U.S. patent application number 14/952080 was filed with the patent office on 2016-06-23 for extended or raised nozzle for pdc bits.
The applicant listed for this patent is SMITH INTERNATIONAL, INC.. Invention is credited to James Layne Larsen, James C. Minikus, Philip G. Trunk.
Application Number | 20160177630 14/952080 |
Document ID | / |
Family ID | 56128821 |
Filed Date | 2016-06-23 |
United States Patent
Application |
20160177630 |
Kind Code |
A1 |
Trunk; Philip G. ; et
al. |
June 23, 2016 |
EXTENDED OR RAISED NOZZLE FOR PDC BITS
Abstract
A drill bit includes a bit body having a pin end capable of
attaching to a drill string, a cutting end having a plurality of
blades extending radially therefrom and separated by a plurality of
channels therebetween, and a fluid plenum open to receiving
drilling fluid from the drill string. The drill bit further
includes at least one cutting element in a cutter pocket formed on
the plurality of blades, at least one fluid flow passageway
extending from the fluid plenum to at least one nozzle bore, at
least one nozzle attached to the at least one nozzle bore and
having a nozzle face spaced apart from the bit body, and an
protruding body having an transition surface extending from the bit
body to proximate the nozzle face. A width of the protruding body
varies along a height of the protruding body from proximate the bit
body to proximate the nozzle face.
Inventors: |
Trunk; Philip G.; (Spring,
TX) ; Larsen; James Layne; (Spring, TX) ;
Minikus; James C.; (Montgomery, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SMITH INTERNATIONAL, INC. |
Houston |
TX |
US |
|
|
Family ID: |
56128821 |
Appl. No.: |
14/952080 |
Filed: |
November 25, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62096473 |
Dec 23, 2014 |
|
|
|
Current U.S.
Class: |
175/57 ;
175/393 |
Current CPC
Class: |
E21B 10/602
20130101 |
International
Class: |
E21B 10/60 20060101
E21B010/60; E21B 7/00 20060101 E21B007/00; E21B 10/42 20060101
E21B010/42 |
Claims
1. A drill bit, comprising: a bit body having: a cutting end having
a plurality of blades extending radially therefrom and separated by
a plurality of channels therebetween; and a fluid plenum configured
to receive drilling fluid; at least one cutting element one of the
plurality of blades; at least one fluid flow passageway extending
from the fluid plenum to at least one nozzle bore; at least one
nozzle attached to the at least one nozzle bore, the nozzle having
a nozzle face that is spaced apart from the bit body; and a
protruding body having a transition surface extending from the bit
body to proximate to the nozzle face at an angle, a width of the
protruding body varying along a height of the protruding body from
proximate the bit body to proximate the nozzle face.
2. The drill bit of claim 1, wherein the width of the protruding
body varies at a constant slope along the height.
3. The drill bit of claim 1, wherein the width of the protruding
body varies in steps along the height.
4. The drill bit of claim 1, wherein the at least one nozzle bore
is in a trailing side of one of the plurality of blades.
5. The drill bit of claim 1, wherein the at least one nozzle bore
is disposed in the bit body adjacent to a trailing side of one of
the plurality of blades.
6. The drill bit of claim 1, wherein the at least one nozzle bore
is located in a radial position corresponding to a nose region or a
shoulder region of the drill bit.
7. The drill bit of claim 1, wherein the nozzle face extends at
least 0.5 inches from a surface of the bit body adjacent to the at
least one nozzle.
8. The drill bit of claim 7, wherein the distance from the nozzle
face along the longitudinal axis of the nozzle to a cutting profile
of the drill bit is 1.5 inches or less.
9. A drill bit, comprising: a bit body having: a cutting end having
a plurality of blades extending radially therefrom and separated by
a plurality of channels therebetween; and a fluid plenum configured
to receiving drilling fluid; at least one cutting element on one of
the plurality of blades; at least one fluid flow passageway
extending from the fluid plenum to at least one nozzle bore
disposed in the cutting end configured to allow drilling fluid to
be discharged from the drill bit; and at least one nozzle having: a
lower portion attached to the at least one nozzle bore below an
outer surface of the bit body; and an upper portion extending
beyond the outer surface of the bit body.
10. The drill bit of claim 9, wherein the at least one nozzle bore
is disposed in a trailing side of one of the plurality of
blades.
11. The drill bit of claim 9, wherein the at least one nozzle bore
is disposed in the bit body adjacent to a trailing side of one of
the plurality of blades.
12. The drill bit of claim 9, wherein the at least one nozzle bore
is located in a radial position corresponding to a nose region or a
shoulder region of the drill bit.
13. The drill bit of claim 9, further comprising a raised portion
protruding from the bit body adjacent to the nozzle upper portion
to divert cuttings away from the nozzle upper portion.
14. The drill bit of claim 9, wherein a nozzle face of the at least
one nozzle extends at least 0.5 inches from a surface of the bit
body adjacent to the at least one nozzle.
15. The drill bit of claim 14, wherein the distance from the nozzle
face along the longitudinal axis of the nozzle to a cutting profile
of the drill bit is 1.5 inches or less.
16. A method of drilling a formation, the method comprising:
inserting a drill bit into a wellbore through a formation to engage
the formation, the drill bit comprising: a bit body having: an end
configured to be attached to a drill string; a cutting end having a
plurality of blades extending radially therefrom and separated by a
plurality of channels therebetween; and a fluid plenum configured
to receive drilling fluid from the drill string; at least one
cutting element disposed in a cutter pocket formed on the plurality
of blades; at least one fluid flow passageway extending from the
fluid plenum to at least one nozzle bore disposed in the cutting
end allowing drilling fluid to be discharged from the drill bit;
and at least one nozzle attached to the at least one nozzle bore,
the nozzle extending a distance from an outer surface of the bit
body; rotating the drill bit; and while rotating, pumping drilling
fluid through the drill string and the drill bit.
17. The method of claim 16, wherein the at least one nozzle further
comprises a nozzle face, and wherein at least a portion of the bit
body surrounding the at least one nozzle is a raised body portion,
and the width of the raised bit body portion varies along the
height of the raised bit body portion from proximate a top surface
of the bit body to proximate the nozzle face.
18. The method of claim 16, the at least one nozzle further
comprising: a nozzle face; a lower portion attached to the at least
one nozzle bore and below an outer surface of the bit body; and an
upper portion extending beyond the outer surface of the bit body,
wherein the width of the upper portion varies along the height of
the upper portion from proximate the outer surface of the bit body
to proximate the nozzle face.
19. The method of claim 16, wherein the at least one nozzle bore is
disposed in a trailing side of one of the plurality of blades.
20. The method of claim 16, wherein the at least one nozzle bore is
located in a nose region or a shoulder region of the drill bit.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This Application claims the benefit of and priority to U.S.
Provisional Application 62/096,473 filed on Dec. 23, 2014, the
entirety of which is incorporated herein by reference.
BACKGROUND
[0002] In drilling a borehole, such as for the recovery of
hydrocarbons or for other applications, it is conventional practice
to connect a drill bit on the lower end of an assembly of drill
pipe sections that are connected end-to-end so as to form a drill
string. The bit is rotated by rotating the drill string at the
surface or by actuation of downhole motors or turbines, or by both
methods. With weight applied to the drill string, the rotating bit
engages the earthen formation causing the bit to cut through the
formation material by either abrasion, fracturing, or shearing
action, or through a combination of one or more of these or other
cutting methods, thereby forming a borehole.
[0003] Many different types of drill bits have been developed and
found useful in drilling such boreholes. Two predominate types of
drill bits are roller cone bits and fixed cutter (or rotary drag)
bits. Most fixed cutter bit designs include a plurality of blades
angularly spaced about the bit face. The blades project radially
outward from the bit body and form flow channels, or junk slots,
therebetween. In addition, cutting elements are typically grouped
and mounted on several blades in radially extending rows. The
configuration or layout of the cutting elements on the blades may
vary widely, depending on a number of factors such as the formation
to be drilled.
[0004] A conventional drag bit is shown in FIG. 1. The drill bit 10
includes a bit body 12 and a plurality of blades 14 extending
radially from the bit body 12. The blades 14 are separated by
channels or junk slots 16 that enable drilling fluid to flow
between and both clean and cool the blades 14 and cutters 18.
Cutters 18 are held in the blades 14 at set angular orientations
and radial locations to present working surfaces 20 with a desired
back rake and/or side rake angle against a formation to be drilled.
Typically, the working surfaces 20 are generally perpendicular to
the axis 19 and side surface 21 of a cylindrical cutter 18. Thus,
the working surface 20 and the side surface 21 meet or intersect to
form a circumferential cutting edge 22.
[0005] Orifices are typically formed in the drill bit body 12 and
positioned in the junk slots 16. The orifices are commonly adapted
to accept nozzles 23. Orifices may also be referred to as nozzle
bores. The orifices allow drilling fluid to be discharged through
the bit between the cutting blades 14 for lubricating and cooling
the drill bit 10, the blades 14, and the cutters 18. The drilling
fluid also cleans and removes the cuttings as the drill bit rotates
and penetrates the geological formation. Without proper flow
characteristics, insufficient cooling of the cutters may result in
cutter failure during drilling operations. The junk slots 16, which
may also be referred to as "fluid courses," are positioned to
provide additional flow channels for drilling fluid and to provide
a passage for formation cuttings to travel past the drill bit 10
toward the surface of a wellbore.
[0006] The drill bit 10 includes a shank 24 and a crown 26. The
shank 24 is typically formed of steel or a matrix material and
includes a threaded pin 28 for attachment to a drill string. The
crown 26 has a cutting face 30 and outer side surface 32. Materials
used to form drill bit bodies are selected to provide adequate
strength and toughness, while providing good resistance to abrasive
and erosive wear.
[0007] The combined plurality of surfaces 20 of the cutters 18
effectively forms the cutting face 30 of the drill bit 10. Once the
crown 26 is formed, the cutters 18 are positioned in the cutter
pockets 34 and affixed by any suitable method, such as brazing,
adhesive, mechanical means such as interference fit, or the like.
The design depicted provides the cutter pockets 34 inclined with
respect to the surface of the crown 26. The cutter pockets 34 are
inclined such that cutters 18 are oriented with the working face 20
at a desired rake angle in the direction of rotation of the bit 10
so as to enhance cutting.
SUMMARY
[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.
[0009] In one aspect, embodiments disclosed herein relate to a
drill bit that includes a bit body, a cutting end having a
plurality of blades extending radially therefrom and separated by a
plurality of channels therebetween, and a fluid plenum configured
to receive drilling fluid. The drill bit further includes at least
one cutting element on one of the plurality of blades, at least one
fluid flow passageway extending from the fluid plenum to at least
one nozzle bore, at least one nozzle attached to the at least one
nozzle bore and having a nozzle face, and a raised body defining a
transition surface extending from the bit body to proximate the
nozzle face. A width of the raised body varies along a height of
the transition surface from proximate the bit body to proximate the
nozzle face.
[0010] In another aspect, embodiments disclosed herein relate to a
drill bit that includes a bit body, a cutting end having a
plurality of blades extending radially therefrom and separated by a
plurality of channels therebetween, and a fluid plenum configured
to receive drilling fluid. The drill bit further includes at least
one cutting element on one of the plurality of blades, at least one
fluid flow passageway extending from the fluid plenum to at least
one nozzle bore disposed in the cutting end allowing drilling fluid
to be discharged from the drill bit, and at least one nozzle. The
at least one nozzle includes a lower portion attached to the at
least one nozzle bore below an outer surface of the bit body, and
an upper portion extending beyond the outer surface of the bit
body.
[0011] In yet another aspect, embodiments disclosed herein relate
to a method of drilling a formation that includes inserting a drill
bit into a wellbore through a formation to engage the formation.
The drill bit includes a bit body having a pin end capable of
attaching to a drill string, a cutting end having a plurality of
blades extending radially therefrom and separated by a plurality of
channels therebetween, and a fluid plenum configured to receive
drilling fluid from the drill string. The drill bit further
includes at least one cutting element disposed in a cutter pocket
formed on the plurality of blades, at least one fluid flow
passageway extending from the fluid plenum to at least one nozzle
bore disposed in the cutting end allowing drilling fluid to be
discharged from the drill bit, and at least one nozzle attached to
the at least one nozzle bore and extending a distance from an outer
surface of the bit body. The method further includes rotating the
drill bit, and while rotating, pumping drilling fluid through the
drill string and the drill bit.
[0012] Other aspects and advantages of the claimed subject matter
will be apparent from the following description and the appended
claims.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 shows a conventional PDC drill bit.
[0014] FIG. 2 shows a top view of a PDC drill bit according to
embodiments of the present disclosure.
[0015] FIG. 3 shows a side view of a PDC drill bit according to
embodiments of the present disclosure.
[0016] FIG. 4 shows a partial cross-sectional view of a drill bit
according to embodiments of the present disclosure.
[0017] FIG. 5 shows a partial cross-sectional view of a drill bit
according to embodiments of the present disclosure.
[0018] FIG. 6 shows a partial cross-sectional view of a drill bit
according to embodiments of the present disclosure.
DETAILED DESCRIPTION
[0019] In one aspect, embodiments disclosed herein relate to the
use of extended or raised nozzles in PDC fixed cutter drill bits.
For example, such extended or raised nozzles may terminate at a
distance away or removed from the bit body surface from which the
nozzles extend. One or more embodiments disclosed herein relate to
increasing the proximity of a nozzle outlet to the cutting
structure of a drill bit for increased cutting element cooling and
increased cleaning of the bit face. Such embodiments may be
suitable for drill bits having tall blades. Methods for extending
or raising nozzles in PDC drill bits and the location and sizing of
such extended or raised nozzles are also disclosed.
[0020] PDC bits having tall blades, which may be present, for
example, on drill bits having a highly sloped bit body, that may be
referred to as a "bullet body," (such as the type disclosed in U.S.
Patent Publication No. 2013/0341101, which is herein incorporated
by reference in its entirety), may be designed for drilling through
soft formations. However, the use of taller blades may space the
outlet of the nozzles (conventionally flush with or recessed within
the bit body) further from the cutting elements located on the
blades due to the increased blade height, which may create
inadequate cleaning (and cooling) of such cutting elements
(particularly those in the shoulder region of the bit where the
blade height may be the greatest). Specifically, as a result of the
increased blade height, the drilling fluid exiting the nozzles may
have a lower velocity when impacting the cutting face of the
blades, resulting in poor cutter cleaning and cooling. However, use
of the nozzles that spaces the outlet away from the bit body
surface (e.g., raises it above the bit body surface), as disclosed
herein, may allow for an increased fluid velocity when the fluid
hits the cutting elements, as compared to fluid that exits a nozzle
outlet that is flush with or recessed within the bit body
surface.
[0021] A PDC bit cutting face as defined by the cutters on the
blades (e.g., cutting profile) may generally be divided into three
regions: a cone region, a shoulder region, and a gage region. The
cone region includes the radially innermost region of the PDC bit
extending generally from the bit axis to the shoulder region. A
cone region is generally concave. Adjacent to the cone region is
the shoulder (or the upturned curve) region. In most conventional
fixed cutter bits, the shoulder region is generally convex. Moving
radially outward, adjacent to the shoulder region is the gage
region which extends parallel to the bit axis at the outer radial
periphery of the bit. The axially lowermost point of the convex
shoulder region defines a nose. At the nose, the slope of a tangent
line to the convex shoulder region is zero.
[0022] FIGS. 2 and 3 show a top view and side view, respectively,
of a PDC drill bit according to embodiments of the present
disclosure. The drill bit 200 has a bit body 210 with a
longitudinal axis L extending therethrough. A plurality of blades
220 extends from the bit body 210, radially from the bit body
surface and axially along the bit body surface from a bit cutting
face 202 towards a bit connection end. Each blade 220 has a
formation facing surface 222 and side walls 224. As shown, the side
walls 224 of the blades 220 extend a height from the bit body 210
to the formation facing surface 222. Blade side walls 224 may have
a sloped or curved transition into the formation facing surface
222, as well as a sloped or curved transition into bit body 210. In
some embodiments, a blade side wall 224 may intersect the formation
facing surface 222 substantially perpendicularly, optionally with a
radiused transition. Side walls 224 that face in the rotational
direction of the bit may often be referred to as the blade leading
face 225, while side walls 224 that face opposite the rotational
direction of the bit may often be referred to as a trailing face
226. Additionally, a blade side wall 224 may face other directions,
such as toward the center of the bit, or longitudinal axis L, at
the most radially interior portion of blade 220, represented by
227.
[0023] Cutting elements known in the art may be disposed on the
plurality of blades 220 at the blade leading face 225, for example.
For example, a plurality of polycrystalline diamond compact ("PDC")
cutters 228 (i.e., cutting elements having a PDC table forming a
cutting face mounted to a substrate) may be disposed along a blade
leading face 225, such that the cutting faces of the PDC cutters
face in the direction of the bit's rotation. Thus, as the bit
rotates, the cutting faces of the PDC cutters may contact and cut
the earthen formation to be drilled. However, the present
disclosure is not so limited and may include cutting elements
spaced rearward of the leading face 225 in one or more
embodiments.
[0024] The drill bit 200 also has at least one junk slot or fluid
course 230. Each junk slot 230 is defined by the bit body surface
210 and the side walls 224 of adjacent blades 220. In effect, the
junk slots 230 form passages or channels between the blades 220
that may be used to direct drilling fluids and any cuttings from
drilling an earthen formation between the blades and up the
wellbore. For example, drilling fluid may be directed through the
junk slots to evacuate the cuttings from drilling and to cool the
bit cutting elements. Additionally, at least one nozzle bore 240 is
formed in the bit body 210, within a junk slot area 230. Each
nozzle bore 240 has an intersecting surface 245 formed between the
bit body surface 210 of a junk slot 230 and an inner surface of the
nozzle bore 240, such that intersecting surface 245 extends axially
away from the bit body 210 to the outlet of the nozzle bore 240,
adjacent the nozzle face. Intersecting surface 245 is defined by
the bit body shape and nozzle bore size and orientation. Further,
as shown in FIG. 2, a nozzle 246 may be disposed within a nozzle
bore 240, and have a nozzle face 247 exposed to the environment.
The nozzle 246 may be used to direct drilling fluid through the
junk slots 230.
[0025] Referring now to FIG. 4, a partial cross-sectional view of a
drill bit 400 according to embodiments of the present disclosure is
shown. As shown in FIG. 4, the bit body 410 contains a fluid plenum
425 (e.g., fluid reservoir or fluid channel) therein to allow
drilling fluid through the bit 400 that is pumped down the drill
string. From the fluid plenum 425, fluid flows through a fluid flow
passageway 430 extending from the fluid plenum 425 to at least one
nozzle bore 440 to exit the bit. In one or more embodiments, the
drill bit 400 may include at least one raised nozzle 446 retained
within a nozzle bore 440. The distal end of or outlet of nozzle 446
and nozzle bore 440 extend beyond the surrounding bit body 410.
Nozzle 446 is illustrated as being threadedly retained within bore
440 at the proximal end of nozzle bore 440, however other
mechanisms and relative locations of retention may also be used.
Nozzle face 447 is at the distal end of nozzle 446, and in various
embodiments, may be slightly exposed, flush with, or recessed
within the distal end of nozzle bore 440. As mentioned, raised
nozzle 446 extends a distance beyond the surrounding bit body 410,
with the transition between the bit body 410 and the distal end of
the nozzle bore 440 being defined by a transition surface 445
(e.g., intersecting surface), resulting in a raised body portion.
Transition surface 445 surrounding the nozzle bore 440 may be built
up or raised, as shown in FIG. 4, such that the at least one nozzle
446 is closer to the cutting end 402 of the bit than the bit body
410 surface. Further, as illustrated, the nozzle face 447 may be
substantially flush with the distal end of the nozzle bore or
recessed by up to approximately 0.25 inches therefrom or other
amounts within the range of 0 to approximately 0.25 inches. The
transition surface 445 and raised body portion may be formed
integral with the bit or formed separately from the bit and
attached thereto using welding or other methods known in the art to
attach elements to a drill bit. For example, the transition surface
and raised body portion could also be formed as a separate insert
piece that is threaded into an oversized nozzle bore, and the
nozzle may then be threaded into the transition surface. If the
transition surface 445 and raised body portion is formed separately
from the bit, the transition surface may be formed from a material
similar to the bit body 410 material, for example, the transition
surface 445 may be formed from a steel or matrix material (e.g.,
tungsten carbide matrix material). The amount of material forming
transition surface 445 and other characteristics of the material
forming transition surface 445 (i.e., shape, elongation, diameter,
slope) may be determined using tools such as computational fluid
dynamics (CFD), finite element analysis (FEA), or other methods
known in the art to analyze elements of a drill bit during
simulation or operation in various applications. For example, the
shape and slope may be selected so as to reduce the impact on the
flow of fluid and cuttings through the junk slot.
[0026] Raising a nozzle above the bit body 410 surface may place
the nozzle face closer to the cutting end of the bit and thus
decrease the distance traveled by the drilling fluid from the
nozzle to the cutting elements. By decreasing the distance between
a nozzle and the cutting elements, the drilling fluid may have a
higher velocity when contacting the cutting end of the bit and
therefore increase the cleaning and cooling of the cutting end
features of the bit. As shown in FIG. 4, the material underlying
the transition surface 445 and surrounding the nozzle 446 that
extends away from surrounding surface of the bit body 410, e.g.,
the raised body portion, may have a varying width (w) along its
height (h), such that the thickness tapers towards the distal end
of the nozzle bore 440. For example, height may be defined as the
height of the portion that protrudes above the bit face and the
width may be the width of the material between the bore and the
transition surface above the bit face. In some embodiments, the
height (h) and the width (w) may range from about a 3:1 to about a
1:3 ratio. In such embodiments, this raised portion width may vary
continuously (e.g., at a linear slope or at an exponential slope)
or incrementally (e.g., stepwise at several different slopes) along
its height, and may be symmetrical or asymmetrical about a nozzle
longitudinal axis.
[0027] FIG. 5 illustrates a partial cross-sectional view of a drill
bit 500 according to embodiments of the present disclosure. As
shown in FIG. 5, the bit body 510 contains a fluid plenum 525
within to allow drilling fluid from the drill string to flow
through the bit via at least one fluid flow passageway 530
extending from the fluid plenum 525 to at least one nozzle bore
540. In contrast to the embodiment illustrated in FIG. 4, nozzle
bore 540 is entirely recessed within the bit body 510 and does not
extend beyond the surrounding surface of bit body 510. However, as
illustrated in FIG. 5, the drill bit 500 may include at least one
raised nozzle 546 retained within recessed nozzle bore 540, and
raised nozzle 546 extends beyond the surface of bit body 510. That
is, nozzle 546 includes a lower portion 551 and an upper portion
553. In such embodiments, the lower portion 551 attaches to the
nozzle bore 540 and extends upwards to a surface of the bit body
510, and the upper portion 553 extends from an outer surface of the
bit body 510 to the nozzle face 547 (the distal end of the nozzle
546) and extends outward beyond the diameter of the nozzle bore.
The lower portion 551 may be secured in the nozzle bore by a
threaded attachment, welding, or other methods to secure a nozzle
in a bit body known in the art. As shown in FIG. 5, the upper
portion 553 may have a varying width (w) along its height (h),
wherein the width may vary gradually or incrementally along its
height. In some embodiments, the height (h) and the width (w) may
range from about a 3:1 to about a 1:3 ratio. In such embodiments,
the raised portion may be symmetrical or asymmetrical about a
nozzle longitudinal axis. Alternatively, in some embodiments, the
nozzle may simply extend upward from the bit face and not have a
width wider than the nozzle bore width.
[0028] In embodiments of the present disclosure, including either
of the illustrated embodiments, the nozzle face 447, 547 may extend
at least about 0.25 inches, at least about 0.5 inches, or at least
about 0.75 inches from the bit body surface. For example, the
nozzle face 447, 547 may extend about 0.25 inches to about 4
inches, about 0.25 inches to about 2 inches, about 0.5 inches to
about 1 inches, or about 0.5 inches to about 0.75 inches from the
bit body surface. In some embodiments, the nozzle face 447, 547 may
extend a distance such that the nozzle face 447, 547 is within
about 2.5 inches, about 1.5 inches, or about 0.75 inches from a
point on the bottom of the borehole determined by the intersection
of the nozzle longitudinal axis and the bottom of the borehole as
defined by the cutting profile of the bit. For example, the nozzle
face 447, 547 may extend a distance such that the nozzle face 447,
547 is within about 0.25 inches and about 2.5 inches, about 0.5
inches and about 2 inches, or about 0.75 inches and about 1.5
inches from a point on the bottom of the borehole determined by the
intersection of the nozzle longitudinal axis and the bottom of the
borehole as defined by the cutting profile of the bit. In other
embodiments, the nozzle face 447, 547 may extend an axial distance
from the bit body surface ranging from 0 to about 80% (e.g., about
10% to about 70%, about 20% to about 60%, about 30% to about 50%)
of the distance from the bit body surface to the nose of adjacent
blades.
[0029] It is also within the scope of the present disclosure that
the nozzle face 447, 547 may be located such that it extends the
aforementioned distance from the bit body surface and also be
within the aforementioned distance from the bottom of the borehole.
According to some embodiments, bit sizes ranging from 5 to 30
inches may have raised nozzles 446, 546 such that nozzle face 447,
547 extends away from the bit body surface a distance, which may be
measured based on the axial distance from the nozzle face and the
nose of adjacent blades (defined as being the axially lowermost
point along the blade, where the slope of the tangent line is
zero). Such axial distance between the nozzle face and nose of the
blade may range from less than 10 inches, 8 inches, 4 inches, 2
inches or 1 inch, and in some embodiments, greater than 0.25
inches, 0.5 inches, 1 inch, 2 inches, or 4 inches, where any lower
limit can be used in combination with any upper limit.
[0030] Referring back to FIGS. 2 and 3, nozzle bores 240 may be
formed at various locations on the bit. For example, nozzle bores
240 may be formed proximate to the radial center of the bit cutting
end, or bit longitudinal axis L, as shown by nozzle bore 242 in
FIGS. 2 and 3. In such embodiments, nozzle bores 240 may be located
in a radial position corresponding to the cone and/or nose region
of the bit. Other nozzle bores 240 may be formed, for example,
distant from the radial center of the cutting end, such as shown by
nozzle bore 244 in FIG. 2. In such embodiments, nozzle bores 240
may be located in a radial position corresponding to the nose
and/or shoulder region of the bit.
[0031] According to one or more embodiments, nozzle bores 240 may
be formed in the bit body 210 proximate to an adjacent blade,
distant from an adjacent blade, or equidistant between adjacent
blades. The positions of nozzles and nozzle bores may be designed
to optimize the flow of cuttings and/or drilling fluids through the
blades and away from the bit. For example, as stated above, nozzle
bores may be disposed at various locations within the junk slot
areas. As another example, nozzles may be oriented in particular
directions such that the nozzle faces 247 form selected angles with
respect to the immediately surrounding bit body 210 surface. That
is, the nozzles may be angled to point toward the adjacent leading
blade face.
[0032] In some embodiments, at least one nozzle bore 240 may be
disposed in the bit body 210 adjacent to the trailing face 226 of
the plurality of blades 220 and/or in the trailing face 226 of the
plurality of blades 220, where the at least one nozzle bore 240 is
oriented towards the cutting elements of the nearest blade. In
other embodiments, at least one nozzle bore 240 may be disposed in
the bit body 210 adjacent to the leading face 225 of the plurality
of blades 220 and/or in the leading face 225 of the plurality of
blades 220, where the at least one nozzle bore 240 is oriented
towards the cutting elements of the nearest blade.
[0033] Referring to FIG. 6, a partial cross-sectional view of a
drill bit 600 according to embodiments of the present disclosure is
shown. According to some embodiments, a raised nozzle may impede
the flow of drilling fluids and any cuttings from drilling an
earthen formation between blades through the junk slots or fluid
flow passageways due to its location and/or geometry. In such
embodiments, as shown in FIG. 6, a flow diverter 610 protruding
from bit body 510 may be positioned such that it shields the raised
nozzle 546 from drilling fluid and cutting flow 620 flowing through
junk slot or fluid flow passageway 630 and diverts the drilling
fluid and cutting flow 620 around the raised nozzle 546. In some
embodiments, the flow diverter 610 may have a sloped side 612 to
allow the drilling fluid and cutting flow 620 to smoothly flow over
a top and/or a side of the flow diverter 610. The flow diverter 610
may be formed integral with the bit or formed separately from the
bit and attached thereto using welding or other methods known in
the art to attach elements to a drill bit. If the flow diverter 610
is formed separately from the bit and attached thereto, the flow
diverter 610 may be either attached directly to the raised nozzle
546, attached to the bit body 510 such that the flow diverter 610
is flush with the raised nozzle 546, or attached to the bit body
510 such that there is a distance between the flow diverter 610 and
the raised nozzle 546. The geometry of the flow diverter 610 may be
determined using tools such as computational fluid dynamics (CFD),
finite element analysis (FEA), or other methods known in the art to
analyze elements of a drill bit during simulation or operation in
various applications
[0034] The articles "a," "an," and "the" are intended to mean that
there are one or more of the elements in the preceding
descriptions. The terms "comprising," "including," and "having" are
intended to be inclusive and mean that there may be additional
elements other than the listed elements. Additionally, it should be
understood that references to "one embodiment" or "an embodiment"
of the present disclosure are not intended to be interpreted as
excluding the existence of additional embodiments that also
incorporate the recited features. For example, any element
described in relation to an embodiment herein may be combinable
with any element of any other embodiment described herein. Numbers,
percentages, ratios, or other values stated herein are intended to
include that value, and also 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 the variation to be
expected in a suitable manufacturing or production process, and may
include values that are within 5%, within 1%, within 0.1%, or
within 0.01% of a stated value.
[0035] Further, it should be understood that any directions or
reference frames in the preceding description are merely relative
directions or movements. For example, any references to "up" and
"down" or "above" or "below" are merely descriptive of the relative
position or movement of the related elements.
[0036] 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.
* * * * *