Drill Bits With a Fluid Cushion For Reduced Friction and Methods of Making and Using Same
A drill bit is disclosed that in one configuration may include at least one cutter on a face section of the bit and at least one opening proximate the at least one cutter configured to discharge fluid under pressure onto the formation to create a fluid cushion between the drill bit and the formation during a drilling operation. An actuation device associated with the drill bit may be utilized to provide fluid under pressure to the at least one opening.
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This application claims priority from the U.S. Provisional Patent Application having the Ser. No. 61/142,049 filed Dec. 31, 2008.
BACKGROUND INFORMATION1. Field of the Disclosure
This disclosure relates generally to drill bits and systems that utilize the same for drilling wellbores.
2. Background of the Art
Oil wells (also referred to as “wellbores” or “boreholes”) are drilled with a drill string that includes a tubular member having a drilling assembly (also referred to as the “bottomhole assembly” or “BHA”). The BHA typically includes devices and sensors that provide information relating to a variety of parameters relating to the drilling operations (“drilling parameters”), behavior of the BHA (“BHA parameters”) and parameters relating to the formation surrounding the wellbore (“formation parameters”). A drill bit is attached to the bottom end of the BHA. The drill bit is rotated by rotating the drill string and/or by a drilling motor (also referred to as a “mud motor”) in the BHA to disintegrate the rock formation to drill the wellbore. A large number of wellbores are drilled along contoured trajectories. For example, a single wellbore may include one or more vertical sections, deviated sections and horizontal sections through differing types of rock formations. When a drilling condition changes, it is desirable to alter one or more drilling parameters, such as rate of penetration (ROP), depth of cut (DOC) of the drill bit cutters, weight-on-bit (WOB), rotational speed of the drill bit (RPM), etc., to alter a behavior of the drill bit, such as whirl. stick-slip, vibration, etc. The ROP is typically controlled by controlling the weight-on-bit (WOB) and RPM. WOB is controlled by varying the hook load at the surface and the RPM is controlled by altering the drill string rotation at the surface and/or by controlling the drilling motor speed in the BHA. Such methods require the drilling system or operator to take actions at the surface. Therefore, the impact of such surface actions on the drill bit behavior is not substantially immediate—it occurs a later time period, depending upon the wellbore depth.
Therefore, there is a need to provide an improved drill bit and a system for using the same for controlling drill bit behavior during drilling of wellbores.
SUMMARYIn one aspect, a drill bit is disclosed that, in one configuration, includes one or more cutters on a face section thereof and one or more fluid openings proximate to the cutters. The fluid openings are configured to discharge fluid under pressure onto the formation during drilling. The discharged fluid provides a cushion between the drill bit face and the formation, which reduces friction between the drill bit face and the formation.
In another aspect, a method of making a drill bit is disclosed that may include: providing one or more cutters on a face section of the drill bit and providing one or more fluid channels proximate to the cutters configured to discharge high pressure fluid onto the formation to reduce friction between the drill bit face and the formation during drilling of a wellbore.
In another aspect, a method of drilling a wellbore is provided that may include: conveying a drill bit attached to a bottomhole assembly into the wellbore, the drill bit having one or more cutters on a face section thereof and one or more fluid channels proximate to the cutters configured to discharge fluid under pressure on the formation to create a fluid cushion between the formation and the face section to reduce friction between the formation and the face section; and drilling the wellbore using the drill bit while discharging the fluid under pressure onto the formation.
Examples of certain features of the apparatus and method disclosed herein are summarized rather broadly in order that the detailed description thereof that follows may be better understood. There are, of course, additional features of the apparatus and method disclosed hereinafter that will form the subject of the claims.
The disclosure herein is best understood with reference to the accompanying figures in which like numerals have generally been assigned to like elements and in which:
Drill string 118 is shown conveyed into the wellbore 110 from a rig 180 at the surface 167. The exemplary rig 180 shown is a land rig for ease of explanation. The apparatus and methods disclosed herein may also be utilized with offshore rigs (not shown) used for drilling wellbores under water. A rotary table 169 or a top drive 168 coupled to the drill string 118 may be utilized to rotate the drill string 118, BHA 130 and the drill bit 150 to drill the wellbore 110. A drilling motor 155 (also referred to as the “mud motor”) may be provided in the BHA 130 to rotate the drill bit 150. The drilling motor 155 may be used alone to rotate the drill bit 150 or to superimpose the rotation of the drill bit 150 by the drill string 118. A control unit (or controller) 190, which may be a computer-based unit, may be placed at the surface 167 to receive and process data transmitted by the sensors in the drill bit 150 and the sensors in the BHA 130, and to control selected operations of the various devices and sensors in the BHA 130. The surface controller 190, in one embodiment, may include a processor 192, a data storage device (or a computer-readable medium) 194 for storing data, algorithms and computer programs 196 accessible to the processor 192. The data storage device 194 may be any suitable device, including, but not limited to, a read-only memory (ROM), a random-access memory (RAM), a flash memory, a magnetic tape, a hard disk and an optical disk. During drilling, a drilling fluid 179 from a source thereof is pumped under pressure into the tubular member 116. The drilling fluid is discharged at the bottom of the drill bit 150 and returned to the surface via the annular space 120 (also referred as the “annulus”) between the drill string 118 and the inside wall 142 of the wellbore 110.
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Thus, in one aspect, a drill bit is disclosed that in one configuration may include a face section or bottom face that includes one or more cutters thereon configured to penetrate into a formation; at least one opening proximate a cutter configured to discharge fluid under pressure onto the formation; and an actuation device configured to supply the fluid under pressure to the at least one opening when the drill bit is engaged for cutting the formation. The at least one opening may comprise a plurality of openings and the actuation device may be configured to supply the fluid under pressure to each of the openings. In one aspect, the actuation device may be configured to supply a drilling fluid flowing through the drill bit to the openings when the drill bit is engaged in drilling the wellbore. In another aspect, the actuation device may comprise a control valve in a fluid line that supplies the fluid to the openings to control the amount of the fluid supplied to such openings. A suitable pump may be utilized to supply the fluid to the control valve. The control valve may be any suitable valve for use downhole, including, but not limited to, a one-way valve and an electrical valve. In another aspect, the actuation device may include a ring device configured to open and close a fluid passage to the openings. In another aspect, a controller associated with the drill bit may be configured to control the actuation device for providing fluid under pressure to the openings. The controller also may modulate the fluid supply to the openings.
In another aspect, a method for drilling a wellbore is provided, which method, in one aspect, may include: conveying a drill bit attached to a bottomhole assembly into the wellbore, the drill bit having at least one fluid channel proximate one or more cutters on a face section of the drill bit and one or more fluid channels proximate the one or more cutters configured to discharge fluid under pressure on to the formation to create a fluid cushion between the formation and the face section to reduce friction between the formation and the face section; and drilling the wellbore using the drill bit while supplying fluid under pressure to the one or more channels. In one aspect, when more than one fluid channel is provided, the method may further include providing the fluid to each channel at the same pressure. In another aspect, the method may further include controlling the pressure of the supplied fluid in response to a selected parameter. The selected parameter may include, but is not limited to, change of formation type (e.g. from hard to soft formation and vice versa), vibration, whirl, stick-slip, acceleration bending moment, oscillation, torque and rate of penetration. In another aspect, the fluid may be supplied using a suitable actuation device, including, but not limited to: a pump unit that supplies fluid under pressure to the one or more channels and a mechanical device that opens and closes a fluid supply line to the one or more fluid channels.
In yet another aspect, an apparatus for use in drilling a wellbore is provided, which, in one aspect may include: a drill bit attached to a bottom end of a bottomhole assembly, the drill bit having a face section that includes one or more cutters and at least one opening configured to discharge fluid from the drill bit and an actuation device configured to supply fluid under pressure to the at least one opening. The apparatus may further include a controller configured to control the actuation device to control the supply of the fluid to the at least one opening. In one aspect, the controller may be configured to control the actuation device in response to a parameter, including, but not limited to: vibration, stick-slip, weight-on-bit, rate of penetration of the drill bit; bending moment, tangential acceleration; axial acceleration; radial acceleration; a drill bit fluctuation, a dysfunction relating to the drill bit, and a dysfunction relating to the drill string or bottomhole assembly. In one aspect, the actuation device may be a pump that supplies fluid under pressure; and a mechanical motion device that opens and closes a fluid path to the at least one opening. The apparatus may further include a sensor that provides signals relating to the pressure of the fluid supplied to the at least one opening. In another aspect, the apparatus may include a plurality of openings proximate cutters and wherein the actuation device supplies the fluid under pressure to each such opening at the same pressure.
The foregoing disclosure is directed to certain specific embodiments for ease of explanation. Various changes and modifications to such embodiments, however, will be apparent to those skilled in the art. It is intended that all such changes and modifications within the scope and spirit of the appended claims be embraced by the disclosure herein.
Claims
1. A drill bit, comprising:
- a face section that includes one or more cutters thereon configured to penetrate into a formation;
- at least one opening in the drill bit configured to discharge fluid under pressure onto the formation; and
- an actuation unit configured to supply the fluid under pressure to the at least one opening when the drill bit is engaged for cutting the formation.
2. The drill bit of claim 1, wherein the at least one opening comprises a plurality of openings and wherein the actuation unit is configured to supply the fluid under pressure to each of the openings.
3. The drill bit of claim 1, wherein the at least one opening is located at one or: a face section; gage section; and cone section.
4. The drill bit of claim 1, wherein the actuation unit comprises a control valve in a fluid line that supplies the fluid to the at least one opening to control the amount of the fluid to the at least one opening.
5. The drill bit of claim 4, further comprising a pump configured to supply the fluid to the valve.
6. The drill bit of claim 4, wherein the control valve is one of: a one-way valve; and
- an electrical valve.
7. The drill bit of claim 1, wherein the actuation unit includes a ring device configured to open and close a fluid passage to the at least one opening.
8. The drill bit of claim 1, further comprising a controller configured to control the actuation device for providing fluid under pressure to the at least one opening.
9. The drill bit of claim 1, further comprising a sensor that provides signals relating to the pressure of the fluid supplied to the at least one opening.
10. A method of drilling a wellbore, comprising:
- conveying a drill bit attached to a bottomhole assembly into the wellbore, the drill bit having at least one cutter on a face section of the drill bit and at least one opening proximate to at least one cutter, the at least one opening configured to discharge a fluid under pressure onto a formation when the drill bit is engaged in cutting the formation;
- drilling the wellbore by rotating the drill bit; and
- supplying the fluid under pressure to the at least one opening to create a fluid cushion between the face section of the drill bit and the formation.
11. The method of claim 10, wherein the at least one opening includes a plurality of openings and wherein the method further comprises providing fluid under substantially the same pressure to each of the openings.
12. The method of claim 10, further comprising controlling the supply of the fluid to the at least one opening in response to a selected parameter.
13. The method of claim 12, wherein the selected parameter relates to one or more of: a dysfunction relating to the drill bit; a dysfunction relating to the bottomhole assembly; a change of formation; vibration; whirl; stick-slip; bending moment;
- oscillation; torque; rate of penetration; weight-on-bit; tangential acceleration; axial acceleration; radial acceleration; and drill bit fluctuation.
14. The method of claim 10, wherein supplying the fluid under pressure comprises using an actuation device that is one of: a pump configured to supply the fluid under pressure to the at least one opening; and a mechanical device that opens and closes a fluid supply line to the at least one opening.
15. A method of manufacturing a drill bit, comprising:
- providing a drill bit having at least one cutter on a face section of the drill bit; and
- forming at least one opening proximate the at least one cutter configured to discharge a fluid under pressure onto a formation when the drill bit is engaged in cutting the formation.
16. The method of claim 15, further comprising providing a fluid supply unit configured to supply the fluid under pressure to the at least one opening via a fluid channel.
17. The method of claim 16, further comprising providing a control unit configured to control the fluid supply unit in response to a parameter of interest.
18. The method of claim 17, further comprising providing a sensor configured to provide a measurement relating to the parameter of interest.
19. The method of claim 17, wherein the parameter of interest is one or more of: a dysfunction relating to the drill bit; a dysfunction relating to the bottomhole assembly; a change of formation; vibration; whirl; stick-slip; bending moment; oscillation; torque; rate of penetration; weight-on-bit; tangential acceleration; axial acceleration; radial acceleration; and drill bit fluctuation.
20. The method of claim 15, further comprising controlling the supply of the fluid to the at least one opening in response to a selected parameter.
Type: Application
Filed: Dec 22, 2009
Publication Date: Jul 1, 2010
Applicant: BAKER HUGHES INCORPORATED (Houston, TX)
Inventors: Thorsten Schwefe (Spring, TX), Chad J. Beuershausen (Magnolia, TX), Britney E. Meckfessel (Conroe, TX), Trung Huynh (Houston, TX)
Application Number: 12/644,641
International Classification: E21B 21/10 (20060101); E21B 21/00 (20060101); E21B 10/60 (20060101); E21B 7/00 (20060101); E21B 44/00 (20060101); B21K 5/04 (20060101);