DRILLING APPARATUS WITH WINGS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. § 119 (e) to U.S. Provisional Patent Application No. 63/670,018, filed on Jul. 11, 2024, the entirety of which is incorporated herein by reference.

FIELD OF THE DISCLOSURE

The disclosure relates to a drilling apparatus and, in particular, is directed to a drill bit or an inline underreamer with wings that are capable of insertion into a wellbore in a first configuration, drilling within the wellbore in a second configuration, and removal from the wellbore in the first configuration.

BACKGROUND

The background description includes information that may be useful in understanding the present inventive subject matter. It is not an admission that any of the information provided herein is prior art and/or material to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.

Select techniques such as those used in the water, oil, and gas industries involve drilling within an existing wellbore (i.e., an injection or production wellbore) in a subterranean formation. One such technique is underreaming, which may be used to create a borehole at the end of a wellbore (i.e., beyond the end of casing within the wellbore) that is of an equal or greater diameter than that of the existing wellbore diameter. For example, a borehole may be needed within the subterranean formation beyond the end of casing within the existing wellbore to increase the total length of the existing wellbore (and the casing therein). For instance, the wellbore may require a diameter that is increased as compared to an internal diameter of the casing within the wellbore, to allow the casing to advance down the wellbore while retaining the same internal diameter of the casing once advanced.

An underreamer is a type of drilling apparatus that can be inserted into the existing wellbore to create the additional borehole with the increased diameter at the end of the existing wellbore. The underreamer may be inserted into the existing wellbore in a first, smaller-diameter configuration that is no greater than (i.e., is less than or equal to) the existing interior diameter of the wellbore. The underreamer may then be expanded to a second, larger diameter configuration that is greater than the interior diameter of the wellbore. Following the completion of a reaming process that increases the interior diameter of the existing wellbore to at least the second, larger diameter, the underreamer can be retracted back into the first, smaller-diameter configuration prior to removal from the wellbore (i.e., back through the casing).

The amount the diameter of the existing wellbore can be increased is dependent on the diameter of the underreamer in the second, larger-diameter configuration. Known methods of increasing the diameter of the underreamer to the second, larger-diameter configuration have become increasingly complex, which requires additional manufacturing during the fabrication process of the underreamer that results in lost time and increased cost. The more complex designs of known underreamers additionally can result in an apparatus that is more likely to fail during operation. Failure during operation may prevent successful extraction of the underreamer from the existing wellbore through the casing, potentially impacting the operation of the existing wellbore.

SUMMARY

Due to these and other deficiencies of known underreamers, there exists a long-felt but unmet need for a drilling apparatus that is of increased diameter when in the second, larger-diameter configuration during the reaming process. The drilling apparatus should be less complex than existing underreamer technologies, to reduce manufacturing time and cost and to additionally reduce the possibility of failure during operation. The drilling apparatus should be modular to allow for the ability to have multiple sets of wings on-site for repair or replacement, to reduce equipment cost and operation time being lost to downtime during maintenance of the drilling apparatus. For example, the multiple sets of wings should include wings with different diameters for the second, larger configuration for the drilling apparatus, and the drilling apparatus should include a hinge assembly that allows for the ability to switch between the different diameters for the second, larger configuration as desired on-site.

Embodiments of the present disclosure are directed to a drilling apparatus with a body and a plurality of wings. Each wing of the plurality of wings is coupled to the body via a connector. Each wing is able to expand via rotation about an axis through the connector between a first collapsed position and a second expanded position, and is optionally assisted in maintaining the second expanded position via hydraulic or pneumatic pressure within the existing wellbore. For example, the hydraulic pressure may be created via the injection of drilling fluid (i.e., drilling fluid, water or mud, or the like) through the body of the drilling apparatus. By way of another example, the pneumatic pressure may be created via the injection of air through the body of the drilling apparatus. When the plurality of wings is in the first collapsed position, the drilling apparatus has a first, smaller diameter than can fit into an existing wellbore (i.e., and through the existing casing therein). When the plurality of wings is in the second expanded position, the drilling apparatus has a second, larger diameter for reaming the subterranean formation within the existing wellbore. The second, larger diameter is increased relative to the interior diameter of the existing wellbore, such that rotating the drilling apparatus drills or reams a borehole at the end of the existing wellbore to increase the diameter of the existing wellbore to the second, larger diameter. Following a completion of the drilling or reaming process, the plurality of wings can return to the first collapsed position for removal or extraction of the drilling apparatus from the wellbore (i.e., through the casing). Additional casing material may then be run into the new length (or depth) of the wellbore in the second, larger diameter borehole, to maintain the first, smaller diameter of the total length of the casing throughout the wellbore.

In some embodiments, such as where the borehole beyond the existing casing is not pre-drilled, a proximal end of the drilling apparatus including a connector for a drill string, and the main body includes a drill bit end with cutting edges at a distal end of the drilling apparatus to drill the wellbore either prior to expansion of the wings or with the wings expanded. It is noted, however, that the drilling apparatus may be in line with but not immediately attached to the drill bit, such that the drill bit is more distal of the drilling apparatus within the wellbore.

In additional embodiments, including where the wellbore is pre-drilled and/or where a drill bit precedes the insertion of the drilling apparatus within the wellbore, the drilling apparatus is able to couple to sections of drilling string via connectors at both the proximal and distal ends of the drilling apparatus. In addition or in the alternative, the body of the drilling apparatus may include a drill bit, a bullnose, or other pilot assembly (i.e., a non-toothed distal tip that is rounded, pointed, wedged, flat, or the like).

In additional embodiments, the plurality of wings has a second, larger diameter than a first diameter of the main body. The plurality of wings may be a first set of wings that are able to be uncoupled from the main body, including on-site, and interchanged with a second set of a plurality of wings. The second set of the plurality of wings have a third, different diameter than both the first diameter of the main body and the second diameter of the removed first set of the plurality of wings. For example, the third, different diameter may be greater than the second, larger diameter, such that the drilling apparatus may be used in a step-wise manner to increase the diameter of the existing wellbore through the incremental increase of the diameter of the existing wellbore with the interchanging of the sets of the plurality of wings (i.e., similar to pilot hole drilling).

Embodiments of the present disclosure are directed to a drilling apparatus that is an expandable drill bit positioned at or proximate to an end of a drill string. The expandable drill bit is insertable into existing casing within a wellbore in a collapsed configuration. The expandable drill bit includes a body with a threaded connection, a central bore, and a hinge system including a connector and knuckles for each of a plurality of extendable wings. When rotated, the plurality of wings extends (i.e., swings or rotates) outward through the force of centripetal energy, adjusting the expandable drill bit to an expanded configuration by increasing the diameter of the drill bit for underreaming purposes. Optionally, the plurality of wings may be assisted during extension by drilling fluid or air forced out through openings in a center core tube of the body. When underreaming operations have been completed, the plurality of wings can be retracted through a unique closure method as described throughout the disclosure, allowing the expandable drill bit to be retracted through the existing casing using standard hole-drilling techniques.

Embodiments of the present disclosure are directed to a drilling apparatus that is an inline underreamer that is positionable anywhere along a drill string, including between sections of the drill string. The inline underreamer is insertable into existing casing within a wellbore in a collapsed configuration. The inline underreamer includes a body with a threaded connection on the aft-end, a threaded connection on the fore-end, a central bore, and a hinge system including a connector and knuckles for each of a plurality of extendable wings. When rotated, the plurality of wings extends (i.e., swings or rotates) outward through the force of centripetal energy, adjusting the inline underreamer to an expanded configuration by increasing the diameter of the inline underreamer for underreaming purposes. Optionally, the plurality of wings may be assisted during extension by drilling fluid or air forced out through openings in a center core tube of the body. When underreaming operations have been completed, the plurality of wings can be retracted through a unique closure method as described throughout the disclosure, allowing the inline underreamer to be retracted through the existing casing using standard hole-drilling techniques.

A first aspect of the present disclosure is to provide a drilling apparatus for drilling in a subterranean formation. The drilling apparatus comprises a main body including a plurality of blades, each blade of the plurality of blades including at least a first cutting edge. The drilling apparatus comprises a connector at a proximal end of the main body, the connector being operable to couple to a drill string. The drilling apparatus comprises a plurality of wing assemblies. Each of the plurality of wing assemblies comprises a wing with a hinge portion and at least a second cutting edge, a knuckle coupled to the main body, and a pin inserted into the hinge portion and the knuckle. A longitudinal axis of the pin is substantially parallel with a longitudinal axis of the main body. Each wing of the plurality of wing assemblies is rotatable between a collapsed position with a first surface of the wing proximate to the main body, and an expanded position with a second surface of the wing proximate to a respective blade of the plurality of blades. The wing rotates from the collapsed position to the expanded position about the longitudinal axis of the pin with a rotation of the main body via the drill string.

The drilling apparatus of the first aspect may include, optionally, that the drilling apparatus has a first diameter when each wing of the plurality of wing assemblies is in the collapsed position, that the drilling apparatus has a second diameter when each wing of the plurality of wing assemblies is in the expanded position, and that the second diameter is greater than the first diameter.

The drilling apparatus of the first aspect may include one or more of the previous embodiments and, optionally, that the first diameter is defined by a width of the plurality of blades, and that the second diameter is defined by a width of the plurality of wing assemblies when each wing of the plurality of wing assemblies is in the expanded position.

The drilling apparatus of the first aspect may include one or more of the previous embodiments and, optionally, that the wing of each of the plurality of wing assemblies is a first wing with a first width, that the first wing is interchangeable with a second wing via removal of the pin inserted into the hinge portion of the first wing and the knuckle in each wing assembly, that the second wing has a second width that is different from the first width of the first wing, and that the drilling apparatus has a third diameter when the second wings of the plurality of wing assemblies are in the expanded position that is different from the both the first diameter and the second diameter.

The drilling apparatus of the first aspect may include one or more of the previous embodiments and, optionally, that the knuckle is positioned within a pocket defined between adjacent blades of the plurality of blades, and that the collapsed position of the wing proximate to the main body is within the pocket.

The drilling apparatus of the first aspect may include one or more of the previous embodiments and, optionally, that the drilling apparatus is an expandable drill bit with a distal tip of the main body substantially coming to a point.

The drilling apparatus of the first aspect may include one or more of the previous embodiments and, optionally, that the drilling apparatus is an inline underreamer with a second connector at a distal tip of the main body, the second connector being operable to couple to a second section of the drill string.

A second aspect of the present disclosure is to provide a method for drilling a subterranean formation. The method may include, but is not limited to, inserting a drilling apparatus into a wellbore that has a first diameter, the drilling apparatus including a main body and a plurality of wings. Each wing of the plurality of wings is coupled to the main body via a respective pin. The method may include, but is not limited to, extending the drilling apparatus through the wellbore. The method may include, but is not limited to, actuating the plurality of wings of the drilling apparatus from a collapsed position to an expanded position. Each wing rotates about a longitudinal axis through the respective pin that is substantially parallel to a longitudinal axis through the main body. The method may include, but is not limited to, performing a drilling process with the plurality of wings of the drilling apparatus in the expanded position. The method may include, but is not limited to, retracting the drilling apparatus within the wellbore following the drilling process. The method may include, but is not limited to, collapsing the plurality of wings of the drilling apparatus for removal of the drilling apparatus from the wellbore.

The method of the second aspect may include, optionally, that the collapsing the plurality of wings of the drilling apparatus for removal of the drilling apparatus from the wellbore comprises engaging a bottom edge of the wellbore with the drilling apparatus when the wings of the drilling apparatus are in the expanded position.

The method of the second aspect may include one or more of the previous embodiments and, optionally, that the bottom edge of the wellbore is a bottom edge of existing casing within the wellbore.

The method of the second aspect may include one or more of the previous embodiments and, optionally, that the drilling apparatus has a first apparatus diameter that is no greater than a first wellbore diameter of the wellbore when the plurality of wings is in the collapsed position, that the drilling apparatus has a second apparatus diameter that is greater than the first wellbore diameter of the wellbore when the plurality of wings is in the expanded position, and that the drilling process increases the first wellbore diameter of the wellbore to a second wellbore diameter that is at least the second apparatus diameter of the drilling apparatus.

The method of the second aspect may include one or more of the previous embodiments and, optionally, that herein the plurality of wings is a first plurality of wings with a first expanded position. The method may include, but is not limited to, removing the respective pin from each wing of the first plurality of wings to uncouple the first plurality of wings from the main body. The method may include, but is not limited to, interchanging the first plurality of wings with a second plurality of wings. The method may include, but is not limited to, inserting the respective pin into each second wing of the second plurality of wings to couple the second plurality of wings to the main body. The drilling apparatus has a second apparatus diameter defined by the second plurality of wings in a second expanded position. The second apparatus diameter is different from a main body diameter defined by a plurality of blades of the drilling apparatus and a first apparatus diameter defined by the first plurality of wings in the first expanded position.

A third aspect of the present disclosure is to provide an expandable drill bit configured to perform an underreaming operation in a wellbore. The expandable drill bit comprises a body with a blade. The body extends along a longitudinal axis. The body has a first radius measured from the longitudinal axis to a first cutting edge of the blade. The expandable drill bit comprises a first hinge portion fixed to the body. The expandable drill bit comprises a wing with a second cutting edge and a second hinge portion configured to intermesh with the first hinge portion. The expandable drill bit comprises a pin inserted through an aperture defined by the intermeshed first and second hinge portions such that the wing is rotatably interconnected to the body. In a retracted position, the second cutting edge is a first distance from the longitudinal axis, the first distance being less than the first radius. In an expanded position, the second cutting edge is a second distance from the longitudinal axis, the second distance being greater than the first radius.

The drilling apparatus of the third aspect may include, optionally, that the aperture defined by the intermeshed first and second hinge portions has an aperture axis that is approximately parallel to the longitudinal axis.

The drilling apparatus of the third aspect may include one or more of the previous embodiments and, optionally, that the body further comprises: a tube extending along the longitudinal axis; and a channel configured to direct a fluid from the tube radially away from the longitudinal axis and against the wing such that the wing rotates from the retracted position to the expanded position.

A fourth aspect of the present disclosure is directed to a drilling apparatus for drilling in a subterranean formation. The drilling apparatus includes a main body including a plurality of blades, each blade of the plurality of blades including at least a first cutting edge. The drilling apparatus includes a plurality of wing assemblies. Each wing assembly of the plurality of wing assemblies include a wing with a hinge portion and at least a second cutting edge, a corresponding knuckle of the main body, and a connector inserted into the hinge portion and the corresponding knuckle. A wing of a wing assembly of the plurality of wing assemblies is rotatable between a collapsed position and an expanded position. The wing rotates from the collapsed position to the expanded position about a longitudinal axis of the connector in response to a rotation of the main body.

The drilling apparatus of the fourth aspect may include, optionally, that the drilling apparatus has a first diameter when each wing of the plurality of wing assemblies is in the collapsed position, that the drilling apparatus has a second diameter when each wing of the plurality of wing assemblies is in the expanded position, and that the second diameter is greater than the first diameter.

The drilling apparatus of the fourth aspect may include one or more of the previous embodiments and, optionally, that the first diameter is defined at least in part by a width of a blade of the plurality of blades, and that the second diameter is defined at least in part by a width of a wing of the plurality of wing assemblies when the wing is in the expanded position.

The drilling apparatus of the fourth aspect may include one or more of the previous embodiments and, optionally, the width of the wing is greater than the width of the blade.

The drilling apparatus of the fourth aspect may include one or more of the previous embodiments and, optionally, that the wing of each of the plurality of wing assemblies is a first wing with a first width, wherein the first wing is interchangeable with a second wing via removal of the connector inserted into the hinge portion of the first wing and the corresponding knuckle in each wing assembly, that the second wing has a second width that is different from the first width of the first wing, that the drilling apparatus has a third diameter that includes the second width of the second wing when the second wing is in the expanded position, and that the third diameter is different from the both the first diameter and the second diameter.

The drilling apparatus of the fourth aspect may include one or more of the previous embodiments and, optionally, that in the collapsed position a first surface of the wing is proximate to the main body, and that in the expanded position a second surface of the wing is proximate to a blade of the plurality of blades.

The drilling apparatus of the fourth aspect may include one or more of the previous embodiments and, optionally, that the corresponding knuckle is positioned within a pocket defined between adjacent blades of the plurality of blades, and that the wing is proximate to the main body within the pocket when the wing is in the collapsed position.

The drilling apparatus of the fourth aspect may include one or more of the previous embodiments and, optionally, that the drilling apparatus is an expandable drill bit with a distal end of the drilling apparatus substantially coming to a point.

The drilling apparatus of the fourth aspect may include one or more of the previous embodiments and, optionally, that the drilling apparatus is an inline underreamer with a connector at a distal end of the drilling apparatus.

The drilling apparatus of the fourth aspect may include one or more of the previous embodiments and, optionally, that the longitudinal axis of the connector is substantially parallel with a longitudinal axis of the main body.

A fifth aspect of the present disclosure is directed to a system for drilling in a subterranean formation. The system includes a drilling apparatus. The drilling apparatus includes a main body including a plurality of blades, each blade of the plurality of blades including at least a first cutting edge. The drilling apparatus includes a plurality of wing assemblies. Each wing assembly of the plurality of wing assemblies includes a wing with a hinge portion and at least a second cutting edge, a corresponding knuckle of the main body, and a connector inserted into the hinge portion and the corresponding knuckle. A wing of a wing assembly of the plurality of wing assemblies is rotatable between a collapsed position and an expanded position. The system includes a drill string in communication with the main body. The wing rotates from the collapsed position to the expanded position about a longitudinal axis of the connector in response to a rotation of the main body via the drill string.

The drilling apparatus of the fifth aspect may include, optionally, that the main body comprises a channel configured to direct a fluid from the drill string radially away from a longitudinal axis of the main body and against one or more wings of the plurality of wing assemblies such that the one or more wings rotates between the collapsed position and the expanded position.

The drilling apparatus of the fifth aspect may include one or more of the previous embodiments and, optionally, that the main body is in communication with the drill string at a proximal end of the drilling apparatus, and wherein a distal end of the drilling apparatus includes a drill tip.

The drilling apparatus of the fifth aspect may include one or more of the previous embodiments and, optionally, that the drill string includes a first section and a second section, that the first section of the drill string is coupled to a first connector at a proximal end of the drilling apparatus, and that the second section of the drill string is coupled to a second connector at a distal end of the drilling apparatus.

The drilling apparatus of the fifth aspect may include one or more of the previous embodiments and, optionally, that the wing of the plurality of wing assemblies is a first wing with a first mass and a first centripetal force associated with the rotation of the main body via the drill string, that the first wing is interchangeable with a second wing via removal of the connector inserted into the hinge portion of the first wing and the corresponding knuckle, and insertion of the connector into a hinge portion of the second wing and the corresponding knuckle, that the second wing has a second mass with a second centripetal force associated with the rotation of the main body, and that the second centripetal force is different than the first centripetal force.

A sixth aspect of the present disclosure is directed to a method for drilling into a subterranean formation. The method may include, but is not limited to, inserting a drilling apparatus into a wellbore that has a first diameter, the drilling apparatus including a main body and a plurality of wings. Each wing of the plurality of wings is coupled to the main body via a respective connector through a respective hinge portion of each wing and a corresponding knuckle of the main body. The method may include, but is not limited to, extending the drilling apparatus through the wellbore. The method may include, but is not limited to, actuating the plurality of wings of the drilling apparatus from a collapsed position to an expanded position. The method may include, but is not limited to, performing a drilling process with the plurality of wings of the drilling apparatus in the expanded position. The method may include, but is not limited to, retracting the drilling apparatus within the wellbore following the drilling process. The method may include, but is not limited to, collapsing the plurality of wings of the drilling apparatus for removal of the drilling apparatus from the wellbore.

The method of the sixth aspect may include, optionally, that the collapsing of the plurality of wings of the drilling apparatus for removal of the drilling apparatus from the wellbore includes engaging a bottom edge of the wellbore with the drilling apparatus with the plurality of wings when the plurality of wings of the drilling apparatus are in the expanded position.

The method of the sixth may include one or more of the previous embodiments and, optionally, that the first diameter includes a width of a blade of the plurality of blades, and that the second diameter includes a width of a wing of the plurality of wing assemblies when the wing is in the expanded position.

The method of the sixth may include one or more of the previous embodiments and, optionally, that the bottom edge of the wellbore is a bottom edge of existing casing within the wellbore.

The method of the sixth may include one or more of the previous embodiments and, optionally, that the drilling apparatus has a first apparatus diameter that is no greater than a first wellbore diameter of the wellbore when the plurality of wings are in the collapsed position, that the drilling apparatus has a second apparatus diameter that is greater than the first wellbore diameter of the wellbore when the plurality of wings are in the expanded position, and that the drilling process increases the first wellbore diameter of the wellbore to a second wellbore diameter that is at least the second apparatus diameter of the drilling apparatus.

The method of the sixth may include one or more of the previous embodiments and, optionally, that the plurality of wings is a first plurality of wings with a first expanded position. The method may include, but is not limited to, removing the respective connector from the respective hinge portion of each wing of the first plurality of wings to uncouple the first plurality of wings from the corresponding knuckle of the main body. The method may include, but is not limited to, interchanging the first plurality of wings with a second plurality of wings. The method may include, but is not limited to, inserting the respective connector into a respective hinge portion of each second wing of the second plurality of wings to couple the second plurality of wings to a corresponding knuckle of the main body. The drilling apparatus has a second apparatus diameter defined by the second plurality of wings in a second expanded position. The second apparatus diameter is different from the first apparatus diameter defined by the first plurality of wings in the first expanded position.

The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.”

The use of “substantially” in the present disclosure, when referring to a measurable quantity (e.g., a diameter or other distance) and used for purposes of comparison, is intended to mean within 5% of the comparative quantity. The terms “substantially similar to,” “substantially the same as,” and “substantially equal to,” as used herein, should be interpreted as if explicitly reciting and encompassing the special case in which the items of comparison are “similar to,” “the same as” and “equal to,” respectively.

As used herein, unless otherwise specified, the terms “about,” “approximately,” etc., when used in relation to numerical limitations or ranges, mean that the recited limitation or range may vary by up to 10%. By way of non-limiting example, “about 750” can mean as little as 675 or as much as 825, or any value therebetween. When used in relation to ratios or relationships between two or more numerical limitations or ranges, the terms “about,” “approximately,” etc. mean that each of the limitations or ranges may vary by up to 10%; by way of non-limiting example, a statement that two quantities are “approximately equal” can mean that a ratio between the two quantities is as little as 0.9:1.1 or as much as 1.1:0.9 (or any value therebetween), and a statement that a four-way ratio is “about 5:3:1:1” can mean that the first number in the ratio can be any value of at least 4.5 and no more than 5.5, the second number in the ratio can be any value of at least 2.7 and no more than 3.3, and so on.

The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein. The use of “engaged with” and variations thereof herein is meant to encompass any direct or indirect connections between components.

It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C. § 112 (f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the summary, brief description of the drawings, detailed description, abstract, and claims themselves.

All external references are hereby incorporated by reference in their entirety whether explicitly stated or not.

These and other advantages will be apparent from the disclosure contained herein. The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. The Summary is neither intended nor should it be construed as being representative of the full extent and scope of the present disclosure. Moreover, references made herein to “the present disclosure,” or aspects thereof should be understood to mean certain embodiments of the present disclosure and should not necessarily be construed as limiting all embodiments to a particular description. The present disclosure is set forth in various levels of detail in the Summary as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

It is to be appreciated that any embodiment, feature, or aspect described herein can be claimed in combination with any other embodiment(s), feature(s), or aspect(s) as described herein, regardless of whether the features or aspects come from the same described embodiment. For example, any one or more aspects described herein can be combined with any other one or more aspects described herein. In addition, any one or more features described herein can be combined with any other one or more features described herein. Further, any one or more embodiments described herein can be combined with any other one or more embodiments described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Those of skill in the art will recognize that the following description is merely illustrative of the principles of the disclosure, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this disclosure and is not meant to limit the inventive concepts disclosed herein.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosure.

FIG. 1A illustrates a perspective view of a drilling apparatus with wings in a collapsed position, in accordance with one or more embodiments of the present disclosure;

FIG. 1B illustrates a first side view of the drilling apparatus of FIG. 1A;

FIG. 1C illustrates a second side view of the drilling apparatus of FIG. 1A, with section line 2-2;

FIG. 1D illustrates an end view of the drilling apparatus of FIG. 1A;

FIG. 2 illustrates a section view of the drilling apparatus at the section line 2-2 in FIG. 1C;

FIG. 3A illustrates a perspective view of the drilling apparatus of FIG. 1A with the wings in an expanded position;

FIG. 3B illustrates a first side view of the drilling apparatus of FIG. 3A;

FIG. 3C illustrates a second side view of the drilling apparatus of FIG. 3A, with section line 4-4;

FIG. 3D illustrates an end view of the drilling apparatus of FIG. 3A;

FIG. 3E illustrates a partial perspective view of the drilling apparatus of FIG. 3A;

FIG. 4 illustrates a section view of the drilling apparatus at the section line 4-4 in FIG. 3C;

FIG. 5 illustrates a flow diagram of a drilling method or process using the drilling apparatus of FIG. 1A;

FIG. 6 illustrates the drilling apparatus of FIG. 1A in casing with the wings in a collapsed position;

FIG. 7 illustrates the drilling apparatus of FIG. 6 through the casing with the wings in the collapsed position;

FIG. 8 illustrates the drilling apparatus of FIG. 7 through the casing with the wings in the expanded position;

FIG. 9 illustrates the drilling apparatus of FIG. 8 through the casing and in a borehole with the wings in the expanded position, during a drilling process such as underreaming;

FIG. 10 illustrates the drilling apparatus of FIG. 9 through the casing and in the borehole with the wings in the expanded position, after the drilling process but prior to collapse of the wings; and

FIG. 11 illustrates the drilling apparatus of FIG. 10 within the casing with the wings in the collapsed position after the drilling process.

FIG. 12A illustrates a perspective view of a drilling apparatus with wings in a collapsed position, in accordance with one or more embodiments of the present disclosure;

FIG. 12B illustrates a first side view of the drilling apparatus of FIG. 12A;

FIG. 12C illustrates a second side view of the drilling apparatus of FIG. 12A, with section line 13-13;

FIG. 13 illustrates a section view of the drilling apparatus at the section line 13-13 in FIG. 12C;

FIG. 14A illustrates a perspective view of the drilling apparatus of FIG. 12A with the wings in an expanded position;

FIG. 14B illustrates a first side view of the drilling apparatus of FIG. 14A;

FIG. 14C illustrates a second side view of the drilling apparatus of FIG. 14C, with section line 15-15;

FIG. 15 illustrates a section view of the drilling apparatus at the section line 15-15 in FIG. 14C;

FIG. 16 illustrates a flow diagram of a drilling method or process using the drilling apparatus of FIG. 12A;

FIG. 17 illustrates the drilling apparatus of FIG. 12A in casing with the wings in a collapsed position;

FIG. 18 illustrates the drilling apparatus of FIG. 17 through the casing with the wings in the collapsed position;

FIG. 19 illustrates the drilling apparatus of FIG. 18 through the casing with the wings in the expanded position;

FIG. 20 illustrates the drilling apparatus of FIG. 19 through the casing and in a borehole with the wings in the expanded position, during a drilling process such as underreaming;

FIG. 21 illustrates the drilling apparatus of FIG. 20 through the casing and in the borehole with the wings in the expanded position, after the drilling process but prior to collapse of the wings; and

FIG. 22 illustrates the drilling apparatus of FIG. 21 within the casing with the wings in the collapsed position after the drilling process.

It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the disclosure is not necessarily limited to the particular embodiments illustrated herein.

Reference Number	Component

100	Drilling Apparatus
102	Main Body
103	Drill Tip
104	Connector
106	Proximal End
108	Distal End
110	Wing Assembly
112	Wing
114	Cutting Edge
116	Tube
118	Blade
120	Hinge Assembly
122	Knuckle
124	Hinge Portion
126	Connector
128	Surface of Wing
130	Surface of Blade
132	Cutting Edge
134	Pocket
136	Width of Blade
138	Width of Wing
140	Aperture or Channel
142	Aperture
500	Method or Process
502	Insert a Drilling Apparatus into a Wellbore
504	Extend the Drilling Apparatus through the Wellbore
506	Actuate Wings of the Drilling Apparatus from
	a Collapsed Position to an Expanded Position
508	Perform a Drilling Process with the Wings of
	the Drilling Apparatus in the Expanded Position
510	Retract the Drilling Apparatus within the Wellbore
	Following the Drilling Process
512	Collapse the Wings of the Drilling Apparatus for
	Removal of the Drilling Apparatus from the
	Wellbore
514	Interchange the Wings of the Drilling Apparatus
	with a Second Set of Wings
600	Wellbore
602	Casing
604	Drill String
606	Smaller Diameter of Drilling Apparatus in
	a Collapsed Position
608	Interior Diameter of Casing or Wellbore
610	Larger Diameter of Drilling Apparatus in Expanded
	Position
612	Borehole
614	Second Diameter of Borehole
616	Taper
1200	Drilling Apparatus
1202	Connector
1600	Method or Process
1602	Insert a Drilling Apparatus into a Wellbore
1604	Extend the Drilling Apparatus through the Wellbore
1606	Actuate Wings of the Drilling Apparatus from a
	Collapsed Position to an Expanded Position
1608	Perform a Drilling Process with the Wings of
	the Drilling Apparatus in the Expanded Position
1610	Retract the Drilling Apparatus within the Wellbore
	Following the Drilling Process
1612	Collapse the Wings of the Drilling Apparatus for
	Removal of the Drilling Apparatus from the
	Wellbore
1614	Interchange the Wings of the Drilling Apparatus
	with a Second Set of Wings
LB	Longitudinal Axis of Main Body
LC	Longitudinal Axis of Connector

DETAILED DESCRIPTION

Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure. The Detailed Description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment of the drilling apparatus with wings would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent application, which would still fall within the scope of the claims. Additionally, any combination of features shown in the various figures can be used to create additional embodiments of the present disclosure. Thus, dimensions, aspects, and features of one embodiment of the drilling apparatus with wings can be combined with dimensions, aspects, and features of another embodiment of the drilling apparatus with wings to create the claimed embodiment.

In general, embodiments of the present disclosure are directed to a drilling apparatus that is less complex than existing underreamer technologies to reduce manufacturing time and cost, and to additionally reduce the possibility of failure during operation. Embodiments of the present disclosure are directed to a drilling apparatus with a drag-wing configuration that has an improved expansion ratio as compared to known underreamer technologies. Embodiments of the present disclosure are also directed to a drilling apparatus that is modular to allow for the ability to have multiple sets of wings on-site for repair or replacement, to reduce equipment cost and operating time being lost to downtime during maintenance of the drilling apparatus. For example, the multiple sets of wings include wings with different diameters for the second, larger configuration for the drilling apparatus, and the drilling apparatus includes a hinge assembly that allows for the ability to switch between the different diameters of the second, larger configuration as desired on-site.

Embodiments of the present disclosure are directed to drilling apparatus with wings. The drilling apparatus is usable for downhole drilling operations in the water, oil, gas industries, including to increase the length and/or the diameter of an existing wellbore. To this effect, the drilling apparatus is insertable into the existing wellbore when in a first, smaller diameter configuration (e.g., a collapsed configuration) and adjustable to a second, larger diameter configuration via the actuation of wings (e.g., an expanded configuration). Optionally, the wings are modular, such that the wings may be interchanged with an additional set of wings. With the additional set of wings, the drilling apparatus is still insertable in the first, smaller diameter configuration and expandable to a third, different diameter configuration via the actuation of the additional set of wings. In addition, the additional set of wings allows for on-site or in-the-field replacement, reducing the need for additional complete drilling apparatuses and/or reducing downtime as opposed to the drilling apparatus being set to the manufacturer for re-tooling.

FIG. 1A-4 in general illustrate a drilling apparatus 100, in accordance with one or more embodiments of the present disclosure. The drilling apparatus 100 includes a main body 102. The main body 102 includes a drill tip 103. The drill tip 103 may be integrally formed with the main body 102. Alternatively, the drill tip 103 may be separately-fabricated and coupled to the main body 102 including, but not limited to, through a friction or interference fit between surfaces of the main body 102 and the drill tip 103, via a mechanical interconnection of an interlocking assembly with components on the main body 102 and the drill tip 103, via fasteners that engage one or more of the main body 102 and the drill tip 103, via welding or another coupling or joining process, via an adhesive between surfaces of the main body 102 and the drill tip 103, and the like.

In embodiments, the drilling apparatus 100 includes a connector 104. For example, the connector 104 is positioned at a proximal end 106 of the drilling apparatus 100, opposite a distal end 108 of the drilling apparatus 100. The connector 104 may be integrally formed with the main body 102. Alternatively, the connector 104 may be separately-fabricated and coupled to the main body 102 including, but not limited to, through a friction or interference fit between surfaces of the main body 102 and the connector 104, via a mechanical interconnection of an interlocking assembly with components on the main body 102 and the connector 104, via fasteners that engage one or more of the main body 102 and the connector 104, via welding or another coupling or joining process, via an adhesive between surfaces of the main body 102 and the connector 104, and the like.

The drilling apparatus 100 includes a plurality of wing assemblies 110, where each wing assembly 110 includes a wing 112. The wings 112 are able to actuate between a collapsed position and an expanded position. Reference will be made to the wing assemblies 110 in detail further herein. In addition, any and/or all of the wing assemblies 110 may include further subassemblies as described in detail further herein, which may each be considered subassemblies of the drilling apparatus 100.

In embodiments, the connector 104 at the proximal end 106 of the drilling apparatus 100 is configured to couple the main body 102 to a drill string 604, where the drill string 604 assists in the insertion of the drilling apparatus 100 into the wellbore 600 (i.e., as shown in FIGS. 6-11). As described in detail further herein, in at least one embodiment fluid (i.e., drilling fluid, water, mud, air, or the like) may be transferred to the main body 102 (e.g., including, but not limited to, through the drill string 604 and/or through the connector 104), to assist in the expanding of the wings 112 of the wing assemblies 110 from the collapsed position to the expanded position.

In embodiments, the distal end 108 of the drilling apparatus 100 may include a plurality of cutting edges 114 on the main body 102. For example, the plurality of cutting edges 114 may assist the drill tip 103 in drilling the borehole within the wellbore to a first, smaller diameter while the wings 112 of the plurality of wing assemblies 110 are in the collapsed position. In addition, the plurality of cutting edges 114 may assist the drill tip 103 in drilling the borehole within the wellbore while the wings 112 of the plurality of wing assemblies 110 are in the expanded position for drilling the borehole to a second, larger diameter. It is noted that at least some of the plurality of cutting edges 114 may be (or include) drag wing cutter teeth, for purposes of the present disclosure.

In general, the plurality of cutting edges 114 may have any slope or curvature, such as where the cutting edge 114 is a smooth blade edge or a serrated blade edge. In addition, in at least some embodiments, the plurality of cutting edges 114 may optionally form a stair-step pattern (e.g., between adjacent cutting edges 114).

In some configurations, the plurality of cutting edges 114 are proximate to the drill tip 103. In other configurations, at least a portion of the drill tip 103 may be formed from one or more of the plurality of cutting edges 114.

In embodiments, the main body 102 may include a tube 116 and a plurality of blades 118 that extend outward from the tube 116. For example, a cutting edge 114 of the plurality of cutting edges 114 may be formed as an integral component of a particular blade 118 of the plurality of blades 118. By way of another example, one or more of the plurality of blades 118 may be reinforced with hardened inserts to form a particular cutting edge 114 of the plurality of cutting edges 114.

It is noted that the tube 116 may be solid or hollow, without departing from the scope of the present disclosure. For example, the tube 116 may be hollow where fluid (i.e., drilling fluid, water, mud, air, or the like) is pumped through the main body 102 from the drill string via the connector 104. By way of another example, the tube 116 may substantially solid, aside from plumbing or wiring run through the tube 116 to actuate the wing assemblies 110. By way of another example, the tube 116 may be fully solid.

In addition, it is noted that the tube 116 may have any cross-section known in the art. As such, although FIGS. 2 and 4 illustrate a tube 116 with a circular cross-section, the cross-section illustrated in FIGS. 2 and 4 should not be understood as limiting but rather merely illustrative of the present disclosure. For example, the tube 116 may be elliptical, triangular, rectangular, or any N-sided polygon in cross-section.

Each wing assembly 110 of the plurality of wing assemblies 110 may correspond to a particular blade 118 of the plurality of blades 118. In one non-limiting example, there are four blades 118 and four wing assemblies 110, to increase the rate of penetration within the subterranean formation. It is noted that the drilling apparatus 100 may have any number of blades 118 and corresponding wing assemblies 110. In addition, it is noted that the drilling apparatus 100 may not have the same number of blades 118 and wing assemblies 110. Further, it is noted that the wing assemblies 110 of the drilling apparatus 100 may not correspond to a particular blade 118. As such, although FIGS. 2 and 4 illustrate four blades 118 with four corresponding wing assemblies 110 having respective wings 112, the number of blades 118 and corresponding wing assemblies 110 illustrated in FIGS. 2 and 4 should not be understood as limiting but rather merely illustrative of the present disclosure.

In general, the plurality of wing assemblies 110 may be spaced apart around at least a portion of the circumference of the tube 116 (and thus the main body 102). For example, the plurality of wing assemblies 110 may be spaced apart around the entire circumference of the tube 116. For instance, the plurality of wing assemblies 110 may be spaced approximately equidistant about the entire circumference of the tube 116. By way of another example, the plurality of wing assemblies 110 may be spaced apart in only a portion of the circumference of the tube 116. By way of another example, the plurality of wing assemblies 110 may be spaced in a non-equidistant manner about the entire circumference (or in only a portion of the circumference) of the tube 116.

Similarly, the plurality of blades 118 may be spaced apart around at least a portion of the circumference of the tube 116 (and thus the main body 102). For example, the plurality of blades 118 may be spaced apart around the entire circumference of the tube 116. For instance, the plurality of blades 118 may be spaced approximately equidistant about the entire circumference of the tube 116. By way of another example, the plurality of blades 118 may be spaced apart in only a portion of the circumference of the tube 116. By way of another example, the plurality of blades 118 may be spaced in a non-equidistant manner about the entire circumference (or in only a portion of the circumference) of the tube 116.

In general, the plurality of cutting edges 132 may have any slope or curvature, such as where the cutting edge 132 is a smooth blade edge or a serrated blade edge. In addition, in at least some embodiments, the plurality of cutting edges 132 optionally form a stair-step pattern (e.g., between adjacent cutting edges 132).

In some configurations, the plurality of blades 118 are proximate to the drill tip 103. In other configurations, at least a portion of the drill tip 103 may be formed from one or more of the plurality of blades 118.

In embodiments, each wing assembly 110 of the plurality of wing assemblies 110 may include a respective hinge assembly 120, such that the drilling apparatus 100 includes a plurality of hinge assemblies 120. For example, the hinge assembly 120 may include a knuckle 122 coupled to (or integrally formed with) the main body 102 (i.e., to a particular blade 118 and/or to the tube 116 of the main body 102). In addition, the hinge assembly 120 may include a hinge portion 124 positioned at one end of the corresponding wing 112 of the wing assembly 110. For example, the hinge portion 124 may be formed as an integral component of the wing 112. By way of another example, the hinge portion 124 may be separately fabricated from and affixed to the wing 112 via one or more processes including, but not limited to, welding, brazing, and the like. Further, the hinge assembly 120 may include a connector 126 (i.e., a pin, axle, or other component) that passes through the knuckle 122 and the hinge portion 124 to secure the wing 112 to the main body 102. For example, the connector 126 may be secured in place following insertion within the knuckle 122 and the hinge portion 124 via processes including, but not limited to, welding, cross-pinning, threading of complementary components, and the like.

In some embodiments, the wing assemblies 110 include wings 112 that are designed in a drag-wing configuration. A longitudinal axis Le of the connector 126 of each of the plurality of hinge assemblies 120 securing the respective wings 112 to the main body 102 runs substantially parallel to a longitudinal axis LB through the main body 102. In at least one non-limiting example, one or more of the plurality of hinge assemblies 120 may be a piano hinge-like configuration with the knuckle 122, the hinge portion 124, and the connector 126.

It is noted herein that at least a portion of the connector 126 may be threaded, with complimentary threading within the knuckle 122 and/or the hinge portion 124. Alternatively, where the connector 126 extends through the knuckle 122 and/or the hinge portion 124, one or more of the plurality of hinge assemblies 120 may include a fastener (i.e., a cotter pin, a clip, a nut, or the like) that engages the extruding end of the connector 126. Further, one or more of the plurality of hinge assemblies 120 may include a mechanical detent with a biasing element or other interlocking assembly that holds the connector 126 within the knuckle 122 and the hinge portion 124, where the interlocking assembly includes a first component on the connector 126 and a second component on at least one of the knuckle 122 and the hinge portion 124. Further, the connector 126 may be held in place within the knuckle 122 and the hinge portion 124 via a friction or interference fit between surfaces of the connector 126 and the knuckle 122 and/or the hinge portion 124.

Rotation of the main body 102 (i.e., via a drill string 604, as shown in FIGS. 6-11) causes the wings 112 to rotate about the longitudinal axis Le of the connector 126 from the collapsed configuration to the expanded configuration, in contrast to lateral-expanding cutting arms and/or tooth-wheel or roller-cone configurations of known underreamer technologies that rotate about a lateral axis that is at an angle (i.e., substantially perpendicular) to the longitudinal axis LB of the main body 102. The longitudinal configuration of the wings 112 of the drilling apparatus 100 takes advantage of the rotation imparted on the main body 102 (i.e., by the drill string 604), by utilizing the rotation as a mechanical advantage via centripetal motion to expand the wings 112, thus reducing the need for a complex build as compared to known underreamer technologies.

In particular, in some configurations a wing 112 of a wing assembly 110 has a mass with a centripetal force associated with the rotation of the main body 102 (e.g., via the drill string 604). Where there are multiple wing assemblies 110 that include wings 112 which are interchangeable on the main body 102, each of the wings 112 may have a mass with a centripetal force associated with the rotation of the main body 102. It is noted that the different interchangeable wings 112 may have different or substantially similar masses and associated centripetal forces, without departing from the scope of the present disclosure.

As illustrated in a comparison between FIGS. 2 and 4, expansion of the wings 112 from the collapsed position proximate to the main body 102 to the expanded position proximate to a respective blade 118 may be stopped via contact of a surface 128 of the wing 112 to a surface 130 of the blade 118. For example, as illustrated in FIG. 2, the surface 128 of the wing 112 is at a non-parallel angle to the surface 130 of the blade 118 when the wings 112 are in the collapsed position. By way of another example, as illustrated in FIG. 4, the surface 128 of the wing 112 may be substantially parallel to the surface 130 of the blade 118 when the wings 112 are in the expanded position.

It is contemplated that the plurality of hinge assemblies 120 (and/or the plurality of wing assemblies 110, in general) may include additional components that additionally (or alternatively) limit or stop the rotation of the wings 112 between the collapsed position and the expanded position. For example, the hinge assemblies 120 may include, but are not limited to tab or stop delimiters, struts, springs, pistons or other actuators (e.g., hydraulic, pneumatic, or electrically-driven), or other components configured to prevent motion beyond a predetermined point and/or assist in the returning of the wing 112 to the collapsed position.

In embodiments, the plurality of wings 112 include a respective set of one or more cutting edges 132. For example, the one or more cutting edges 132 may be positioned on an outermost surface of the wing 112. In some instances, the one or more cutting edges 132 are positioned at an end opposite the end of the wing 112 with the hinge portion 124. For example, the one or more cutting edges 132 may be formed as an integral component of the wing 112. By way of another example, the wing 112 may be reinforced with hardened inserts to form the one or more cutting edges 132. For instance, the plurality of cutting edges 132 may be (or include) hardened teeth or cutting inserts capable of drilling the borehole within the wellbore while the wings 112 of the plurality of wing assemblies 110 are in the expanded position for drilling the borehole to a second, larger diameter. It is noted that at least some of the one or more cutting edges 132 may be (or include) drag wing cutter teeth, for purposes of the present disclosure.

In some configurations, where the wings 112 are in the expanded position, the cutting edges 132 may substantially overlap with the cutting edges 114, as illustrated in at least FIG. 3C. For example, the cutting edges 132 may be formed with a substantially similar slope, curvature, or stair-step pattern as the cutting edges 114, such that there is a generally seamless transition between the cutting surfaces of the cutting edges 132 and the cutting edges 114 from the drill tip 103 to the outermost edge of the wings 112 when the wings 112 are in the expanded position. It is noted that this generally seamless transition may reduce drag caused by the differently-timed engagement of the cutting edges 114 and 132, and/or may reduce the possibility or interference in the operation of the drilling apparatus 100 by removed subterranean structure getting stuck between the non-overlapping cutting edges 114 and 132 during the underreaming process. However, it is contemplated that the cutting edges 132 and 114 may not substantially overlap, without departing from the scope of the present disclosure.

In embodiments, a wing assembly 110 of the plurality of wing assemblies 110 is positioned within a pockets 134 defined between adjacent blades 118 of the plurality of blades 118. In one non-limiting example, each wing assembly 110 of the plurality of wing assemblies 110 is positioned within a respective pocket 134 defined between respective adjacent blades 118 of the plurality of blades 118. In another non-limiting example, multiple wing assemblies 110 of the plurality of wing assemblies 110 are positioned within a particular pocket 134 defined between respective adjacent blades 118 of the plurality of blades 118.

The pocket 134 has a depth defined in at least one dimension by the width 136 of the adjacent blades 118 that form boundaries of the pocket 134. The wing 112 of the particular wing assembly 110 positioned within a particular pocket 134 may be of a width 138 that is no greater than (i.e., is less than or equal to) the width 136 of the blade 118 when the wing 112 is in the collapsed position. With the use of the connectors 126 within the hinge assembly 120, the wings 112 are interchangeable for additional wings 112 having a different width 138. It is noted, however, that the width 138 of the wing 112 when in the collapsed position may be limited to the width 136 of the blade 118, as the width of the wing 112 exceeding the width 136 of the blade 118 when in the collapsed position would cause the wing 112 to exceed the first, smaller diameter of the drilling apparatus 100.

Although the width 138 of the wing 112 may be limited to the width 136 of the blade 118 when the wing 112 is collapsed to stay within the first, smaller diameter, the expansion of the wing 112 (such as by rotating or pivoting the wing to the expanded position) causes the drilling apparatus 100 to have a second, greater diameter that is larger than the interior diameter of the wellbore (i.e., the nominal inner diameter of casing within the wellbore). In one non-limiting example, a drilling apparatus 100 with a collapsed diameter of about or approximately 7.875 inches may be used in a steel casing having a nominal internal diameter of 8 inches where the wings 112 are in the collapsed position. However, the drilling apparatus 100 may have an expanded diameter of about or approximately 10.238 inches when the wings 112 are in the expanded position, which will result in an increased wellbore diameter of about or approximately 10.238 inches. In this example, the expansion of the wings 112 results in an increase in wellbore diameter to approximately 130% of the original wellbore diameter.

In embodiments, as illustrated in at least FIG. 3E, the tube 116 of the main body 102 includes one or more channels 140 within the pocket 134. The one or more channels 140 may be configured to provide fluid (i.e., drilling fluid, water, mud, air, or the like) to a particular pocket 134 (e.g., from the drill string via the connector 104), to assist in the actuation of the one or more wings 112 within the particular pocket 134 from the collapsed position to the expanded position and/or maintaining of the one or more wings 112 within the particular pocket 134 in the expanded position. In addition, the one or more channels 140 may include, or end at, one or more apertures 142 (i.e., that are directed toward the distal end 108 of the drilling apparatus 100). It is noted that these channels 140 with apertures 142 may be optional, such as where the centripetal motion of the drilling apparatus 100 during rotation is sufficient to cause the wings 112 to expand outward to the second, larger diameter. It is contemplated that the hinge assembly 120 (and/or the wing assembly 110, in general) may include components such as, but not limited to, struts, springs, pistons or other actuators (e.g., hydraulic, pneumatic, or electrically-driven), or the like that cause the wings 112 to stay within the collapsed position absent the centripetal force and/or hydraulic or pneumatic pressure, and additionally to cause the wings 112 to return to the collapsed position when the centripetal force and/or hydraulic or pneumatic pressure is removed.

In one non-limiting example, such as where the drilling apparatus 100 is an expandable drill bit, the drilling apparatus 100 includes a main body 102 with a tube 116, a plurality of blades 118, and a knuckle 122 fabricated from high-strength steel, where the cutting edges 114 of the plurality of blades 118 are fabricated from a tungsten carbide, a polycrystalline diamond (PCD), or another hardened cutting insert. The drilling apparatus includes a wing assembly 110 with a wing 112 having a hinge portion 124 fabricated from high-strength steel, where the wing 112 includes the cutting edges 132 fabricated from a tungsten carbide, a polycrystalline diamond (PCD), or another hardened cutting insert. A high-strength steel connector 126 (e.g., which may be threaded along at least a portion of the length of the connector 126) couple the knuckle 122 and the hinge portion 124 together. It is noted that the cutting edges 114, 132, when formed of a material such as a tungsten carbide or a polycrystalline diamond (PCD), allow for the removal of formation within sandstone shelves. However, it is contemplated that in some embodiments the cutting edges 114, 132 may be formed of other materials suitable for removal of material in other geological or subterranean formations.

Although the embodiments illustrated in FIGS. 1A-4 illustrate a threaded connector 104 at the proximal end 106 of the drilling apparatus 100 and a drill tip 103 with cutting edges 114 at the distal end 108 of the drilling apparatus 100, it should be understood that the distal end 108 may instead be a bullnose or other end (i.e., where the borehole is already pre-drilled to a first, smaller diameter) that is not configured to drill (e.g., cither alone or with the assistance of the cutting edges 114 and/or 132), without departing from the scope of the present disclosure.

FIG. 5 is a method or process 500 flow diagram illustrating the operation of the drilling apparatus 100, in accordance with one or more embodiments or the present disclosure. While a general order for the steps of the method or process 500 is shown in FIG. 5, the method or process can include more or fewer steps or can arrange the order of the steps differently (including simultaneously, substantially simultaneously, or sequentially) than those shown in FIG. 5.

FIGS. 6-11 in general illustrate the drilling apparatus 100 of FIGS. 1A-4, as representations of the steps of the method or process 500. It is noted that the method or process 500 shall be explained with reference to the components, devices, subassemblies, environments, etc. described in conjunction with FIGS. 1A-4 and illustrated in FIGS. 6-11. For example, it is noted that the embodiments as illustrated in FIGS. 6-11 should be understood as being directed to the embodiments described with respect to FIGS. 1A-4, and vice versa, without departing from the scope of the present disclosure.

In one or more operations of the process 500 (i.e., pre-process operations or operations of a separate process), the drilling apparatus 100 is fabricated. For example, the fabrication of the drilling apparatus 100 includes one or more of: fabricating, obtaining, or otherwise acquiring the main body 102 with the tube 116 having knuckles 122 and the blades 118 having cutting edges 114; fabricating, obtaining, or otherwise acquiring the drill tip 103 (e.g., either integrally with or separately from the main body 102); fabricating, obtaining, or otherwise acquiring the connector 104 (e.g., either integrally with or separately from the main body 102); and fabricating, obtaining, or otherwise acquiring the wing assemblies 110 including the wings 112 having the hinge portions 124 and cutting edges 132. For example, the cutting edge 114 may be formed as an integral component of the blade 118, or the blade 118 may be reinforced with hardened inserts to form the cutting edge 114. By way of another example, the hinge portion 124 may be formed as an integral component of the wing 112, or the hinge portion 124 may be separately fabricated from and affixed to the wing 112 via one or more processes including, but not limited to, welding, brazing, and the like. By way of another example, the cutting edge 132 may be formed as an integral component of the wing 112, or the wing 112 may be reinforced with hardened inserts to form the cutting edge 132. The wings 112 couple to the main body 102 via connectors 126 of respective hinge assemblies 120. For example, the connector 126 may be secured in place following insertion within the knuckle 122 and the hinge portion 124 via processes including, but not limited to, welding, cross-pinning, threading of complementary components, and the like.

It is noted that the same individual or different individuals may perform the one or more above steps to fabricate the drilling apparatus 100 and the following steps, without departing from the scope of the present disclosure.

In embodiments, a drilling apparatus is inserted 502 into a wellbore. FIG. 6 illustrates the drilling apparatus 100 inserted into a wellbore 600 (or within a drive shoe positioned within the wellbore) with casing 602 (although it should be understood the wellbore 600 may not include casing 602, without departing from the scope of the present disclosure). The main body 102 of the drilling apparatus 100 is in communication with a drill string 604. For example, the main body 102 may be coupled to the drill string 604 via the connector 104 of the drilling apparatus 100. The wings 112 of the drilling apparatus 100 are in a collapsed position during insertion, such that the outer diameter of the drilling apparatus 100 as defined at least in part by a width 136 of the plurality of blades 118 is a first, smaller diameter 606, which is no greater than (i.e., is less than or equal to) an inner nominal diameter 608 of the casing 602 (or the wellbore 600, where there is no casing 602). In some instances, the diameter 606 of the drilling apparatus 100 is approximately twice the width 136 of a blade 118, including where two blades 118 are set on opposing sides of the main body 102. It should be understood that the diameter 606 may be considered an apparatus diameter 606 or a main body diameter 606, for purposes of the present disclosure. In addition, it should be understood that the diameter 608 may be considered a wellbore diameter 608, for purposes of the present disclosure.

In embodiments, the drilling apparatus extends 504 through the wellbore. FIG. 7 illustrates the drilling apparatus 100 extending through the casing 602 and into a subterranean formation past the distal end of the casing 602 (i.e., either within the wellbore 600, or beyond the wellbore 600 and into uncut subterranean formation). The wings 112 of the drilling apparatus 100 are still in the collapsed position, such that the outer diameter of the drilling apparatus 100 is the first, smaller diameter 606 defined by the width 136 of the blades 118, which is no greater than (i.e., is less than or equal to) the inner nominal diameter 608 of the casing 602 (or the wellbore 600, where there is no casing 602).

In embodiments, wings of the drilling apparatus are actuated 506 from a collapsed position to an expanded position. FIG. 8 illustrates the drilling apparatus 100 extending through the casing 602 and into the subterranean formation. The wings 112 of the drilling apparatus 100 are actuated into an expanded position, such that the outer diameter of the drilling apparatus 100 as defined at least in part by the wings 112 is a second, larger diameter 610, which is larger than the inner nominal diameter 608 of the casing 602. In some instances, the diameter 610 of the drilling apparatus 100 is approximately twice the width 138 of a wing 112, including where two wings 112 are set on opposing sides of the main body 102. In some configurations of the drilling apparatus 100, the diameter 610 may be up to 130% larger (or up to 1.3 times larger) than the inner nominal diameter 608 of the casing 602. It should be understood that the diameter 610 may be considered an apparatus diameter 610, for purposes of the present disclosure.

The wings 112 are actuated into the expanded position via the hinge assembly 120, including via axial rotation about an axis through the connector 126 (not shown) through the knuckle 122 of the main body 102 and the hinge portion 124 of the wing 112. For example, this actuation may occur with the application of a centripetal force while the drilling apparatus 100 rotates. By way of another example, the actuation may occur via hydraulic or pneumatic pressure applied to the wing 112 via hydraulic fluid (i.e., drilling fluid, water, mud, or the like) or air (respectively) through channels 140 within the pocket 134 in which the wing 112 was previously nested when in the collapsed position.

In embodiments, a drilling process is performed 508 with the wings of the drilling apparatus in the expanded position. FIG. 9 illustrates the drilling apparatus 100 extending through the casing 602 and into the subterranean formation. The wings 112 of the drilling apparatus 100 are actuated into an expanded position, such that the outer diameter of the drilling apparatus 100 is still the second, larger diameter 610 defined by the width 138 of the wings 112, which is larger than the inner nominal diameter 608 of the casing 602 (or the wellbore 600, where there is no casing 602). The drilling apparatus 100 is rotated, drilling the subterranean formation (i.e., via a reaming or underreaming process) to create a borehole 612 with a second diameter 614 that is at least the second, larger diameter 610 of the drilling apparatus 100. It should be understood that the diameter 614 may be considered a wellbore diameter 614, for purposes of the present disclosure.

In embodiments, the drilling apparatus is retracted 510 back into the wellbore, following the drilling process. FIG. 10 illustrates the drilling apparatus 100 after the drilling process, retracted partially back up to the casing 602 so that the wings 112 are proximate to a bottom edge of the wellbore 600 (i.e., to a bottom edge of the casing 602 within the wellbore 600). The wings 112 of the drilling apparatus 100 are still actuated into an expanded position, such that the outer diameter of the drilling apparatus 100 is the second, larger diameter 610 defined by the width 138 of the wings 112, which is larger than the inner nominal diameter 608 of the casing 602 (or the wellbore 600, where there is no casing 602).

In embodiments, the wings of the drilling apparatus are collapsed 512 for removal of the drilling apparatus from the wellbore. FIG. 11 illustrates the drilling apparatus 100 within the wellbore 600, with the wings 112 in the collapsed position after the drilling process. The wings 112 of the drilling apparatus 100 have retracted into the collapsed position, such that the outer diameter of the drilling apparatus 100 is the first, smaller diameter 606 defined by the width 136 of the blades 118, which is no greater than (i.e., is less than or equal to) the inner nominal diameter 608 of the casing 602 and less than the second diameter 614 of the borehole 612. In general, however, the collapsed position for the wings 112 may be any diameter less that the inner nominal diameter 608, which is not necessarily the first, smaller diameter 606, without departing from the scope of the present disclosure.

In some embodiments, the wings 112 may be actuated into the collapsed position (i.e., positioned within the pockets 134) by retracting the drilling apparatus 100 and the drill string 604 to the bottom edge at the end of the casing 602 (or drive shoe or unbored subterranean formation, where the wellbore 600 does not include casing 602). Placing slight upward pressure on the drill string 604 will allow the upper edge of the wing 112 to contact the well casing 602, drive shoe, or unbored formation (i.e., the bottom edge of the wellbore 600 and/or casing 602 therein within the subterranean formation, through which the drilling apparatus 100 previously passed to create the borehole 612 via the drilling process). Rotating the drill string 604 in a direction (i.e., for an exemplary approximately one-quarter revolution, or approximately 90 degrees) opposite the direction of rotation during drilling causes contact of the upper edge of the wings 112 with the well casing 602, drive shoe, or unbored formation. The combination of the backward or reverse rotation and the engagement of a taper 616 on the upper edge of the wings 112 to the bottom edge of the wellbore 600 (or casing 602 therein), collapses the wings 112 into the pockets 134 on the main body 102.

In other embodiments, the wings 112 may be collapsed via the use of struts, springs, pistons or other actuators (e.g., hydraulic, pneumatic, or electrically-driven) installed on the main body 102, that cause the wings 112 to collapse (i.e., via application of a force) when the rotation of the drilling apparatus 100 is stopped and/or the hydraulic or pneumatic pressure is removed. For example, the wings 112 may be spring-loaded, and biased to be in the collapsed position absent one or more of the application of force via rotation of the drilling apparatus 100 and/or the hydraulic or pneumatic pressure. In other examples, the wings 112 may be positively actuated both outward to the expanded position and inward to the collapsed position.

It is noted that the collapsing of the wings 112 may occurring prior to or during the retraction of the drilling apparatus 100, without departing from the scope of the present disclosure. For example, the wings 112 may engage with the subterranean formation surrounding the wellbore 600 prior to retraction and during a rotation of the drill string 604, causing the wings 112 to collapse before the retraction of the drilling apparatus 100 begins.

In embodiments, the wings are optionally interchanged 514 with a second set of wings. For example, the connector 126 may be removed from the hinge assembly 120 to disengage the hinge portion 124 of the wing 112 from the knuckle 122, the first wing 112 may be interchanged with a second wing 112, and the connector 126 may be inserted into the knuckle 122 and the hinge portion 124 of the second wing 112. Following the interchange of the wings 112, one or more of the inserting 502, the extending 504, the actuating 506, the performing 508, the retracting 510, and/or the collapsing 512 may be performed again to further increase the diameter of the borehole 612. Additional interchanging 514 may also occur, with further performing of one or more of the inserting 502, the extending 504, the actuating 506, the performing 508, the retracting 510, and/or the collapsing 512 to further increase the diameter of the borehole 612.

FIGS. 12A-15 in general illustrate a drilling apparatus 1200, in accordance with one or more embodiments of the present disclosure. It should be understood that embodiments directed to the drilling apparatus 100 may read on the drilling apparatus 1200, and vice versa, unless otherwise noted. In general, it should be understood that the distal end 108 of the drilling apparatus 100 may include a threaded connector (i.e., where the drilling apparatus 100 is an inline underreamer) to form the drilling apparatus 1200, without departing from the scope of the present disclosure.

The drilling apparatus 1200 includes a connector 1202 at the distal end 108 in place of the drill tip 103. The connector 1202 may be integrally formed with the main body 102. Alternatively, the connector 1202 may be separately-fabricated and coupled to the main body 102 including, but not limited to, through a friction or interference fit between surfaces of the main body 102 and the connector 1202, via a mechanical interconnection of an interlocking assembly with components on the main body 102 and the connector 1202, via fasteners that engage one or more of the main body 102 and the connector 1202, via welding or another coupling or joining process, via an adhesive between surfaces of the main body 102 and the connector 1202, and the like.

In embodiments, the connector 1202 at the distal end 108 of the drilling apparatus 1200 may be in addition to the connector 104 at the proximal end 106 of the drilling apparatus 1200. Including the connector 104 and the connector 1202 allows for the drilling apparatus 1200 to be inserted in-line between sections of drill string 604.

It is contemplated that the connector 1202 at the distal end 108 may be used to connect to other more-distal drill string elements. For example, the connector 1202 may be used to connect to a near reamer stabilizer to assist in centering the drilling apparatus 1200 and reducing lateral vibration during underreaming operations. Additionally, the connector 1202 may be used to connect an inline shroud or sleeve to shield components of the drilling apparatus 1200 during insertion of the drilling apparatus 1200 into the wellbore and drilling, thereby reducing the risk of tool damage, borehole hang-up, or premature actuation.

In some configurations, the plurality of cutting edges 114 and/or the plurality of blades 118 are proximate to the connector 1202. In other configurations, at least a portion of the connector 1202 may be formed from one or more of the plurality of cutting edges 114 and/or the plurality of blades 118. For example, the connector 1202 may have cutting edges 114 that assist in underreaming, while also providing the necessary features to couple to more-distal casing string or other more-distal drill string elements for the drilling apparatus 1200 to be an inline underreamer.

In one non-limiting example, the drilling apparatus 1200 includes the main body 102 with the tube 116, the plurality of blades 118, the connectors 104 and 1202, and the knuckle 122 fabricated from high-strength steel, where the cutting edges 114 of the plurality of blades 118 are fabricated from a tungsten carbide, a polycrystalline diamond (PCD), or another hardened cutting insert. The drilling apparatus includes the wing assembly 110 with the wing 112 having the hinge portion 124 fabricated from a suitable material (such as a high-strength steel), where the wing 112 includes the cutting edges 132 fabricated from a tungsten carbide, a polycrystalline diamond (PCD), or another hardened cutting insert. A high-strength steel connector 126 (e.g., which may be, but is not limited to, a pin that is threaded along at least a portion of the length of the connector 126) couple the knuckle 122 and the hinge portion 124 together. It is noted that the cutting edges 114, 132, when formed of a material such as a tungsten carbide or a polycrystalline diamond (PCD), allow for the removal of formation within sandstone shelves. However, it is contemplated that in some embodiments the cutting edges 114, 132 may be formed of other materials suitable for removal of material in other geological or subterranean formations.

FIG. 16 is a method or process 1600 flow diagram illustrating the operation of the drilling apparatus 1200, in accordance with one or more embodiments or the present disclosure. While a general order for the steps of the method or process 1600 is shown in FIG. 16, the method or process can include more or fewer steps or can arrange the order of the steps differently (including simultaneously, substantially simultaneously, or sequentially) than those shown in FIG. 16.

FIGS. 17-22 in general illustrate the drilling apparatus 1200 of FIGS. 12A-15 (and, to the extent there is overlapping subject matter, portions of the drilling apparatus 100 of FIGS. 1A-4), as representations of the steps of the method or process 1600. It is noted that the method or process 1600 shall be explained with reference to the components, devices, subassemblies, environments, etc. described in conjunction with FIGS. 12A-15 and illustrated in FIGS. 17-22. For example, it is noted that the embodiments as illustrated in FIGS. 17-22 should be understood as being directed to the embodiments described with respect to FIGS. 12A-15, and vice versa, without departing from the scope of the present disclosure.

In one or more operations of the process 1600 (i.e., pre-process operations or operations of a separate process), the drilling apparatus 1200 is fabricated. For example, the fabrication of the drilling apparatus 1200 includes one or more of: fabricating, obtaining, or otherwise acquiring the main body 102 with the tube 116 having knuckles 122 and the blades 118 having cutting edges 114; fabricating, obtaining, or otherwise acquiring the connector 1202 (e.g., either integrally with or separately from the main body 102); fabricating, obtaining, or otherwise acquiring the connector 104 (e.g., either integrally with or separately from the main body 102); and fabricating, obtaining, or otherwise acquiring the wing assemblies 110 including the wings 112 having the hinge portions 124 and cutting edges 132. For example, the cutting edge 114 may be formed as an integral component of the blade 118, or the blade 118 may be reinforced with hardened inserts to form the cutting edge 114. By way of another example, the hinge portion 124 may be formed as an integral component of the wing 112, or the hinge portion 124 may be separately fabricated from and affixed to the wing 112 via one or more processes including, but not limited to, welding, brazing, and the like. By way of another example, the cutting edge 132 may be formed as an integral component of the wing 112, or the wing 112 may be reinforced with hardened inserts to form the cutting edge 132. The wings 112 couple to the main body 102 via connectors 126 of respective hinge assemblies 120. For example, the connector 126 may be secured in place following insertion within the knuckle 122 and the hinge portion 124 via processes including, but not limited to, welding, cross-pinning, threading of complementary components, and the like.

It is noted that the same individual or different individuals may perform the one or more above steps to fabricate the drilling apparatus 1200 and the following steps, without departing from the scope of the present disclosure.

In one or more operations of the process 1500 (i.e., pre-process operations or operations of a separate process), the drilling apparatus 1200 may be coupled to more-distal casing string 604. For example, the main body 102 may be coupled to more-distal casing string 604 via the connector 1202. It is noted that the more-distal casing string 604 is illustrated in FIGS. 17 and 21-22, but is removed from FIGS. 18-20 solely for purposes of clarity only-rather, it should be understood that the more-distal casing string 604 remains coupled to the drilling apparatus 1200 during the performing of one or more operations of the process 1500, including during the operations of the process 1600 illustrated in FIGS. 18-20.

In embodiments, a drilling apparatus is inserted 1602 into a wellbore. FIG. 17 illustrates the drilling apparatus 1200 inserted into a wellbore 600 (or within a drive shoe positioned within the wellbore) with casing 602 (although it should be understood the wellbore 600 may not include casing 602, without departing from the scope of the present disclosure). The main body 102 of the drilling apparatus 1200 is in communication with a drill string 604. For example, the main body 102 may be coupled to the drill string 604 via the connector 104 of the drilling apparatus 1200. The wings 112 of the drilling apparatus 1200 are in a collapsed position during insertion, such that the outer diameter of the drilling apparatus 1200 as defined at least in part by the plurality of blades 118 is a first, smaller diameter 606, which is no greater than (i.e., is less than or equal to) an inner nominal diameter 608 of the casing 602 (or the wellbore 600, where there is no casing 602). In some instances, the diameter 606 of the drilling apparatus 1200 is approximately twice the width 136 of a blade 118, including where two blades 118 are set on opposing sides of the main body 102. It should be understood that the diameter 606 may be considered an apparatus diameter 606 or a main body diameter 606, for purposes of the present disclosure. In addition, it should be understood that the diameter 608 may be considered a wellbore diameter 608, for purposes of the present disclosure.

In embodiments, the drilling apparatus extends 1604 through the wellbore. FIG. 18 illustrates the drilling apparatus 1200 extending through the casing 602 and into a subterranean formation past the end of the casing 602 (i.e., cither within the wellbore 600, or beyond the wellbore 600 and into uncut subterranean formation). The wings 112 of the drilling apparatus 1200 are still in the collapsed position, such that the outer diameter of the drilling apparatus 1200 is the first, smaller diameter 606 defined by the width 136 of the blades 118, which is no greater than (i.e., is less than or equal to) the inner nominal diameter 608 of the casing 602 (or the wellbore 600, where there is no casing 602).

In embodiments, wings of the drilling apparatus are actuated 1606 from a collapsed position to an expanded position. FIG. 19 illustrates the drilling apparatus 1200 extending through the casing 602 and into the subterranean formation. The wings 112 of the drilling apparatus 1200 are actuated into an expanded position, such that the outer diameter of the drilling apparatus 1200 as defined at least in part by the wings 112 is a second, larger diameter 610, which is larger than the inner nominal diameter 608 of the casing 602. In some instances, the diameter 610 of the drilling apparatus 1200 is approximately twice the width 138 of a wing 112, including where two wings 112 are set on opposing sides of the main body 102. In some configurations, the diameter 610 may be up to 130% larger (or up to 1.3 times larger) than the inner nominal diameter 608 of the casing 602. It should be understood that the diameter 610 may be considered an apparatus diameter 610, for purposes of the present disclosure.

The wings 112 are actuated into the expanded position via the hinge assembly 120, including via axial rotation about an axis through the connector 126 (not shown) through the knuckle 122 of the main body 102 and the hinge portion 124 of the wing 112. For example, this actuation may occur with the application of a centripetal force while the drilling apparatus 1200 rotates. By way of another example, the actuation may occur via hydraulic or pneumatic pressure applied to the wing 112 via hydraulic fluid (i.e., drilling fluid, water, mud, or the like) or air (respectively) through channels 140 within the pocket 134 in which the wing 112 was previously nested when in the collapsed position.

In embodiments, a drilling process is performed 1608 with the wings of the drilling apparatus in the expanded position. FIG. 20 illustrates the drilling apparatus 1200 extending through the casing 602 and into the subterranean formation. The wings 112 of the drilling apparatus 1200 are actuated into an expanded position, such that the outer diameter of the drilling apparatus 1200 is still the second, larger diameter 610 defined by the width 138 of the wings 112, which is larger than the inner nominal diameter 608 of the casing 602 (or the wellbore 600, where there is no casing 602). The drilling apparatus 1200 is rotated, drilling the subterranean formation (i.e., via a reaming or underreaming process) to create a borehole 612 with a second diameter 614 that is at least the second, larger diameter 610 of the drilling apparatus 1200. It should be understood that the diameter 614 may be considered a wellbore diameter 614, for purposes of the present disclosure.

In embodiments, the drilling apparatus is retracted 1610 back into the wellbore, following the drilling process. FIG. 21 illustrates the drilling apparatus 1200 after the drilling process, retracted partially back up to the casing 602 so that the wings 112 are proximate to a bottom edge of the wellbore 600 (i.e., to a bottom edge of the casing 602 within the wellbore 600). The wings 112 of the drilling apparatus 1200 are still actuated into an expanded position, such that the outer diameter of the drilling apparatus 1200 is the second, larger diameter 610 defined by the width 138 of the wings 112, which is larger than the inner nominal diameter 608 of the casing 602 (or the wellbore 600, where there is no casing 602).

In embodiments, the wings of the drilling apparatus are collapsed 1612 for removal of the drilling apparatus from the wellbore. FIG. 22 illustrates the drilling apparatus 1200 within the wellbore 600, with the wings 112 in the collapsed position after the drilling process. The wings 112 of the drilling apparatus 1200 have retracted into the collapsed position, such that the outer diameter of the drilling apparatus 1200 is the first, smaller diameter 606 defined by the width 136 of the blades 118, which is no greater than (i.e., is less than or equal to) the inner nominal diameter 608 of the casing 602 and less than the second diameter 614 of the borehole 612. In general, however, the collapsed position for the wings 112 may be any diameter less that the inner nominal diameter 608, which is not necessarily the first, smaller diameter 606, without departing from the scope of the present disclosure.

In some embodiments, the wings 112 may be actuated into the collapsed position (i.e., positioned within the pockets 134) by retracting the drilling apparatus 1200 and the drill string 604 to the bottom edge at the end of the casing 602 (or drive shoe or unbored subterranean formation, where the wellbore 600 does not include casing 602). Placing slight upward pressure on the drill string 604 will allow the upper edge of the wing 112 to contact the well casing 602, drive shoe, or unbored formation (i.e., the bottom edge of the wellbore 600 and/or casing 602 therein within the subterranean formation, through which the drilling apparatus 1200 previously passed to create the borehole 612 via the drilling process). Rotating the drill string 604 in a direction (i.e., for an exemplary approximately one-quarter revolution, or approximately 90 degrees) opposite the direction of rotation during drilling causes contact of the upper edge of the wings 112 with the well casing 602, drive shoe, or unbored formation. The combination of the backward or reverse rotation and the engagement of a taper 616 on the upper edge of the wings 112 to the bottom edge of the wellbore 600 (or casing 602 therein), collapses the wings 112 into the pockets 134 on the main body 102.

In other embodiments, the wings 112 may be collapsed via the use of struts, springs, pistons or other actuators (e.g., hydraulic, pneumatic, or electrically-driven) installed on the main body 102, that cause the wings 112 to collapse (i.e., via application of a force) when the rotation of the drilling apparatus 1200 is stopped and/or the hydraulic or pneumatic pressure is removed. For example, the wings 112 may be spring-loaded, and biased to be in the collapsed position absent one or more of the application of force via rotation of the drilling apparatus 1200 and/or the hydraulic or pneumatic pressure. In other examples, the wings 112 may be positively actuated both outward to the expanded position and inward to the collapsed position.

It is noted that the collapsing of the wings 112 may occurring prior to or during the retraction of the drilling apparatus 1200, without departing from the scope of the present disclosure. For example, the wings 112 may engage with the subterranean formation surrounding the wellbore 600 prior to retraction and during a rotation of the drill string 604, causing the wings 112 to collapse before the retraction of the drilling apparatus 1200 begins.

In embodiments, the wings are optionally interchanged 1614 with a second set of wings. For example, the connector 126 may be removed from the hinge assembly 120 to disengage the hinge portion 124 of the wing 112 from the knuckle 122, the first wing 112 may be interchanged with a second wing 112, and the connector 126 may be inserted into the knuckle 122 and the hinge portion 124 of the second wing 112. Following the interchange of the wings 112, one or more of the inserting 1602, the extending 1604, the actuating 1606, the performing 1608, the retracting 1610, and/or the collapsing 1612 may be performed again to further increase the diameter of the borehole 612. Additional interchanging 1614 may also occur, with further performing of one or more of the inserting 1602, the extending 1604, the actuating 1606, the performing 1608, the retracting 1610, and/or the collapsing 1612 to further increase the diameter of the borehole 612.

It is noted that the interchanging 1614 of the sets of wings 112 may occur after uncoupling the more-distal drill string 604 from the main body 102, such that the more-distal drill string 604 is recoupled to the main body 102 prior to performing of one or more of the inserting 1602, the extending 1604, the actuating 1606, the performing 1608, the retracting 1610, and/or the collapsing 1612. Alternatively, it is noted that the interchanging 1614 of the sets of wings 112 may occur while the more-distal drill string 604 remains coupled to the main body 102.

In this regard, advantages of the present disclosure include, but are not limited to, a drilling apparatus that is less complex than existing technologies to reduce manufacturing time and cost, and to additionally reduce the possibility of failure during operation. In particular, it is contemplated that the improved design of the drilling apparatus as described through the present disclosure may result in up to about an 83% profit margin as compared to known underreamer technologies. Advantages of the present disclosure also include, but are not limited to, a drag-wing configuration that has an improved expansion ratio as compared to known underreamer technologies. In some instances, it is contemplated that the improved design of the drilling apparatus results in an increase from a 13% average expansion ratio to a minimum 26% expansion ratio.

Advantages of the present disclosure also include, but are not limited to, a drilling apparatus that is modular to allow for the ability to have multiple sets of wings on-site for repair or replacement, to reduce equipment cost and lost downtime during maintenance of the drilling apparatus. For example, the multiple sets of wings include wings with diameters for the second, larger configuration for the drilling apparatus, and the drilling apparatus includes a hinge assembly that allows for the ability to switch between the different diameters of the second, larger configuration as desired on-site.

Advantages of the present disclosure are also directed to a drilling apparatus with wings. The drilling apparatus is usable for downhole drilling operations in the water, oil, gas industries, including to increase the length and/or the diameter of an existing wellbore. To this effect, the drilling apparatus is insertable in a first, smaller diameter configuration and expandable to a second, larger diameter configuration via the actuation of wings. Optionally, the wings may be modular, such that the wings may be interchanged with an additional set of wings. With the additional set of wings, the drilling apparatus is still insertable in the first, smaller diameter configuration and expandable to a third, larger diameter configuration via the actuation of the additional set of wings.

It is understood that the drilling apparatus described throughout the present disclosure offers numerous advantages in the water, oil, and gas industries.

For example, the diameter of the drilling apparatus can be adjusted on-site, reducing the need for multiple bits and enhancing operational flexibility. This ability to adjust as needed on-site can significantly reduce drilling time and costs while improving overall efficiency.

By way of another example, the drilling apparatus requires less manufacturing time and cost and is less complex in terms of design. With sufficient cost savings to the end user or operator, the end user or operator (i.e., at a drilling site and/or on a drilling rig) can keep more than one drilling apparatus having more than one diameter configuration on-site.

By way of another example, the wings (and thus the wear parts of the drilling apparatus) are modular. The wings can be replaced in on-site, reducing downtime typically required to send bits to a repair facility for repair and rebuild. In addition, the wings can also be manufactured for different wellbore diameters and changed out as needed in the field.

By way of another example, the drilling apparatus can achieve higher penetration rates with higher expansion ratios between the collapsed and expanded configurations due to the longer wings, reducing or eliminating any corkscrew effect that may affect known underreamer technologies. In particular, the cork-screw effect occurs due to shorter wing lengths and high penetration rates employed by the known underreamer technologies. In contrast, the drilling apparatus can achieve higher penetration rates and a clean bore without any corkscrew effect.

By way of another example, configurations of the drilling apparatus may permit placement at a bottom hole position of the drill string or at an intermediate or inline position of the drill string between sections of drill string. In these configurations, many components of the drilling apparatus may remain common between the expandable drill bit configuration as generally illustrated in FIGS. 1A-11 and the inline underreamer configuration as generally illustrated in FIGS. 12A-22, thereby simplifying operations and enhancing design flexibility to accommodate varying drilling requirements. For instance, locating the drilling apparatus at the bottom hole position of the drill string enables reaming to total depth and supports a simplified bottom hole assembly layout. Alternatively, positioning the drilling apparatus at the intermediate or inline position of the drill string may be advantageous for isolating sensitive measurement tools from shock and vibration associated with reaming operations, while also minimizing interference with directional control in modern drilling systems. The ability to use common components between the expandable drill bit and the inline underreamer configurations can streamline planning, reduce procurement complexity, and simplify training requirements.

Methods and apparatuses used for underreaming for water, oil, and gas industries are disclosed in U.S. Pat. Nos. 11,767,715, 11,225,838, 11,377,909, 11,408,230, 11,428,049, 11,686,196, 11,767,715, U.S. Patent Publication. No. 2023/0167691, U.S. Patent Publication. No. 2023/0167716, and U.S. Patent Publication. No. 2023/0220733, which are each incorporated herein in their entirety by reference.

While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be understood that such modifications and alterations are within the scope and spirit of the present disclosure, as set forth in the following claims. Further, the disclosure described herein is capable of other embodiments and of being practiced or of being carried out in various ways. It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.