CROSS-REFERENCE TO RELATED APPLICATIONS

10001 1 This patent application claims priority from, and incorporates by reference the entire disclosure of, U.S. Provisional Patent Application No. 63/414,130 filed on October 7, 2022.

TECHNICAL FIELD

[0002] The present disclosure relates generally to downhole tools and more particularly, but not by way of limitation, to an anti -torque downhole tool.

BACKGROUND

[0003] This section provides background information to facilitate a better understanding of the various aspects of the disclosure. It should be understood that the statements in this section of this document are to be read in this light, and not as admissions of prior art.

[0004] A common problem that occurs during downhole drilling is stick-slip vibration. Stickslip vibrations occur when the bit unexpectedly slows down due to, for example, changes in the rock formation. The bit, e g., a poly cry staline diamond compact (PDC) bit, will have an axial load upon it from the drill string bearing dow n upon the bit. When the rock formation changes, the bit sometimes experiences increased resistance that slows the rotation of the bit. The sudden change in rotational speed causes the drill string to twist and act like a long torsion spring. If the encountered resistance is great enough, the bit can break loose and the drill string will spin backward. This action can cause tool joints to back off. Repeated stick and release can also cause damage to downhole sensor tools, such as MWD. RWD, LWD, vibration sensors, rotary drilling tools, reamers, drill bits, etc. PDC bits are especially susceptible to having cutters chipped and broken from the impact of this severe stick-slip action and rotation reversals.

SUMMARY

[0005] This summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it to be used as an aid in limiting the scope of the claimed subject matter.

[0006] In some aspects, an anti-torque tool includes an upper annular cavity formed between first and second tubular members, a piston disposed in the upper annular cavity and separating the upper annular cavity into an upper portion and a lower portion, a lower annular cavity formed between third and fourth tubular members, at least one spring disposed within the lower annular cavity, a fifth tubular member disposed proximal the at least one spring such that the at least one spring is biased against the fifth tubular member, and a ball screw system. The ball screw system includes a first ball race formed into an outer surface of the fifth tubular member, the ball screw system further comprising a sixth tubular member disposed around at least a portion of the fifth tubular member and comprising at least one pair of ball guide inserts.

[0007] In some aspects, the anti-torque tool includes an accumulator screen configured to filter fluid passing from a central bore of the first tubular member and the upper portion of the upper annular cavity.

[0008] In some aspects, the anti-torque tool includes an oil metering port disposed in the lower portion of the upper annular cavity and configured to allow oil to flow between the upper and lower annular cavities.

[0009] In some aspects, the ball screw system comprises three separate ball tracks with three pairs of ball guide inserts and channels.

[0010] In some aspects, the anti-torque tool includes a bearing disposed between the at least one spring and the fifth tubular member to allow axial rotation between the fifth tubular member and the at least one spring.

[0011] In some aspects, the ball screw system is configured such that a length of the anti-torque tool shortens when the fifth tubular member rotates in a first direction and the length of the anti-torque tool lengthens when the fifth tubular member rotates in a direction opposite the first direction.

[0012] In some aspects, the anti-torque tool includes an oil metering port disposed in the lower portion of the upper annular cavity and configured to allow oil to flow between the upper and lower annular cavities, and the flow of oil between the upper and lower annular cavities dampens movement of the fifth tubular member as the length of the anti-torque tool changes.

[0013] In some aspects, a method of making an anti -torque tool includes providing a first and a second tubular member that form an upper annular cavity therebetween, placing a piston in the upper annular cavity, the piston separating the upper annular cavity into an upper portion and a lower portion. The method includes providing third and fourth tubular members that form a lower annular cavity therebetween, at least one of the third and fourth tubular members being connected to at least one of the first and second tubular members, placing at least one spring within the lower annular cavity, providing a fifth tubular member proximal the at least one spring such that the at least one spring is biased against the fifth tubular member, and providing a ball screw system that comprises a first ball race formed into an outer surface of the fifth tubular member, the ball screw system further comprising a sixth tubular member disposed around at least a portion of the fifth tubular member and comprising at least one pair of ball guide inserts.

[0014] In some aspects, the method includes providing an accumulator screen configured to filter fluid passing from a central bore of the first tubular member and the upper portion of the upper annular cavity.

[0015] In some aspects, the method includes providing an oil metering port disposed in the lower portion of the upper annular cavity and configured to allow oil to flow between the upper and lower annular cavities.

[0016] In some aspects, the ball screw' system comprises three separate ball tracks with three pairs of ball guide inserts and channels.

[0017] In some aspects, the method includes providing a bearing disposed betw een the at least one spring and the fifth tubular member to allow' axial rotation between the fifth tubular member and the at least one spring.

[0018] In some aspects, the ball screw system is configured such that a length of the anti-torque tool shortens w'hen the fifth tubular member rotates in a first direction and the length of the anti-torque tool lengthens when the fifth tubular member rotates in a direction opposite the first direction. [0019] In some aspects, the method includes providing an oil metering port disposed in the lower portion of the upper annular cavity- and configured to allow oil to flow between the upper and lower annular cavities, and the flow of oil between the upper and lower annular cavities dampens movement of the fifth tubular member as the length of the anti-torque tool changes.

[0020] In some aspects, an anti-torque tool includes an upper annular cavity formed between first and second tubular members, a piston disposed in the upper annular cavity and separating the upper annular cavity into an upper portion and a lower portion, a lower annular cavity formed between third and fourth tubular members, at least one spring disposed within the lower annular cavity, a fifth tubular member disposed proximal the at least one spring such that the at least one spring is biased against the fifth tubular member, the fifth tubular member comprising a round thread on an exterior surface of the fifth tubular member, and a sixth tubular member that coaxially receives a portion of the fifth tubular member, the sixth tubular member comprise a round thread on an interior surface of the sixth tubular member that is configured to engage the round thread of the fifth tubular member.

[0021] In some aspects, the anti -torque tool includes an accumulator screen configured to filter fluid passing from a central bore of the first tubular member and the upper portion of the upper annular cavity.

[0022] In some aspects, the anti-torque tool includes an oil metering port disposed in the lower portion of the upper annular cavity and configured to allow oil to flow between the upper and lower annular cavities.

[0023] In some aspects, the anti-torque tool includes a bearing disposed between the at least one spring and the fifth tubular member to allow- axial rotation between the fifth tubular member and the at least one spring.

[0024] In some aspects, the round threads of the fifth and sixth tubular members are configured such that a length of the anti-torque tool shortens when the fifth tubular member rotates in a first direction and the length of the anti-torque tool lengthens when the fifth tubular member rotates in a direction opposite the first direction.

[0025] In some aspects, the anti-torque tool includes an oil metering port disposed in the lower portion of the upper annular cavity and configured to allow oil to flow between the upper and lower annular cavities, and the flow of oil between the upper and lower annular cavities dampens movement of the fifth tubular member as the length of the anti-torque tool changes.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] A more complete understanding of the subject matter of the present disclosure may be obtained by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein:

[0027] FIG. 1 is a cross-sectional view of an anti-torque tool in an extended position according to aspects of the disclosure;

[0028] FIGS. 2A-2B illustrate a ball sub sleave according to aspects of the disclosure;

[0029] FIGS. 3A and 3B are cross-sectional views of an anti-torque tool in an extended position (FIG. 3A) and a collapsed position (FIG. 3B) according to aspects of the disclosure; and

[0030] FIG. 4 is a cross-sectional view of an anti-torque tool in a collapsed position according to aspects of the disclosure.

DETAILED DESCRIPTION

[0031] It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. The section headings used herein are for organizational purposes and are not to be construed as limiting the subject matter described. Reference will now be made to more specific embodiments of the present disclosure and data that provides support for such embodiments. However, it should be noted that the disclosure below is for illustrative purposes only and is not intended to limit the scope of the claimed subject matter in any way.

[0032] FIG. 1 is a cross-sectional view of an anti-torque tool 100 according to aspects of the disclosure. FIG. 1 illustrates tool 100 with numerous section breaks in order to provide a more compact, detailed view of the components of tool 100. Tool 100 includes an accumlator sub 102 that is located at an uphole end of tool 100. An upper end of sub 102 may be connected to a drill string or other downhole tool components. Sub 102 houses an accumulator screen 104 and an accumulator sleeve 106. An upper annular cavity is formed between sub 102 and sleeve 106, with an accumulator piston 108 disposed therein. The upper annular cavity is divided into an upper portion 107 and a lower portion 109. Upper portion 107 is in fluid communication with wellbore fluid and lower portion 109 is in fluid communication with a second fluid (e.g., a lubricating oil). Wellbore fluid is free to enter and leave upper portion 107 as dictated by equilibrium pressure between portions 107/109 on either side of piston 108. Fluid entering the upper annular cavity passes through screen 104, which prevents large parti cles/debris within the wellbore fluid from entering upper portion 107 of the upper annular cavity. The operation of piston 108 will be discussed in more detail below.

[0033] An oil metering port 110 fluidly couples lower portion 109 to a lower annular cavity that contains a plurality of springs 114 (e.g., Bellville springs). The lower annular cavity' is formed between a spring housing 112 and a spring tube 118. Housing 112 is coupled at its uphole end to sub 102. A bolt 116 provides access to the lower annular cavity for oil addition/removal. The oil passing through metering port 110 dampens and lubricates the movement of springs 114/tool mandrel 120 during operation of tool 100. A bearing 115 is positioned at the bottom of the stack of springs 114 to allow free rotational movement of tool mandrel 120 relative to springs 114.

[0034] A ball sub sleeve 122 is coupled to housing 112 and includes a ball screw system. FIGS. 2A and 2B are perspective and cross-sectional views of ball sub sleeve 122 according to aspects of the disclosure. Ball sub sleeve 122 includes a body 123 and a bottom seal sub 134 couples to body 123. Bottom seal sub 134 includes a plurality of seals 138 that seal an interior of ball sub sleeve 122 to keep drilling fluids out of ball races 128/130 to ensure smooth operation thereof. Bottom seal sub 134 includes a plurality' of tabs 142 (similar to a castle nut).

[0035] Ball screw systems operate in a similar manner to lead screws, but differ in that ball screw systems use ball bearings - not threads - within helical channels formed between a screw and a nut. Ball screw systems can also utilize a recirculating system where the ball bearings are recirculated as rotation of the system continues. For example, as the screw rotates through the nut. the ball bearings travel along a helical channel formed between an outer surface of the screw and an inner surface of the nut. Eventually the ball bearings reach the end of the helical channel and exit into an external channel that connects both ends of the helical channel together. The ball bearings travel through the external channel and are fed back into the helical channel. In other words, the ball bearings travel in a closed-loop circuit and may travel the circuit in either direction depending on the direction of rotation of the screw. In some aspects, the ball bearings may be lubricated as they travel through the external channel. Ball screw systems provide several advantages over lead screw designs, including reduced friction, smooth motion, and precision. The reduction in friction can be attributed to rolling friction vs. the sliding friction of a lead screw and the ability to lubricate the ball bearings as they are recirculated through the ball screw system.

[0036] The ball screw system includes one or more ball races 130 (see FIG. 1). Each ball race 130 pairs with a ball race 128 formed into tool mandrel 120 to form a ball track that receives a plurality of ball bearings. Each track connects to a pair of ball guide inserts 132 and channels 124 that allow the plurality of ball bearings to be recycled to/from the ball track as tool mandrel 120 rotates. The ball screw system allows tool mandrel 120 to rotate relative to sub 102 such that rotation in a first direction shortens a length of tool 100 and rotation in an opposite direction increases a length of tool 100. In some aspects, a single ball screw system is used to provide rotation between tool mandrel 120 and sub 102. In some aspects, two or more ball screw systems are incorporated. In aspects having multiple ball screw systems, the races may be configured in an intertwined orientation, with starts evenly spaced about the circumference (e.g., 180 degrees apart for two ball screw' systems, 120 degrees apart for three ball screw systems, etc.). The number of ball screw systems used depends on various design considerations. The exemplary' aspect shown in FIGS. 2A and 2B shows a three-ball screw system setup (the third ball return track is disposed on a back side).

[0037] FIGS. 3 A and 3B are a cross-sectional views of anti-torque tool 100 in an extended position (FIG. 3A) and a collapsed position (FIG. 3B) according to aspects of the disclosure. Tool 100 has an upper portion 101 that may move axially relative to a lower portion 103. Upper portion 101 extends between accumulator sub 102 and bottom5 seal sub 134. Lower portion 103 comprises tool mandrel 120. In the extended position, springs 114 bias upper portion 101 away from lower portion 103. When a stick-slip condition occurs, a drill bit attached dow nhole from tool 100 experiences an increase in torque that is transferred to tool mandrel 120. In response to the increased torque acting upon tool mandrel 120, tool mandrel 120 rotates and moves in an uphole direction, shortening a length of tool 100 due to the geometry’ of ball races 128/130 (i.e.. lower portion 103 moves axially toward upper portion 101). As tool mandrel 120 moves uphole, springs 114 are compressed. This uphole movement of tool mandrel 120 will continue until either an equilibrium is reached with springs 114 or tool mandrel 120 reaches the fully collapsed position shown in FIG. 3B. As springs 114 are compressed, the plurality' of ball bearings cycle through ball races 128/130 and are recycled via channels 124 connected to ball guide inserts 132 (see FIGS. 2A-2B). The recycling design provides a smooth operating rotation and is also relatively compact. As noted above, oil surrounds springs 114 to dampen the motion of springs 114/tool mandrel 120. Dampening the motion of springs 114 helps to reduce shock loads to tool 100. As the length of tool 100 shortens, the oil in low er annular cavity is forced through oil metering port 110 and into lower portion 109 of the upper annular cavity. This oil displaces piston 108, which translates upward. The upward movement of piston 108 displaces well fluid from upper portion 107 of upper annular cavity and into the bore passing through tool 100. The operation of piston 108 helps to dampen the rotational motion of tool mandrel 120 to reduce the likelihood of damage to components of tool 100 and to prevent over-rotation of tool mandrel 120. In some aspects, piston 108 includes one or more seals (e.g., o-rings) that prevent oil from flowing around piston 108.

[0038] FIG. 4 is a cross-section view of anti-torque tool 100 in a collapsed position according to aspects of the disclosure. Anti-torque tool 100, as configured in FIG. 4. is similar to the configuration shown in FIG. 1 , but the ball screw system has been replaced with a round thread system. For the configuration of FIG. 4, tool mandrel 120 has been replaced with a tool mandrel 152. Tool mandrel 152 is similar to tool mandrel 120, but includes round threads 154 formed into an outer surface of tool mandrel 154. Round threads 154 engage round threads 156 that are formed into an inner surface of a sub 150.

[0039] Round threads belong to the product group of sliding threads and can absorb higher forces than conventional v-shaped threads. Round threads are the strongest of the common ■‘Knuckle” threads. The knuckle thread profile is a highly rounded thread form. The round shape helps to prevent dirt buildup and mechanical damage. The large space between the rounded crests and roots provide space for debris to be shifted to not interfere with the thread. It is also more resistant to wear and tear than other threads as there are no delicate edges. Knuckle threads have very wide rounded crests and roots, and they also use steep thread angle. Approximately the middle third of each thread flank is flat. Compared to the ball screw system, the round thread configuration of FIG. 4 offers a simpler design that is capable of high loads.

[0040] In contrast to conventional V-shaped threads, rounded threads offer several benefits. In comparison, V-shaped threads are more susceptible to damage, galling, and debris. V-shaped threads also have sharp edges, which have a greater risk of galling and create stress concentration that can lead to possible fracture and fatigue failure. In addition to reducing the likelihood of these issues, the rounded threads of the anti -torque tool of FIG. 4 offer improved tolerance to misalignment caused by bending as compared to V- shaped threads.

[0041] Although various embodiments of the present disclosure have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the present disclosure is not limited to the embodiments disclosed herein, but is capable of numerous rearrangements, modifications, and substitutions without departing from the spirit of the disclosure as set forth herein.

[0042] The term “substantially'’ is defined as largely but not necessarily wholly what is specified, as understood by a person of ordinary skill in the art. In any disclosed embodiment, the terms “substantially”, “approximately”, “generally”, and “about” may be substituted with “within [a percentage] of’ what is specified, where the percentage includes 0.1, 1, 5, and 10 percent.

[0043] The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the disclosure. Those skilled in the art should appreciate that they may readily use the disclosure as a basis for designing or modifying other processes and structures for carry ing out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the disclosure. The scope of the invention should be determined only by the language of the claims that follow. The term “comprising” within the claims is intended to mean “including at least” such that the recited listing of elements in a claim are an open group. The terms “a”, “an”, and other singular terms are intended to include the plural forms thereof unless specifically excluded.# [0044] Conditional language used herein, such as, among others, “can”, “might”, “may”, “e.g.”, and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment.

[0045] While the above detailed description has shown, described, and pointed out novel features as applied to various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the devices or algorithms illustrated can be made without departing from the spirit of the disclosure. As will be recognized, the processes described herein can be embodied within a form that does not provide all of the features and benefits set forth herein, as some features can be used or practiced separately from others. The scope of protection is defined by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

[0046] Although various embodiments of the method and apparatus of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth herein.#