Coiled Tubing Applications and Measurement Tool

Abstract

An apparatus and system for generating pressure pulses and gathering down-hole sensory information for enhancing and completing a well bore within a coiled tubing operation including: a valve longitudinally and axially positioned within the center of a pulser section and electronics to transmit and record down-hole sensory information. The main fluid flow is interrupted by the main valve which is operated by the controlled pilot fluid stream. The main fluid flow proceeds toward one or more pressure sensors to measure the fluid flow pressure with sensors that send signals to a Digital Signal Processor (DSP) that controls a valve which generates controllable and measurable energy pulses. Recorded downhole sensory information such as temperature, fluid bore and annulus pressure, weight/axial force, torque, vibration, shock, gravity tool-face, casing collar locator, gamma, flow and battery condition can be transmitted in real-time via pressure pulses to the surface with pulser or downloaded for analysis.

We claim: 
     
         1 . An apparatus that generates pressure pulses in a drilling fluid within a well bore that exists within a coiled tubing assembly, said apparatus comprising: a tool within which exists a valve portion longitudinally and axially positioned within a center portion of a main valve assembly, said assembly including a main valve, a main valve pressure chamber, and a main valve orifice with said main valve, such that as said drilling fluid flows downward along said well bore said drilling fluid splits into both an inlet main fluid stream and a pilot fluid stream, wherein said pilot fluid stream flows through a pilot flow annulus and into a pilot flow inlet channel, wherein said pilot fluid stream then flows into a main valve fluid feed channel until it reaches said main valve pressure chamber and through a pilot valve section that functions as a pulser generating portion of said tool that further comprises a pilot valve housing, a pilot shaft positioned in a central axial position within said tool supported by thrust bearings, a seal carrier, upper and lower rotary seals, and a pilot inlet cam and a pilot outlet cam such that said pilot shaft can rotate said pilot inlet cam and pilot outlet cam inside a pilot sleeve with matching orifices so that said pilot fluid stream is controlled by movement of said pilot inlet cam and said pilot outlet cam and wherein said pilot fluid stream fluid flows into and through a pilot flow outlet channel such that said pilot fluid stream fluid recombines with a main fluid flow to become a main exit fluid flow. 
     
     
         2 . The tool of  claim 1 , wherein said upper and lower rotary seals exist within an oil filled pressure chamber and act to separate a portion of said pilot fluid stream fluid above or in front of said upper rotary seal from a portion exposed to atmospheric pressure that exists below or behind said lower rotary seal so that a drive shaft, a motor, and additional sections below said upper and lower rotary seals prevent pilot fluid stream fluid from entering and damaging said motor and associated electronics. 
     
     
         3 . The tool of  claim 1 , wherein said pilot shaft is rotated by an electrical motor which is connected to said drive shaft and wherein said pilot inlet cam and said pilot outlet cam are positioned on said shaft so that both cams can rotate and so that when said pilot inlet cam is in an open position it allows said pilot fluid stream fluid to enter said main valve and simultaneously said pilot outlet cam maintains a closed position that prevents said pilot fluid stream fluid to exit through a reverse flow check valve. 
     
     
         4 . The reverse flow check valve of  claim 3 , wherein said reverse flow check valve allows reverse fluid flow through said tool. 
     
     
         5 . The reverse check valve and reverse fluid flow of  claim 4 , wherein resultant reverse fluid flow is does not cause pulsing of fluid while operation of a normal pulsing mode exists during a forward flow condition. 
     
     
         6 . The tool of  claim 1 , wherein a frequency of opening and closing of a pilot inlet cam and a pilot outlet cam directly influences and determines one or more frequencies of said main valve opening and closing to create pressure pulses in a main fluid column above or in front of said main valve orifice. 
     
     
         7 . The pilot flow check valve of  claim 3 , wherein upon a controlled signal said motor rotates said pilot shaft to position said pilot inlet cam to open and closed positions and wherein when said pilot inlet cam is a closed position said pilot outlet cam is in an open position said pilot fluid stream fluid behind or below said main valve to allowed escape through said reverse flow check valve and to join said main fluid flow. 
     
     
         8 . The pilot flow check valve of  claim 7 , wherein said reverse flow check valve allows pilot fluid stream fluid to exit said main valve so that said pilot fluid stream fluid can return to a rear or lower position with respect to said main valve orifice. 
     
     
         9 . The reverse flow check valve and reverse fluid flow of  claim 5 , wherein said check valve prevents fluid flow back into said tool by not allowing fluid to enter said pilot flow outlet channel which ensures blockage of fluid flow in a reverse direction through said tool and also allows closure of said main valve, thereby stopping further fluid flow. 
     
     
         10 . The tool of  claim 1 , wherein a coupling mechanism toward a motor housing and wherein one or more annular pressure sensors measuring a pressure of flowing fluid is located inside a sensor sub assembly with sensors that send signals to a Digital Signal Processor (DSP) that controls tools and multiple sensors in real time while continuing to generate controllable, large, measurable, rapid energy pulses, improvement of weight on bit and an ability to time drill plugs allows for generation of small cuttings that are easily removed from downhole and also adjustment of pulse amplitude at any time without removing said tool from any coiled tubing downhole completion and/or drilling applications. 
     
     
         11 . A system that generates pressure pulses in a drilling fluid within a well bore that exists within a coiled tubing assembly, said system comprising: a tool within which exists a valve portion longitudinally and axially positioned within a center portion of a main valve assembly, said assembly including a main valve, a main valve pressure chamber, and a main valve orifice with said main valve, such that as said drilling fluid flows downward along said well bore said drilling fluid splits into both an inlet main fluid stream and a pilot fluid stream, wherein said pilot fluid stream flows through a pilot flow annulus and into a pilot flow inlet channel, wherein said pilot fluid stream then flows into a main valve fluid feed channel until it reaches said main valve pressure chamber and through a pilot valve section that functions as a pulser generating portion of said tool that further comprises a pilot valve housing, a pilot shaft positioned in a central axial position within said tool supported by thrust bearings, a seal carrier, upper and lower rotary seals, and a pilot inlet cam and a pilot outlet cam such that said pilot shaft can rotate said pilot inlet cam and pilot outlet cam inside a pilot sleeve with matching orifices so that said pilot fluid stream is controlled by movement of said pilot inlet cam and said pilot outlet cam and wherein said pilot fluid stream fluid flows into and through a pilot flow outlet channel such that said pilot fluid stream fluid recombines with a main fluid flow to become a main exit fluid flow. 
     
     
         12 . A method for generating pressure pulses in a drilling fluid within a well bore that exists within a coiled tubing assembly, said method comprising: a tool within which exists a valve portion longitudinally and axially positioned within a center portion of a main valve assembly, said assembly including a main valve, a main valve pressure chamber, and a main valve orifice with said main valve, such that as said drilling fluid flows is flowing downward along said well bore said drilling fluid splitting into both an inlet main fluid stream and a pilot fluid stream, wherein said pilot fluid stream is flowing through a pilot flow annulus and into a pilot flow inlet channel, wherein said pilot fluid stream then continues to flow into a main valve fluid feed channel until it reaches said main valve pressure chamber and continues through a pilot valve section that functions as a pulser generating portion of said tool further comprising a pilot valve housing, a pilot shaft positioned in a central axial position within said tool supported by thrust bearings, a seal carrier, upper and lower rotary seals, and a pilot inlet cam and a pilot outlet cam such that said pilot shaft can be rotating said pilot inlet cam and pilot outlet cam inside a pilot sleeve with matching orifices so that said pilot fluid stream is being controlled by movement of said pilot inlet cam and said pilot outlet cam and wherein said pilot fluid stream fluid continues flowing into and through a pilot flow outlet channel such that said pilot fluid stream fluid recombines with a main fluid flow for becoming a main exit fluid flow.