Patent Application
20220178214
The present disclosure relates to polycrystalline diamond elements for use as protection between tubulars that are movably engaged with one another; to apparatus and systems including the same; and to methods of making, assembling, and using the same.
Several downhole oil well construction and production applications involve relatively smaller diameter tubulars movably coupled (e.g., in sliding, rotating, and/or reciprocating engagement) with (e.g., inside) relatively larger diameter tubulars. These applications include, but are not limited to, a drill pipe string operating inside casing and a sucker rod string operating inside production tubing.
Wear on the internal diameter of the relatively larger, outer tubular and on the outer diameter of the relatively smaller, inner tubular, especially at the upset coupling or connection diameters of the inner pipe or sucker rod, is frequently problematic. These wear problems are accelerated in directionally drilled wells where gravity causes the inner tubular and its connections to engage with and “ride” on the inner, low-side of the larger diameter tubular (e.g., casing or production tubing). Additionally, wells with relatively high deviation changes create rub points for the interface of the inner and outer tubulars.
In drilling operations, such wear can lead to failed drill string and loss of the drill string below the failure. Such wear can also cause problems to the integrity of the well due to casing wear. In production operations, such wear can lead to failure of the sucker rod string or cause wear of the production tubing. A production tubing failure causes the operator to have to prematurely service the well, adding cost and losing production.
Over time, technology has been developed to reduce the contact and wear at the interface of the inner and outer tubulars by attaching sacrificial protectors or guides at intervals around the outer surface of the inner tubular string. In drilling applications, these sacrificial protectors or guides are typically referred to as “pipe protectors.” In production applications, these sacrificial protectors or guides are typically referred to as “rod guides.” In both drilling and production applications, these sacrificial protectors or guides are typically made from molded rubber, nylon, plastic, polymer, polyurethane, synthetic polyamide, or polyether ether ketone (PEEK). Pipe protectors are typically mounted on a metal frame. Rod guides may be molded directly onto the rod lengths and may or may not include a metal frame. With any of the materials currently used for sacrificial protectors or guides, relatively higher temperatures result in an increase in the rate of abrasive wear of the sacrificial protectors or guides.
Replacing drill pipe, sucker rod strings, and/or production tubing is expensive and time consuming. In the case of production applications, the avoidance of wear problems involves working over the well to replace guides and clear debris from the production tubing. In so called unconventional wells, the frequency of workovers to replace sucker rod guides can be as often as every three months.
What is needed is a technology to extend the lifespan of pipe protectors and rod guides without increasing or significantly increasing the coefficient of friction of the engagement of the protectors/guides with the outer tubulars.
Polycrystalline diamond elements have, in the past, been contraindicated for engagement with the inner surfaces of casing or production tubing. Without being bound by theory, polycrystalline diamond, including thermally stable polycrystalline diamond and polycrystalline diamond compact, has been considered as contraindicated for use in the engagement with ferrous metals, and other metals, metal alloys, composites, hardfacings, coatings, or platings that contain more than trace amounts of diamond solvent-catalyst including cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, or tantalum. Further, this prior contraindication of the use of polycrystalline diamond extends to so called “superalloys” including iron-based, cobalt-based and nickel-based superalloys containing more than trace amounts of diamond solvent-catalyst. The surface speeds typically used in machining of such materials typically ranges from about 0.2 m/s to about 5 m/s. Although these surface speeds are not particularly high, the load and attendant temperature generated, such as at a cutting tip, often exceeds the graphitization temperature of diamond (i.e., about 700° C.), which can, in the presence of diamond solvent-catalyst, lead to rapid wear and failure of components, such as diamond tipped tools. Without being bound by theory, the specific failure mechanism is believed to result from the chemical interaction of the carbon bearing diamond with the carbon attracting material that is being machined. An exemplary reference concerning the contraindication of polycrystalline diamond for diamond solvent-catalyst containing metal or alloy machining is U.S. Pat. No. 3,745,623. The contraindication of polycrystalline diamond for machining diamond solvent-catalyst containing materials has long caused the avoidance of the use of polycrystalline diamond in all contacting applications with such materials.
Some embodiments of the present disclosure include a sucker rod assembly. The assembly includes production tubing positioned within a wellbore. The production tubing has an internal cavity wall defining a cavity of the production tubing. The internal cavity wall is a metal surface including a metal that contains at least 2 wt. % of a diamond solvent-catalyst based on a total weight of the metal. A sucker rod string is positioned within the cavity of the production tubing. The sucker rod string includes a first sucker rod, a second sucker rod, and a sucker rod coupler. The first sucker rod is coupled with a first end of the sucker rod coupler, and the second sucker rod is coupled with a second end of the sucker rod coupler. A plurality of polycrystalline diamond elements are coupled with the sucker rod coupler. Each polycrystalline diamond element has an engagement surface of polycrystalline diamond. The engagement surfaces of polycrystalline diamond are positioned along the sucker rod string to interface engagement between the sucker rod string and the metal surface of the production tubing.
Some embodiments of the present disclosure include a method of interfacing engagement between a sucker rod string and production tubing. The method includes providing a sucker rod string having a first sucker rod, a second sucker rod, and a sucker rod coupler. The first sucker rod is coupled with a first end of the sucker rod coupler, and the second sucker rod is coupled with a second end of the sucker rod coupler. The method includes positioning a plurality of polycrystalline diamond elements on the sucker rod coupler. Each polycrystalline diamond element has an engagement surface of polycrystalline diamond. The method includes providing production tubing positioned within a wellbore. The production tubing has an internal cavity wall defining a cavity. The internal cavity wall is a metal surface including a metal that contains at least 2 wt. % of a diamond solvent-catalyst based on a total weight of the metal. The method includes positioning the sucker rod string within the cavity of the production tubing such that the engagement surfaces of polycrystalline diamond are positioned along the sucker rod string to interface engagement between the sucker rod string and the metal surface of the production tubing.
Some embodiments of the present disclosure include a downhole tubular assembly. The assembly includes a tubular having a first end, a second end, and a tool joint at the second end.
A plurality of polycrystalline diamond elements are coupled with the tool joint. Each polycrystalline diamond element has an engagement surface of polycrystalline diamond. The assembly includes casing in a wellbore. The casing has an internal wall having a metal surface. The metal surface includes a metal that contains at least 2 wt. % of a diamond solvent-catalyst based on a total weight of the metal. The tubular is positioned within the casing such that the engagement surfaces of the polycrystalline diamond are positioned to interface engagement between the tool joint and the internal wall of the casing.
Some embodiments of the present disclosure include a method of interfacing engagement between a tool joint and casing. The method includes providing a tubular having a first end, a second end, and a tool joint at the second end. The method includes coupling a plurality of polycrystalline diamond elements with the tool joint. Each polycrystalline diamond element has an engagement surface of polycrystalline diamond. The method includes providing casing in a wellbore. The casing has an internal wall having a metal surface. The metal surface includes a metal that contains at least 2 wt. % of a diamond solvent-catalyst based on a total weight of the metal. The method includes positioning the tubular in the casing such that the engagement surfaces of the polycrystalline diamond are positioned to interface engagement between the tool joint and the internal wall of the casing.
So that the manner in which the features and advantages of the systems, apparatus, and/or methods of the present disclosure may be understood in more detail, a more particular description briefly summarized above may be had by reference to the embodiments thereof which are illustrated in the appended drawings that form a part of this specification. It is to be noted, however, that the drawings illustrate only various exemplary embodiments and are therefore not to be considered limiting of the disclosed concepts as it may include other effective embodiments as well.
Certain embodiments of the present disclosure include polycrystalline diamond elements for use as protection between tubulars that are movably engaged with one another, protectors or guides including the polycrystalline diamond elements; tubular assemblies including the protectors or guides, apparatus and systems including the tubular assemblies; and to methods of making, assembling, and using the polycrystalline diamond elements, the protectors or guides, the tubular assemblies, and the apparatus and systems.
Certain embodiments of the present disclosure include an engagement interface configured to interface the engagement of two different tubulars. With reference to
Engagement interface 10 includes a plurality of polycrystalline diamond elements 14. Each polycrystalline diamond element 14 is coupled with body 12. For example, each polycrystalline diamond element 14 may be embedded within body 12 or otherwise coupled to body 12. In embodiments where body 12 is a polymer body, body 12 may be molded onto, over, or with polycrystalline diamond elements 14 via a polymer molding process. For example,
Body 12 includes body engagement surface 16, and each polycrystalline diamond element 14 includes a diamond engagement surface 18. As shown in
Engagement interface 10 may provide protection at the interface of two different tubulars that are movably (e.g., slidingly and/or rotatably) engaged with one another. In some embodiments, engagement interface 10 is a drill pipe protector. In other embodiments, engagement interface 10 is a sucker rod guide. While shown and described herein as a drill pipe protector and a sucker rod guide, the engagement interface disclosed herein is not limited to being a drill pipe protector or a sucker rod guide, and may be another structure that is capable of being coupled with a tubular and interfacing movable engagement between that tubular and another tubular. In some embodiments, rather than being coupled with a tubular, the engagement interface is integral with the tubular. In some embodiments, the engagement interface is static relative to one tubular (i.e., the tubular to which the engagement interface is coupled), and is movable relative to the other tubular (i.e., is movably engaged with the other tubular).
Certain embodiments include tubular assemblies that include the engagement interfaces disclosed herein positioned to interface the engagement between the tubulars of the tubular assemblies. With reference to
Tubular 30 is a hollow tubular having inner wall 32 defining cavity 34 therethrough, such as a pipe or other conduit. Tubular 30 has outer wall 36. Tubular 30 has an outer diameter 38 defined by outer wall 36, and an inner diameter 31 defined by inner wall 32.
In some embodiments, as shown in
Outer diameter 48 of tubular 40 and inner diameter 31 of tubular 30 are sized such that tubular 40 may be coupled or engaged at least partially within cavity 34 of tubular 30, as shown in
As shown in
Tubular 40 is rotatably engaged within tubular 30 such that one or both of tubulars 30 and 40 are rotatable in one or both directions 54 and 56 (as shown in
Thus, tubular 40 is movably engaged within tubular 30 such that one or both of tubulars 30 and 40 are movable relative to the other tubular. As used herein, “movably engaged,” in reference to engaged tubulars, refers to an engagement between at least two tubulars that allows at least one of the tubulars to move relative to the other of the tubulars. For example, tubular 40 may move (e.g., slide and/or rotate) relative to tubular 30, tubular 30 may move relative to tubular 40, or combinations thereof.
Engagement interfaces 10 may be positioned on and coupled with the larger diameter tubular for interfacing engagement thereof with the smaller diameter tubular, or engagement interfaces 10 may be positioned on and coupled with the smaller diameter tubular for interfacing engagement thereof with the larger diameter tubular. In
As used herein, “opposing tubular” refers to a tubular that is movably engaged with a different tubular, where the different tubular has at least one of the engagement interfaces coupled thereon to interface engagement with the opposing tubular.
With reference to
Polycrystalline diamond element 14a is exemplary of an “underexposed” polycrystalline diamond element, such that the polycrystalline diamond element is positioned below plane 24a defined by body engagement surface 16a. Thus, in operation polycrystalline diamond element 14a will engage with another tubular after the body engagement surface 16a is worn down sufficiently to expose the diamond engagement surface 18a of the polycrystalline diamond element 14a, as shown in
Polycrystalline diamond element 14b, as shown in
Polycrystalline diamond element 14c, as shown in
Thus, in some embodiments, the polycrystalline diamond elements disclosed herein provide “back-up wear resistance capability” to the associated engagement interface. As used herein, “back-up wear resistance capability” refers to the arrangement of the polycrystalline diamond elements relative to the body such that, the diamond engagement surfaces engage with an opposing tubular only after sufficient wear of the body has occurred (e.g., as shown in
As shown in
Having described engagement interfaces, generally, certain embodiments and applications thereof will now be described in further detail.
In some embodiments, the engagement interfaces disclosed herein are provided on a sucker rod guide, such as for interfacing the engagement between a sucker rod string movably positioned within production tubing. For example, with reference to
With reference to
Body 12 of sucker rod guide 104 includes base 13 circumferentially surrounding sucker rod 102. Body 12 also includes protrusions 110 extending outward from base 13, away from sucker rod 102. In some embodiments, protrusions 110 are in the form of peaks, blades, ribs, fins, or vanes extending outward from sucker rod 102. Protrusions 110 are spaced radially about base 13 and sucker rod 102, such that cavities or valleys 111 are positioned between adjacent protrusions 110. Each protrusion 110 defines a body engagement surface 16 for engagement with, for example, production tubing to protect and/or guide sucker rod 102 during operation thereof.
At least one polycrystalline diamond element is coupled with the sucker rod guides disclosed herein. As shown in
Each polycrystalline diamond element 14 may be embedded within body engagement surface 16 or otherwise attached to sucker rod guide 104, such that polycrystalline diamond elements 14 are positioned to protect and guide the engagement between sucker rod 102 and, for example, production tubing. As shown, polycrystalline diamond elements 14 have convex engagement surfaces 18 for engagement with production tubing and are in the form of inserts that are inserted into sucker rod guide 104. However, the polycrystalline diamond elements disclosed herein are not limited to this particular arrangement, shape, or number.
In some embodiments, the sucker rod guide disclosed herein (e.g., the sucker rod guide of
In some embodiments, the engagement interfaces disclosed herein are provided on a pipe protector of a pipe (e.g., a drill pipe), such as for interfacing the engagement between a drill pipe and casing during drilling operations where the drill pipe is movably positioned within the casing. For example, with reference to
With reference to
Drill pipe protector 820 includes body 822, also referred to as a sleeve, which defines a portion of the wear surface or body engagement surface 16. Embedded within body 822 is frame 200, forming cage 222, as shown in
With reference to
With reference to
Drill pipe protector 920 in
The technology of the present application preferably employs convex polycrystalline diamond elements, preferably polished polycrystalline diamond compact (PDC) elements, to provide primary, concurrent, or back-up wear resistance capability to protectors for drill pipe or sucker rods. However, the polycrystalline diamond elements of the present technology may alternatively be planar with radiused or highly radiused edges. The polycrystalline diamond elements of the current application may be, for example, thermally stable polycrystalline diamond or PDC. In some embodiments, the polycrystalline diamond elements are backed (e.g., supported) or unbacked (e.g., unsupported), such as by tungsten carbide. As would be understood by one skilled in the art, the polycrystalline diamond elements disclosed herein may be non-leached, leached, leached and backfilled, or coated (e.g., via CVD) all by methods known in the art.
In some embodiments, the polycrystalline diamond elements disclosed herein may have diameters as small as 3 mm (about ⅛″) or as large as 75 mm (about 3″), for example, depending on the application and the configuration and diameter of the engaged surface. Some of the polycrystalline diamond elements disclosed herein will have diameters of from 8 mm (about 5/16″) to 25 mm (about 1″). One skilled in the art would understand that the polycrystalline diamond elements are not limited to these particular dimensions and may vary in size and shape depending on the particular application.
In certain applications, the polycrystalline diamond elements disclosed herein have increased cobalt content transitions layers between the outer polycrystalline diamond surface and a supporting tungsten carbide slug. In some applications, the polycrystalline diamond elements disclosed herein may be unsupported by tungsten carbide and may be substantially “standalone”, discrete polycrystalline diamond bodies that are directly mounted (e.g., onto tubular member). In embodiments where the polycrystalline diamond elements are planar face or domed polycrystalline diamond elements, the polycrystalline diamond elements may be mounted in a manner to allow the polycrystalline diamond elements to rotate about its own axis. Reference is made to U.S. Pat. No. 8,881,849, to Shen et. al., as a non-limiting example of methods to provide for a polycrystalline diamond element that spins about its own axis while in facial contact with a diamond reactive material.
Although the polycrystalline diamond elements are most commonly available in cylindrical shapes, it is understood that the technology of the application may be practiced with polycrystalline diamond elements that are square, rectangular, oval, any of the shapes described herein with reference to the Figures, or any other appropriate shape known in the art.
In some embodiments, the polycrystalline diamond elements are subjected to edge radius treatment. In some embodiments of the technology of this application that employ planar or concave polycrystalline diamond elements, it is preferred to employ edge radius treatment of such polycrystalline diamond elements. One purpose of employing an edge radius treatment is to reduce or avoid potential for outer edge cutting or scribing at the outer limits of the linear engagement area of a given polycrystalline diamond element with the opposing tubular (e.g., a curved surface).
The polycrystalline diamond elements of the present application may be deployed in a manner that preferably precludes any edge or sharp contact between the polycrystalline diamond elements and ferrous materials with which they are slidingly engaged (e.g., ferrous casing or production tubing). The preclusion of edge contact can overcome the potential for machining of the ferrous material and chemical interaction between the diamond and ferrous material.
In some embodiments, the polycrystalline diamond elements of the present application may be mounted on a metal frame and over-molded by a thermoplastic material, or other common materials used for protectors. The polycrystalline elements of the present application may be underexposed, flush mounted, or exposed relative to the protector or guide body.
In certain embodiments, the polycrystalline diamond elements of the present application may be molded directly into protector materials and retained therein. Such molding may occur directly onto the parent tubular or may occur separate from the parent tubular and then the molded parts may be attached in a separate step. Alternatively, sockets may be molded into the thermoplastic or alternative body material and the polycrystalline diamond elements may then be mounted afterwards using gluing, or threading or other methods as known in the art. In some embodiments, the polycrystalline diamond elements may be mounted on couplings of a sucker rod assembly. In yet another alternative the polycrystalline diamond elements of the current application may be attached to a metal frame that is not over molded but, rather, acts as the primary frame with the polycrystalline diamond elements providing substantially all of the wear resistance and stand-off distance of the protector. In another alternative embodiment, the polycrystalline diamond elements of the current technology may be mounted in subassemblies that allow for the polycrystalline diamond elements to rotate about their own axis, as is known in the art.
The polycrystalline diamond elements of the current technology may be recovered from used protectors or guides and reused in freshly molded or deployed protectors or guides. The ability to recover and reuse the polycrystalline diamond elements reduces the ultimate cost of the use of the technology.
In certain applications, the polycrystalline diamond element, or at least the engagement surface thereof, is lapped or polished, optionally highly lapped or highly polished. As used herein, a surface is defined as “highly lapped” if the surface has a surface finish (Ra) of 20 μin Ra or about 20 μin Ra, such as a surface finish (Ra) ranging from about 18 to about 22 μin Ra. As used herein, a surface is defined as “polished” if the surface has a surface finish (Ra) of less than about 10 μin Ra, or of from about 2 to about 10 μin Ra. As used herein, a surface is defined as “highly polished” if the surface has a surface finish (Ra) of less than about 2 μin Ra, or from about 0.5 μin Ra to less than about 2 μin Ra. In some embodiments, the engagement surface has a surface finish (Ra) ranging from 0.5 μin Ra to 40 μin Ra, or from 2 μin Ra to 30 μin Ra, or from 5 μin Ra to 20 μin Ra. or from 8 μin Ra to 15 μin Ra, or less than or equal to 32 μin Ra, or less than 20 μin Ra, or less than 10 μin Ra, or less than 2 μin Ra, or any range therebetween. Polycrystalline diamond that has been polished to a surface finish (Ra) of 0.5 μin Ra has a coefficient of friction that is about half of standard lapped polycrystalline diamond with a surface finish of 20-40 μin Ra. U.S. Pat. Nos. 5,447,208 and 5,653,300 to Lund et al. provide disclosure relevant to polishing of polycrystalline diamond. As would be understood by one skilled in the art, surface finish may be measured with a profilometer or with Atomic Force Microscopy. Surface finish may be determined in accordance with ASME B46.1-2009.
In some embodiments, the opposing tubular, or at least the surface thereof, is or includes a diamond reactive material. As used herein, a “diamond reactive material” is a material that contains more than trace amounts of diamond solvent-catalyst. As used herein, a diamond reactive material that contains more than “trace amounts” of diamond solvent-catalyst contains at least 2 percent by weight (wt. %) diamond solvent-catalyst based on a total weight of the diamond reactive material. In some embodiments, the diamond reactive materials disclosed herein contain from 2 to 100 wt. %, or from 5 to 95 wt. %, or from 10 to 90 wt. %, or from 15 to 85 wt. %, or from 20 to 80 wt. %, or from 25 to 75 wt. %, or from 25 to 70 wt. %, or from 30 to 65 wt. %, or from 35 to 60 wt. %, or from 40 to 55 wt. %, or from 45 to 50 wt. % of diamond solvent-catalyst based on a total weight of the diamond reactive material. Some examples of known diamond solvent-catalysts (also referred to as “diamond catalyst,” “diamond solvent,” “diamond catalyst-solvent,” “catalyst-solvent,” or “solvent-catalyst”) are disclosed in: U.S. Pat. Nos. 6,655,845; 3,745,623; 7,198,043; U.S. Pat. Nos. 8,627,904; 5,385,715; 8,485,284; 6,814,775; 5,271,749; 5,948,541; 4,906,528; U.S. Pat. Nos. 7,737,377; 5,011,515; 3,650,714; U.S. Pat. Nos. 2,947,609; and 8,764,295. As would be understood by one skilled in the art, diamond solvent-catalysts are chemical elements, compounds, or materials (e.g., metals) that are capable of reacting with polycrystalline diamond (e.g., catalyzing and/or solubilizing), resulting in the graphitization of the polycrystalline diamond, such as under load and at a temperature at or exceeding the graphitization temperature of diamond (i.e., about 700° C.). Thus, diamond reactive materials include materials that, under load and at a temperature at or exceeding the graphitization temperature of diamond, can lead to wear, sometimes rapid wear, and failure of components formed of polycrystalline diamond, such as diamond tipped tools. Diamond solvent-catalysts include, but are not limited to, iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, and tantalum.
Diamond reactive materials include, but are not limited to, metals, metal alloys, and composite materials that contain more than trace amounts of diamond solvent-catalyst. In some embodiments, the diamond reactive materials are in the form of hard facings, coatings, or platings. For example, and without limitation, the diamond reactive material may contain ferrous, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, tantalum, or alloys thereof. In some embodiments, the diamond reactive material is a steel or cast iron. In some embodiments, the diamond reactive material is a superalloy including, but not limited to, iron-based, cobalt-based and nickel-based superalloys. In some embodiments, the opposing engagement surface (i.e., the surface in opposing engagement with the polycrystalline diamond engagement surface) is a metal surface. As used herein, a metal surface is a surface of a material that is primarily metal, by weight percent. In some embodiments, the opposing engagement surface contains from 2 to 100 wt. %, or from 5 to 95 wt. %, or from 10 to 90 wt. %, or from 15 to 85 wt. %, or from 20 to 80 wt. %, or from 25 to 75 wt. %, or from 25 to 70 wt. %, or from 30 to 65 wt. %, or from 35 to 60 wt. %, or from 40 to 55 wt. %, or from 45 to 50 wt. % of diamond solvent-catalyst based on a total weight of the material of the opposing engagement surface. In some embodiments, the opposing engagement surface contains from 2 to 100 wt. %, or from 5 to 95 wt. %, or from 10 to 90 wt. %, or from 15 to 85 wt. %, or from 20 to 80 wt. %, or from 25 to 75 wt. %, or from 25 to 70 wt. %, or from 30 to 65 wt. %, or from 35 to 60 wt. %, or from 40 to 55 wt. %, or from 45 to 50 wt. % of iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, or tantalum. In some embodiments, the opposing engagement surface contains at least 50 wt. %, at least 55 wt. %, at least 60 wt. %, at least 65 wt. %, at least 70 wt. %, at least 75 wt. %, at least 80 wt. %, at least 85 wt. %, at least 90 wt. %, at least 95 wt. %, or 100 wt. % of a metal, where the metal is a diamond reactive material.
In certain embodiments, the opposing tubular, or at least the surface thereof, is not and/or does not include (i.e., specifically excludes) so called “superhard materials.” As would be understood by one skilled in the art, “superhard materials” are a category of materials defined by the hardness of the material, which may be determined in accordance with the Brinell, Rockwell, Knoop and/or Vickers scales. For example, superhard materials include materials with a hardness value exceeding 40 gigapascals (GPa) when measured by the Vickers hardness test. As used herein, superhard materials include materials that are at least as hard as tungsten carbide tiles and/or cemented tungsten carbide, such as is determined in accordance with one of these hardness scales, such as the Brinell scale. One skilled in the art would understand that a Brinell scale test may be performed, for example, in accordance with ASTM E10-14; the Vickers hardness test may be performed, for example, in accordance with ASTM E384; the Rockwell hardness test may be performed, for example, in accordance with ASTM E18; and the Knoop hardness test may be performed, for example, in accordance with ASTM E384. The “superhard materials” disclosed herein include, but are not limited to, tungsten carbide (e.g., tile or cemented), infiltrated tungsten carbide matrix, silicon carbide, silicon nitride, cubic boron nitride, and polycrystalline diamond. Thus, in some embodiments, the opposing tubular is partially or entirely composed of material(s) (e.g., metal, metal alloy, composite) that is softer (less hard) than superhard materials, such as less hard than tungsten carbide (e.g., tile or cemented), as determined in accordance with one of these hardness tests, such as the Brinell scale. As would be understood by one skilled in the art, hardness may be determined using the Brinell scale, such as in accordance with ASTM E10-14. As would be understood by one skilled in the art, a “superalloy” is a high-strength alloy that can withstand high temperatures. In certain embodiments, the opposing tubular, or at least the surface thereof, is not and/or does not include (i.e., specifically excludes) diamond.
Some examples of surfaces disclosed herein that may be or include diamond reactive material are: inner wall 32 shown in
In some embodiments, the engagement interfaces disclosed herein are provided on the couplings of a tubular, such as a rod (e.g., a sucker rod), rather than or in addition to being on a guide of the tubular (e.g., rod). In some such embodiments, sucker rod couplers ar or include the engagement interfaces. The engagement interfaces on the couplings can interface the engagement between a sucker rod string movably positioned within production tubing. A sucker rod is a rod (e.g., a steel rod) that is used to make up the mechanical assembly between the surface and downhole components of a rod pumping system. A sucker rod string or assembly may include a plurality of sucker rods coupled together. In some embodiments, the plurality of sucker rods are threadably coupled together. For example, a rod coupler may be coupled with a first sucker rod and with a second sucker rod such that the first and second sucker rods are coupled together via the rod coupler. Exemplary sucker rods may be from 20 to 40 feet, or from 24 to 35 feet, or from 25 to 30 feet in length, and may be threaded at each end to enable coupling with the rod coupler.
With references to
Sucker rod coupler 1102 includes a plurality of polycrystalline diamond elements 1114 on coupler body 1104. The polycrystalline diamond elements 1114 may be the same or similar to those described throughout this disclosure, including those described with reference to
In some embodiments, the tubulars disclosed herein include joints for coupling with other components, such as with other tubulars or with tools (e.g., a tool joint).
A plurality of polycrystalline diamond elements 1114 are positioned on joint section 1508, such that engagement surfaces 1120 interface engagement between tubular 1502 and opposing engagement surface 1321.
Thus, in some embodiments, the PDC elements disclosed herein are positioned on a tool joint. The tool joint may be at one end of a drill pipe, for example, that includes threads and has a larger outer diameter (OD) than a remainder of the drill pipe. In some embodiments, tubulars with such tool joints (e.g., joint section 1508) do not have couplers, such as those shown in
From the descriptions and figures provided above it can readily be understood that the technology of the present application may be employed in a broad spectrum of applications, including those in downhole environments. The technology provided herein additionally has broad application to other industrial applications. One skilled in the art would understand that the present disclosure is not limited to use with drill pipes and sucker rods or even to use in downhole applications, and that the concepts disclosed herein may be applied to the engagement between any surfaces.
Although the present embodiments and advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
The present application claims the benefit of U.S. Provisional Patent Application No. 63/083,252 (pending), filed on Sep. 25, 2020, entitled “Sucker Rod Couplings with Polycrystalline Diamond Elements”, the entirety of which is incorporated herein by reference. The present application is also a Continuation-in-Part of U.S. patent application Ser. No. 16/529,310 (pending), filed on Aug. 1, 2019, entitled “Polycrystalline Diamond Tubular Protection” which itself claims the benefit of U.S. Provisional Patent Application No. 62/713,681 (expired), filed on Aug. 2, 2018, entitled “Polycrystalline Diamond Tubular Protection,” the entireties of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63083252 | Sep 2020 | US | |
| 62713681 | Aug 2018 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16529310 | Aug 2019 | US |
| Child | 17461382 | US |
