Patent Application
20150068809
The disclosure relates generally to coring tools for obtaining core samples of earth formations. More specifically, disclosed embodiments relate to coring tools including core bits and drilling plugs designed for use with the core bits during non-coring drilling using the coring tools. The disclosure also includes methods of using such coring tools.
When seeking information regarding the characteristics of an earth formation, such as, for example, the hydrocarbon content in the formation, a core sample may be obtained from the earth formation. The core sample may then be analyzed to determine the characteristics of the earth formation. Core samples may be obtained using coring tools. Coring tools conventionally include a core bit, which may include an inner bore and a cutting structure surrounding the inner bore. As the coring tool is driven into an earth formation, typically at the bottom of a previously formed borehole, the core bit may remove earth material around a core sample, which is received into the inner bore. A receptacle may be connected to the core bit, and may extend longitudinally above the core bit. The core sample may be received into the receptacle, and may be retained in the receptacle by a core catcher to keep the core sample within the receptacle as the core bit is withdrawn from the borehole.
In many cases, it may be desirable to alternate between coring operations and conventional drilling operations without tripping (i.e., removing) the drill string from the borehole. Accordingly, coring tools have been developed wherein the receptacle may be removed from the core bit by a wireline device, and a corresponding plug may be lowered by a wireline device and positioned concentrically within the inner bore of the core bit so as to plug the inner bore while the core bit is used to drill through the formation without coring. The corresponding plug may feature cutting structures positioned to engage and degrade the formation. The assembled core bit and plug may engage the formation and advance through the formation in a manner similar to a conventional drilling bit.
A coring tool may comprise a core bit comprising at least one cutting structure extending from adjacent an inner bore of the core bit to an outer gage of the core bit. A drill plug may be configured to close the inner bore of the core bit, and the drill plug may comprise at least one cutting structure. An indexing device may be disposed between the drill plug and the core bit. The indexing device may be configured to maintain a predetermined angular relationship between the core bit and the drill plug. The at least one cutting structure of the core bit and the at least one cutting structure of the drill plug may form a substantially continuous cutting structure at the predetermined angular relationship.
A coring tool may comprise a core bit with an inner bore extending longitudinally through a body of the core bit, and a coupling member configured for attachment of the coring tool to a drill string. A drill plug may be sized and configured to be inserted into the inner bore of the core bit. An indexing device configured to maintain a predetermined angular relationship between the core bit and the drill plug may be disposed between the core bit and the drill plug and located longitudinally along the coring tool at a location distal to the coupling member of the coring tool.
A method of drilling with a coring tool may comprise removing a core sample receptacle from an inner bore of a core bit, inserting a drill plug into the inner bore of the core bit, rotating the drill plug relative to the core bit to reach a predetermined angular relationship, rotationally locking the drill plug relative to the core bit at the predetermined angular relationship, and drilling through a formation with the core bit and drill plug.
While the disclosure concludes with claims particularly pointing out and distinctly claiming specific embodiments, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description when read in conjunction with the accompanying drawings, in which:
The illustrations presented herein are not meant to be actual views of any particular coring tool or component thereof, but are merely idealized representations employed to describe illustrative embodiments. Thus, the drawings are not necessarily to scale.
Disclosed embodiments relate generally to coring tools including core bits with corresponding drill plugs, the core bits and drill plugs configured for improved drilling efficiency, including increased rate of penetration (ROP) and enhanced cleaning. More specifically, disclosed are embodiments of core bits and drill plugs featuring complementary cutting structures and indexing devices that maintain a predetermined angular orientation between the core bit and the corresponding drill plug during drilling.
Referring to
The coring tool 100 may further include a receptacle 114, often referred to in the art as an “inner barrel,” configured to receive a core sample 154 at least partially within the receptacle 114. The receptacle 114 may be connected to the core bit 102. For example, the receptacle 114 may be located partially within the central opening 112 with a lower end of the receptacle 114 being located adjacent to the inner surface 110 of the core bit 102. As another example, the receptacle 114 may be located longitudinally above the core bit 102. The receptacle 114 may be rotatable relative to the core bit 102, such that the receptacle 114 may remain rotationally stationary as it receives a coring sample while the core bit 102 rotates to cut the coring sample. The receptacle 114 may be generally tube-shaped and may include an inner surface 116 defining a bore 118 extending at least partially through the receptacle 114. The bore 118 may be sized and configured to receive a core sample 154 formed using the core bit 102 longitudinally (i.e., in a direction parallel to a direction in which the coring tool 100 is advanced when procuring a core sample 154) within the bore 118. The receptacle 114, and particularly the bore 118 extending through the receptacle 114, may extend for at least as long as a desired longitudinal length of a core sample 154 to be analyzed. In some embodiments, the receptacle 114 may be rotatable with respect to the drill string 101 such that rotation of the drill string 101 does not necessarily produce corresponding rotation of the receptacle 114. The receptacle 114 may be formed from a material suitable for use in a downhole environment, such as, for example, aluminum or steel alloys.
The coring tool 100 may include an outer barrel 122 connected to the core bit 102. The outer barrel 122 may comprise, for example, a generally tubular member, the lower end of which may be attached to the core bit 102. The outer barrel 122 may be connected to the remainder of the drill string 101 and may transfer loads (e.g., weight-on-bit and torque) to the core bit 102 to drive the core bit 102 into an underlying earth formation. The receptacle 114 may be located within the outer barrel 122, and a flow path 124 may be defined between the receptacle 114 and the outer barrel 122 to enable drilling fluid to be pumped to the core bit 102 (e.g., to nozzles on the core bit 102 or simply out the central opening 112 proximate the inner surface 110), which may serve to remove cuttings produced while coring.
The outer barrel 122 may include a stabilizer 126 configured to stabilize the core bit 102 as it is driven into an underlying earth formation in some embodiments. In other embodiments, one or more stabilizers may be connected to the coring tool 100 (e.g., instead of, or in addition to, the stabilizer 126 incorporated into the coring tool 100 itself). The stabilizer 126 may include blades 128 extending radially outward from a remainder of the outer barrel 122. The blades 128 may contact and ride against walls of a borehole to stabilize the core bit 102 as it is advanced (e.g., driven linearly or driven linearly and rotationally). The blades 128 may be fixed in position in some embodiments. In other embodiments, the blades 128 may be extendable to a radially outermost position in which they contact and ride against the borehole wall and retractable to a radially innermost position in which they do not contact the borehole wall. The stabilizer 126 may be located longitudinally adjacent to the core bit 102 (i.e., there may not be any radially protruding features on the coring tool 100 between the core bit 102 and the stabilizer 126). For example, the outer barrel 122 may be the first section of the drill string 101 attached to the core bit 102. In some embodiments, a shank 130 may be used to attach the core bit 102 to the outer barrel 122. The stabilizer 126 may be said to be longitudinally adjacent to the core bit 102. Thus, there may not be any additional drill string sections (e.g., subs) between the outer barrel 122 on which the stabilizer 126 is located and the core bit 102.
In some situations, it may be desirable to alternate between coring operations and conventional drilling operations without necessitating the costly and time-consuming step of tripping (i.e., removing) the drill string 101 from the well bore 156. Accordingly, receptacle 114 may be removable from the core bit 102 (e.g., by wireline device), and a drill plug may be inserted into the central opening 112 of the core bit (e.g., also by wireline device). Referring now to
In some aspects of the present disclosure, the first portion 201 and the second portion 203 of the drill plug 200 may comprise two or more separate components, and the two or more separate components may be formed from different materials. For example, the first portion 201 of the drill plug 200 including the drilling face 202 may be formed from a material highly resistant to abrasion, such as a composite material including tungsten carbide particles suspended in a continuous metal alloy, such as bronze or steel. The second portion 203 (e.g., a shank) of the drill plug 200 may be formed from a different material, such as steel. The material of the second portion 203 may be chosen based on ease of manufacturing and machining, so that the second portion 203 may be more easily formed and affixed or connected to the wireline device 204. The first portion 201 and the second portion 203 may be affixed to one another by brazing, mechanical fasteners, an interference fit (e.g., wherein a portion of the matrix material first portion 201 is placed in compression by a portion of the steel second portion 203), threads, or other methods.
Similarly, the core bit 102 may include two or more separate portions. For example, the core bit 102 may include a bit body 207 cast or sintered from a material suitable for use in a downhole environment, such as a cemented tungsten carbide composite material. The core bit 102 may also include a shank 130. The shank 130 may be made from a material different from the material of the of the bit body 207. For example, the shank 130 may be made from a material with good machinability, such as steel, and may include features such as a tool joint (e.g., threaded box member 209) for connecting the core bit 102 to the drill string 101. The bit body 207 and the shank 130 may be attached together by brazing or other suitable methods to create the bit body of the core bit 102.
The drill plug 200 may include an indexing device 300. The indexing device 300 may be configured to establish a fixed angular relationship between the core bit 102 and the drill plug 200 when the drill plug 200 is inserted into the core bit 102 and the indexing mechanism 300 is engaged. For example, when the drill plug 200 is fully inserted into the core bit 102, the indexing device 300 may prevent relative rotational movement between the core bit 102 and the drill plug 200. In some embodiments of the present disclosure, the indexing device 300 may allow the drill plug 200 to be completely inserted into the core bit 102 in any angular orientation, and the indexing device 300 may engage only when the core bit 102 and the drill plug 200 are rotated relative to one another to reach a predetermined angular relationship. In other embodiments, the indexing device may prevent the drill plug 200 from being fully inserted into the core bit 102 before a predetermined angular relationship between the core bit 102 and the drill plug 200 is established.
Referring now to
The indexing device 300 may be configured to permit relative longitudinal movement between the core bit 102 and the drill plug 200 while simultaneously preventing relative rotational movement therebetween. For example, longitudinal ends of the locking element 303 may feature inclined portions 309 oriented at acute angles to the longitudinal axis 310 of the core bit 102 and the drill plug 200. When longitudinal movement of the drilling plug 200 with respect to the core bit 102 is initiated, such as when removing the drilling plug 200 from the core bit 102 by wireline device 204 (
When it is desired to cease coring operations and begin drilling, the coring receptacle 114 (
The indexing device 300 may be positioned directly between the core bit 102 and the drill plug 200 at the interface therebetween to minimize angular misalignment of the face 106 of the core bit 102 relative to the face of the drill plug 200. In previously known coring tools, the rotational locking between the drill plug 200 and the core bit 102 was achieved at a location remote from the interface between the core bit 102 and the drill plug 200 at a location vertically above the core bit 102. As a result, angular misalignment often occurred between the core bit 102 and the drill plug 200 due to rotational strain of the components below the locking device, and due to limited movement at joints between tool components below the locking device. In one aspect of the present disclosure, the second recess 308 may be formed in the shank 130 of the core bit 102.
During drilling and coring operations, torque and weight on bit (WOB) may be applied to the core bit 102 through the drill string 101 (
In other aspects of the present disclosure, the indexing device 300 may include geometric features disposed on the lateral side surface of drilling plug 200 and corresponding, complementary and interlocking geometric features disposed on the inner surface 110 of the core bit 102 within the central opening 112 of the core bit 102. The geometric features on the lateral side surface of the plug 200 may be configured to interlock with the geometric features on the inner surface 110 in the central opening 112 of the core bit 102 in a manner that permits the drill plug to be inserted into or removed from the central opening 112 of the core bit 102 in a longitudinal direction while preventing any relative rotational movement between the drilling plug 200 and the core bit 102.
For example, referring now to
In some embodiments, the indexing device including the alternating pattern of protrusions 400 and 402 and recesses 401 and 403 may be configured to permit full insertion of the drill plug 200 into the core bit 102 only in a predetermined angular orientation. For example, the alternating pattern of recesses and protrusions may include one or more geometrically anomalous features. The geometrically anomalous feature may be configured to permit full insertion of the drill plug 200 into the core bit 102 in only one angular orientation. For example, one of the protrusions 400 on the outer diameter of the drill plug 200 may be larger than all other protrusions 400. One of the recesses 403 in the inner bore of the core bit 102 may be correspondingly larger, such that the larger protrusion may only fit within the correspondingly larger recess. Thus, the drill plug 200 may not be fully inserted into the core bit 102 until the larger protrusion and larger recess are aligned, thereby placing the core bit 102 and the drill plug 200 in a predetermined angular relationship.
When it is desired to cease coring operations and begin drilling, the coring receptacle 114 (
Referring now to
The indexing mechanism 300 (
The core bit 102 may also include fluid nozzles 503 in communication with fluid passages in the core bit 102. The fluid nozzles 503 may be configured to direct a flow of drilling fluid from the flow path 124 (
In some embodiments of the present disclosure, the predetermined angular relationship between the core bit 102 and the drill plug 200 may include a single angular relationship. In other embodiments, the predetermined angular relationship may include multiple angular relationships. Accordingly, the features of the core bit 102 and the drill plug 200 may be configured to align at multiple angles, such as every one hundred and twenty (120) degrees of relative rotation between the core bit 102 and drill plug 200. For example, the features of the core bit 102 and the drill plug 200 may include three blades spaced equidistantly around the rotational axis of the core bit and configured to form substantially continuous blades in any of three angular orientations one hundred and twenty (120) degrees apart.
The blades 104 and inner blades 500 may be configured with fluid courses 505 (i.e., spaces) therebetween in which formation chips dislodged by cutting elements 501 can collect to be swept away by the flow of drilling fluid. The fluid courses 505 may begin near a center of the drilling face 202 of the drilling plug 200 and extend along the surface of the core bit 102 to the outer gage 108.
In another aspect of the present disclosure, a method of drilling with a coring tool may comprise removing a core sample receptacle from an inner bore of a core bit with a wireline device, inserting a drill plug into the inner bore of the core bit with a wireline device, rotating the drill plug relative to the core bit to reach a predetermined angular relationship, and drilling through a formation with the core bit and drill plug. The method of drilling with a coring tool may include rotating the drill plug relative to the core bit to reach the predetermined angular relationship subsequent to inserting the drill plug into the inner bore of the core bit. The method of drilling with a coring tool may include inserting the drill plug into the inner bore of the core bit subsequent to rotating the drill plug relative to the core bit to reach the predetermined angular relationship. The method of drilling with a coring tool may include removing the drill plug from the inner bore of the core bit with a wireline device subsequent to drilling. The method of drilling with a coring tool may also comprise reinserting the core sample receptacle into the inner bore of the core bit with a wireline device subsequent to removing the drill plug.
Additional, nonlimiting embodiments within the scope of this disclosure include:
A coring tool, comprising: a core bit comprising at least one cutting structure extending from adjacent an inner bore of the core bit to an outer gage of the core bit; a drill plug configured to close the inner bore of the core bit, the drill plug comprising at least one cutting structure; and an indexing device disposed between the drill plug and the core bit, the indexing device configured to maintain a predetermined angular relationship between the core bit and the drill plug, wherein the at least one cutting structure of the core bit and the at least one cutting structure of the drill plug form a substantially continuous cutting structure at the predetermined angular relationship.
The coring tool of embodiment 1, wherein the indexing device comprises a movable locking element disposed in a recess of the drill plug, the locking element comprising a protruding portion corresponding to a recess in the inner bore of the core bit, the indexing device comprising at least one biasing element configured to urge the protruding portion of the locking element into the recess in the inner bore of the core bit.
The coring tool of embodiments 1 or 2, wherein the indexing device comprises at least one geometric feature disposed on an outer diameter of the drill plug and at least one corresponding geometric feature disposed on an inner diameter of the coring plug, the corresponding geometric features configured to interlock to maintain the predetermined angular relationship between the core bit and the drill plug.
The coring tool of embodiment 3, wherein the at least one geometric feature disposed on the outer diameter of the drill plug and the at least one geometric feature disposed on the inner diameter of the coring plug comprise a pattern of alternating recesses and protrusions.
The coring tool of embodiment 4, wherein the pattern of alternating recesses and protrusions comprises an anomalous recess and a corresponding anomalous protrusion.
The coring tool of any one of embodiments 1 through 5, wherein the core bit comprises a shank and the indexing device is disposed between the drill plug and the shank of the core bit.
The coring tool of any one of embodiments 1 through 6, wherein the at least one cutting structure of the core bit comprises a blade with a plurality of hard material cutting elements mounted on the blade.
The coring tool of any one of embodiments 1 through 7, wherein the at least one cutting structure of the drill plug comprises a blade with at least one hard material cutting element mounted on the blade of the drill plug.
The coring tool of any one of embodiments 1 through 8, wherein the predetermined angular relationship comprises a single angular orientation between the core bit and the drill plug.
The coring tool of any one of embodiments 1 through 8, wherein the predetermined angular relationship comprises two or more angular orientations between the core bit and the drill plug.
A coring tool, comprising: a core bit with an inner bore extending longitudinally through a body of the core bit; a coupling member configured for attachment of the coring tool to a drill string; a drill plug sized and configured to be inserted into the inner bore of the core bit; and an indexing device configured to maintain a predetermined angular relationship between the core bit and the drill plug, the indexing device disposed between the core bit and the drill plug and located longitudinally along the coring tool at a location distal to the coupling member of the coring tool.
The coring tool of embodiment 11, wherein the core bit and the drill plug comprise complementary cutting structures, the complementary cutting structures together forming a substantially continuous cutting structure at the predetermined angular relationship between the core bit and the drill plug.
The coring tool of embodiments 11 or 12, wherein the substantially continuous cutting structure comprises: a blade extending over at least a portion of the drill plug and at least a portion of the core bit; and a plurality of cutting elements mounted on the blade.
The coring tool of any one of embodiments 11 through 13, wherein the indexing device is disposed between the drill plug and a shank of the core bit.
The coring tool of any one of embodiments 11 through 14, wherein the indexing device is disposed at least partially in a shank of the drill plug.
A method of drilling with a coring tool, comprising: removing a core sample receptacle from an inner bore of a core bit; inserting a drill plug into the inner bore of the core bit; rotating the drill plug relative to the core bit to reach a predetermined angular relationship; rotationally locking the drill plug relative to the core bit at the predetermined angular relationship; and drilling through a formation with the core bit and drill plug.
The method of embodiment 16, further comprising rotating the drill plug relative to the core bit to reach the predetermined angular relationship subsequent to inserting the drill plug into the inner bore of the core bit.
The method of embodiment 16, further comprising inserting the drill plug into the inner bore of the core bit subsequent to rotating the drill plug relative to the core bit to reach the predetermined angular relationship.
The method of any one of embodiments 16 through 18, further comprising removing the drill plug from the inner bore of the core bit subsequent to drilling without removing the coring tool from a wellbore formed by the drilling.
The method of any one of embodiments 16 through 19, further comprising reinserting the core sample receptacle into the inner bore of the core bit subsequent to removing the drill plug without removing the coring tool from the wellbore.
While certain illustrative embodiments have been described in connection with the figures, those of ordinary skill in the art will recognize and appreciate that the scope of this disclosure is not limited to those embodiments explicitly shown and described herein. Rather, many additions, deletions, and modifications to the embodiments described herein may be made to produce embodiments within the scope of this disclosure, such as those hereinafter claimed, including legal equivalents. In addition, features from one disclosed embodiment may be combined with features of another disclosed embodiment while still being within the scope of this disclosure, as contemplated by the inventors.
