Apparatus and methods for sponge coring

A core barrel assembly for sponge coring, comprising:

• an outer barrel assembly including a core bit disposed at a lower end thereof and an opposing upper end configured for attachment to a drill string:
• a first inner tube section having a lower end disposed proximate said core bit and an opposing upper end, at least a portion of an interior wall of said first inner tube section comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• at least one other inner tube section having a lower end secured to said upper end of said first inner tube section and an opposing upper end disposed proximate said upper end of said outer barrel assembly, at least a portion of an interior wall of said at least one other inner tube section comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• a layer of webbing material disposed in said layer of sponge material in one of said first and said at least one other inner tube sections, said layer of webbing material extending longitudinally and circumferentially about a bore defined within said at least one of said first and said at least one other inner tube sections;
• a chamber for receiving a core sample bounded by said interior wall of said first inner tube section and said interior wall of said at least one other inner tube section and extending substantially from said lower end of said first inner tube section to said upper end of said at least one other inner tube section;
• and
• a breakable fluid seal mechanism providing a breakable fluid seal within said chamber between said first inner tube section and said at least one other inner tube section, comprising:
• a first sealing element secured to said upper end of said first inner tube section, said first sealing element including a sealing device configured to provide a breakable fluid seal between said sealing device and said interior wall of said first inner tube section;
• and
• a second sealing element secured to said lower end of said at least one other inner tube section, said second sealing element including a sealing device configured to provide a breakable fluid seal between said sealing device of said second sealing element and said interior wall of said at least one other inner tube section, said second sealing element attached to said first sealing element.

A core barrel assembly for sponge coring, comprising:

• an outer barrel assembly including a core bit disposed at a lower end thereof and an opposing upper end configured for attachment to a drill string;
• a first inner tube section having a lower end disposed proximate said core bit and an opposing upper end, at least a portion of an interior wall of said first inner tube section comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• at least one other inner tube section having a lower end secured to said upper end of said first inner tube section and an opposing upper end disposed proximate said upper end of said outer barrel assembly, at least a portion of an interior wall of said at least one other inner tube section comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• a layer of webbing material disposed in said layer of sponge material in at least one of said first and said at least one other inner tube sections, said layer of webbing material extending longitudinally and circumferentially about a bore defined within said at least one of said first and said at least one other inner tube sections, wherein said layer of webbing material is disposed proximate an inner surface of said layer of sponge material;
• and
• a chamber for receiving a core sample bounded by said interior wall of said first inner tube section and said interior wall of said at least one other inner tube section and extending substantially from said lower end of said first inner tube section to said upper end of said at least one other inner tube section.

A core barrel assembly for use in sponge coring, comprising:

• an outer barrel assembly including a core bit secured to a lower end thereof and an opposing upper end configured for attachment to a drill string;
• an inner barrel assembly disposed within said outer barrel assembly and secured thereto, said outer barrel assembly configured to rotate freely relative to said inner barrel assembly, said inner barrel assembly extending to a lower end proximate said core bit from an opposing upper end, at least a portion of an interior wall of said inner barrel assembly comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• a piston configured to provide a fluid seal between an outer cylindrical surface of said piston and said interior wall of said inner barrel assembly;
• at least one laterally movable locking element associated with said piston, said at least one locking element configured to engage a cooperative structure of said interior wall of said inner barrel assembly when said at least one locking element is at a first position and to disengage said cooperative structure when said at least one locking element is at a second position;
• and
• a slidable piston rod associated with said piston, said piston rod located and configured to maintain said at least one locking element at said first position when said piston rod is at one position, said piston rod further configured for travel relative to said piston to another position where said at least one locking element is free to move to said second position.

A core barrel assembly for use in sponge coring having a pressure compensated inner barrel assembly, comprising:

• an outer barrel assembly including a core bit secured to a lower end thereof and an opposing upper end configured for attachment to a drill string;
• an inner barrel assembly disposed within said outer barrel assembly and secured thereto, said outer barrel assembly configured to rotate freely relative to said inner barrel assembly, said inner barrel assembly extending to a lower end proximate said core bit from an opposing upper end, at least a portion of an interior wall of said inner barrel assembly comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• a sealing mechanism disposed proximate said lower end of said inner barrel assembly configured to provide a fluid seal between said sealing mechanism and said interior wall of said inner barrel assembly;
• a pressure compensation mechanism disposed proximate said upper end of said inner barrel assembly and configured to provide a fluid seal between said pressure compensation mechanism and said interior wall of said inner barrel assembly, a region within said interior wall of said inner barrel assembly between said sealing mechanism and said pressure compensation mechanism forming a chamber;
• a pressure relief element disposed on said pressure compensation mechanism configured to maintain fluid contained within said chamber at or below a specified pressure;
• wherein said pressure compensation mechanism comprises a cylindrical housing having said pressure relief element disposed thereon, said cylindrical housing configured to provide a movable fluid seal between an outer surface of said cylindrical housing and said interior wall of said inner barrel assembly;
• and
• a thermal compensation mechanism coupled to said pressure compensation mechanism and configured to move said pressure compensation mechanism through said inner barrel assembly in response to a change in temperature to expand the volume of said chamber, wherein said thermal compensation mechanism comprises an adjusting sleeve slidably disposed in said inner barrel assembly, said adjusting sleeve having one end secured to said cylindrical housing of said pressure compensation mechanism and further including an opposing end configured to abut an end of said sponge liner disposed in said inner barrel assembly, said adjusting sleeve configured to move said cylindrical housing through said inner barrel assembly in response to thermal expansion of said sponge liner.

A core barrel assembly for use in sponge coring having a pressure compensated inner barrel assembly, comprising:

• an outer barrel assembly including a core bit secured to a lower end thereof and an opposing upper end configured for attachment to a drill string;
• an inner barrel assembly disposed within said outer barrel assembly and secured thereto, said outer barrel assembly configured to rotate freely relative to said inner barrel assembly, said inner barrel assembly extending to a lower end proximate said core bit from an opposing upper end, at least a portion of an interior wall of said inner barrel assembly comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• a sealing mechanism disposed proximate said lower end of said inner barrel assembly configured to provide a fluid seal between said sealing mechanism and said interior wall of said inner barrel assembly, wherein said sealing mechanism comprises:
• a piston configured to provide a fluid seal between an outer cylindrical surface of said piston and said interior wall of said inner barrel assembly;
• at least one laterally movable locking element associated with said piston, said at least one locking element configured to engage a cooperative structure of said interior wall of said inner barrel assembly when said at least one locking element is at a first position and to disengage said cooperative structure when said at least one locking element is at a second position;
• and
• a slidable piston rod associated with said piston, said piston rod located and configured to maintain said at least one locking element at said first position when said piston rod is at one position, said piston rod further configured for travel relative to said piston to another position where said at least one locking element is free to move to said second position;
• a pressure compensation mechanism disposed proximate said upper end of said inner barrel assembly and configured to provide a fluid seal between said pressure compensation mechanism and said interior wall of said inner barrel assembly, a region within said interior wall of said inner barrel assembly between said sealing mechanism and said pressure compensation mechanism forming a chamber;
• and
• a pressure relief element disposed on said pressure compensation mechanism configured to maintain fluid contained within said chamber at or below a specified pressure.

A core barrel assembly for use in sponge coring, comprising:

• an outer barrel assembly including a core bit secured to a lower end thereof and an opposing upper end configured for attachment to a drill string;
• a first inner tube section disposed in said outer barrel assembly and having a lower end disposed proximate said core bit and an opposing upper end, said first inner tube section having a bore extending therethrough bounded by an interior wall, at least a portion of said interior wall comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• at least one other inner tube section disposed in said outer barrel assembly and having a lower end and an opposing upper end disposed proximate said upper end of said outer barrel assembly, said at least one other inner tube section having a bore extending therethrough bounded by an interior wall, at least a portion of said interior wall comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• and
• a breakable fluid seal device disposed between said first inner tube section and said at least one other inner tube section and providing a breakable fluid seal between said bore of said first inner tube section and said bore of said at least one other inner tube section, said breakable fluid seal device comprising:
• a lower seal assembly including a housing having a lower end attached to said upper end of said first inner tube section and an opposing upper end, said housing further including a cylindrical bore extending therethrough and a seal element disposed therein and configured to provide a breakable fluid seal in said cylindrical bore, said cylindrical bore in fluid communication with said bore of said first inner tube section;
• and
• an upper seal assembly including a housing having an upper end attached to said lower end of said at least one other inner tube section and an opposing lower end attached to said upper end of said housing of said lower seal assembly, said housing of said upper seal assembly further including a cylindrical bore extending therethrough and a seal element disposed therein and configured to provide a breakable fluid seal in said cylindrical bore of said housing of said upper seal assembly, said cylindrical bore in fluid communication with said cylindrical bore in said housing of said lower seal assembly and said bore of said at least one other inner tube section;
• wherein at least one of said seal element in said lower seal assembly and said seal element in said upper seal assembly is selected from a group consisting of a dome-shaped diaphragm, a conically shaped diaphragm, a ball valve, and a releasable piston.

A core barrel assembly for use in sponge coring, comprising:

• an outer barrel assembly including a core bit secured to a lower end thereof and an opposing upper end configured for attachment to a drill string;
• a first inner tube section disposed in said outer barrel assembly and having a lower end disposed proximate said core bit and an opposing upper end, said first inner tube section having a bore extending therethrough bounded by an interior wall, at least a portion of said interior wall comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• at least one other inner tube section disposed in said outer barrel assembly and having a lower end and an opposing upper end disposed proximate said upper end of said outer barrel assembly, said at least one other inner tube section having a bore extending therethrough bounded by an interior wall, at least a portion of said interior wall comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• a breakable fluid seal device disposed between said first inner tube section and said at least one other inner tube section and providing a breakable fluid seal between said bore of said first inner tube section and said bore of said at least one other inner tube section, said breakable fluid seal device comprising:
• a lower seal assembly including a housing having a lower end attached to said upper end of said first inner tube section and an opposing upper end, said housing further including a cylindrical bore extending therethrough and a seal element disposed therein and configured to provide a breakable fluid seal in said cylindrical bore, said cylindrical bore in fluid communication with said bore of said first inner tube section;
• and
• an upper seal assembly including a housing having an upper end attached to said lower end of said at least one other inner tube section and an opposing lower end attached to said upper end of said housing of said lower seal assembly, said housing of said upper seal assembly further including a cylindrical bore extending therethrough and a seal element disposed therein and configured to provide a breakable fluid seal in said cylindrical bore of said housing of said upper seal assembly, said cylindrical bore in fluid communication with said cylindrical bore in said housing of said lower seal assembly and said bore of said at least one other inner tube section;
• a sealing mechanism disposed proximate said lower end of said first inner tube section configured to provide a fluid seal between said sealing mechanism and said interior wall of said first inner tube section;
• a pressure compensation mechanism disposed proximate said upper end of said at least one other inner tube section configured to provide a fluid seal between said pressure compensation mechanism and said interior wall of said at least one other inner tube section;
• a chamber bounded by said bore in said first inner tube section, said cylindrical bore in said housing of said lower seal assembly, said cylindrical bore in said housing of said upper seal assembly, and said bore in said at least one other inner tube section and extending between said sealing mechanism and said pressure compensation mechanism when said seal element of said lower seal assembly and said seal element of said upper seal assembly are open;
• and
• a pressure relief element disposed on said pressure compensation mechanism configured to maintain fluid contained within said chamber at or below a specified pressure;
• and
• a thermal compensation mechanism coupled to said pressure compensation mechanism and configured to move said pressure compensation mechanism through said bore of said at least one other inner tube section in response to a change in temperature to expand the volume of said chamber;
• wherein said pressure compensation mechanism comprises a cylindrical housing having said pressure relief element disposed thereon, said cylindrical housing configured to provide a movable fluid seal between an outer surface of said cylindrical housing and said interior wall of said at least one other inner tube section;
• and
• wherein said thermal compensation mechanism comprises an adjusting sleeve slidably disposed in said at least one other inner tube section, said adjusting sleeve having one end secured to said cylindrical housing of said pressure compensation mechanism and further including an opposing end configured to abut an end of said sponge liner disposed in said at least one other inner tube section, said adjusting sleeve configured to move said cylindrical housing through said at least one other inner tube section in response to thermal expansion of said sponge liner.

A core barrel assembly for use in sponge coring, comprising:

• an outer barrel assembly including a core bit secured to a lower end thereof and an opposing upper end configured for attachment to a drill string;
• a first inner tube section disposed in said outer barrel assembly and having a lower end disposed proximate said core bit and an opposing upper end, said first inner tube section having a bore extending therethrough bounded by an interior wall, at least a portion of said interior wall comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• at least one other inner tube section disposed in said outer barrel assembly and having a lower end and an opposing upper end disposed proximate said upper end of said outer barrel assembly, said at least one other inner tube section having a bore extending therethrough bounded by an interior wall, at least a portion of said interior wall comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• a breakable fluid seal device disposed between said first inner tube section and said at least one other inner tube section and providing a breakable fluid seal between said bore of said first inner tube section and said bore of said at least one other inner tube section, said breakable fluid seal device comprising:
• a lower seal assembly including a housing having a lower end attached to said upper end of said first inner tube section and an opposing upper end, said housing further including a cylindrical bore extending therethrough and a seal element disposed therein and configured to provide a breakable fluid seal in said cylindrical bore, said cylindrical bore in fluid communication with said bore of said first inner tube section;
• and
• an upper seal assembly including a housing having an upper end attached to said lower end of said at least one other inner tube section and an opposing lower end attached to said upper end of said housing of said lower seal assembly, said housing of said upper seal assembly further including a cylindrical bore extending therethrough and a seal element disposed therein and configured to provide a breakable fluid seal in said cylindrical bore of said housing of said upper seal assembly, said cylindrical bore in fluid communication with said cylindrical bore in said housing of said lower seal assembly and said bore of said at least one other inner tube section;
• a sealing mechanism disposed proximate said lower end of said first inner tube section configured to provide a fluid seal between said sealing mechanism and said interior wall of said first inner tube section, wherein said sealing mechanism comprises:
• a piston configured to provide a fluid seal between an outer cylindrical surface of said piston and said interior wall of said first inner tube section;
• at least one laterally movable locking element associated with said piston, said at least one locking element configured to engage a cooperative structure of said interior wall of said first inner tube section when said at least one locking element is at a first position and to disengage said cooperative structure when said at least one locking element is at a second position;
• and
• a slidable piston rod associated with said piston, said piston rod located and configured to maintain said at least one locking element at said first position when said piston rod is at one position, said piston rod further configured for travel relative to said piston to another position where said at least one locking element is free to move to said second position;
• a pressure compensation mechanism disposed proximate said upper end of said at least one other inner tube section configured to provide a fluid seal between said pressure compensation mechanism and said interior wall of said at least one other inner tube section;
• a chamber bounded by said bore in said first inner tube section, said cylindrical bore in said housing of said lower seal assembly, said cylindrical bore in said housing of said upper seal assembly, and said bore in said at least one other inner tube section and extending between said sealing mechanism and said pressure compensation mechanism when said seal element of said lower seal assembly and said seal element of said upper seal assembly are open;
• and
• a pressure relief element disposed on said pressure compensation mechanism configured to maintain fluid contained within said chamber at or below a specified pressure.

A core barrel assembly, comprising:

• an outer barrel assembly including a core bit secured to a lower end thereof and an opposing upper end configured for attachment to a drill string;
• an inner barrel assembly disposed within said outer barrel assembly including a lower end and an opposing upper end;
• and
• a bearing assembly disposed at said lower end of said inner barrel assembly adjacent said core bit configured to radially position and orient said inner barrel assembly relative to a rotational axis of said outer barrel assembly and further configured to maintain said lower end of said inner barrel assembly at a substantially fixed longitudinal position along said rotational axis of said outer barrel assembly;
• and
• a latch mechanism disposed on one of an interior wall of said core bit and an interior wall of said inner barrel assembly configured, in cooperation with said bearing assembly, to maintain said lower end of said inner barrel assembly at said substantially fixed longitudinal position;
• wherein said upper end of said inner barrel assembly is freely movable within said outer barrel assembly along said rotational axis thereof.

A method of sponge coring, comprising:

• providing a sponge core barrel apparatus comprising an outer barrel assembly having a core bit secured to a lower end thereof and an opposing upper end connected to a drill string, said sponge core barrel apparatus further including an inner barrel assembly disposed within said outer barrel assembly and having an interior wall, at least a portion of said interior wall of said inner barrel assembly comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid, said inner barrel assembly further including a sealed chamber extending from proximate a lower end thereof to proximate an opposing upper end, said chamber containing a presaturation fluid;
• maintaining said presaturation fluid within said chamber at or below a specified pressure;
• and
• providing a reusable first sealing mechanism disposed proximate said lower end of said inner barrel assembly and configured to provide a fluid seal between said first sealing mechanism and said interior wall of said inner barrel assembly.

A method of sponge coring, comprising:

• providing an outer barrel assembly having a core bit secured to a lower end thereof and an opposing upper end secured to a drill string;
• providing a first inner tube section having a lower end and an opposing upper end, an interior wall of said first inner tube section comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• providing a fluid seal at said lower end of said first inner tube section;
• providing at least one other inner tube section having a lower end and an opposing upper end, an interior wall of said at least one other inner tube section comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• providing a fluid seal at said upper end of said at least one other inner tube section;
• providing a breakable fluid seal between said first inner tube section and said at least one other inner tube section;
• filling said first inner tube section with a presaturation fluid;
• filling said at least one other inner tube section with a presaturation fluid;
• securing said upper end of said first inner tube section to said lower end of said at least one other inner tube section to form an inner barrel assembly, said inner barrel assembly including an interior chamber having a length extending substantially from said lower end of said first inner tube section to said upper end of said at least one other inner tube section;
• breaking said breakable fluid seal;
• disposing said inner barrel assembly in said outer barrel assembly, said lower end of said first inner tube section disposed proximate said core bit;
• and
• receiving a core sample within said interior chamber of said inner barrel assembly of a length substantially equal to said length of said interior chamber.

A method of sponge coring, comprising:

• providing an outer barrel assembly having a core bit secured to a lower end thereof and an opposing upper end secured to a drill string;
• providing a first inner tube section having a lower end and an opposing upper end, an interior wall of said first inner tube section comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• providing a fluid seal at said lower end of said first inner tube section;
• providing a fluid seal at said upper end of said first inner tube section;
• filling said first inner tube section with a presaturation fluid;
• providing at least one other inner tube section having a lower end and an opposing upper end, an interior wall of said at least one other inner tube section comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• providing a fluid seal at said lower end of said at least one other inner tube section;
• providing a fluid seal at said upper end of said at least one other inner tube section;
• filling said at least one other inner tube section with a presaturation fluid;
• securing said upper end of said first inner tube section to said lower end of said at least one other inner tube section to form an inner barrel assembly, said inner barrel assembly including an interior chamber having a length extending substantially from said lower end of said first inner tube section to said upper end of said at least one other inner tube section;
• breaking said fluid seal at said upper end of said first inner tube section;
• breaking said fluid seal at said lower end of said at least one other inner tube section;
• disposing said inner barrel assembly in said outer barrel assembly, said lower end of said first inner tube section disposed proximate said core bit;
• and
• receiving a core sample within said interior chamber of said inner barrel assembly of a length substantially equal to said length of said interior chamber.

A method of sponge coring, comprising:

• suspending an outer barrel assembly through a floor of a drilling rig with at least a portion of an upper end thereof extending above said drilling rig floor, an opposing lower end of said outer barrel assembly having a core bit secured thereto;
• disposing a sealing mechanism proximate a lower end of a first inner tube section to provide a fluid seal proximate said lower end of said first inner tube section;
• disposing a seal element proximate an opposing upper end of said first inner tube section to provide a fluid seal proximate said upper end of said first inner tube section and to form a chamber within said first inner tube section between said sealing mechanism and said seal element;
• filling said chamber of said first inner tube section with a presaturation fluid, at least a portion of an interior wall of said first inner tube section comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• disposing a seal element proximate a lower end of at least one other inner tube section to provide a fluid seal proximate said lower end of said at least one other inner tube section;
• disposing a second sealing mechanism proximate an opposing upper end of said at least one other inner tube section to provide a fluid seal proximate said upper end of said at least one other inner tube section and to form a chamber within said at least one other inner tube section between said seal element proximate said lower end of said at least one other inner tube section and said second sealing mechanism;
• filling said chamber of said at least one other inner tube section with said presaturation fluid, at least a portion of an interior wall of said at least one other inner tube section comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• suspending said at least one other inner tube section above said first inner tube section and connecting said upper end of said first inner tube section to said lower end of said at least one other inner tube section;
• opening said seal element proximate said upper end of said first inner tube section and said seal element proximate said lower end of said at least one other inner tube section to form a single continuous chamber extending through said first inner tube section and said at least one other inner tube section between said sealing mechanism and said second sealing mechanism;
• and
• lowering said first inner tube section and said at least one other inner tube section into said outer barrel assembly.

A core barrel assembly for sponge coring, comprising:

• an outer barrel assembly including a core bit disposed at a lower end thereof and an opposing upper end configured for attachment to a drill string;
• a first inner tube section having a lower end disposed proximate said core bit and an opposing upper end, a majority of an interior wall of said first inner tube section comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• at least one other inner tube section having a lower end secured to said upper end of said first inner tube section and an opposing upper end disposed proximate said upper end of said outer barrel assembly, a majority of an interior wall of said at least one other inner tube section comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• a first sealing mechanism disposed proximate said lower end of said first inner tube section and configured to provide a fluid seal between said first sealing mechanism and said interior wall of said first inner tube section;
• and
• a second sealing mechanism disposed proximate said upper end of said at least one other inner tube section and configured to provide a fluid seal between said second sealing mechanism and said interior wall of said at least one other inner tube section;
• and
• a chamber for receiving a core sample bounded by said interior wall of said first inner tube section and said interior wall of said at least one other inner tube section and extending substantially from said lower end of said first inner tube section to said upper end of said at least one other inner tube section.

A core barrel assembly for sponge coring, comprising:

• an outer barrel assembly including a core bit disposed at a lower end thereof and an opposing upper end configured for attachment to a drill string;
• a first inner tube section having a lower end disposed proximate said core bit and an opposing upper end, a majority of an interior wall of said first inner tube section comprising a layer of sponge material adapted to absorb at least one specified reservoir fluid;
• at least one other inner tube section having a lower end secured to said upper end of said first inner tube section and an opposing upper end disposed proximate said upper end of said outer barrel assembly, a majority of an interior wall of said at least one other inner tube section comprising a layer of sponge material adapted to absorb said at least one specified reservoir fluid;
• and
• a breakable fluid seal mechanism providing a breakable fluid seal within said chamber between said first inner tube section and said at least one other inner tube section, comprising:
• a first sealing element secured to said upper end of said first inner tube section, said first sealing element including a sealing device configured to provide a breakable fluid seal between said sealing device and said interior wall of said first inner tube section;
• and
• a second sealing element secured to said lower end of said at least one other inner tube section, said second sealing element including a sealing device configured to provide a breakable fluid seal between said sealing device of said second sealing element and said interior wall of said at least one other inner tube section, said second sealing element attached to said first sealing element.