U.S. patent application number 15/014317 was filed with the patent office on 2017-08-03 for reaming system, device, and assembly.
The applicant listed for this patent is Chimere Nkwocha. Invention is credited to Chimere Nkwocha.
Application Number | 20170218705 15/014317 |
Document ID | / |
Family ID | 57995234 |
Filed Date | 2017-08-03 |
United States Patent
Application |
20170218705 |
Kind Code |
A1 |
Nkwocha; Chimere |
August 3, 2017 |
REAMING SYSTEM, DEVICE, AND ASSEMBLY
Abstract
A reaming assembly having an inner mandrel including spiral
lobes disposed on an outer surface thereof. The inner mandrel is
hollow and is sized large enough to freely pass a standard drill
bit therethrough. The reaming assembly includes an outer mandrel
disposed around the inner mandrel and includes spiral lobes
disposed on an inner surface of the outer mandrel. The outer
mandrel has a number of spiral lobes equal to the number of spiral
lobes of the inner mandrel plus one. The reaming assembly includes
a spacing between the outer surface of the inner mandrel and the
inner surface of the outer mandrel through which fluid is pumped to
generate torque therebetween; wherein at least one of the inner and
outer mandrel is free to rotate.
Inventors: |
Nkwocha; Chimere; (Houston,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nkwocha; Chimere |
Houston |
TX |
US |
|
|
Family ID: |
57995234 |
Appl. No.: |
15/014317 |
Filed: |
February 3, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 7/203 20130101;
E21B 29/002 20130101; E21B 4/02 20130101; E21B 10/26 20130101; E21B
17/14 20130101 |
International
Class: |
E21B 4/02 20060101
E21B004/02; E21B 10/26 20060101 E21B010/26 |
Claims
1. A reaming power assembly, comprising: a) an inner mandrel having
spiral lobes disposed on an outer surface thereof; b) an outer
mandrel disposed around the inner mandrel and having spiral lobes
disposed on an inner surface of the outer mandrel; and c) a spacing
between the outer surface of the inner mandrel and the inner
surface of the outer mandrel through which fluid may be pumped to
generate torque therebetween; wherein at least one of the inner and
outer mandrel is free to rotate.
2. The assembly of claim 1, wherein the outer mandrel has a number
of spiral lobes equal to the number of spiral lobes of the inner
mandrel plus one.
3. The assembly of claim 1, wherein one of the inner and outer
mandrel is non-rotatably coupled to an end of a casing and the
other is non-rotatably coupled to a bit or shoe.
4. The assembly of claim 1, further comprising an upper flow
diverter that diverts fluid flow from a center region of the
reaming assembly to the spacing between the inner and outer
mandrels.
5. The assembly of claim 1, further comprising a lower flow
diverter that diverts fluid flow from the spacing between the inner
and outer mandrels to a center region of the reaming assembly.
6. The assembly of claim 1, wherein the inner mandrel is
hollow.
7. The assembly of claim 6, wherein the hollow of the inner mandrel
is sized large enough to freely pass a standard drill bit
therethrough.
8. The assembly of claim 1, further comprising upper and lower
bearing assemblies rotatably coupled between the inner and outer
mandrels.
9. The assembly of claim 1, further comprising: a) an elongated
tubular housing, including: a1) a first end having a fluid inlet
aperture; a2) a second end, opposite the first end, having a fluid
outlet aperture; and a3) a coupling structure at the first end of
the housing that selectably mates with a bottom end of a casing
tube.
10. The assembly of claim 9, further comprising a reaming tool
functionally coupled to an end of the assembly such that torque
therefrom may be used to rotate the reaming tool.
11. The assembly of claim 9, further comprising a casing tube
coupled to the housing.
12. A reaming device, comprising: a) a hollow inner mandrel having
spiral lobes disposed on an outer surface thereof; b) an outer
mandrel disposed around the inner mandrel and having spiral lobes
disposed on an inner surface of the outer mandrel; and c) a spacing
between the outer surface of the inner mandrel and the inner
surface of the outer mandrel through which fluid may be pumped to
generate torque therebetween; wherein at least one of the inner and
outer mandrel is free to rotate; wherein the outer mandrel has a
number of spiral lobes equal to the number of spiral lobes of the
inner mandrel plus one.
13. The device of claim 12, wherein one of the inner and outer
mandrel is non-rotatably coupled to an end of a casing and the
other is non-rotatably coupled to a bit or shoe.
14. The device of claim 13, further comprising an upper flow
diverter that diverts fluid flow from a center region of the
reaming assembly to the spacing between the inner and outer
mandrels.
15. The device of claim 14, further comprising a lower flow
diverter that diverts fluid flow from the spacing between the inner
and outer mandrels to a center region of the reaming assembly.
16. The device of claim 15, wherein the hollow of the inner mandrel
is sized large enough to freely pass a standard drill bit
therethrough.
17. The device of claim 16, further comprising upper and lower
bearing assemblies rotatably coupled between the inner and outer
mandrels.
18. The device of claim 17, further comprising: a) an elongated
tubular housing, including: a1) a first end having a fluid inlet
aperture; a2) a second end, opposite the first end, having a fluid
outlet aperture; and a3) a coupling structure at the first end of
the housing that selectably mates with a bottom end of a casing
tube; b) a first bearing pack disposed circumferentially about the
first end of the housing; and c) a reaming tool functionally
coupled to the auger.
19. The device of claim 18, further comprising a casing tube
coupled to the housing
20. A reaming system, comprising: a) an inner mandrel having spiral
lobes disposed on an outer surface thereof; wherein the inner
mandrel is hollow; wherein the hollow of the inner mandrel is sized
large enough to freely pass a standard drill bit therethrough; b)
an outer mandrel disposed around the inner mandrel and having
spiral lobes disposed on an inner surface of the outer mandrel; c)
a spacing between the outer surface of the inner mandrel and the
inner surface of the outer mandrel through which fluid may be
pumped to generate torque therebetween; wherein at least one of the
inner and outer mandrel is free to rotate; wherein the outer
mandrel has a number of spiral lobes equal to the number of spiral
lobes of the inner mandrel plus one; wherein one of the inner and
outer mandrel is non-rotatably coupled to an end of a casing and
the other is non-rotatably coupled to a bit or shoe; d) an upper
flow diverter that diverts fluid flow from a center region of the
reaming assembly to the spacing between the inner and outer
mandrels; e) a lower flow diverter that diverts fluid flow from the
spacing between the inner and outer mandrels to a center region of
the reaming assembly; f) an upper and lower bearing assemblies
rotatably coupled between the inner and outer mandrels; g) an
elongated tubular housing, including: g1) a first end having a
fluid inlet aperture; g2) a second end, opposite the first end,
having a fluid outlet aperture; and g3) a coupling structure at the
first end of the housing that selectably mates with a bottom end of
a casing tube; h) a first bearing pack disposed circumferentially
about the first end of the housing; i) a reaming tool functionally
coupled to the inner mandrel or outer mandrel such that torque
therefrom rotates the reaming tool; and j) a casing tube coupled to
the housing.
Description
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The present invention relates to drilling, specifically to
reaming systems, assemblies, and devices, including reaming
assemblies associated to horizontal drilling.
[0003] Description of the Related Art
[0004] A reamer is a type of rotary cutting tool used to clean
and/or enlarge the size of a previously formed hole, generally to
leave the sides of the hole sufficiently smooth for later purposes.
The process of so cleaning and/or enlarging the hole is called
reaming. There are many different types of reamer and they may be
designed for use as a hand tool or in a machine tool, such as a
milling machine or drill press, in drilling system for drilling for
oil, and/or in other earth drilling contexts, etc.
[0005] In the context of drilling for oil, once a hole is drilled,
the hole so drilled will generally not maintain a clean, smooth
profile. Drilling changes the fundamental characteristics of the
surrounding and produces a void with respect to pressure, water
content, and even chemical interactions may occur by exposing the
materials surrounding the hole to the air. Further, natural
layering, fissures, facture lines and etc. may react different to
the hole than the surrounding material. Accordingly, such holes
will often end up with discontinuities that make it difficult to
operate the hole as desired. Thus, reaming systems/devices may be
used to make the sides of the hole sufficiently smooth for
continued operation. Also, it is often useful to follow the reaming
with a pipe that then prevents further distortion of the
surrounding material from intruding on the working portion of the
hole.
[0006] Where a pipe follows the reaming device, it would be
difficult and expensive to retrieve the reaming device since the
pipe is literally right behind the device and the device must have
a large enough profile to make room for the pipe. Accordingly, the
reaming device is generally left in the hole at the bottom of the
pipe. Wherein further drilling needs to occur, the drill will
generally just drill through the reaming device on its way
past.
[0007] Horizontal drilling includes added difficulties, especially
including difficulties in sliding tools/mandrels/pipes/etc. inside
the hole, since the weight of such will rest against the side of
the hole. This makes it much more difficult to advance a drill or
reamer during horizontal operation.
[0008] Some improvements have been made in the field. Examples of
references related to the present invention are described below in
their own words, and the supporting teachings of each reference are
incorporated by reference herein:
[0009] U.S. Pat. No. 2,084,096, issued to Everett, discloses a
self-supporting, self-guiding rotary oil well drilling, apparatus
and "particularly to that type embodying two rotary drill bits, two
rotary drill stems therefor and an operating block for operating
the said rotary drill bits and stems, a-gatherer, container and
retainer for drill bit cuttings, a propelling shaft therefor and
differential gears for operating the said shaft, and electrically
driven motors for operating the aforesaid mechanism, however, while
the present invention is embodied in an apparatus of this type,
there are certain features which may of course be utilized in
rotary oil well drilling apparatus different from the specific form
shown, and other means of power such as steam, hydraulic or
compressed air pressure may be utilized in actuating and rotating
the drill bits and other mechanism in connection with the operation
of the aforesaid rotary oil well drilling apparatus.
[0010] U.S. Pat. No. 7,823,657, issued to Zeni, discloses drilling
assemblies, drilling reamer arm assemblies, and methods of
drilling. In one implementation, a drilling assembly includes a
cutting head apparatus configured to cut into earthen material as
the cutting head apparatus is rotated. A drive shaft extends aft of
and is configured to rotate the cutting head apparatus. A plurality
of reamer arm assemblies projects radially outward of the drive
shaft and are mounted for rotation therewith aft of the cutting
head apparatus. Individual of the reamer arm assemblies include a
radial inner portion extending radially outward of the drive shaft.
A radial outer portion connects with and extends radially outward
of the radial inner portion. The radial outer portion includes a
cutter. At least one breakaway retainer fastens the radial inner
and outer portions together and restrains the radial outer portion
from moving relative to the radial inner portion towards the
cutting head apparatus and the drive shaft. Other aspects are
contemplated.
[0011] U.S. Pat. No. 7,938,204, issued to Buske, discloses a reamer
bit for use in earth boring operations comprising a body, mounting
elements on the bit body having rolling cutters, and nozzles
configured to emit a cleaning spray that is angled with respect to
the well bottom. The cleaning spray may be angled up to about
20.degree. with respect to the well bottom. The reamer may further
include a pilot bit on a drill pipe extending downward from the
reamer body.
[0012] U.S. Pat. No. 8,201,643, issued to Soby et al., discloses a
system and method for enabling longitudinal and radial drilling in
a wellbore is described. The system and method enable an operator
to perforate the casing of a wellbore with an under-reamer at the
end of a drill string and, without removing the drill string from
the wellbore, initiate and complete lateral jetting of the wellbore
into the surrounding formation. The system utilizes a perforation
tool having a ball seat, which upon seating a drop ball in the ball
seat enables the perforation tool to move from a closed position to
an open position thereby allowing access to the formation using a
jetting tool. Prior to seating the drop ball, an under-reaming
operation may be performed using a hydraulic pressure activated
under-reaming tool.
[0013] U.S. Pat. No. 8,205,689, issued to Radford, discloses
drilling systems and methods for enlarging a borehole that include
at least one expandable reamer and at least one expandable
stabilizer axially spaced therefrom in a tubular string, such as a
drill string, the at least one expandable reamer and the at least
one expandable stabilizer being independently actuatable by
different-sized actuation devices. A relatively lower tool is
actuatable by a smaller actuation device, such as a drop ball,
which passes through a relatively higher tool in the drill string
without triggering the higher tool.
[0014] The inventions heretofore known suffer from a number of
disadvantages which include being limited in use, being expensive,
not being powerful enough, failing to provide strong torque, being
slow, resulting in slow reaming, not being scalable, failing to
extend reach, failing to overcome obstructions, not allowing for an
easy drill-through, failing to reduce the need for evacuation to
push a casing, not being capable of drilling surface case and/or
surface holes, not able to directionally drill surface holes, not
allowing one to drill and run casing at the same time without
rotating the entire casing, not allowing you to drill and run
casing in a non-vertical hole, being unduly complex, being
difficult to use, being limited in application, being limited in
adaptability, being limited in conversion, being limited in torque,
having too slow a rotation, not being usable with a variety of
shoes, and/or failing to prevent a shoe from falling off when
drilling through the system.
[0015] What is needed is a reaming system, device and/or assembly
that solves one or more of the problems described herein and/or one
or more problems that may come to the attention of one skilled in
the art upon becoming familiar with this specification.
SUMMARY OF THE INVENTION
[0016] The present invention has been developed in response to the
present state of the art, and in particular, in response to the
problems and needs in the art that have not yet been fully solved
by currently available reaming systems. Accordingly, the present
invention has been developed to provide an efficient and effective
horizontal drilling and reaming assembly.
[0017] According to one embodiment of the invention, there is a
reaming assembly that may include an inner mandrel that may have
spiral lobes disposed on an outer surface thereof. The inner
mandrel may be hollow. The hollow of the inner mandrel may be sized
large enough to freely pass a standard drill bit therethrough.
[0018] The reaming assembly may include an outer mandrel that may
be disposed around the inner mandrel and may have spiral lobes
disposed on an inner surface of the outer mandrel. The outer
mandrel may have a number of spiral lobes equal to the number of
spiral lobes of the inner mandrel plus one. One of the inner and
outer mandrel may be non-rotatably coupled to an end of a casing
and the other may be non-rotatably coupled to a bit or shoe.
[0019] The reaming assembly may include a spacing that may be
between the outer surface of the inner mandrel and the inner
surface of the outer mandrel through which fluid may be pumped to
generate torque therebetween; wherein at least one of the inner and
outer mandrel may be free to rotate.
[0020] The reaming assembly may include an upper flow diverter that
may divert fluid flow from a center region of the reaming assembly
to the spacing between the inner and outer mandrels.
[0021] The reaming assembly may include a lower flow diverter that
may divert fluid flow from the spacing between the inner and outer
mandrels to a center region of the reaming assembly. The reaming
assembly may include upper and lower bearing assemblies rotatably
coupled between the inner and outer mandrels.
[0022] The reaming assembly may include an elongated tubular
housing that may have a first end that may have a fluid inlet
aperture. The elongated tubular housing may include a second end
that may be disposed opposite the first end, and may have a fluid
outlet aperture. The elongated tubular housing may include a
coupling structure that may be at the first end of the housing that
may be selectably mated with a bottom end of a casing tube.
[0023] The reaming assembly may include a reaming tool that may be
functionally coupled to the inner or outer mandrel such that torque
therefrom is transmitted to the reaming tool. The reaming assembly
may include a casing tube that may be coupled to the housing.
[0024] Reference throughout this specification to features,
advantages, or similar language does not imply that all of the
features and advantages that may be realized with the present
invention should be or are in any single embodiment of the
invention. Rather, language referring to the features and
advantages is understood to mean that a specific feature,
advantage, or characteristic described in connection with an
embodiment is included in at least one embodiment of the present
invention. Thus, discussion of the features and advantages, and
similar language, throughout this specification may, but do not
necessarily, refer to the same embodiment.
[0025] Furthermore, the described features, advantages, and
characteristics of the invention may be combined in any suitable
manner in one or more embodiments. One skilled in the relevant art
will recognize that the invention can be practiced without one or
more of the specific features or advantages of a particular
embodiment. In other instances, additional features and advantages
may be recognized in certain embodiments that may not be present in
all embodiments of the invention.
[0026] These features and advantages of the present invention will
become more fully apparent from the following description and
appended claims, or may be learned by the practice of the invention
as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] In order for the advantages of the invention to be readily
understood, a more particular description of the invention briefly
described above will be rendered by reference to specific
embodiments that are illustrated in the appended drawing(s). It is
noted that the drawings of the invention are not to scale. The
drawings are mere schematics representations, not intended to
portray specific parameters of the invention. Understanding that
these drawing(s) depict only typical embodiments of the invention
and are not, therefore, to be considered to be limiting its scope,
the invention will be described and explained with additional
specificity and detail through the use of the accompanying
drawing(s), in which:
[0028] FIG. 1 is a perspective view of a reaming assembly with
cutaway, according to one embodiment of the invention;
[0029] FIG. 2 is a cross-sectional view of a an upper flow diverter
of a reaming assembly, according to one embodiment of the
invention;
[0030] FIG. 3 is a perspective view of a reaming assembly with
cut-away, according to one embodiment of the invention;
[0031] FIG. 4 is a top plan cross-sectional view of an inner
mandrel and an outer mandrel of a reaming assembly, according to
one embodiment of the invention;
[0032] FIGS. 5 and 6 are perspective views of portions of a reaming
assembly with cutaway, according to one embodiment of the
invention; and
[0033] FIG. 7 is a side elevational view of a reaming system,
according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
exemplary embodiments illustrated in the drawing(s), and specific
language will be used to describe the same. It will nevertheless be
understood that no limitation of the scope of the invention is
thereby intended. Any alterations and further modifications of the
inventive features illustrated herein, and any additional
applications of the principles of the invention as illustrated
herein, which would occur to one skilled in the relevant art and
having possession of this disclosure, are to be considered within
the scope of the invention.
[0035] Reference throughout this specification to an "embodiment,"
an "example" or similar language means that a particular feature,
structure, characteristic, or combinations thereof described in
connection with the embodiment is included in at least one
embodiment of the present invention. Thus, appearances of the
phrases an "embodiment," an "example," and similar language
throughout this specification may, but do not necessarily, all
refer to the same embodiment, to different embodiments, or to one
or more of the figures. Additionally, reference to the wording
"embodiment," "example" or the like, for two or more features,
elements, etc. does not mean that the features are necessarily
related, dissimilar, the same, etc.
[0036] Each statement of an embodiment, or example, is to be
considered independent of any other statement of an embodiment
despite any use of similar or identical language characterizing
each embodiment. Therefore, where one embodiment is identified as
"another embodiment," the identified embodiment is independent of
any other embodiments characterized by the language "another
embodiment." The features, functions, and the like described herein
are considered to be able to be combined in whole or in part one
with another as the claims and/or art may direct, either directly
or indirectly, implicitly or explicitly.
[0037] As used herein, "comprising," "including," "containing,"
"is," "are," "characterized by," and grammatical equivalents
thereof are inclusive or open-ended terms that do not exclude
additional unrecited elements or method steps. "Comprising" is to
be interpreted as including the more restrictive terms "consisting
of" and "consisting essentially of."
[0038] FIG. 1 is a perspective view of a reaming assembly with
cutaway, according to one embodiment of the invention. There is
shown a reaming assembly 10 including an outer mandrel 18
(partially cut-away) coupled to an upper and a lower flow diverters
34, 38 and an upper and lower bearing assemblies 42, 44, and an
auger-like inner mandrel 12 disposed within the outer mandrel 18.
Each of the two mandrels include spiral lobes facing towards each
other (i.e. the lobes on the inner mandrel are on the outside,
while the lobes of the out mandrel are on the inside, See FIG. 4).
The spiral lobes are mismatched such that they rotate against each
other when fluid is pumped through the space between them and
generate vibration (notation) as one rotates past the other.
[0039] According to one embodiment of the invention, there is a
reaming assembly 10 for installing a casing 50 that generates
sufficient torque to drill or ream through substantially any
obstruction in a wellbore. The reaming assembly 10 agitates a drill
string by generating a shock-wave due to the notation of a tool.
This extends the reach of the casing 50 by creating agitation which
in some extended reach wells (e.g. horizontal wells that are longer
than the vertical section of the well) the assembly 10 could run
the casing 50 further than normally would be able to do without the
need for extra hydraulic or mechanical evacuation. The strong
torque allows the assembly 10 to drill with a casing bit. This is
supposed to replace a jetting assembly in deep water operations.
The power is generated by a long rotor/stator (generally, the
longer the rotor, the more torque that will be generated). The
external part of the whole tool rotates about the internal. There
are two versions of the tool. In one, the inner mandrel (not shown)
is the rotor (i.e. rotates) and the outer mandrel 18, as shown, is
the stator (i.e. stays fixed relative to the casing). In the other,
the outer mandrel 18 is the rotor (rotates) and the inner mandrel
is the stator (does not rotate). The bit 32 at the front end is
connected to whichever is the rotor so that the bit 32 turns as
fluid is pumped through the assembly.
[0040] The rotor and stator or the inner and outer mandrels have
spiral lobes that face each other and the lobes bouncing past each
other during rotation is what causes the vibration/agitation. The
inner mandrel may be hollow and sized so that a drill bit just
passes through it and does not need to drill. The inner mandrel may
also be of a drillable material so it may be drilled out. The
version with the rotating outer mandrel 18, as shown, may be a more
robust tool that may be appropriate for more challenging well
types. The reaming assembly 10 will generally have one fewer lobes
on the inner mandrel 12 as compared to the outer mandrel 18 and
this allows for strong consistent torque.
[0041] This allows for better turning and prevents the lobes from
matching and locking up. When making the assembly and putting the
inner mandrel into the outer mandrel, the inner mandrel will turn
into the outer mandrel so that the lobes match and it may fit.
Whichever part, either the inner mandrel or the outer mandrel is
connected to the casing adapter 52, the shoe/bit 32 at the front is
connected to the other, since that will be the one that rotates and
the other may be fixedly coupled to the casing 50 which does not
turn.
[0042] According to one embodiment of the invention, the reaming
assembly 10 includes a casing 50, a casing adapter 52, an upper end
cap, an upper bearing assembly 42, an upper flow diverter 34 (upper
flow joint assembly), an inner mandrel, an outer mandrel 18, a
centralizer 54, a lower flow diverter 38 (lower flow joint
assembly), a lower bearing assembly 44, a lower cap, and a reamer
shoe 32.
[0043] According to one embodiment of the invention, there is a
casing 50, and a casing adapter 52 fixedly coupled to the casing 50
(casing mates into the casing adapter through a box connection) and
to either the inner mandrel or the outer mandrel 18 and rotatably
coupled to the other (could be via the upper cap) upper end cap
(forces flow through the lobes and not through the hollow center of
the inner mandrel) is fixedly connected to the outer mandrel and
rotatably coupled to the upper bearing assembly. The upper bearing
assembly is rotatably coupled between the inner mandrel and the
outer mandrel. The upper flow diverter 34 (upper flow joint
assembly) is in fluid connection between an interior of the casing
50 and the power section (the space between lobes that are facing
each other) inner mandrel is disposed within the outer mandrel. The
outer mandrel surrounds the inner mandrel. The centralizer is
disposed around one or more of the casing adapter and the outer
mandrel. The lower flow diverter 38 (lower flow joint assembly) is
in fluid connection between the power section (the space between
lobes that are facing each other) and the interior of the reamer
shoe 32. The lower bearing assembly 44 is rotatably coupled between
the inner mandrel and the outer mandrel. The lower cap (protects
the lower bearing assembly) which is fixedly coupled to the outer
mandrel and either fixedly coupled to the shoe 32. If the outer
mandrel is rotating or rotatably coupled to the shoe via a
projection, if not the reamer shoe is fixedly coupled to the rotor
(whichever one is rotating, i.e. inner or outer mandrel).
[0044] According to one embodiment of the invention, there is a
hollow rotor having an external part of the tool which rotates
along with the reamer shoe and the lobed power section. There may
be a casing which may be any weight, size, strength, and/or grade.
There may be a casing adapter to connect to a casing, which type
may depend on the casing (e.g. box connection if the casing has a
threaded end). There may be an upper end cap which may be
sufficient to protect the bearing assembly and/or make any
connections required at that region. There may be an upper bearing
assembly, which may include but is not limited to ball bearings and
friction bearings. There may be an upper flow diverter associated
with or within an upper flow joint assembly. The upper flow
diverter may be a drillable tube that diverts fluid flow from being
central (i.e. how it is when it comes down the casing) to being
medial (i.e. between the inner and outer mandrels).
[0045] There may be an internal/inner mandrel that may be hollow or
not, may have continuous or discontinuous lobes, may have one fewer
lobe than how many lobes are on an external/outer mandrel, and/or
may consist essentially of a drillable material or not. There may
be an external/outer mandrel that may generally comprise not
drillable material which may generally be solid steel, may
generally have one more lobe than an associated internal mandrel,
and may generally include continuous or discontinuous lobes. There
may be one or more centralizers that may be functionally coupled to
an exterior surface of the assembly to help keep the assembly
centered within a hole.
[0046] There may be a lower flow diverter that may be associated
with or part of a lower flow joint assembly and may include a
tube/channel that diverts flow from a medial region (i.e. between
the inner and outer mandrels) to a more central region of the
assembly (i.e. an interior cavity of a reaming shoe). There may be
a lower bearing assembly similar to the upper bearing assembly.
There may be a lower cap similar to an upper cap. There may be a
reaming/reamer shoe such as but not limited to an eccentric nose
reamer shoe or a casing bit.
[0047] The reaming assembly 10 includes an inner mandrel 12 that
includes spiral lobes disposed on an outer surface thereof. The
illustrated reaming assembly 10 includes an outer mandrel 18
disposed around the inner mandrel and has spiral lobes disposed on
an inner/interior surface of the outer mandrel 18. One of the inner
and outer mandrels are non-rotatably coupled to an end 28 of a
casing 50 and the other is non-rotatably coupled to a bit or shoe
32. Thereby at least one of the inner and outer mandrel is free to
rotate when fluid pumped through the space between the two lobed
mandrels causes torque therebetween.
[0048] The illustrated reaming assembly 10 includes an upper flow
diverter 34 to divert fluid flow from a center region, not shown in
FIG. 1, of the reaming assembly 10 to the spacing between the inner
and outer mandrels. The reaming assembly 10 includes a lower flow
diverter 38 to divert fluid flow from the spacing between the inner
and outer mandrels to a center region of the reaming assembly 10.
The illustrated reaming assembly 10 includes upper and lower
bearing assemblies 42, 44 rotatably coupled between the inner and
outer mandrels.
[0049] The casing 50 includes a first end 62 including a fluid
inlet aperture 64 and a second end 66, disposed opposite the first
end 62, and includes a fluid outlet aperture 68. The casing 50
includes a casing adapter 52 or a coupling structure that is at the
first end 62 of the casing 50 that is selectably mated with a
casing tube.
[0050] The reaming assembly 10 includes an auger 70 disposed within
the casing and is functionally coupled to a lower bearing assembly
44 such that the auger may rotate with respect to an attached
casing tube and including a rotation transmission structure that
transfers rotation motion. The reaming assembly 10 includes a
reaming tool, such as a bit or shoe 32 that is functionally coupled
to the auger 70. The reaming assembly 10 includes a casing tube
coupled to the casing 50.
[0051] FIG. 2 is a cross-sectional view of a an upper flow diverter
of a reaming assembly, according to one embodiment of the
invention. There is shown an upper flow diverter 34 that diverts
fluid flow from a center region 36 of the reaming assembly to a
spacing 24 in between an inner mandrel 12 and an outer mandrel
18.
[0052] The illustrated upper flow diverter 34 that diverts fluid
flow from a center region 36 of a reaming assembly to a spacing 24
between an inner mandrel 12 and an outer mandrel 18 of a reaming
assembly. The inner mandrel 12 includes spiral lobes 14 disposed on
an outer surface thereof. The inner mandrel 12 is hollow. The
hollow of the inner mandrel 12 is sized large enough to freely pass
a standard drill bit therethrough.
[0053] The outer mandrel 18 is disposed around the inner mandrel 12
and has spiral lobes 20 disposed on an inner surface of the outer
mandrel 18. The outer mandrel 18 generally has a number of spiral
lobes 20 equal to the number of spiral lobes 14 of the inner
mandrel 12 plus one 26. The one-lobe difference between the inner
and outer mandrels has thus far been an optimum number of lobes to
produce the best torque and notation within the reaming
devices/assemblies/systems. One of the inner and outer mandrels are
non-rotatably coupled to an end of a casing and the other is
non-rotatably coupled to a bit or shoe.
[0054] The illustrated spacing 24 is between the outer surface of
the inner mandrel 12 and the inner surface of the outer mandrel 18
through which fluid is pumped to generate torque therebetween;
wherein at least one of the inner 12 and outer mandrels 18 is free
to rotate. The upper flow diverter 34 diverts fluid flow from a
center region of the reaming assembly to the spacing 24 between the
inner and outer mandrels 12, 18. There is also a lower flow
diverter, not shown in FIG. 2, that diverts fluid flow from the
spacing 24 between the inner and outer mandrels 12, 18 to a center
region 36 of the reaming assembly.
[0055] FIG. 3 is a perspective view of a reaming assembly with
cutaway, according to one embodiment of the invention. There is
shown a reaming assembly 10 including an outer mandrel 18, coupled
to an upper and a lower flow diverters 34, 38 and an upper and
lower bearing assemblies 42, 44.
[0056] The reaming assembly 10 includes an inner mandrel 12 that
includes spiral lobes disposed on an outer surface thereof. The
illustrated reaming assembly 10 includes an outer mandrel 18
disposed around the inner mandrel and has spiral lobes disposed on
an inner surface of the outer mandrel 18, not shown in FIG. 1. One
of the inner and outer mandrels are non-rotatably coupled to an end
28 of a casing 50 and the other is non-rotatably coupled to a bit
or shoe 32. At least one of the inner and outer mandrel is free to
rotate.
[0057] The illustrated reaming assembly 10 includes an upper flow
diverter 34 to divert fluid flow from a center region, not shown in
FIG. 1, of the reaming assembly 10 to the spacing between the inner
and outer mandrels. The reaming assembly 10 includes a lower flow
diverter 38 to divert fluid flow from the spacing between the inner
and outer mandrels to a center region of the reaming assembly 10.
The illustrated reaming assembly 10 includes upper and lower
bearing assemblies 42, 44 rotatably coupled between the inner and
outer mandrels.
[0058] The casing 50 includes a first end 62 including a fluid
inlet aperture 64 and a second end 66, disposed opposite the first
end 62, and includes a fluid outlet aperture 68. The casing 50
includes a casing adapter 52 or a coupling structure that is at the
first end 62 of the casing 50 that is selectably mated with a
casing tube.
[0059] The reaming assembly 10 includes an auger 70 disposed within
the casing and is functionally coupled to a lower bearing assembly
44 such that the auger may rotate with respect to an attached
casing tube and including a rotation transmission structure that
transfers rotation motion. The reaming assembly 10 includes a
reaming tool, such as a bit or shoe 32 that is functionally coupled
to the auger 70. The reaming assembly 10 includes a casing tube
coupled to the casing 50.
[0060] FIG. 4 is a top plan cross-sectional view of an inner
mandrel and an outer mandrel of a reaming assembly, according to
one embodiment of the invention. An upper flow diverter diverts
fluid flow from a center region of a reaming assembly to a spacing
24 in between the inner mandrel 12 and the outer mandrel 18.
[0061] The illustrated upper flow diverter 34 that diverts fluid
flow from a center region 36 of a reaming assembly to a spacing 24
between an inner mandrel 12 and an outer mandrel 18 of a reaming
assembly. The inner mandrel 12 includes spiral lobes 14 disposed on
an outer surface thereof. The inner mandrel 12 is hollow. The
hollow of the inner mandrel 12 is sized large enough to freely pass
a standard drill bit therethrough.
[0062] The outer mandrel 18 is disposed around the inner mandrel 12
and has spiral lobes 20 disposed on an inner surface of the outer
mandrel 18. The outer mandrel 18 has a number of spiral lobes 20
equal to the number of spiral lobes 14 of the inner mandrel 12 plus
one. In particular, the illustrated inner mandrel has nine lobes
while the illustrated outer mandrel has ten lobes. One of the inner
and outer mandrels are non-rotatably coupled to an end of a casing
and the other is non-rotatably coupled to a bit or shoe.
[0063] The illustrated spacing 24 is between the outer surface of
the inner mandrel 12 and the inner surface of the outer mandrel 18
through which fluid is pumped to generate torque therebetween;
wherein at least one of the inner 12 and outer mandrels 18 is free
to rotate. The upper flow diverter diverts fluid flow from a center
region of the reaming assembly to the spacing 24 between the inner
and outer mandrels 12, 18.
[0064] FIGS. 5 and 6 are partial cutaway views of lower and upper
bearing assemblies (44 and 42) of FIG. 1 respectively.
[0065] Each of the lower and upper bearing assemblies includes a
port 41 and 21 that provides fluid connection between the center
region and the spacing between the two mandrels, with the lower
port 41 allowing for a return of the fluid to the central region
after it flows between the two mandrels and the upper port allowing
for the fluid to divert from the central region to then flow
between the two mandrels towards the lower portion of the assembly
10 (See FIG. 1). One of the inner and outer mandrels are
non-rotatably coupled to an end of a casing and the other is
non-rotatably coupled to a bit or shoe 32. At least one of the
inner and outer mandrel is free to rotate and by operation of lower
and upper bearing packs 43 and 23 respectively.
[0066] The illustrated reaming assembly 10 includes an upper flow
diverter 34 to divert fluid flow from a center region, not shown in
FIG. 1, of the reaming assembly 10 to the spacing between the inner
and outer mandrels. The reaming assembly 10 includes a lower flow
diverter 38 to divert fluid flow from the spacing between the inner
and outer mandrels to a center region of the reaming assembly 10.
The illustrated reaming assembly 10 includes upper and lower
bearing assemblies 42, 44 rotatably coupled between the inner and
outer mandrels.
[0067] The casing 50 includes a first end 62 including a fluid
inlet aperture 64 and a second end 66, disposed opposite the first
end 62, and includes a fluid outlet aperture 68. The casing 50
includes a casing adapter 52 or a coupling structure that is at the
first end 62 of the casing 50 that is selectably mated with a
casing tube.
[0068] The reaming assembly 10 includes an auger 70 disposed within
the casing and is functionally coupled to a lower bearing assembly
44 such that the auger may rotate with respect to an attached
casing tube and including a rotation transmission structure that
transfers rotation motion. The reaming assembly 10 includes a
reaming tool, such as a bit or shoe 32 that is functionally coupled
to the auger 70. The reaming assembly 10 includes a casing tube
coupled to the casing 50.
[0069] FIG. 7 is a side elevational view of a reaming system,
according to one embodiment of the invention. There is shown a
reaming system 11 designed to cut the final size and finish of a
horizontal drill hole. Generally, a reaming system, device, etc.
will not make the original hole, but instead, enlarge and/or clean
or otherwise make more smooth the interior of a previously drilled
or bored hole. The illustrated reaming system 11 includes a rig
structure (derrick) 14 supporting a casing 13 lead by a mandrel
assembly 38 that is disposed within a hole 39. The derrick 14
includes structure and devices to operate the mandrel assembly and
to permit the addition of more casing sections as the mandrel
assembly works its way down the hole. Accordingly, the reaming
system 11 advantageously allows for a hole to be reamed and lined
with a casing for future operations, such as but not limited to oil
production. Similar reaming systems may be constructed for reaming
in other contexts, wherein the derrick is replaced with appropriate
support structure and/or wherein the casing may or may not be
present.
[0070] The illustrated reaming system 11 includes a derrick 14 for
supporting the components and parts of the reaming system 11 during
use. A derrick is a lifting device generally including a guyed
mast, as in a gin pole, which may be articulated over a load by
adjusting its guys. The term derrick is also applied to the
framework supporting a drilling apparatus in an oil rig.
[0071] The illustrated derrick includes a crown block 83. The
illustrated crown block 83 is functionally coupled to a traveling
block 82 that travels vertically within the derrick 14. A crown
block is the stationary section of a block and tackle that contains
a set of pulleys or sheaves through which the drill line (wire
rope) is threaded and is opposite and above the traveling block. A
traveling block is the freely moving section of a block and tackle
that contains a set of pulleys or sheaves through which the drill
line (wire rope) is threaded is opposite (and under) the crown
block (the stationary section). The combination of the traveling
block, crown block and wire rope drill line gives the ability to
lift weights in the hundreds of thousands of pounds. On larger
drilling rigs, when raising and lowering the derrick, line tensions
over a million pounds are not unusual.
[0072] The illustrated derrick 14 includes a motor 84 or other
power source that may be used to operate one or more pumps,
winches, drills, and/or the like and combinations thereof. The
motor 84 may be used to pump fluid through the casing and thereby
through the mandrel assembly to cause a shoe at a bottom portion of
the mandrel assembly to rotate at high speeds and with strong
torque to effectively ream the hole.
[0073] The illustrated derrick 14 also includes a blowout preventer
86 functionally coupled around a top of the hole 39. The blowout
preventer 86 is generally a large, specialized valve or similar
mechanical device, usually installed redundantly in stacks, used to
seal, control and monitor oil and gas wells. Blowout preventers
were developed to cope with extreme erratic pressures and
uncontrolled flow (formation kick) emanating from a well reservoir
during drilling. Kicks may lead to a potentially catastrophic event
known as a blowout. In addition to controlling the down hole
(occurring in the drilled hole) pressure and the flow of oil and
gas, blowout preventers are intended to prevent tubing (e.g. drill
pipe and well casing), tools and drilling fluid from being blown
out of the wellbore (also known as bore hole, the hole leading to
the reservoir) when a blowout threatens. Blowout preventers improve
the safety of crew, rig (the equipment system used to drill a
wellbore) and environment, and to the monitoring and maintenance of
well integrity; thus blowout preventers are intended to provide
fail-safety to the systems that include them.
[0074] The reaming system 11 includes a mandrel assembly 38 coupled
to a bottom end of the casing 13 and configured to ream a drill
hole when a shoe is coupled to a bottom end thereof. The mandrel
assembly 38 may be coupled to the bottom end of the casing in a
variety of manners, including but not limited to mating threads,
snap-fits, friction fitting, adhesives, bolts, and the like and
combinations thereof. The mandrel assembly 38 grips a shoe, which
is the operating component that interfaces with the interior of the
hole to be reamed and abrades away material, thereby reaming the
hole. The shoe generally includes protrusions that, when the shoe
spins, impact with non-smooth regions of the interior of the hole
and thereby abrade the same making such regions more smooth and
increasing the effective interior diameter of the same so that the
casing can follow behind without getting stuck.
[0075] Generally, after the drilling is completed for a particular
section of a hole, one puts a casing down the hole to create a
smooth interior bore through which additional work may be
completed. However, the hole is generally not perfect and often
includes defects that can stop the casing from going all the way
down. Accordingly, it is desirable to put a reaming tool, the
operating tip of which is usually called a shoe, towards the bottom
to ream out the hole as the casing slides down.
[0076] In one non-limiting embodiment, there is a reaming system,
device, and/or mandrel assembly that is, advantageously, a low
costs system that attaches to any of a great variety of shoes (e.g.
float shoe, reamer shoe, guide shoe) from a variety of
manufacturers. It includes an internal/central axle that rotates
inside a housing and/or includes a pin-down connection (e.g. pin to
pin, box-pin) to couple to a shoe so it can connect to any
tool/shoe. The internal axle spins when you pump fluid through the
mandrel assembly and spins a sub that is connected to the shoe
which therefore also spins. The internal axle and/or other
centrally positioned parts are generally of an aluminum and/or zinc
alloy (or other material that may be drilled through rather easily,
since the mandrel assembly is generally left at a bottom of the
hole when the casing is finished being installed). There is an
internal corkscrew/auger shaped set of blades/lobes that cause the
internal axle to rotate and thus cause the tool to rotate when
fluid is pumped through the housing that contains the
corkscrew/auger.
[0077] It is understood that the above-described embodiments are
only illustrative of the application of the principles of the
present invention. The present invention may be embodied in other
specific forms without departing from its spirit or essential
characteristics. The described embodiment is to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
[0078] For example, although the illustrated system/assembly
includes a single centralizer, the invention may be practiced
without multiple centralizers or even with no centralizer.
[0079] Additionally, although the figures illustrate an outer
mandrel having ten spiral lobes on an interior thereof, a different
number of lobes and/or lobes of different slopes, curvatures,
sizes, shapes and the like may be present.
[0080] Finally, it is envisioned that the components of the device
may be constructed of a variety of materials, including but not
limited to metals (both drillable and not), plastics, ceramics,
composites and the like and combinations thereof.
[0081] Thus, while the present invention has been fully described
above with particularity and detail in connection with what is
presently deemed to be the most practical and preferred embodiment
of the invention, it will be apparent to those of ordinary skill in
the art that numerous modifications, including, but not limited to,
variations in size, materials, shape, form, function and manner of
operation, assembly and use may be made, without departing from the
principles and concepts of the invention as set forth in the
claims. Further, it is contemplated that an embodiment may be
limited to consist of or to consist essentially of one or more of
the features, functions, structures, methods described herein.
* * * * *