Embodiments of the subject matter disclosed herein generally relate to a drilling enhancement tool for use in a well, and more particularly, to a tool for carrying out multiple functions typically addressed using multiple drilling tools in a well.
Well drilling has developed into a precision industry not only for the oil and gas sector, but also for the water exploration sector. Some boreholes are being made to follow precisely predetermined paths through the earth and are being precisely sized (conditioned) for the installation of casing to line the borehole, as well as to facilitate re-entry using open hole logging tools. This precision is accomplished by means of specialized tools and equipment installed with a drill string bottom hole assembly, i.e., that portion of the drill string between the bit at the lowermost distal end up to the remainder of the drill string.
One commonly used bottom hole tool is the stabilizer, which is installed in the bottom hole assembly to reduce or preclude excessive lateral movement or oscillation of the drill string during drilling operations. Stabilizers are provided with diameters substantially equal to the diameter of the borehole, which is determined by the cutting diameter of the bit being used.
In some cases, the borehole is undersized at certain points, i.e., has a diameter less than that desired one for the installation of casing, etc. This may be caused by various factors, such as hard rock structures that intrude into the bore hole even after the bit has passed. Such intrusions are normally removed by the installation of a roller reamer to the bottom hole assembly, then positioning the reamer at the desired depth and operating the drill string to ream out the intrusion.
Such specialized earth boring tools as stabilizers and roller reamers are generally manufactured as single special purpose devices, and are not well suited for other roles than their specific purposes. Keyseat wipers (i.e., devices to widen a portion of a bore hole where the drill string has cut into the side of the passage to form a keyhole-shaped cross section), as well as fixed blade cutters, are also typically used in a drill string configuration to assist in wellbore conditioning. A keyseat wiper is used to remove keyseats that develop during the drilling process. Fixed blade cutters are also typically used when roller reamers alone cannot provide the needed wellbore conditioning. Friction reducers are also used in a bottom hole assembly to reduce the torque resistance in deviated wells, i.e., wells that deviate from the vertical direction. They allow free rotation of the drill string at the dog leg, which adds power to the bit, increases the rate of penetration, and decreases the fatigue of the drill string and rotary equipment. A typical drill string would require a combination of such tools to complete the drilling operation.
Thus, a multifunction wellbore conditioning tool solving the aforementioned problems is desired and was presented in International Patent Application WO 2018/094318 (herein, “the '318 application”), the entire content of which is incorporated herein by reference. One embodiment of the '318 application is shown in
A working sleeve 114 is installed about the central portion 106 of the shaft 102 between the first and second housings 110 and 112, and is free to move rotationally and axially relative to the shaft 102, unless it is locked with one of the two housings 110 and 112, as described further below. The sleeve 114 has a first end portion 116, a central portion 118, and a second end portion 120 opposite the first end portion 116. The working sleeve (sleeve 114) includes a plurality of straight or helically disposed external cutting elements 122 separated by straight or helical flutes 124 therebetween, the cutting elements 122 permitting the sleeve 114 to function as a combination of a cutter, keyseat wiper, friction reducer, reamer, keyseat wiper, and stabilizer. Rotational and axial translational friction between the sleeve 114 and shaft 102 is reduced by a ball bearing system 126, which is disposed between the shaft 102 and the working sleeve 114. The ball bearing system 126 extends along the longitudinal axis of the shaft 102 as much as the sleeve 114.
The working sleeve 114 is retained in a neutral position on the central portion 106 of the shaft 102, clear of the two housings 110 and 112, by first and second spring sets 134 and 136. The first and second spring sets 134 and 136 are installed concentrically about the shaft 102, between the first end 104 and the central portion 106 and between the second end 108 and the central portion 106, respectively, of the shaft 102. The first and second spring sets 134 and 136 are provided within the first and second housings 110 and 112 to bear against the first and second spring seat 140a and second spring seat 140b. The first and second spring seats 140a and 140b are connected to ends 116 and 120 respectively, of the working sleeve 114. The first spring 134 is secured to a first thrust transmitting system 138a and the first spring seat 140a, and the second spring 136 is secured to a second thrust transmitting system 138b and the second spring seat 140b in a similar manner, but in a mirror image to the first spring 134 and its corresponding thrust transmitting system 138a and spring seat 140a. Thus, the first spring 134, first thrust transmitting system 138a, and first spring seat 140a are rotationally fixed to one another, as are the second spring 136, second thrust transmitting system 138b, and second spring seat 140b. The two thrust transmitting systems 138a, 138b are either retained within their respective housings 110 and 112 by keys that are inserted into corresponding keyholes or slots in the sides of the housings 110 and 112, and into outer circumferential grooves formed about the two thrust transmitting system 138a, 138b, or, retained to the shaft by thrust carrying disc 142 attached to the shaft and into inner circumferential grooves formed about the two thrust transmitting systems 138a, 138b. This construction allows the working sleeve 114 to rotate freely relative to the shaft 102. This also allows the two springs 134, 136 to work together to create a spring assembly of equivalent stiffness equal to the combined stiffness of the individual springs depending on the spring sets attachment technique. When installed, the ends of the two springs 134 and 136 are fixedly connected to the ball bearing system 126 so that a force applied to one spring is transmitted to the other spring. In other words, the two springs are not independent of each other.
Each housing 110, 112 has a sleeve engagement end 150a and 150b, that are facing one another. The working sleeve 114 has first and second housing engagement ends 152a and 152b, disposed about the respective opposite first and second end portions 116 and 120 of the sleeve. The sleeve engagement end 150a of the first housing 110 and the adjacent housing engagement end 152a of the first end portion 116 of the working sleeve 114 collectively form a first clutch mechanism. Similarly, the sleeve engagement end 150b of the second housing 112 and the adjacent housing engagement end 152b of the second end portion 120 of the working sleeve 114 collectively form a second clutch mechanism. The first and second clutch mechanisms include first and second dog clutches, i.e., mechanisms that lock up abruptly to apply full drill string torque to the working sleeve 114 due to sudden solid contact between mating teeth or other protrusions of the clutch mechanism.
The first dog clutch mechanism of the tool 100 includes a first pair of axially oriented teeth or faces 154a on the sleeve engagement end 150a of the first housing 110, which selectively engage corresponding teeth or faces 156a extending from the sleeve engagement end 152a of the first end portion 116 of the sleeve 114. The teeth 154a of the first housing 110 are circumferentially distributed and separated by protruded ramps. Similarly, the teeth 156a of the first end portion 116 of the sleeve 114 are circumferentially distributed and have spiral ramps extending therebetween. This construction causes the first dog clutch to lock up, i.e., to cause the working sleeve 114 to rotate in unison with the housing 110 (and thus the shaft 102) when the shaft 102 and housing 110 are rotating in a clockwise direction when viewed from above. However, the ramp configuration between the teeth allows the dog clutch mechanism to slip when the housing 110 rotates counterclockwise relative to the sleeve 114. Thus, if the working sleeve 114 encounters axial resistance sufficient to override the compression of the first spring 134 and the tensile force of the second spring 136, or the corresponding stack of disc springs used instead, and force the two components of the first dog clutch into engagement with one another, the sleeve 114 will be forced into rotation in unison with the shaft 102 and housing 110 by engagement of the first dog clutch mechanism, thereby reaming or otherwise conditioning the borehole by application of the full drill string torque to the working sleeve 114 as drilling continues.
In the event that the working sleeve 114 “hangs up” or is caught on some protrusion as the drill string (and thus the shaft 102) is withdrawn from the borehole, the shaft 102 will be drawn upward through the sleeve 114. If sufficient tensile force is applied to the sleeve 114, it will cause the second spring 136 to compress and the first spring 134 to extend to the extent that the two sets of dog clutch teeth 154b and 156b of the second end of the assembly will engage. It is noted that this engagement will only occur if the shaft 102 (and the second housing 112 immovably affixed thereto) is rotating in a clockwise direction when viewed from above. Rotation of the shaft 102 and housing 112 in the opposite direction will allow the sloped or ramp surfaces to slide relative to one another, without rotary engagement of the working sleeve 114. It will be seen that the orientation of the sloped surfaces between each of the axial teeth 154a, 156a and 154b, 156b may be reversed for drill strings that rotate in a counterclockwise direction.
However, the system discussed above with regard to
All these potential problems require a new system that is capable of avoiding the possible failings of the tools discussed above.
According to an embodiment, there is a multifunctional drilling enhancement tool that includes a shaft having a bore extending along a longitudinal direction (X), a main cutting device rotatably and slidably attached to the shaft, a first housing fixedly attached to a first end of the shaft, a second housing fixedly attached to a second end of the shaft, first and second proximal engagement elements attached to opposite ends of the main cutting device, and first and second distal engagement elements attached to corresponding ends of the first and second housings, so that the first distal engagement element is directly facing the first proximal engagement element, and the second distal engagement element is directly facing the second proximal engagement element. The first distal engagement element has removable first distal inserts, the first proximal engagement element has removable first proximal inserts, and the first distal inserts are configured to directly contact the first proximal inserts to transmit a rotation from the first housing to the main cutting device.
According to another embodiment, there is a multifunctional drilling enhancement tool that includes a main cutting device rotatably and slidably attached to a shaft, a first housing fixedly attached to a first end of the shaft, a second housing fixedly attached to a second end of the shaft, a first secondary cutting device formed on an outside of the first housing, and a second secondary cutting device formed on an outside of the second housing.
According to yet another embodiment, there is a method for conditioning a drill hole in a well, and the method includes attaching a tool between a drilling element and a drill line, wherein the tool has a main cutting device located centrally, and first and second secondary cutting devices located at the ends of the tool, lowering the tool and the drilling element in a well, rotating the tool with the drill line so that either the first or the second secondary cutting device cuts into a constriction formed in the well, raising the tool from the well, and replacing one or more inserts attached to a proximal or distal engagement element. The proximal or distal engagement element is configured to transmit a rotation from a first or second housing to the main cutting device.
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
The following description of the embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to a multifunctional drilling enhancement tool.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
According to an embodiment, a drilling enhancement tool capable of carrying out multiple functions in introduced and these functions are typically addressed by multiple drilling tools. The tool includes new cutting structures on the tool housing, which expands the tool's capability to cut through swelling or irregular formations. In one application, the tool has an improved mechanism for engagement of the rotating body with the tool housing such that inserts of the clutching mechanism can be replaced when worn. In another application, the tool has a new bearing design to allow the tool to slightly bend along curved wells. In one application, the tool has new internal independent top and bottom housing spring design so that the application of a force on one spring does not affect or is not transmitted to the other spring.
As illustrated in
Protective sleeves 220A and 220B are provided adjacent and partially within each of the proximal engagement element 216 and 218, as shown in
The other ends of the sleeves 220A and 220B are located inside distal engagement elements 222 and 224, which are attached to corresponding housings 230 and 232. Each of the proximal and distal engagement elements have corresponding inserts, which are discussed in more detail later. The housing 230 is configured to hold the secondary cutting device 250 while the housing 232 is configured to hold the secondary cutting device 252. In one implementation, the housing 230 has a first external diameter D1, at the distal end from the main cutting device 210, and a second external diameter D2, at the proximal end relative to the main cutting device 210, where D1 is smaller than D2. The secondary cutting device 250 is located at the transition zone TZ, between the first diameter D1 and the second diameter D2, and may include one or more cutting elements 251 distributed along the transition zone. Each cutting element 251 may include a substrate to which a hard material shaped for cutting is attached to. In one embodiment, as illustrated in
Also not visible in
To maintain the main cutting device 210 centered between the first and second housings 230 and 232, a first spring device 208 is placed between the radial bearing device 203 and the axial ball bearing system 206, and a second spring device 209 is placed between the radial bearing device 204 and the axial ball bearing system 207. To protect the bearing systems from debris and various liquids present in the well, the protective sleeves 220A and 220B are provided between and under the proximal and distal engagement elements 216, 218, 222, and 224.
The proximal engagement elements 216, 218 and the distal engagement elements 222, 224 are configured to engage to each other in pairs, when the tool is pushed down or up the well, so that a rotation of the first housing 230 or a rotation of the second housing 232, also makes the main cutting device 210 to rotate when the corresponding proximal and distal engagement elements connect to each other. In this respect, note that
In other words, when the main cutting device 210 encounters axial resistance sufficient to override the compression of the spring 208 or 209, and the corresponding proximal and distal engagement elements come into engagement with one another as the main shaft slides relative to the main cutting device 210, the main cutting device will be forced into rotation in unison with the shaft 202 and one of the housings 230 or 232 by engagement of the proximal and distal engagements elements, thereby reaming or otherwise conditioning the borehole by application of the full drill string torque to the main drilling device 210 as the drilling process continues.
The proximal and distal engagement elements are now discussed in more detail with regard to
The lips of the engagement elements 222 and 216 are shaped to lock with each other only when they rotate in a given direction (e.g., clockwise), but to slip past each other when they rotate in the opposite direction (e.g., anti-clockwise). In this regard,
The lip 820 (or profile) of the proximal engagement element 216, which directly engages the lip (not shown) of the distal engagement element 222, is shaped, in the embodiment illustrated in
These four regions repeat between two adjacent inserts, as shown in
The tool 200 having the engagement elements with the inserts (or teeth) illustrated in
Note that the proximal and distal engagement elements may be attached to their corresponding main cutter device 210 or housings 230 and 232 by various means, for example, press-fit, welding, screws, or threads. This embodiment shows the tool having four inserts 216A per engagement element, consistent with the engagement elements shown in
The tool 200 can be used for many purposes in a well. For example, after drilling a well, traditionally, it is necessary for reaming every stand to eliminate ledging, spiraling, and other bore-hole irregularities. The tool 200 is capable to minimize the need to ream every stand as it acts on the well immediately after the drill bit, thus clearing the hole irregularities and leaving a smoother bore hole in one trip.
In another embodiment, it is necessary to use a tool to perform hard back-reaming through a swelling shale and other types of tight spots while pulling it out of the hole. In this case, the tool would minimize the back reaming time by providing a more efficient back reaming with PDC cutters as compared to the blunt stabilizer. When facing any tight spots, the tool body would engage the spots and the PDC cutters 252 would start to efficiently ream through the tight spot. As the tool 200 comes in full gauge and on top of the bottom hole assembly (BHA) above all stabilizers and reamers, the rest of the BHA elements should follow smoothly after the tool does the back-reaming.
The tool may also be used to reduce or eliminate the wiper trips, which are typically performed after a section is completed, to adjust the bore hole condition and eliminate hole irregularities for smoother casing run. In this regard, note that prior to deploying the casing, after drilling the well, the walls of the well need to make a smooth, constant diameter bore or otherwise the casing will not slide inside the well. Thus, the tool 200 in the BHA may minimize the need for wiper trips as the tool performs all the bore hole shape/size adjustments while drilling and while pulling it out of the well.
It is also possible, in a typical well, to have a completely stuck pipe in the well due to the tight spots and thus, the drill line is jarred and/or over-pulled to free the stuck pipe. The tool 200's presence in the BHA should minimize the potential of such drilling problems as the tool 200 has the ability to drill through the tight spots. Conventional stabilizers on the other hand are not equipped with any cutting structures so they can easily get jammed into the tight spot.
Because the tool 200 has the cutting structures rotating on bearings, it greatly reduces the BHA torque and BHA stick-slip, allowing to apply higher weight on bit and drilling parameters to achieve higher rate of penetration values for more economic drilling.
When the tool 200 is placed inside a well, as shown in
A method for conditioning a drill hole in a well is now discussed with regard to
The disclosed embodiments provide a multifunctional drilling enhancement tool that is capable of achieving one or more functions performed by individual traditional devices, e.g., reaming, wiper trips, minimizing stuck pipes, and increasing the rate of production. It should be understood that this description is not intended to limit the invention. On the contrary, the embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
Although the features and elements of the present embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.
This application is a U.S. National Stage Application of International Application No. PCT/IB2020/059382, filed on Jun. 10, 2020, which claims priority to U.S. Provisional Patent Application No. 62/911,618, filed on Oct. 7, 2019, entitled “MULTIFUNCTIONAL DRILLING ENHANCEMENT TOOL,” and U.S. Provisional Patent Application No. 62/930,047, filed on Nov. 4, 2019, entitled “MULTIFUNCTIONAL DRILLING ENHANCEMENT TOOL,” the disclosures of which are incorporated herein by reference in their entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/IB2020/059382 | 10/6/2020 | WO |
Publishing Document | Publishing Date | Country | Kind |
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WO2021/070057 | 4/15/2021 | WO | A |
Number | Name | Date | Kind |
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3767263 | Gootee | Oct 1973 | A |
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10378280 | Carter | Aug 2019 | B2 |
20120132469 | Robson | May 2012 | A1 |
20190360280 | Ahmed | Nov 2019 | A1 |
Number | Date | Country |
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2018094318 | May 2018 | WO |
Entry |
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International Search Report in corresponding/related International Application No. PCT/IB2020/059382, date of mailing Jan. 18, 2021. |
Written Opinion of the International Searching Authority in corresponding/related International Application No. PCT/IB2020/059382, date of mailing Jan. 18, 2021. |
Number | Date | Country | |
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20230313621 A1 | Oct 2023 | US |
Number | Date | Country | |
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62930047 | Nov 2019 | US | |
62911618 | Oct 2019 | US |