Patent Application
20220389765
The present disclosure relates to earth-boring tools containing through-the-blade fluid ports and related methods of making such earth-boring tools.
Many different tools used in the oil exploration and production industry utilize bodies or components comprising steel which are exposed to very abrasive and erosive environments. For example, subterranean drilling operations generally employ a rotary drill bit that is rotated while being advanced through rock formations. Cutting elements or structures affixed to the rotary drill bit cut the rock while drilling fluid removes formation debris and carries it back to the surface. The drilling fluid is pumped from the surface through the drill string and out through one or more (usually a plurality of) nozzles located in junk slots of the drill bit. The nozzles direct jets or streams of the drilling fluid to clean and cool cutting surfaces of the drill bit and for the aforementioned debris removal.
The life of a drill bit having PDC cutting elements is typically extended when it is adequately lubricated and cooled during the drilling process. In contrast, having inadequate drilling fluid flow to the face of a drill bit allows formation cuttings to collect on the faces of the cutting elements. This collection of cuttings isolates the cutting elements from the drilling fluid. This also reduces the rate of penetration of the drill bit and if the debris collection is sufficiently high the cutting elements may overheat which increases the wear rate. Adequate and continuous fluid flow is critical to the success of the drill bit. However, repeated exposure to solids-laden drilling fluid may cause severe abrasion and erosion on the interior of the drill bit and nozzles on the bit face exposed to the fluid flow. Excessive abrasion and erosion may lead to complete failure of the drill bit. Accordingly, there exists a continuing need for developments to improve the fluid flow for drill bits and, especially for steel drilling tool bodies, to improve the erosion and/or wear resistance of the tool body.
Some embodiments of the present disclosure include earth-boring tools including at least one blade having a face surface, a cutting edge, and a rotationally leading surface. The earth-boring tool may additionally include at least one fluid port extending through the at least one blade, and a fluid port manifold having an opening at a first end and a plurality of openings along a length providing fluid communication between the at least one fluid port and a primary fluid passage of the earth-boring tool.
Some embodiments of the present disclosure include an earth-boring tool comprising a tool body having at least one fluid port manifold located in the tool body and having an opening at a first end in fluid communication with a primary fluid passage, and a plurality of openings along a length of the at least one fluid port manifold. The earth-boring tool may additionally include a plurality of fluid port sleeves, each fluid port sleeve of the plurality of fluid port sleeves extending into a corresponding opening of the plurality of openings along the length of the at least one fluid port manifold.
Some embodiments of the present disclosure include a method of forming an earth-boring tool, the method including disposing a fluid port manifold within an opening of a body of the earth-boring tool, the opening extending from an outer surface of the body to a primary fluid passage. The method may further include disposing at least one fluid port sleeve within at least one fluid port, the at least one fluid port extending through a blade of the body to an opening in the fluid port manifold.
The illustrations presented herein are not meant to be actual views of any particular component, device, or system, but are merely idealized representations which are employed to describe embodiments of the present invention.
As used herein, the terms “earth-boring tool” means and includes earth-boring tools for forming, enlarging, or forming and enlarging a borehole. Non-limiting examples of earth-boring tools include fixed cutter (drag) bits, fixed cutter coring bits, fixed cutter eccentric bits, fixed cutter bi-center bits, fixed cutter reamers, expandable reamers with blades bearing fixed cutters, and hybrid bits including both fixed cutters and rotatable cutting structures (e.g., roller cones).
As used herein, the term “cutting elements” means and includes, for example, superabrasive (e.g., polycrystalline diamond compact or “PDC”) cutting elements employed as fixed cutting elements, as well as tungsten carbide inserts and superabrasive inserts employed as cutting elements mounted to a body of an earth-boring tool.
As used herein, the singular forms following “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
As used herein, the term “may” with respect to a material, structure, feature, or method act indicates that such is contemplated for use in implementation of an embodiment of the disclosure, and such term is used in preference to the more restrictive term “is” so as to avoid any implication that other compatible materials, structures, features, and methods usable in combination therewith should or must be excluded.
As used herein, any relational term, such as “first,” “second,” “top,” “bottom,” “upper,” “lower,” etc., is used for clarity and convenience in understanding the disclosure and accompanying drawings, and does not connote or depend on any specific preference or order, except where the context clearly indicates otherwise. For example, these terms may refer to an orientation of elements of an earth-boring tool when disposed within a borehole in a conventional manner. Furthermore, these terms may refer to an orientation of elements of an earth-boring tool when as illustrated in the drawings.
As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0 percent met, at least 95.0 percent met, at least 99.0 percent met, at least 99.9 percent met, or even 100.0 percent met.
As used herein, the term “about” used in reference to a given parameter is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the given parameter, as well as variations resulting from manufacturing tolerances, etc.).
The drill string 110 may extend to a rig 120 at surface 122. The rig 120 shown is a land rig 120 for ease of explanation. However, the apparatuses and methods disclosed equally apply when an offshore rig 120 is used for drilling boreholes under water. A rotary table 124 or a top drive may be coupled to the drill string 110 and may be utilized to rotate the drill string 110 and to rotate the drilling assembly 114, and thus the drill bit 116 to drill the borehole 102. A drilling motor 126 may be provided in the drilling assembly 114 to rotate the drill bit 116. The drilling motor 126 may be used alone to rotate the drill bit 116 or to superimpose the rotation of the drill bit 116 by the drill string 110. The rig 120 may also include conventional equipment, such as a mechanism to add additional sections to the tubular member 112 as the borehole 102 is drilled. A surface control unit 128, which may be a computer-based unit, may be placed at the surface 122 for receiving and processing downhole data transmitted by sensors 140 in the drill bit 116 and sensors 140 in the drilling assembly 114, and for controlling selected operations of the various devices and sensors 140 in the drilling assembly 114. The sensors 140 may include one or more of sensors 140 that determine acceleration, weight on bit, torque, pressure, cutting element positions, rate of penetration, inclination, azimuth formation/lithology, etc. In some embodiments, the surface control unit 128 may include a processor 130 and a data storage device 132 (or a computer-readable medium) for storing data, algorithms, and computer programs 134. The data storage device 132 may be any suitable device, including, but not limited to, a read-only memory (ROM), a random-access memory (RAM), a flash memory, a magnetic tape, a hard disk, and an optical disk. During drilling, a drilling fluid from a source 136 thereof may be pumped under pressure through the tubular member 112, which discharges at the bottom of the drill bit 116 and returns to the surface 122 via an annular space (also referred as the “annulus”) between the drill string 110 and an inside sidewall 138 of the borehole 102.
The drilling assembly 114 may further include one or more downhole sensors 140 (collectively designated by numeral 140). The sensors 140 may include any number and type of sensors 140, including, but not limited to, sensors generally known as the measurement-while-drilling (MWD) sensors or the logging-while-drilling (LWD) sensors, and sensors 140 that provide information relating to the behavior of the drilling assembly 114, such as drill bit rotation (revolutions per minute or “RPM”), tool face, pressure, vibration, whirl, bending, and stick-slip. The drilling assembly 114 may further include a controller unit 142 that controls the operation of one or more devices and sensors 140 in the drilling assembly 114. For example, the controller unit 142 may be disposed within the drill bit 116 (e.g., within a shank 208 and/or crown 210 of a bit body of the drill bit 116). The controller unit 142 may include, among other things, circuits to process the signals from sensor 140, a processor 144 (such as a microprocessor) to process the digitized signals, a data storage device 146 (such as a solid-state-memory), and a computer program 148. The processor 144 may process the digitized signals, and control downhole devices and sensors 140, and communicate data information with the surface control unit 128 via a two-way telemetry unit 150.
The earth-boring tool 200 may include a body 202 including a pin 206, a shank 208, and a crown 210. In some embodiments, the bulk of the body 202 may be constructed of steel, or of a ceramic-metal composite material including particles of hard material (e.g., tungsten carbide) cemented within a metal matrix material. The body 202 of the earth-boring tool 200 may have an axial center defining a center longitudinal axis 204 that may generally coincide with a rotational axis of the earth-boring tool 200. The center longitudinal axis 204 of the body 202 may extend in a direction hereinafter referred to as an “axial direction.”
The body 202 may be configured to connect to a drill string 110 (
The crown 210 may include a plurality of blades 214, and may include receptacles 216 configured for coupling roller cone elements (not shown) thereto. For example, the receptacles 216 may be configured to affix mechanically attached roller cone elements such as described in U.S. Pat. No. 10,107,039 to Schroder, issued Oct. 23, 2018, and titled “HYBRID BIT WITH MECHANICALLY ATTACHED ROLLER CONE ELEMENTS,” the specification of which is incorporated herein in its entirety by this reference.
Each blade 214 of the plurality of blades 214 of the earth-boring tool 200 may include a face surface 218, a rotationally leading surface 220, and a rotationally trailing surface 222. The face surface 218 may be positioned and configured to interface a formation at the bottom of a borehole during drilling operations. The face surface 218 may be oriented substantially parallel to an intended rotational direction of the earth-boring tool 200 during drilling operations. The rotationally leading surface 220, and the rotationally trailing surface 222, may be oriented substantially perpendicular to the intended rotational direction of the earth-boring tool 200 during drilling operations.
A cutting edge 224 may be located at an interface between the face surface 218 and the rotationally leading surface 220, and may include a plurality of cutting elements 226 fixed therein. The plurality of cutting elements 226 of each blade 214 may be located in a row along a profile of the blade 214 proximate the rotationally leading surface 220 of the blade 214. In some embodiments, the plurality of cutting elements 226 of the plurality of blades 214 may include PDC cutting elements 226.
The earth-boring tool 200 may include at least one fluid port 228 extending through at least one blade 214. In some embodiments, the earth-boring tool 200 may include a plurality of fluid ports 228 extending through a blade. The positioning of fluid ports 228 through the blade 214 may provide fluid openings located proximate to the cutting edge 224 of the blade 214, which may provide superior cooling and cleaning of the cutting edge 224 during drilling operations when compared to fluid ports located at the bottom of junk slots 230 and distal from the cutting edge 224.
As shown in
The fluid port manifold 232 may be a substantially straight tubular structure having the opening 234 at the first end. In some embodiments, the fluid port manifold 232 may have an enclosed and sealed second end 242, opposite the first end. In further embodiments, the fluid port manifold 232 may have an open second end 242, and an external seal may be installed on the body 202 of the earth-boring tool 200. The second end 242 may additionally include a flange 244, which may be positioned against a seat 246 in the body 202 of the earth-boring tool 200 to facilitate proper positioning of the fluid port manifold 232 in the body 202. The length and inner diameter of the fluid port manifold 232 may vary depending on factors such as the size of the earth-boring tool 200 and the number of blades 214 on the body 202 of the earth-boring tool 200. As a non-limiting example, the length of the fluid port manifold 232 may be between about 0.5 inch (1.27 cm) and about 18 inches (45.72 cm). As another non-limiting example, the inner diameter of the fluid port manifold 232 may be between about 0.25 inch (0.635 cm) and about 4 inches (10.16 cm).
Each of the fluid port sleeves 240A, 240B may also be a substantially straight tubular structure, and may have an opening at each of a first end and an opposing second end. Like the fluid port manifold 232, the second end of each of the fluid port sleeves 240A, 240B may include a flange 248, which may be positioned against a seat 250 in the body 202 of the earth-boring tool 200 to facilitate proper positioning of the fluid port sleeve 240A, 240B in the body 202. The length and inner diameter of the fluid port sleeves 240A, 240B may vary depending on factors such as the size of the earth-boring tool 200 and the number of blades 214 on the body 202 of the earth-boring tool 200. As a non-limiting example, the length of the fluid port sleeves 240A, 240B may be between about 0.5 inch (1.27 cm) and about 18 inches (45.72 cm). As another non-limiting example, the inner diameter of the fluid port sleeves 240A, 240B may be between about 0.25 inch (0.635 cm) and about 4 inches (10.16 cm).
The fluid port manifold 232, and each fluid port sleeve 240A, 240B may be comprised of a wear resistant material, such as a ceramic material, or a ceramic-metal matrix composite material. For example, the fluid port manifold 232, and each fluid port sleeve 240A, 240B may be made comprised of silicon carbide, or cobalt-cemented tungsten carbide. Additionally, the fluid port manifold 232, and each fluid port sleeve 240A, 240B may be brazed to the body 202. Accordingly, the fluid port manifold 232 and the fluid port sleeves 240 A, 240B may provide erosion and abrasion protection to the body 202 of the earth-boring tool 200 from fluid, which may contain abrasive particles suspended therein, being directed therethrough.
Each fluid port sleeve 240A, 240B may have a length extending from the fluid port manifold 232. In some embodiments, the length of each fluid port sleeve 240A, 240B may be substantially the same, such as shown in
The fluid port manifold 232 may extend along a primary axis 252, and each of the fluid port sleeves 240A, 240B may extend upon a respective primary axis 254. In some embodiments, the primary axis 254 of each of the fluid port sleeves 240A, 240B may be oriented at substantially the same angle relative to the primary axis 252 of the fluid port manifold, as shown in
Additionally, the fluid port sleeves 240A, 240B may be oriented at specific radial orientations relative to the primary axis 252 of the fluid port manifold 232. In some embodiments, some or all of the fluid port sleeves 240A, 240B may be oriented at the same radial orientation relative to the primary axis 252 of the fluid port manifold 232. For example, as shown in
As a non-limiting example, the orientation of the primary axis 254 of a fluid port sleeve 240A, 240B relative to the primary axis 252 of the fluid port manifold 232 may vary from perpendicular in any direction (e.g., tilt or rotation) by about 60 degrees.
In addition to a fluid port sleeve 240A, 240B, one or more of the fluid ports 228 may be configured to also receive a nozzle 256. As shown in
In some embodiments, at least one of the fluid ports 228 may extend through the rotationally leading surface 220 of at least one blade 214, as shown in
By providing fluid ports 228 extending through the blade 214, the exits of the fluid ports 228 may be positioned closer to the cutting edge 224 of the blade 214 and provide improved cooling and cleaning. For example, areas of the blade 214 that may experience extensive heat and abrasion, such as a shoulder area 260 (see
In some embodiments, such as shown in
Referring again to
Referring again to
The fluid port manifold 232 may be inserted into the opening, and the flange 244 of the fluid port manifold 232 may be seated in the opening 270. Optionally, an external seal (not shown) may be installed in the opening 270 after insertion of the fluid port manifold 232. The openings 238 extending along the length of the fluid port manifold 232 may be aligned with the fluid ports 228 in the body 202. The fluid port sleeves 240A, 240B may then be inserted into the fluid ports 228 in the body 202 and the first end of each fluid port sleeve 240A, 240B may be inserted into a respective opening 238 in the fluid port manifold 232. The flange 248 at the second end of each fluid port sleeve 240A, 240B may be seated in each respective fluid port 228. The fluid port manifold 232 and each of the fluid port sleeves 240A, 240B may then be coupled to the body 202 of the earth-boring tool 200, such as by brazing, epoxy, and/or threaded retention. In some embodiments, one or more nozzle 256 may then be disposed into one or more fluid port 228 adjacent a fluid port sleeve 240A, 240B.
Additional non-limiting example embodiments of the disclosure are described below.
Embodiment 1: An earth-boring tool comprising at least one blade having a face surface, at least one fluid port extending through the at least one blade, and a fluid port manifold having an opening at a first end and a plurality of openings along a length providing fluid communication between the at least one fluid port and a primary fluid passage of the earth-boring tool.
Embodiment 2: The earth-boring tool of embodiment 1, wherein the at least one fluid port comprises a plurality of fluid ports.
Embodiment 3: The earth-boring tool of embodiment 2, further comprising a plurality of fluid port sleeves, each of the plurality of fluid port sleeves positioned within a corresponding fluid port of the plurality of fluid ports.
Embodiment 4: The earth-boring tool of embodiment 3, further comprising a fluid port manifold providing fluid communication between each of the plurality of fluid port sleeves and a primary fluid passage.
Embodiment 5: The earth-boring tool of any of embodiments 2 through 4, wherein a first fluid port sleeve of the plurality of fluid port sleeves has a longitudinal length that is different than a longitudinal length of a second fluid port sleeve of the plurality of fluid port sleeves.
Embodiment 6: The earth-boring tool of any of embodiments 2 through 5, wherein a primary axis of a first fluid port sleeve of the plurality of fluid port sleeves is oriented at a first angle relative to a primary axis of the fluid port manifold and a primary axis of a second fluid port sleeve of the plurality of fluid port sleeves is oriented at a second angle relative to the primary axis of the fluid port manifold, the second angle being different than the first angle.
Embodiment 7: The earth-boring tool of any of embodiments 2 through 6, wherein a primary axis of a first fluid port sleeve of the plurality of fluid port sleeves is oriented at a first radial orientation relative to a primary axis of the fluid port manifold and a primary axis of a second fluid port sleeve of the plurality of fluid port sleeves is oriented at a second radial orientation relative to the primary axis of the fluid port manifold, the second radial orientation being different than the first radial orientation.
Embodiment 8: The earth-boring tool of any of embodiments 2 through 7, further comprising a nozzle positioned in at least one fluid port of the plurality of fluid ports.
Embodiment 9: The earth-boring tool of any of embodiments 2 through 8, wherein the fluid port manifold, and each fluid port sleeve is comprised of a ceramic material.
Embodiment 10: The earth-boring tool of any of embodiments 2 through 9, wherein the fluid port manifold, and each fluid port sleeve is comprised of silicon carbide.
Embodiment 11: The earth-boring tool of any of embodiments 2 through 10, wherein the fluid port manifold, and each fluid port sleeve is brazed to the tool body.
Embodiment 12: The earth-boring tool of any of embodiments 1 through 11, wherein the at least one fluid port extends through the rotationally leading surface of the at least one blade.
Embodiment 13: The earth-boring tool of any of embodiments 1 through 11, wherein the rotationally leading surface of the at least one blade comprises a surface oriented substantially perpendicular to an intended direction of rotation.
Embodiment 14: The earth-boring tool of any of embodiments 1 through 13, wherein the at least one blade further comprises a rotationally trailing surface, and wherein the at least one fluid port extends through the rotationally trailing surface of the at least one blade.
Embodiment 15: An earth-boring tool, comprising a tool body; at least one fluid port manifold located in the tool body and having an opening at a first end in fluid communication with a primary fluid passage, and a plurality of openings along a length of the at least one fluid port manifold; and a plurality of fluid port sleeves, each fluid port sleeve of the plurality of fluid port sleeves extending into a corresponding opening of the plurality of openings along the length of the at least one fluid port manifold.
Embodiment 16: The earth-boring tool of embodiment 15, wherein a second end of the at least one fluid port manifold, opposite the first end, is sealed.
Embodiment 17: The earth-boring tool of embodiment 15, wherein a second end of the at least one fluid port manifold, opposite the first end, is open.
Embodiment 18: A method of forming an earth-boring tool, the method comprising: disposing a fluid port manifold within an opening of a body of the earth-boring tool, the opening extending from an outer surface of the body to a primary fluid passage; and disposing at least one fluid port sleeve within at least one fluid port, the at least one fluid port extending through a blade of the body to an opening in the fluid port manifold.
Embodiment 19: The method of embodiment 18, further comprising brazing each of the fluid port manifold and the at least one fluid port sleeve to the body of the earth-boring tool.
Embodiment 20: The method of embodiment 18 or 19, further comprising disposing at least one nozzle within the at least one fluid port, adjacent the at least one fluid port sleeve.
While the disclosed device structures and methods are susceptible to various modifications and alternative forms in implementation thereof, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the present disclosure is not limited to the particular forms disclosed. Rather, the present invention encompasses all modifications, combinations, equivalents, variations, and alternatives falling within the scope of the present disclosure as defined by the following appended claims and their legal equivalents.
