow area defined by the flow ports
`
`84, 86, similar to that described above with reference to
`
`the first described embodiment.
`
`The
`
`fluctuating fluid flow rate and fluid pressure
`
`l0
`
`l5
`
`20
`
`25
`
`NOV
`
`EXNbfi2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`12
`
`which is produced by the operation of the valve may be used
`
`to operate
`
`a
`
`shock
`
`sub or may
`
`be
`
`used
`
`to move
`
`a
`
`reciprocating mass which impacts on an anvil, both with the
`
`aim of providing a percussive or hammer action to assist in
`
`drilling in hard rock.
`
`The variation in fluid flow rate
`
`may also be utilised,
`
`alone or
`
`in conjunction with a
`
`percussive or
`
`hammer
`
`tool,
`
`to provide pulsed flow of
`
`drilling fluid from the drill bit nozzles.
`
`As will be evident
`
`to those of skill in the art this
`
`embodiment
`
`of
`
`the
`
`invention is
`
`of
`
`relatively simple
`
`construction and
`
`thus
`
`may
`
`be
`
`robust
`
`and
`
`relatively
`
`inexpensive to manufacture and maintain. This is achieved,
`
`in part, by utilising the oscillation of the rotor of the
`
`positive displacement motor,
`
`in contrast
`
`to conventional
`
`uses of such motors in which every effort is made to negate
`
`or isolate this movement.
`
`It will be clear to those of skill
`
`in the art
`
`that
`
`these embodiments are merely exemplary of
`
`the present
`
`invention and that various modifications and improvements
`
`may be made thereto without departing from the scope of the
`
`invention.
`
`The above described embodiments utilise 1:2
`
`Moineau
`
`principle motors,
`
`but
`
`of
`
`course
`
`other
`
`configurations of Moineau motors,
`
`such as 2:3 or 3:4
`
`motors, may be utilised to provide different
`
`torque or
`
`speed characteristics and perhaps permit
`
`the motor
`
`to be
`
`used to drive additional devices,
`
`and other
`
`forms of
`
`positive displacement motors may be utilised.
`
`l0
`
`l5
`
`20
`
`25
`
`NOV
`
`EXNbfi2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`CLAIMS
`
`l3
`
`1.
`
`Downhole flow pulsing apparatus comprising:
`
`a housing for
`
`location in a string,
`
`the housing
`
`defining a
`
`throughbore
`
`to
`
`permit
`
`passage
`
`of
`
`fluid
`
`therethrough;
`
`a valve located in the bore defining a flow passage
`
`and including a valve member,
`
`the valve member being
`
`movable to vary the area of
`
`the flow passage to,
`
`in use,
`
`provide a varying fluid flow therethrough; and
`
`a
`
`fluid
`
`actuated
`
`positive
`
`displacement motor
`
`operatively associated with the valve for driving the valve
`
`member.
`
`2.
`
`The apparatus of claim 1 wherein the speed of
`
`the
`
`motor is directly proportional to the rate of flow of fluid
`
`through the motor.
`
`3.
`
`The apparatus of claim 1 or
`
`2 wherein the positive
`
`displacement drive motor includes a rotor and the rotor is
`
`linked to the valve member.
`
`4.
`
`The apparatus of claim 3 wherein the rotor is utilised
`
`to rotate the valve member.
`
`5.
`
`The apparatus of claim 4 wherein the rotor is linked
`
`to the valve member via a universal joint which
`
`NCfi/
`
`EXNbfi2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`accommodates transverse movement of the rotor.
`
`14
`
`6.
`
`The apparatus of claim 4 wherein the rotor is linked
`
`to the valve member to communicate transverse movement of
`
`the rotor to the valve member.
`
`7.
`
`The apparatus of claim 6 wherein the valve member co-
`
`operates with a
`
`second valve member,
`
`each valve member
`
`defining a
`
`flow port,
`
`the alignment of
`
`the flow ports
`
`varying with the transverse movement of
`
`the first valve
`
`member.
`
`8.
`
`The apparatus of any of the preceding claims wherein
`
`the positive displacement motor operates using the Moineau
`
`principle and includes a lobed rotor which rotates within
`
`a lobed stator,
`
`the stator having one more rotor than the
`
`I'OtOI' .
`
`9.
`
`The apparatus of claim 8,
`
`including a 1:2 Moineau
`
`motor.
`
`10.
`
`The apparatus of
`
`any of
`
`the preceding claims,
`
`in
`
`combination with a drill bit connected to the housing.
`
`11.
`
`The
`
`apparatus
`
`of
`
`claim 10
`
`further
`
`comprising a
`
`pressure responsive device which expands or retracts in
`
`response to the varying fluid pressure created by
`
`the varying flow passage area,
`
`the expansion or retraction
`
`NOV
`
`EXNbfi2011
`
` NOV
`Exhibit 2011
`
`

`
`W0 97/44555
`
`PCT/GB97/01343
`
`providing a percussive effect.
`
`15
`
`12.
`
`The apparatus of any of the preceding claims, wherein
`
`the valve includes first and second valve members each
`
`defining a respective axial flow opening and which openings
`
`are aligned to collectively define an open axial drilling
`
`fluid flow port
`
`through the valve,
`
`the first member being
`
`rotatable about a longitudinal axis of the housing to vary
`
`the alignment of
`
`the openings and thus vary the open area
`
`of
`
`said port
`
`to,
`
`in
`
`use,
`
`provide
`
`a
`
`varying
`
`flow
`
`therethrough and variation of the fluid pressure.
`
`13.
`
`Flow pulsing apparatus
`
`for
`
`a drill
`
`string,
`
`the
`
`apparatus comprising:
`
`a housing for location in a drill string above a drill
`
`bit,
`
`the housing defining a throughbore to permit passage
`
`of drilling fluid therethrough;
`
`a valve located in the bore and including first and
`
`second valve members each defining a respective axial flow
`
`opening and which openings are aligned to collectively
`
`define an open axial drilling fluid flow port
`
`through the
`
`valve,
`
`the
`
`first member
`
`being
`
`rotatable
`
`about
`
`a
`
`longitudinal axis of the housing to vary the alignment of
`
`the openings and thus vary the open area of said port
`
`to,
`
`in use, provide a varying flow therethrough and variation
`
`of the drilling fluid pressure; and
`
`drive means operatively associated with the valve for
`
`rotating the first member.
`
`NOV
`
`EXNbfi2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`16
`
`14.
`
`The apparatus of clamn 12 or
`
`13 wherein the valve
`
`openings are of similar shape such that when the openings
`
`are aligned the maximum flow area of the axial
`
`flow port
`
`corresponds to the area of each opening.
`
`15.
`
`The apparatus of claim 14 wherein the axis of rotation
`
`of the first valve member is offset from the second member
`
`such that rotation of the first member moves the openings
`
`out of alignment.
`
`16.
`
`The apparatus of claim 14 wherein the valve openings
`
`are non—circular.
`
`17.
`
`The apparatus of claim 16 wherein the valve openings
`
`are in the form of transverse slots on a common axis.
`
`18.
`
`A flow pulsing drilling method comprising the steps;
`
`providing a valve in a drill string bore including
`
`first and second valve members each defining a respective
`
`axial
`
`flow opening and which openings collectively define
`
`an open axial flow port through the valve; and
`
`rotating the first member about a longitudinal axis to
`
`vary the alignment of the openings such that the open area
`
`of
`
`said axial
`
`flow port varies with said rotation to
`
`provide variable flow therethrough and thus produce varying
`
`fluid pressure in the drilling fluid.
`
`NOV
`
`EXNbfi2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`1/6
`
`
`
`
`
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`
`1
`
`SUBSTITUTE SHEET (RULE 26)
`
`NOV
`
`Exhibit 2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`2/6
`
`
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`SUBSTITUTE SHEET (RULE 26)
`
`NOV
`
`Exhibit 2011
`
` NOV
`Exhibit 2011
`
`
`

`
`WO 97/44565
`
`3/6
`
`PCTIGB97/01343
`
`29
`
` 1
`
`FlG.l+
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`j.
`
`0 15 30 45 60 75 90 10512013515016S180195210
`
`360
`
`ANGLE
`
`FLUID FLOW AREA v VALVE ROTATION ANGLE
`
`FIG . S
`
`SUBSTITUTE SHEET (RULE 26)
`
`NOV
`
`Exhibit 2011
`
` NOV
`Exhibit 2011
`
`

`
`WO 97/44565
`
`%2,E
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`
`nF.LUm
`
`NOV
`
`Exhibit 2011
`
` NOV
`Exhibit 2011
`
`
`
`
`
`
`

`
`WO 97/44565
`
`PCT/GB97/01343
`
`5/6
`
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`SUBSTITUTE SHEET (RULE 26)
`
`NOV
`
`Exhibit 2011
`
` NOV
`Exhibit 2011
`
`
`
`
`

`
`m.O_m3833
`
`
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`
`Exhibit 201
`
`SUBSTITUTE SHEET (RULE 26)
`
` NOV
`Exhibit 2011
`
`
`
`

`
`
`
`ional Application No
`
`
`
`INTERNATIONAL SEARCH REPORT
`
`lnti
`
`PCT/GB 97/01343
`
`
`. CLASSlFI(IA'l'l0N
`UBJECI" MA'l'[‘l.-IR
`
`
`
`ipc 6
`521323730
`E2134 oz
`E2187/18
`E2187/24
`
`
`
`
`
`According to lntemational Patent Classification (IPC) or to both national classification and lP(?
`B. FIELDS SEARCHED
`
`
`
`Mimmum documentation searched (classification system followed by classification symbols)
`IPC 6
`E2lB
`
`Documentation searched other than mimmum documentation to the extent that such documents are included in the fields searched
`
`Electiromc data base consulted during the intemauonal search (name of data base and, where practical. search terms used)
`
`C. DOCUMENTS CONSIDERED TO BE RELEVANT
`
`Category "
`
`Citation of document. with indication, where appropriate, of the relevant passages
`
`Relevant to claim N0-
`
`
`
`
`
`EP 0 335 543 A (PILOT DRILLING CONTROL
`LIMITED) 4 October 1989
`see column 2,
`line 10 — column 3,
`figures
`
`line 19;
`
`
`
`
`
`
`
`
`
`
`
`
`
`cited in the application
`see column 10,
`line 44 - line 66; figure
`
`10
`
`
`
`
`
`Further documents are listed in the continuation of box C.
`Patent family members are listed in annex.
`_'1'"
`' Special categories of cited documents :
`
`‘A’ document defining the general state of the art which is not
`considered to be of particular relevance
`
`E erarlier document but published on or after the intemauonal
`'1'": date
`‘L’ document which may throw doubts on priority claim(s) or
`which is cited to establish the publication date of another
`dado“ or other spend rum“ (:5 specified)
`'0' document referring to an oral disclosure. use. exhibition or
`other means
`‘P’ document published prior to the international filing date but
`later than the pnonty date claimed
`
`later document published after the international filing date
`or priority date and not in conflict with the application but
`med '0 undcmand mt pnnclplc or theory undcflymg ‘he
`invention
`-x- document of pamculm, mevmcc; the cmmcd mvmuon
`