BACKUP CUTTING ELEMENTS ON NON-CONCENTRIC EARTH-BORING TOOLS AND RELATED METHODS
An apparatus for engaging a subterranean borehole includes a bi-center bit having backup cutting elements thereon. The bi-center bit includes a pilot bit section and a reamer bit section adjacent to the pilot bit section. The pilot bit section includes at least one primary cutting element and at least one backup cutting element rotationally trailing and laterally offset from the at least one primary cutting element. Methods of drilling a subterranean borehole include engaging a first portion of a borehole with a reamer bit section of a drill bit and simultaneously engaging a second, opposing portion of the borehole with a pilot bit section adjacent to the reamer bit section.
This application is related to U.S. patent application Ser. No. 12/498,516, filed Jul. 7, 2009, pending, titled “BACKUP CUTTING ELEMENTS ON NON-CONCENTRIC REAMING TOOLS.”
TECHNICAL FIELDEmbodiments of the invention relate to drill bits and tools for subterranean drilling and, more particularly, embodiments relate to drill bits for enlarging the diameter of a subterranean borehole employing primary and backup cutting elements.
BACKGROUNDBoreholes are formed in subterranean formations for various purposes including, for example, extraction of oil and gas from subterranean formations and extraction of geothermal heat from subterranean formations. Boreholes may be formed in subterranean formations using earth-boring tools such as, for example, drill bits and reamer devices.
To drill a borehole with a drill bit, the drill bit is rotated and advanced into the subterranean formation under an applied axial force, commonly known as “weight on bit,” or WOB. As the drill bit rotates, the cutting elements or abrasive structures thereof cut, crush, shear, and/or abrade away the formation material to form the borehole, depending on the type of bit and the formation to be drilled. A diameter of the borehole drilled by the drill bit may be defined by the cutting structures disposed at the largest outer diameter of the drill bit.
The drill bit is coupled, either directly or indirectly, to an end of what is referred to in the art as a “drill string,” which comprises a series of elongated tubular segments connected end-to-end that extends into the borehole from the surface of the formation. Often various subs and other components, such as a downhole motor, a steering sub or other assembly, a measuring while drilling (MWD) assembly, a ream while drilling (RWD) assembly, one or more stabilizers, or a combination of some or all of the foregoing, as well as the drill bit, may be coupled together at the distal end of the drill string at the bottom of the borehole being drilled. This assembly of components is referred to in the art as a “bottom hole assembly” (BHA).
The drill bit may be rotated within the borehole by rotating the drill string from the surface of the formation, or the drill bit may be rotated by coupling the drill bit to a down-hole motor, which is also coupled to the drill string and disposed proximate the bottom of the borehole. The downhole motor may comprise, for example, a hydraulic Moineau-type motor having a shaft, to which the drill bit is mounted, that may be caused to rotate by pumping fluid (e.g., drilling fluid or “mud”) from the surface of the formation down through the center of the drill string, through the hydraulic motor, out from nozzles in the drill bit, and back up to the surface of the formation through the annulus between the outer surface of the drill string and the exposed surface of the formation within the borehole. As noted above, when a borehole is being drilled in a formation, axial force or “weight” is applied to the drill bit (and reamer device, if used) to cause the drill bit to advance into the formation as the drill bit drills the borehole therein.
Boreholes may be enlarged by using a non-concentric drilling tool such as an eccentric bit or a bi-center bit. Eccentric bits or bi-center bits may be particularly useful in enlarging a borehole below a “tight” or undersized portion thereof. Eccentric bits or bi-center bits may also be particularly useful when performing a RWD process. Examples of eccentric bits and bi-center bits are disclosed in U.S. Pat. Nos. 4,635,738 and 5,957,223.
A bi-center bit generally includes a pilot bit section, which may be similar in configuration to the drill bits discussed previously. The bi-center bit also includes an eccentrically laterally extended or enlarged reamer bit portion that, when the bit is rotated about its drilling axis, produces an enlarged borehole. The smaller diameter pilot section is employed to commence the drilling and establish the drilling axis. Rotation of the bit remains centered about the drilling axis as the second, upper and larger radius, reamer bit section extending beyond the pilot bit section diameter to one side of the bit engages the formation to enlarge the borehole.
Rather than employing a one-piece drilling structure, such as an eccentric bit or a bi-center bit, to enlarge a borehole, an extended bottom hole assembly (extended bi-center assembly) with a pilot bit at the distal end thereof and a reamer assembly some distance above may also be employed to enlarge a borehole. This arrangement permits the use of any standard bit type (e.g., a rock bit or a drag bit) as the pilot bit, and the extended nature of the assembly permits greater drill string flexibility when passing through tight spots in the borehole as well as the opportunity to effectively stabilize the pilot bit so that the pilot hole and the following reamer will take the path intended for the borehole. The assignee of the present invention has designed reaming structures (so-called “reamer wings”) which generally comprise a tubular body having a fishing neck with a threaded connection at the top thereof, and a tong die surface at the bottom thereof, also with a threaded connection. Such reamer wings are disclosed in, for example, U.S. Pat. No. RE 36,817 to Pastusek et al. and U.S. Pat. No. 5,765,653 to Doster et al. both of which are assigned to the assignee of the present invention and the disclosure of each of which is incorporated in its entirety by this reference. The upper mid-portion of the reamer wing includes one or more longitudinally extending blades projecting generally radially outwardly from the tubular body, the outer edges of the blades carrying superabrasive cutting elements (e.g., polycrystalline diamond compacts (PDC)). The lower mid-portion of the reamer wing may include a stabilizing pad having an arcuate exterior surface the same or slightly smaller than the radius of the pilot hole on the exterior of the tubular body and longitudinally below the blades. The stabilizing pad may also be sized so that the rotational diameter traversed by the stabilizing pad may be the same as, or even greater than, the physical diameter of the pilot bit to enhance the stabilization provided by the stabilizing pad when engaging a pilot borehole of greater diameter than a physical diameter of the pilot bit. The stabilizer pad is characteristically placed on the opposite side of the tubular body with respect to the reamer wing blades so that the reamer wing will ride on the pad due to the resultant force vector generated by the cutting of the blade or blades as the enlarged borehole is cut.
BRIEF SUMMARYIn some embodiments, the present invention includes a bi-center bit for drilling subterranean formations. The bi-center bit includes a pilot bit section having a first gage diameter and a reamer bit section adjacent to the pilot bit section. The pilot bit section includes at least one primary cutting element and at least one backup cutting element rotationally trailing the at least one primary cutting element disposed thereon for engaging a subterranean formation. The at least one backup cutting element is offset from the at least one primary cutting element in a direction substantially transverse to an intended rotational path of the at least one primary cutting element during rotational operation of the bi-center bit. The reamer bit section includes at least one blade extending radially beyond the first gage diameter for rotationally engaging a subterranean formation.
In additional embodiments, a bi-center bit for drilling subterranean formations includes an eccentric reamer comprising at least one radially extending blade. The at least one radially extending blade includes at least one reamer cutting element disposed thereon for rotationally engaging a first portion of a subterranean borehole. A pilot bit coupled to the eccentric reamer includes at least two laterally adjacent primary cutting elements disposed on the pilot bit for engaging a subterranean borehole and at least one backup cutting element rotationally trailing the at least two primary cutting elements and disposed at least partially laterally intermediate the at least two primary cutting elements.
In yet additional embodiments, the present invention includes a method of drilling a subterranean borehole. The method includes engaging a first portion of a borehole with a portion of a reamer bit section of a drill bit and simultaneously engaging a second, opposing portion of the borehole with a portion of a pilot bit section adjacent to the reamer bit section. The second, opposing portion of the borehole may be engaged with at least two laterally adjacent primary cutting elements and with at least one backup cutting element rotationally trailing and disposed laterally intermediate the at least two primary cutting elements.
Illustrations presented herein are not meant to be actual views of any particular drill bit or other earth-boring tool, but are merely idealized representations that are employed to describe the present invention. Additionally, elements common between figures may retain the same numerical designation.
The various drawings depict embodiments of the invention as will be understood by the use of ordinary skill in the art and are not necessarily drawn to scale.
The bi-center bit 100 also includes reamer bit section 114 (e.g., an eccentric reamer). The reamer bit section 114 may include radially extending blades 140 that may have primary PDC cutting elements 120 mounted thereto. As shown in
In some embodiments, the backup cutting elements 121 may be disposed in a position rotationally trailing the primary cutting elements 120 and the longitudinal axis of each of the backup cutting elements 121 may extend substantially between and, in some embodiments, parallel to, the longitudinal axes of the primary cutting elements 120. It is noted that while the embodiment of
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If the bi-center bit 100 or portions thereof is a particle-matrix type bit formed of sintered tungsten carbide particles in a suitable matrix, the backup cutting element pockets 110 in the bi-center bit 100 are formed by casing the backup cutting element pockets 110 in the bi-center bit 100. Methods of manufacturing the bi-center bit 100 as a particle-matrix composite bit are described in, for example, pending U.S. patent application Ser. No. 11/271,153, filed Nov. 10, 2005 and entitled “Earth-Boring Rotary Drill Bits and Methods of Forming Earth-Boring Rotary Drill Bits,” and pending U.S. patent application Ser. No. 11/272,439, filed Nov. 10, 2005 and entitled “Earth-Boring Rotary Drill Bits and Methods of Manufacturing Earth-Boring Rotary Drill Bits Having Particle-Matrix Composite Bit Bodies,” each of which is assigned to the assignee of the present invention and the disclosure of each of which application is incorporated herein in its entirety by this reference.
Referring still to
In some embodiments, the backup cutting elements 121 may be placed to substantially oppose the blades 140 of the reamer bit section 114. For example, the backup cutting elements 121 may be placed on blades 118 of the pilot bit section 112, which are opposite to (i.e., on opposing lateral sides of the bi-center bit 100) the blades 140 of the reamer bit section 114. As discussed above, the backup cutting elements 121 may be located laterally intermediate the primary cutting elements 120 and may at least partially prevent matrix wear of a matrix portion 158 of the blades 118 between the laterally adjacent primary cutting elements 120. Such wear may be at least partially caused by imbalance forces (e.g., a resultant force vector generated by the eccentric blades 140 of the reamer bit section 114) due to the cutting forces created by the primary cutting elements 120 generated as the enlarged borehole is cut. Such imbalance forces may cause a matrix portion 158 of the blades 118 to contact (e.g., rub against) portions of the subterranean borehole during a drilling operation. Excessive contact between the matrix portion 158 of the blades 118 and the subterranean borehole may result in wear and, ultimately, failure of the bi-center bit 100. Locating the backup cutting elements 121 laterally intermediate the primary cutting elements 120 may reduce the amount of wear on a matrix portion 158 of the blades 118 as the backup cutting elements 121 may tend to contact the subterranean borehole rather than a matrix portion 158 of the bi-center bit 100.
The exposure of the backup cutting elements 121 (i.e., the distance the cutting elements 120, 121 extend away from the surface of the bi-center bit 100) may vary from the primary cutting elements 120 or may vary between the backup cutting elements 121. For example, the backup cutting elements 121 may be underexposed relative to the primary cutting elements 120 along the cutting element profile for a blade 118. In some embodiments, the exposure of the backup cutting elements 121 may vary depending on the location of the backup cutting elements 121. For example, the backup cutting elements 121 located in a cone region 136 of the pilot bit section 112 may exhibit relatively less exposure as compared to the backup cutting elements 121 located in the shoulder region 138 of the pilot bit section 112. For example, the backup cutting elements 121 located in the cone region 136 may be underexposed (e.g., by approximately 0.025 inch (0.635 millimeter)) from the primary cutting elements 120 while the backup cutting elements 121 located in the shoulder region 138 may have a exposure substantially equal to or only slightly less than the exposure of the primary cutting elements 120 (e.g., by approximately 0.01 inch (0.254 millimeter)).
In some embodiments, the primary cutting elements 120 and the backup cutting elements 121 of the bi-center bit 100 may each have similar or differing back rake and side rake angles such as the cutting elements described in, for example, U.S. patent application Ser. No. 12/498,516, which was filed Jul. 7, 2009 and entitled “Backup Cutting Elements on Non-Concentric Reaming Tools,” which is assigned to the assignee of the present invention and the disclosure of which is incorporated herein in its entirety by this reference.
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While the present invention has been disclosed herein with reference to illustrated embodiments, those of ordinary skill in the art will understand and appreciate that the invention is not so limited, and that additions, deletions and modifications to the disclosed embodiments may be made without departing from the scope of the invention. The present invention is limited only by the appended claims and their legal equivalents, which include within their scope all equivalent devices and methods according to principles of the invention as described.
Claims
1. A bi-center bit for drilling subterranean formations, comprising:
- a pilot bit section having a first gage diameter and including at least one primary cutting element and at least one backup cutting element rotationally trailing the at least one primary cutting element disposed thereon for engaging a subterranean formation, wherein the at least one backup cutting element is offset from the at least one primary cutting element in a direction substantially transverse to an intended rotational path of the at least one primary cutting element during rotational operation of the bi-center bit; and
- a reamer bit section adjacent to the pilot bit section, the reamer bit section comprising at least one blade extending radially beyond the first gage diameter for rotationally engaging a subterranean formation.
2. The bi-center bit of claim 1, wherein the pilot bit section comprises a plurality of blades, each blade of the plurality of blades having a plurality of primary cutting elements and a plurality of backup cutting elements rotationally trailing at least one primary cutting element of the plurality of primary cutting elements.
3. The bi-center bit of claim 2, wherein at least one backup cutting element of the plurality of backup cutting elements on at least one blade of the plurality of blades is offset from at least one primary cutting element of the plurality of primary cutting elements on at least another blade of the plurality of blades.
4. The bi-center bit of claim 1, wherein the reamer bit section comprises a reamer wing and wherein the pilot bit section comprises a fixed-cutting element drill bit, the reamer wing and the fixed-cutting element drill bit being coupled to form the bi-center bit.
5. The bi-center bit of claim 1, wherein the at least one blade of the reamer bit section comprises two blades extending radially beyond the first gage diameter.
6. The bi-center bit of claim 5, wherein the at least one backup cutting element comprises a plurality of backup cutting elements and wherein at least one backup cutting element of the plurality of backup cutting elements is positioned to substantially laterally oppose at least one blade of the two blades of the reamer bit section.
7. The bi-center bit of claim 6, wherein at least one backup cutting element of the plurality of backup cutting elements is positioned on a shoulder region of the pilot bit section, wherein at least another backup cutting element of the plurality of backup cutting elements is positioned on a cone region of the pilot bit section, and wherein the at least one backup cutting element of the plurality of backup cutting elements has an exposure greater than the exposure of the at least another backup cutting element of the plurality of backup cutting elements.
8. The bi-center bit of claim 1, further comprising at least one additional backup cutting element rotationally trailing the at least one backup cutting element.
9. The bi-center bit of claim 1, wherein the at least one backup cutting element is oriented at a back rake angle of about ninety (90) degrees.
10. The bi-center bit of claim 9, wherein the at least one backup cutting element comprises an ovoid shape.
11. A bi-center bit for drilling subterranean formations, comprising:
- an eccentric reamer comprising at least one radially extending blade, the at least one radially extending blade including at least one reamer cutting element disposed thereon for rotationally engaging a first portion of a subterranean borehole; and
- a pilot bit coupled to the eccentric reamer comprising: at least two primary cutting elements disposed on the pilot bit for engaging a subterranean borehole; and at least one backup cutting element rotationally trailing the at least two primary cutting elements and disposed at least partially laterally intermediate the at least two primary cutting elements.
12. The bi-center bit of claim 11, wherein the at least one reamer cutting element of the eccentric reamer is configured to rotationally engage a first portion of a subterranean borehole while the at least one backup cutting element of the pilot bit is configured to rotationally engage a second, opposing portion of a subterranean borehole.
13. The bi-center bit of claim 11, wherein the at least one backup cutting element is disposed laterally intermediate the at least two primary cutting elements at an equal lateral distance from each of the at least two primary cutting elements.
14. The bi-center bit of claim 11, wherein at least one radially extending blade of the eccentric reamer comprises two radially extending, circumferentially spaced blades.
15. The bi-center bit of claim 14, wherein the at least one backup cutting element comprises a plurality of backup cutting elements and wherein at least one backup cutting element of the plurality of backup cutting elements is positioned to substantially laterally oppose at least one radially extending blade of the two radially extending, circumferentially spaced blades.
16. A method of drilling a subterranean borehole, the method comprising:
- engaging a first portion of a borehole with a portion of a reamer bit section of a drill bit; and
- simultaneously engaging a second, opposing portion of the borehole with a portion of a pilot bit section adjacent to the reamer bit section, comprising: engaging the second, opposing portion of the borehole with at least two primary cutting elements; and engaging the second, opposing portion of the borehole with at least one backup cutting element rotationally trailing and disposed laterally intermediate the at least two primary cutting elements.
17. The method of claim 16, further comprising positioning at least two backup cutting elements on a shoulder region of the pilot bit section.
18. The method of claim 17, wherein positioning at least two backup cutting elements on a shoulder region of the drill bit comprises at least partially preventing wear of a matrix portion of the pilot bit by locating the at least two backup cutting elements on a shoulder region of the pilot bit section.
19. The method of claim 16, further comprising positioning a plurality of backup cutting elements on a portion of the pilot bit section.
20. The method of claim 19, wherein positioning a plurality of backup cutting elements on a portion of the pilot bit section comprises positioning at least one backup cutting elements of the plurality of backup cutting elements on a shoulder region of the pilot bit section to exhibit an exposure greater than an exposure of at least one backup cutting elements of the plurality of backup cutting elements on a cone region of the pilot bit section.
Type: Application
Filed: Oct 29, 2009
Publication Date: May 5, 2011
Inventors: William A. Moss (Conroe, TX), David L. Rickabaugh (Spring, TX), Mark E. Anderson (The Woodlands, TX)
Application Number: 12/608,832
International Classification: E21B 10/26 (20060101); E21B 10/62 (20060101); E21B 7/00 (20060101);