U.S. patent application number 16/170270 was filed with the patent office on 2019-02-28 for hybrid rotary cone drill bit.
The applicant listed for this patent is VAREL INTERNATIONAL IND., L.P.. Invention is credited to DAVID MICHEL HARRINGTON, KYLE NOBILE, KARL W. ROSE, MATTHEW CHARLES STROEVER.
Application Number | 20190063161 16/170270 |
Document ID | / |
Family ID | 52479327 |
Filed Date | 2019-02-28 |
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United States Patent
Application |
20190063161 |
Kind Code |
A1 |
NOBILE; KYLE ; et
al. |
February 28, 2019 |
HYBRID ROTARY CONE DRILL BIT
Abstract
A hybrid rotary cone drill bit includes a plurality of legs. A
bearing shaft extends from each leg, and a rotary cone is
rotationally coupled to each bearing shaft. At least one rotary
cone includes a nose row of cutting structures, an inner row of
cutting structures, and a gage row of cutting structures. The nose
row and the inner row of cutting structures are formed of milled
teeth. The gage row of cutting structures is formed of cutter
inserts.
Inventors: |
NOBILE; KYLE; (WHITE
SETTLEMENT, TX) ; STROEVER; MATTHEW CHARLES; (SPRING,
TX) ; HARRINGTON; DAVID MICHEL; (DALLAS, TX) ;
ROSE; KARL W.; (BURLESON, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VAREL INTERNATIONAL IND., L.P. |
CARROLLTON |
TX |
US |
|
|
Family ID: |
52479327 |
Appl. No.: |
16/170270 |
Filed: |
October 25, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15018542 |
Feb 8, 2016 |
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16170270 |
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13975094 |
Aug 23, 2013 |
9376866 |
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15018542 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 10/52 20130101;
E21B 10/08 20130101; E21B 29/00 20130101; E21B 33/1204 20130101;
E21B 10/16 20130101; E21B 29/002 20130101 |
International
Class: |
E21B 10/52 20060101
E21B010/52; E21B 10/16 20060101 E21B010/16; E21B 10/08 20060101
E21B010/08; E21B 29/00 20060101 E21B029/00; E21B 33/12 20060101
E21B033/12 |
Claims
1. A rotary cone drill bit, comprising: a plurality of legs; a
bearing shaft extending from each leg; and first and second rotary
cones, each rotary cone rotatably mounted to a respective bearing
shaft, wherein: each rotary cone defines a generally conical
surface, each rotary cone has a nose row of cutting structures, an
inner row of cutting structures, and a gage row of cutting
structures, each cutting structure extends from the respective
generally conical surface, the nose row of the cutting structures
of each rotary cone comprises milled teeth, the inner row of the
cutting structures of each rotary cone comprises milled teeth, the
gage row of cutting structures of each rotary cone consists of
cutter inserts, and each cutter insert includes a cutting portion
disposed above the respective generally conical surface and a lower
base portion disposed below the respective generally conical
surface.
2. The rotary cone drill bit of claim 1, wherein: the rotary cone
drill bit further comprises a third rotary cone, and the inner row
of the cutting structures of the third rotary cone comprises milled
teeth.
3. The rotary cone drill bit of claim 2, wherein: the nose row of
the first rotary cone is disposed closer to a center rotational
axis of the drill bit than the nose row of the third rotary cone,
and the nose row of the third rotary cone is disposed closer to the
center rotational axis than the nose row of the second rotary
cone.
4. The rotary cone drill bit of claim 3, wherein the third rotary
cone includes an adjacent to gage row of cutter inserts intermeshed
and extending from a same land as the gage row of cutter
inserts.
5. The rotary cone drill bit of claim 1, wherein each of the milled
teeth is formed of steel.
6. The rotary cone drill bit of claim 1, wherein the cutter inserts
are tungsten carbide cutter inserts.
7. The rotary cone drill bit of claim 1, wherein the cutter inserts
are selected from a group consisting of: polycrystalline diamond
compact cutter inserts, impregnated diamond segment cutter inserts,
polycrystalline cubic boron nitride compact cutter inserts, and
ceramic cutter inserts.
8. The rotary cone drill bit of claim 1, wherein the cutter inserts
are each interference fit into respective sockets formed in each
rotary cone.
9. The rotary cone drill bit of claim 1, wherein the cutter inserts
are each brazed into respective sockets formed in each rotary
cone.
10. The rotary cone drill bit of claim 1, wherein the cutter
inserts are each welded into respective sockets formed in each
rotary cone.
11. The rotary cone drill bit of claim 1 wherein the cutter inserts
are each adhered using an adhesive into respective sockets formed
in each rotary cone.
12. The rotary cone drill bit of claim 1, wherein each of the
cutter inserts is conical-shaped.
13. The rotary cone drill bit of claim 1, wherein each of the
cutter inserts is chisel-shaped.
14. The rotary cone drill bit of claim 1, wherein each of the
rotary cones includes a base surface and a heel surface, the heel
surface being axially disposed between the base surface and the
gage row of cutter inserts, the heel surface not supporting a
cutting structure.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to bits for drilling
a wellbore, and more particularly to a hybrid rotary cone drill bit
for use in conditioning a wellbore and drilling out hydraulic
fracture equipment (e.g. frac plugs) or bridge plugs.
BACKGROUND
[0002] A roller cone rock bit is a cutting tool used in oil, gas,
and mining fields to break through earth formations to shape a
wellbore. In shaping the wellbore, the roller cone bit drills
through different geological materials making up different rock
formations. Although the drill bit encounters different formations
at different depths in drilling through rock, generally speaking
all parts of the drill bit are drilling the same type of rock
formation at the same time.
[0003] In hydraulic fracturing operations, a frac plug is secured
to a casing that lines the borehole. The frac plug is something of
a disposable tool because after the frac plug has performed its
function, it is drilled out using a roller cone rock bit
manufactured to International Association of Drilling Contractors
(IADC) standards, and the drilled out pieces of the plug are
flushed up the wellbore by the drilling mud. A frac plug is a
generally cylindrical component formed of different materials
disposed at different radial positions moving from a generally
hollow center. In contrast to drilling through rock formations,
when drilling out a frac plug, the drill bit simultaneously drills
through different materials. The different materials create
different penetration efficiencies and wear characteristics on
different parts of the bit.
[0004] Reference is made to U.S. Pat. No. 5,131,480 to Lockstedt
(the disclosure of which is incorporated by reference), which
discloses a milled tooth rotary cone rock bit where a heel row of
each cone is relieved and tungsten carbide chisel inserts are
inserted in the relieved heel row. The heel row inserts cooperate
with the gage row milled teeth and progressively cut more of the
gage row of the bore hole as the gage row milled teeth wear.
SUMMARY
[0005] In an embodiment, a hybrid rotary cone drill bit includes a
plurality of legs. A bearing shaft extends from each leg, and a
rotary cone is rotationally coupled to each bearing shaft. At least
one rotary cone includes a nose row of cutting structures, an inner
row of cutting structures, and a gage row of cutting structures.
The nose row and the inner row of cutting structures include milled
teeth. The gage row of cutting structures includes cutter
inserts.
[0006] In certain embodiments, the cutter inserts are tungsten
carbide inserts and the milled teeth are formed of steel. The
cutter inserts may be conical-shaped or chisel-shaped.
[0007] The hybrid rotary cone drill bit of the present disclosure
is employed to drill out different materials of a plug
simultaneously. The location of the cutter inserts and the milled
teeth on the rotary cones allows the different materials of the
plug to be effectively drilled out. Specifically, the relatively
harder material of a plug slip disposed on an outer diameter of the
plug is effectively drilled out by the cutter inserts disposed on
an outer diameter of the bit, while the relatively softer material
of the plug body is effectively drilled out by milled teeth
disposed radially inward of the cutter inserts.
[0008] Other aspects, features, and advantages will become apparent
from the following detailed description when taken in conjunction
with the accompanying drawings, which are a part of this disclosure
and which illustrate, by way of example, principles of the
inventions disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a more complete understanding of the present invention
and the advantages thereof, reference is now made to the following
brief description, taken in connection with the accompanying
drawings and detailed description, wherein like reference numerals
represent like parts, in which:
[0010] FIG. 1 illustrates a hybrid rotary cone drill bit disposed
in a drill out position directly above a cross section of a frac
plug set in a borehole;
[0011] FIG. 2A illustrates a face of a hybrid rotary cone drill bit
according to the teachings of the present disclosure;
[0012] FIG. 2B illustrates a cross section with rotational
projections showing the position of milled teeth and cutter inserts
in a borehole according to the teachings of the present
disclosure;
[0013] FIG. 3A illustrates a face of an alternate embodiment of a
hybrid rotary cone drill bit according to the teachings of the
present disclosure; and
[0014] FIG. 3B illustrates a cross section with rotational
projections showing the position of milled teeth and cutter inserts
in a borehole according to the teachings of an alternate embodiment
of the present disclosure.
DETAILED DESCRIPTION OF THE DRAWINGS
[0015] Reference is now made to FIG. 1, which shows a hybrid drill
bit 10 or more specifically a hybrid rotary cone drill bit 10. The
hybrid rotary cone drill bit 10 is illustrated in a borehole or
wellbore 12 lined with a metal casing 16. The bit 10 is shown in a
drill out position above a cross section of a casing plug or plug
14. The hybrid drill bit 10 includes three legs 18 (two shown) that
depend from a bit body (not shown). As described in more detail
below, each of the legs 18 supports a rotary cone 20. Each of the
rotary cones 20 includes two different types of cutting structures.
The cutting structures closest to the casing 16 in the wellbore 12
are cutter inserts 22, for example, tungsten carbide inserts. The
cutting structures towards the center of the wellbore 12 are milled
teeth 24. The cutter inserts 22 are conical-shaped but may be
dome-shaped, chisel-shaped, double conical-shaped, ovoid-shaped, or
any other shape suitable for drilling out a casing plug 14.
[0016] The hybrid drill bit 10 is configured to drill out the
entirety of a borehole and/or a frac plug secured within a
borehole. Thus, the hybrid drill bit 10 is configured to drill out
either rock formation or portions of a frac plug from the
centerline of the borehole and extending to the full radius of the
borehole. The hybrid drill bit 10 differs from a reamer in that a
reamer is not configured to drill out a central portion of a
borehole proximate the centerline. Rather, a reamer is configured
to ream a hole that has already been at least partially formed.
[0017] In certain borehole operations, such as hydraulic fracturing
or fracking, a plug 14, such as a frac plug, is used to isolate a
portion of a wellbore 12 to be fracked. The plug 14 acts as a
one-way valve and allows a specific section of the borehole to be
isolated and pressurized for the hydraulic fracking operation.
After the plug 14 has performed its function, it is drilled out in
a drill out operation using the hybrid rotary cone drill bit 10
according to the teachings of the present disclosure. In a drill
out operation, the hybrid rotary cone drill bit 10 is attached to a
drill string and is rotated such that its cutting elements crush,
rip, and break apart the plug 14. Drilling fluid pumped through the
bit 10 flushes the pieces of the plug 14 back to the surface. Plugs
other than frac plugs may be secured in a borehole and may be
drilled out with a hybrid rotary cone drill bit 10 according to the
teachings of the present disclosure. For example, the hybrid rotary
cone drill bit 10 may be used to drill out bridge plugs and other
types of plugs that engage a casing 16.
[0018] In preparation for fracking, the plug 14 is positioned at
the desired location in the borehole 12 such that an outer diameter
portion of the plug 14 grips the casing 16 and secures or sets the
plug 14 in position. Once set, the plug 14 will withstand
pressurization of the zone in the borehole without moving or
slipping. To set the plug 14, a slip 26 that is generally in the
form of a ring surrounding a portion of a plug body 28 is caused to
engage the casing 16 and create a type of seal. For purposes of
this disclosure, the plug body 28 includes any portion of the plug
not formed of relatively harder material that is engaged with the
casing 16 to set the plug in position and create a seal. Although
the plug body 28 is primarily disposed radially internal to the
slip 26, some portions of the plug body 28 may be disposed above or
below and aligned with the slips 26.
[0019] In the embodiment illustrated in FIG. 1, an upper and a
lower slip 26 are shown. The slips 26 each include a plurality of
ridges 29 that bite into the casing to provide a robust grip. The
slips 26 expand and may partially fracture such that some of the
slips 26 embed into the metal casing 16. To maintain the grip of
the plug 14 under high pressures, the slip 26 is generally formed
from a hard material. In certain plugs 14, the slip 26 is formed
from cast iron. Once set, the slip 26 occupies a space between the
casing 16 and the plug body 28, which may be up to an inch inside
the diameter of the casing. For example, a casing 16 of a borehole
may have a diameter of approximately twelve inches and the slip 26
may have an outer diameter of approximately twelve inches and an
inner diameter of approximately ten inches.
[0020] In certain embodiments, the slip 26 may include tungsten
carbide or ceramic inserts that embed into the casing 16 for a
better grip. A plug including such inserts is disclosed in U.S.
Pat. No. 5,984,007 to Yuan (the disclosure of which is incorporated
by reference). In contrast to the very hard material of the slip
26, the plug body 28 is generally formed of softer material than
the slip 26 and/or any inserts that are included in the slip 26.
For example, the plug body 28 is often formed of a composite
material, a thermoplastic, or a softer metal, such as brass.
[0021] Because the plug 14 includes relatively softer materials in
its inner portions and relatively harder materials in its outer
portions, during drill out the hybrid rotary cone drill bit 10
simultaneously contacts and breaks apart both relatively harder and
relatively softer materials. As such, during the drill out using
the hybrid bit 10, the cutter inserts 22 engage the slip 26 and/or
the plug inserts that are adjacent, contacting, or embedded into
the casing 16. This is because the cutter inserts 22 are disposed
on the outer diameter of the bit 10, which in operation are closest
to the casing 16. For example, the cutter inserts 22 may be
disposed on the outer one inch diameter of the cutting face of the
bit 10. Thus, a hybrid rotary cone drill bit 10 with a face
defining a twelve inch outer diameter may have milled teeth from
its center to an approximately 10 inch diameter while the outer one
inch radius (two inch diameter) of the face is where the cutter
inserts 22 are disposed.
[0022] The softer bit body 28 is drilled out by the milled teeth
24, but the milled teeth are generally not subjected to the hard
material of the slip 26, which increases the overall durability of
the bit 10. The milled teeth 24 are more aggressive, efficient, and
better suited for penetrating, gripping, and cutting the softer
material of the plug body 28. In contrast, the cutter inserts 22
are less efficient in cutting and ripping the material of the plug
body 28. Moreover, if the cutter inserts 22 are used to drill out
the plug body 28, the steel substrate of the rotary cone 20 is
subject to wear, which often results in expensive cutter inserts
separating from the rotary cone 20 and being lost in the
borehole.
[0023] The cutter inserts 22 are typically formed of very hard
material, such as tungsten carbide. The cutter inserts 22 may
alternatively be other very hard material incorporated into a
cutting structure, such as a polycrystalline diamond compact, an
impregnated diamond segment, a polycrystalline cubic boron nitride
compact, or the cutter inserts 22 may be formed of any of the
material in the family of ceramic materials. The hard material
incorporated into the cutter inserts 22 does not wear as fast as
the steel substrate when it drills through or otherwise contacts
the substantially equally hard material of the slip 26 and or slip
inserts. Thus, the cutter inserts 22 wear less than the milled
teeth 24 when drilling out the hard material of the slip 26 and or
slip inserts of the plug 14.
[0024] Reference is made to FIGS. 2A and 2B, which illustrate in
more detail the rotary cones 20 of the hybrid drill bit 10
according to the teachings of the present disclosure. FIG. 2A shows
the face 30 of the hybrid rotary cone drill bit. FIG. 2B is a
cross-section taken through one of the rotary cones shown in FIG.
2A. In addition, FIG. 2B illustrates a rotational projection of the
position of the cutting elements of each of the three rotary cones
as the bit rotates in the borehole. FIG. 2B shows a bearing shaft
21 extending from the leg 18 of the bit. Each rotary cone is
rotatably mounted to a bearing shaft 21.
[0025] FIG. 2A shows rotary cone one 32a, rotary cone two 32b, and
rotary cone three 32c (collectively illustrated as rotary cone 32
in FIG. 2B). Rotary cones are also referred to as roller cones.
Each of the rotary cones 32a, 32b, 32c defines a generally conical
surface 33 (see FIG. 2B) and includes two different cutting
elements extending from the generally conical surface 33. For
example, rotary cone one 32a includes a nose row, which is disposed
in the centermost area of the drill bit and is formed of a
plurality of milled teeth 36a. As previously discussed, the milled
teeth 36a are milled into the steel of the substrate of the rotary
cone 32a and are aggressive cutting structures. The bit substrate
also may be formed from a matrix metal or any other material
suitable for earth boring drill bits.
[0026] According to the teachings of the present disclosure, the
nose row milled teeth 36a are disposed in a central portion of the
bit to drill through the corresponding softer material center
portion of a plug, referred to as the plug body. The nose row
milled teeth 36a efficiently drill through this softer material at
a higher rate of penetration than other types of cutting
structures, including cutter inserts 22. Each of rotary cones two
and three also include nose rows of milled teeth 36b, 36c. The
relative drilling positions among the nose rows of milled teeth are
shown in FIG. 2B.
[0027] Disposed from the nose row milled teeth toward a base 38 of
the rotary cone 32 is an inner row of cutting structures. The
cutting structures forming the inner row are milled teeth 42a
formed similarly to the nose row milled teeth 36a. Each of rotary
cones one, two, and three have one inner row of milled teeth 42a,
42b, 42c. Similar to the nose row milled teeth 36a, 36b, 36c, the
inner row milled teeth 42a, 42b, 42c are also disposed to drill
through the inner portion of the plug 14 or plug body 28, which
generally is formed from softer materials, such as composites,
thermoplastics, or softer metals. The relative drilling positions
among the inner rows of milled teeth 42a, 42b, 42c for each rotary
cone 32a, 32b, 32c are illustrated in FIG. 2B. Alternate
embodiments of a hybrid rotary cone drill bit according to the
teachings of the present disclosure may include more than one inner
row of milled teeth. For example, a larger drill bit will have
larger rotary cones, which will tend to have one or more additional
inner rows of milled teeth to drill out larger diameter plugs.
[0028] A gage row of cutter inserts 46 is disposed closest to the
base of the rotary cone 32. The gage row of cutter inserts 46
extend from the generally conical surface 33 of the rotary cone 32.
Each of rotary cones one, two, and three includes gage rows of
cutter inserts 46a, 46b, 46c. In the embodiment shown in FIGS. 2A
and 2B, the cutter inserts 46 are conical-shaped. In addition, the
cutter inserts 46 of each of the three cones 32 are generally
aligned during rotation, such that the cutter inserts 46 of all
three cones 32a, 32b, 32c are illustrated by a single cutter insert
projection in FIG. 2B. In an alternate embodiment, the gage row of
the rotary cone 32 may include both milled teeth and cutter
inserts. The milled teeth may be slightly internally offset and
intermeshed with the cutter inserts or the milled teeth may be
interspersed within the gage row of cutter inserts.
[0029] As shown in FIG. 2B, the cutter inserts 46 are disposed
closest to the casing 16 during drill out. As such, when drilling
out a plug, the cutter inserts 46 will drill out the outermost
diameter portion of the plug including those portions of the plug
that are embedded into or otherwise securing the plug to the casing
16. As previously described, the outermost diameter portion of the
plug 14 is referred to as the slip 26 and is generally formed from
hard material that is more likely to wear the steel of the rotary
cones 32 than the softer plug body 28. Thus, the cutter inserts 46
are better suited to drill out such hardened material, such as a
cast iron slip and/or or tungsten carbide or ceramic slip
inserts.
[0030] As seen in the cross section of FIG. 2B, the cutter inserts
46 include a cutting portion 48, which is disposed above the
generally conical surface 33 of the rotary cone 32 and a lower base
portion 50, which is disposed below the generally conical surface
33 of the rotary cone. A hole or socket 54 is formed in the
generally conical surface 33 of the rotary cone 32, either by
casting or machining, that receives the lower base portion 50 of
the cutter insert 46 in a press or interference-type fit. The lower
base portion 50 may be welded or brazed into the socket 54. In
addition, an adhesive may be used to secure the lower base portion
50 into the socket 54. The cutter insert 46 illustrated is
conical-shaped, but alternatively the cutter insert may be
chisel-shaped or any other suitable shape for the cutting portion
48 of the cutter insert 46.
[0031] Disposed between the gage row 44 and the base 38 is a heel
56 of the rotary cone 32. The heel 56 and the base 38 are not
considered part of the generally conical surface 33 of the rotary
cone 32. There are generally no cutting elements, milled tooth or
cutter inserts, on the base 38 or the heel 56 of the rotary cone
32.
[0032] The milled teeth 36a, 36b, 36c of the nose rows (especially
the nose row milled teeth 36a of cone one 32a) provide a
penetrating cutting structure to drill out the center portion of
the plug. In addition, the tooth profile of the milled teeth is
better suited to penetrate the softer material of the bit body.
Together, these characteristics of the milled teeth allow the
cutter to penetrate and "chew" up the softer material of the plug
body while simultaneously the harder cutter inserts 46, for example
tungsten carbide inserts, dislodge the slip 26 from the casing and
break the slip apart into chunks to be flushed up the borehole.
[0033] Reference is now made to FIGS. 3A and 3B, which illustrate
an alternate embodiment of a hybrid rotary cone drill bit according
to the teachings of the present disclosure. FIG. 3A shows the face
60 of the hybrid rotary cone drill bit. FIG. 3B illustrates a
cross-section taken through one of the rotary cones shown in FIG.
3A. In addition, FIG. 3B illustrates a rotational projection of the
position of the cutting elements of each of the three rotary cones
62 as the bit rotates.
[0034] Similar to the embodiment of FIGS. 2A and 2B, each of the
rotary cones 62 includes a nose row of milled teeth 66a, 66b, 66c.
Also, rotary cones one and two 62a, 62b each include an inner row
of milled teeth 70a, 70b. An inner row 68c of rotary cone three 62c
includes a row of cutter inserts 72c. However, in an alternate
embodiment, all three of the rotary cones 62 may each include an
inner row of milled teeth. Also, as discussed with respect to the
embodiment shown in FIGS. 2A and 2B, the cones 62 may include more
than one inner row of milled teeth.
[0035] Each of the three cones 62 include a gage row of cutter
inserts 76a, 76b, 76c (represented by reference number 76 in FIG.
3B) configured to drill out and break apart the harder material of
the slip 26 of the plug 14 or slip inserts that may be embedded in
the casing 16. The gage row of rotary cone two 62b includes an
adjacent-to-gage row of cutter inserts 78b intermeshed with gage
row of cutter inserts 76b. The adjacent-to-gage row cutter inserts
78b are secured into recesses formed in the same land 80b as the
gage row cutter inserts 76b. The degree of intermeshing is shown in
FIG. 3B. Other embodiments of the present disclosure may include
adjacent-to-gage row cutter inserts on cones one and/or three in
addition to rotary cone two. The adjacent-to-gage row cutter
inserts 78b are used to break apart larger slips 26 and protect the
milled teeth from contacting and being worn by the harder material
of the slip.
[0036] As shown in FIG. 3B, a base portion 80 of the cutter inserts
of inner row 72c, gage rows 74, and adjacent-to-gage row 78b is
secured into a socket 82 formed in the rotary cone; a cutting
portion 84 extends beyond the outer generally conical surface 33 of
the rotary cone, as described above with respect to FIG. 2B. The
gage row cutter inserts 76 shown are gage-chisel-shaped inserts.
However, any suitable cutter insert including chisel-shaped,
dome-shaped, conical-shaped, double conical-shaped, ovoid-shaped,
and the like may be used in the hybrid rotary cone drill bit
according to the teachings of the present disclosure.
[0037] The foregoing describes only some embodiments of the
invention(s), and alterations, modifications, additions and/or
changes can be made thereto without departing from the scope and
spirit of the disclosed embodiments, the embodiments being
illustrative and not restrictive.
* * * * *