Method and apparatus for taking an undisturbed core sample
FIELD OF THE INVENTION 
     This invention relates to coring devices, specifically those which can take an undisturbed core sample. The device has particular applications to the environmental field, but may be useful in other contexts where there is a need to obtain an undisturbed sample. 
     BACKGROUND OF THE INVENTION 
     Coring devices have been in use for many years to obtain specimens, either at the surface or in a subterranean well. Typical of such devices are U.S. Pat. Nos. 4,356,872; 4,518,050; 3,794,127; 4,081,040; 3,438,452; 3,064,742; 3,146,837; 2,170,716; 1,784,886; 3,139,147; 4,807,707; 2,382,992; 4,669,554; 4,310,057; 2,141,261; 4,350,051; 4,335,622; 4,804,050; and 2,740,477. 
     Some of these devices have incorporated a ball valve at the lower end to close off the core barrel after a sample is obtained. This feature is shown in U.S. Pat. Nos. 3,146,837; and 4,356,872. These ball valves are mounted in the tool, with the core barrel typically extending through the ball valve when the valve is in the open position to obtain the core specimen. Once the sample has been obtained and the core barrel is retracted, upon return of the core barrel into the tool, a linkage device has been employed to close off the ball valve to isolate the core barrel within the tool. This feature is also shown in U.S. Pat. No. 4,256,192, as well as in Eastman Christensen Technical Data Sheet entitled &#34;Pressure Coring Service.&#34; 
     In the past, devices resembling a clam shell, referred to as full closure core catchers, have been used at the lower end of the core barrel to recover loose, soft or unconsolidated formations practically and efficiently. The core catchers are spring-loaded devices which are also helpful in gripping more consolidated formations securely and retaining them in the core barrel. Typical patents illustrating this feature are U.S. Pat. Nos. 4,606,416; 4,552,229; 4,553,613; 4,607,710; and 4,605,075; and Society of Petroleum Engineers (SPE) paper SPE-15385, entitled &#34;Improved Coring and Core-Handling Procedures for the Unconsolidated Sands of the Green Canyon Area, Gulf of Mexico,&#34; by L. E. Whitebay of Conoco, Inc., presented at the 61st Annual Technical Conference and Exhibition of the Society of Petroleum Engineers held in New Orleans, La., Oct. 5-8, 1986. 
     Also generally of interest to the field of core sample taking are U.S. Pat. No. 3,163,241 and SPE paper 14297 entitled &#34;New Technology in Tools for Recovery of Representative Cores from Uncemented Sand Formations,&#34; by G. A. Tibbitts, Drilling Research Laboratory, and S. R. Radford, then with Norton Christensen Inc. and an inventor of this apparatus. This paper was delivered at the 60th Annual Technical Conference and Exhibition of SPE held in Las Vegas, Nev., Sep. 22-25, 1985. 
     While there have been many different designs of coring devices available in the past, they have not addressed the issue of taking an undisturbed specimen from a formation which is not contaminated by the well fluids. The apparatus of the present invention has unique characteristics to allow it to obtain such undisturbed specimens. 
     SUMMARY OF THE INVENTION 
     The invention is a coring device which has features to seal off from the well fluids prior to taking of the specimen. The apparatus can be hydraulically or pneumatically actuated to move an inner string which is connected to a core barrel. Prior to moving the core barrel, an outer tube is sealingly pushed into the formation. Once the outer tube has been set into the formation, the inner tube drives the core barrel into the formation, leaving behind a rabbit. A clam shell is located at the forward end which stays open as the core barrel is driven into the formation and closes as the core barrel is withdrawn into the outer tube to retain the core. The pneumatic or hydraulic pressure continues to be applied to the inner string as the core barrel is withdrawn into the outer tube. Upon full retraction of the core barrel into the outer tube, a ball valve is actuated to seal off the core barrel. At that time, the hydraulic or pneumatic pressure is removed and the apparatus is pulled to the surface. The core barrel has a venting feature to allow any gas in the core barrel to escape as the core barrel fills with the core sample. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIGS. 1(A-C) are a sectional view of the apparatus of the present invention in the run-in position. 
     FIGS. 2(A-D) are the apparatus shown in FIGS. 1(A-C) during the insertion of the core barrel into the formation. 
     FIGS. 3(A-D) show the core barrel retrieved into the outer tube, with the tool in the position of retrieval from the wellbore. 
     FIG. 4 is a sectional view taken at the line 4--4 in FIG. 1. 
     FIG. 5 is a sectional view taken at the line 5--5 in FIG. 1. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The apparatus A of the present invention is shown in the run-in position in FIGS. 1(A-C). A connection 10 is located at upper end 12 of the slip joint 14. A tubing string (not shown) is connected to connection 10 to facilitate the lowering of the apparatus A into a wellbore to obtain an undisturbed core sample. A pressure source P with an accumulator A&#39; is used to actuate the apparatus. Other means of actuating the apparatus A are also within the scope of the invention. 
     Slip joint 14 has an internal passage 16 extending therethrough. Inner tube 18 is slidably mounted over slip joint 14, as seen by comparing the position of inner tube 18 in FIGS. 1(A-C) and 2(A-D). Toward the upper end of inner tube 18 is seal 20 to provide a sealing engagement between inner tube 18 and slip joint 14 as inner tube 18 translates with respect to slip joint 14. A wiper 22 is also mounted to inner tube 18 adjacent seal 20 to facilitate the sealing functions of seal 20. Those skilled in the art can appreciate that when the tool goes into the position as shown in FIGS. 2(A-D), the drilling fluids that are in the wellbore and the formation fluids that may also be in the wellbore will come in contact with surface 24. Accordingly, wiper 22 removes any accumulations of well fluids or drilling mud from surface 24 prior to contact of seal 20 with surface 24. Inner tube 18 is an elongated tubular member that has an upper passage 26, which is in flow communication with passage 16 of slip joint 14. In the run-in position as shown in FIGS. 1(A- C), slip joint 14 has a lower seal 28. The seal 28 isolates portions of passage 26 from passage 16 disposed between seal 28 and seal 20. Further down the tool, as indicated in FIGS. 1(A-C) and 2(A-D), passage 26 extends into passage 30. Passage 30 is then in fluid communication with passage 32, which extends through cross-flow block 34. A pair of seals 36 and 38 seal between cross-flow block 34 and passage 40. Passage 40 is in fluid communication with passage 32 and from cross-flow block 34 to piston 42 has an annular shape around vent tube 44. The purpose of vent tube 44 will be described below in the discussion of how a core is taken. At this point, those skilled in the art can appreciate that flow in passage 46 can enter cross-flow block 34 and exit the apparatus through aligned passages 48 and 50. Passage 48 is in cross-flow block 34 while passage 50 is in inner tube 18. During the operation of the tool, the relative position of cross-flow block 34 with respect to inner tube 18 remains unchanged, leaving passages 48 and 50 in constant alignment. 
     Piston 42 has a tapered upper surface 52. Vent tube 44 is sealed into piston 42 via seal 54. As passage 40 extends downwardly toward tapered surface 52, it branches laterally through openings 56 in inner tube 18. An annular space 58 is defined between outer tube 60 and inner tube 18 and extends from the upper end at a location adjacent seal 62 to its lowermost portion at seal 64. Wiper 66 is mounted adjacent seal 62 to wipe off any well fluids or drilling mud from surface 68 prior to seal 62 making contact with surface 68. Outer tube 60 has an upper shoulder 70 which can selectively come in contact with shoulder 72 on inner tube 18 for purposes of further driving outer tube 60 into the formation to be cored, as will be explained below. 
     A plurality of shear pins 74 retain piston 42 in the position shown in FIG. 1 until sufficient pressure is built up from the surface through passages 16, 30, 32, 40, and annulus 58 to shear pin 74 and allow piston 42 to start moving downwardly as shown in FIGS. 2(A-D). 
     Located within piston 42 is passage 76, which is in fluid communication with passages 46, 48, and 50 to provide a vent path out of the tool for any accumulated vapors during coring, as will be described below. Also located in passage 76 is check valve 78. Check valve 78 is of standard construction and is known to those skilled in the art. The preferred embodiment includes a check valve which is a spring-loaded ball. Passage 76 connects to the lower end of inner tube 18 which comprises the core barrel 80. At the lower end of core barrel 80 is a tapered section 82 to facilitate driving the core barrel 80 into the formation. Also at the lower end of core barrel 80 is a rabbit 84, which is initially held to core barrel 80 by shear pin 86. While the rabbit 84 is in the position shown in FIGS. 1(A-C), it extends slightly beyond tapered surface 82. A peripheral seals between the rabbit 84 and the core barrel 80. The core barrel 80 can be equipped with a liner 90 which can be removably mounted. The lower end 94 of core barrel 80, which contains taper 82, is threadedly connected at threads 92 to the remainder of the core barrel. As will be later described, when the core is pulled to the surface, it can be removed from the core barrel 80 by unthreading threads 92 to remove the lower end 94 of core barrel 80. When the lower end 94 is removed, the liner 90 is removed with it. Thereafter, a new liner 90 can be inserted and the process repeated. 
     Also mounted to lower end 94 is a clam shell 96, shown in FIGS. 1(A-C) in the open position, circumscribing rabbit 84, and shown in FIG. 2 in the closed position as the specimen in the core barrel 80 is returned to within outer tube 60. 
     As shown in FIGS. 1(A-C), a ball valve assembly, generally referred to as 98, is included in the apparatus A. In the run-in position, the core barrel 80 extends through the ball valve assembly 98, which is then in the open position (see FIG. 5). As shown in FIG. 5, ball valve assembly 98 comprises of a ball 100, which is retained by pins 102. A link 104 is connected to ball 100 to actuate it upon movement of operator assembly 106. Operator assembly 106 comprises of a ring 108 connected to link 104. Connected to ring 108 is an elongated tubular member 110 terminating in an inwardly oriented shoulder 112. A spring 114 bears on shoulder 112 as well as ring 116. A second elongated tubular member 118 is threadedly connected to member 110 at threads 120. Ring 116 has an inwardly oriented shoulder 122 which catches a shoulder 124, as shown in FIG. 3. The engagement between shoulders 122 and 124 lifts ring 116 away from elongated member 118 and ultimately pulls up elongated member 110, which in turn pulls up ring 108 and link 104, turning ball 100 from the position shown in FIGS. 1(A-C) to the position shown in FIG. 3 after the core barrel 80 clears the ball 100 (see FIGS. 3(A-D). 
     The ball 100 rides against a seat 126 for sealing to the outer tube 60. The seat 126 is held in place by retainer 128 which is sealed against the outer tube 60 by seal 130. 
     Located near the lowermost end of outer tube 60 is seal 132, which prevents entry of formation fluids or drilling fluids into outer tube 60 as it is run into the formation before a core is taken. 
     It should be noted that the cross-sectional area of tapered surface 134, located adjacent seal 64, is greater than the cross-sectional area of tapered surface 136 so that when fluid pressure is exerted in annulus 58 there exists a net downward pressure applied on outer tube 60 to help retain outer tube 60 lodged in the formation during coring. 
     As shown in FIGS. 2(A-D) and 4, a vent passage 138 communicates with annular passage 140, wherein is housed operator assembly 106. Also located in passage 138 is a bleed valve 143, which can be used at the surface after coring to vent any accumulated fluid pressure in passage 140 prior to disassembly of the tool. 
     Looking now at the upper end of the tool, it can be seen that slip joint 14 has a shoulder 142, which can be brought into selective contact with shoulder 144 to selectively further drive the inner tube 18 as desired when taking a core. The various parts of the apparatus A now having been described, its operation will be described in detail. The apparatus A is connected to a tubing string and lowered to the desired depth in the wellbore adjacent the formation that is to be cored. Pumping facilities such as pump P are provided at the surface to raise the pressure in the tubing string and through passages 16, 30, 32, 40, 56, and 58. Accumulator facilities A&#39; are also provided at the surface. Those skilled in the art will appreciate that accumulators of the bladder type, including a gas pocket above the bladder, can be useful in storing potential energy and converting potential energy to kinetic energy at a desired moment. The reason the accumulators are used with the apparatus of the present invention is to assist in the transfer of potential energy to kinetic energy at the piston 42 to assist the piston 42 to fully stroke. 
     All the components of the apparatus A of the present invention having been described, its operation will now be reviewed in detail. FIG. 1(A-C) indicate the position of the apparatus A as it is being run into the wellbore. The assembly is lowered until tapered surface 82 contacts the formation. Further letting up on the drillstring results in penetration of the formation by tapered surface 146. Seal 88 prevents migration of formation fluids or drilling mud past rabbit 84 into the inside 148 of core barrel 80. Once the outer tube 60 is sufficiently embedded into the formation in the position shown in FIGS. 1(A-C), pressure at the surface is increased to build up pressure through a flowpath comprising passages 16, 30, 32, 40, 56, and 58. Upon build-up of sufficient pressure on tapered surface 52 of piston 42, shear pins 74 are all sheared. Since rabbit 84 is butted up against the formation sufficiently into the formation to isolate well fluids from entering within the core barrel, as indicated by numeral 148, the shearing of pins 74 sends piston 42 in motion. Piston 42 is accelerated in part due to the sudden shearing of screws 74, plus the effect of the accumulated energy in the accumulator A&#39; at the surface. As piston 42 accelerates, it moves in conjunction with vent tube 44 and cross-flow block 34 as the entire inner tube 18 moves downwardly. After initial movement of the core barrel 80, shear pin 86 is sheared, leaving the rabbit 84 up against the formation. As the core barrel 80 moves further into the formation as a result of the pressure acting on piston 42, the clam shell 96 clears rabbit 84 which is held stationary up against the formation. Upon full extension of core barrel 80, the process of retaining the sample obtained begins, and reference is required to FIGS. 2(A-D). It should be noted that during the time that the core barrel is driven into the formation, ball valve assembly 98 is in the open position, as shown in FIGS. 1(A-C). It should also be noted that by embedding the outer tube 60 sufficiently into the formation and further by provision of seal 132 and seal 88, the well fluids are isolated from chambers 148 and 140. By the time movement of the core barrel 80 occurs, there&#39;s been sufficient embedment of the outer tube 60 into the formation to isolate the apparatus A from well fluids. As the core barrel 80 is driven into the formation, the volume of chamber 148 between check valve 78 and rabbit 84 decreases. To allow any vapors accumulated in chamber 148 to escape, the check valve 78 is operable to relieve pressure in chamber 148 through tube 44 and out of the apparatus A through aligned passages 48 and 50. 
     As previously stated, the difference in cross-sectional areas between tapered surfaces 134 and 136 (see FIGS. 2(A-D) provides for a net downward force on outer tube 60 when pressure is applied into passage 40. This feature helps to retain outer tube 60 within the formation as core barrel 80 is driven into the formation past rabbit 84. If for any reason core barrel 80 has not sufficiently embedded itself in the formation, the operator at the surface can let up on the drillstring (not shown) thereby lowering slip joint 14 with respect to inner tube 18 until shoulder 142 hits against shoulder 144. In this manner, by repeatedly pulling up and letting off at the surface on the drillstring, the inner tube 18 to which the core barrel 80 is connected can be further driven into the formation. 
     It is now desired to retrieve the sample obtained and reference is made to FIGS. 2(A-D) and 3(A-D). To retrieve the sample, the operator at the surface pulls up on the drillstring, which in turn, due to the connection of the drillstring to slip joint 14, exerts an upward pull on slip joint 14 until shoulder 150 hits surface 152 (see FIGS. 3(A-D). Thereafter, as slip joint 14 is pulled up (see FIGS. 2(A-D), core barrel 80 is pulled back into outer tube 60. As the core barrel 80 moves back into outer tube 60, the motion in this direction causes clam shell 96 to pivot to the closed position shown in FIGS. 2(A-D). This retains loose or unconsolidated specimens obtained in chamber 148 from falling out. As the core barrel 80 moves further into outer tube 60 and clears ball 100, shoulder 124 hits against shoulder 122. This puts an upward force on ring 116, which pushes spring 114 upwardly, which in turn puts an upward force on elongated tubular member 110 which is connected to ring 108, which is in turn connected to link 104. As a result of the movements of the members just described, ring 108 is lifted upwardly. Since link 104 is connected offcenter to ball 100, a rotational motion results to ball 100, putting it in the position shown in FIGS. 3(A-D). While all this is going on, pressure from the surface continues to be applied through passages 16, 30, 32, 40, 56, and 58. Once the ball 100 is put in the closed position as shown in FIG. 3, the pressure applied at the surface is removed. At that time the apparatus is in the position shown in FIGS. 3(A-D), with the core barrel 80 completely within the outer tube 60 and valve assembly 98 in the closed position. Similarly, the clam shell 96 is also in the closed position to retain the core sample just obtained within chamber 148. Thus, before the outer tube 60 is extracted from the formation, the chamber 148 is isolated from any migration of well fluids or formation fluids into chamber 148. 
     Thereafter, further upward pulling on the tubing string with shoulder 150 up against surface 152 results in removal of outer tube 60 from the formation. The tubing string is retrieved to the surface in the usual manner and the apparatus A is disconnected when it is brought to the surface. Any accumulated pressure in chamber 140 can be vented through the use of valve 143, as shown in FIG. 4. When the apparatus A is at the surface, pivot pin 102 is rotated to open ball 100. Downward force puts shoulder 144 into contact with shoulder 142, and continuing downward force pushes inner tube 80 through ball 100. Threads 92 are then undone, allowing removal of lower end 94. This exposes liner 90 (if used), for removal, thus allowing the core to then be cut up or otherwise subjected to any analysis or test. 
     The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention.