U.S. patent application number 14/322420 was filed with the patent office on 2015-01-08 for high stiffness tool for expanding a wellbore.
The applicant listed for this patent is SMITH INTERNATIONAL, INC.. Invention is credited to Adam R. Aquino, Scott S. Dahlgren, David R. Hall, Jonathan D. Marshall.
Application Number | 20150008041 14/322420 |
Document ID | / |
Family ID | 52132046 |
Filed Date | 2015-01-08 |
United States Patent
Application |
20150008041 |
Kind Code |
A1 |
Hall; David R. ; et
al. |
January 8, 2015 |
High Stiffness Tool For Expanding A Wellbore
Abstract
A downhole tool may be used to enlarge and widen a wellbore. The
downhole tool may include a reamer with a mandrel that includes a
rib extending radially outward from a cylindrical body of the
mandrel. The rib may define one or more grooves. A cutter block or
other expandable member may be positioned adjacent the rib and may
include one or more extensions that mate with the grooves. The rib
and cutter block may be positioned within a slot of a housing. The
housing may also include one or more grooves on a surface along the
slot. The grooves along the slot and the grooves on rib may mate
with extensions on opposing sides of the expandable member to
define a path by which the expandable member moves between expanded
and retracted positions.
Inventors: |
Hall; David R.; (Provo,
UT) ; Marshall; Jonathan D.; (Springville, UT)
; Aquino; Adam R.; (Provo, UT) ; Dahlgren; Scott
S.; (Provo, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SMITH INTERNATIONAL, INC. |
Houston |
TX |
US |
|
|
Family ID: |
52132046 |
Appl. No.: |
14/322420 |
Filed: |
July 2, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61842034 |
Jul 2, 2013 |
|
|
|
61859665 |
Jul 29, 2013 |
|
|
|
Current U.S.
Class: |
175/57 ;
175/406 |
Current CPC
Class: |
E21B 10/322
20130101 |
Class at
Publication: |
175/57 ;
175/406 |
International
Class: |
E21B 10/32 20060101
E21B010/32; E21B 7/28 20060101 E21B007/28 |
Claims
1. A reamer for widening a wellbore, comprising: a housing defining
a plurality of slots; a plurality of expandable members positioned
within the plurality of slots; and a mandrel within the housing,
the mandrel including a plurality of ribs extending into the
plurality of slots.
2. The reamer of claim 1, the plurality of expandable members being
configured to expand and retract within the plurality of slots.
3. The reamer of claim 1, the plurality of expandable members each
including at least one extension configured to mate with a
corresponding groove on at least one of the housing or the
plurality of ribs.
4. The reamer of claim 3, the housing and the plurality of ribs
each including at least one groove configured to mate with
extensions of the plurality of expandable members.
5. The reamer of claim 4, the plurality of expandable members being
positioned to have a first side adjacent at least one groove of the
housing, and a second side adjacent at least one groove of the
plurality of ribs.
6. The reamer of claim 1, the housing including a plurality of
housings configured to move longitudinally relative to the
mandrel.
7. The reamer of claim 1, further comprising: at least one piston
configured to expand the plurality of expandable members.
8. The reamer of claim 1, further comprising: at least one biasing
member configured to return the plurality of expandable members
toward a retracted position.
9. A method for widening a wellbore, comprising: tripping a
downhole tool into a wellbore, the downhole tool including a reamer
having a mandrel coupled to at least one cutter block; providing
fluid to the downhole tool through the mandrel; using the fluid to
expand the at least one cutter block relative to the mandrel, and
along a path defined by a rib extending radially from the mandrel;
and rotating the downhole tool while the at least one cutter block
is expanded, and thereby widening the wellbore.
10. The method of claim 9, wherein using the fluid to expand the at
least one cutter block relative to the mandrel includes using a
piston to expand the at least one cutter block.
11. The method of claim 9, wherein the path is defined by one or
more mating grooves and extensions of the rib and the at least one
cutter block.
12. The method of claim 11, wherein the one or more mating grooves
and extensions are oriented at an angle relative to a longitudinal
axis of the mandrel.
13. The method of claim 9, wherein the reamer includes a housing
defining at least one slot, the at least one cutter block and the
rib being positioned in the at least one slot.
14. The method of claim 13, wherein the at least one cutter block
includes at least one extension on a first side of the at least one
cutter block and at least one extension on a second side of the at
least one cutter block, the first and second sides of the at least
one cutter block being opposing sides, and wherein the rib includes
at least one groove mating with the at least one extension on the
first side, and wherein the housing includes at least one groove
mating with the at least one extension on the second side.
15. The method of claim 9, wherein using the fluid to expand the at
least one cutter block includes expanding the at least one cutter
block radially and longitudinally relative to the mandrel.
16. The method of claim 15, wherein in an expanded position, the at
least one cutter block is engaged with the fin of the mandrel.
17. The method of claim 9, wherein using the fluid to expand the at
least one cutter block includes moving a housing of the reamer
axially to expand the at least one cutter block.
18. A reamer, comprising: a mandrel including a substantially
cylindrical body, a flow bore, and a rib extending radially from
the substantially cylindrical body; a housing defining a
substantially cylindrical shape with a slot, the rib of the mandrel
being positioned in the slot; an expandable member in the slot
between the rib and a side of the slot; a piston assembly in
communication with the flow bore of the mandrel and configured to
hydraulically actuate the expandable member from a retracted
position to an expanded position; and a biasing member coupled to
the housing and configured to mechanically drive the expandable
member from the expanded position toward the retracted
position.
19. The reamer of claim 18, the rib being integrally formed in the
mandrel.
20. The reamer of claim 18, the housing, rib, and expandable member
defining a plurality of mating grooves and extensions that define a
path that is angled relative to a longitudinal axis of the mandrel
and along which the expandable member moves between the retracted
and expanded positions.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of, and priority to,
U.S. Patent Application Ser. No. 61/842,034, filed on Jul. 2, 2013
and entitled "HIGH STIFFNESS REAMER WITH INDEPENDENTLY EXPANDING
CUTTING TOOLS" and to U.S. Patent Application Ser. No. 61/859,665,
filed on Jul. 29, 2013 and entitled "HIGH STIFFNESS REAMER WITH
EXTENDED DEGRADATION TOOLS". The foregoing applications are
expressly incorporated herein by this reference in their
entireties.
BACKGROUND
[0002] In the drilling of oil and gas wells, a drill bit is coupled
to a drill string and rotated. Fluid may flow through the drill
string and out nozzles in the drill bit. The fluid may cool the
drill bit, flush cuttings away from the face of the drill bit, and
carry the cuttings to the surface of the wellbore.
[0003] Drilling may be used to create a wellbore having a
particular diameter, but the diameter of a portion of the wellbore
may be enlarged for various reasons. For example, the diameter of
the wellbore may be enlarged to provide clearance for running
casing, to obtain adequate annular space in the hole for cementing,
to enlarge zones for gravel pack completion or cementing, and for
other purposes.
[0004] Reamers (also known as underreamers) are used for enlarging
the diameter of the wellbore. A reamer generally has two states,
namely an inactive or retracted state where the cutter blocks of
the reamer are in a radially inward, retracted position and the
reamer maintains a diameter small enough to pass through the
existing wellbore or casing strings, and an active, expanded, or
deployed state where cutter blocks are in an outward, radially
extended position. In the active state, the cutter blocks can be
used to enlarge the diameter of the wellbore.
SUMMARY
[0005] In accordance with an embodiment of the present disclosure,
a reamer for widening a wellbore may include a housing. The housing
may have various slots therein, and multiple expandable members may
be located within the slots. A mandrel inside the housing may
include ribs that also extend into the slots.
[0006] In accordance with another embodiment of the present
disclosure, a method for widening a wellbore may include tripping a
downhole tool into the wellbore. The downhole tool may include a
reamer with a mandrel coupled to a cutter block. Fluid may be
provided to the downhole tool through the mandrel, and the fluid
may be used to expand the cutter block. The cutter block may expand
relative to the mandrel along a path defined by a rib that extends
radially from the mandrel. The downhole tool may then be rotated
while the cutter block is expanded to widen the wellbore.
[0007] In another embodiment, a reamer is disclosed and includes a
mandrel including a cylindrical body, a flow bore, and a rib. The
rib may extend radially from the cylindrical body. A cylindrical
housing may include a slot and the rib of the mandrel may be
positioned in the slot. An expandable member in the slot and
between the rib and a side of the slot may be hydraulically
actuated by a piston assembly. The piston assembly may communicate
with the flow bore of the mandrel to obtain the hydraulic force to
move the expandable member to an expanded position. A biasing
member coupled to the cylindrical housing may mechanically drive
the expandable member to a retracted position.
[0008] This summary is provided to introduce a selection of
concepts that are further described below in the detailed
description. This summary is not intended to identify key or
essential features of the claimed subject matter, nor is it
intended to be used as an aid in limiting the scope of the claimed
subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic view of a drilling system according to
some embodiments of the present disclosure;
[0010] FIG. 2-1 is a perspective view of a reamer in an inactive or
collapsed state, according to some embodiments of the present
disclosure;
[0011] FIG. 2-2 is a perspective view of the reamer of FIG. 2-1,
with the reamer in an active or expanded state, according to some
embodiments of the present disclosure;
[0012] FIG. 3 is a perspective view of a mandrel for use with the
reamer of FIGS. 2-1 and 2-2, according to some embodiments of the
present disclosure;
[0013] FIG. 4 is a perspective view of another reamer for use with
a reamer, according to some embodiments of the present
disclosure;
[0014] FIG. 5 is a partial perspective, exploded view of a reamer
for expanding a diameter of a wellbore, according to some
embodiments of the present disclosure;
[0015] FIG. 6 is a partial cross-sectional view of the reamer of
FIG. 5, according to some embodiments of the present disclosure;
and
[0016] FIG. 7 is a partial perspective view of another reamer for
expanding a diameter of a wellbore, according to some embodiments
of the present disclosure.
DETAILED DESCRIPTION
[0017] In accordance with some aspects of the present disclosure,
embodiments herein relate to downhole tools. More particularly,
embodiments disclosed herein may relate to downhole tools and
bottomhole assemblies ("BHA") that include an underreamer, which
may also be referred to as a reamer. An example BHA may include a
reamer that may be used to expand a diameter of a wellbore along a
full or partial length of the wellbore. In still other aspects,
embodiments of the present disclosure may relate to high stiffness
reamers including a mandrel guiding cutter blocks or other
expandable members of the reamer as the expandable members move
between retracted and expanded positions.
[0018] Referring now to FIG. 1, a schematic diagram is provided of
an example downhole system 100 that may utilize wellbore
enlargement systems, assemblies, devices, and methods in accordance
with embodiments of the present disclosure. FIG. 1 shows an example
wellbore 101 formed in a formation 102. A portion of the wellbore
101 may be cased or, as shown in FIG. 1, the wellbore 101 may be
uncased or an openhole wellbore.
[0019] In the particular embodiment illustrated in FIG. 1, a BHA
103 may be provided to facilitate enlargement of the wellbore 101,
to cut into the formation 102, and the like. The BHA 103 may be
connected to a drill string 104. In FIG. 1, the drill string 104 is
illustrated as extending from the surface and having the BHA 103
suspended therefrom. The drill string 104 may be composed of one or
more tubular members. The tubular members of the drill string 104
may themselves have any number of configurations. As an example,
the drill string 104 may include segmented/jointed drill pipe, slim
drill pipe, wired drill pipe, coiled tubing, or the like.
[0020] The BHA 103 may include any number of components that may be
used to perform one or more downhole operations. As an example, the
BHA 103 may include a drill bit 105, one or more stabilizers 106, a
reamer 107, jars, drill collars, communication subs,
measurement-while-drilling (MWD) tools, logging-while-drilling
(LWD) tools, other components, or any combination of the foregoing.
In some embodiments, the stabilizers 106 may be used to maintain
the BHA 103 in a centered position within the wellbore 101. In at
least some embodiments, such centralization may reduce or minimize
vibrations within the BHA 103 and the drill string 104 during a
downhole operation, may center the drill bit 105, the reamer 107,
or other components during a wellbore enlargement or other downhole
operation, or provide other features.
[0021] The drill bit 105 may include a roller cone bit, a fixed
cutter bit, a percussion hammer bit, a diamond impregnated bit, or
some other drill bit configured for use in for drilling into the
formation 102 surrounding the wellbore 101 and extending the length
of the wellbore 101. In other embodiments, however, the drill bit
105 may have other structures or uses. For instance, the drill bit
105 may be a milling bit for downhole milling operations (e.g.,
grinding up plugs or downhole tools during a remedial operation).
In still other embodiments, the drill bit 105 may include another
reamer for expanding the diameter of the wellbore 101.
[0022] In the particular embodiment shown in FIG. 1, a reamer 107
may be provided. The reamer 107 may be used to expand a diameter of
a portion of the wellbore 101. In at least some embodiments, the
reamer 107 may include expandable members that may be used to
expand a diameter of the wellbore 101 beyond the diameter formed by
the drill bit 105. In at least some embodiments, the expandable
members of the reamer 107 may include cutter blocks that can be
selectively expanded and retracted. For instance, when the BHA 103
is tripped/inserted into the wellbore 101, the cutter blocks may be
in a retracted position and have a diameter that is about equal to,
or less than, a diameter of the wellbore 101. Upon reaching a
desired depth, formation structure, or the like, a signal may be
sent from the surface (e.g., through wireless, mud pulse, fluid
pressure, ball drop, string rotation, or other activation
techniques) to expand the cutter blocks so that they engage the
formation 102 around the wellbore 101. As the BHA 103 is rotated
and moved axially within the wellbore, the expandable members may
cut radially outward into the formation 102 and expand the diameter
of the wellbore 101 along an axial length of the wellbore 101.
[0023] The particular components included on the BHA 103 may be
varied in any number manners, and the BHA 103 may include
additional or other components 108 for use in any number of
manners. By way of example, other components of the BHA 103, or
which may be coupled to the BHA, may include one or more LWD tools,
one or more MWD tools, memory or data storage devices, motors
(e.g., mud motors, turbine motors, positive displacement motors,
etc.), rotary steerable and directional drilling equipment (e.g.,
point-the-bit components, push-the-bit components, pad-in-bit
components), casing-while-drilling or liner-while-drilling tools,
disconnect subs or equipment, circulation subs, communication
equipment (e.g., pulsers, a signal processor, acoustic processors,
wireless processors, signal boosters, fiber optic components, mud
pulse telemetry receivers/transmitters), cleaning nozzles, plugs,
anchors, packers, isolation/sealing devices, liner hangers, other
devices or tools, or some combination of the foregoing.
[0024] As shown in FIG. 1, a drilling rig 108 may be used to convey
the drill string 104 and BHA 103 into the wellbore 101. In an
example embodiment, the drilling rig 108 may include a derrick and
hoisting system 109, a rotating system, a mud circulation system,
or other components. The derrick and hoisting system 109 may
suspend the drill string 104, and the drill string 104 may pass
through a wellhead 110 and into the wellbore 101. In some
embodiments, the drilling rig 108 or the derrick and hoisting
system 109 may include a draw works, a fast line, a crown block,
drilling line, a traveling block and hook, a swivel, a deadline, or
other components. An example rotating system may be used, for
instance, to rotate the drill string 104 and thereby also rotate
one or more components of the BHA 103. Example rotating systems may
include a top drive, kelly, rotary table, or other components.
Although the downhole system 100 is shown in FIG. 1 as being on
land, those of skill in the art will recognize that embodiments of
the present disclosure are also equally applicable to offshore and
marine environments.
[0025] Turning now to FIGS. 2-1 and 2-2, partial perspective views
of a downhole tool are provided. In particular, FIG. 2-1
illustrates the downhole tool as a reamer 207 in a retracted,
inactive, or collapsed state while FIG. 2-2 illustrates the
downhole tool as a reamer 207 in an expanded or active state.
[0026] The reamer 207 may include any number of components or
features that allow it to be used in a downhole operation, such as
an operation to expand the diameter of a wellbore. For instance,
the reamer 207 may include a mandrel 211, a fluid inlet 212, a
fluid outlet 213, one or more pistons 214, one or more biasing
member 215, one or more expandable members 216, other components,
or any combination of the foregoing.
[0027] The reamer 207 may be designed to allow expansion of the one
or more expandable members 216 as a result of increased pressure
due to flow through the fluid inlet 212. Fluid entering the inlet
212 may flow through a bore in the mandrel 212 and out the fluid
outlet 213. The flow and increased pressure may occur when the
reamer 207 reaches a certain depth within a wellbore, and may act
on the one or more pistons 214 to drive the expandable members 216
radially outward and into engagement with the formation around the
wellbore. Rotation and axial movement of the reamer 207 may then
allow the wellbore to be widened.
[0028] The reamer 207 may further include a body or housing 217 in
which one or more slots 218 may be formed. The housing 217 may be
substantially cylindrical, hexagonal, octagonal, or have some other
regular or irregular geometric cross-sectional shape. The housing
217 may be formed of a single component, or multiple components may
collectively make up the housing 217.
[0029] The housing 217 may be hollow or tubular, and the slots 218
may, in some embodiments, extend through a thickness of a wall of
the housing 217. In some embodiments, the slots 218 may be aligned
with the expandable members 216. As a result, when the fluid flow
increases pressure in the mandrel 211 and the pistons 214, the
pistons 214 may move (e.g., in an uphole direction) and cause the
expandable members 216 to move radially outward through the slots
218. When the fluid pressure is reduced in the mandrel 211, the
pistons 214 may move in an opposite direction (e.g., in a downhole
direction) and allow the expandable members 216 to move radially
inward through the slots 218, and toward a compressed or inactive
position.
[0030] In some embodiments, the pistons 214 (or a single piston)
may be located around the mandrel 211 and proximate the fluid
outlet 213. The housing 217 may be located axially between the
pistons 214 and the one or more biasing members 215. As discussed
in greater detail with respect to FIG. 6, the biasing members 215
(or a single biasing member) may be positioned around the mandrel
and expansion of the expandable members 216 may overcome the bias
of the biasing members 215 (e.g., by compressing the springs or
other biasing members 215). As the fluid stops flowing, or as the
fluid flow decreases, the biasing members 215 may cause the
expandable members 216 to move toward the inactive or retracted
position. For instance, the biasing members 216 may cause the
expandable members 216 (or the housing 217) to move toward the
pistons 214, which may potentially also move the pistons 214.
[0031] As discussed herein, as fluid flows from the fluid inlet 212
and through the reamer 207 (e.g., toward or through the fluid
outlet 213), the expandable members 216 may be actuated from
collapsed, inactive, or retracted positions to expanded or active
positions. In some embodiments, the collapsed, inactive, or
retracted position of the expandable members 216 (or the collapsed,
inactive, or retracted state of the reamer 207) may be defined as
when the expandable members 216 are substantially positioned within
the housing 217. The reamer 207 may widen the wellbore by cutting,
shearing, impacting, or otherwise degrading formation material
adjacent the expandable members 216 when the reamer 207 is in the
expanded or active state. In some embodiments, the expandable
members 216 may move at equal rates or distances when expanded or
retracted. In other embodiments, however, the expandable members
216 may move at different rates or distances. For instance, each of
the pistons 214 or biasing members 215 may be differently
configured to operate at a different time or rate. When each
expandable member 216 is expanded, each expandable member 216 may
contribute to expanding and widening the wellbore.
[0032] In some embodiments, the housing 217 and/or the mandrel 211
may be used in expanding and/or retracting the expandable members
216. As seen in FIGS. 2-1 and 2-2, for instance, the housing 217
may include one or more grooves 219 that mate with one or more
ridges, splines, or other extensions 220 of the expandable members
216. In particular, the extensions 220 may be formed in opposing
lateral side surfaces of the expandable members 216, and
corresponding grooves 219 may be formed on the sides of the housing
217 on each side of the expandable members 216.
[0033] The grooves 219 and extensions 220 may, in some embodiments,
be formed at an angle relative to the longitudinal axis of the
reamer 207. For instance, the grooves 219 and extensions 220 may be
formed at an angle that is between 5.degree. and 90.degree. from
the longitudinal axis of the reamer 207. More particularly, the
angle may be within a range having lower and/or upper limits
including any of 5.degree., 10.degree., 15.degree., 17.degree.,
20.degree., 23.degree., 25.degree., 30.degree., 40.degree.,
50.degree., 60.degree., 75.degree., 80.degree., 85.degree.,
90.degree., and any values therebetween. For instance, the angle
may be less than 40.degree., greater than 15.degree., between
15.degree. and 30.degree., between 17.degree. and 23.degree.,
between 20.degree. and 60.degree., or between 75.degree. and
90.degree.. In one example, the angle may be 90.degree., which may
facilitate moving the expandable members 216 in a radial direction
that is perpendicular to the mandrel 211 and/or the longitudinal
axis of the reamer 207. In another example, such as where the angle
is less than 90.degree., the expandable members 216 may expand and
retract by moving both longitudinally and axially along a path that
is non-parallel and non-perpendicular relative to the mandrel 211,
the housing 217, or the longitudinal axis.
[0034] In the same or other embodiments, the mandrel 211 may also
include grooves 221 that mate with the extensions 220 of the
expandable members 216 (e.g., extensions 220 on an opposite side of
the expandable members 216 as compared to the extensions 220 that
mate with the grooves 219). In some embodiments, the grooves 221
may be angled relative to the longitudinal axis of the reamer 207.
For instance, the grooves 221 may be at a same or different angle
than the grooves 219. In some embodiments, the extensions 210 on
opposing sides of the expandable members 216 may be at the same
angle, while in other embodiments the extensions 220 on opposing
sides of the expandable members 216 may be oriented at different
angles.
[0035] As discussed in more detail herein, one or more ribs 222 may
be coupled to, or integrally formed with, the mandrel 211. The ribs
222 may include wings, extensions, appendages, or other features
that extend radially outward from a central body or tube of the
mandrel 211. The ribs 222 may align with the slots 218 and the
expandable members 216. For instance, each rib 222 may be located
along a side of one expandable member 216. The grooves 221 in the
rib 222 may mate with the extensions 220, so that as the expandable
members 216 expand or retract a corresponding one of the ribs 222
may engage the extensions 220 and guide the expandable members 216.
In other embodiments, the ribs 222 may be formed or positioned on
both sides of the expandable members 216. Further, while the
illustrated embodiment may include grooves 219, 221 on the housing
217 and ribs 222, respectively, in other embodiments, the grooves
219, 221 may be replaced with extensions and the extensions 220 on
the expandable members 216 may be replaced with grooves.
[0036] The ribs 222 may extend radially from a cylindrical or other
similarly shaped body of the mandrel 211, and may assist in holding
the expandable members 216 in an expanded position and/or in
guiding the expandable members 216 between expanded and retracted
positions. In some embodiments, moment forces on the expandable
members 216 may increase as the radial distance between the
expandable members 216 and a longitudinal axis of the reamer 207
increases. By fixing the ribs 222 to the mandrel 211, additional
support for the expandable members 216 may be provided at or
proximate the outer surface of the housing 207.
[0037] In particular, the ribs 222 may extend at least partially
through the slots 218 in some embodiments. For instance, the ribs
222 may extend radially outward from the body of the mandrel 211
and to a position that is radially adjacent the housing 217. In
some embodiments, the ribs 222 may extend radially outward to be
about aligned with the outer surface of the housing 217. As will be
appreciated by a person having ordinary skill in the art in view of
the present disclosure, when the ribs 222 have a radius that is
greater than a radius of the opening or bore within the housing
217, the housing 217 may not be able to slide over the mandrel 211
and the ribs 222. In such an embodiment, the housing 217 may be
formed of multiple segments that can be positioned around the
mandrel 211 and secured together using welding, clamps, clasps,
mechanical fasteners, or other connectors. In other embodiments,
the ribs 222 may not be integral with the mandrel 211, and the ribs
222 may be coupled to the mandrel 211 after the mandrel 211 is
installed within the housing 217. In some embodiments, the mandrel
211 may hold the fluid pressure within the reamer 207 and the
housing 217 may not be fluid-tight.
[0038] The reamer 207 may include any number of different
configurations for the mandrel 211, ribs 222, housing 217,
expandable members 216, and the like. For instance, the reamer 207
may include three (3) expandable members 216. As a result, there
may also be three (3) slots 218 in the housing 217, and three (3)
ribs 222. In other embodiments there may be six (6) ribs 222. The
number of expandable members 216 may, however, be varied, and in
other embodiments there may be one (1), two (2), four (4), five
(5), six (6), eight (8), ten (10), or more expandable members
216.
[0039] FIGS. 3 and 4 illustrate example mandrels 311, 411 in
additional detail. The mandrels 311, 411 may be used in a downhole
tool that includes expandable members. More particularly, the
mandrels 311, 411 may be used to provide additional structural
integrity or higher stiffness for expandable members such as cutter
blocks of a reamer.
[0040] More particularly, FIG. 3 is a perspective view of a mandrel
311 for use in a reamer or other downhole tool. The mandrel 311 may
include a body 323 and a plurality of ribs 322 extending radially
from the body 323. In some embodiments, the body 323 may be
substantially cylindrical, and the cross-sectional shape of the
body 323 may be substantially constant. In other embodiments,
however, the cross-sectional shape of the body 323 may vary. For
instance, FIG. 3 illustrates a body 323 that changes in size. More
particularly, the distal end portions may have a larger
cross-sectional size relative to an intermediate portion 324. In at
least the illustrated embodiment, the ribs 322 may extend radially
outward from the intermediate portion 324. Grooves 321 in the ribs
322 may extend along a full radial length of the ribs 322. As a
result, cutter blocks or other expandable members that retract into
a reamer or other downhole tool may retract to a position that is
proximate the reduced diameter of the intermediate portion 324. By
retracting further into the downhole tool, corresponding cutter
blocks or other expandable members may have an increased size
allowing for a larger range of expansion and a greater ratio
between the expanded radius and the retracted radius of the
downhole tool. For instance, in some embodiments, the ratio of a
downhole tool in expanded state relative to the retracted state may
be between 1.15:1 and 1.75:1. In other embodiments, the ratio may
be less than 1.15:1 or greater than 1.75:1. When the mandrel 311
thus includes a plurality of ribs 322 that extend radially outward
from the body 323 and radially into the body 323 of the mandrel
311, a corresponding reamer may expand a wellbore to a larger
diameter due to an increased range of motion that the cutter blocks
or other expandable members can move through.
[0041] In FIG. 3, the mandrel 311 may include three (3) ribs 322
extending radially outward from the body 322. The three (3) ribs
322 may be spaced circumferentially around the mandrel 311 at
120.degree. increments, such that there may be substantially equal
spacing between the three ribs 322. In other embodiments, however,
a mandrel may include or otherwise be coupled to more or fewer than
three (3) ribs. FIG. 4, for instance, is a perspective view of a
mandrel 411 for a reamer or other downhole tool, in which a body
423 is coupled to two (2) ribs 422. The two (2) ribs 422 may be
circumferentially offset around the mandrel at 180.degree.
increments relative to a longitudinal axis of the mandrel 411. With
the mandrel 411 including two (2) ribs 422, a corresponding reamer
may be able to expand a wellbore to a larger diameter than may be
possible for a similarly sized configuration that includes a larger
number of ribs on the mandrel. When the reamer is in a retracted
state, a larger number of ribs 422 may be limited in the positions
they could occupy in or along the body 423 of the mandrel 411 due
to interference between one another. This could limit the size of a
reamer that could fit inside a finite space defined by the diameter
of a wellbore, or the size of an expandable member or cutter block
that could fit inside a finite space defined by a housing of a
reamer.
[0042] FIG. 5 is a partial perspective view of a reamer 507
according to still another embodiment of the present disclosure.
The reamer 507 may include a plurality of expandable members 516, a
plurality of housings 517, and a mandrel 511. The mandrel 511 may
include, or be coupled to, a plurality of ribs 522 cooperating with
corresponding slots 518 in a corresponding one of the plurality of
housings 517. A cutter block or other expandable member 516 and a
rib 522 may be positioned in each corresponding slot 518.
[0043] The expandable members 516 may include extensions 520 on one
or both sides thereof. One side of the expandable members 516 (and
thus the extensions 520 on that side) may be adjacent the housing
517, while the other side of the expandable members (and thus the
extensions 520 on that side) may be adjacent a corresponding rib
522. The housing 517 may include grooves 519 on a side adjacent the
slot 518 and a corresponding expandable member 516. The grooves 519
may mate with the extensions 520 on the expandable member 516. The
rib 522 may include one or more grooves 521 on a side adjacent the
corresponding expandable member 516 such that the extensions 520 on
the expandable member 516 can slide along the grooves 521 in the
rib 522.
[0044] Each expandable member 516 may be positioned between a
corresponding rib 522 and a housing 517. In other words, the
grooves 521 on the rib 522 and the slot 518 may function as tracks
on which the extensions 520 on the expandable member 516 may slide
when actuated. The orientation of the expandable member 516 with
respect to a mating rib 522 and mating housing 517 may allow the
expandable member 516 to be in contact with both the housing 517
and the rib 522, thereby distributing the stress associated with
the reaming or other downhole operation over the length of the
expandable member 516, and along the mandrel 511 and the housing
517. Each of the plurality of expandable members 516 may be
similarly oriented.
[0045] FIG. 6 is a partial cross-sectional view of a reamer 607 in
accordance with another embodiment of the present disclosure. The
reamer 607 may include a mandrel 611, a fluid inlet 612, and a
fluid outlet 613. The mandrel 611 may define a flow bore 624 having
a substantially cylindrical shape, and which optionally extends
between the fluid inlet 612 and the fluid outlet 613. A fluid may
pass through the flow bore 624. The mandrel 611 may further include
a plurality of ribs 622 that extend radially outward from a
longitudinal axis of the mandrel 611.
[0046] In some embodiments, the reamer 607 may further include a
plurality of piston assemblies 614 and at least one biasing member
615 (e.g., a compression spring). The reamer 607 may also include a
plurality of housings 617, each of which may include or define at
least one slot 618. The plurality of piston assemblies 614 may be
located radially around the mandrel 611 and/or proximate the fluid
outlet 613. The plurality of housings 617 and/or the at least one
biasing member 615 may also be located radially around the mandrel
611 (e.g., a reduced cross-sectional area portion or body of the
mandrel 611). The plurality of housings 617 may be located
longitudinally between the least one biasing member 615 and the
plurality of piston assemblies 614. In some embodiments, the
plurality of piston assemblies 614 may be coupled to the plurality
of housings 617 by a plurality of connectors 625.
[0047] In at least some embodiments, the plurality of piston
assemblies 614 may be in fluid communication with the flow bore
624. For instance, a plurality of fluid channels 626 that extend
radially between the flow bore 624 and the plurality of piston
assemblies 614 may fluidly couple the plurality of piston
assemblies 614 to the flow bore 624. As a result, when a fluid
flows from the fluid inlet 612 toward the fluid outlet 613, some of
the fluid may enter the plurality of fluid channels 626. This flow
of fluid in the fluid channels 626 may actuate the plurality of
piston assemblies 614. Due to the connector 625 connecting the
plurality of piston assemblies 614 to the plurality of housings
617, the plurality of housings 617 may then move. When the
plurality of housings 617 moves axially (e.g., in an uphole
direction toward the fluid inlet 612 and the at least one biasing
member 615) with respect to the mandrel 611, the expandable members
616 may be forced to move to an expanded position. As the plurality
of housings 617 are actuated toward the at least one biasing member
615, the at least one biasing member 615 may be compressed.
[0048] As the fluid stops or slows through the flow bore 624 and
the plurality of fluid channels 626, the at least one biasing
member 615 may actuate the plurality of housings 617 and move the
plurality of housings 617 toward the plurality of piston assemblies
614 (e.g., in a downhole direction). When the plurality of housings
617 are actuated toward the plurality of piston assemblies 614, the
expandable members 616 may be de-actuated to a collapsed position.
Thus, in the embodiment shown in FIG. 6, the reamer 607 may be
actuated and de-actuated by moving the plurality of housings 617
relative to the mandrel 611. In other embodiments, however, the
reamer 607 may activated and de-actuated by moving the expandable
members 616 relative to the mandrel 611 and while the plurality of
housings 617 remain stationary relative to the mandrel 611.
[0049] FIG. 7 is a perspective view of a reamer 707 according to
still other embodiments of the present disclosure. The reamer 707
may include a mandrel 711, a plurality of housings 717, a plurality
of expandable members 716, and a plurality of piston assemblies
within a piston section 714. The mandrel 711 may include a
substantially cylindrical shaped body, and a plurality of ribs 722
that extend radially outward therefrom. Together, the plurality of
housings 717 may form a substantially cylindrical shape around a
portion of the mandrel 711. In some embodiments, one of the
plurality of housings 717 may include or define a slot 718 in which
a rib 722 and an expandable member 716 are located. The expandable
member 716 may be positioned between a side of the rib 722 and a
side of the slot 718. A particular piston assembly (see FIG. 6) of
the piston section 714 may correspond to each expandable member 716
or housing 717. For instance, one of the plurality of housings 717
may be coupled to a corresponding piston assembly using a connector
(e.g., connector 625 of FIG. 6). Such a connector may allow for
axial movement of a housing 717 but restrict rotational or radial
movement of individual housings of the plurality of housings 717.
Connectors may also couple different housings 717 together, in
addition to coupling corresponding piston assemblies together. In
some embodiments, the connector also may ensure that one piston
assembly is aligned with a corresponding housing 617, as well as
ensure that another piston assembly is aligned with its
corresponding housing 617. This may allow each expansion region 727
of the reamer 707 to move independently of one another in an axial
direction. An expansion region may be defined as an expandable
member 716 along with a corresponding one of the housings 717 and
piston assemblies 714.
[0050] The plurality of housings 717 may be coupled together in any
number of manners. For instance, mechanical fasteners,
slot-and-tab, and other connectors may be used. By way of
illustration, in some embodiments, each of the plurality of
housings 717 may include a side with a slot that runs parallel to
the longitudinal axis of the mandrel 711, and a side with a tab or
ridge, such that a ridge on one of the plurality of housings 717
may fit into a slot on an adjacent one of the plurality of housings
717. Each of the plurality of housings 717 may be similarly
fastened to their respective adjacent housings 717. Each of the
plurality of piston assemblies of the piston section 714 may be
similarly fastened to their respective adjacent piston
assemblies.
[0051] Using slots and ridges to join adjacent components may allow
components to move in an axial direction, as may be allowed by
using the connectors, while potentially restricting or preventing
relative rotational or radial movement between adjoining
components. In some embodiments, for instance, one piston assembly
may exert an axial force on a corresponding housing, which may
actuate an expandable member to an expanded or active position.
Though each additional expandable member may be likewise actuated
to an expanded or active position, each of the expandable members
may be in slightly different spatial orientations due to
inconsistencies in geometry resulting from wear or manufacturing
error.
[0052] In the description herein, various relational terms are
provided to facilitate an understanding of various aspects of some
embodiments of the present disclosure. Relational terms such as
"bottom," "below," "top," "above," "back," "front," "left",
"right", "rear", "forward", "up", "down", "horizontal", "vertical",
"clockwise", "counterclockwise," "upper", "lower", and the like,
may be used to describe various components, including their
operation and/or illustrated position relative to one or more other
components. Relational terms do not indicate a particular
orientation for each embodiment within the scope of the description
or claims. For example, a component of a bottomhole assembly that
is described as "below" another component may be further from the
surface while within a vertical wellbore, but may have a different
orientation during assembly, when removed from the wellbore, or in
a deviated borehole. Accordingly, relational descriptions are
intended solely for convenience in facilitating reference to
various components, but such relational aspects may be reversed,
flipped, rotated, moved in space, placed in a diagonal orientation
or position, placed horizontally or vertically, or similarly
modified. Certain descriptions or designations of components as
"first," "second," "third," and the like may also be used to
differentiate between similar components. Such language is not
intended to limit a component to a singular designation. As such, a
component referenced in the specification as the "first" component
may be the same or different than a component that is referenced in
the claims as a "first" component.
[0053] Furthermore, while the description or claims may refer to
"an additional" or "other" element, feature, aspect, component, or
the like, it does not preclude there being a single element, or
more than one, of the additional element. Where the claims or
description refer to "a" or "an" element, such reference is not be
construed that there is just one of that element, but is instead to
be inclusive of other components and understood as "at least one"
of the element. It is to be understood that where the specification
states that a component, feature, structure, function, or
characteristic "may," "might," "can," or "could" be included, that
particular component, feature, structure, or characteristic is
provided in some embodiments, but is optional for other embodiments
of the present disclosure. The terms "couple," "coupled,"
"connect," "connection," "connected," "in connection with," and
"connecting" refer to "in direct connection with," or "in
connection with via one or more intermediate elements or members."
Components that are "integral" or "integrally" formed include
components made from the same piece of material, or sets of
materials, such as by being commonly molded or cast from the same
material, or commonly machined from the same piece of material
stock. Components that are "integral" should also be understood to
be "coupled" together.
[0054] Although various example embodiments have been described in
detail herein, those skilled in the art will readily appreciate in
view of the present disclosure that many modifications are possible
in the example embodiments without materially departing from the
present disclosure. Accordingly, any such modifications are
intended to be included in the scope of this disclosure. Likewise,
while the disclosure herein contains many specifics, these
specifics should not be construed as limiting the scope of the
disclosure or of any of the appended claims, but merely as
providing information pertinent to one or more specific embodiments
that may fall within the scope of the disclosure and the appended
claims. Any described features from the various embodiments
disclosed may be employed in combination.
[0055] A person having ordinary skill in the art should realize in
view of the present disclosure that equivalent constructions do not
depart from the spirit and scope of the present disclosure, and
that various changes, substitutions, and alterations may be made to
embodiments disclosed herein without departing from the spirit and
scope of the present disclosure. Equivalent constructions,
including functional "means-plus-function" clauses are intended to
cover the structures described herein as performing the recited
function, including both structural equivalents that operate in the
same manner, and equivalent structures that provide the same
function. It is the express intention of the applicant not to
invoke means-plus-function or other functional claiming for any
claim except for those in which the words `means for` appear
together with an associated function. Each addition, deletion, and
modification to the embodiments that falls within the meaning and
scope of the claims is to be embraced by the claims.
[0056] While embodiments disclosed herein may be used in oil, gas,
or other hydrocarbon exploration or production environments, such
environments are merely illustrative. Systems, tools, assemblies,
reamers, wellbore expansion systems, methods, and other components
of the present disclosure, or which would be appreciated in view of
the disclosure herein, may be used in other applications and
environments. In other embodiments, cutting inserts, cutting tools,
milling tools, methods of milling, methods of cutting, methods of
initiating a cutout, or other embodiments discussed herein, or
which would be appreciated in view of the disclosure herein, may be
used outside of a downhole environment, including in connection
with other systems, including within automotive, aquatic,
aerospace, hydroelectric, manufacturing, other industries, or even
in other downhole environments. The terms "well," "wellbore,"
"borehole," and the like are therefore also not intended to limit
embodiments of the present disclosure to a particular industry. A
wellbore or borehole may, for instance, be used for oil and gas
production and exploration, water production and exploration,
mining, utility line placement, or myriad other applications.
[0057] Certain embodiments and features may have been described
using a set of numerical values that may provide lower and upper
limits. It should be appreciated that ranges including the
combination of any two values are contemplated unless otherwise
indicated, and that a particular value may be defined by a range
having the same lower and upper limit. Any numerical value is
"about" or "approximately" the indicated value, and takes into
account experimental error and variations that would be expected by
a person having ordinary skill in the art. Any numbers,
percentages, ratios, measurements, or other values stated herein
are therefore intended to include the stated value as well as other
values that are about or approximately the stated value, as would
be appreciated by one of ordinary skill in the art encompassed by
embodiments of the present disclosure. A stated value should
therefore be interpreted broadly enough to encompass values that
are at least close enough to the stated value to perform a desired
function or achieve a desired result. The stated values include at
least experimental error and variations that would be expected by a
person having ordinary skill in the art, as well as the variation
to be expected in a suitable manufacturing or production process. A
value that is about or approximately the stated value and is
therefore encompassed by the stated value may further include
values that are within 5%, within 1%, within 0.1%, or within 0.01%
of a stated value.
[0058] The abstract included with this disclosure is provided to
allow the reader to quickly ascertain the general nature of some
embodiments of the present disclosure. It is submitted with the
understanding that it will not be used to interpret or limit the
scope or meaning of the claims.
* * * * *