Various types of tools are used to form wellbores in subterranean formations for recovering hydrocarbons, such as oil and gas lying beneath the surface. Examples of such tools include rotary drill bits, hole openers, reamers, and coring bits. One common type of drill bit used to drill wellbores is known as a “fixed cutter” or “drag” bit. Rotary drill bits include fixed cutter drill bits, such as polycrystalline diamond (“PDC”) cutters.
In conventional wellbore drilling, a drill bit is mounted on the end of a drill string, which may be several miles long. In practice, at the surface of the wellbore, a rotary table or top drive may turn the drill string, including the drill bit arranged at the bottom of the hole to increasingly penetrate the subterranean formation, while drilling fluid is pumped through the drill string. As the drill bit operates and comes into contact with the ground formation, material cut by the drill bit (generally referred to as cuttings, formation cuttings, or chips) is removed from the face of the drill bit and sent up the wellbore via the drilling fluid.
On occasion, however, cuttings may become clogged in the system, which may result in partial or full blockage of hydraulic operations. It follows that blockage may lead to delays in drilling operations, while remedial measures are undertaken to remove the blockage. Such delays are often costly, time consuming, and hamper the efficiency of drilling operations.
Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily, but may be, to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms.
Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results. Moreover, all statements herein reciting principles and aspects of the disclosure, as well as specific examples thereof, are intended to encompass equivalents thereof. Additionally, the term, “or,” as used herein, refers to a non-exclusive or, unless otherwise indicated.
Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to a direct interaction between the elements and may also include an indirect interaction between the elements described.
Unless otherwise specified, use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well, regardless of the wellbore orientation; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” “downstream,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical or horizontal axis. Unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water, such as ocean or fresh water.
Various values and/or ranges may be explicitly disclosed in certain embodiments herein. However, values/ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited. Similarly, values/ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited. In the same way, values/ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the numerical range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. Similarly, an individual value disclosed herein may be combined with another individual value or range disclosed herein to form another range.
The present disclosure is based, at least in part, on the acknowledgment that current available shaped cutters (e.g., 3D shaped PDC cutters) have either two basic surfaces: either a convex surface for medium to hard formation cutting, or a concave surface for soft to medium formation cutting. Unfortunately, a shaped cutter may need to cut into various different rock types regardless of the style of cutter being used.
Provided are systems and methods for wellbore drilling and, more particularly, example embodiments may use one or more cutting elements that can accommodate these varying different rock types. In at least one embodiment, each cutting element includes a cutting face having one or more specifically shaped cutting features extending therefrom, for example including both a convex portion and a concave portion. In at least one other embodiment, each cutting element includes a cutting face having two or more specifically shaped cutting features extending therefrom, for example including both a convex portion and a concave portion. In at least one embodiment, each of the two or more shaped cutting features is convex shaped, but also angles inwardly and downwardly from a radial exterior point of the cutting feature to a radial interior point of the cutting feature. In at least one embodiment, the radial interior point of each cutting feature is a radial CenterPoint (CP) of the cutting element. In at least one embodiment, the cutting face includes at least three of the disclosed shaped cutting features. In at least one other embodiment, the cutting face includes at least four of the disclosed shaped cutting features.
In at least one embodiment, each of the two or more shaped cutting features are substantially smooth (e.g., but for surface imperfections) from the radial exterior point to the radial interior point. Further to the present disclosure, each of the two or more shaped cutting features may have one or more teeth extending at least partially (e.g., or fully) from the radial exterior point to the radial interior point. For example, in at least one embodiment, the two or more shaped cutting features may have three or more teeth extending from the radial exterior point to the radial interior point. In at least one embodiment, the one or more teeth are one or more rounded teeth, and in yet another embodiment the one or more teeth are one or more sharp teeth.
The drill bit 140 may be a fixed-cutter bit. However, the drill bit 140 may comprise any suitable drill bit (e.g., a roller cone bit, a hybrid bit, etc.) and remain within the scope of the disclosure. The drill bit 140 may employ one or more cutting elements (e.g., as shown in
A pump 155 (e.g., a mud pump) may be used to circulate drilling fluid 160 through a feed pipe 165 and to the kelly 130, which conveys the drilling fluid 160 downhole through the interior of the drill string 125 and through one or more orifices in the drill bit 140. The drilling fluid 160 may then be circulated back to the surface via an annulus 170 defined between the drill string 125 and the walls of the wellbore 145. At the surface, the recirculated or spent drilling fluid 160 exits the annulus 170 and may be conveyed to one or more fluid processing unit(s) 175 via an interconnecting flow line 180. After passing through the fluid processing unit(s) 175, “cleaned” drilling fluid 160 is deposited into a nearby retention pit 185 (e.g., a mud pit). While illustrated as being arranged at the outlet of the wellbore 145 via the annulus 170, those skilled in the art will readily appreciate that the fluid processing unit(s) 175 may be arranged at any other location in the drilling assembly 105 to facilitate its proper function, without departing from the scope of the scope of the disclosure.
It is also to be recognized that the drilling fluid 160 may also directly or indirectly affect the various downhole equipment and tools that it may come into contact during operation. Such equipment and tools may include, but are not limited to, wellbore casing, wellbore liner, completion string, insert strings, drill string, coiled tubing, slickline, wireline, drill pipe, drill collars, mud motors, downhole motors and/or pumps, surface-mounted motors and/or pumps, centralizers, turbolizers, scratchers, floats (e.g., shoes, collars, valves, etc.), logging tools and related telemetry equipment, actuators (e.g., electromechanical devices, hydromechanical devices, etc.), sliding sleeves, production sleeves, plugs, screens, filters, flow control devices (e.g., inflow control devices, autonomous inflow control devices, outflow control devices, etc.), couplings (e.g., electro-hydraulic wet connect, dry connect, inductive coupler, etc.), control lines (e.g., electrical, fiber optic, hydraulic, etc.), surveillance lines, drill bits and reamers, sensors or distributed sensors, downhole heat exchangers, valves and corresponding actuation devices, tool seals, packers, cement plugs, bridge plugs, and other wellbore isolation devices, or components, and the like. Any of these components, among others, may be included in the systems generally described above and depicted in
Moreover, the drill bit 200 may include a metal shank 205 with a mandrel or metal blank 215 securely attached thereto (e.g., at weld location 220). The metal blank 215 extends into bit body 225. The metal shank 205, in certain embodiments, includes a threaded connection 210 distal to the metal blank 215. The bit body 225 may include a plurality of cutter blades 230 formed on the exterior of the bit body 225. Further, the cutter blades 230 may be spaced from each other on the exterior of the bit body 225 to form fluid flow paths or junk slots 255 therebetween.
As illustrated, the plurality of pockets 245 may be formed in the cutter blades 230 in predetermined positions. The cutting elements 250 may each be securely mounted (e.g., via brazing) in corresponding pockets 245 to engage and remove portions of a subterranean formation during drilling operations. That is, each cutting element 250 may be configured to scrape and gouge formation materials from the bottom and sides of a wellbore during rotation of the drill bit 200 by an attached drill string.
A nozzle 240 may be positioned in each nozzle opening 235 and positioned to clear cuttings/chips of formation material from cutting elements 250 through evacuation features of the drill bit 200, including junk slots 255. The bit body 225 may further include the plurality of cutter blades 230 that are separated by the junk slots 255. As the drill bit 200 operates and comes into contact with the ground formation, cuttings are removed from the face of the drill bit 200 and sent up the wellbore via drilling fluid. However, as set forth above, cuttings may generally become clogged in the system, which may result in partial or full blockage of hydraulic operations.
Accordingly, during drilling operations, cuttings may be directed toward higher fluid velocities, via the plurality of cutting elements, to accelerate cuttings removal. Generally, the center of the drill bit 200 may experience low fluid velocities which may cause poor cutting removal. Accordingly, each cutting element 250 may include one or more features that facilitate cutting removal by directing cuttings toward the annulus of the wellbore. In particular, each cutting clement 250 may include one or more relief surfaces that are asymmetric (e.g., as discussed herein).
Turning now to
The cutting section 320, in one or more embodiments, includes a cutting face 325. In the illustrated embodiment, the cutting section 320 further includes two or more shaped cutting features 330 extending from the cutting face 325. In at least one embodiment, the two or more shaped cutting features 330 are formed using an ablation process, such as a laser ablation process, from an original diamond table face, thus resulting in the two or more shaped cutting features 330 and the cutting face 325. Nevertheless, the present disclosure is not limited to any specific process, ablation or otherwise, for creating the two or more shaped cutting features 330. In the illustrated embodiment of
Each of the two or more shaped cutting features 330, in at least one embodiment, is convex shaped, but also angles inwardly and downwardly from a radial exterior point of the cutting feature 330 to a radial interior point of the cutting feature 330. Accordingly, in at least one embodiment a thickness of the two or more shaped cutting features 330 near the radial exterior point is greater than a thickness of the two or more shaped cutting features 330 near the radial interior point. It should be noted that the convexity of the two or more shaped cutting features 330 need not be a true curved surface, but may also be V-shaped as well, and thus include one or more ridges proximate a center thereof.
In at least one embodiment, the two or more shaped cutting features 330 angle inwardly and downwardly from the radial exterior point of the cutting feature 330 to a radial interior point thereof at an angle (φ), which may also be referred to as the internal rake angle, as shown in
Turning now to
Turning now to
Turning now to
Beyond those embodiments disclosed above, the present disclosure is directed to a cutting element with multiple (e.g., more than one) point loading regions spaced (e.g., equally spaced) around a circumference of the cutting face. In at least one embodiment, the point loading regions attach to surfaces that extend away from the circumference as ridges in a mostly ‘V’ shape (or plow shape). In such an embodiment, each half of the V extends to the adjacent point loading region. The ridges connecting the point loading regions are raised off the flat surface of the cutting face, and in most embodiments curved. This curved ridge thus acts as a chip breaker.
Aspects disclosed herein include:
Aspects A, B, and C may have one or more of the following additional elements in combination: Element 1: wherein the two or more shaped cutting features are four or more shaped cutting features. Element 2: wherein the two or more shaped cutting features are six or more shaped cutting features. Element 3: wherein the two or more shaped cutting features are eight or more shaped cutting features. Element 4: wherein the two or more shaped cutting features are ten or more shaped cutting features. Element 5: wherein the two or more shaped cutting features are angled outward by an angle (φ) ranging from 0.5 degrees to 20 degrees. Element 6: wherein each of the two or more shaped cutting features has one or more teeth extending at least partially from a radial exterior point to a radial interior point thereof. Element 7: wherein the one or more teeth are one or more rounded teeth. Element 8: wherein the one or more teeth are one or more sharp teeth. Element 9: wherein each of the two or more shaped cutting features has three or more teeth extending at least partially from a radial exterior point to a radial interior point thereof.
Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.
This application claims the benefit of U.S. Provisional Application Ser. No. 63/604,961, filed on Dec. 1, 2023, entitled “CUTTING ELEMENT INCLUDING TWO OR MORE SHAPED CUTTING FEATURES WITH BOTH A CONVEX PORTION AND A CONCAVE PORTION,” commonly assigned with this application and incorporated herein by reference in its entirety.
Number | Date | Country | |
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63604961 | Dec 2023 | US |