While drilling a wellbore with a drill string, drilling fluid is typically circulated through the wellbore by pumping the drilling fluid into the drill string. At the end of the drill string is a drill bit with nozzles. The drilling fluid pumped into the drill string exits into the bottom of the wellbore through the nozzles in the drill bit and moves up an annulus between the drill string and the wellbore to the surface, where the drilling fluid is received, cleaned, and circulated back into the wellbore. Drilling fluid serves various purposes, including cleaning the bottom of the wellbore; cooling, cleaning, and lubricating the drill bit; maintaining the wall of the wellbore; transporting formation cuttings from the drill bit to the surface; and preventing formation fluid influx to the well.
The process of transporting formation cuttings from the drill bit to the surface is known as hole cleaning. Failure to perform efficient hole cleaning may lead to development of cuttings bed in the annulus. Cuttings bed in an annulus leads to complications in drilling, such as decreased annulus area for return flow to the surface, increased torque and drag on the drill string that can prevent continued drilling to a target depth, formation fracturing due to the increased effective density acting on the formation, and mechanical sticking of the drill pipe.
Hole cleaning is affected by various factors, such as flow rate of the drilling fluid, rheological properties of the drill fluid, inclination angle of the hole, rotation of the drill string, eccentricity of the drill pipe in the hole, rate of penetration of the drilling, and characteristics of the formation cuttings, e.g., density, size, and shape of the cuttings. A critical flow rate exists below which cuttings slump down and form a stationary cuttings bed in the annulus. It is generally desirable to maintain the flow rate through the annulus above the critical flow rate to avoid development of stationary cuttings bed. A higher flow rate is typically achieved by increasing the fluid pump rate. However, flow rate is constrained by the allowed equivalent circulating density, which is constrained at a lower end by formation pore pressure gradient and at an upper end by fracture gradient and by the standpipe pressure. In some drilling scenarios, it may not be possible to increase the flow rate to a level high enough to avoid development of stationary cuttings bed.
In current drilling operations, drilling rig crews depend on following a set of “best practices” to ensure proper hole cleaning. These best practices include applying a minimum pipe rotation and a minimum flow rate for each hole size, keeping drilling fluid rheology within a certain range based on hole size, pumping hole cleaning sweeps, and performing short round trips every 1000 ft of drilled new formation to evaluate the hole condition. A hole cleaning sweep is a drilling fluid with two different characteristics. When the sweep reaches the annulus, the sweep will create a turbulent flow, which will help in moving cuttings out of the hole.
In a first summary example, a hole cleaning apparatus includes a tool body having a lengthwise axis and a wall defining a bore that is aligned with the lengthwise axis. The hole cleaning apparatus includes one or more rotating assemblies coupled to the tool body. Each of the rotating assemblies includes a turbine wheel, an impeller, and a link rod. The turbine wheel is disposed adjacent to an inner surface of the wall and exposed to the bore. The impeller is disposed adjacent to an outer surface of the wall in a position corresponding to the turbine wheel. Each of the turbine wheel and impeller has a respective axis of rotation that is transverse to the lengthwise axis. The link rod operatively couples the turbine wheel to the impeller and is used to transfer mechanical energy generated by the turbine wheel to the impeller.
In the first summary example, the link rod may pass through a portion of the wall of the tool body between the turbine wheel and the impeller. The link rod may be rotatably supported by a bearing mounted in the portion of the wall of the tool body.
In the first summary example, the turbine wheel may have a higher hydrodynamic drag in comparison to the impeller when the turbine wheel and the impeller are immersed in a fluid. The impeller may be a radial impeller.
In the first summary example, the hole cleaning apparatus may include an impeller casing mounted around the impeller to provide a chamber around the impeller that guides flow from the impeller. The impeller casing may have an opening forming an outlet port that is fluidly connected to the chamber. The chamber may be a volute chamber. An external shield may be disposed around the tool body with a space between the external shield and the tool body to accommodate the impeller casing and the impeller. The external shield may include an opening forming an inlet port that is fluidly connected to the chamber.
In the first summary example, the hole cleaning apparatus may include a plurality of the rotating assemblies coupled to the tool body. The rotating assemblies may be uniformly distributed along a circumference of the tool body.
In a second summary example, a drill string includes a drill bit and one or more drill pipes coupled together to form a conduit that is fluidly connected to the drill bit. The drill string includes one or more hole cleaning apparatuses disposed along the conduit. Each hole cleaning apparatus includes a tool body having a lengthwise axis and a wall defining a bore that is aligned with the lengthwise axis and fluidly connected to the conduit. Each hole cleaning apparatus includes one or more rotating assemblies coupled to the tool body. Each rotating assembly includes a turbine wheel, an impeller, and a link rod. The turbine wheel is disposed adjacent to an inner surface of the wall and exposed to the bore. The impeller is disposed adjacent to an outer surface of the wall in a position corresponding to the turbine wheel. Each of the turbine wheel and impeller has a respective axis of rotation that is transverse to the lengthwise axis. The link rod operatively couples the turbine wheel to the impeller and is used to transfer mechanical energy generated by the turbine wheel to the impeller.
In the second summary example, for each corresponding turbine wheel and impeller, the turbine wheel may have a higher hydrodynamic drag in comparison to the impeller when the turbine wheel and the impeller are immersed in a fluid. The impeller may be an open impeller or a semi-open impeller. The impeller may be a radial impeller.
In the second summary example, an impeller casing may be mounted around each impeller. The impeller casing provides a chamber around the impeller that guides flow from the impeller. Each impeller casing may have an opening forming an outlet port that is fluidly connected to the respective chamber. The chamber may be a volute chamber. An external shield may be disposed around the tool body of each hole cleaning apparatus with a space between the external shield and the tool body to accommodate the impeller casing(s) and impeller(s) associated with the hole cleaning apparatus. The external shield may include an opening forming an inlet port that is fluidly connected to the chamber. Each impeller casing may be connected to the external shield.
In the second summary example, a plurality of rotating assemblies may be coupled to the tool body of each hole cleaning apparatus. The rotating assemblies may be uniformly distributed along a circumference of the respective tool body.
In a third summary example, a method includes disposing a drill string including at least one hole cleaning apparatus in a wellbore, pumping fluid into the drill string while operating the drill string to cut into a subsurface formation around the wellbore, and returning the fluid pumped into the drill string and cuttings from the subsurface formation to a surface through an annulus between the drill string and the wellbore. During pumping of the fluid into the drill string, the method includes rotating at least one turbine wheel disposed inside a tool body of the hole cleaning apparatus by the fluid passing through the drill string. The method additionally includes rotating at least one impeller disposed outside the tool body of the hole cleaning apparatus in response to rotation of the at least one turbine wheel. A pressure of the fluid in the annulus at a location of the at least one impeller is increased by rotation of the at least one impeller.
In the third summary example, the at least one turbine wheel may be rotated about an axis of rotation that is transverse to a lengthwise axis of the tool body of the hole cleaning apparatus, and the at least one impeller may be rotated about an axis of rotation that is transverse to a lengthwise axis of the tool body of the hole cleaning apparatus.
The foregoing general description and the following detailed description are exemplary of the invention and are intended to provide an overview or framework for understanding the nature of the invention as it is claimed. The accompanying drawings are included to provide further understanding of the invention and are incorporated in and constitute a part of the specification. The drawings illustrate various embodiments of the invention and together with the description serve to explain the principles and operation of the invention.
The following is a description of the figures in the accompanying drawings. In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn are not necessarily intended to convey any information regarding the actual shape of the particular elements and have been solely selected for ease of recognition in the drawing.
In the following detailed description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations and embodiments. However, one skilled in the relevant art will recognize that implementations and embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, and so forth. In other instances, related well known features or processes have not been shown or described in detail to avoid unnecessarily obscuring the implementations and embodiments. For the sake of continuity, and in the interest of conciseness, same or similar reference characters may be used for same or similar objects in multiple figures.
A hole cleaning apparatus that may be installed in a drill string is described herein. The hole cleaning apparatus includes one or more rotating assemblies that operate to increase the pressure in the annulus of a wellbore while the drill string is used in the wellbore. The extra pressure will assist in transporting formation cuttings up the annulus. Advantageously, the hole cleaning apparatus will reduce the need for hole sweeps to ensure proper hole cleaning.
In one example, as illustrated in
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Impellers 108 are disposed adjacent to an outer wall surface 216 of wall 205 and in positions corresponding to turbine wheels 104 in recesses 212. In the portion of wall 205 disposed between each corresponding turbine wheel 104 and impeller 108, a hole 220 is formed. Link rod 112 passes through hole 220 and operatively connects corresponding turbine wheel 104 and impeller 108. A bearing 224 may be mounted in hole 220 to support rotation of link rod 112. When each rotating assembly 100 is assembled to tool body 204 as shown in
In one implementation, an external shield 248 is disposed around tool body 204 and impellers 108. External shield 248 may be a tubular wall and may be attached to tool body 204, as shown in
Impeller casings that guide impeller flow up hole cleaning apparatus 200 may be provided. As shown in
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Wellbore 304 is drilled by operating drill bit 316 to cut into surrounding subsurface formation 320. Typically, this involves rotating drill string 300 from the surface using a top drive 324 (or a rotary table in other examples). During drilling, a surface pump 328 is operated to pump drilling fluid (also known as mud) into drill string 300. The fluid pumped into drill string 300 will exit through nozzles in drill bit 316 into the bottom of wellbore 304 and then move up an annulus 332 between wellbore 304 and drill string 300 towards the surface, carrying along cuttings of the subsurface formation. At the surface, the fluid is diverted into a mud treatment system, cleaned up, and pumped back into the drill string.
Movement of fluid in annulus 332 is slightly different for the hole cleaning apparatus with impeller casings. As shown in
In both flow patterns shown in
The detailed description along with the summary and abstract are not intended to be exhaustive or to limit the embodiments to the precise forms described. Although specific embodiments, implementations, and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the relevant art.