U.S. patent application number 11/714653 was filed with the patent office on 2007-09-13 for system and method for reducing wear in drill pipe sections.
This patent application is currently assigned to ATT Technology Trust, Ltd. d/b/a Arnco Technology Trust, Ltd., ATT Technology Trust, Ltd. d/b/a Arnco Technology Trust, Ltd.. Invention is credited to John S. Arnoldy.
Application Number | 20070209839 11/714653 |
Document ID | / |
Family ID | 38477779 |
Filed Date | 2007-09-13 |
United States Patent
Application |
20070209839 |
Kind Code |
A1 |
Arnoldy; John S. |
September 13, 2007 |
System and method for reducing wear in drill pipe sections
Abstract
A system and method is provided for protecting the exterior
surface of drill pipe bodies from abrasion and wear during drilling
operations alternatively using a hardbanded pipe collar inserted
into a drill pipe body; a hardbanded pipe sleeve slid over a
section of the drill pipe body; or a hardbanded circumferential
built up section of the drill pipe body.
Inventors: |
Arnoldy; John S.; (Houston,
TX) |
Correspondence
Address: |
RICHARD D. FLADUNG;STRASBURGER & PRICE, LLP
1401 MCKINNEY, SUITE 2200
HOUSTON
TX
77010
US
|
Assignee: |
ATT Technology Trust, Ltd. d/b/a
Arnco Technology Trust, Ltd.
Houston
TX
|
Family ID: |
38477779 |
Appl. No.: |
11/714653 |
Filed: |
March 6, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60780118 |
Mar 8, 2006 |
|
|
|
Current U.S.
Class: |
175/57 ;
175/325.1 |
Current CPC
Class: |
E21B 17/1085
20130101 |
Class at
Publication: |
175/57 ;
175/325.1 |
International
Class: |
E21B 17/10 20060101
E21B017/10 |
Claims
1. A drill pipe, comprising: a first tool joint and a second tool
joint; a pipe body having an outer diameter; and a pipe collar
having an outer diameter greater than said pipe body outer diameter
and positioned between said first tool joint and said second tool
joint.
2. The drill pipe of claim 1, wherein said collar is spin welded at
its two ends to the pipe body.
3. The drill pipe of claim 1, wherein said collar is fabricated
from forged steel.
4. The drill pipe of claim 1, wherein a portion of said collar is
covered with a wear resistant alloy.
5. The drill pipe of claim 1, wherein said collar is substantially
in the center of the pipe body.
6. A drill pipe comprising: a first tool joint and a second tool
joint; a pipe body having an outer diameter; and a wear resistant
alloy built up on said pipe body outer surface said first tool
joint and said second tool joint so that the outer diameter of said
built up alloy is greater than said pipe body outer diameter.
7. The drill pipe of claim 6, wherein said alloy is built up
substantially in the center of the pipe body.
8. A drill pipe comprising: a first tool joint and a second tool
joint; a pipe body having an outer diameter; and a pipe sleeve
having an outer diameter greater than said pipe body outer diameter
and positioned between said first tool joint and said second tool
joint.
9. The drill pipe of claim 8, wherein said sleeve is fabricated
from forged steel.
10. The drill pipe of claim 8, wherein a portion of the outer
surface of said sleeve is covered with a wear resistant alloy.
11. The drill pipe of claim 8, wherein said sleeve is substantially
in the center of the pipe body.
12. The drill pipe of claim 8, wherein said sleeve is fixed to the
pipe body by welding.
13. A method of manufacturing a drill pipe comprising the steps of:
providing a first section of a drill pipe body and a second section
of a drill pipe body, each having an outer diameter; positioning a
pipe collar having an outer diameter greater than the outer
diameter of either of said drill pipe body sections and between
said drill pipe body sections; and fixing the pipe collar to said
drill pipe body sections.
14. The method of claim 13 wherein a portion of the outer surface
of said collar is covered with a wear resistant alloy.
15. A method of manufacturing a drill pipe comprising the steps of:
sliding a pipe sleeve over a drill pipe body; and fixing the pipe
sleeve with the drill pipe body.
16. The method of claim 15 wherein a portion of the outer surface
of said sleeve is covered with a wear resistant alloy.
17. The method of claim 15, further comprising the steps of:
cooling the drill pipe body before the step of sliding; heating a
pipe sleeve before the step of sliding; and sliding said heated
sleeve over said cooled body.
18. A method for drilling a wellbore having a first wellbore axis
and a second wellbore axis deviated from the first axis, comprising
the steps of: positioning a drill pipe section having an increased
diameter section between the ends of the drill pipe section with a
drill string; deviating the drill pipe section from the first
wellbore axis to the second wellbore axis; moving the drill pipe
section in the wellbore so that the increased diameter section of
the drill pipe section contacts the surface of the wellbore; and
reducing wear to said drill pipe section during the step of
moving.
19. The method of claim 18, wherein the step of reducing wear
comprises applying a wear resistant alloy to a portion of the
increased diameter section.
20. The method of claim 18, further comprising the step of:
reducing friction forces between the surface of the wellbore and
the increased diameter section.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/780,118 filed Mar. 8, 2006, of the same title,
which is incorporated herein by reference for all purposes in its
entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
REFERENCE TO MICROFICHE APPENDIX
[0003] N/A
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates to the field of oilfield drilling
equipment, and in particular to a system and method for the
protection of the exterior surface of tubulars, such as drill pipe,
from abrasion and wear during a drilling operation.
[0006] 2. Description of the Related Art
[0007] Drilling operations for oil, gas, and other natural
resources typically use a plurality of assembled drill sections
that vary in length from several hundred feet to several miles. A
drill string consists of a plurality of discrete drill pipe
sections that are threaded together as the drill sting is advanced
into the wellbore. Drill pipe section central bodies come in at
least three ranges of lengths: Range 1 varies from 18 to 22 feet
(5.5 to 6.7 m), Range 2 varies from 27 to 30 feet (8.2 to 9.1 m),
and Range 3 varies from 38 to 45 feet (11.6 to 13.7 m). Range 2 is
the most commonly used for a drill pipe section. Drill pipe section
body outside diameters typically range from approximately 3 V2
inches to approximately 63/4 inches but other diameters have been
used. The referenced pipe body lengths do not include the tool
joints, which make the drill pipe sections approximately one foot
(30 cm) longer.
[0008] Because most of the drill pipe body walls are not thick
enough to cut threads into, tool joints are spin welded to each end
of the pipe body. The tool joints are threaded so the drill pipe
sections can be made up or connected together to form the drill
string. Each drill pipe section has one male tool joint, referred
to as the pin end, and one female tool joint, referred to as the
box end. The outside diameter of the tool joint is typically
greater than the outside diameter of the pipe body. Before the tool
joints can be welded to the drill pipe body, upsets (an increase in
outside diameter) are created at both ends of the pipe body using
heat and force. The upset thickens the last 3 or 4 inches of the
pipe body walls. Most drill pipe sections are fabricated from
steel.
[0009] Drill collar sections are heavy walled pipe generally
installed on and below the drill string. Generally, drill collar
sections are heavier than a drill pipe body per linear distance,
and are used to put weight on the drill bit for drilling. Drilling
fluid or mud is pumped through the drill collar sections and the
drill pipe sections. Drill collar sections or joints are either 30
feet (9.1 m) or 31 feet (9.4 m) long. Unlike drill pipe sections,
the walls of drill collar sections are thick enough that it is not
necessary to add tool joints. Instead, threads can be cut directly
into each drill collar section. The drill collar sections can have
box and pin ends.
[0010] A wellbore is normally drilled vertically with a drill bit
positioned on the end of the drill string. There has been a long
history of wear problems with downhole drilling equipment because
approximately 95 percent of the earth's surface is composed of
siliceous materials. Siliceous earth particles are very abrasive,
with a hardness of about 800 Brinell hardness number (bhn), which
causes considerable wear on prone surfaces. Drilling operations are
usually periodically interrupted to place casing in the wellbore to
stabilize the walls. As a result, the drill string commonly
operates both in the open wellbore and in the casing.
[0011] In normal vertical drilling operations, the shoulders of the
tool joints undergo or experience considerable wear when the drill
string is rotated through underground formations. The shoulder of
the tool joint is that part of the tool joint where there is a
transition from the drill pipe body outside diameter to the tool
joint outside diameter. The tool joints typically come in contact
with the sides of the wellbore or casing because the tool joints
have the largest outside diameter of the drill string. The wear is
amplified when the drilling mud contains abrasive formation
particles being flushed out of the borehole. The wear resulting
from this amplified wear also usually occurs on the shouldered
areas of the tool joints.
[0012] There have been numerous attempts to hardband tool joints.
Hardfacing or hardbanding is the placement of a thickened band of
hardened wear resistant alloy, that is harder than siliceous earth
materials, over a surface subject to wear. Tool joints have
typically been hardbanded at the bottom (near the shoulder) of the
box end. Tungsten carbide has typically been used as the
hardbanding alloy. For a description of the prior art of
hardbanding tool joints, reference is made to U.S. Pat. Nos.
4,665,996; 4,256,518; and 3,067,593. The '996 patent proposes
placement of the alloy on the "principal bearing surface of the
drill pipe," which is defined in the specification as "that part of
the pipe having the largest diameter," which on a standard drill
pipe is "at the ends of the pipe joint." For a description of the
prior art of hardbanding alloys, such as tungsten carbide
particles, used on tool joints, reference is made to U.S. Pat. Nos.
4,942,059; 4,431,902; 4,277,108; 3,989,554; 2,262,211; and
2,259,232.
[0013] U.S. Pat. No. 5,224,559 proposes a hardfacing alloy and a
method for application to tool joints in which the alloy contains
primary carbides that have a hardness of about 1700 bhn. Hardfacing
materials that are harder than siliceous earth materials are
brittle and usually crack during application. Although the alloy
proposed in the '559 patent still cracks during application, it is
satisfactory for use on tool joints by providing longer wear life,
and reducing damage to casing. Prior to the '559 patent, no
hardfacing material that cracked during application was used. U.S.
Pat. No. 6,375,895 B1 proposes a hardfacing alloy suited for wear
prone surfaces of tool joints, drill collars, and stabilizers that
remains crack free while reducing casing wear.
[0014] More recently, directional drilling has evolved to provide
deviation of drilling from a vertical axis towards a horizontal
axis over large bending radiuses of curvature. Directional drilling
makes it possible to reach subsurface areas laterally remote from
the point where the bit enters the earth. The drill string can
follow an angled or curved path that deviates anywhere from a few
degrees off the vertical axis to a substantially horizontal axis.
In directional drilling, Range 3 bodies are sometimes used in drill
pipe sections, along with larger pipe body diameters that are still
less than the tool joint diameter. As a result of this relatively
larger diameter and longer drill pipe body, the tool joints do not
always protect the drill pipe body from contact with the open
wellbore and/or the casing. The consequence is exposure of the
drill pipe body to wear mechanisms that can affect its integrity to
a significant degree. Further, when individual drill pipe sections
within the drill string are caused to bend during directional
drilling, the middle portions of the drill pipe sections often come
in contact with the sides of the wellbore or the casing. It has
recently been found that in many types of directional drilling,
particularly where there is a substantial change in the direction
of the wellbore, the exterior body of the drill pipe sections
experience significant wear. Also, frictional and torsional forces
resisting the rotation of the drill string are increased, making
drilling more difficult and costly.
[0015] Pub. No. U.S. 2006/0102354 proposes a thermal spraying
process in combination with an iron based alloy to provide a
protective wear resistant layer on downhole drilling equipment.
[0016] The above discussed U.S. Pat. Nos. 2,259,232; 2,262,211;
3,067,593; 3,989,554; 4,256,518; 4,277,108; 4,431,902; 4,665,996;
4,942,059; 5,224,559; and 6,375,895 B1; and Pub. No. U.S.
2006/0102354 are incorporated herein by reference for all purposes
in their entirety. The '559 and '895 patents have been assigned to
the assignee of the present invention.
[0017] A need exists to protect drill pipe bodies, particularly in
directional drilling operations, where significant wear can
occur.
BRIEF SUMMARY OF THE INVENTION
[0018] A system and method for protecting the exterior surface of
drill pipe bodies is disclosed that alternatively uses a hardbanded
pipe collar that is inserted and welded into a drill pipe body; a
hardbanded pipe sleeve that is slid over a portion of the drill
pipe body; or a hardbanded circumferential section of the drill
pipe body. The present invention can be implemented in alternative
methods, which include cutting the pipe body and inserting and
fixing in place a hardbanded pipe collar; hardbanding a
circumferential section of the exterior surface of the pipe body;
sliding a hardbanded pipe sleeve over a section of the drill pipe
body and fixing it in place; and/or sliding a heated hardbanded
pipe sleeve over a cooled pipe body, and then allowing the
temperatures of each component to equalize.
[0019] The system and method could be implemented with typical
drill pipe sections using welding methods currently in use. The
system and method would minimize wear to the drill pipe bodies,
particularly when used in directional drilling. The system and
method would minimize torsional and frictional forces that resist
rotation of the drill pipe bodies, particularly when used in
directional drilling. The system and method would preferably use
known tool joint hardfacing alloys.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A better understanding of the present invention can be
obtained with the following detailed descriptions of the various
disclosed embodiments in the drawings:
[0021] FIG. 1 is a cut away side view of a drill pipe section with
the pipe body cut and a hardbanded pipe collar positioned for
welding thereon.
[0022] FIG. 2 is a cut away side view of a drill pipe section that
has been hardbanded circumferentially in a center of the drill pipe
body.
[0023] FIG. 3 is a cut away side view of a drill pipe section with
a hardbanded pipe sleeve that has been slid into place on the drill
pipe body and welded into position.
[0024] FIG. 4 is a side view of a drill pipe section and a cut away
side view of a hardbanded pipe sleeve.
[0025] FIG. 5 is an elevational view of the present invention used
in directional drilling.
[0026] FIG. 6 is an enlarged elevational view illustrating the
present invention used to reduce wear when in contact with the
wellbore surface.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Generally, the present invention involves a system and
method for the protection of the exterior surface of a drill pipe
body 2 from wear during drilling operations using a hardbanded pipe
collar 12, hardbanded pipe sleeves 16 or 16A, or a section of the
drill pipe body 2 that has been hardfaced 14. Turning to FIGS. 1-4,
the present invention can be implemented by alternative methods,
which include cutting the drill pipe body 2 to provide two end
locations (8, 10) and fixing a hardbanded pipe collar 12
therebetween using welding (FIG. 1); hardbanding 14 a
circumferential section of the exterior surface of the pipe body 2
(FIG. 2); sliding a hardbanded pipe sleeve 16 over a section of the
drill pipe body 2 and then fixing it in place using welding (FIG.
3); and/or sliding a heated hardbanded pipe sleeve 16A over a
cooled pipe body 2, and then allowing the temperatures of the
sleeve 16A and the body 2 to equalize (FIG. 4). The pipe collar 12,
pipe sleeves (16, 16A) and hardbanded 14 pipe body section are
preferably positioned substantially in the center of the drill pipe
body 2 where they can provide the most benefit in protection of the
drill pipe body 2 during directional drilling or other operations.
However, other placement locations anywhere between the tool joints
(4, 6) are contemplated. The location in the center of the drill
pipe body 2 also minimizes the frictional and torsional forces
resisting the rotation of the drill string. A hardened wear
resistant alloy 14 with a low coefficient of friction can be
selected if desired.
[0028] FIG. 1 illustrates the drill pipe body 2 cut in two
locations (8, 10) substantially near the center of its length,
creating three sections: two pipe body sections (3, 5) that are
attached to the tool joints (4, 6), and a center pipe body section
(not shown). The center pipe section is removed. A forged steel
pipe section 11, preferably having a length similar to the removed
center pipe section, is attached between the two pipe body sections
(3, 5) and their respective tool joints (4, 6). The pipe section 11
is preferably welded into place at locations (8, 10) using the same
spin weld procedure used to attach the tool joints (4, 6) onto the
ends of the drill pipe body 2. It is contemplated that other
materials besides forged steel can be used for the pipe section 11.
It is also contemplated that other attachment methods besides spin
welding can be used to attach the pipe section 11 to the pipe body
sections (3, 5). The forged steel pipe 11 is then welded or
hardbanded with a hardened wear resistant alloy 14, such as
described in the '559 and '895 patents. One such hardened wear
resistant alloy is 300XT, available from ATT Technology, Ltd. d/b/a
Arnco Technology Trust, Ltd. and/or Triten Alloy Products Group, a
subsidiary of the Triten Corporation, both of Houston, Tex.
Alternatively, the pipe section 11 can be hardbanded with a
hardened wear resistant alloy 14 before the pipe section 11 is
attached to the drill pipe body 2. It should be understood that a
collar 12 means both the pipe section 11 with no hardened wear
resistant alloy 14 welded to it, and also means the pipe section 11
with hardened wear resistant alloy 14 welded circumferentially on
all or a portion of the exterior surface of the pipe section
11.
[0029] The collar 12 could be approximately three feet (0.91 m) in
length, although other lengths are contemplated. Although the
collar 12 is preferably the same length as the aforementioned
center pipe section that was removed, it is also contemplated that
the collar 12 may be a different length than the center pipe
section that was removed. It is contemplated that the outside
diameter and wall thickness of the pipe section 11 before
hardbanding 14 will be substantially the same as pipe body sections
(3, 5). However, other pipe section 11 thicknesses and outside
diameters are contemplated, including thicknesses and outside
diameters that are greater and/or less that the respective
thicknesses and outside diameters of the pipe body sections (3, 5).
It is contemplated that the aforementioned hardbanding alloy 14 may
either completely or only partially circumferentially cover the
outer surface of the collar 12. It is also contemplated that the
hardbanding alloy 14 may be placed by welding on the shouldered
transitional area between the pipe body sections (3, 5) and the
collar 12.
[0030] FIG. 2 illustrates a hardened wear resistant alloy 14, such
as described in the '559 and '895 patents, circumferentially welded
on the exterior surface of a portion of the pipe body 2. The
hardbanding 14 is substantially in the center of the drill pipe
body 2. It is contemplated that the hardbanding 14 will be
approximately three feet (0.91 m) in length, although other lengths
are contemplated.
[0031] FIG. 3 illustrates a pipe section 15 hardbanded with a
hardened wear resistant alloy 14, such as described in the '559 and
'895 patents. The pipe section 15 can be made of forged steel,
although other materials are contemplated. The inside diameter of
the pipe section 15 is slightly greater than the outside diameter
of the drill pipe body 2 so that the pipe section 15 can then be
slid over the drill pipe body 2, and fixed in place substantially
in the center of the drill pipe body 2 length. If the pin end 6
outside diameter is greater than the inside diameter of the pipe
section 15, then the pipe section 15 can be slid into place before
the increased diameter pin end 6 is fixed to the pipe body 2.
Alternatively, the increased diameter pin end 6 can be removed
before the pipe section 15 is positioned on the body 2. The pipe
section 15 can be fixed in place by welding, although other methods
are contemplated. Alternatively, it is also contemplated that the
pipe section 15 can be hardbanded with the hardened wear resistant
alloy 14 after the pipe section 15 is positioned or fixed in place
on the pipe body 2. It should be understood that a sleeve 16 means
both the pipe section 15 with no hardened wear resistant alloy 14
welded to it, and also means the pipe section 15 with hardened wear
resistant alloy 14 welded circumferentially on all or a portion of
the exterior surface of the pipe section 15. It is contemplated
that the sleeve 16 will be approximately three feet (0.91 m) in
length, although other lengths are contemplated. It is contemplated
that the aforementioned hardbanding alloy 14 may either completely
or only partially circumferentially cover the outer surface of the
sleeve 16. It is also contemplated that the hardbanding alloy may
be placed by welding on the shouldered transitional area between
the pipe body 2 and the sleeve 16. It is also contemplated that the
sleeve could be fabricated completely from a hardbanding alloy,
i.e., without a separate pipe section.
[0032] FIG. 4 illustrates a pipe section 17 hardbanded with a
hardened wear resistant alloy 14, such as described in the '559 and
'895 patents. The pipe section 17 can be made of forged steel,
although other materials are contemplated. The pipe section 17 can
then be heated to expand its internal diameter. The drill pipe body
2 can be chilled to reduce its external diameter. The pipe section
17 can then be slid over the drill pipe body 2, and positioned at
substantially the center of the drill pipe body 2 length. The
temperatures of the pipe section 17 and the pipe body 2 can then be
allowed to equalize. The friction or interference fit between the
pipe section 17 and the pipe body 2 should secure the pipe section
17 in place to a predetermined force. Alternatively, the pipe
section 17 can be further fixed in place with welding.
Alternatively, the hardened wear resistant alloy 14 can be welded
to the pipe section 17 after the pipe section 17 is positioned on
the pipe body 2. Other methods are also contemplated. If the pin
end 6 outside diameter is greater than the inside diameter of the
pipe section 17, then the pipe section 17 can be slid into place
before the pin end 6 is fixed to the pipe body 2. Alternatively,
the increased diameter pin end 6 can be removed before the pipe
section 17 is placed. It should be understood that a sleeve 16A
means both the pipe section 17 with no hardened wear resistant
alloy 14 welded to it, and also means the pipe section 17 with
hardened wear resistant alloy 14 welded circumferentially on all or
a portion of the exterior surface of the pipe section 17. It is
also contemplated that the sleeve could be fabricated completely
from a hardbanding alloy, i.e., without a separate pipe
section.
[0033] It is contemplated that the sleeve 16A will be approximately
three feet (0.91 m) in length, although other lengths are
contemplated. It is contemplated that the aforementioned
hardbanding alloy 14 may either completely or only partially
circumferentially cover the outer surface of the sleeve 16A. It is
also contemplated that the hardbanding alloy 14 may be placed by
welding on the shouldered transitional area between the pipe body 2
and the sleeve 16A.
[0034] It should be understood that even though FIGS. 1-4 show
exemplary drill pipe sections, the present invention can also be
used with drill collars. It should also be understood that even
though FIGS. 1-4 show only one pipe collar 12, pipe sleeve (16,
16A), or hardbanded 14 section per drill pipe body, it is
contemplated that more than one could be used per drill pipe body
2. It is also contemplated that any one of the four could be used
in combination with any other of the four. Further, it should be
understood that the present invention can be used with new drill
pipe or be retrofitted to used drill pipe.
[0035] Method of Use
[0036] Protecting drill pipe section bodies 2 and reducing
frictional forces thereon during directional drilling uses the pipe
collar 12, pipe sleeve (16, 16A), or section of drill pipe body 2
that has been hardbanded 14 of the present invention. A wellbore W
created by directional drilling is shown in FIG. 5. In typical
directional drilling, the drill bit on the end of the drill string
DS initially enters the borehole B below the derrick D and proceeds
downward along a vertical axis, represented by A1. At some point
after entering the borehole B, the drill string DS deviates or
changes direction from the vertical wellbore axis A1 to at least
one other direction, represented by wellbore axis A2 in FIG. 5,
which other axis A2 intersects with the vertical axis A1 at one
point. It should be understood that the wellbore axis of the drill
string DS can change many times while drilling a well, as is shown
in FIG. 5. It should be understood that although FIG. 5 shows a
land drilling rig D, the present invention is equally applicable
for offshore drilling.
[0037] FIG. 6 shows one complete drill pipe section in the drill
string DS. The pipe sleeve 16 is in contact with the wellbore W
surface S during the directional drilling. While the drill string
DS is rotating, the pipe sleeve 16 protects the drill pipe body 2
from wear, and reduces frictional forces on the drill string DS.
Although a pipe sleeve 16 is shown in FIG. 6, it should be
understood that a pipe collar 12, pipe sleeve 16A, or section of
pipe body 2 that has been hardbanded 14 could be used either
alternatively or in combination. It should also be understood that
even thought FIGS. 5-6 show drilling in an open wellbore W, the
present invention is equally applicable for rotation of the drill
string DS inside a cased wellbore W.
[0038] The foregoing disclosure and description of the invention
are illustrative and explanatory thereof, and various changes in
the details of the illustrated apparatus and system, and the
construction and the method of operation may be made without
departing from the spirit of the invention.
* * * * *