AU2006208449B2 - Roller reamer - Google Patents

Abstract

This invention describes a reaming tool (10) for attachment to a drill string having a body (12) that has connection means (14a, 14b) at either end for attachment to a drill string, at least one roller reamer (16) rotatably mounted to the body (12), and at least one channel (18) extending on the body positioned to intersect with the roller reamer (16). This ensures that flushing fluid flow is directed to each roller reamer (16).

Description

WO 2006/079166 PCT/AU2006/000088 1 ROLLER REAMER FIELD OF THE INVENTION In general, the present invention relates to devices used to enlarge or maintain a 5 bore hole at a required diameter using a reaming action. In particular, it relates to a reamer having rollers. BACKGROUND OF THE INVENTION It is often necessary when drilling a bore hole to maintain or enlarge the diameter 10 of the bore hole with second and subsequent passes of cutting components. This is necessary due to drill bit wear and gradual reduction in the gauge diameter of the hole. Also, certain materials being drilled can swell, which results in reduction of the bore hole diameter after the drill bit has past. 15 Reamers can be used in association with a drill bit to ensure that a bore hole is drilled to a constant diameter. A roller-type reamer has cutting components rotatably mounted. The roller reamer is commonly used in the drilling industry, one purpose being to ream the hole just behind the drill bit to maintain hole size. A roller reamer can also act as a stabiliser above the drill bit to stabilise the drill 20 bit and drill string against the deviating tendencies encountered during drilling. One problem with roller reamers is that under the conditions encountered during drilling, rock chips and other debris can build up behind the roller, which may jam or slow rotation of the rollers thereby reducing their effectiveness. Also, even 25 under normal operating conditions, rotation of the rollers can also cause the roller to increase in temperature which further increases the stress on the rotating parts. Increased stress may cause those rotating parts to wear more quickly. This is a costly problem because the reamer will have to be brought to the surface, dismantled and reassembled. 30 2 The technique of reaming is a significant step in achieving the required diameter of the bore hole. Accordingly there is always a need for reamers with improved construction and longevity. It is an object of the present invention to reduce or eliminate some or all of the disadvantages of roller reamers discussed above, or 5 at least to provide a useful alternative. Other objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present 10 invention is disclosed. SUMMARY OF THE INVENTION In one form the invention may be said to reside in a reaming tool for attachment to a drill string comprising: 15 a body rotatable in a direction of rotation and having connection means at either end for attachment to a drill string, the body defining a longitudinal axis; at least one roller reamer rotatably mounted to the body, the at least one roller reamer defining an axis of rotation, the axis of rotation being inclined with respect to the longitudinal axis of the body in a direction away from the direction 20 of rotation of the body; and at least one channel defining a channel axis extending on the body and being inclined with respect to the longitudinal axis of the body in a direction toward the direction of rotation of the body such that the channel intersects the roller reamer and the axis of the roller reamer intersects the channel axis. 25 The roller reamer may be substantially cylindrical in shape and extend substantially along the body. Preferably a number of roller reamers are spaced radially around the body. Further preferably the roller reamers are inclined at an angle to the longitudinal axis of the body and may have an outer surface that is 3 generally curved along the longitudinal axis of the roller to result in a "barrel" shape. The rollers may be fluted with a series of helically shaped flutes where the outer 5 surface of the ribs formed between the flutes contact the surface of the hole to be drilled. In one form, the channels extend along the body and are inclined at an angle to the longitudinal axis. 10 In one form, when in use, the channels direct fluid flow over and around the rollers substantially in the direction of the helically shaped flutes of the rollers. The outer surfaces of the ribs formed between the flutes of the rollers may have 15 hardened elements attached to provide wear resistance. For example, a plurality of carbide inserts may be inserted within each of these surfaces, or hard facing (wear resistant coating) may be used. In one form, the carbide inserts are positioned such that when the roller is rotated 20 the tracks of adjacent carbide inserts overlap, providing optimum reaming efficiency. In a further aspect, the invention maybe said to reside in a drilling tool comprising a body rotatable in a direction of rotation and defining a longitudinal 25 axis and a reaming portion having at least one roller reamer rotatably mounted to the body of said drilling tool, the at least one roller reamer defining an axis of rotation and being inclined in a direction away from the direction of rotation of the body, the axis of rotation further being inclined relative to the longitudinal axis of the body, and at least one channel extending on the body and being 30 inclined with respect to the longitudinal axis 3a of the body in a direction toward the direction of rotation of the body and positioned to intersect with the roller reamer. In yet a further aspect, the invention may be said to reside ina reaming tool for attachment 5 to a drill string, the reaming tool comprising: a body rotatable in a direction of rotation and defining a longitudinal axis and having at least one connector at an end for attachment to a drill string; and a reamer portion defining at least one pocket extending along an axis inclined in a direction away from the direction of rotation of the body, the reamer portion comprising: 10 at least one roller reamer rotatably mounted within the at least one pocket, the roller reamer defining an axis of rotation that is radially offset from and skewed relative to the longitudinal axis of the body, the at least one roller reamer further including a helical flute extending along the length of the at least one roller reamer, and a plurality of wear resistant members disposed adjacent the helical flute; and 15 at least one channel on the reamer portion extending at an angle from the at least one pocket, the channel extending on the body and being inclined with respect to the longitudinal axis of the body in a direction toward the direction of rotation of the body and defining a fluid passage for directing fluid towards the at least one roller reamer. 20 In a further aspect, the invention may be said to reside in a reaming tool for attachment to a drill string, the reaming tool comprising a body having connection means at each end for attachment to a drill string, the body defining a longitudinal axis, at least one roller reamer rotatably mounted to the body, and having a rotational axis inclined with respect to the longitudinal axis of the body, and 25 at least one channel having a channel axis extending on the body so as to be inclined with respect to the longitudinal axis of the body in a direction opposite the direction of inclination of the rotational axis of the roller reamer and disposed such that the channel intersects the roller reamer and the rotational axis of the roller reamer intersects the channel axis. 30 In yet a further aspect, the invention may be said to reside in a drilling tool comprising a body defining a longitudinal axis, at least one roller reamer rotatably mounted to the body, and having a rotational axis inclined with respect to the longitudinal axis of the body, and at least one channel having a channel axis extending on the body so as to be inclined with 35 respect to the longitudinal axis of the body in a direction opposite the direction of inclination of the rotational axis of the roller reamer and disposed such that the channel intersects the roller reamer and the rotational axis of the roller reamer intersects the channel axis.

3b Other variations and alternatives for the invention will be readily understood by a person skilled in the art and should be understood to be included within the scope of the invention. In order to fully understand this invention, a preferred embodiment will now be described. 5 However, it should be realised that the scope of the invention is not to be limited to the features of this embodiment. BRIEF DESCRIPTION OF THE DRAWINGS This embodiment is illustrated in the accompanying drawings in which: 10 Figure 1 shows a side view of the reaming tool; Figure 2 is a top view of the reamer of Figure 1; and Figure 3 shows a close up of part of Figure 1. In the following description, like reference characters designate like or corresponding parts 15 throughout the several views of the drawings. Referring to Figure 1, the reaming tool 10 includes an elongate body 12 with threaded portions 14a and 14b at either end that connect the reaming tool to the drill rods of a drill string or the drill bit at the end of the drill string (not shown). 20 WO 2006/079166 PCT/AU2006/000088 4 The skilled addressee will understand that any means of incorporating the reaming tool 10 into the drill string could be used. This includes a combination of a drill bit with roller reamers located behind the drill bit 5 The elongate body 12 has an enlarged portion which includes roller reaming elements 16. In use, the enlarged portion is subjected to aggressive wear, given the change in diameter. Therefore, hard facing 17 can be provided at each end of the enlarged portion. The hard facing 17 can be a plurality of carbide inserts or, alternatively, as in the embodiment described, the hard facing 17 can be a 10 tungsten carbide coating which is metallurgically bonded onto the enlarged portion of the elongate body 12. In this embodiment the reaming tool 10 has three roller readers 16 which are rotatably mounted about the circumference of the elongate body 12. In Figure 1 15 only two of the roller reamers 16 can be seen, the third is screened from view. It should be understood that any number of roller reamers 16 could be used, however three is preferred for a smaller diameter tool. Each of the roller readers 16 is substantially cylindrical and can be tapered from each end to form a barrel shape to improve the reaming process. The roller reamers 16 are positioned at an 20 angle to the longitudinal axis of the elongate body 12. This inclination together with the curvature along the longitudinal axis of the roller reamers 16 means that each roller reamer 16 has improved contact with the hole; the roller reamers 16 being in contact with the hole along the entire length of the roller reamer. 25 The elongate body 12 has channels 18 which extend along its surface. The channels 18 are preferably also inclined at an angle to the longitudinal axis of the elongate body. In Figure 2 a top view of the enlarged portion of elongate body 12 is shown. The 30 channels 18 of the elongate body 12 can be seen as well as a part of each of the WO 2006/079166 PCT/AU2006/000088 5 three roller reamers 16. From this view it is clear that the channels 18 and roller reamers 16 are sequentially arranged and evenly spaced around the periphery of the reaming tool. A fluid annulus 19 is formed between the elongate body 12 and the side walls of the bore hole (not shown). Drilling fluid, which is forced down 5 the drill string and over the cutting components of the drill bit, is then forced up the fluid annulus 19 past the reaming tool 10. Turning now to Figure 3, there is shown a close up of the enlarged portion of the elongate body 12 of Figure 1. The roller reamers 16 can be seen in more detail. In 10 particular there can be seen a plurality of helical flutes 20 with intervening ribs 22. The outer surfaces of the ribs 22 have spherical-head tungsten carbide inserts 24 inserted therein. These provide a hard wear resistant surface. It is an option that the carbide inserts 24 are positioned such that when the roller reaming element 16 is rotated, the tracks of adjacent carbide inserts 24 on each rib 22 15 overlap, providing optimum reaming efficiency. In addition, the spiral configuration of the intervening ribs 22 result in increased contact between the roller reamer 16 and the bore hole wall which further improves the stability of the tool. 20 It should be understood that any shape of carbide inserts 24, as well as any configuration of carbide inserts 24 on the ribs 22 could be used which has the effect of reaming the bore hole. For example the carbide inserts could be flat or pointed. Alternatively the carbide inserts could be replaced with a hard facing (wear resistant coating). 25 The channels 18 of the elongate body 12 each extend from a peripheral edge of the roller reamers 16, the effect is that each channel 18, intersects with a roller reamer 16. It will be appreciated that because of the position of the channels 18, a portion of the drilling fluid travelling up the fluid annulus 19, will flow through 30 the channel 18 and over and around each roller reamer 16. The drilling fluid will 6 carry away with it rock chips and other debris which otherwise may be trapped around a roller reamer 16. The helical flutes 20 of the roller reamer 16 are preferably positioned so that when the drilling fluid passes over the roller reamer 16, the helical flutes facilitate the upward flow of drilling fluid through the 5 channels 18. The flow of drilling fluid alleviates the stress on the roller reamers 16 as well as acts to decrease their temperature, and the temperature of carbide inserts 24 which could otherwise increase during operation. Also, there is a reduction in frictional heat build-up in the carbides 24 due to improved flow of drilling fluid. 10 Although a preferred embodiment of the apparatus of the present invention has been described in the foregoing detailed description, it will be understood that the invention is not limited to the embodiment disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing 15 from the scope of the invention. Modifications and variations such as would be apparent to a skilled addressee are deemed within the scope of the present invention. For example, more or fewer roller reamers could be included within the elongate 20 body of the reaming tool. In such an arrangement there would be a corresponding number of channels. These examples are not intended as an exhaustive list, and are only intended to be indicative of other embodiments still in accordance with the present invention. 25 It will be understood that the term "comprise" and any of its derivatives (eg. comprises, comprising) as used in this specification is to be taken to be inclusive of features to which it refers, and is not meant to exclude the presence of any additional features unless otherwise stated or implied.

7 The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge. 5 It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that various modifications can be made without departing from the principles of the 10 invention. Therefore, the invention should be understood to include all such modifications in its scope.

Claims (12)

1. A reaming tool for attachment to a drill string, the reaming tool comprising a body having connection means at each end for attachment to a drill string, the body defining a longitudinal axis, 5 at least one roller reamer rotatably mounted to the body, and having a rotational axis inclined with respect to the longitudinal axis of the body, and at least one channel having a channel axis extending on the body so as to be inclined with respect to the longitudinal axis of the body in a direction opposite the direction of inclination of the rotational axis of the roller reamer and disposed such that the channel intersects the roller reamer and 10 the rotational axis of the roller reamer intersects the channel axis.

2. The reaming tool according to claim 1, comprising three radially spaced roller reamers and three channels. 15

3. The reaming tool according to claim 2, having a plurality of roller reamers each mounted so that its rotational axis is inclined with respect to the longitudinal axis of the body.

4. The reaming tool according to claim 3, having a plurality of channels, the longitudinal axis of each of the channels being inclined with respect to the longitudinal axis of the body in a direction 20 opposite the direction of inclination of the rotational axis of the roller reamer.

5. The reaming tool according to any one of the preceding claims, wherein the width of each channel where it intersects its respective roller reamer is substantially as wide as the roller reamer. 25

6. The reaming tool according to any one of the preceding claims, wherein the longitudinal axis of the or each of the channels either side of its respective roller reamer are not aligned.

7. The reaming tool according to any one of the preceding claims, wherein the body further comprises a larger diameter portion located intermediate the ends of the body, the or each roller 30 reamer and the or each channel being located on the larger diameter portion.

8. The reaming tool according to any one of the preceding claims, wherein the or each roller reamer has one or more helical channels extending along its length. 35 9. The reaming tool according to any one of the preceding claims, comprising a plurality of channels intersecting the or each roller reamer.

9

10. A drilling tool comprising a body defining a longitudinal axis, at least one roller reamer rotatably mounted to the body, and having a rotational axis inclined with respect to the longitudinal axis of the body, and 5 at least one channel having a channel axis extending on the body so as to be inclined with respect to the longitudinal axis of the body in a direction opposite the direction of inclination of the rotational axis of the roller reamer and disposed such that the channel intersects the roller reamer and the rotational axis of the roller reamer intersects the channel axis. 10

11. A reaming tool substantially as herein described with reference to the accompanying drawings.

12. A drilling tool substantially as herein described with reference to the accompanying drawings.