US20090301785A1 - Integrated Spiral Blade Collar - Google Patents
Integrated Spiral Blade Collar Download PDFInfo
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- US20090301785A1 US20090301785A1 US12/134,646 US13464608A US2009301785A1 US 20090301785 A1 US20090301785 A1 US 20090301785A1 US 13464608 A US13464608 A US 13464608A US 2009301785 A1 US2009301785 A1 US 2009301785A1
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- Prior art keywords
- collar
- proximal
- distal
- spiral blade
- segment
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/16—Drill collars
Definitions
- the present application provides an integrated spiral blade collar.
- a drill string generally has a bit connected to its lower end that drills a borehole through an earth formation as the drill string and the bit are rotated.
- the drill string typically includes a length of relatively heavy drill collars at its lower end to provide weight on the bit.
- a drill collar generally is constructed to provide a predetermined radial spacing of the longitudinal axis of the drill string with respect to the borehole wall.
- Drill collars commonly have three or four “straight” blades that contact the formation. The straight blades generally run substantially parallel to the longitudinal axis along substantially the length of the drill collar.
- the contact area between the formation and the “straight” blades of such drill collars is relatively small.
- the relatively small contact area tends to provide only limited stabilization of the bottom-hole assembly (BHA).
- BHA bottom-hole assembly
- the contact between the “straight” blades and the formation can increase torque during drilling operations.
- the straight blades also generally do not significantly promote the lifting of cuttings up the borehole.
- the present application provides an integrated spiral blade collar (“ISBC”).
- ISBC integrated spiral blade collar
- the application provides an ISBC comprising: a collar comprising a wall defining a bore, the collar having a longitudinal axis extending from a proximal end to a distal end; the collar comprising a first engagement mechanism at the proximal end and a second engagement mechanism at the distal end; the collar comprising one or more integral blades extending radially outward from an outer surface and forming a spiral around the longitudinal axis of the collar from at or near the proximal end to at or near the distal end of the collar, the spiral being at an angle of from 1° to 89° relative to the longitudinal axis of the collar.
- the application provides a method of increasing performance during drilling operations, the method comprising: mechanically engaging a bottom hole assembly (BHA) with a proximal end or a distal end of an ISBC comprising a wall defining a bore comprising a first engagement mechanism at a proximal end, a second engagement mechanism at a distal end, and a longitudinal axis extending therebetween, the ISBC comprising one or more integral blades extending from an outer surface of the ISBC and spiraling around the longitudinal axis from at or near the proximal end to at or near the distal end, the spiral being at an angle relative to the longitudinal axis; and, drilling through a formation to an improved final depth at which the ISBC must be replaced, the improved final depth being greater than the final depth to which a comparable straight blade collar or standard pack assembly drills through the same formation.
- BHA bottom hole assembly
- the application provides a method of increasing performance during drilling operations, the method comprising: mechanically engaging a bottom hole assembly (BHA) with a proximal end or a distal end of an ISBC comprising a wall defining a bore comprising a first engagement mechanism at a proximal end, a second engagement mechanism at a distal end, and a longitudinal axis extending therebetween, the ISBC comprising one or more integral blades extending from an outer surface of the ISBC and spiraling around the longitudinal axis from at or near the proximal end to at or near the distal end, the spiral being at an angle relative to the longitudinal axis; and, rotating the ISBC at a rotation rate, thereby producing an improved rate of penetration of 1.5 times or more greater than the rate of penetration achieved using a comparable straight blade collar or standard pack assembly drilling through the same formation.
- BHA bottom hole assembly
- FIG. 1A is a schematic isometric view of one embodiment of a near bit integrated spiral blade collar (“ISBC”).
- ISBC near bit integrated spiral blade collar
- FIG. 1B is a schematic isometric view of a sting ISBC.
- FIG. 2 is an enlarged view of the box 12 of the near bit ISBC of FIG. 1 .
- FIG. 3 is a longitudinal sectional view at line C-C in FIG. 2 .
- FIG. 4A is a cross sectional view along line B-B of FIG. 2 .
- FIG. 4B is a cross sectional view of an alternative embodiment along line B-B of FIG. 2 .
- FIG. 4C is a cross sectional view of another alternative embodiment along line B-B of FIG. 2 .
- FIG. 4D is a cross sectional view of another alternative embodiment along line B-B of FIG. 2 .
- FIG. 5 is an enlarged, truncated view of the ISBC of FIG. 1A .
- FIG. 6 is a longitudinal sectional view at line D-D along the distal extension 21 in FIG. 5 .
- FIG. 7 is a graph of predictions and goals related to time required to drill to 13,500 feet through a formation using a straight blade tricollar vs. actual time required to drill using an integrated spiral blade collar.
- the present application provides an integrated spiral blade collar (“ISBC”).
- ISBC provides a number of advantages compared to straight blade collars.
- the ISBC minimizes torque during drilling.
- the ISBC lifts more cuttings up the borehole than a comparable straight blade collar. In one embodiment, the ISBC stabilizes the BHA due to increased contact between the blades and the formation. In one embodiment, the ISBC provides more effective weight on the bit. In one embodiment, the ISBC reduces stresses on the bit. In one embodiment, the ISBC enhances bit life. In one embodiment, the ISBC increases the rate of penetration (ROP) of the ISBC. In one embodiment, the ISBC reduces the mechanical specific energy.
- ROP rate of penetration
- the ISBC produces an improved rate of penetration through a given formation compared to the rate of penetration achieved using a comparable straight blade collar.
- an ISBC having three blades (sometimes referred to as a tricollar ISBC) achieved 1.5 times the rate of penetration achieved using a straight blade collar having three blades.
- a standard pack assembly generally comprises one or more stablizers, one or more straight tricollars, and/or one or more roller reamers.
- the tricollar ISBC achieved 2 or more times the rate of penetration achieved using a standard pack assembly during the three runs.
- the ISBC produces an improved rate of penetration of 1.5 times or more greater than the rate of penetration achieved using a comparable straight blade collar or standard pack assembly drilling through the same formation. In one embodiment, the ISBC produces an improved rate of penetration of 2 times or more greater than the rate of penetration achieved using a standard pack assembly drilling through the same formation.
- the ISBC exhibits an extended life compared to a straight blade tricollar and/or standard pack assembly.
- the ISBC drills to an improved final depth in a subterranean formation, at which point the ISBC must be replaced.
- the improved final depth is greater than the final depth to which a comparable straight blade collar or standard pack assembly drills through the same formation.
- the improved final depth is 2 or more times the final depth to which a standard pack assembly drills through the same formation.
- the ISBC comprises one or more spiral blades.
- the ISBC comprises a plurality of spiral blades separating a plurality of substantially planar surfaces. The one or more spiral blades spiral from at or near the proximal end of the collar to at or near the distal end of the collar.
- the number of blades may vary.
- the ISBC comprises one blade.
- the ISBC comprises a plurality of blades.
- the ISBC comprises two blades.
- the ISBC comprises three blades separating three substantially planar surfaces extending from at or near the proximal end of the collar to at or near the distal end of the collar.
- the number of blades, the length of the blades, and/or the rotation rate may be increased, if desired, in order to increase the lifting of cuttings up the borehole. Without limiting the application to a particular theory of operation, the increase in lifting of cuttings is believed to result from Archimedes theory of suction.
- the lifting of cuttings up the borehole using the ISBC may be increased even further by substantially planar surfaces that are somewhat concave.
- FIGS. 4B , 4 C, and 4 D are cross sections of ISBCs which have such concave surfaces.
- FIG. 1A illustrates an exemplary embodiment of a “near bit” ISBC.
- the near bit ISBC comprises a collar 10 having a longitudinal axis 29 - 29 .
- the near bit ISBC comprises a box 12 , a proximal intervening segment 14 , a proximal segment 16 , an intermediate intervening segment 17 , an intermediate segment 18 , a distal intervening segment 19 , a distal segment 20 , and a distal extension 21 .
- the proximal intervening segment 14 and the intermediate intervening segment 17 provide make-up and/or break-up space that may be used to apply torque to engage and/or disengage the ISBC.
- the distal extension 21 serves as a fishing neck for fishing the ISBC out of the borehole, if necessary.
- the box 12 comprises an engagement mechanism at a proximal end 46 . In one embodiment, the box comprises an engagement mechanism at a distal end 46 a adjacent to the proximal intervening segment 14 .
- Suitable engagement mechanisms for the ISBC generally, engage the ISBC to a separate desired component in a fixed rotational relationship.
- the fixed rotational relationship may be permanent or temporary.
- the engagement mechanism permanently engages the ISBC in a fixed rotational relationship with a separate component.
- the engagement mechanism releasably engages the ISBC in a temporary fixed rotational relationship with a separate desired component.
- Suitable engagement mechanisms include, for example, mating threads, hooks and eyes, a matching slot and die, a welded engagement, and a fused engagement.
- the engagement mechanism is external threads on a pin that mate with internal threads on a box.
- the box 12 comprises proximal box threads 48 ( FIG. 3 ) adapted to engage the external threads of a pin on a desired component.
- the BHA often comprises externally threaded pins.
- the embodiment in FIG. 1A comprising the box 12 is sometimes referred to as a “near bit” ISBC.
- the ISBC is a “sting” ISBC.
- a sting ISBC is depicted in FIG. 1B .
- the “sting” ISBC of FIG. 1B is substantially the same as the “near bit” ISBC of FIG. 1A except that there is no box 12 .
- the proximal end 15 of the proximal intervening segment 14 is a pin 15 comprising exterior threads.
- the pin 15 mates with a box 12 , or with the distal inner threads 77 ( FIG. 6 ) of another ISBC 10 .
- FIG. 2 An enlarged view of an exemplary embodiment of the box 12 of FIG. 1A is seen in FIG. 2 .
- the box 12 has the longitudinal axis 29 - 29 .
- FIG. 3 is a cross section taken along the longitudinal axis 29 at line C-C of FIG. 2 .
- the proximal end 46 of the box 12 comprises proximal box threads 48 .
- the proximal box threads 48 may be any suitable threads adapted to engage external threads on a desired pin.
- the proximal box threads 48 are adapted to engage pin 15 of another ISBC 10 .
- the proximal box threads 48 are adapted to engage a pin in mechanical communication with the BHA.
- the edge 49 at the proximal end 46 of the box 12 is beveled at an angle.
- the angle relative to the longitudinal axis 29 - 29 may vary.
- the edge 49 is beveled at an angle of from about 0° to 90°.
- the edge 49 is beveled at an angle of from about 0° to 89°.
- the edge 49 is beveled at an angle of from about 0° to 45°.
- the edge 49 is beveled at an angle of about 45° relative to the longitudinal axis 29 - 29 .
- the inner diameter 51 at the proximal end of the proximal box threads 48 may vary.
- the ISBC comprises a bore 24 .
- the inner diameter 51 of the proximal box threads 48 is the same as the inner diameter 45 of the bore 24 ( FIG. 4A ).
- the bore 24 extends along the longitudinal axis along the length of the collar 10 .
- complimentary engagement mechanisms are engaged in or with the bore.
- the inner diameter 45 of the bore 24 extending from the proximal box threads 48 ( FIG. 3 ) to the distal segment threaded section 77 ( FIG. 6 ), may vary. In one embodiment, the inner diameter 45 of the bore 24 varies from about 5.7 cm (2.25 inches) to about 10.8 centimeters (4.25 inches). In one embodiment, the inner diameter of the bore 24 varies from about 5.7 cm (2.25 inches) to about 8.9 cm (3.5 inches). In one embodiment, the inner diameter of the bore 24 is about 5.7 cm (2.25 inches). In one embodiment, the inner diameter of the proximal box threads 48 also is 5.7 cm (2.25 inches). In one embodiment, the proximal box threads comprise an American Petroleum Institute (API) Reg Box with a 2F3R float bore.
- API American Petroleum Institute
- box blade 28 and the box blade 30 abut opposed edges of a box substantially planar surface 31 .
- box blade 28 and the box blade 30 have rounded proximal ends 28 a and 30 a .
- box blade 30 extends from the rounded box proximal end 30 a to a tapered box distal end 30 b.
- FIGS. 4A-4D are cross sections taken at line B-B of FIG. 2 showing alternative embodiments of the collar 10 .
- a cross section taken at any location distal to the proximal end of the proximal box hardface pad 100 a ( FIG. 5 ) and extending to the distal end 105 of the distal hardface pad 104 c ( FIG. 5 ) will have substantially the same outer surface configuration as that depicted in FIG. 4A-4D , depending upon the embodiment.
- the wall 26 defines a bore 24 .
- the bore 24 depicted in FIG. 4A is substantially cylindrical.
- the bore 24 may have other configurations. Suitable configurations for the bore 24 include, for example, rectangular, triangular, oval, or any other suitable configuration.
- the bore 24 is cylindrical.
- the wall 26 may comprise any material having sufficient mechanical strength. Suitable materials include, for example, metal, metal alloys, or composites. In one embodiment, the wall 26 comprises iron or cast iron. In one embodiment, the wall 26 comprises stainless steel. In one embodiment, the wall 26 comprises tungsten carbide.
- the wall 26 has first, second, and third box substantially planar surfaces 32 , 34 , and 36 , respectively.
- lines 38 a , 38 b , and 38 c drawn along the box substantially planar surfaces 32 , 34 , and 36 form a triangle.
- the angle “A” found at each corner of the triangle may vary.
- the lines 38 a , 38 b , and 38 c form a substantially equilateral triangle.
- the angle “A” at each corner of the triangle is approximately 60°.
- the first, second, and third box substantially planar surfaces 32 , 34 , and 36 are separated by a first box blade 40 , a second box blade 42 , and a third box blade 44 , respectively.
- a “substantially planar surface” is not a surface that necessarily is flat.
- a substantially planar surface may be concave, convex, may have a “concave” or “convex” “V” structure, or may comprise notches, grooves, or other indentations or projections.
- such configurations are substantially planar as long as lines drawn along their surfaces from a triangle, a rectangle, a pentangle, or similar closed geometric structure which corresponds to the number of blades on the ISBC.
- FIGS. 4B-4D Exemplary alternative embodiments comprising concave surfaces are depicted in FIGS. 4B-4D , in which like numbers indicate like parts.
- the wall 26 has a first substantially concave surface 32 , a second substantially concave surface 34 , and a third substantially concave surface 36 , separated by a first blade 40 , a second blade 42 , and a third blade 44 , respectively.
- the blade edges 32 a , 32 b , 34 a , 34 b , 36 a , 36 b are relatively sharp. In one embodiment, some of the edges 32 a , 32 b , 34 a , 34 b , 36 a , 36 b , are sharp and others are rounded.
- one or more of the blades 40 , 42 , 44 comprise hardface pads. In one embodiment, all of the blades 40 , 42 , 44 comprise hardface pads.
- Suitable hardface pads comprise material that is harder than the material from which the wall 26 is made.
- the hardface pads comprise a material that is harder than stainless steel.
- the substantially planar surfaces comprise a plurality of spaced hardface pads comprising cobalt, tungsten carbide fragments.
- Hardface pads comprising cobalt, tungsten carbide fragments are commercially available from a variety of sources.
- suitable hardface pads are commercially available from Vital Metals Ltd.
- the size of the hardface pads may vary. Increasing the size and the exposed surface area of the hardface pads tends to increase torque during drilling. Decreasing the size and the exposed surface area of the hardface pads tends to decrease torque during drilling.
- the hardface pads may be affixed to the blades using any suitable method. In one embodiment, the surface of the ISBC to which a hardface pad is to be affixed is heat melted and the hardface pad is bonded to the heat-melted surface.
- hardface pads cover substantially all of the cross-sectional surface of the first box blade 40 , the second box blade 42 , and the third box blade 44 , leaving slightly rounded edges 32 a , 32 b , 34 a , 34 b , 36 a , 36 b adjacent to the hardface pads.
- hardface pads cover much of the cross-sectional surface of the first blade 40 , the second blade 42 , and the third blade 44 , but an exposed area 41 remains adjacent to each of the rounded edges 32 a , 32 b , 34 a , 34 b , 36 a , and 36 b.
- a triangle is formed when lines 38 a , 38 b , and 38 c are drawn between the edges 32 a - 32 b abutting surface 32 , the edges 34 a - 34 b abutting surface 34 , and the edges 36 a - 36 b abutting surface 36 .
- the number of blades may be more or less than three. Lines drawn along the substantially planar surfaces between the blades will form the closed geometric structure corresponding to the number of blades of the ISBC>
- the box blades 28 and 30 ( FIG. 3 ) comprise a plurality of box spaced hardface pads, designated in FIG. 2 as 31 a , 31 b , and 31 c .
- the box blades 28 , 30 ( FIG. 3A ) comprise three box hardface pads 31 a , 31 b , and 31 c , respectively, per blade.
- the blades 28 , 30 do not comprise hardface pads. Where the blades do comprise hardface pads, the number, size, and spacing of the hardface pads may vary. In one embodiment, the entire cross-sectional surface of the blades is covered with hardface pads. In one embodiment, portions of the blades are not covered with hardface pads. In one embodiment, the hardface pads are longitudinally spaced. In one embodiment, the hardface pads do not cover small portions of the edges of the blades 28 , 30 . In one embodiment, the hardface pads are both longitudinally spaced and the hardface pads do not cover small portions of the edges of the blades.
- the length of the hardface pads may vary.
- the pad-to-pad distance between the distal end of one hardface pad and the proximal end of an adjacent hardface pad also may vary.
- the length of the hardface pads and the pad-to-pad distance is determined by the size of commercially available hardface pads.
- the blades 28 , 30 comprise three hardface pads each having a length of about 17.8 cm (7 inches). In one embodiment, the pad-to-pad distance is about 12.7 cm (5 inches).
- the box length which extends from the proximal end 47 of box hardface pad 31 a to the distal end 35 of box hardface pad 31 c , may vary. In one embodiment, the box length is about 78.7 cm (31 inches).
- the blades 28 , 30 comprise distal ends 30 b which taper inward at an angle relative to the longitudinal axis 29 - 29 to form the outer surface of the proximal intervening segment 14 .
- the tapered angle may vary. In one embodiment, the tapered angle varies from about 10 to 89°. In one embodiment, the tapered angle varies from about 10 to 45°. In one embodiment, the tapered angle varies from about 10 to 20°. In one embodiment, the distal end 30 b is tapered inward at an angle of about 12° relative to the longitudinal axis 29 - 29 .
- the outer surface of the proximal intervening segment 14 may have a variety of configurations. Examples of suitable configurations include cylindrical, rectangular, triangular, oval, or any other suitable configuration. In one embodiment, the outer surface of the proximal intervening segment 14 is cylindrical. As previously explained, the proximal intervening segment 14 provides make-up and/or break-up space that may be used to apply torque to engage and/or disengage the ISBC.
- the number of times that a blade (e.g., blade 30 ) spirals around the longitudinal axis from a proximal end to a distal end of the ISBC depends on the angle X formed between the longitudinal axis 29 - 29 and a line drawn along the longitudinal axis of the blade 30 .
- X is from 1° to 89°. In one embodiment, X is from 10 to 45°. In one embodiment, X is 450.
- FIG. 5 is an enlarged, truncated view of the near bit ISBC 10 of FIG. 1 a comprising the box 12 , the proximal intervening segment 14 , the proximal segment 16 , the intermediate intervening segment 17 , the intermediate segment 18 , the distal intervening segment 19 , and the distal segment 20 .
- the presence or absence, size, and spacing of hardface pads on the proximal blades 63 may vary.
- the proximal blades 63 comprise proximal hardface pads 100 a , 100 b , and 100 c .
- the proximal blades 63 comprise proximal hardface pads 100 a , 100 b , and 100 c , having similar dimensions and similar spacing to the box hardface pads 31 a , 31 b , and 31 c.
- the proximal ends 62 a of the proximal blades 63 also are tapered inward at an angle relative to the longitudinal axis 29 - 29 to form the outer surface of the intermediate intervening segment 17 .
- the angle of tapering may vary.
- the proximal ends 62 a of the proximal blades 63 are tapered inward at an angle of from about 0° to about 90° relative to the longitudinal axis.
- the proximal ends 62 a of the proximal blades 63 are tapered inward at an angle of from about 0° to about 45° relative to the longitudinal axis.
- the proximal ends 62 a of the proximal blades 63 are tapered inward at an angle of from about 0° to about 20° relative to the longitudinal axis. In one embodiment, the proximal ends 62 a of the proximal blades 63 are tapered inward at an angle of about 12° relative to the longitudinal axis.
- the proximal blades 63 and the proximal substantially planar surfaces 62 , 64 spiral distally to become the intermediate intervening blades 63 a ( FIG. 1A ) and the intermediate intervening substantially planar surfaces 64 a ( FIG. 1A ).
- the intermediate intervening blades 63 a and the intermediate intervening substantially planar surfaces 64 a spiral distally to become the intermediate blades 71 and the intermediate substantially planar surfaces 68 , 70 .
- the presence or absence, size, and spacing of hardface pads on the intermediate blades 71 may vary.
- the intermediate blades 71 comprise intermediate hardface pads 102 a , 102 b , and 102 c .
- the intermediate blades 71 comprise intermediate hardface pads 102 a , 102 b , 102 c having similar dimensions and similar spacing to the proximal hardface pads 31 a , 31 b , and 31 c.
- the distal intermediate blades 71 and the intermediate substantially planar surfaces 68 , 70 spiral distally to become the corresponding distal intervening blades 71 a ( FIG. 1A ) and the distal intervening substantially planar surfaces 70 a ( FIG. 1A ).
- the distal intervening blades 71 a and the distal intervening substantially planar surfaces 70 a of the intervening distal segment 19 spiral distally to become the distal blades 73 and the distal substantially planar surfaces 72 of the distal segment 20 , illustrated in FIG. 5 .
- the presence or absence, size, and spacing of distal hardface pads 104 a , 104 b , 104 c on the distal blades 73 of the distal segment 20 may vary.
- the distal blades 73 comprise distal hardface pads 104 a , 104 b , and 104 c .
- the distal blades 73 comprise distal hardface pads 104 a , 104 b , 104 c having similar dimensions and similar spacing to the box hardface pads 31 a , 31 b , and 31 c.
- the distal ends 73 a of the distal blades 73 are tapered at an angle relative to the longitudinal axis 29 - 29 .
- the angle of tapering may vary. In one embodiment, the tapered angle varies from about 10 to 90°. In one embodiment, the tapered angle varies from about 1° to 89°. In one embodiment, the tapered angle varies from about 1° to 45°. In one embodiment, the tapered angle varies from about 1° to 20°. In one embodiment, the distal ends 73 a of the distal blades 73 are tapered at an angle of about 12° relative to the longitudinal axis 29 - 29 .
- the configuration of the outer surface of the collar 10 extending from the proximal end 101 of the most proximal hardface pad 100 a on the proximal segment 16 to the distal end 105 of the most distal hardface pad 104 c on the distal segment 20 is substantially uniform.
- FIG. 6 is a cross section through the distal extension 21 along line D-D of FIG. 5 .
- the distal extension 21 illustrated in FIGS. 1 , 5 , and 6 is cylindrical.
- the distal extension 21 may have a variety of configurations.
- the outer surface of the distal extension 21 may form a cylinder, a rectangle, a triangle, an oval, or another geometric configuration.
- the distal extension 21 is cylindrical.
- the distal extension 21 provides make-up and/or break-up space that may be used to apply torque to engage and/or disengage the ISBC.
- the distal end of the distal extension 21 comprises distal inner threads 77 .
- the distal inner threads 77 may be any suitable threads.
- the distal inner threads 77 are adapted to engage a threaded pin on a desired component.
- the desired component is a sting ISBC 10 ( FIG. 1B ), a roller reamer, or drill bit.
- the distal inner threads 77 are adapted to engage a threaded pin 15 on a sting ISBC 10 ( FIG. 1B ) or on a drill bit.
- the distal inner threads 77 are a 0.9 m (31 ⁇ 2 inch) I.F. Box with 0.9 m (31 ⁇ 2 inch) float bore.
- the external diameter 76 of the distal extension 21 may vary.
- the external diameter 76 of the distal extension 21 may be the same as or different that the external diameter of the proximal intervening segment 14 .
- the external diameter 76 of the distal extension 21 is substantially the same as the external diameter of the proximal intervening segment 14 . In one embodiment, the external diameter 76 of the distal extension 21 is about 12.7 cm (5 inches).
- the collar 10 may have a variety of lengths and dimensions.
- the total length of the collar 10 from the proximal end 47 of the box hardface pad 31 a ( FIG. 2 ) to the distal end 105 of the distal hardface pad 104 c may vary.
- the total length of the collar 10 on the same basis is about 9.45 meters (31 feet).
- the dimensions of the various segments of the collar 10 will vary with the length of the collar 10 .
- the segment length of the box 12 , the proximal segment 16 , the intermediate segment 18 , and the distal segment 20 is different.
- the segment length of the box 12 , the proximal segment 16 , the intermediate segment 18 , and the distal segment 20 is the same.
- each of the box 12 , the proximal segment 16 , the intermediate segment 18 , and the distal segment 20 have a segment length of about 0.79 meters (31 inches).
- the distance 13 ( FIG. 5 ) between the most proximal portion of the rounded end 30 a and the most distal portion of the tapered end 30 b of the box blade 30 also will vary with the total length of the collar 10 . In one embodiment, the distance 13 is about 0.85 meters (33.5 inches).
- the length 23 of the proximal intervening segment 14 ( FIG. 5 ), extending from the distal end 35 of the proximal hardface pad 31 c to the proximal end 101 of the proximal hardface pad 100 a , will vary depending upon the total length of the collar 10 . In one embodiment, the length 23 of the proximal intervening segment 14 ( FIG. 5 ) is approximately 0.4 meters (15.5 inches, or 15 17/32′′).
- the distance 23 a between the box tapered end 30 b and the proximal tapered end 62 a will vary with the total length of the collar 10 . In one embodiment, the distance 23 a is about 0.3 meter (12 inches).
- the intermediate intervening segment length 106 also will vary with the total length of the collar 10 . In one embodiment, the intermediate intervening segment length 106 is about 2.3 meters (90.97 inches, or 7 feet, 6 and 31/32 inches).
- the distal intervening segment length 108 will vary with the total length of the collar 10 .
- the distal intervening segment length 108 may be the same as or different than the intermediate intervening segment length 106 .
- the distal intervening segment length 108 is about 2.3 meters (90.97 inches, or 7 feet, 6 and 31/32 inches).
- the distal extension length 110 also will vary with the total length of the collar 10 . In one embodiment, the distal extension length 110 is about 1.3 meter (49.75 inches).
- the collar 10 may be formed in any suitable manner.
- the surface of a suitable cylindrical bar or tube is milled to form the various segments using procedures familiar to a person of ordinary skill in the art.
- the engagement mechanism at the distal end of the distal segment is engaged with a complimentary engagement mechanism on a desired component.
- the engagement mechanism at the distal end ( 77 ) is engaged with a complimentary engagement mechanism of another ISBC 10 .
- an engagement mechanism at the distal end ( 77 ) is engaged, for example, with a complimentary engagement mechanism on the drill pipe, on a non-magnetic drill collar (Monel), on a mud motor, or on a heavy weighted drill pipe.
- the distal inner threads 77 are engaged with a pin on a desired component. In one embodiment, the distal inner threads 77 are engaged with the pin 15 of a sting ISBC 10 ( FIG. 1B ).
- the proximal box threads 48 are engaged with the distal inner threads 77 of a sting ISBC 10 ( FIG. 1B ). In one embodiment, the proximal box threads 48 are engaged with a complimentary externally threaded pin on the BHA. In one embodiment, the proximal box threads 48 are engaged with a pin on the drill pipe, on a non-magnetic drill collar (Monel), on a mud motor, or on a heavy weighted drill pipe.
- Monel non-magnetic drill collar
- FIG. 7 is a graph of predictions and goals related to time required to drill to 13,500 feet through the Pinedale Anticline using a straight blade tricollar.
- the assumptions using the straight blade tricollar were (a) predicted progress under ideal conditions; (a) required progress to meet internal cost per foot target of $250/foot; and (b) required progress to remain within budget.
- FIG. 7 also graphs the depths actually achieved drilling through the formation using a ISBC.
- goals (a)-(c) were exceeded using the ISBC.
- 13,500 ft was reached two full days ahead of budget (b), and one full day ahead of the projected goal given ideal conditions (a).
Abstract
An integrated spiral blade collar comprising: a collar comprising a wall defining a bore, the collar having a longitudinal axis extending from a proximal end to a distal end; the collar comprising a first engagement mechanism at the proximal end and a second engagement mechanism at the distal end; the collar comprising one or more integral blades extending radially outward from an outer surface and forming a spiral around the longitudinal axis of the collar from at or near the proximal end to at or near the distal end of the collar, the spiral being at an angle of from 1° to 89° relative to the longitudinal axis of the collar.
Description
- The present application provides an integrated spiral blade collar.
- A drill string generally has a bit connected to its lower end that drills a borehole through an earth formation as the drill string and the bit are rotated. The drill string typically includes a length of relatively heavy drill collars at its lower end to provide weight on the bit.
- A drill collar generally is constructed to provide a predetermined radial spacing of the longitudinal axis of the drill string with respect to the borehole wall. Drill collars commonly have three or four “straight” blades that contact the formation. The straight blades generally run substantially parallel to the longitudinal axis along substantially the length of the drill collar.
- Unfortunately, the contact area between the formation and the “straight” blades of such drill collars is relatively small. The relatively small contact area tends to provide only limited stabilization of the bottom-hole assembly (BHA). The contact between the “straight” blades and the formation can increase torque during drilling operations. The straight blades also generally do not significantly promote the lifting of cuttings up the borehole.
- A need exists for collars with configurations that: (a) provide greater stabilization; (b) reduce torque; and, (c) promote the lifting of cuttings up the borehole.
- The present application provides an integrated spiral blade collar (“ISBC”).
- In one embodiment, the application provides an ISBC comprising: a collar comprising a wall defining a bore, the collar having a longitudinal axis extending from a proximal end to a distal end; the collar comprising a first engagement mechanism at the proximal end and a second engagement mechanism at the distal end; the collar comprising one or more integral blades extending radially outward from an outer surface and forming a spiral around the longitudinal axis of the collar from at or near the proximal end to at or near the distal end of the collar, the spiral being at an angle of from 1° to 89° relative to the longitudinal axis of the collar.
- In another embodiment, the application provides a method of increasing performance during drilling operations, the method comprising: mechanically engaging a bottom hole assembly (BHA) with a proximal end or a distal end of an ISBC comprising a wall defining a bore comprising a first engagement mechanism at a proximal end, a second engagement mechanism at a distal end, and a longitudinal axis extending therebetween, the ISBC comprising one or more integral blades extending from an outer surface of the ISBC and spiraling around the longitudinal axis from at or near the proximal end to at or near the distal end, the spiral being at an angle relative to the longitudinal axis; and, drilling through a formation to an improved final depth at which the ISBC must be replaced, the improved final depth being greater than the final depth to which a comparable straight blade collar or standard pack assembly drills through the same formation.
- In yet another embodiment, the application provides a method of increasing performance during drilling operations, the method comprising: mechanically engaging a bottom hole assembly (BHA) with a proximal end or a distal end of an ISBC comprising a wall defining a bore comprising a first engagement mechanism at a proximal end, a second engagement mechanism at a distal end, and a longitudinal axis extending therebetween, the ISBC comprising one or more integral blades extending from an outer surface of the ISBC and spiraling around the longitudinal axis from at or near the proximal end to at or near the distal end, the spiral being at an angle relative to the longitudinal axis; and, rotating the ISBC at a rotation rate, thereby producing an improved rate of penetration of 1.5 times or more greater than the rate of penetration achieved using a comparable straight blade collar or standard pack assembly drilling through the same formation.
-
FIG. 1A is a schematic isometric view of one embodiment of a near bit integrated spiral blade collar (“ISBC”). -
FIG. 1B is a schematic isometric view of a sting ISBC. -
FIG. 2 is an enlarged view of thebox 12 of the near bit ISBC ofFIG. 1 . -
FIG. 3 is a longitudinal sectional view at line C-C inFIG. 2 . -
FIG. 4A is a cross sectional view along line B-B ofFIG. 2 . -
FIG. 4B is a cross sectional view of an alternative embodiment along line B-B ofFIG. 2 . -
FIG. 4C is a cross sectional view of another alternative embodiment along line B-B ofFIG. 2 . -
FIG. 4D is a cross sectional view of another alternative embodiment along line B-B ofFIG. 2 . -
FIG. 5 is an enlarged, truncated view of the ISBC ofFIG. 1A . -
FIG. 6 is a longitudinal sectional view at line D-D along thedistal extension 21 inFIG. 5 . -
FIG. 7 is a graph of predictions and goals related to time required to drill to 13,500 feet through a formation using a straight blade tricollar vs. actual time required to drill using an integrated spiral blade collar. - The present application provides an integrated spiral blade collar (“ISBC”). The ISBC provides a number of advantages compared to straight blade collars. In one embodiment, the ISBC minimizes torque during drilling.
- In one embodiment, the ISBC lifts more cuttings up the borehole than a comparable straight blade collar. In one embodiment, the ISBC stabilizes the BHA due to increased contact between the blades and the formation. In one embodiment, the ISBC provides more effective weight on the bit. In one embodiment, the ISBC reduces stresses on the bit. In one embodiment, the ISBC enhances bit life. In one embodiment, the ISBC increases the rate of penetration (ROP) of the ISBC. In one embodiment, the ISBC reduces the mechanical specific energy.
- In one embodiment, the ISBC produces an improved rate of penetration through a given formation compared to the rate of penetration achieved using a comparable straight blade collar. During three runs, an ISBC having three blades (sometimes referred to as a tricollar ISBC) achieved 1.5 times the rate of penetration achieved using a straight blade collar having three blades.
- A standard pack assembly generally comprises one or more stablizers, one or more straight tricollars, and/or one or more roller reamers. The tricollar ISBC achieved 2 or more times the rate of penetration achieved using a standard pack assembly during the three runs.
- Hence, in one embodiment, the ISBC produces an improved rate of penetration of 1.5 times or more greater than the rate of penetration achieved using a comparable straight blade collar or standard pack assembly drilling through the same formation. In one embodiment, the ISBC produces an improved rate of penetration of 2 times or more greater than the rate of penetration achieved using a standard pack assembly drilling through the same formation.
- During the three runs, the straight blade tricollar and the standard pack assembly had to be replaced after drilling 2500 feet. In contrast, the ISBC did not have to be replaced until reaching 4000 feet.
- Hence, in one embodiment, the ISBC exhibits an extended life compared to a straight blade tricollar and/or standard pack assembly. In one embodiment, the ISBC drills to an improved final depth in a subterranean formation, at which point the ISBC must be replaced. In one embodiment, the improved final depth is greater than the final depth to which a comparable straight blade collar or standard pack assembly drills through the same formation. In one embodiment, the improved final depth is 2 or more times the final depth to which a standard pack assembly drills through the same formation.
- Rather than having one or more straight blades, the ISBC comprises one or more spiral blades. In one embodiment, the ISBC comprises a plurality of spiral blades separating a plurality of substantially planar surfaces. The one or more spiral blades spiral from at or near the proximal end of the collar to at or near the distal end of the collar.
- The number of blades may vary. In one embodiment, the ISBC comprises one blade. In one embodiment, the ISBC comprises a plurality of blades. In one embodiment, the ISBC comprises two blades. In one embodiment, the ISBC comprises three blades separating three substantially planar surfaces extending from at or near the proximal end of the collar to at or near the distal end of the collar.
- The number of blades, the length of the blades, and/or the rotation rate, may be increased, if desired, in order to increase the lifting of cuttings up the borehole. Without limiting the application to a particular theory of operation, the increase in lifting of cuttings is believed to result from Archimedes theory of suction. The lifting of cuttings up the borehole using the ISBC may be increased even further by substantially planar surfaces that are somewhat concave.
FIGS. 4B , 4C, and 4D are cross sections of ISBCs which have such concave surfaces. - ISBCs according to the present application will be better understood with reference to the Figures, which are illustrative only and should not be construed as limiting the claims.
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FIG. 1A illustrates an exemplary embodiment of a “near bit” ISBC. Referring toFIG. 1A , the near bit ISBC comprises acollar 10 having a longitudinal axis 29-29. The near bit ISBC comprises abox 12, aproximal intervening segment 14, aproximal segment 16, anintermediate intervening segment 17, anintermediate segment 18, adistal intervening segment 19, adistal segment 20, and adistal extension 21. Theproximal intervening segment 14 and theintermediate intervening segment 17 provide make-up and/or break-up space that may be used to apply torque to engage and/or disengage the ISBC. Thedistal extension 21 serves as a fishing neck for fishing the ISBC out of the borehole, if necessary. - In one embodiment, the
box 12 comprises an engagement mechanism at aproximal end 46. In one embodiment, the box comprises an engagement mechanism at adistal end 46 a adjacent to the proximal interveningsegment 14. - Suitable engagement mechanisms for the ISBC, generally, engage the ISBC to a separate desired component in a fixed rotational relationship. The fixed rotational relationship may be permanent or temporary. In one embodiment, the engagement mechanism permanently engages the ISBC in a fixed rotational relationship with a separate component. In one embodiment, the engagement mechanism releasably engages the ISBC in a temporary fixed rotational relationship with a separate desired component. Suitable engagement mechanisms include, for example, mating threads, hooks and eyes, a matching slot and die, a welded engagement, and a fused engagement. In one embodiment, the engagement mechanism is external threads on a pin that mate with internal threads on a box.
- In one embodiment, the
box 12 comprises proximal box threads 48 (FIG. 3 ) adapted to engage the external threads of a pin on a desired component. The BHA often comprises externally threaded pins. For this reason, the embodiment inFIG. 1A comprising thebox 12 is sometimes referred to as a “near bit” ISBC. - In one embodiment, the ISBC is a “sting” ISBC. A sting ISBC is depicted in
FIG. 1B . The “sting” ISBC ofFIG. 1B is substantially the same as the “near bit” ISBC ofFIG. 1A except that there is nobox 12. Instead, theproximal end 15 of the proximal interveningsegment 14 is apin 15 comprising exterior threads. In one embodiment, thepin 15 mates with abox 12, or with the distal inner threads 77 (FIG. 6 ) of anotherISBC 10. - An enlarged view of an exemplary embodiment of the
box 12 ofFIG. 1A is seen inFIG. 2 . Thebox 12 has the longitudinal axis 29-29. -
FIG. 3 is a cross section taken along thelongitudinal axis 29 at line C-C ofFIG. 2 . As seen fromFIG. 3 , in one embodiment, theproximal end 46 of thebox 12 comprisesproximal box threads 48. Theproximal box threads 48 may be any suitable threads adapted to engage external threads on a desired pin. In one embodiment, theproximal box threads 48 are adapted to engagepin 15 of anotherISBC 10. In one embodiment, theproximal box threads 48 are adapted to engage a pin in mechanical communication with the BHA. - In one embodiment, the
edge 49 at theproximal end 46 of thebox 12 is beveled at an angle. The angle relative to the longitudinal axis 29-29 may vary. In one embodiment, theedge 49 is beveled at an angle of from about 0° to 90°. In one embodiment, theedge 49 is beveled at an angle of from about 0° to 89°. In one embodiment, theedge 49 is beveled at an angle of from about 0° to 45°. In one embodiment, theedge 49 is beveled at an angle of about 45° relative to the longitudinal axis 29-29. Theinner diameter 51 at the proximal end of theproximal box threads 48 may vary. In one embodiment, the ISBC comprises abore 24. In one embodiment, theinner diameter 51 of theproximal box threads 48 is the same as theinner diameter 45 of the bore 24 (FIG. 4A ). - In one embodiment, the
bore 24 extends along the longitudinal axis along the length of thecollar 10. In this embodiment, complimentary engagement mechanisms are engaged in or with the bore. Theinner diameter 45 of thebore 24, extending from the proximal box threads 48 (FIG. 3 ) to the distal segment threaded section 77 (FIG. 6 ), may vary. In one embodiment, theinner diameter 45 of thebore 24 varies from about 5.7 cm (2.25 inches) to about 10.8 centimeters (4.25 inches). In one embodiment, the inner diameter of thebore 24 varies from about 5.7 cm (2.25 inches) to about 8.9 cm (3.5 inches). In one embodiment, the inner diameter of thebore 24 is about 5.7 cm (2.25 inches). In one embodiment, the inner diameter of theproximal box threads 48 also is 5.7 cm (2.25 inches). In one embodiment, the proximal box threads comprise an American Petroleum Institute (API) Reg Box with a 2F3R float bore. - In the frontal view of the box 12 (
FIG. 2 ), thebox blade 28 and thebox blade 30 abut opposed edges of a box substantiallyplanar surface 31. InFIG. 2 ,box blade 28 and thebox blade 30 have rounded proximal ends 28 a and 30 a. InFIG. 2 ,box blade 30 extends from the rounded boxproximal end 30 a to a tapered boxdistal end 30 b. -
FIGS. 4A-4D are cross sections taken at line B-B ofFIG. 2 showing alternative embodiments of thecollar 10. In one embodiment, a cross section taken at any location distal to the proximal end of the proximalbox hardface pad 100 a (FIG. 5 ) and extending to thedistal end 105 of thedistal hardface pad 104 c (FIG. 5 ) will have substantially the same outer surface configuration as that depicted inFIG. 4A-4D , depending upon the embodiment. - In the embodiment of
FIG. 4A , thewall 26 defines abore 24. Thebore 24 depicted inFIG. 4A is substantially cylindrical. However, thebore 24 may have other configurations. Suitable configurations for thebore 24 include, for example, rectangular, triangular, oval, or any other suitable configuration. In one embodiment, thebore 24 is cylindrical. - The
wall 26 may comprise any material having sufficient mechanical strength. Suitable materials include, for example, metal, metal alloys, or composites. In one embodiment, thewall 26 comprises iron or cast iron. In one embodiment, thewall 26 comprises stainless steel. In one embodiment, thewall 26 comprises tungsten carbide. - In the embodiment depicted in
FIG. 4A , thewall 26 has first, second, and third box substantiallyplanar surfaces FIG. 4A , lines 38 a, 38 b, and 38 c drawn along the box substantiallyplanar surfaces FIG. 4A-4D , thelines planar surfaces first box blade 40, asecond box blade 42, and athird box blade 44, respectively. - Unless specified to the contrary, a “substantially planar surface” is not a surface that necessarily is flat. For example, a substantially planar surface may be concave, convex, may have a “concave” or “convex” “V” structure, or may comprise notches, grooves, or other indentations or projections. As used herein, such configurations are substantially planar as long as lines drawn along their surfaces from a triangle, a rectangle, a pentangle, or similar closed geometric structure which corresponds to the number of blades on the ISBC.
- Exemplary alternative embodiments comprising concave surfaces are depicted in
FIGS. 4B-4D , in which like numbers indicate like parts. InFIGS. 4B-4D , thewall 26 has a first substantiallyconcave surface 32, a second substantiallyconcave surface 34, and a third substantiallyconcave surface 36, separated by afirst blade 40, asecond blade 42, and athird blade 44, respectively. - In
FIG. 4B , the blade edges 32 a, 32 b, 34 a, 34 b, 36 a, 36 b, are relatively sharp. In one embodiment, some of theedges - In one embodiment, one or more of the
blades blades - Suitable hardface pads comprise material that is harder than the material from which the
wall 26 is made. In one embodiment, the hardface pads comprise a material that is harder than stainless steel. In one embodiment, the substantially planar surfaces comprise a plurality of spaced hardface pads comprising cobalt, tungsten carbide fragments. Hardface pads comprising cobalt, tungsten carbide fragments are commercially available from a variety of sources. For example, suitable hardface pads are commercially available from Vital Metals Ltd. The size of the hardface pads may vary. Increasing the size and the exposed surface area of the hardface pads tends to increase torque during drilling. Decreasing the size and the exposed surface area of the hardface pads tends to decrease torque during drilling. The hardface pads may be affixed to the blades using any suitable method. In one embodiment, the surface of the ISBC to which a hardface pad is to be affixed is heat melted and the hardface pad is bonded to the heat-melted surface. - In
FIG. 4C , hardface pads cover substantially all of the cross-sectional surface of thefirst box blade 40, thesecond box blade 42, and thethird box blade 44, leaving slightly roundededges FIG. 4D , hardface pads cover much of the cross-sectional surface of thefirst blade 40, thesecond blade 42, and thethird blade 44, but an exposedarea 41 remains adjacent to each of therounded edges - A triangle is formed when
lines edges 32 a-32b abutting surface 32, theedges 34 a-34b abutting surface 34, and theedges 36 a-36b abutting surface 36. The number of blades may be more or less than three. Lines drawn along the substantially planar surfaces between the blades will form the closed geometric structure corresponding to the number of blades of the ISBC> - Referring back to
FIG. 2 , in one embodiment, thebox blades 28 and 30 (FIG. 3 ) comprise a plurality of box spaced hardface pads, designated inFIG. 2 as 31 a, 31 b, and 31 c. In one embodiment, thebox blades 28, 30 (FIG. 3A ) comprise threebox hardface pads - In one embodiment, the
blades blades - The length of the hardface pads may vary. The pad-to-pad distance between the distal end of one hardface pad and the proximal end of an adjacent hardface pad also may vary. In one embodiment, the length of the hardface pads and the pad-to-pad distance is determined by the size of commercially available hardface pads. In one embodiment, the
blades - The box length, which extends from the
proximal end 47 ofbox hardface pad 31 a to thedistal end 35 ofbox hardface pad 31 c, may vary. In one embodiment, the box length is about 78.7 cm (31 inches). - In one embodiment, the
blades segment 14. The tapered angle may vary. In one embodiment, the tapered angle varies from about 10 to 89°. In one embodiment, the tapered angle varies from about 10 to 45°. In one embodiment, the tapered angle varies from about 10 to 20°. In one embodiment, thedistal end 30 b is tapered inward at an angle of about 12° relative to the longitudinal axis 29-29. - The outer surface of the proximal intervening
segment 14 may have a variety of configurations. Examples of suitable configurations include cylindrical, rectangular, triangular, oval, or any other suitable configuration. In one embodiment, the outer surface of the proximal interveningsegment 14 is cylindrical. As previously explained, the proximal interveningsegment 14 provides make-up and/or break-up space that may be used to apply torque to engage and/or disengage the ISBC. - Referring again to
FIG. 1A , the number of times that a blade (e.g., blade 30) spirals around the longitudinal axis from a proximal end to a distal end of the ISBC depends on the angle X formed between the longitudinal axis 29-29 and a line drawn along the longitudinal axis of theblade 30. In one embodiment, X is from 1° to 89°. In one embodiment, X is from 10 to 45°. In one embodiment, X is 450. -
FIG. 5 is an enlarged, truncated view of thenear bit ISBC 10 ofFIG. 1 a comprising thebox 12, the proximal interveningsegment 14, theproximal segment 16, theintermediate intervening segment 17, theintermediate segment 18, thedistal intervening segment 19, and thedistal segment 20. - As with the
box 12, the presence or absence, size, and spacing of hardface pads on theproximal blades 63 may vary. In the embodiment ofFIG. 5 , theproximal blades 63 compriseproximal hardface pads proximal blades 63 compriseproximal hardface pads box hardface pads - In the embodiment of
FIG. 5 , the proximal ends 62 a of theproximal blades 63 also are tapered inward at an angle relative to the longitudinal axis 29-29 to form the outer surface of theintermediate intervening segment 17. The angle of tapering may vary. In one embodiment, the proximal ends 62 a of theproximal blades 63 are tapered inward at an angle of from about 0° to about 90° relative to the longitudinal axis. In one embodiment, the proximal ends 62 a of theproximal blades 63 are tapered inward at an angle of from about 0° to about 45° relative to the longitudinal axis. In one embodiment, the proximal ends 62 a of theproximal blades 63 are tapered inward at an angle of from about 0° to about 20° relative to the longitudinal axis. In one embodiment, the proximal ends 62 a of theproximal blades 63 are tapered inward at an angle of about 12° relative to the longitudinal axis. - In the embodiment depicted in
FIG. 5 , theproximal blades 63 and the proximal substantiallyplanar surfaces intermediate intervening blades 63 a (FIG. 1A ) and the intermediate intervening substantiallyplanar surfaces 64 a (FIG. 1A ). - The
intermediate intervening blades 63 a and the intermediate intervening substantiallyplanar surfaces 64 a (FIG. 1A ) spiral distally to become theintermediate blades 71 and the intermediate substantiallyplanar surfaces box 12, the presence or absence, size, and spacing of hardface pads on theintermediate blades 71 may vary. In the embodiment ofFIG. 5 , theintermediate blades 71 compriseintermediate hardface pads intermediate blades 71 compriseintermediate hardface pads proximal hardface pads - In the embodiment depicted in
FIG. 5 , the distalintermediate blades 71 and the intermediate substantiallyplanar surfaces distal intervening blades 71 a (FIG. 1A ) and the distal intervening substantiallyplanar surfaces 70 a (FIG. 1A ). - The
distal intervening blades 71 a and the distal intervening substantiallyplanar surfaces 70 a of the interveningdistal segment 19 spiral distally to become thedistal blades 73 and the distal substantiallyplanar surfaces 72 of thedistal segment 20, illustrated inFIG. 5 . - As with the
box 12, the presence or absence, size, and spacing ofdistal hardface pads distal blades 73 of thedistal segment 20 may vary. In the embodiment ofFIG. 5 , thedistal blades 73 comprisedistal hardface pads distal blades 73 comprisedistal hardface pads box hardface pads - In one embodiment, the distal ends 73 a of the
distal blades 73 are tapered at an angle relative to the longitudinal axis 29-29. The angle of tapering may vary. In one embodiment, the tapered angle varies from about 10 to 90°. In one embodiment, the tapered angle varies from about 1° to 89°. In one embodiment, the tapered angle varies from about 1° to 45°. In one embodiment, the tapered angle varies from about 1° to 20°. In one embodiment, the distal ends 73 a of thedistal blades 73 are tapered at an angle of about 12° relative to the longitudinal axis 29-29. - Because the
distal intervening section 19 is not tapered at either a proximal end or at a distal end, the configuration of the outer surface of thecollar 10 extending from theproximal end 101 of the mostproximal hardface pad 100 a on theproximal segment 16 to thedistal end 105 of the mostdistal hardface pad 104 c on thedistal segment 20 is substantially uniform. -
FIG. 6 is a cross section through thedistal extension 21 along line D-D ofFIG. 5 . Thedistal extension 21 illustrated inFIGS. 1 , 5, and 6 is cylindrical. However, thedistal extension 21 may have a variety of configurations. For example the outer surface of thedistal extension 21 may form a cylinder, a rectangle, a triangle, an oval, or another geometric configuration. In one embodiment, thedistal extension 21 is cylindrical. As explained previously, thedistal extension 21 provides make-up and/or break-up space that may be used to apply torque to engage and/or disengage the ISBC. - As seen from
FIG. 6 , the distal end of thedistal extension 21 comprises distalinner threads 77. The distalinner threads 77 may be any suitable threads. The distalinner threads 77 are adapted to engage a threaded pin on a desired component. In one embodiment, the desired component is a sting ISBC 10 (FIG. 1B ), a roller reamer, or drill bit. In one embodiment, the distalinner threads 77 are adapted to engage a threadedpin 15 on a sting ISBC 10 (FIG. 1B ) or on a drill bit. In one embodiment, the distalinner threads 77 are a 0.9 m (3½ inch) I.F. Box with 0.9 m (3½ inch) float bore. - The
external diameter 76 of thedistal extension 21 may vary. Theexternal diameter 76 of thedistal extension 21 may be the same as or different that the external diameter of the proximal interveningsegment 14. - In one embodiment, the
external diameter 76 of thedistal extension 21 is substantially the same as the external diameter of the proximal interveningsegment 14. In one embodiment, theexternal diameter 76 of thedistal extension 21 is about 12.7 cm (5 inches). - The
collar 10 may have a variety of lengths and dimensions. For example, the total length of thecollar 10 from theproximal end 47 of thebox hardface pad 31 a (FIG. 2 ) to thedistal end 105 of thedistal hardface pad 104 c may vary. In one embodiment, the total length of thecollar 10 on the same basis is about 9.45 meters (31 feet). - The dimensions of the various segments of the
collar 10 will vary with the length of thecollar 10. In one embodiment, the segment length of thebox 12, theproximal segment 16, theintermediate segment 18, and thedistal segment 20 is different. In one embodiment, the segment length of thebox 12, theproximal segment 16, theintermediate segment 18, and thedistal segment 20 is the same. In one embodiment, each of thebox 12, theproximal segment 16, theintermediate segment 18, and thedistal segment 20 have a segment length of about 0.79 meters (31 inches). - The distance 13 (
FIG. 5 ) between the most proximal portion of therounded end 30 a and the most distal portion of thetapered end 30 b of thebox blade 30 also will vary with the total length of thecollar 10. In one embodiment, thedistance 13 is about 0.85 meters (33.5 inches). - The
length 23 of the proximal intervening segment 14 (FIG. 5 ), extending from thedistal end 35 of theproximal hardface pad 31 c to theproximal end 101 of theproximal hardface pad 100 a, will vary depending upon the total length of thecollar 10. In one embodiment, thelength 23 of the proximal intervening segment 14 (FIG. 5 ) is approximately 0.4 meters (15.5 inches, or 15 17/32″). - The
distance 23 a between the box taperedend 30 b and the proximaltapered end 62 a will vary with the total length of thecollar 10. In one embodiment, thedistance 23 a is about 0.3 meter (12 inches). - The intermediate
intervening segment length 106 also will vary with the total length of thecollar 10. In one embodiment, the intermediateintervening segment length 106 is about 2.3 meters (90.97 inches, or 7 feet, 6 and 31/32 inches). - The distal
intervening segment length 108 will vary with the total length of thecollar 10. The distalintervening segment length 108 may be the same as or different than the intermediateintervening segment length 106. In one embodiment, the distalintervening segment length 108 is about 2.3 meters (90.97 inches, or 7 feet, 6 and 31/32 inches). - The
distal extension length 110 also will vary with the total length of thecollar 10. In one embodiment, thedistal extension length 110 is about 1.3 meter (49.75 inches). - The
collar 10 may be formed in any suitable manner. In one embodiment, the surface of a suitable cylindrical bar or tube is milled to form the various segments using procedures familiar to a person of ordinary skill in the art. - In operation and use, the engagement mechanism at the distal end of the distal segment is engaged with a complimentary engagement mechanism on a desired component. In one embodiment, the engagement mechanism at the distal end (77) is engaged with a complimentary engagement mechanism of another
ISBC 10. In one embodiment, an engagement mechanism at the distal end (77) is engaged, for example, with a complimentary engagement mechanism on the drill pipe, on a non-magnetic drill collar (Monel), on a mud motor, or on a heavy weighted drill pipe. - In one embodiment, the distal
inner threads 77 are engaged with a pin on a desired component. In one embodiment, the distalinner threads 77 are engaged with thepin 15 of a sting ISBC 10 (FIG. 1B ). - In one embodiment, the
proximal box threads 48 are engaged with the distalinner threads 77 of a sting ISBC 10 (FIG. 1B ). In one embodiment, theproximal box threads 48 are engaged with a complimentary externally threaded pin on the BHA. In one embodiment, theproximal box threads 48 are engaged with a pin on the drill pipe, on a non-magnetic drill collar (Monel), on a mud motor, or on a heavy weighted drill pipe. - The application will be better understood with reference to the following examples, which are illustrative only and not intended to limit the claims.
-
FIG. 7 is a graph of predictions and goals related to time required to drill to 13,500 feet through the Pinedale Anticline using a straight blade tricollar. The assumptions using the straight blade tricollar were (a) predicted progress under ideal conditions; (a) required progress to meet internal cost per foot target of $250/foot; and (b) required progress to remain within budget.FIG. 7 also graphs the depths actually achieved drilling through the formation using a ISBC. - As seen from
FIG. 7 , goals (a)-(c) were exceeded using the ISBC. Using the ISBC, 13,500 ft was reached two full days ahead of budget (b), and one full day ahead of the projected goal given ideal conditions (a). - Persons of ordinary skill in the art will recognize that many modifications may be made to the embodiments described herein. The embodiments described herein are meant to be illustrative only and should not be taken as limiting the invention, which will be defined in the claims.
Claims (21)
1. An integrated spiral blade collar comprising:
a collar comprising a wall defining a bore, the collar having a longitudinal axis extending from a proximal end to a distal end;
the collar comprising a first engagement mechanism at the proximal end and a second engagement mechanism at the distal end;
the collar comprising one or more integral blades extending radially outward from an outer surface and forming a spiral around the longitudinal axis of the collar from at or near the proximal end to at or near the distal end of the collar, the spiral being at an angle of from 1° to 89° relative to the longitudinal axis of the collar.
2. The integrated spiral blade collar of claim 1 wherein the angle is 45° relative to the longitudinal axis.
3. The integrated spiral blade collar of claim 1 wherein the collar comprises two or more integral blades extending radially outward from the outer surface separated by a plurality of substantially planar surfaces.
4. The integrated spiral blade collar of claim 2 wherein the collar comprises two or more integral blades extending radially outward from the outer surface separated by a plurality of substantially planar surfaces.
5. The integrated spiral blade collar of claim 1 wherein the collar comprises three or more integral blades extending radially outward from the outer surface separated by a plurality of substantially planar surfaces.
6. The integrated spiral blade collar of claim 1 wherein the collar comprises three or more integral blades extending radially outward from the outer surface separated by a plurality of substantially planar surfaces.
7. The integrated spiral blade collar of claim 1 the one or more integral blades comprise two or more spaced hardface pads comprising cobalt, tungsten carbide fragments.
8. The integrated spiral blade collar of claims 1 wherein the substantially planar surfaces comprise a concave surfaces extending between sharp blade edges.
9. The integrated spiral blade collar of claim 7 wherein the substantially planar surfaces comprise a concave surfaces extending between rounded blade edges.
10. The integrated spiral blade collar of claim 7 wherein the first and second engagement mechanisms comprise bores comprising internal threads.
11. The integrated spiral blade collar of claim 7 wherein the first engagement mechanism is a pin comprising external threads and the second engagement mechanism comprises a bore comprising internal threads.
12. The integrated spiral blade collar of claim 8 wherein the first and second engagement mechanisms comprise bores comprising internal threads.
13. The integrated spiral blade collar of claim 8 wherein the first engagement mechanism is a pin comprising external threads and the second engagement mechanism comprises a bore comprising internal threads.
14. The integrated spiral blade collar of claim 6 wherein:
the collar comprises a proximal intervening segment comprising a wall defining a bore extending therethrough, the proximal intervening segment comprising a proximal end comprising a proximal pin comprising proximal exterior threads and a distal end;
the bore extending through the distal end of the proximal intervening segment and through a proximal end of a proximal segment having the longitudinal axis and a distal end, the proximal segment comprising a plurality of proximal substantially planar surfaces separating a plurality of proximal blades comprising a plurality of proximal spaced hardface pads comprising cobalt, tungsten carbide fragments;
the bore extending through the distal end of the proximal segment and through a proximal end of an intermediate intervening segment having a distal end, the intermediate intervening segment comprising three intermediate intervening substantially planar surfaces separating three intermediate intervening blades;
the bore extending through the distal end of the intermediate intervening segment and through a proximal end of an intermediate segment having a distal end, the intermediate segment comprising three intermediate substantially planar surfaces separating three intermediate blades comprising a plurality of intermediate spaced hardface pads comprising cobalt, tungsten carbide fragments;
the bore extending through the distal end of the intermediate segment and through a proximal end of a distal intervening segment having a distal end, the distal intervening segment comprising a plurality of distal intervening blades separating a plurality of distal intervening substantially planar surfaces;
the bore extending through the distal end of the distal intervening segment and through a proximal end of a distal segment comprising a distal end, the distal segment comprising a plurality of distal substantially planar surfaces separating a plurality of distal blades comprising a plurality of distal spaced hardface pads comprising cobalt, tungsten carbide fragments; and,
the bore extending through a distal end of the distal segment and through a proximal end of a distal extension to distal interior threads.
15. The integrated spiral blade collar of claim 14 wherein the bore extends through a proximal end of the proximal intervening segment and through a distal end of a box engaged with the proximal end of the proximal intervening segment, the box having a proximal end comprising box proximal interior threads, the box comprising a plurality of box substantially planar surfaces separating a plurality of box blades comprising a plurality of box spaced hardface pads comprising cobalt, tungsten carbide fragments.
16. The integrated spiral blade collar of claim 15 wherein the proximal pin of the proximal intervening segment is threadingly engaged with box distal interior threads of a separate integrated spiral blade collar.
17. The integrated spiral blade collar of claim 15 wherein the wall of the proximal segment is continuous with the wall of the box.
18. A method of increasing performance during drilling operations, the method comprising:
mechanically engaging a bottom hole assembly (BHA) with a proximal end or a distal end of an integrated spiral blade collar comprising a wall defining a bore comprising a first engagement mechanism at a proximal end, a second engagement mechanism at a distal end, and a longitudinal axis extending therebetween, the integrated spiral blade collar comprising one or more integral blades extending from an outer surface of the integrated spiral blade collar and spiraling around the longitudinal axis from at or near the proximal end to at or near the distal end, the spiral being at an angle relative to the longitudinal axis; and,
drilling through a formation to an improved final depth at which the integrated spiral blade collar must be replaced, the improved final depth being greater than the final depth to which a comparable straight blade collar or standard pack assembly drills through the same formation.
19. The method of claim 18 wherein the improved final depth is two or more times the final depth to which a standard pack assembly drills through the same formation.
20. A method of increasing performance during drilling operations, the method comprising:
mechanically engaging a BHA with a proximal end or a distal end of an integrated spiral blade collar comprising a wall defining a bore comprising a first engagement mechanism at a proximal end, a second engagement mechanism at a distal end, and a longitudinal axis extending therebetween, the integrated spiral blade collar comprising one or more integral blades extending from an outer surface of the integrated spiral blade collar and spiraling around the longitudinal axis from at or near the proximal end to at or near the distal end, the spiral being at an angle relative to the longitudinal axis; and,
rotating the integrated spiral blade collar at a rotation rate, thereby producing an improved rate of penetration of 1.5 times or more greater than the rate of penetration achieved using a comparable straight blade collar or standard pack assembly drilling through the same formation.
21. The method of claim 20 wherein the improved rate of penetration is 2 times or more greater than the rate of penetration achieved using a standard pack assembly drilling through the same formation.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/134,646 US20090301785A1 (en) | 2008-06-06 | 2008-06-06 | Integrated Spiral Blade Collar |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/134,646 US20090301785A1 (en) | 2008-06-06 | 2008-06-06 | Integrated Spiral Blade Collar |
Publications (1)
Publication Number | Publication Date |
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US20090301785A1 true US20090301785A1 (en) | 2009-12-10 |
Family
ID=41399263
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/134,646 Abandoned US20090301785A1 (en) | 2008-06-06 | 2008-06-06 | Integrated Spiral Blade Collar |
Country Status (1)
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US (1) | US20090301785A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20220049558A1 (en) * | 2020-08-17 | 2022-02-17 | Saudi Arabian Oil Company | Reduced differential sticking drilling collar |
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US4630690A (en) * | 1985-07-12 | 1986-12-23 | Dailey Petroleum Services Corp. | Spiralling tapered slip-on drill string stabilizer |
US5363931A (en) * | 1993-07-07 | 1994-11-15 | Schlumberger Technology Corporation | Drilling stabilizer |
US5697460A (en) * | 1993-05-15 | 1997-12-16 | Stewart; Arthur Deacey | Drill pipe for directional drilling |
US20060207801A1 (en) * | 2005-03-16 | 2006-09-21 | Clayton Charley H | Technique for drilling straight bore holes in the earth |
US7316277B2 (en) * | 2004-03-27 | 2008-01-08 | Schlumberger Technology Corporation | Bottom hole assembly |
-
2008
- 2008-06-06 US US12/134,646 patent/US20090301785A1/en not_active Abandoned
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4630690A (en) * | 1985-07-12 | 1986-12-23 | Dailey Petroleum Services Corp. | Spiralling tapered slip-on drill string stabilizer |
US5697460A (en) * | 1993-05-15 | 1997-12-16 | Stewart; Arthur Deacey | Drill pipe for directional drilling |
US5363931A (en) * | 1993-07-07 | 1994-11-15 | Schlumberger Technology Corporation | Drilling stabilizer |
US7316277B2 (en) * | 2004-03-27 | 2008-01-08 | Schlumberger Technology Corporation | Bottom hole assembly |
US20060207801A1 (en) * | 2005-03-16 | 2006-09-21 | Clayton Charley H | Technique for drilling straight bore holes in the earth |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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US20220049558A1 (en) * | 2020-08-17 | 2022-02-17 | Saudi Arabian Oil Company | Reduced differential sticking drilling collar |
GB2599783A (en) * | 2020-08-17 | 2022-04-13 | Saudi Arabian Oil Co | Reduced differential sticking drilling collar |
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AS | Assignment |
Owner name: SHELL OIL COMPANY, TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:AREFI, BOB;REEL/FRAME:021796/0809 Effective date: 20080825 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |