US 11,280,437 B2Granted

Sealed gap sub

AssigneeEvolution Engineering Inc.

InventorsLuke A. Stack, Aaron W. Logan, Justin C. Logan, Patrick R. Derkacz, Gavin Gaw-Wae Lee, Hasan Alper Hepguvendik, Mojtaba Kazemi Miraki, Daniel W. Ahmoye, Kurtis K. L. West, Angelica J. B. Francoeur

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Abstract

One or more seals may be provided in a gap sub to prevent the ingress of drilling fluid into an insulating gap between a male member of the gap sub and a female member of the gap sub. A first seal may comprise an internal gap sub seal provided near the tip of the male member of the gap sub. A second seal may comprise an external gap sub seal provided near the tip of the female member of the gap sub. The first and second seals may comprise non-conductive materials. The first and second seals may each comprise one or more O-rings. The first and second seals may comprise one or more lips, protrusions or flanges to engage the male and/or female members of the gap sub for maintaining contact with the male and/or female members during deformation of the gap sub.

Claims42

Dependent claims

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
wherein the tip of the male member engages a first internal shoulder formed into the internal bore of the first seal.

11 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
a second electrically-insulating seal between the female member and the male member, wherein:
the second seal is located within the opening of the female member at a tip of the female member;
the second seal is located externally to the male member adjacent the at least a portion of the male member matingly received in the opening of the female member;
and
the second seal comprises a generally tubular body comprising a non-conductive material;
an external O-ring compressed in an external channel defined at least in part by an external groove on the second seal and an internal surface of the female member;
and
an internal O-ring compressed in an internal channel defined at least in part by an internal groove on the second seal and an external surface of the male member.

18 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
a second electrically-insulating seal between the female member and the male member, wherein:
the second seal is located within the opening of the female member at a tip of the female member;
the second seal is located externally to the male member adjacent the at least a portion of the male member matingly received in the opening of the female member;
and
the second seal comprises a generally tubular body comprising a non-conductive material;
and
a third electrically-insulating seal between the female member and the male member, wherein the third seal is concentric to and axially spaced apart from the second seal.

17 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
a second electrically-insulating seal between the female member and the male member, wherein:
the second seal is located within the opening of the female member at a tip of the female member;
the second seal is located externally to the male member adjacent the at least a portion of the male member matingly received in the opening of the female member;
and
the second seal comprises a generally tubular body comprising a non-conductive material;
wherein one or more protrusions extending radially inward from the female member are received by one or more external recesses of the second seal.

16 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
a second electrically-insulating seal between the female member and the male member, wherein:
the second seal is located within the opening of the female member at a tip of the female member;
the second seal is located externally to the male member adjacent the at least a portion of the male member matingly received in the opening of the female member;
and
the second seal comprises a generally tubular body comprising a non-conductive material;
wherein one or more protrusions extending radially outwardly from the male member are received by one or more internal recesses of the second seal.

16 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
a second electrically-insulating seal between the female member and the male member, wherein:
the second seal is located within the opening of the female member at a tip of the female member;
the second seal is located externally to the male member adjacent the at least a portion of the male member matingly received in the opening of the female member;
and
the second seal comprises a generally tubular body comprising a non-conductive material;
wherein:
the second seal comprises one or more indents;
at least a portion of the one or more electrically insulating bodies are adjacent the second seal and are spaced circumferentially around the male member;
and
the one or more indents abut the at least a portion of the one or more electrically insulating bodies that are adjacent the second seal and are spaced circumferentially around the male member.

20 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
wherein a curable material is injected to substantially fill the insulating gap between the male member and the female member around the bodies;
wherein a flange protrudes from an outer surface of the generally tubular body of the first seal and the flange is effective to prevent the curable material from progressing past the flange during injection of the curable material.

12 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
wherein a curable material is injected to substantially fill the insulating gap between the male member and the female member around the bodies;
wherein a ramp portion protrudes from an outer surface of the generally tubular body of the first seal and the ramp portion is effective to direct the curable material away from the generally tubular body during injection of the curable material.

12 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
a second electrically-insulating seal between the female member and the male member, wherein:
the second seal is located within the opening of the female member at a tip of the female member;
the second seal is located externally to the male member adjacent the at least a portion of the male member matingly received in the opening of the female member;
and
the second seal comprises a generally tubular body comprising a non-conductive material;
wherein a first dielectric material is injected into a first gap defined at least in part by a first side of the second electrically insulating seal and a second dielectric material is injected into a second gap defined at least in part by a second side of the second electrically insulating seal.

16 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
wherein the first seal comprises one or more retainers within the internal bore of the first seal to hold the first seal between the tip of the male member and the female member;
wherein each of the one or more retainers is a spring to apply force exerted radially outward on an inner surface of the internal bore of the first seal.

12 more elements

A gap sub comprising:

a male member;
a female member, the female member comprising an opening, wherein the opening matingly receives at least a portion of the male member in a radially spaced apart relationship to provide an electrically-insulating gap separating the male and female members;
the male and female members having bores in fluid communication with one another to define a bore of the gap sub;
one or more electrically insulating bodies disposed between the male member and the female member, the bodies spaced apart around the male member to maintain the male member and the female member in the radially spaced apart relationship;
a first electrically-insulating seal disposed between a tip of the male member and the female member, the first seal located within the opening of the female member, wherein the first seal comprises a generally tubular body comprising:
a first section having a first internal diameter approximately equal to the external diameter of the tip of the male member;
and
a second section, defining an internal bore of the first seal, having an internal diameter approximately equal to an internal diameter of the bore of the male member and an internal diameter of the bore of the female member;
and
wherein:
the first section of the first seal engages the tip of the male member;
and
the internal bore of the male member abuts and is aligned with the internal bore of the first seal and the internal bore of the female member abuts and is aligned with the internal bore of the first seal, the first seal preventing fluid from entering the insulating gap between the male member and the female member from the bore of the gap sub;
a second electrically-insulating seal between the female member and the male member, wherein:
the second seal is located within the opening of the female member at a tip of the female member;
the second seal is located externally to the male member adjacent the at least a portion of the male member matingly received in the opening of the female member;
and
the second seal comprises a generally tubular body comprising a non-conductive material;
wherein a ramp portion protrudes from an outer surface of the generally tubular body of the second seal and the ramp portion is effective to direct a curable material away from the generally tubular body during injection of the curable material.

16 more elements

Dependencies are inferred from the claim text.

Facts

Application: 16/473,210Filed 22 Dec 2017 · us provisional application
Priority: 23 Dec 2016
Published: US 2019/0316712 A117 Oct 2019
Granted: 22 Mar 2022
Term ends: Not estimatedThe source records don’t support an estimate.

Classification10 codes

F16L 25/02
Construction or details of pipe joints not provided for in, or of interest apart from, groups F16L13/00 - F16L23/00: specially adapted for…
E21B 17/003
Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings: with electrically conducting or…
E21B 17/0285
Electrical or electro-magnetic connections: characterised by electrically insulating elements
E21B 17/04
Couplings; joints: between rod or the like and bit or between rod and rod or the like