1. Field of the Disclosure
This disclosure relates generally to drill bits and systems for using same for drilling wellbores.
2. Background of the Art
Oil wells (also referred to as wellbores or boreholes) are drilled with a drill string that includes a tubular member having a drilling assembly (also referred to as the drilling assembly or bottomhole assembly or “BHA”) which includes a drill bit attached to the bottom end thereof. The drill bit is rotated to disintegrate the rock formation to drill the wellbore. The BHA includes devices and sensors for providing information about a variety of parameters relating to the drilling operations (drilling parameters), the behavior of the BHA (BHA parameters) and the formation surrounding the wellbore being drilled (formation parameters). A large number of wellbores are drilled along a contoured trajectory. For example, a single wellbore may include one or more vertical sections, deviated sections and horizontal sections. Some BHAs include adjustable knuckle joints to form a deviated wellbore or elements such as arms or paddles on a rotary steerable drilling system for directional control. Such steering devices are typically disposed on the BHA, i.e., away from the drill bit. However, it is desirable to have steering devices that are close to or on the drill bit to effect steering, improve rate of penetration of the drill bit and/or to extend the drill bit life. Further, it is desirable to have a mechanism on the bit to effect steering that has few components and moving parts to improve reliability and reduce downtime.
A drill bit according to one embodiment includes a center member configured to rotate at a first speed and an outer member disposed outside the center member, wherein the outer member is configured to rotate at a second speed. The drill bit also includes a first cutter disposed on the center member and a second cutter disposed on the outer member, wherein the first speed and second speeds are configured to control a resultant side force of the drill bit.
A method for making a drill bit according to one aspect includes providing a center bit configured to rotate at a first speed; and providing an outer bit disposed outside the center bit, wherein the outer bit is configured to rotate at a second speed, wherein the first speed and second speeds are configured to control a resultant side force of the drill bit.
The disclosure, in one aspect, provides examples of certain features of the apparatus and method disclosed herein are summarized rather broadly in order that the detailed description thereof that follows may be better understood. There are, of course, additional features of the apparatus and method disclosed hereinafter that will form the subject of the claims appended hereto.
The disclosure herein is best understood with reference to the accompanying figures in which like numerals have generally been assigned to like elements and in which:
In an aspect, a suitable drilling fluid 131 (also referred to as “mud”) from a source 132 thereof, such as a mud pit, is circulated under pressure through the drill string 120 by a mud pump 134. The drilling fluid 131 passes from the mud pump 134 into the drill string 120 via a desurger 136 and the fluid line 138. The drilling fluid 131a from the drilling tubular discharges at the borehole bottom 151 through openings in the drill bit 150. The returning drilling fluid 131b circulates uphole through the annular space 127 between the drill string 120 and the borehole 126 and returns to the mud pit 132 via a return line 135 and drill cutting screen 185 that removes the drill cuttings 186 from the returning drilling fluid 131b. A sensor S1 in line 138 provides information about the fluid flow rate. A surface torque sensor S2 and a sensor S3 associated with the drill string 120 provide information about the torque and the rotational speed of the drill string 120. Rate of penetration of the drill string 120 may be determined from the sensor S5, while the sensor S6 may provide the hook load of the drill string 120.
In some applications, the drill bit 150 is rotated by only rotating the drill pipe 122. However, in other applications, a downhole motor 155 (mud motor) disposed in the drilling assembly 190 also rotates the drill bit 150. The rate of penetration (“ROP”) for a given drill bit and BHA largely depends on the WOB or the thrust force on the drill bit 150 and its rotational speed.
A surface control unit or controller 140 receives signals from the downhole sensors and devices via a sensor 143 placed in the fluid line 138 and signals from sensors S1-S6 and other sensors used in the system 100 and processes such signals according to programmed instructions provided from a program to the surface control unit 140. The surface control unit 140 displays desired drilling parameters and other information on a display/monitor 142 that is utilized by an operator to control the drilling operations. The surface control unit 140 may be a computer-based unit that may include a processor 142 (such as a microprocessor), a storage device 144, such as a solid-state memory, tape or hard disc, and one or more computer programs 146 in the storage device 144 that are accessible to the processor 142 for executing instructions contained in such programs. The surface control unit 140 may further communicate with a remote control unit 148. The surface control unit 140 may process data relating to the drilling operations, data from the sensors and devices on the surface, data received from downhole and may control one or more operations of the downhole and surface devices.
The drilling assembly 190 also contain formation evaluation sensors or devices (also referred to as measurement-while-drilling (“MWD”) or logging-while-drilling (“LWD”) sensors) determining resistivity, density, porosity, permeability, acoustic properties, nuclear-magnetic resonance properties, corrosive properties of the fluids or formation downhole, salt or saline content, and other selected properties of the formation 195 surrounding the drilling assembly 190. Such sensors are generally known in the art and for convenience are generally denoted herein by numeral 165. The drilling assembly 190 may further include a variety of other sensors and devices 159 for determining one or more properties of the drilling assembly (such as vibration, bending moment, acceleration, oscillations, whirl, stick-slip, etc.) and drilling operating parameters, such as weight-on-bit, fluid flow rate, pressure, temperature, rate of penetration, azimuth, tool face, drill bit rotation, etc. For convenience, all such sensors are denoted by numeral 159.
Still referring to
Similarly, drilling mud is directed to waterways 222 located in center bit 204. The waterways 222 direct the mud to center cutter section 224, where the center cutter section 224 comprises center cutters 226, such as fixed PDC cutters. The center bit 204 also includes a power unit, such as motor 228 and electronics 230, where the motor 228 and electronics 230 are configured to power and control a speed of rotation (or revolutions per minute or “RPM”) of the center bit 204. The motor 228 is connected to connecting member 231, which comprises a fixed connection 232, electrical connection 234 and rotational decoupling 236. The fixed connection 232 and electrical connection provide physical and electrical connections between the outer bit 202 and center bit 204. For example, electrical, fluid and control lines from the BHA and drill string may be routed to the center bit via the fixed connection 232 and electrical connection. The rotational decoupling 236 includes a suitable mechanism, such as bearings, to enable relative rotation of the outer bit 202 and center bit 204. Further, a suitable electrical connection, such as an inductive coupling or conductive rings, may route electrical signals from the outer bit 202 to the inner bit 204. As depicted, an electrical line 240 provides a link for signals between a position sensor 238 and electronics 230. The position sensor 238 indicates a relative position and movement of the center bit 204 to the outer bit 202. A mechanism that allows relative movement, such as bearings (indicated by elements 242 and 244) provides a coupling and support while enabling the center bit 204 and outer bit 202 to rotate at different speeds.
The illustrated drill bit 200 provides control over a steering direction for the bit and drill string by controlling the rotational speeds (RPMs) of the outer bit 202 and inner bit 204. In an embodiment, the outer bit 202 is designed with a selected amount of rotational imbalance, causing a resultant side force in a selected radial direction as the outer bit 202 is rotated. This force from the outer bit 202 may be described as a side force or steering force, where the side force urges the bit in a selected direction. Similarly, the center bit 204 is designed with a selected amount of rotational imbalance, causing a resultant side force in a selected radial direction as the center bit 204 is rotated. In the depicted arrangement, the drill bit 200 and selected electronics, controllers and motors may control and power the speed for the center bit 204 and outer bit 202. Accordingly, the rotation of each bit (202, 204) may be separately powered and controlled. Further, the center bit 204 rotation and corresponding side force is in a first direction and the outer bit 202 and corresponding side force is in a second direction. By controlling the speed of the center and outer bit, the combined resultant force (or total force) of the center bit 204 side force and the outer bit 202 side force urges the drill bit 200 and drill string in a selected third direction.
With continued reference to
A drilling apparatus that includes a drill bit made according to this disclosure may be utilized to drill a wellbore in various modes, including, but not limited to, a steering mode and a non-steering mode. In the steering mode, for example, the inner bit may be rotated at twice the speed of the outer bit (2:1 ratio). In this example, the resultant side force changes from a maximum (largest) to minimum (least) and back to maximum. In this example, the drilling assembly will steer to a particular direction, for example 12 o'clock direction. To change the direction of the maximum resultant force from 12 o'clock direction to another direction, the ratio 2:1 may be changed, as desired, to a higher or lower value for a selected time period and then changed back to 2:1 ratio so as to maintain the drilling direction along the new adjusted direction. In a drilling mode (non-steering), the rotational speed ratio may be kept at 1:1 so as to maintain a constant resultant side force (maximum, minimum or a side force between the maximum and minimum side forces). In this mode, the adjusted resultant constant side force (maximum, minimum or one in between) rotates with the drill bit and thus with the drilling assembly.
Thus, in one aspect drilling apparatus is provide that includes a drill bit that in one embodiment may include a center member including a first cutter configured to rotate at a first speed, an outer member including a second cutter disposed outside the center member configured to rotate at a second speed; and wherein the first speed and second speed cooperate to control a resultant side force on the outer member to control a drilling direction. In one aspect, the first speed may be equal to the second speed. In another aspect, the second speed may be two times the first speed. In another aspect one speed may be half the other speed. The first cutter and second cutter may be any suitable cutters, including, but not limited to, polycrystalline diamond compact cutters and roller cones. In a particular configuration, the drill bit includes a cone and a shank wherein the center member is disposed inside the outer member in both the cone and shank. In another aspect, the drill bit further includes a side force member disposed at the cone of the drill bit or shank of the drill bit. In aspects, during drilling, the first cutter contacts a formation at a face of the drill bit and the second cutter contacts the formation at a side and the face of the drill bit. In another aspect, the drill bit further includes power unit, such as a motor configured to rotate the outer member. An adjustable gear mechanism coupled to the motor may be utilized to provide power for rotation of the center bit.
In another aspect, a method for making a drill bit is provided, which method, in one embodiment includes: providing a center bit configured to rotate at a first speed; and providing an outer bit disposed outside the center bit, wherein the outer bit is configured to rotate at a second speed, and wherein the first speed and second speed are configured to control a resultant side force on the drill bit during drilling of a formation. The cutters may be of any suitable type including PDC cutters and roller cones. The method may further include providing a power unit configured to rotate the outer bit. The method may further include providing an adjustable gear mechanism coupled to the power unit to provide power for the rotation of the center bit.
In yet another aspect, the disclosure provides a method of drilling wellbore. An embodiment of the method includes conveying a drill string in the wellbore that includes a drill bit having first drill bit in a second drill bit; drilling the wellbore by rotating the first drill bit at a speed that differs from the rotational speed of the second drill bit. In one aspect, the method further includes rotating the first drill bit a speed that is about two times the rotational speed of the second drill bit. In aspects, during drilling the first drill bit provides a first side force during drilling of the wellbore and the second drill bit provides a second side force during drilling of the wellbore and a resultant side force that is a combination of the first side force and the second side force and wherein the method further include altering the rotational speed of the first drill bit during drilling of the wellbore to alter magnitude and/or direction of the resultant side force.
While the foregoing disclosure is directed to certain embodiments, various changes and modifications to such embodiments will be apparent to those skilled in the art. It is intended that all changes and modifications that are within the scope and spirit of the appended claims be embraced by the disclosure herein.
This application takes priority from U.S. Provisional application Ser. No. 61/378,771, filed on Aug. 31, 2010, which is incorporated herein in its entirety by reference.
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Number | Date | Country | |
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Number | Date | Country | |
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61378771 | Aug 2010 | US |