Electrical Kelly Cock Assembly

This invention relates to a kelly cock valve assembly.

In carrying out well drilling operations it is a known practice in the art to transport electrical energy between the surface and a downhole location by positioning interconnected sections of electrical cable or the like within the tubular drill string to establish a continuous electrical path therebetween. However, when such techniques are employed a problem is presented in controlling the flow of well fluids through the tubular drill string, preventing internal blow-outs, and the like, for conventional kelly cock assemblies and similar internal safety valve assemblies cannot be interconnected in the drill string for conventional fluid flow control operation without interrupting the continuous electrical path provided by the interconnected electrical cables.

So far as is known, no one previously has provided a satisfactory kelly cock assembly or other internal safety valve assembly which solves such problem.

Accordingly, the present invention pertains to a new and improved kelly cock apparatus adapted for interconnection in a tubular drill string above or below a kelly joint thereof. The apparatus is provided with an electrical conductor means extending therethrough for interconnection with adjoining electrical cable sections provided in adjoining tubular members to provide a continuous electrical pathway through the kelly cock and tubular members therewith. Positioning means are provided for positioning the electrical conductor means around a fluid flow control means in the kelly cock so as to permit operation of the fluid flow control means simultaneously with the flow of electrical energy through the electrical conductor means.

FIG. 1 is an elevational view, partially cut away and in cross-section, illustrating the preferred embodiment of the invention with the electrical cable conductor means positioned within and extending the length of the tubular body between the tubular body and a fluid flow control means so as to permit simultaneous control of fluid flow and transmission of electrical energy therethrough;

FIG. 2 is a cross-sectional view of the inventive apparatus taken along line 2--2 of FIG. 1 illustrating the electrical cable conductors extending from the axially aligned electrical cable terminal connector in side-by-side, spaced relationship within a slot of a spacer sleeve for spaced longitudinal parallel arcuate alignment adjacent the tubular body inner wall between the tubular body inner wall and the fluid flow control means;

FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1 but having the spherical flow closure element of the flow closure means shown rotated to an open position for passage of fluids through the tubular body and illustrating the electrical cable conductors and conductor positioning means positioned between the tubular body and the flow control element of the flow control means in spaced longitudinal parallel alignment; and

FIG. 4 is an elevational view, partially cut away and in cross-section, illustrating in detail the electrical cable conductor positioning means positioning a portion of one electrical cable conductor between the tubular member inner wall and the fluid flow control means of the assembly illustrated in FIG. 1.

In the drawings the letter K designates the electrical kelly cock assembly of this invention, which is comprised of a tubular body T having a longitudinal bore B therethrough, a fluid flow control means F and an electrical cable conductor means C, each respectively mounted within the bore B. The electrical cable conductor means C extends the longitudinal length of the bore B for transmitting electrical energy therethrough. Positioning means P is also provided for positioning a portion of the electrical cable conductor means C in the tubular body T but disposed to one side of the fluid flow control means F so that the fluid flow control means F can be operated, as will be explained in detail.

The kelly cock assembly K is adapted for interconnection in a tubular drill string with drill pipe joints, a kelly joint, and the like, prewired with interconnected lengths of electrical cable either above or below the kelly joint. The kelly cock assembly K may be operated to control the flow of fluids within the tubular drill string to prevent internal blowouts and/or pressure kicks therethrough, and the like, simultaneously with the transportation of electrical energy between the surface and a subsurface location, as will be more fully explained.

Considering the invention in more detail, the tubular body T is preferably cylindrical in shape with a length for convenient handling and interconnection in a tubular drill string, and has a cross-sectional diameter of a size sufficient to permit its passage through annular blowout preventors, the rotary table, and like apparatus conventionally employed in normal well drilling operations. The tubular body T may be formed in one or more sections which are threaded or otherwise coupled together for convenience in manufacture, assembly, repair and the like. As illustrated in FIG. 1, the tubular body T is preferably conveniently made up of a main tubular body section 10 having a cylindrical inner wall 10a defining a longitudinal main bore 10b, and a tubular body supporting section 12 threadably connected with one end of the main body section 10 in a conventional manner, such as by cooperative engagement of internal threads 10c and external threads 12a. The tubular body support section 12 has a side wall thickness greater than that of the main tubular body section and is provided with a longitudinal bore 12b and an enlarged longitudinal counterbore 12c which are longitudinally coextensive with each other and with the main body section bore 10b so as to form the longitudinal extending bore B. More particularly, the counterbore 12c is defined by the support body portion 12d and an upwardly facing annular shoulder 12e, and has a cross-sectional diameter smaller than the cross-sectional diameter of the main tubular body bore 10a. Similarly, the longitudinal bore 12b is defined by the support body inner wall portion 12f and has a cross-sectional diameter smaller than the support body counterbore 12c, as illustrated in FIG. 1.

An inwardly threaded box end 10d is provided with the main tubular body section 10 for threaded connection with an externally threaded pin end of the lower end of an adjoining drill pipe or kelly joint in the conventional manner (not shown). Similarly, the tubular body support section 12 has an externally threaded pin end 12g adapted for connection with a box end of a lower pipe or kelly joint of the drilling string for interconnecting the kelly cock assembly in the drill string (also not shown).

As illustrated in FIG. 1, the electrical cable conductor means C extends substantially the entire longitudinal length of the tubular body T within the tubular body bore B, and includes a plurality of longitudinally extending insulated electrical conductors 14, 16, 18 and 20 which are integrally connected at their respective opposing ends with male and female-type electrical terminal connectors 22 and 24. These terminal connectors 22 and 24 are axially mounted adjacent the main tubular body section box end 10d and the support body section pin end 12g, respectively, and face longitudinally in opposing directions for interconnection in a known manner with like connectors of adjoining prewired drill pipe joints, a kelly joint or the like.

Preferably, at least three conductors, 14, 16 and 18, are provided which include an electrical energy transporting metallic core or wire 14a, 16a, 18a of sufficient size to transport electrical power between the surface and a downhole or subsurface location for powering a downhole electrical drilling apparatus or the like. Additionally, a fourth conductor, 20, including a metallic core or wire 20a of a smaller size sufficient to transport telemetry signals between the surface and a subsurface location is provided. Each of the conductors further include a concentric layer of suitable insulating material, 14b, 16b, 18b and 20b, respectively, preferably a conventional elastomeric insulating material (FIG. 2).

As illustrated in FIGS. 1 and 2, the electrical conductors 14, 16, 18 and 20 extend substantially laterally from each of the axially mounted male and female terminal connectors towards the main tubular body section inner wall 10a and are positioned in spaced, side-by-side longitudinal parallel alignment with each other between the main tubular body section inner wall 10a and the fluid flow control means F. More particularly, the central portions of the conductors 14, 16, 18 and 20 are positioned substantially equidistant adjacent the inner wall 10a in longitudinally, parallel alignment therewith and extend between it and the fluid flow control means F in the aforementioned side-by-side longitudinal parallel alignment (FIG. 3). Such central portions of the conductors 14, 16, 18 and 20 are fixedly held in such alignment separate from the tubular body bore B between the inner wall 10a and fluid flow control means F by the positioning means P as described hereafter.

The male and female-type terminal connectors 22, 24 may be of any conventional construction which permits rapid interconnection of the electrical cable conductor means C with electrical cable sections provided with the adjoining kelly joint, tubular drill pipe sections and the like upon interconnection of the kelly cock K into a prewired tubular drill string. Preferably, the male-type connector 22 includes a body 22a and a tapered protrusion 22b. A plurality of outwardly facing annular contact rings 22c, 22d, 22e and 22f are provided on the protrusion 22b which are integrally connected in a known manner to the electrical conductors 14, 16, 18 and 20. On the other hand, the female connector 24 includes a longitudinal tubular body 24a having a longitudinal truncated bore (not shown) which is adapted to receive the protrusion similar to 22b of a terminal connector mounted in an adjoining tubular drill pipe or kelly joint. Additionally, the female connector 24 is provided with inwardly facing annular contact rings (also not shown) integrally mounted in a known manner with the connectors 14, 16, 18 and 20 which are adapted to engage the outwardly facing contact rings similar to 22c, 22d, 22e and 22f to provide electrical continuity through the tubular drill string.

Each of the terminal connectors 22 and 24 face longitudinally outwardly so as to provide the aforementioned interconnection with similar terminal connectors and are held in the aforementioned axial alignment by means of support members 26 and 28, respectively. The connector support member 26 includes an inner annular ring 26a, mounted with the connector body 22a and a concentric outer annular ring 26b, which are, respectively, fixedly interconnected by means of a plurality of equal length radial blades 26c. The outer annular ring has an outer diameter slightly less than that of the tubular body bore 10b and slidably engages the inner wall 10a. The support member 28 may be of similar construction, but preferably only includes an inner annular ring 28a mounted with the female connector body 24a and a plurality of equal length radial blades 28b. The female support member 28 is received in the tubular body support section counterbore 12b wherein the radial blades 28b engage and are supported by the upwardly facing annular shoulder 12e. The support members 26 and 28 thus position the terminal connectors 22 and 24 in alignment with the longitudinal axis A of the tubular body T adjacent each end 10d and 12g while permitting the passage of fluids through the tubular body longitudinal bore B between the radially extending blades 26c and 28b.

The terminal connectors 22 and 24 may be fixedly mounted with the respective support members 26 and 28 in any conventional manner. As illustrated, the male terminal connector body 22a may include an outwardly extending annular flange 22g, an annular threaded portion 22h and an inwardly threaded nut 22i. Upon positioning the terminal connector body 22a within the support member annular inner ring 26a and tightening the nut 22i in a known manner, the nut 22i and the outwardly extending flange 22g engage the support member annular inner ring 26a on opposite sides and thereby fixedly mount the terminal connector 22 therewith. A similar arrangement (not shown) is provided to fixedly interconnect the female connector 24 with its support member 28.

A pair of longitudinal tubular spacer sleeves 30, 32 are provided for supporting and positioning the fluid flow control means F and cable conductor positioning means P within the tubular body bore B substantially centrally from the tubular body end 10d and 12g. As shown in FIG. 1, the tubular spacer sleeves 30 and 32 are respectively disposed on opposing sides of the fluid flow control means F and extend longitudinally concentrically about the tubular body axis A in substantially parallel alignment therewith and with each other. The upper spacer sleeve 32 has an outer cross-sectional diameter slightly smaller than the main tubular body bore 10b and slidably engages the main tubular body inner wall 10a. The lower spacer sleeve 30 has a smaller cross-sectional diameter so as to permit its lower end 30a to be received and supported within the tubular body support section counterbore 12b, as shown.

Preferably, an annular support ring 34 having an inwardly and upwardly facing annular groove 34a for receiving the lower sleeve lower end 30a is positioned within the counterbore 12b on top of and in engagement with the female terminal connector support member 28. The lower sleeve lower end 30a is received in the annular ring inner groove 34a engaging the upwardly facing annular shoulder 34b whereby it is fixedly supported for the aforementioned parallel alignment concentrically about the tubular body longitudinal axis A. Additionally, the lower spacer sleeve 30 has an outwardly extending flange 30b slightly below its upper end 30c which engages the main tubular body inner wall 10a so as to position the lower sleeve upper end 30c concentrically about and in substantially parallel alignment with the tubular body longitudinal axis A. The flange 30b is cut-away on one side to provide a planar surface 30i (FIG. 1) to facilitate assembly.

The upper spacer sleeve 32 has a longitudinal slot 32a extending its entire length substantially parallel with the tubular body longitudinal axis A while the lower spacer sleeve 30 is provided with an opening 30d below its outwardly extending annular flange 30b which extends to its lower end 30a. The longitudinal slot 32a and lower sleeve opening 30d are positioned in substantially parallel longitudinal alignment with each other so as to permit the electrical cable conductors 14, 16, 18 and 20 to extend therethrough for the aforementioned side-by-side spaced longitudinal parallel alignment arcuately adjacent the main tubular body inner wall 10a.

As shown, the upper spacer sleeve 32 engages the fluid flow control means F at a downwardly facing annular shoulder 32b formed at its lower end 32c while its upper end 32d provides an upwardly facing annular shoulder 32d which engages and supports the male connector support member annular peripheral ring 26b. Such engagement is maintained by an annular snap ring 36 received in an inwardly facing annular groove 10e of the main tubular body 10 also engaging the support member annular peripheral ring 26b on its opposing side.

As illustrated in FIGS. 1 and 2, the fluid flow control means F comprises a rotatably shiftable ball-type flow closure element 40 provided with a bore 40a and having a spherical outer sealing surface 40b disposed between a pair of annular valve seats 42, 44 having smooth annular seating surfaces 42a, 44a, respectively, in sealing engagement with the closure element spherical outer sealing surface 40b. The spherical closure element 40 also has its laterally opposite sides cut away externally to provide two opposite parallel planar surfaces 40c and 40d spaced unequal distances from the closure element bore 40a for providing a sufficient amount of space between the planar surface 40c and the main tubular body inner wall 10a for the electrical conductor portions and conductor positioning means P. Further, an outwardly opening operating recess 40e is formed in the opposing planar surface 40d for receiving a projection 46a of a valve operating member 46.

The valve operating member 46 is rotatably mounted with the main tubular body section wall 10 in a conventional manner, such as by employing a conventional bearing or bushing mount 46b and extends through an opening 10f in the tubular body side wall 10 so as to permit the flow closure element 40 to be rotated by external operation. A suitably shaped recess 46c is provided for receiving a suitable tool (not shown) for such external operation. Additionally, an annular seal 46d, such as a conventional O-ring made of conventional sealing material, is received in an outwardly facing annular groove 46e for sealing engagement with the surface 10g forming the side wall opening 10f to prevent leakage of fluids therethrough.

The lower annular valve seat 44 is supported by the lower spacer sleeve 30 at its upper end 30c. More particularly, the lower annular valve seat 44 has an outer diameter slightly smaller than the lower spacer sleeve 30 inner diameter which has an inwardly facing annular flange 30e forming an upwardly facing shoulder 30f adjacent its upper end 30c for supporting the annular lower valve seat 44. Preferably, an annular resilient member 47, made of a suitable resilient material such as rubber, is provided between the annular shoulder 30f and the lower valve seat 44 to provide contact force between the valve seat annular surface 44a and the closure element outer spherical surface 40b.

Further, the upper annular valve seat 42 is carried by an annular valve seat carrier member 48 having an outwardly projecting annular collar 48a carrying a suitable sealing means 48b, such as one or more conventional O-ring seals made of conventional sealing material, on its outer annular peripheral edge for sealing engagement with the main tubular body inner wall 10a so as to prevent fluid flow therebetween. As shown, the upper annular valve seat 42 is received in an inwardly and downwardly facing annular groove 48c provided with the valve seat carrier 48. Preferably, the upper valve seat 42 is provided with an outwardly facing annular groove 42b carrying a suitable annular sealing means 42c, such as an O-ring seal, for sealing engagement with the valve seat carrier annular groove 48c and an annular recess 42d in its smooth annular seating surface 42a also carrying such suitable sealing means 42e for sealing engagement with the closure element spherical outer sealing surface 40b. Such sealing means 42c and 42e cooperate with the peripheral seal 48b carried by the valve seat carrier collar 48a to form a bulkhead to prevent the passage of fluids through the tubular body bore B of the apparatus K except through the closure element counterbore 40a when the closure element 40 is rotated to a position where the closure element bore 40a is coextensive with the main tubular body bore 10a above the valve seat carrier 48 and the longitudinally extending bore 30g formed by the lower spacer sleeve member 30.

As previously mentioned, the positioning means P fixedly positions the central portions of the electrical conductors 14, 16, 18 and 20 between the fluid flow control means F and the main tubular body section inner wall 10a in spaced longitudinal parallel relationship therewith and with each other, respectively. As illustrated in the drawings, the positioning means P includes a plurality of substantially rigid longitudinally extending tubular members 50, 51, 52 and 53, each having one of the electrical conductor metallic wires 14a, 16a, 18a or 20a extending longitudinally therethrough substantially along each tube's longitudinal axis. Each of the substantially rigid tubes 50, 51, 52 and 53, preferably made of steel, are aligned in substantially spaced parallel longitudinal alignment with respect to each other, with the longitudinal axis A of the tubular body T and the inner wall 10a and extend through an equal plurality of longitudinally aligned openings 48c, 48d, 48e and 48f (FIG. 3) and 30h (FIG. 4), respectively, provided in the valve seat carrier collar 48 and the lower spacer sleeve annular flange 30b (other openings identical to 30h not shown). Such alignment means positions the substantially rigid tubular members 50 in arcuate spaced longitudinal alignment with the main tubular body inner wall 10a. Additionally, such alignment means positions the tubular bodies 50, 51, 52 and 53 longitudinally between the tubular body inner wall 10a and the planar surface 40c of the spherical flow closure element 40 so rotation of the flow closure element 40 is uninterrupted by such bodies 50, 51, 52 and 53 or the conductors therewith (FIG. 3).

In the drawings, the details of the positioning means P are illustrated for positioning only one of the conductors, 14 (FIG. 3). However, identical construction is similarly provided for such positioning of each of the other conductors 16, 18 and 20. For the purpose of brevity, only the details illustrated will be fully described herein.

Referring now to FIG. 3 of the drawings, the rigid tubular member 50 has the electrical conductor metallic core or wire 14a extending longitudinally therethrough along its longitudinal axis. A concentric layer 54 of a suitable potting compound, such as epoxy cement, is provided in the annular space between the conductor wire 14a and the tubular member inner wall 50a to fixedly position the conductor wire 14a therein and to provide additional rigid support. Preferably, the potting compound concentric layer 54 extends substantially the entire length of the rigid tube 50 and also surrounds a portion of the conductor concentric insulation layer 14b which is extended through the tube upper end 50b a desired distance.

Similarly, a concentric layer 55 of a suitable elastomeric material is provided about the insulated conductor 14 and the rigid tube upper end 50b which forms a fluid-tight seal with the rigid tube upper end 50b and reinforcement protection to the conductor 14. The elastomeric concentric layer 55 may be of the same type of elastomeric insulating material as the conductor insulating layer 14b and may be integrally molded thereto. Additionally, the rigid tube upper end 50b is preferably provided with exterior annular threads 50c so as to improve adhesion or interconnection of the elastomeric concentric layer 55 thereto and form the aforementioned fluid-tight seal therebetween.

For convenience in construction, assembly, etc., the conductor wire 14a is segregated and connector means M are provided for conductor wire interconnection and for fixedly mounting the rigid tube 50 with the valve seat carrier collar 48 and the lower spacer sleeve annular flange 30b. As shown, the electrical conductor wire 14a extends longitudinally outwardly from the rigid tube lower end 50d where it is segregrated and thus, forms a male-type electrical connector 14c. A concentrically mounted annular seal 56 of suitable elastomeric sealing material is provided to prevent leakage of fluids through the tube 50 which is disposed between the conductor wire 14a and the tube lower end 50d. The remainder electrical conductor wire lower portion 14d, integrally connected with the axially mounted female terminal connector 24 (FIG. 1), has a second female connector 14e integrally connected with its opposing end 14f having a recess 14g for receiving the formed male-type connector 14c.

A connector nut 58 having the lower conductor wire female-type connector 14e mounted therein is provided which is adapted for threadable connection with the rigid tube lower end 50d by means of cooperative rotating engagement of inwardly facing annular threads 58a and outwardly facing annular threads 50e provided, respectively, with the nut upper end 58b and tube lower end 58d. The conductor wire lower portion 14d and its concentric insulation layer 14b extend through a longitudinal opening 58c provided in the connector nut lower end 58d and is held in substantially axial alignment therewith by means of a concentric layer of potting material 59, such as epoxy cement, mentioned hereinbefore.

Electrical cable conductor wire interconnection and fixed positioning of the rigid tube 50 can thus be accomplished by threadably interconnecting the threads 58a and 50e and rotating the connector nut 58 relative to the rigid tube 50. During such rotation, the connector nut upper end 58b engages the lower spacer sleeve annular flange 30b and an annular snap ring 60 received in an outwardly facing annular groove 50f of the rigid tube 50 engages an also provided annular spacer 61 which in turn engages the valve seat carrier collar upper surface 48d. Such engagement of respective elements forcibly retains the rigid tube in the described position.

Simultaneously during such rotation the conductor wire male-type connector 14c is received and engages the female-type connector 14e to provide electrical continuity through the conductor wire 14a. Further, the elastomeric seal 56 engages the connector nut potting compound concentric layer 59 to provide a fluid-tight seal and thus, prevents leakage of fluids inwardly through the rigid tube 50.

In order to prevent fluid leakage through the valve seat carrier collar opening 48c, the rigid tube 50 carries an annular seal 50g, such as a conventional O-ring of resilient material, in an outer annular groove 50h which sealingly engages the valve seat carrier collar 48. Such sealing engagement further establishes the aforementioned bulk-heading of fluid flow through the tubular body bore B.

As previously mentioned, identical construction is similarly provided for fixedly positioning each of the other conductors 16, 18 and 20 and tubular bodies 51, 52 and 53, respectively, between the tubular section inner wall 10a and flow control element planar surface 40c.

As mentioned hereinbefore, the kelly cock apparatus K of this invention is particularly adapted for interconnection into a prewired tubular drill string so as to provide the flow of electrical energy from the surface to a subsurface location simultaneously with the control of fluids through the tubular drill string. The kelly cock apparatus K of this invention may be threadably interconnected into a tubular drill string in a conventional manner as described hereinbefore. During such threadable interconnection the male terminal connector 22 and female terminal connector 24 respectively interconnect with similar female and male-type interconnectors provided with electrical cable sections of adjoining pre-wired drill pipe joints or a prewired kelly joint. Such interconnection establishes the aforementioned electrical continuity for transportation of electrical energy through the tubular drill string.

Upon interconnection into the tubular drill string the flow of fluids therethrough may be controlled by rotation of the ball-type spherical flow control element 40. Fluid flow is established by rotation of the closure element 40 to a position (as shown in FIG. 3) where the element's bore 40a is coextensive with the tubular body main section bore 10b and the lower spacer sleeve bore 30g. As known, such fluid flow control is particularly beneficial in preventing fluid pressure kickbacks or internal blowouts and to permit interconnection of other drill pipe joints into the tubular drill string without loss of fluid.

The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size and shape as well as in the details of the illustrative construction may be made without departing from the spirit and scope of the invention.