Wellbores may be drilled into a surface location or seabed for a variety of exploratory or extraction purposes. For example, a wellbore may be drilled to access fluids, such as liquid and gaseous hydrocarbons, stored in subterranean formations and to extract the fluids from the formations. Wellbores used to produce or extract fluids may be lined with casing around the walls of the wellbore. A variety of drilling methods may be utilized depending partly on the characteristics of the formation through which the wellbore is drilled.
A wellbore may be initially drilled with a first diameter. A portion of the wellbore may be expanded using a reamer. In some embodiments, the reamer may be located uphole of the bit in the same bottom hole assembly. In some embodiments, the reamer may increase the diameter of the wellbore after a pilot hole has been drilled. Some reamers may include reamer blocks that may be selectively expanded to increase the diameter of the wellbore.
In some embodiments, an expandable tool includes a housing having a longitudinal axis, an expandable block, a resilient member, a spring retainer, and a spacer. The expandable block is at least partially disposed within the housing and is configured to move longitudinally between a retracted configuration and an expanded configuration. The resilient member is configured to bias the expandable block to the retracted configuration. The spring retainer is disposed about the resilient member, and includes a retainer length. The spacer includes a spacer length, and is disposed between the expandable block and the spring retainer. A position of the expandable block along the longitudinal axis in the expanded position is based at least in part on the retainer length and the spacer length.
This summary is provided to introduce a selection of concepts that are further described in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Additional features and aspects of embodiments of the disclosure will be set forth herein, and in part will be obvious from the description, or may be learned by the practice of such embodiments.
In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
This disclosure generally relates to devices, systems, and methods for adjusting expansion of a reamer block.
The drill string 105 may include several joints of drill pipe 108 connected end-to-end through tool joints 109. The drill string 105 transmits drilling fluid through a central bore and transmits rotational power from the drill rig 103 to the BHA 106. In some embodiments, the drill string 105 may further include additional components such as subs, pup joints, etc. The drill pipe 108 provides a hydraulic passage through which drilling fluid is pumped from the surface. The drilling fluid discharges through selected-size nozzles, jets, or other orifices in the bit 110 for the purposes of cooling the bit 110 and cutting structures thereon, and for lifting cuttings out of the wellbore 102 as it is being drilled.
The BHA 106 may include the bit 110 or other components. An example BHA 106 may include additional or other components (e.g., coupled between to the drill string 105 and the bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (“MWD”) tools, logging-while-drilling (“LWD”) tools, downhole motors, underreamers, section mills, hydraulic disconnects, jars, vibration or dampening tools, other components, or combinations of the foregoing.
In some embodiments, the BHA 106 may include one or more expandable tools. Expandable tools may include any tool having a variable diameter, such as stabilizers, reamers, mills, casing cutters, plugs, packers, any other expandable tool, and combinations thereof. An expandable tool may have a retracted diameter and an expanded diameter. In accordance with embodiments of the present disclosure, to change the expanded diameter of the reamer, a technician or drilling operator may insert a spacer between the expandable block of the expandable tool and a spring retainer. The spacer may help to limit the longitudinal movement of the expandable block, thereby limiting the radial expansion of the expandable block.
The BHA 106 may further include a rotary steerable system (RSS). The RSS may include directional drilling tools that change a direction of the bit 110, and thereby the trajectory of the wellbore. At least a portion of the RSS may maintain a geostationary position relative to an absolute reference frame, such as gravity, magnetic north, and/or true north. Using measurements obtained with the geostationary position, the RSS may locate the bit 110, change the course of the bit 110, and direct the directional drilling tools on a projected trajectory.
In general, the drilling system 100 may include other drilling components and accessories, such as special valves (e.g., kelly cocks, blowout preventers, and safety valves). Additional components included in the drilling system 100 may be considered a part of the drilling tool assembly 104, the drill string 105, or a part of the BHA 106 depending on their locations in the drilling system 100.
The bit 110 in the BHA 106 may be any type of bit suitable for degrading downhole materials. For instance, the bit 110 may be a drill bit suitable for drilling the earth formation 101. Example types of drill bits used for drilling earth formations are fixed-cutter or drag bits and/or rolling cutter bits. In other embodiments, the bit 110 may be a mill used for removing metal, composite, elastomer, other materials downhole, or combinations thereof. For instance, the bit 110 may be used with a whipstock to mill into casing 107 lining the wellbore 102. The bit 110 may also be a junk mill used to mill away tools, plugs, cement, other materials within the wellbore 102, or combinations thereof. Swarf or other cuttings formed by use of a mill may be lifted to surface or may be allowed to fall downhole.
In downhole drilling operations, a reamer or other cutting tool may be used to increase the diameter of a wellbore. In some situations, a reamer may be located on the same bottomhole assembly (BHA) as a bit. In this manner, as the bit erodes a formation with a bit diameter, the reamer may follow the bit and erode the formation with a reamer diameter. This may allow for larger wellbores to be drilled in a single pass or trip downhole. In other words, the pilot hole may be drilled immediately while reaming the wellbore. In some situations, a reamer may be tripped into an existing wellbore to increase the diameter of the existing wellbore in a different pass or trip than the bit. Put another way, a pilot hole may be drilled before the reamer is inserted into the wellbore.
In some situations, a reamer may be an expandable reamer. In an expandable reamer, a plurality of reamer blocks may expand from a housing to erode the formation. An expandable reamer may have an expanded configuration and a retracted configuration. In the retracted configuration, a cutting surface of the reamer blocks is radially located at or inward from an outer surface of the housing. In this manner, as the reamer is tripped into a wellbore, the reamer blocks may not contact and erode portions of the wellbore wall. In the expanded configuration, the reamer blocks are radially expanded out of the housing so that the cutting surface is located radially outward from the housing. In this manner, as the reamer is rotated, the reamer may erode portions of the wellbore wall and expand the diameter along portions of the wellbore.
The expandable block 216 may be expanded using an expansion force. For example, the reamer block may be expanded using a hydraulic pressure differential between an interior of the housing and an exterior of the housing. A flow tube may flow through the housing and past the reamers. The flow tube may include one or more ports into a piston chamber. A piston may be longitudinally movable and connected to the piston chamber. As the pressure from the drilling fluid on the piston increases, the piston may move longitudinally. The piston may push on the reamer blocks, which may slide on rails 219. The rails 219 may be angled radially outward such that as the piston moves the reamer blocks longitudinally, the reamer blocks may move radially outward into the expanded configuration. A resilient member may push against the reamer blocks with a biasing force in the downhole direction 213 that opposes the expansion force applied by the piston. Thus, when the hydraulic pressure on the piston overcomes the biasing force, the reamer blocks may be moved outward to the expanded configuration. In this manner, the reamer may be a hydraulically activated reamer. In other words, to activate the reamer, the pressure of the drilling fluid passing through the flow tube may be increased.
In some embodiments, the reamer may be used while drilling. For example, a reamer may be used while simultaneously drilling a pilot hole. In some embodiments, the reamer may be tripped downhole to cut material after a hole has been drilled. For example, the reamer may cut a section of a casing, may drill through a packer or a plug, or may ream a wider section of the wellbore.
The reamer has an expanded diameter (e.g., the diameter of a circle circumscribed about the outer wall of the reamer blocks in the expanded configuration) and a retracted diameter (e.g., the diameter of a circle circumscribed about the outer surface of the housing in the retracted configuration). The reamer ratio is the ratio between the expanded diameter and the retracted diameter. In some embodiments, the reamer ratio may be in a range having an upper value, a lower value, or upper and lower values including any of 2.5, 2.4, 2.3, 2.2, 2.1, 2.0, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, or any value therebetween. For example, the reamer ratio may be greater than 1.1. In another example, the reamer ratio may be less than 2.5. In yet other examples, the reamer ratio may be any value in a range between 1.1 and 2.5. In some embodiments, it may be critical that the reamer ratio is greater than 2.0 to sufficiently expand the wellbore diameter.
In some embodiments, the expandable tool may be hydraulically actuated. For example, the reamer may be actuated by increasing the pressure and/or flow rate of the drilling fluid. In some embodiments, the expandable tool may be electromechanically actuated. In some embodiments, the expandable tool may be actuated using any other actuation mechanism. The expandable tool 212 shown includes a flow tube 222 that may flow through a center of the housing 214. The flow tube 222 may run through a longitudinal axis 223 of the housing 214. Fluid flow, such as drilling fluid, flows through the flow tube from left to right in the embodiment shown. The fluid flow may enter a piston chamber (e.g., the piston chamber 225 in
In some embodiments, a resilient member 230 (e.g., spring) may be arranged around the flow tube 222 and longitudinal axis 223 to apply a biasing force against an upper plate 231. The upper plate 231 may apply a retraction force against the expandable block 216 that opposes the expansion force applied by the piston 228. To transition the expandable tool 212 from the retracted configuration to the expanded configuration, hydraulic pressure pushes on the piston 228, which pushes on the expandable block 216 with an expansion force, thereby urging the expandable block 216 to move longitudinally in the uphole direction 221. This expansion force is resisted by the biasing force of the resilient member 230. Thus, when the expansion force overcomes the biasing force, the expandable blocks 216 are urged longitudinally. The expandable tool 212 may be selectively actuated by increasing the pressure and/or the flow rate of the drilling fluid to increase the expansion force. As the expandable blocks 216 move longitudinally, rails 219 on the opening in the housing 214 direct the expandable blocks 216 radially outward. In the embodiment shown, the resilient member 230 is a coil spring coiled around the flow tube 222. However, in some embodiments, the resilient member 230 may be any other resilient member, including a pneumatic cylinder, a hydraulic cylinder, a linear motor, a compressible material, any other resilient member 230, and combinations thereof.
In the retracted configuration shown in
In some embodiments, the spring retainer 232 may set an expansion limit for the expandable block 216. For example, a retainer length 235 of the spring retainer 232 may determine the expansion distance for the expandable block 216. In some examples, a shorter spring retainer 232 may allow the upper plate 231 to be pushed a further longitudinal distance along the longitudinal axis 223 (e.g., further in the uphole direction 221). Further longitudinal movement of the upper plate 231 enables the expandable block 216 to extend further radially from the housing 214, thereby increasing the diameter of the expandable tool 212 in the expanded configuration. In some embodiments, a longer spring retainer 232 may allow the upper plate 231 to be pushed a shorter amount along the longitudinal axis 223 (e.g., further to the right in the view shown in
In some embodiments, the longitudinal position of the spring retainer 232 may be adjusted to adjust the expansion distance of the expandable block. For example, the spring retainer 232 may be threaded to the housing 214 and/or the flow tube 222. The longitudinal position of the spring retainer 232 may be adjusted by rotating the spring retainer 232 within the housing 214. In this manner, the expansion distance of the expandable block 216 may be adjusted by adjusting the longitudinal position of the spring retainer 232. The compression of the resilient member 230 when the upper plate 231 or spacer 236 interfaces with the spring retainer 232 may be adjusted by adjusting the longitudinal position of the spring retainer 232.
In the expanded configuration, the expandable block 216 extends from the housing 214 so that the outer surface 220 of the expandable block 216 is located an expansion distance (collectively 233) away from the housing. In some embodiments, the expansion distance may be half of the difference in the expanded diameter of the reamer compared to the retracted diameter of the reamer. In some embodiments, the expansion distance may be in a range having an upper value, a lower value, or upper and lower values including any of 1.5 in. (3.8 cm), 1.6 in. (4.1 cm), 1.7 in. (4.3 cm), 1.8 in. (4.6 cm), 1.9 in. (4.8 cm), 2.0 in. (5.1 cm), 2.1 in. (5.3 cm), 2.2 in. (5.6 cm), 2.3 in. (5.8 cm), 2.4 in. (6.1 cm), 2.5 in. (6.4 cm), 3.0 in. (7.62 cm), 4.0 in. (10.16 cm), 5.0 in. (12.7 cm), 6.0 in. (15.24 cm), 8.0 in. (20.32 cm), 10.0 in. (25.40 cm), 12.0 in. (30.48 cm), 15.0 in. (38.10 cm), 18.5 in. (46.99 cm), or any value therebetween. For example, the expansion distance may be greater than 1.5 in (3.8 cm). In another example, the expansion distance may be less than 18.5 in (46.99 cm). In yet other examples, the expansion distance may be any value in a range between 1.5 in (3.8 cm) and 18.5 in (46.99 cm). In some embodiments, it may be critical that the expansion distance be greater than 2.0 in. (5.1 cm) to sufficiently increase the diameter of the wellbore. In some embodiments, each expandable block 216 may have the same expansion distance. In some embodiments, different expandable blocks 216 may have different expansion distances.
In some situations, a drilling operator may desire to change the expansion distance 233. For example, the drilling operator may desire to ream a different diameter portion of a wellbore, or to re-use the expandable tool 212 in a different wellbore having different wellbore parameters. To save on material costs, the drilling operator may desire to re-use the expandable tool 212 and change the expansion distance 233 of the expandable block 216.
Conventionally, the expansion distance 233 of the expandable block 216 is changed by changing the position of the spring retainer 232 and/or replacing the spring retainer 232 with a spring retainer having a different retainer length. Reducing the retainer length, moving the spring retainer 232 in the downhole direction 213, or enabling more compression of the resilient member may increase the expansion distance 233 of the expandable block 216. However, adjusting the position of the spring retainer 232 and/or replacing the spring retainer 232 may be burdensome and take a lot of time. Indeed, adjusting the position of and/or replacing the spring retainer 232 may involve a partial or full disassembly of the expandable tool 212. Disassembly may provide access to the spring retainer 232 for adjustment or replacement. After the spring retainer is adjusted or replaced, the expandable tool 212 may be reassembled. The reassembly may take up to two or more hours. Furthermore, adjustment or replacement of the spring retainer 232 may be performed in a shop. Transportation of the expandable tool 212 to and from the shop takes additional time and resources. Thus, adjusting the position of and/or replacing the spring retainer 232 may take significant amounts of time and resources.
In accordance with embodiments of the present disclosure, the expansion distance 233 of the expandable block 216 may be adjusted without adjusting, moving, or replacing the spring retainer 232. In the view shown in
In some embodiments, the expansion distance 233 of the expandable block 216 may be adjusted without breaking seals, resealing, and pressure testing the expandable tool 212. This may allow a drilling operator or technician to quickly and efficiently change the expansion distance 233 of the expandable block 216 to a modified expansion distance 233 (i.e., intermediate distance) between the maximum expansion limit and the retracted configuration. In the view shown in
In accordance with embodiments of the present disclosure, the expansion distance 233 of the expandable block 216 may be adjusted by inserting a spacer 236 between the upper plate 231 and the spring retainer 232. The spacer 236 may be used together with the spring retainer 232 to adjust the range of motion for the upper plate 231 to move along the longitudinal axis. When the expandable block 216 is being extended, the spacer 236 spanning the spacer length along the longitudinal axis interfaces with the spring retainer 232, thereby limiting further movement of the expandable block 216 along the longitudinal axis 223.
In some embodiments, the spacer 236 may have a sizing plate 238 extending along the longitudinal axis that limits the expansion distance 233 of the expandable block 216 provided by the spring retainer 232 alone. To change the expansion distance 233 of the expandable block 216, a drilling operator or technician may adjust the length of the sizing plate 238. In this manner, by selecting a spacer 236 having a particular length of sizing plate 238, the expansion distance of the expandable block 216 may be quickly and easily adjusted. For example, in
In some embodiments, the spacer 236 may be installed with the expandable block 216 set to expand the maximum expansion limit. In this manner, changing the expansion distance 233 may involve replacing a first spacer with a second spacer having a different length sizing plate 238.
In some embodiments, the sizing plate 238 is configured to contact the spring retainer 232 when the expandable tool 212 is in expanded configuration. In some embodiments, the sizing plate 238 may be seamlessly integrated (e.g., integrally formed) with the spacer 236. In some embodiments, the sizing plate 238 may be removably attached to the spacer 236 to allow different lengths sizing plates 238 to be removably attached to the spacer 236.
In some embodiments an expandable tool 212 having a first spacer 236-1 and an associated a first expansion distance 233-1 of the expandable block 216 in the expanded configuration may be changed or replaced with a second spacer 236-2 associated with a second expansion distance 233-2 of the expandable block 216 in the expanded configuration. This may allow the drilling operator to selectively adjust the expansion distance 233 of the expandable block 216 in the expanded configuration by replacing the spacer 236. This may increase the versatility of the expandable tool 212 and reduce the time and cost used to change the expanded diameter of the expandable tool 212.
In
In some embodiments, to install and/or replace the spacer 236, the spring cover 234 may be disconnected by removing the fastener 240. When the fastener 240 is removed, the spring cover 234 may be removed. The spacer 236 may then be placed on or adjacent to the upper plate 231. The spring cover 234 may be replaced, and the fastener 240 may be inserted through the spring cover 234, the spacer 236, and the upper plate 231. The fastener 240 may then be tightened to secure the spring cover 234, the spacer 236, and the upper plate 231 to each other. This may allow the expansion distance 233 of the expandable block 216 in the expanded configuration to be quickly and easily adjusted. In some embodiments, replacing the spacer 236 by removing the spring cover 234 may be performed in the field, thereby saving time and money.
To move between the retracted configuration shown in
When a piston 228 exerts expansion force onto a lower plate 229, the lower plate 229 transfers the expansion force to the expandable block 216, thereby moving the upper plate 231 towards the resilient member 230 and compressing the resilient member 230. Contact of a spring retainer 232 with a sizing plate 238 may provide the limit for compression of the resilient member 230 and therefore the limit for the expansion distance 233 of the expandable block 216 of the expandable tool 212 in the expanded configuration. In the expanded configuration shown in
To change the expansion distance of an expandable tool 212 in the expanded configuration, a spacer 236 with a different length sizing plate 238 may be used. To change the spacer 236 a fastener 240 may be removed which holds the spring cover 234 to the spacer 236 and to the upper plate 231. After the fastener 240 is removed, the spring cover 234 may be moved, which fully exposes the spacer 236 when the expandable tool 212 is in retracted configuration. The spacer 236 may be disposed radially outside of the resilient member, and disposed longitudinally along at least a portion of the resilient member 230. The benefit of changing the spacer 236, rather than changing the spring retainer 232, is that removing the spring cover 234 is much quicker than removing one or more of the housing 214, the upper plate 231, and the expandable block 216. Moreover, the spacer 236 may be changed without adjusting or removing the resilient member 230.
In accordance with embodiments of the present disclosure, each expandable block 216 on the expandable tool 212 may have a spacer 236. For example, an expandable tool 212 may include three expandable blocks 216 spaced around the circumference of the expandable tool. Each expandable block 216 may include a spacer 236 located between the respective expandable block 216 and the upper plate 231. The expansion distance 233 of each expandable block 216 may be adjusted by changing the respective spacers 236. In some embodiments, each expandable block 216 may have a spacer 236 with the same size sizing plate 238. This may allow each expandable block 216 to have the same modified expansion distance 233. In some embodiments, different expandable blocks may have spacers 236 that have different sized sizing plates 238, resulting in different expansion distances 233.
In some embodiments, an expandable tool may include one or more spacer sets. A spacer set may be a set of spacers that are installed in a single reamer. Each spacer 336 in a spacer set may have the same spacer length 339, and may be associated with a modified expansion distance. By switching out different spacer sets, a drilling operator or technician may quickly and easily change the expansion distance and thereby the expanded diameter of the expandable tool.
By installing spacers between the expandable blocks and the spring cover having different length sizing plates, a modified expansion diameter may be created. For example, the first spacer 336-1 of
The embodiments of the expandable tool have been primarily described with reference to wellbore drilling operations; the expandable tools described herein may be used in applications other than the drilling of a wellbore. In other embodiments, expandable tools according to the present disclosure may be used outside a wellbore or other downhole environment used for the exploration or production of natural resources. For instance, expandable tools of the present disclosure may be used in a borehole used for placement of utility lines. Accordingly, the terms “wellbore,” “borehole” and the like should not be interpreted to limit tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.
One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, not all features of an actual embodiment may be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous embodiment-specific decisions will be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one embodiment to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, any element described in relation to an embodiment herein may be combinable with any element of any other embodiment described herein. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.
A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.
The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that is within standard manufacturing or process tolerances, or which still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.
The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. Changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application claims the benefit of, and priority to, U.S. Patent Application 63/229,823 entitled “Adjustable Reamer” filed on Aug. 5, 2021, which is incorporated herein by this reference in its entirety.
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Number | Date | Country | |
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20230039209 A1 | Feb 2023 | US |
Number | Date | Country | |
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63229823 | Aug 2021 | US |