Reaming Device and Method

Description

CROSS-REFERENCE

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/691,547 , filed on Sep. 6, 2024, which is incorporated by reference herein in its entirety.

BACKGROUND

In the oil and gas drilling process, reamers are positioned in the drill string to clean and open up the wellbore as the reamer travels through it. Reamers are designed to smooth out irregularities and ensure that the wellbore is the desired diameter. They provide a more stable and uniform wellbore. Reamers can be used in vertical drilling operations, directional drilling operations, and horizontal drilling operations. FIG. 1 illustrates one type of conventional reaming device 2 including two eccentric reamer portions 4 with stabilization blades 6 between the reamer portions 4. The stabilization blades 6 are typically designed to position the reamer in the wellbore and to facilitate the circulation of cuttings to the surface. FIG. 2 illustrates another type of conventional reaming device 8 including two eccentric reamer portions 9. These conventional reaming devices are designed to contact and cut on the wellbore wall constantly while the drill string is going into and coming out of the wellbore. The continuous cutting by conventional reamers increases the frequency of stick slip complications and increases vibrations experienced by the drill string. The continuous cutting of conventional reamers also wears down casing disposed within the wellbore and wears down the cutters on the reamers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a prior art device.

FIG. 2 is a side view of another prior art device.

FIG. 3-11 are side views of various embodiments of the reaming device disclosed herein.

FIG. 12 is a side detail view of one embodiment of the reaming device in a default position.

FIG. 13 is a side detail view of the reaming device of FIG. 12 in an activated position.

FIG. 14A is a side view of one embodiment of a shield of the reaming device disclosed herein.

FIG. 14B is a sectional view of the shield embodiment shown in FIG. 14A.

FIG. 15A is a side view of a second embodiment of a shield of the reaming device disclosed herein.

FIG. 15B is a sectional view of the shield embodiment shown in FIG. 15A.

FIG. 16A is a side view of a third embodiment of a shield of the reaming device disclosed herein.

FIG. 16B is a sectional view of the shield embodiment shown in FIG. 16A.

FIG. 17 is a sectional view of one embodiment of the shield in the default position positioned in a wellbore.

FIG. 18 is a sectional view of the shield of FIG. 17 in the activated position in the wellbore.

FIG. 19-21 are sectional views of other embodiments of the shield of the reaming device disclosed herein.

FIG. 22 is a sectional view of an embodiment of the shield including a torsional spring, with the shield in the default position.

FIG. 23 is a sectional view of the shield of FIG. 22 in the activated position.

FIG. 24 is a sectional view of another embodiment of the shield including a coil spring, with the shield in the default position.

FIG. 25 is a sectional view of the shield of FIG. 24 in the activated position.

FIG. 26 is a sectional view of another embodiment of the shield including a leaf spring, with the shield in the default position.

FIG. 27 is a sectional view of the shield of FIG. 26 in the activated position.

FIG. 28 is a sectional view of another embodiment of the shield including a compressible fluid chamber, with the shield in the default position.

FIG. 29 is a sectional view of the shield of FIG. 28 in the activated position.

FIG. 30 is a sectional view of yet another embodiment of the shield including a piston and a non-compressible fluid chamber in the default position.

FIG. 31 is a lateral sectional view of yet another embodiment of the shield including a spring cooperating with a rack and pinion arrangement, with the shield in the default position.

FIG. 32 is a detail view taken from FIG. 31.

FIG. 33 is a lateral sectional view of the shield of FIG. 31 in the activated position.

FIG. 34 is a lateral sectional view of yet another embodiment of the shield including a leaf spring, with the shield in the default position.

FIG. 35 is a lateral sectional view of the shield of FIG. 34 in the activated position.

FIG. 36 is a lateral sectional view of yet another embodiment of the shield including a leaf spring, with the shield in the default position.

FIG. 37 is a lateral sectional view of the shield of FIG. 36 in the activated position.

FIG. 38 is a lateral sectional view of another embodiment of the shield including an energized piston, with the shield in the default position.

FIG. 39 is a lateral sectional view of the shield of FIG. 38 in the activated position

FIG. 40 is a plan view of the reaming device disposed in a wellbore with two shields in the default position.

FIG. 41 is a plan view of the reaming device of FIG. 40 with one shield contacting a restriction in the wellbore.

FIG. 42 is a plan view of the reaming device of FIG. 40 with one shield in the activated position after engaging the restriction in the wellbore, thereby allowing cutting mechanisms on the adjacent reamer to engage and clear the restriction.

FIG. 43A is a plan view of another embodiment of the reaming device disposed in a wellbore with two shields in the default position.

FIG. 43B is a sectional view of the reaming device of FIG. 43A in the default position.

FIG. 44A is a plan view of the reaming device of FIG. 43A with one shield in the activated position after engaging a restriction in the wellbore, thereby allowing cutting mechanisms on the adjacent reamer to engage and clear the restriction.

FIG. 44B is a sectional view of the reaming device of FIG. 44A in the activated position.

FIG. 45 is a schematic view of the reaming device in a drill string disposed within a wellbore.

DETAILED DESCRIPTION OF SELECTED EMBODIMENTS

Disclosed herein is a reaming device including reamers that are prevented from cutting and interacting with the bore wall until the reaming device encounters a wellbore restriction, such as a restricted wellbore diameter, a restriction or ledge in the wellbore, or loose rock in the wellbore. The reamers are shielded in the reaming device's default position until the device is activated by a wellbore restriction, thereby moving the device into the activated position in which the reamers are allowed to cut or clean the wellbore. The reaming device of the present invention is passively activated, i.e., the reaming device is activated without any communication with the surface.

Numerous embodiments of the reaming device are illustrated in FIG. 3-45 and described herein. Many alternate embodiments within the scope of the claimed invention will be readily apparent to a skilled artisan.

FIG. 3-11 illustrate various embodiments of the reaming device 10, which includes a tool body 12, two reamers 14, and one or more shields 16. The tool body 12 is a generally cylindrical structure containing a central bore and an outer surface. The tool body 12 may be formed of multiple cylindrical segments or one cylindrical element. Each reamer 14 is disposed on the tool body 12. For example, each reamer 14 may be integrally formed with the tool body 12. Alternatively, each reamer 14 may be securely affixed to the tool body 12. The reamers 14 are axially spaced apart and may be configured in any angular arrangement relative to one another. For example, the axial space between the reamers 14 may be in the range of 3 feet to 12 feet. The two reamers 14 may be diametrically opposed as shown in the embodiments of FIGS. 3, 5, 6, 10, and 11; angularly aligned as shown in the embodiments of FIGS. 4 and 7-9; or otherwise angularly misaligned. Optionally, the reaming device 10 may include more than two reamers 14.

The reaming device 10 may include one shield 16 as shown in the embodiment of FIG. 8-10, two shields 16 as shown in the embodiments of FIG. 3-6 and 11, or three or more shields 16 as shown in FIG. 7. Each shield 16 is a structure that extends a variable radial distance beyond the outer surface of the tool body 12. Each shield 16 is positioned adjacent or proximate to a reamer 14 along the tool body 12. As used herein, “proximate” means separated by a small axial distance along the axial length of the tool body 12. In some embodiments, two shields 16 are positioned upstream and downstream, respectively, of both reamers 14 as shown in FIGS. 3 and 4 such that both reamers are 14 are disposed between the shields 16. In other embodiments, two shields 16 are positioned between two reamers 14 as shown in FIGS. 5 and 6. In still other embodiments, one shield 16 may be positioned between two reamers 14, with two shields 16 positioned upstream and downstream, respectively, of the two reamers 14 as shown in FIG. 7. In other embodiments, one shield 16 may be positioned between two reamers 14 as shown in FIG. 8-10. In some embodiments, two or more shields 16 may be disposed at the same axial position along the tool body 12 as shown in FIG. 11. Accordingly, each shield 16 may be positioned upstream or downstream of the reamer 14 to which the shield is proximate (i.e., the “proximate reamer”). Each shield 16 may be angularly aligned with the proximate reamer 14 as shown in FIG. 3-4, 6-8, and 10-11. Alternatively, each shield 16 may be diametrically opposed to, or otherwise angularly misaligned with, the proximate reamer 14 as shown in FIGS. 5, 9, and 11. In still other embodiments, the reaming device 10 may include one or more shields 16 that are angularly aligned with the proximate reamer 14 and one or more other shields 16 that are angularly misaligned with the proximate reamer 14. Each of the shields 16 may be independently activated.

With reference to FIG. 12, each reamer 14 includes a plurality of cutting mechanisms 18 (i.e., cutters). An outer cutting edge 20 is defined by the outer surface of the cutting mechanism 18 that extends the greatest distance from the central axis 21 of the tool body 12. Line R in FIG. 12 represents the extent to which the outer cutting edge 20 of reamer 14 extends beyond the outer surface of tool body 12. Each shield 16 extends beyond the outer surface 23 of tool body 12. The outer shield edge 22 is defined by the point on shield 16 that extends the greatest distance from the central axis 21 of the tool body 12 in the default position. The reamer 14 is in a disengaged mode when the shields 16 are in the default position. In the default position illustrated in FIG. 12, the outer shield edge 22 of each shield 16 extends beyond the outer cutting edge 20 of the proximate reamer 14. Line S in FIG. 12 represents the extent to which the outer shield edge 22 of shield 16 extends beyond the outer surface 23 of tool body 12. In the default position, outer shield edge 22 and line S are a greater distance from the outer surface 23 of tool body 12 than outer cutting edge 20 and line R. In this way, each shield 16 prevents the proximate reamer 14 from cutting on the surrounding wellbore surface or casing surface in the default position. Each shield 16 is biased toward this default position. As used herein, “extend beyond” means that the outer surface of one structure is a greater distance from the central axis of a cylindrical body than the outer surface of another structure.

Referring to FIG. 13, each shield 16 is configured to move into an activated position when the shield 16 is activated by engaging or otherwise contacting a restriction in the wellbore. In the activated position illustrated in FIG. 13, the outer shield edge 22 extends a smaller distance from the outer surface 23 of the tool body 12 than outer cutting edge 20, which is represented by line S being positioned between line R and the outer surface 23 of tool body 12. In other words, in the activated position, shield 16 and its outer shield edge 22 are disposed radially inward of the outer cutting edge 20 of reamer 14 to which shield 16 is proximate.

With reference to FIGS. 14A and 14B, each shield 16 may include a pad, which may be in the shape of a curved plate. The surface of the pad may be formed of a hard layer made of hardmetal or metal powder mixed with diamond, tungsten carbide, or ceramic components. The hard layer may be also formed from solid tungsten carbide or ceramic components such as tiles, buttons, or tungsten carbide segments of any shape and form. The hard layer may be applied by brazing, welding, plasma transfer arc or laser process. The hard layer of the pad can also be achieved by surface treading and therefore hardening the pad base metal. The pad may also be formed out of solid tungsten carbide or any hard material with a hardness over 40 HRC. The pad of shield 16 may have an outer surface that is angularly aligned with the surface of the cutting mechanisms of the proximate reamer 14. In some embodiments, shield 16 may be configured to pivot about a hinge 26. In these embodiments, the unhinged side of shield 16 may be biased in a generally outward direction toward the default position, and activation of the shield 16 may cause the shield 16 to pivot about hinge 26 such that the unhinged side of shield 16 moves in a generally inward direction to the activated position.

Referring to FIGS. 15A and 15B, each shield 16 may include a plurality of protrusions 30 each angularly aligned with at least one cutting mechanism of the proximate reamer 14. The protrusions can be formed as pistons, slips, ribs, or any other radially moveable element. In the default position illustrated in FIGS. 15A and 15B, an outer surface of each protrusion 30 extends beyond the outer surface of the cutting mechanism with which the protrusion is angularly aligned. The protrusions 30 may be biased in a generally outward direction toward this default position, and activation of the shield 16 may cause the protrusions 30 to retract in a generally inward direction to the activated position. In certain embodiments, each of the protrusions 30 may be independently activated.

With reference to FIGS. 16A and 16B, each shield 16 may include an eccentric sleeve 32 configured to rotationally slide around the tool body 12. The eccentric sleeve may be crescent-shaped or generally cylindrical with a shield section along the eccentric sleeve's circumference having an outer shield surface 33 that is sufficiently spaced apart from the tool body 12's central axis such that the outer shield surface 33 extends beyond the outer cutting edge 20 in the default position. The eccentric sleeve 32 may be biased toward the default position in which the eccentric sleeve 32 is angularly aligned with the cutting mechanisms of a proximate reamer 14. In these embodiments, the eccentric sleeve 32 is configured to rotate around the tool body 12 into the activated position when the shield 16 is activated.

Referring to FIG. 17, the reaming device may be disposed in a wellbore 36 through a subterranean formation 38. In the default position illustrated in FIG. 17, outer shield edge 22 of shield 16 may be in contact with the wellbore surface 39. In some circumstances, the outer shield edge 22 of shield 16 may be spaced apart from wellbore surface 39 without activating the shield 16.

With reference to FIG. 18, shield 16 is activated when the outer shield edge 22 engages the wellbore wall 39 in a way that causes the force exerted on the outer shield edge 22 to exceed a predetermined activation force value such as in a case of a restricted diameter of the wellbore 36 or a ledge. The predetermined activation force value is the force that overcomes the force biasing the shield 16 toward the default position. In the illustrated embodiment, activation of the shield 16 causes outer shield edge 22 to pivot inward into the activated position shown in FIG. 18.

FIG. 19 illustrates an embodiment of the reaming device that includes two shields 16 disposed at the same axial position on the tool body 12. The shields 16 are configured to pivot about hinges 26. In this embodiment, the hinges 26 of the two shields 16 are proximate to one another and the outer shield edges 22 of the two shields 16 are proximate to one another. The shields 16 can be activated separately.

FIG. 20 illustrates another embodiment of the reaming device that includes two shields 16 disposed at the same axial position on the tool body 12. The shields 16 are configured to pivot about hinges 26. In this embodiment, each hinge 26 is proximate to the outer shield edge 22 of the other shield 16. The shields 16 can be activated separately.

FIG. 21 illustrates an embodiment of the reaming device that includes three shields 16 disposed at the same axial position on the tool body 12. The shields 16 are configured to pivot about hinges 26. In this embodiment, each hinge 26 is proximate to the outer shield edge 22 of another shield 16. The shields 16 can be activated separately.

FIG. 22-30 illustrate various embodiments of the reaming device 10 including a shield 16 that is configured to pivot about hinge 26 relative to the tool body 12. In these embodiments, the outer shield edge 22 of the shield 16 is biased in a generally outward direction by a biasing mechanism. Limited examples of biasing mechanisms are shown in the illustrated embodiments. In FIGS. 22 and 23, the biasing mechanism is a torsional spring 42. In FIGS. 24 and 25, the biasing mechanism is a coil spring 44. In FIGS. 26 and 27, the biasing mechanism is a leaf spring 46. In FIGS. 28 and 29, the biasing mechanism is a compressible fluid chamber 48. In FIG. 30, the biasing mechanism is a piston. For example, the piston in FIG. 30 may be formed by spring or a compressible fluid 50 in communication with a non-compressible fluid chamber 52.

FIG. 31-37 illustrate various other embodiments of the reaming device 10 including shields 16 that are configured to move between the default position and the activated position without a hinge. The embodiment shown in FIG. 31-33 includes a torsional spring 56 secured to a pinion 58. Pinion 58 is fixed in relation to tool body 12, i.e., pinion 58 is prevented from moving relative to the tool body 12. The rack 60 is secured to, or integrally formed with, the shield 16. When the predetermined activation force is applied on the outer shield edge 22, the rack 60 applies a rotational force on the torsional spring 56 that causes the torsional spring 56 to contract and therefore tighten. With the contraction of the torsional spring 56 along the rack 60, the shield 16 retracts radially and axially to the tool body 12. In this way, the predetermined activation force activates the shield 16, thereby moving the shield 16 from the default position (shown in FIGS. 31 and 32), in which the proximate reamer is prevented from cutting, into the activated position (shown in FIG. 33), in which the proximate reamer cuts the wellbore wall to smooth out irregularities or to increase the wellbore size. If the force applied on the outer shield edge 22 decreases below the predetermined activation force, the torsional spring 56 will unwind, thereby allowing the shield 16 to move into the default position.

The embodiment in FIGS. 34 and 35 includes a leaf spring 64 that biases the shield 16 in an outward direction toward the default position (shown in FIG. 34). When the predetermined activation force is applied on the outer shield edge 22, the leaf spring 64 is compressed to allow the shield to move into the activated position (shown in FIG. 35).

The embodiment in FIGS. 36 and 37 includes a shield 16 that is formed of a leaf spring. In this embodiment, a first end 68 of the leaf spring is fixed to the tool body 12 and a second end 70 of the leaf spring slidingly engages the tool body 12. When the predetermined activation force is applied on the outer shield edge 22, the leaf spring is compressed forcing its second end 70 to slide relative to the tool body 12 to allow the central portion of the leaf spring to move toward the central axis of the tool body 12 in the activated position shown in FIG. 37.

In the embodiment shown in FIGS. 38 and 39, shield 16 is formed by one or more energized pistons 71 biased in a generally outward direction toward the default position illustrated in FIG. 38. Each piston 71 may be energized by a compressible fluid disposed within a corresponding chamber 72. Alternatively, each piston 71 may be energized by a coil spring or leaf spring disposed within a corresponding chamber 72. When the predetermined activation force is applied on the outer shield edge 22 of piston 71, the piston 71 compresses the fluid or the springs in chamber 72 to allow the piston 71 to move in a generally inward direction into the activated position shown in FIG. 39. In some embodiments, each piston 71 of the shield 16 may be activated independently.

With reference to FIG. 40, as reaming device 10 is traveling through a wellbore 36 in subterranean formation 38, shield 16 is in the default position in which outer shield edge 22 extends outward beyond outer cutting edge 20 of reamer 14 that is proximate to the shield. In this position, shield 16 spaces reamer 14 apart from wellbore surface 39 to prevent reamer 14 from cutting on wellbore surface 39. Several advantages result from this configuration of minimizing or preventing unnecessary cutting by the reamers 14, including minimizing stick slip effects and reducing potentially harmful vibration, reducing wear on the inner wall of the casing when tripping into the bore hole, and reducing unnecessary wear on the cutting mechanisms of the reamers 14.

Referring to FIG. 41, when outer shield edge 22 of shield 16 engages a restriction 74, or another reduction in the cross-sectional area of the wellbore 36, the restriction 74 exerts a force on outer shield edge 22.

With reference to FIG. 42, when the force on outer shield edge 22 exceeds a predetermined activation force value, shield 16 is activated and moves from the default position into the activated position. In the activated position, the cutting mechanisms of reamer 14 engage and cut the restriction 74 on wellbore surface 39. In this way, the reaming device 10 performs the reaming functions within the wellbore when necessary, but the device reduces the unnecessary cutting time by the reamers in order to reduce wear and reduce stick slip challenges.

FIGS. 43A and 43B illustrate an embodiment of reaming device 10 including a shield 16 including an eccentric sleeve 32. In the illustrated default position, the eccentric sleeve 32 is angularly aligned with the cutting mechanisms of reamer 14 to prevent the cutting mechanisms from engaging or cutting the wellbore surface 39. When outer shield surface 22 engages restriction 74 in wellbore surface 39, shield 16 encounters a reaction torque which will exceed a predetermined activation torque value, thereby causing the eccentric sleeve 32 to rotate (against the rotational bias torque) into the activated position shown in FIGS. 44A and 44B. In the activated position, the eccentric sleeve 32 is angularly misaligned with the cutting mechanisms of reamer 14, thereby allowing the cutting mechanisms to engage and cut or clear the restriction 74 in the wellbore surface 39.

FIG. 45 depicts the reaming device 10 secured in a drill string disposed in a wellbore through subterranean formation 38. The reaming device 10 may be secured upstream of the drill bit 80, steerable motor 82, and measurement-while-drilling section 84 as shown. The shields 16 of the reaming device 10 are biased toward, and remain in, the default position in which the shields 16 prevent the proximate reamers 14 from cutting on the wellbore surface until activated. The shields 16 are passively and automatically activated in response to restrictions in the wellbore or reduced cross-sectional area in the wellbore near the reamer 14 that is in the appropriate position to clear the restriction. When a predetermined activation force is applied to the shields 16, the shields 16 move into the activated position in which the cutting mechanisms of the reamers 14 are allowed to engage and clear the restriction. Once the restriction is cleared and the force on the shield 16 is reduced, the shield 16 is automatically returned to the default position by the biasing mechanism. The shields 16 are activated and then returned to the default position without any signal or adjustment (e.g., no flow rate adjustment, no rotation rate adjustment) from the surface. In other words, the shields 16 are passively activated.

In some embodiments, the predetermined activation force value is high enough to offset the centrifugal forces in a vertical wellbore and high enough to offset the gravitational forces and centrifugal forces in a directional and horizontal wellbore.

As used herein, “passive activation” or “passively activated” means activation of a tool in a wellbore without any communication, signal, or adjustment from the surface of the wellbore. As used herein, “angular arrangement” means the angle formed between, or the relative positions of, a first radius and a second radius, with the first radius extending from a central axis of a cylindrical body to any point on a first structure on the cylindrical body, and the second radius extending from the central axis of the cylindrical body to any point on a second structure on the cylindrical body, which may be, but is not required to be, axially spaced apart from the first structure. As used herein, “diametrically opposed” means an angular arrangement of two structures forming an angle of about 180 degrees (i.e., opposing arrangement). As used herein, “angularly aligned” means an angular arrangement of two structures forming an angle of 0 degrees (i.e., overlapping) for any point on the first structure and any point on the second structure. As used herein, “angularly misaligned” means not angularly aligned.

As used herein, “plurality” means two or more. Except as otherwise specified, the device described herein may include any combination of the described features and/or functions of each of the individual embodiments described. Except as otherwise specified, each method described in this disclosure may include any combination of the described steps in any other, including the absence of certain described steps and combinations of steps used in separate embodiments. Any range of numeric values disclosed herein includes all possible subranges therein.

The preferred embodiments described in this disclosure are illustrative only. A skilled artisan reviewing this disclosure will understand many variations and modifications of these preferred embodiments that are within the scope of the invention, which is defined solely by the following claims when accorded a full range of equivalents.