CA3003991C - Integral tubular member and methods of manufacturing the same - Google Patents
Integral tubular member and methods of manufacturing the same Download PDFInfo
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- CA3003991C CA3003991C CA3003991A CA3003991A CA3003991C CA 3003991 C CA3003991 C CA 3003991C CA 3003991 A CA3003991 A CA 3003991A CA 3003991 A CA3003991 A CA 3003991A CA 3003991 C CA3003991 C CA 3003991C
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- integral
- wear pad
- tubular member
- tubular
- wall thickness
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/10—Wear protectors; Centralising devices, e.g. stabilisers
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/10—Wear protectors; Centralising devices, e.g. stabilisers
- E21B17/1085—Wear protectors; Blast joints; Hard facing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
- B21J5/08—Upsetting
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/02—Couplings; joints
- E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
- E21B17/042—Threaded
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- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Forging (AREA)
Abstract
An integral tubular member with at least one integral wear pad is provided. The integral tubular member is formed from a unitary tubular blank having first and second ends and a tube body extending there-between, the tube body being provided with at least one region of a thickened wall to form the at least one wear pad. A method of forming the integral tubular member is provided.
Description
CA Application Blakes Ref: 15072/00006
2
3 FIELD OF THE DISCLOSURE
4 [0001] The present application relates generally to an integral tubular member and methods of manufacturing an integral tubular member, more specifically an integral tubular 6 member with at least one wear pad and methods of manufacturing an integral tubular member 7 with at least one wear pad.
9 [0002] This section provides background information to facilitate a better understanding of the various aspects of the invention. It should be understood that the statements in this 11 section of this document are to be read in this light, and not as admissions of prior art.
12 [0003] Standard drill pipe, used in oil and gas drilling operations, consists of a thin 13 walled tube with ends that have been upset and thickened in a forging-like process allowing for 14 two non-integral connector ends to be friction welded on to these ends.
These connector ends are typically known as tool joints and are machined to provide threaded. This current 16 manufacturing method of drill pipe requires friction welding and heat treatment technology that 17 does not lend itself to adding features to the tube region of the pipe.
In addition, friction welding 18 is a very specialized and expensive process which would be desirable to avoid.
19 [0004] When deployed for use in oil and gas drilling, drill pipes often wear in multiple areas including the tube body and tool joint portions. Therefore, during drilling operations, it is 21 desirable to protect the drill pipe from wear or to slow the rate of wear to prevent premature 22 failure of the drill pipe. Tool joints are generally thick walled elements and thus wear more 23 slowly than the drill pipe and they may be further protected from wear through a hardbanding 24 application. The thin walled tube body, on the other hand, typically cannot be easily protected from wear and, as a result, the tube wall thickness will eventually become too thin and result in 26 the drill pipe being downgraded to a lower class of drill pipe which prevents its further use in 27 many drilling operations.
28 [0005] Previous attempts at preventing drill pipe tube wear include additional 29 components or features being added to the drill pipe after it is manufactured. For example, clamp style centralizers and wear pads have been developed such as that disclosed in US
23372166.1 CA Application Blakes Ref: 15072/00006 1 3999811; however, these types of devices may loosen and be displaced along the length of the 2 drill pipe, or may even separate during drilling operations. Adhesive or molded centralizers and 3 wear pads have been developed, such as those disclosed in US 3697141 or US 8119047;
4 however, these devices invite small regions of corrosion to develop on the pipe wall immediately underneath the devices. This may be due to the presence of small voids in the bonds between 6 the tube and the wear pad feature, which may be filled by wellbore fluid via capillary action, and 7 resulting in corrosion of the metal drill pipe. In addition, it becomes difficult or impossible to 8 properly inspect the thickness or integrity of the tube body itself as these adhesive or molded 9 features are generally immovable.
[0006] Thus, it is desirable that the centralizer or wear pad features be integral to the 11 tube body and added or incorporated during manufacturing. One method of accomplishing this 12 is to create a tool joint-like feature in the center of the tube body through upsetting and friction 13 welding a pair of short drill pipe tubes together or friction welding two short drill pipe tubes to a 14 third tool joint-like component between them. Such a method is disclosed in US 8783344, which describes utilizing redistributed and upset substrate material and a friction welding process to 16 create a wear pad feature on the drill pipe tube. This method is, however, extremely cost 17 intensive and cumbersome to manufacture as friction welding is a very specialized and 18 expensive process, which would be desirable to avoid. In addition, this method involves the 19 application of a heat treatment step, which results in changes to the material properties of the drill pipe material. In the result, this method would necessitate additional material testing and 21 process validation steps to ensure that the drill pipe meets the required specifications.
23 [0007] In one aspect of the present description, there is provided an integral tubular 24 member formed from a unitary tubular blank, the integral tubular member comprising:
- a first end, a second end opposite the first end, and a tube body extending between the 26 first and second ends;
27 - the first and second ends being adapted for connection to other tubular members;
28 - at least one wear pad formed on the tube body, the at least one wear pad comprising a 29 region of increased wall thickness.
[0008] In another aspect, there is provided a method of manufacturing an integral 31 tubular member having at least one wear pad, the method comprising:
23372166.1 CA Application Blakes Ref: 15072/00006 1 - providing a tubular blank having a first end, a second end and a tube body extending 2 between the first and second ends;
3 - forming the at least one wear pad by processing at least one region of the tube body to 4 provide a wall thickness greater than the wall thickness of the tube body.
- processing the first and second ends to form, respectively, first and second connectors, 6 the first and second connectors comprising means for connecting the integral tubular 7 member to other tubular members.
8 [0009] In one aspect of this disclosure, there is provided an integral tubular member 9 formed from a one piece blank having a longitudinal axis. The integral tubular member includes an external longitudinal cross sectional profile, an internal longitudinal cross sectional profile, 11 the internal and external cross sectional profiles defining a wall there-between. The wall has 12 varied wall thickness along the integral tubular member with at least three bulges where the wall 13 is thicker than the nominal wall thickness of the tubular member. These bulges may be internal 14 bulges, external bulges, or a combination of both.
[0010] In one aspect, there is provided an integral tubular member with at least one 16 integral wear pad formed from a one piece blank having a longitudinal axis, a first end, a second 17 end, a first portion, a central portion, a second portion, an external longitudinal cross sectional 18 profile, an internal longitudinal cross sectional profile, and the internal and external cross 19 sectional profiles defining a wall there-between. The wall has varied wall thickness along the integral tubular member. The first portion of the integral tubular member has at least one 21 internal or external bulge where the wall is thicker than the nominal wall of the integral tubular 22 member, forming an integral connector end with increased strength. The first end of the integral 23 tubular member has a connection feature, the connection feature allowing for the integral 24 tubular member to be coupled to another tubular member. The second portion of the integral tubular member has at least one internal or external bulge where the wall is thicker than the 26 nominal wall of the integral tubular member, forming an integral connector end with increased 27 strength. The second end of the integral tubular member is provided to have a connection 28 feature, the connection feature allowing for the integral tubular member to be coupled to another 29 tubular member. The central portion of the integral tubular member has at least one localized region where the wall is thicker than the nominal wall of the central portion of the integral tubular 31 member, forming at least one integral wear pad.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0011] In one aspect, the at least one wear pad has a metallurgical grain structure and 2 grain direction substantially uniform and unaltered from the one-piece blank substrate.
3 [0012] In one aspect, the at least one integral wear pad has a wall thickness that is 4 between 50-100% greater than the nominal central portion wall thickness.
[0013] In a more specific aspect, the at least one integral wear pad has a nominal wall 6 thickness that is between 70-80% greater than the nominal central portion wall thickness.
7 [0014] In one aspect, the ratio of the nominal tube body outside diameter circumference 8 to the tube body transverse cross sectional area is less than or equal to .450 in/sq.in and the 9 ratio of the at least one integral wear pad outside diameter circumference to the wear pad transverse cross sectional area is greater than .450 in/sq. in.
11 [0015] In one aspect, the nominal integral tubular member tube body wall is equivalent 12 to standard drill pipe tube wall thickness.
13 [0016] In a further aspect, surface hardening or a surface coating is applied to at least 14 one of the at least one wear pads to increase wear resistance.
[0017] There is provided a method of manufacturing an integral tubular member.
A tube 16 is provided that has an outer wall, a hollow interior, a first end, a second end, a first portion, a 17 central portion and a second portion. The first portion is adjacent the first end, the second 18 portion is adjacent the second end and the central portion is positioned between the first portion 19 and the second portion. The first portion of the tube and the second portion of the tube are upset to form an upset tubular. The upset tubular has an outer wall, a hollow interior, a first end, 21 a second end, a first portion, a central portion, and a second portion.
The length of the first 22 portion of the upset tubular has a length of between 25-75% the length of the first portion of the 23 tube. The length of the second portion of the upset tubular has a length of between 25-75% the 24 length of the second portion of the tube. The first portion and the second portion of the upset tubular are processed to form integral connector ends, and the outer wall of the central portion 26 of the upset tubular is processed to form a predetermined outer profile creating an integral 27 tubular member.
28 [0018] In one aspect, the first integral connector end is processed to have a box 29 connection.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0019] In one aspect, the second integral connector end is processed to have a pin 2 connection.
3 [0020] In one aspect, the second integral connector end is processed to have a box 4 connection.
[0021] In one aspect, the first integral connector end is processed to have a pin 6 connection.
7 [0022] In one aspect, the predetermined outer profile is substantially cylindrical and 8 uniform 9 [0023] In one aspect, the predetermined outer profile has at least one integral wear pad.
The integral wear pad has a wall with increased wall thickness. The integral wear pad may be 11 centrally located on the integral tubular member. The integral wear pad may be a fluted wear 12 pad, a bladed wear pad, a ribbed wear pad or any other type of wear pad known in the art.
13 [0024] In one aspect, the tube is made of steel or aluminum alloy.
14 [0025] There is also provided an additional method of manufacturing an integral tubular member with at least one wear pad. A tube is provided that has an outer wall, a hollow interior, 16 a first end, a second end, a first portion, a central portion and a second portion. The first portion 17 is adjacent the first end, the second portion is adjacent the second end and the central portion is 18 positioned between the first portion and the second portion. The first portion of the tube and the 19 second portion of the tube are upset to form an upset tubular. The upset tubular has an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion, and a second 21 portion. The length of the first portion of the upset tubular has a length of between 25-75% the 22 length of the first portion of the tube. The length of the second portion of the upset tubular has a 23 length of between 25-75% the length of the second portion of the tube.
The first portion and the 24 second portion of the upset tubular are processed to form integral connector ends and the outer wall of the central portion of the upset tubular is processed to form a predetermined outer 26 profile. At least one of the first portion, the central portion and the second portion of the upset 27 tubular are processed to have at least one integral wear pad forming an integral tubular member 28 with at least one wear pad.
9 [0002] This section provides background information to facilitate a better understanding of the various aspects of the invention. It should be understood that the statements in this 11 section of this document are to be read in this light, and not as admissions of prior art.
12 [0003] Standard drill pipe, used in oil and gas drilling operations, consists of a thin 13 walled tube with ends that have been upset and thickened in a forging-like process allowing for 14 two non-integral connector ends to be friction welded on to these ends.
These connector ends are typically known as tool joints and are machined to provide threaded. This current 16 manufacturing method of drill pipe requires friction welding and heat treatment technology that 17 does not lend itself to adding features to the tube region of the pipe.
In addition, friction welding 18 is a very specialized and expensive process which would be desirable to avoid.
19 [0004] When deployed for use in oil and gas drilling, drill pipes often wear in multiple areas including the tube body and tool joint portions. Therefore, during drilling operations, it is 21 desirable to protect the drill pipe from wear or to slow the rate of wear to prevent premature 22 failure of the drill pipe. Tool joints are generally thick walled elements and thus wear more 23 slowly than the drill pipe and they may be further protected from wear through a hardbanding 24 application. The thin walled tube body, on the other hand, typically cannot be easily protected from wear and, as a result, the tube wall thickness will eventually become too thin and result in 26 the drill pipe being downgraded to a lower class of drill pipe which prevents its further use in 27 many drilling operations.
28 [0005] Previous attempts at preventing drill pipe tube wear include additional 29 components or features being added to the drill pipe after it is manufactured. For example, clamp style centralizers and wear pads have been developed such as that disclosed in US
23372166.1 CA Application Blakes Ref: 15072/00006 1 3999811; however, these types of devices may loosen and be displaced along the length of the 2 drill pipe, or may even separate during drilling operations. Adhesive or molded centralizers and 3 wear pads have been developed, such as those disclosed in US 3697141 or US 8119047;
4 however, these devices invite small regions of corrosion to develop on the pipe wall immediately underneath the devices. This may be due to the presence of small voids in the bonds between 6 the tube and the wear pad feature, which may be filled by wellbore fluid via capillary action, and 7 resulting in corrosion of the metal drill pipe. In addition, it becomes difficult or impossible to 8 properly inspect the thickness or integrity of the tube body itself as these adhesive or molded 9 features are generally immovable.
[0006] Thus, it is desirable that the centralizer or wear pad features be integral to the 11 tube body and added or incorporated during manufacturing. One method of accomplishing this 12 is to create a tool joint-like feature in the center of the tube body through upsetting and friction 13 welding a pair of short drill pipe tubes together or friction welding two short drill pipe tubes to a 14 third tool joint-like component between them. Such a method is disclosed in US 8783344, which describes utilizing redistributed and upset substrate material and a friction welding process to 16 create a wear pad feature on the drill pipe tube. This method is, however, extremely cost 17 intensive and cumbersome to manufacture as friction welding is a very specialized and 18 expensive process, which would be desirable to avoid. In addition, this method involves the 19 application of a heat treatment step, which results in changes to the material properties of the drill pipe material. In the result, this method would necessitate additional material testing and 21 process validation steps to ensure that the drill pipe meets the required specifications.
23 [0007] In one aspect of the present description, there is provided an integral tubular 24 member formed from a unitary tubular blank, the integral tubular member comprising:
- a first end, a second end opposite the first end, and a tube body extending between the 26 first and second ends;
27 - the first and second ends being adapted for connection to other tubular members;
28 - at least one wear pad formed on the tube body, the at least one wear pad comprising a 29 region of increased wall thickness.
[0008] In another aspect, there is provided a method of manufacturing an integral 31 tubular member having at least one wear pad, the method comprising:
23372166.1 CA Application Blakes Ref: 15072/00006 1 - providing a tubular blank having a first end, a second end and a tube body extending 2 between the first and second ends;
3 - forming the at least one wear pad by processing at least one region of the tube body to 4 provide a wall thickness greater than the wall thickness of the tube body.
- processing the first and second ends to form, respectively, first and second connectors, 6 the first and second connectors comprising means for connecting the integral tubular 7 member to other tubular members.
8 [0009] In one aspect of this disclosure, there is provided an integral tubular member 9 formed from a one piece blank having a longitudinal axis. The integral tubular member includes an external longitudinal cross sectional profile, an internal longitudinal cross sectional profile, 11 the internal and external cross sectional profiles defining a wall there-between. The wall has 12 varied wall thickness along the integral tubular member with at least three bulges where the wall 13 is thicker than the nominal wall thickness of the tubular member. These bulges may be internal 14 bulges, external bulges, or a combination of both.
[0010] In one aspect, there is provided an integral tubular member with at least one 16 integral wear pad formed from a one piece blank having a longitudinal axis, a first end, a second 17 end, a first portion, a central portion, a second portion, an external longitudinal cross sectional 18 profile, an internal longitudinal cross sectional profile, and the internal and external cross 19 sectional profiles defining a wall there-between. The wall has varied wall thickness along the integral tubular member. The first portion of the integral tubular member has at least one 21 internal or external bulge where the wall is thicker than the nominal wall of the integral tubular 22 member, forming an integral connector end with increased strength. The first end of the integral 23 tubular member has a connection feature, the connection feature allowing for the integral 24 tubular member to be coupled to another tubular member. The second portion of the integral tubular member has at least one internal or external bulge where the wall is thicker than the 26 nominal wall of the integral tubular member, forming an integral connector end with increased 27 strength. The second end of the integral tubular member is provided to have a connection 28 feature, the connection feature allowing for the integral tubular member to be coupled to another 29 tubular member. The central portion of the integral tubular member has at least one localized region where the wall is thicker than the nominal wall of the central portion of the integral tubular 31 member, forming at least one integral wear pad.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0011] In one aspect, the at least one wear pad has a metallurgical grain structure and 2 grain direction substantially uniform and unaltered from the one-piece blank substrate.
3 [0012] In one aspect, the at least one integral wear pad has a wall thickness that is 4 between 50-100% greater than the nominal central portion wall thickness.
[0013] In a more specific aspect, the at least one integral wear pad has a nominal wall 6 thickness that is between 70-80% greater than the nominal central portion wall thickness.
7 [0014] In one aspect, the ratio of the nominal tube body outside diameter circumference 8 to the tube body transverse cross sectional area is less than or equal to .450 in/sq.in and the 9 ratio of the at least one integral wear pad outside diameter circumference to the wear pad transverse cross sectional area is greater than .450 in/sq. in.
11 [0015] In one aspect, the nominal integral tubular member tube body wall is equivalent 12 to standard drill pipe tube wall thickness.
13 [0016] In a further aspect, surface hardening or a surface coating is applied to at least 14 one of the at least one wear pads to increase wear resistance.
[0017] There is provided a method of manufacturing an integral tubular member.
A tube 16 is provided that has an outer wall, a hollow interior, a first end, a second end, a first portion, a 17 central portion and a second portion. The first portion is adjacent the first end, the second 18 portion is adjacent the second end and the central portion is positioned between the first portion 19 and the second portion. The first portion of the tube and the second portion of the tube are upset to form an upset tubular. The upset tubular has an outer wall, a hollow interior, a first end, 21 a second end, a first portion, a central portion, and a second portion.
The length of the first 22 portion of the upset tubular has a length of between 25-75% the length of the first portion of the 23 tube. The length of the second portion of the upset tubular has a length of between 25-75% the 24 length of the second portion of the tube. The first portion and the second portion of the upset tubular are processed to form integral connector ends, and the outer wall of the central portion 26 of the upset tubular is processed to form a predetermined outer profile creating an integral 27 tubular member.
28 [0018] In one aspect, the first integral connector end is processed to have a box 29 connection.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0019] In one aspect, the second integral connector end is processed to have a pin 2 connection.
3 [0020] In one aspect, the second integral connector end is processed to have a box 4 connection.
[0021] In one aspect, the first integral connector end is processed to have a pin 6 connection.
7 [0022] In one aspect, the predetermined outer profile is substantially cylindrical and 8 uniform 9 [0023] In one aspect, the predetermined outer profile has at least one integral wear pad.
The integral wear pad has a wall with increased wall thickness. The integral wear pad may be 11 centrally located on the integral tubular member. The integral wear pad may be a fluted wear 12 pad, a bladed wear pad, a ribbed wear pad or any other type of wear pad known in the art.
13 [0024] In one aspect, the tube is made of steel or aluminum alloy.
14 [0025] There is also provided an additional method of manufacturing an integral tubular member with at least one wear pad. A tube is provided that has an outer wall, a hollow interior, 16 a first end, a second end, a first portion, a central portion and a second portion. The first portion 17 is adjacent the first end, the second portion is adjacent the second end and the central portion is 18 positioned between the first portion and the second portion. The first portion of the tube and the 19 second portion of the tube are upset to form an upset tubular. The upset tubular has an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion, and a second 21 portion. The length of the first portion of the upset tubular has a length of between 25-75% the 22 length of the first portion of the tube. The length of the second portion of the upset tubular has a 23 length of between 25-75% the length of the second portion of the tube.
The first portion and the 24 second portion of the upset tubular are processed to form integral connector ends and the outer wall of the central portion of the upset tubular is processed to form a predetermined outer 26 profile. At least one of the first portion, the central portion and the second portion of the upset 27 tubular are processed to have at least one integral wear pad forming an integral tubular member 28 with at least one wear pad.
5 23372166.1 CA Application Blakes Ref: 15072/00006 1 [0026] In one aspect, the first integral connector end is processed to have a box 2 connection.
3 [0027] In one aspect, the second integral connector end is processed to have a pin 4 connection.
[0028] In one aspect, the second integral connector end is processed to have a box
3 [0027] In one aspect, the second integral connector end is processed to have a pin 4 connection.
[0028] In one aspect, the second integral connector end is processed to have a box
6 connection.
7 [0029] In one aspect, the first integral connector end is processed to have a pin
8 connection.
9 [0030] In one aspect, the predetermined outer profile is substantially cylindrical and uniform.
11 [0031] In one aspect, the predetermined outer profile has at least one integral wear pad.
12 The integral wear pad has a wall with increased wall thickness. The integral wear pad may be 13 centrally located on the integral tubular member. The integral wear pad may be a fluted wear 14 pad, a bladed wear pad, a ribbed wear pad or any other type of wear pad known in the art.
[0032] In one aspect, the tube is made of steel or aluminum alloy.
16 [0033] There is also provided a method of manufacturing a drill pipe with at least one 17 integral wear pad having a longitudinal axis. A tube is provided that has an outer wall, a hollow 18 interior, a first end, a second end, a first portion, a central portion and a second portion. The first 19 portion is adjacent the first end, the second portion is adjacent the second end and the central portion is positioned between the first portion and the second portion. The first portion of the 21 tube and the second portion of the tube are upset to form an upset tubular. The upset tubular 22 has an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion 23 and a second portion. The length of the first portion of the upset tubular has a length of between 24 25-75% the length of the first portion of the tube. The length of the second portion of the upset tubular has a length of between 25-75% the length of the second portion of the tube. The outer 26 wall of the central portion of the upset tubular is processed to form a predetermined outer profile 27 having at least one integral wear pad. A tool joint is attached to the first end of the upset tubular 28 and a tool joint is attached to the second end of the upset tubular forming a drill pipe with at 29 least one integral wear pad.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0034] In one aspect, the predetermined outer profile of the outer wall is substantially 2 cylindrical and uniform.
3 [0035] In one aspect, the predetermined outer profile has at least one integral wear pad.
4 The integral wear pad has a wall with increased wall thickness. The integral wear pad may be centrally located on the upset tubular. The integral wear pad may be a fluted wear pad, a bladed 6 wear pad, a ribbed wear pad or any other type of wear pad known in the art.
7 [0036] In one aspect, the tube is made of steel or aluminum alloy.
9 [0037] These and other features will become more apparent from the following description in which references are made to the following drawings, in which numerical 11 references denote like parts. The drawings are for the purpose of illustration only and are not 12 intended to in any way limit the scope of the invention to the particular aspects shown.
13 [0038] FIG. 1 is a side view of an integral tubular member according one aspect of the 14 description, with at least one wear pad.
[0039] FIG. 2 is a side cross-sectional view of the integral tubular member of FIG.1.
16 [0040] FIG. 3 is an end view of the tubular member of FIG. 2 taken along section A-A.
17 [0041] FIG. 4 is an end view of the wear pad of FIG.2 taken along section B-B.
18 [0042] FIG. 5a, 5b and 5c are end views of wear pads according to different aspects, 19 showing different wear pad cross section shapes.
[0043] FIG. 6 is a side cross-sectional view of a tube blank.
21 [0044] FIG. 7 is a side cross-sectional view of the tube blank of FIG. 5 following an 22 upsetting step.
23 [0045] FIG. 8 is a side cross-sectional view of the upset tubular of FIG. 7 after a forming 24 step to provide connector ends.
[0046] FIG. 9 is a side cross-sectional view of a tubular member according to one 26 aspect, provided with a central integral wear pad.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0047] FIG. 10 is a side cross-sectional view of a tubular member according to one 2 aspect, provided with three integral wear pads.
3 [0048] FIG. 11 is a side view of an integral tubular member according one aspect, 4 having a central integral wear pad.
[0049] FIG. 12 is a side view of an integral tubular member according to one aspect, 6 provided with three integral wear pads.
7 [0050] FIG. 13 is a side view of an integral tubular member according to one aspect, 8 provided with five integral wear pads.
9 [0051] FIG. 14 is a side view of an integral tubular member according to one aspect, provided with five integral wear pads of different sizes.
11 [0052] FIG. 15 is a side view of an integral tubular member according to one aspect, 12 provided with three integral wear pads of different sizes.
13 [0053] FIG. 16 is a side view of an integral tubular member according to one aspect, 14 provided with three integral wear pads with different external profiles.
[0054] FIG. 17 is a side cross-sectional view of a tube blank, according to one aspect, 16 used to form a tubular member.
17 [0055] FIG. 18 is a side cross-sectional view of tubular member formed from the tube 18 blank of FIG. 16, following an upsetting step.
19 [0056] FIG. 19 is a side cross-sectional view of the upset tubular member of FIG. 18 provided with a central integral wear pad.
21 [0057] FIG. 20 is a side cross-sectional view of the tubular member of FIG. 19 prior to 22 being provided with tool joints at the ends thereof.
23 [0058] FIG. 21 is a side cross-sectional view of a drill pipe with a central integral wear 24 pad formed from the tubular member and tool joints of FIG. 20.
23372166.1 CA Application Blakes Ref: 15072/00006 2 [0059] In the following discussion and in the claims regarding the integral tubular 3 member with at least one wear pad, the term "one piece blank" generally refers to the single 4 piece semi-finished tubular member immediately prior to the creation of the at least one integral wear pad. It will be understood that the sequence of manufacturing processes required to create 6 the desired one piece blank may be varied without limiting the scope of the invention. For 7 example, the one piece blank may take the form of a raw unprocessed tube or a pre-processed 8 tube that has been put through upsetting, forming, heat treatment, machining, welding or any 9 other process known in the art to produce the desired geometry of the one piece blank.
Reference to "one piece blank substrate" in regards to metallurgical properties and metallurgical 11 grains should be interpreted as the metallurgical properties and grains of the one piece blank 12 immediately prior to creating the at least one wear pad feature. It should not be interpreted to 13 indicate the metallurgical substrate properties during any sequence of manufacturing processes 14 which may occur to create the desired one piece blank. Also, the term "wear pad" should be interpreted in the broadest sense possible to describe features which act sacrificially in slowing, 16 delaying, or otherwise preventing the downgrading of a tubular member due to thinning of wall 17 thickness drilling operations. Such wear pad features are substantially cylindrical in nature and 18 may include features such as flutes, blades, ribs, external bulges, internal bulges, a combination 19 of any such features or any other drilling operations wear features known in the art. Any description of features utilizing sequencing as "first", "second", "third"
etc. is done for the 21 purpose of clarity in describing relative locations and relationships between features and should 22 not be interpreted to imply any ordering, capability, priority or physical location of features 23 relative to a borehole or other external frames of reference.
24 [0060] The term "tubular member" generically refers to the components which make up a typical drill string such as the Bottom Hole Assembly (BHA), Heavy Weight Drill Pipe (HWDP), 26 drill pipe, or any similar components which can replace such components in form and/or 27 function. When describing a specific feature or aspect of the invention the term "integral" refers 28 to the feature or aspect being present on, or, in particular, created from, a substantially one 29 piece blank without attachment methods employed. It will be understood that specific features and aspects such as wear pads may be integral while other features such as tool joints may not 31 be integral without affecting the scope of the invention.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0061] The term "integral tubular member" refers to a component which can be utilized 2 to form a drill string and which is created from a one piece blank. A
"drill pipe" or similar tubular 3 member would typically be created from multiple components.
4 [0062] The term "connector end" refers to and end region of a tubular member having increased wall thickness to allow for connection features such as threads to be manufactured 6 thereon. Further, the term "tool joint" generally refers to a non-integral connector end but which 7 are attached or secured thereto. Tool joints are typical components of a finished drill pipe 8 assembly.
9 [0063] An integral tubular member with wear pad will now be described with reference to FIG. Ito FIG. 5.
11 [0064] With reference to FIG. 1 and FIG. 2, an integral tubular member 100 with at least 12 one wear pad 24 is formed from a one piece blank having a longitudinal axis. As will be 13 understood from the present description, although one wear pad 24 is shown in FIG. 1 and FIG.
14 2, the description is not limited to such single wear pad and the tubular member 100 may be provided with any number of wear pads. The integral tubular member 100 includes an external 16 longitudinal cross sectional profile 102 and an internal longitudinal cross sectional profile 104 17 which together define a wall 106 there-between. The wall 106 has a varied thickness along the 18 length of the tubular member. The internal cross-sectional profile 104 also defines a bore or 19 hollow interior 14 extending along the length of the integral tubular member. The integral tubular member 100 with at least one wear pad 24 is generally cylindrical in shape, its transverse cross 21 section along its length being generally circular in nature as shown in FIG. 3. As also shown, the 22 inner diameter of the integral tubular member varies along its length.
It will be understood that 23 other transverse cross section shapes and any combination of transverse cross section shapes 24 may be possible within the integral tubular member 100 without affecting the scope of the present description. The wall 106 of the integral tubular member 100 is varied in thickness to 26 create localized wear resistance and structural enhancement. An increase in thickness can 27 either be: a localized increase to the external diameter, resulting in an exterior bulge; a localized 28 decrease to the internal diameter, resulting in an interior bulge; or a combination of both. These 29 variations in wall thickness are shown in FIG. 2.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0065] Referring to FIG. 1 and FIG 2, the integral tubular member 100 with at least one 2 wear pad 24 has a first end 16, a second end 18, a first connector end 20, a second connector 3 end 22, a nominal tube body 110 and at least one wear pad 24. The nominal tube body 110 has 4 an external diameter D1 and an internal diameter dl, forming a wall there-between 106 with thickness t1. The first connector end 20 has an external diameter D3, and internal diameter d3, 6 forming a wall there-between 106 with an increased thickness t3 to allow for adding a first 7 connection feature 108. As shown, the first connection feature 108 comprises a thread provided 8 on the internal wall thereof, resulting in a "box" end, as is known in the art. The second 9 connector end 22 has an external diameter D4 and an internal diameter d4, forming a wall 106 with an increased thickness t4 to allow for adding a second connection feature 110. The second 11 connection feature 110 comprises a thread provided on the external wall thereof, resulting in a 12 "pin" end, as is known in the art. The first connector end 20 and second connector end 22 may 13 be formed by an external diameter increase, an internal diameter increase, or a combination of 14 both.
[0066] The connection features 108, 110 allow for one tubular member to be coupled to 16 another similar or dissimilar drilling tubular member. The first connection feature 108 is shown 17 as a box thread rotary shouldered connection. The second connection feature 110 is shown as 18 a pin thread rotary shouldered connection. It will be understood by a person skilled in the art 19 that other designs and configurations of connection features may be possible without affecting the scope of the present description.
21 [0067] The nominal tube body 110 is provided with at least one integral wear pad 24 22 having an external diameter D2 and an internal diameter d2, there-between forming a wall 106 23 of increased thickness t2. As discussed herein, the wear pad 24 serves to enhance wear 24 resistance of the tubular member. It will be understood that the at least one wear pad 24 may be formed by an external diameter increase, an internal diameter increase, or a combination of 26 both. The integral wear pad 24 may be substantially cylindrical in shape, having a transverse 27 cross section A2 along its length being generally circular as shown in FIG. 4. It will be 28 understood that other transverse cross section shapes, and any combination of transverse 29 cross section shapes, may be possible for one or more of the at least one wear pads 24, with each shape being independent of the other. Referring to FIG. 5, that is, FIGs.
5a to 5b, a variety 31 of transverse cross section shapes are shown which may be desirable in any combination for 32 any one of at least one integral wear pads 24 depending on end-use requirements. It will be 23372166.1 CA Application Blakes Ref: 15072/00006 1 understood by a person skilled in the art that the transverse cross sections in FIG. 5 are 2 presented for illustrative purposes and are not to be construed to limit the scope of the invention 3 to the shapes shown.
4 [0068] Referring to FIG. 2, in the aspect shown, the wall 106 varies such that t1 <t2 <t3 = t4. It will be understood by a person skilled in the art that it is only necessary that t2 is greater 6 than t1 to form at least one wear pad in order to enhance wear resistance and that the wall 7 thickness t3 and t4 may vary based on end-use requirements without affecting the scope of the 8 present description.
9 [0069] Referring to FIG. 2, in the aspect shown, the external longitudinal cross section 102 varies such that D1 <D2 < D3 = D4. It will be understood by a person skilled in the art that, 11 for the purpose of the present description, D2 is preferably equal to or greater than D1, and that 12 the external diameters D3 and D4 may vary based on end-use requirements without affecting 13 the scope of the present description.
14 [0070] Referring to FIG. 2, in the aspect shown the at least one integral wear pad 24 is shown as a single integral wear pad located generally in the center of the integral tubular 16 member 100. It will be understood that one or more wear pads 24 may be integrally present in 17 any number of locations along the length of the nominal tube body 110, each with an individual 18 external diameter D2, internal diameter d2, wall thickness t2, and transverse cross section 19 shape A2, which may be the same or different.
[0071] In one aspect the at least one wear pad 24 has a wall thickness t2 that is 21 between 50-100% greater than the nominal tube body 110 wall thickness t1. In another aspect 22 the at least one wear pad 24 has a nominal wall thickness t2 that is between 70-80% greater 23 than the nominal tube body 110 wall thickness t1.
24 [0072] In one aspect the ratio of the nominal tube body circumference formed by outside diameter D1 to the nominal tube body cross sectional area formed by D1 and wall thickness t1 26 is less than or equal to .450 in/sq.in and the ratio of the at least one wear pad circumference 27 formed by outside diameter D2 to the wear pad cross sectional area formed by D2 and wall 28 thickness t2 is greater than .450 in/sq. in.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0073] In another aspect, the metallurgical grain structure and grain direction of the at 2 least one wear pad 24 is substantially unaltered from the one piece blank substrate.
3 [0074] In another aspect, the at least one wear pad 24 is not formed through a 4 redistribution of the one piece blank substrate material.
[0075] In one aspect the tube body wall thickness t1 is equivalent to standard drill pipe 6 tube thickness.
7 [0076] In one aspect, on or more of the wear pads 24 may be treated to increase wear 8 resistance by means of a surface hardening treatment, including providing a surface coating.
9 Various other surface treatments are known in the art to increase wear resistance of the wear pads.
11 [0077] A method of manufacturing integral tubular members of the present description 12 will now be discussed. In this discussion, the term "tube" or "tube blank" is used to describe an 13 initial tubular element having a longitudinal axis, external and internal longitudinal cross-14 sectional profiles defining a wall there-between and the tube wall having a wall thickness which is generally constant along its length. It will be understood that the tube may, in one aspect, be 16 pre-processed, or "tuned", with regards to creating or forming the desired material properties 17 and geometry. Further, the term "upset tubular" is used to describe a semi-finished tubular with 18 a longitudinal axis having external and internal longitudinal cross sectional profiles defining a 19 wall there-between and the upset tubular wall having a wall thickness which is varied along the upset tubular. It is typical that this varied wall thickness is predominantly at the ends of the upset 21 tubular, resulting in the ends having thicker wall portions; however it will be understood that the 22 varied wall may be present in any location of the upset tubular and may exist as an increase or 23 decrease in wall thickness. The term "processing" is used generally to describe manufacturing 24 methods known in the art which act to create dimensional features either through the removal of, addition to, or forming of substrate material. Such processes may include but are not 26 intended to be limited to lathe machining, milling, grinding, welding, cold working, forging, 27 burnishing, etc.
28 [0078] A method of manufacturing an integral tubular member 10 will now be described 29 with reference to FIGs. 7 to 16.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0079] Referring to FIG. 6 and FIG. 7, manufacturing of integral tubular member begins 2 with a tube 40 that has an outer wall 42, a hollow interior 44, first end 46, a second end 48, a 3 first portion 50, a central portion 52 and a second portion 54. First portion 50 is adjacent first 4 end 46, second portion 54 is adjacent second end 48 and central portion 52 is positioned between first portion 50 and second portion 54. As is common, tube 40 may, for example, be 6 made of steel or an aluminum alloy. The present description is not limited to any particular 7 material. It will be understood by a person skilled in the art that tube 40 may be a raw 8 unprocessed tube or may be pre-processed through forming, heat treatment, machining, 9 welding or any other process known in the art. Tube 40 may be made thicker than a conventional drill pipe tube body prior to processing to allow for excess material to be removed 11 during later processing of upset tubular 60, as shown in FIG 2 and FIG.
7.
12 [0080] In one step of the present method, first portion 50 of tube 40 and second portion 13 54 of tube 40 are upset to form an upset tubular 60, shown in FIG. 7. As used herein, the term 14 "upset" or "upsetting" generally refers to a method or process, as known in the art, where the wall thickness and thus transverse cross sectional area of a portion of a tubular member is 16 increased beyond that of the initial nominal wall thickness and transverse cross sectional area.
17 A person skilled in the art will understand how the upsetting process works and the different 18 methods of achieving the upset tubular 60 shown in FIG. 7.
19 [0081] One method of upsetting tube 40, shown in FIG. 6, is to use a controlled and hydraulically driven upsetting method. First portion 50 of tube 40 is heated.
An inner diameter 21 mandrel is inserted into first end 46 and an outer diameter die is positioned around the outside 22 of first portion 50. An annular forging head is used to force first end 46 to fill the annular volume 23 between the inner diameter mandrel and outer diameter die. This method of upsetting is known 24 in the art and it is to be understood that different upsetting methods may be used. Second portion 54 would be upset in a similar manner. The upsetting process may be achieved in one 26 or many cycles depending upon the final desired outer diameter, inner diameter, overall portion 27 length change, final portion lengths of upset tubular and final desired length of upset tubular.
28 [0082] Processing of tube 40 may involve the removal of material through the use of a 29 lathe or milling process or may allow for additive or forming methods of manufacture. For example, a wear pad 24, shown in FIG. 9, could be built up with weld overlay on tube 40, shown 31 in FIG. 6, or upset tubular 60, shown in FIG. 7, or on integral tubular member 10 shown in FIG.
23372166.1 CA Application Blakes Ref: 15072/00006 1 8. Tube 40 may be formed, drawn, forged or burnished to reduce the outer diameter and wall 2 thickness around one or more of the wear pads 24.
3 [0083] Referring to FIG. 7, first portion 62 of upset tubular 60 may have a length of 4 between 25 ¨ 75% the length of first portion 50 of tube, or tube blank, 40, shown in FIG. 6.
Similarly, second portion 64 of upset tubular 60 may have a length of between 25 ¨ 75% the 6 length of second portion 54 of tube 40, shown in FIG. 6. Referring to FIG. 7, upset tubular 60 7 has an outer wall 66, a hollow interior 68, a first end 70, a second end 72, a first portion 62, a 8 central portion 74 and a second portion 64. First portion 62 is adjacent first end 70, second 9 portion 64 is adjacent second end 72 and central portion 74 is positioned between first portion 62 and second portion 64. First portion 62 and second portion 64 of upset tubular 60 are 11 processed to form integral connector ends 20 and 22 shown in FIG 8.
Processing of first portion 12 62 and second portion 64 of upset tubular 60 may include machining of hollow interior 68 and 13 outer wall 66 to create appropriate connector ends 20 and 22, shown in FIG. 8. Connector ends 14 20 and 22 are functionally tool joints and include the outer diameter, inner diameter, taper, inner diameter transitions, hardbanding features and any other feature known in the art. Connector 16 ends 20 and 22 may include box or pin connections. Once connector ends 20 and 22, shown in 17 FIG. 8, have been formed, outer wall 66 of central portion 74 is processed to form a 18 predetermined outer profile. A metal lathe or other machining tool may be used to machine 19 outer wall 66. Outer wall 66 may be processed into a substantially cylindrical and uniform wall or may have integrally formed wear pads depending upon the needs of the user.
21 [0084] Referring to FIG. 8, an integral tubular member 10 has an outer wall 12, hollow 22 interior 14 with a first end 16 and a second end 18. First end 16 has a first connector end 20 23 and second end 18 has a second connector end 22. Connector end 20 and connector end 22 24 are, in one aspect, integrally formed on integral tubular member 10. In the aspect shown, first connector end 20 has a "box" connection and second connector end 22 has a "pin" connection 26 end. As discussed above, and as would be understood by persons skilled in the art, first 27 connector end 20 and second connector end 22 are configured to allow for connection of the 28 first or second connector end of an integral tubular member to the corresponding connector end 29 of another drill string tubular. It will be understood by a person skilled in the art that integral tubular member 10 may have different types of connection ends depending on the type of 31 connection required for any given drill string. For example, integral tubular member 10 may 23372166.1 CA Application Blakes Ref: 15072/00006 1 have two box connections, two pin connections or may have one box connection and one pin 2 connection.
3 [0085] As would be understood, with integral connector ends 20 and 22, there is no 4 need to utilize friction welding and weld heat treatments to create a drilling tubular.
[0086] Referring to FIG. 9, integral tubular member 10 may also have an integral wear 6 pad 24. In the aspect shown, integral wear pad 24 is located generally centrally along integral 7 tubular member 10; however, it will be understood by persons skilled in the art that integral wear 8 pad 24 may be positioned anywhere along the length of the integral tubular member 10.
9 Referring to FIG. 10 through FIG. 16, different aspects of integral wear pads 24 are shown. As can be seen, different sizes of wear pads 24 and different numbers of wear pads 24 may be 11 used. Wear pads 24 may be fluted, bladed, ribbed, spiraled or any other type of wear pad 24 12 known in the art.
13 [0087] Integral tubular member 10 is manufactured in a way that allows connector ends 14 20 and 22 and wear pad 24 to be integrally created. This avoid the need for expensive friction welding and welding heat treatments to create a drilling tubular and allows for a wear pad 24 to 16 be included integrally without attempting to incorporate a separate wear pad onto a tubular 17 member.
18 [0088] Referring to FIG. 9 through FIG. 16, wear pads 24 may be integrally formed and 19 may have different shapes. Wear pads 24 may be cylindrical, fluted, bladed, ribbed or may have any other suitable shape known in the art. It will be understood that outer wall 66 of central 21 portion 74 may be processed to form a predetermined outer profile before first portion 62 and 22 second portion 64 are processed to form connector ends 20 and 22. It may be beneficial to 23 process central portion 74 prior to processing first portion 62 and second portion 64 as an error 24 made to central portion 74 is less likely to be fixable than an error made to first portion 62 or second portion 64.
26 [0089] An alternative method of manufacturing a drilling tubular will now be described 27 with reference to FIG. 17 through FIG. 21.
28 [0090] Referring to FIG. 17, manufacturing of drill pipe with at least one integral wear 29 pad begins with a tube, or tube blank 40 that has an outer wall 42, a hollow interior 44, first end 23372166.1 CA Application Blakes Ref: 15072/00006 1 46, a second end 48, a first portion 50, a central portion 52 and a second portion 54. First 2 portion 50 is adjacent first end 46, second portion 54 is adjacent second end 48 and central 3 portion 52 is positioned between first portion 50 and second portion 54.
As discussed above, 4 tube 40 may be made of any material, such as steel or an aluminum alloy.
It will be understood by a person skilled in the art that tube 40 may be a raw unprocessed tube or may be pre-6 processed through forming, heat treatment, machining, welding or any other process known in 7 the art.
8 [0091] In a first step, first portion 50 of tube 40 and second portion 54 of tube 40 are 9 upset to form an upset tubular 80, as shown in FIG. 18. A person of skill in the art will understand how the upsetting process works and different methods of achieving the upset 11 tubular 80 shown in FIG. 18. Such methods were also discussed above.
12 [0092] Referring to FIG. 18, first portion 82 of upset tubular 80 may, in one aspect, have 13 a length of between 25-75% the length of first portion 50 of tube 40, shown in FIG. 17. Similarly, 14 second portion 84 of upset tubular 80 may have a length of between 25-75% the length of second portion 54 of tube 40, shown in FIG. 17. Referring to FIG. 18, upset tubular 80 has an 16 outer wall 86, a hollow interior 88, a first end 90, a second end 92, a first portion 82, a central 17 portion 94 and a second portion 84. First portion 82 is adjacent first end 90, second portion 84 is 18 adjacent second end 92 and central portion 94 is positioned between first portion 82 and second 19 portion 84. Outer wall 86 is processed to form a predetermined outer profile. In the aspect shown in FIG. 19, the outer profile includes an integrally formed wear pad 100. It will be 21 understood that outer profile may be substantially cylindrical or may have a number of integral 22 wear pads 100 with different features as shown in FIG. 11 through 16. A
metal lathe or other 23 machining tool may be used to machine outer wall 86 of first portion 82, central portion 94 or 24 second portion 84. First portion 82 and second portion 84 may be processed to prepare first end 90 and second end 92, respectively, for attachment of tool joints.
26 [0093] Referring to FIG. 20, in the aspect shown, a box connection tool joint 102 and a 27 pin connection tool joint 104 are provided for attachment to first end 90 and second end 92 of 28 upset tubular 80 to create a finished drill pipe with integral wear pad
11 [0031] In one aspect, the predetermined outer profile has at least one integral wear pad.
12 The integral wear pad has a wall with increased wall thickness. The integral wear pad may be 13 centrally located on the integral tubular member. The integral wear pad may be a fluted wear 14 pad, a bladed wear pad, a ribbed wear pad or any other type of wear pad known in the art.
[0032] In one aspect, the tube is made of steel or aluminum alloy.
16 [0033] There is also provided a method of manufacturing a drill pipe with at least one 17 integral wear pad having a longitudinal axis. A tube is provided that has an outer wall, a hollow 18 interior, a first end, a second end, a first portion, a central portion and a second portion. The first 19 portion is adjacent the first end, the second portion is adjacent the second end and the central portion is positioned between the first portion and the second portion. The first portion of the 21 tube and the second portion of the tube are upset to form an upset tubular. The upset tubular 22 has an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion 23 and a second portion. The length of the first portion of the upset tubular has a length of between 24 25-75% the length of the first portion of the tube. The length of the second portion of the upset tubular has a length of between 25-75% the length of the second portion of the tube. The outer 26 wall of the central portion of the upset tubular is processed to form a predetermined outer profile 27 having at least one integral wear pad. A tool joint is attached to the first end of the upset tubular 28 and a tool joint is attached to the second end of the upset tubular forming a drill pipe with at 29 least one integral wear pad.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0034] In one aspect, the predetermined outer profile of the outer wall is substantially 2 cylindrical and uniform.
3 [0035] In one aspect, the predetermined outer profile has at least one integral wear pad.
4 The integral wear pad has a wall with increased wall thickness. The integral wear pad may be centrally located on the upset tubular. The integral wear pad may be a fluted wear pad, a bladed 6 wear pad, a ribbed wear pad or any other type of wear pad known in the art.
7 [0036] In one aspect, the tube is made of steel or aluminum alloy.
9 [0037] These and other features will become more apparent from the following description in which references are made to the following drawings, in which numerical 11 references denote like parts. The drawings are for the purpose of illustration only and are not 12 intended to in any way limit the scope of the invention to the particular aspects shown.
13 [0038] FIG. 1 is a side view of an integral tubular member according one aspect of the 14 description, with at least one wear pad.
[0039] FIG. 2 is a side cross-sectional view of the integral tubular member of FIG.1.
16 [0040] FIG. 3 is an end view of the tubular member of FIG. 2 taken along section A-A.
17 [0041] FIG. 4 is an end view of the wear pad of FIG.2 taken along section B-B.
18 [0042] FIG. 5a, 5b and 5c are end views of wear pads according to different aspects, 19 showing different wear pad cross section shapes.
[0043] FIG. 6 is a side cross-sectional view of a tube blank.
21 [0044] FIG. 7 is a side cross-sectional view of the tube blank of FIG. 5 following an 22 upsetting step.
23 [0045] FIG. 8 is a side cross-sectional view of the upset tubular of FIG. 7 after a forming 24 step to provide connector ends.
[0046] FIG. 9 is a side cross-sectional view of a tubular member according to one 26 aspect, provided with a central integral wear pad.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0047] FIG. 10 is a side cross-sectional view of a tubular member according to one 2 aspect, provided with three integral wear pads.
3 [0048] FIG. 11 is a side view of an integral tubular member according one aspect, 4 having a central integral wear pad.
[0049] FIG. 12 is a side view of an integral tubular member according to one aspect, 6 provided with three integral wear pads.
7 [0050] FIG. 13 is a side view of an integral tubular member according to one aspect, 8 provided with five integral wear pads.
9 [0051] FIG. 14 is a side view of an integral tubular member according to one aspect, provided with five integral wear pads of different sizes.
11 [0052] FIG. 15 is a side view of an integral tubular member according to one aspect, 12 provided with three integral wear pads of different sizes.
13 [0053] FIG. 16 is a side view of an integral tubular member according to one aspect, 14 provided with three integral wear pads with different external profiles.
[0054] FIG. 17 is a side cross-sectional view of a tube blank, according to one aspect, 16 used to form a tubular member.
17 [0055] FIG. 18 is a side cross-sectional view of tubular member formed from the tube 18 blank of FIG. 16, following an upsetting step.
19 [0056] FIG. 19 is a side cross-sectional view of the upset tubular member of FIG. 18 provided with a central integral wear pad.
21 [0057] FIG. 20 is a side cross-sectional view of the tubular member of FIG. 19 prior to 22 being provided with tool joints at the ends thereof.
23 [0058] FIG. 21 is a side cross-sectional view of a drill pipe with a central integral wear 24 pad formed from the tubular member and tool joints of FIG. 20.
23372166.1 CA Application Blakes Ref: 15072/00006 2 [0059] In the following discussion and in the claims regarding the integral tubular 3 member with at least one wear pad, the term "one piece blank" generally refers to the single 4 piece semi-finished tubular member immediately prior to the creation of the at least one integral wear pad. It will be understood that the sequence of manufacturing processes required to create 6 the desired one piece blank may be varied without limiting the scope of the invention. For 7 example, the one piece blank may take the form of a raw unprocessed tube or a pre-processed 8 tube that has been put through upsetting, forming, heat treatment, machining, welding or any 9 other process known in the art to produce the desired geometry of the one piece blank.
Reference to "one piece blank substrate" in regards to metallurgical properties and metallurgical 11 grains should be interpreted as the metallurgical properties and grains of the one piece blank 12 immediately prior to creating the at least one wear pad feature. It should not be interpreted to 13 indicate the metallurgical substrate properties during any sequence of manufacturing processes 14 which may occur to create the desired one piece blank. Also, the term "wear pad" should be interpreted in the broadest sense possible to describe features which act sacrificially in slowing, 16 delaying, or otherwise preventing the downgrading of a tubular member due to thinning of wall 17 thickness drilling operations. Such wear pad features are substantially cylindrical in nature and 18 may include features such as flutes, blades, ribs, external bulges, internal bulges, a combination 19 of any such features or any other drilling operations wear features known in the art. Any description of features utilizing sequencing as "first", "second", "third"
etc. is done for the 21 purpose of clarity in describing relative locations and relationships between features and should 22 not be interpreted to imply any ordering, capability, priority or physical location of features 23 relative to a borehole or other external frames of reference.
24 [0060] The term "tubular member" generically refers to the components which make up a typical drill string such as the Bottom Hole Assembly (BHA), Heavy Weight Drill Pipe (HWDP), 26 drill pipe, or any similar components which can replace such components in form and/or 27 function. When describing a specific feature or aspect of the invention the term "integral" refers 28 to the feature or aspect being present on, or, in particular, created from, a substantially one 29 piece blank without attachment methods employed. It will be understood that specific features and aspects such as wear pads may be integral while other features such as tool joints may not 31 be integral without affecting the scope of the invention.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0061] The term "integral tubular member" refers to a component which can be utilized 2 to form a drill string and which is created from a one piece blank. A
"drill pipe" or similar tubular 3 member would typically be created from multiple components.
4 [0062] The term "connector end" refers to and end region of a tubular member having increased wall thickness to allow for connection features such as threads to be manufactured 6 thereon. Further, the term "tool joint" generally refers to a non-integral connector end but which 7 are attached or secured thereto. Tool joints are typical components of a finished drill pipe 8 assembly.
9 [0063] An integral tubular member with wear pad will now be described with reference to FIG. Ito FIG. 5.
11 [0064] With reference to FIG. 1 and FIG. 2, an integral tubular member 100 with at least 12 one wear pad 24 is formed from a one piece blank having a longitudinal axis. As will be 13 understood from the present description, although one wear pad 24 is shown in FIG. 1 and FIG.
14 2, the description is not limited to such single wear pad and the tubular member 100 may be provided with any number of wear pads. The integral tubular member 100 includes an external 16 longitudinal cross sectional profile 102 and an internal longitudinal cross sectional profile 104 17 which together define a wall 106 there-between. The wall 106 has a varied thickness along the 18 length of the tubular member. The internal cross-sectional profile 104 also defines a bore or 19 hollow interior 14 extending along the length of the integral tubular member. The integral tubular member 100 with at least one wear pad 24 is generally cylindrical in shape, its transverse cross 21 section along its length being generally circular in nature as shown in FIG. 3. As also shown, the 22 inner diameter of the integral tubular member varies along its length.
It will be understood that 23 other transverse cross section shapes and any combination of transverse cross section shapes 24 may be possible within the integral tubular member 100 without affecting the scope of the present description. The wall 106 of the integral tubular member 100 is varied in thickness to 26 create localized wear resistance and structural enhancement. An increase in thickness can 27 either be: a localized increase to the external diameter, resulting in an exterior bulge; a localized 28 decrease to the internal diameter, resulting in an interior bulge; or a combination of both. These 29 variations in wall thickness are shown in FIG. 2.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0065] Referring to FIG. 1 and FIG 2, the integral tubular member 100 with at least one 2 wear pad 24 has a first end 16, a second end 18, a first connector end 20, a second connector 3 end 22, a nominal tube body 110 and at least one wear pad 24. The nominal tube body 110 has 4 an external diameter D1 and an internal diameter dl, forming a wall there-between 106 with thickness t1. The first connector end 20 has an external diameter D3, and internal diameter d3, 6 forming a wall there-between 106 with an increased thickness t3 to allow for adding a first 7 connection feature 108. As shown, the first connection feature 108 comprises a thread provided 8 on the internal wall thereof, resulting in a "box" end, as is known in the art. The second 9 connector end 22 has an external diameter D4 and an internal diameter d4, forming a wall 106 with an increased thickness t4 to allow for adding a second connection feature 110. The second 11 connection feature 110 comprises a thread provided on the external wall thereof, resulting in a 12 "pin" end, as is known in the art. The first connector end 20 and second connector end 22 may 13 be formed by an external diameter increase, an internal diameter increase, or a combination of 14 both.
[0066] The connection features 108, 110 allow for one tubular member to be coupled to 16 another similar or dissimilar drilling tubular member. The first connection feature 108 is shown 17 as a box thread rotary shouldered connection. The second connection feature 110 is shown as 18 a pin thread rotary shouldered connection. It will be understood by a person skilled in the art 19 that other designs and configurations of connection features may be possible without affecting the scope of the present description.
21 [0067] The nominal tube body 110 is provided with at least one integral wear pad 24 22 having an external diameter D2 and an internal diameter d2, there-between forming a wall 106 23 of increased thickness t2. As discussed herein, the wear pad 24 serves to enhance wear 24 resistance of the tubular member. It will be understood that the at least one wear pad 24 may be formed by an external diameter increase, an internal diameter increase, or a combination of 26 both. The integral wear pad 24 may be substantially cylindrical in shape, having a transverse 27 cross section A2 along its length being generally circular as shown in FIG. 4. It will be 28 understood that other transverse cross section shapes, and any combination of transverse 29 cross section shapes, may be possible for one or more of the at least one wear pads 24, with each shape being independent of the other. Referring to FIG. 5, that is, FIGs.
5a to 5b, a variety 31 of transverse cross section shapes are shown which may be desirable in any combination for 32 any one of at least one integral wear pads 24 depending on end-use requirements. It will be 23372166.1 CA Application Blakes Ref: 15072/00006 1 understood by a person skilled in the art that the transverse cross sections in FIG. 5 are 2 presented for illustrative purposes and are not to be construed to limit the scope of the invention 3 to the shapes shown.
4 [0068] Referring to FIG. 2, in the aspect shown, the wall 106 varies such that t1 <t2 <t3 = t4. It will be understood by a person skilled in the art that it is only necessary that t2 is greater 6 than t1 to form at least one wear pad in order to enhance wear resistance and that the wall 7 thickness t3 and t4 may vary based on end-use requirements without affecting the scope of the 8 present description.
9 [0069] Referring to FIG. 2, in the aspect shown, the external longitudinal cross section 102 varies such that D1 <D2 < D3 = D4. It will be understood by a person skilled in the art that, 11 for the purpose of the present description, D2 is preferably equal to or greater than D1, and that 12 the external diameters D3 and D4 may vary based on end-use requirements without affecting 13 the scope of the present description.
14 [0070] Referring to FIG. 2, in the aspect shown the at least one integral wear pad 24 is shown as a single integral wear pad located generally in the center of the integral tubular 16 member 100. It will be understood that one or more wear pads 24 may be integrally present in 17 any number of locations along the length of the nominal tube body 110, each with an individual 18 external diameter D2, internal diameter d2, wall thickness t2, and transverse cross section 19 shape A2, which may be the same or different.
[0071] In one aspect the at least one wear pad 24 has a wall thickness t2 that is 21 between 50-100% greater than the nominal tube body 110 wall thickness t1. In another aspect 22 the at least one wear pad 24 has a nominal wall thickness t2 that is between 70-80% greater 23 than the nominal tube body 110 wall thickness t1.
24 [0072] In one aspect the ratio of the nominal tube body circumference formed by outside diameter D1 to the nominal tube body cross sectional area formed by D1 and wall thickness t1 26 is less than or equal to .450 in/sq.in and the ratio of the at least one wear pad circumference 27 formed by outside diameter D2 to the wear pad cross sectional area formed by D2 and wall 28 thickness t2 is greater than .450 in/sq. in.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0073] In another aspect, the metallurgical grain structure and grain direction of the at 2 least one wear pad 24 is substantially unaltered from the one piece blank substrate.
3 [0074] In another aspect, the at least one wear pad 24 is not formed through a 4 redistribution of the one piece blank substrate material.
[0075] In one aspect the tube body wall thickness t1 is equivalent to standard drill pipe 6 tube thickness.
7 [0076] In one aspect, on or more of the wear pads 24 may be treated to increase wear 8 resistance by means of a surface hardening treatment, including providing a surface coating.
9 Various other surface treatments are known in the art to increase wear resistance of the wear pads.
11 [0077] A method of manufacturing integral tubular members of the present description 12 will now be discussed. In this discussion, the term "tube" or "tube blank" is used to describe an 13 initial tubular element having a longitudinal axis, external and internal longitudinal cross-14 sectional profiles defining a wall there-between and the tube wall having a wall thickness which is generally constant along its length. It will be understood that the tube may, in one aspect, be 16 pre-processed, or "tuned", with regards to creating or forming the desired material properties 17 and geometry. Further, the term "upset tubular" is used to describe a semi-finished tubular with 18 a longitudinal axis having external and internal longitudinal cross sectional profiles defining a 19 wall there-between and the upset tubular wall having a wall thickness which is varied along the upset tubular. It is typical that this varied wall thickness is predominantly at the ends of the upset 21 tubular, resulting in the ends having thicker wall portions; however it will be understood that the 22 varied wall may be present in any location of the upset tubular and may exist as an increase or 23 decrease in wall thickness. The term "processing" is used generally to describe manufacturing 24 methods known in the art which act to create dimensional features either through the removal of, addition to, or forming of substrate material. Such processes may include but are not 26 intended to be limited to lathe machining, milling, grinding, welding, cold working, forging, 27 burnishing, etc.
28 [0078] A method of manufacturing an integral tubular member 10 will now be described 29 with reference to FIGs. 7 to 16.
23372166.1 CA Application Blakes Ref: 15072/00006 1 [0079] Referring to FIG. 6 and FIG. 7, manufacturing of integral tubular member begins 2 with a tube 40 that has an outer wall 42, a hollow interior 44, first end 46, a second end 48, a 3 first portion 50, a central portion 52 and a second portion 54. First portion 50 is adjacent first 4 end 46, second portion 54 is adjacent second end 48 and central portion 52 is positioned between first portion 50 and second portion 54. As is common, tube 40 may, for example, be 6 made of steel or an aluminum alloy. The present description is not limited to any particular 7 material. It will be understood by a person skilled in the art that tube 40 may be a raw 8 unprocessed tube or may be pre-processed through forming, heat treatment, machining, 9 welding or any other process known in the art. Tube 40 may be made thicker than a conventional drill pipe tube body prior to processing to allow for excess material to be removed 11 during later processing of upset tubular 60, as shown in FIG 2 and FIG.
7.
12 [0080] In one step of the present method, first portion 50 of tube 40 and second portion 13 54 of tube 40 are upset to form an upset tubular 60, shown in FIG. 7. As used herein, the term 14 "upset" or "upsetting" generally refers to a method or process, as known in the art, where the wall thickness and thus transverse cross sectional area of a portion of a tubular member is 16 increased beyond that of the initial nominal wall thickness and transverse cross sectional area.
17 A person skilled in the art will understand how the upsetting process works and the different 18 methods of achieving the upset tubular 60 shown in FIG. 7.
19 [0081] One method of upsetting tube 40, shown in FIG. 6, is to use a controlled and hydraulically driven upsetting method. First portion 50 of tube 40 is heated.
An inner diameter 21 mandrel is inserted into first end 46 and an outer diameter die is positioned around the outside 22 of first portion 50. An annular forging head is used to force first end 46 to fill the annular volume 23 between the inner diameter mandrel and outer diameter die. This method of upsetting is known 24 in the art and it is to be understood that different upsetting methods may be used. Second portion 54 would be upset in a similar manner. The upsetting process may be achieved in one 26 or many cycles depending upon the final desired outer diameter, inner diameter, overall portion 27 length change, final portion lengths of upset tubular and final desired length of upset tubular.
28 [0082] Processing of tube 40 may involve the removal of material through the use of a 29 lathe or milling process or may allow for additive or forming methods of manufacture. For example, a wear pad 24, shown in FIG. 9, could be built up with weld overlay on tube 40, shown 31 in FIG. 6, or upset tubular 60, shown in FIG. 7, or on integral tubular member 10 shown in FIG.
23372166.1 CA Application Blakes Ref: 15072/00006 1 8. Tube 40 may be formed, drawn, forged or burnished to reduce the outer diameter and wall 2 thickness around one or more of the wear pads 24.
3 [0083] Referring to FIG. 7, first portion 62 of upset tubular 60 may have a length of 4 between 25 ¨ 75% the length of first portion 50 of tube, or tube blank, 40, shown in FIG. 6.
Similarly, second portion 64 of upset tubular 60 may have a length of between 25 ¨ 75% the 6 length of second portion 54 of tube 40, shown in FIG. 6. Referring to FIG. 7, upset tubular 60 7 has an outer wall 66, a hollow interior 68, a first end 70, a second end 72, a first portion 62, a 8 central portion 74 and a second portion 64. First portion 62 is adjacent first end 70, second 9 portion 64 is adjacent second end 72 and central portion 74 is positioned between first portion 62 and second portion 64. First portion 62 and second portion 64 of upset tubular 60 are 11 processed to form integral connector ends 20 and 22 shown in FIG 8.
Processing of first portion 12 62 and second portion 64 of upset tubular 60 may include machining of hollow interior 68 and 13 outer wall 66 to create appropriate connector ends 20 and 22, shown in FIG. 8. Connector ends 14 20 and 22 are functionally tool joints and include the outer diameter, inner diameter, taper, inner diameter transitions, hardbanding features and any other feature known in the art. Connector 16 ends 20 and 22 may include box or pin connections. Once connector ends 20 and 22, shown in 17 FIG. 8, have been formed, outer wall 66 of central portion 74 is processed to form a 18 predetermined outer profile. A metal lathe or other machining tool may be used to machine 19 outer wall 66. Outer wall 66 may be processed into a substantially cylindrical and uniform wall or may have integrally formed wear pads depending upon the needs of the user.
21 [0084] Referring to FIG. 8, an integral tubular member 10 has an outer wall 12, hollow 22 interior 14 with a first end 16 and a second end 18. First end 16 has a first connector end 20 23 and second end 18 has a second connector end 22. Connector end 20 and connector end 22 24 are, in one aspect, integrally formed on integral tubular member 10. In the aspect shown, first connector end 20 has a "box" connection and second connector end 22 has a "pin" connection 26 end. As discussed above, and as would be understood by persons skilled in the art, first 27 connector end 20 and second connector end 22 are configured to allow for connection of the 28 first or second connector end of an integral tubular member to the corresponding connector end 29 of another drill string tubular. It will be understood by a person skilled in the art that integral tubular member 10 may have different types of connection ends depending on the type of 31 connection required for any given drill string. For example, integral tubular member 10 may 23372166.1 CA Application Blakes Ref: 15072/00006 1 have two box connections, two pin connections or may have one box connection and one pin 2 connection.
3 [0085] As would be understood, with integral connector ends 20 and 22, there is no 4 need to utilize friction welding and weld heat treatments to create a drilling tubular.
[0086] Referring to FIG. 9, integral tubular member 10 may also have an integral wear 6 pad 24. In the aspect shown, integral wear pad 24 is located generally centrally along integral 7 tubular member 10; however, it will be understood by persons skilled in the art that integral wear 8 pad 24 may be positioned anywhere along the length of the integral tubular member 10.
9 Referring to FIG. 10 through FIG. 16, different aspects of integral wear pads 24 are shown. As can be seen, different sizes of wear pads 24 and different numbers of wear pads 24 may be 11 used. Wear pads 24 may be fluted, bladed, ribbed, spiraled or any other type of wear pad 24 12 known in the art.
13 [0087] Integral tubular member 10 is manufactured in a way that allows connector ends 14 20 and 22 and wear pad 24 to be integrally created. This avoid the need for expensive friction welding and welding heat treatments to create a drilling tubular and allows for a wear pad 24 to 16 be included integrally without attempting to incorporate a separate wear pad onto a tubular 17 member.
18 [0088] Referring to FIG. 9 through FIG. 16, wear pads 24 may be integrally formed and 19 may have different shapes. Wear pads 24 may be cylindrical, fluted, bladed, ribbed or may have any other suitable shape known in the art. It will be understood that outer wall 66 of central 21 portion 74 may be processed to form a predetermined outer profile before first portion 62 and 22 second portion 64 are processed to form connector ends 20 and 22. It may be beneficial to 23 process central portion 74 prior to processing first portion 62 and second portion 64 as an error 24 made to central portion 74 is less likely to be fixable than an error made to first portion 62 or second portion 64.
26 [0089] An alternative method of manufacturing a drilling tubular will now be described 27 with reference to FIG. 17 through FIG. 21.
28 [0090] Referring to FIG. 17, manufacturing of drill pipe with at least one integral wear 29 pad begins with a tube, or tube blank 40 that has an outer wall 42, a hollow interior 44, first end 23372166.1 CA Application Blakes Ref: 15072/00006 1 46, a second end 48, a first portion 50, a central portion 52 and a second portion 54. First 2 portion 50 is adjacent first end 46, second portion 54 is adjacent second end 48 and central 3 portion 52 is positioned between first portion 50 and second portion 54.
As discussed above, 4 tube 40 may be made of any material, such as steel or an aluminum alloy.
It will be understood by a person skilled in the art that tube 40 may be a raw unprocessed tube or may be pre-6 processed through forming, heat treatment, machining, welding or any other process known in 7 the art.
8 [0091] In a first step, first portion 50 of tube 40 and second portion 54 of tube 40 are 9 upset to form an upset tubular 80, as shown in FIG. 18. A person of skill in the art will understand how the upsetting process works and different methods of achieving the upset 11 tubular 80 shown in FIG. 18. Such methods were also discussed above.
12 [0092] Referring to FIG. 18, first portion 82 of upset tubular 80 may, in one aspect, have 13 a length of between 25-75% the length of first portion 50 of tube 40, shown in FIG. 17. Similarly, 14 second portion 84 of upset tubular 80 may have a length of between 25-75% the length of second portion 54 of tube 40, shown in FIG. 17. Referring to FIG. 18, upset tubular 80 has an 16 outer wall 86, a hollow interior 88, a first end 90, a second end 92, a first portion 82, a central 17 portion 94 and a second portion 84. First portion 82 is adjacent first end 90, second portion 84 is 18 adjacent second end 92 and central portion 94 is positioned between first portion 82 and second 19 portion 84. Outer wall 86 is processed to form a predetermined outer profile. In the aspect shown in FIG. 19, the outer profile includes an integrally formed wear pad 100. It will be 21 understood that outer profile may be substantially cylindrical or may have a number of integral 22 wear pads 100 with different features as shown in FIG. 11 through 16. A
metal lathe or other 23 machining tool may be used to machine outer wall 86 of first portion 82, central portion 94 or 24 second portion 84. First portion 82 and second portion 84 may be processed to prepare first end 90 and second end 92, respectively, for attachment of tool joints.
26 [0093] Referring to FIG. 20, in the aspect shown, a box connection tool joint 102 and a 27 pin connection tool joint 104 are provided for attachment to first end 90 and second end 92 of 28 upset tubular 80 to create a finished drill pipe with integral wear pad
10, shown in FIG. 21. It will 29 be understood by a person of skill in the art that different types of tool joints with any type of connection features may be used depending upon the requirements of the user without altering 31 the scope of the invention. The term "attach" should be interpreted in a general sense to refer to 23372166.1 CA Application Blakes Ref: 15072/00006 1 the permanent or semi-permanent affixing of tool joints to the upset tubular. Attachment of box 2 connection tool joint 102 and pin connection tool joint 104 may be performed through welding, 3 threading, press/shrink fitting, gluing/bonding/adhesive or any combination of these, or any 4 other attachment methods known in the art without affecting the scope of the invention being disclosed. Referring to FIG. 21, in the aspect shown, drilling tubular 10 has an outer wall 12, a 6 hollow interior 14, a first end 16 and a second end 18. A box connection tool joint 102 is 7 positioned at first end 16 and a pin connection tool joint 104 is positioned at second end 18.
8 Drilling tubular 10 has an integral wear pad 100.
9 [0094] Any use herein of any terms describing an interaction between elements is not meant to limit the interaction to direct interaction between the subject elements, and may also
8 Drilling tubular 10 has an integral wear pad 100.
9 [0094] Any use herein of any terms describing an interaction between elements is not meant to limit the interaction to direct interaction between the subject elements, and may also
11 include indirect interaction between the elements such as through secondary or intermediary
12 structure unless specifically stated otherwise.
13 [0095] In this patent document, the word "comprising" is used in its non-limiting sense to
14 mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article "a" does not exclude the possibility 16 that more than one of the element is present, unless the context clearly requires that there be 17 one and only one of the elements.
18 [0096] It will be apparent that changes may be made to the illustrative aspects, while 19 falling within the scope of the invention. As such, the scope of the following claims should not be limited by the preferred aspects set forth in the examples and drawings described above, but 21 should be given the broadest interpretation consistent with the description as a whole.
23372166.1
18 [0096] It will be apparent that changes may be made to the illustrative aspects, while 19 falling within the scope of the invention. As such, the scope of the following claims should not be limited by the preferred aspects set forth in the examples and drawings described above, but 21 should be given the broadest interpretation consistent with the description as a whole.
23372166.1
Claims (60)
1. An integral tubular member formed from a unitary tubular blank, the integral tubular member comprising:
- a first end, a second end opposite the first end, and a tube body extending between the first and second ends;
- the first and second ends being adapted for connection to other tubular members;
- at least one wear pad formed on the tube body, the at least one wear pad comprising a region of increased wall thickness.
- a first end, a second end opposite the first end, and a tube body extending between the first and second ends;
- the first and second ends being adapted for connection to other tubular members;
- at least one wear pad formed on the tube body, the at least one wear pad comprising a region of increased wall thickness.
2. The integral tubular member of claim 1, wherein the at least one wear pad has an outer diameter that is equal to or greater than the outer diameter of the tube body.
3. The integral tubular member of claim 1 or 2, wherein the at least one wear pad is formed by weld overlay over the tube body.
4. The integral tubular member of claim 1 or 2, wherein the at least one wear pad is formed by processing the unitary blank to reduce the wall thickness of the tube body in regions adjacent the at least one wear pad.
5. The integral tubular member of any one of claims 1 to 4, wherein the at least one wear pad comprises a wear resistant surface.
6. The integral tubular member of claim 5, wherein the wear resistant surface is formed by a surface hardening treatment or a surface coating.
7. The integral tubular member of any one of claims 1 to 6, wherein the integral tubular member comprises one wear pad.
8. The integral tubular member of claim 7, wherein the wear pad is located generally centrally along the length of the tube body.
9. The integral tubular member of any one of claims 1 to 6, wherein the integral tubular member comprises a plurality of wear pads provided along the length of the tube body.
10. The integral tubular member of claim 9, wherein the plurality of wear pads are generally equidistantly spaced along the length of the tube body.
11. The integral tubular member of any one of claims 1 to 10, wherein the first and second ends are formed with threads for connecting to adjacent tubular members when in use.
12. The integral tubular member of claim 11, wherein at least one of the first and second ends comprises a pin end having an external thread.
13. The integral tubular member of claim 11 or 12, wherein at least one of the first and second ends comprises a box end having an internal thread.
14. The integral tubular member of any one of claims 1 to 13, wherein the at least one wear pad has a wall thickness that is 50-100% greater than the wall thickness of the tube body.
15. The integral tubular member of any one of claims 1 to 13, wherein the at least one wear pad has a wall thickness that is 70-80% greater than the wall thickness of the tube body.
16. The integral tubular member of any one of claims 1 to 15, wherein the at least one wear pad is formed without redistributing material of the tubular blank.
17. The integral tubular member of any one of claims 1 to 16, wherein the tubular blank and the at least one wear pad have respective metallurgical grain structures and grain directions that are substantially the same.
18. An integral tubular member formed from a one piece tubular blank, the integral tubular member defining a longitudinal axis along its length, the integral tubular member having a first end, a second end opposite the first end, a first integral connector end adjacent the first end, a second integral connector end adjacent the second end, a tube body located between the first connector end and second connector end, the first connector end having a first wall thickness, a first outer diameter, and a first inner diameter, and the second connector end having a second wall thickness, a second outer diameter, and a second inner diameter, the tube body having a third wall thickness, a third outer diameter, a third inner diameter, and at least one region of locally increased wall thickness forming at least one wear pad, the at least one wear pad having a fourth wall thickness, a fourth outer diameter, and a fourth inner diameter, the fourth wall thickness being greater than the third wall thickness, the at least one wear pad having a metallurgical grain structure and grain direction substantially uniform and unaltered from the one piece tubular blank.
19. The integral tubular member of claim 18, wherein the at least one integral wear pad has a fourth wall thickness that is between 50-100% greater than the third wall thickness.
20. The integral tubular member of claim 18, wherein the at least one integral wear pad has a fourth wall thickness that is between 70-80% greater than the third wall thickness.
21. The integral tubular member of any one of claims 18 to 20, wherein at least one of the at least one wear pads is located substantially equidistant from the first end and second end.
22. The integral tubular member of any one of claims 18 to 21, wherein a ratio of the circumference formed by the third outside diameter to a transverse cross-sectional area formed by the third outside diameter and the third wall thickness is less than or equal to .450 in/sq.in.
and, the ratio of the circumference formed by the fourth outside diameter to the transverse cross-sectional area formed by the fourth outside diameter and the fourth wall thickness is greater than .450 in/sq. in.
and, the ratio of the circumference formed by the fourth outside diameter to the transverse cross-sectional area formed by the fourth outside diameter and the fourth wall thickness is greater than .450 in/sq. in.
23. The integral tubular member of any one of claims 18 to 22, wherein the third wall thickness is substantially equivalent to a standard drill pipe tube thickness.
24. The integral tubular member of any one of claims 18 to 23, wherein the first connector end is provided a first threaded connection and the second connector end is provided a second threaded connection.
25. The integral tubular member of claim 24, wherein the first threaded connection is a box connection.
26. The integral tubular member of claim 24, wherein the first threaded connection is a pin connection.
27. The integral tubular member of claim 25 or 26, wherein the second threaded connection is a pin connection.
28. The integral tubular member of claim 25 or 26, wherein the second threaded connection is a box connection.
29. A method of manufacturing an integral tubular member having at least one wear pad, the method comprising:
- providing a unitary tubular blank having a first end, a second end and a tube body extending between the first and second ends;
- forming the at least one wear pad by processing at least one region of the tube body to provide a wall thickness greater than the wall thickness of the tube body.
- processing the first and second ends to form, respectively, first and second connectors, the first and second connectors comprising means for connecting the integral tubular member to other tubular members.
- providing a unitary tubular blank having a first end, a second end and a tube body extending between the first and second ends;
- forming the at least one wear pad by processing at least one region of the tube body to provide a wall thickness greater than the wall thickness of the tube body.
- processing the first and second ends to form, respectively, first and second connectors, the first and second connectors comprising means for connecting the integral tubular member to other tubular members.
30. The method of claim 29, wherein the at least one region is formed with an outer diameter that is equal to or greater than the outer diameter of the tube body.
31. The method of claim 29 or 30, wherein the step of forming the at least one wear pad comprises a weld overlay process.
32. The method of claim 29 or 30, wherein the step of forming the at least one wear pad comprises reducing the wall thickness of the tube body in regions adjacent the at least one wear pad.
33. The method of any one of claims 29 to 32, further comprising a surface treatment step, wherein the at least one wear pad is treated to be wear resistant.
34. The method of claim 33, wherein the surface treatment step comprises a surface hardening treatment or an application of a surface coating
35 The method of any one of claims 29 to 34, wherein the step of processing the first and second ends comprises forming threads on the first and second ends for connecting to adjacent tubular members when in use.
36. The method of claim 35, wherein at least one of the first and second ends is formed into a pin end having an external thread.
37. The method of claim 35 or 36, wherein at least one of the first and second ends is formed into a box end having an internal thread
38. The method of any one of claims 29 to 37, wherein the step of forming the at least one wear pad comprises increasing the wall thickness of the at least one region by 50-100%.
39. The method of any one of claims 29 to 37, wherein the step of forming the at least one wear pad comprises increasing the wall thickness of the at least one region by 70-80%.
40. The method of any one of claims 29 to 39, wherein the step of forming the at least one wear pad is performed without redistributing material of the tubular blank.
41. The method of any one of claims 29 to 40, wherein step of forming the at least one wear pad does not alter the metallurgical grain structure and grain direction of the tubular blank.
42 A method of manufacturing an integral tubular member having at least one wear pad, comprising the steps of:
providing a unitary tubular blank having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion being adjacent the first end, the second portion being adjacent the second end and the central portion being positioned between the first portion and the second portion;
upsetting the first portion of the tube and the second portion of the tube to form an upset tubular having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion of the upset tubular having a length of between 25% - 75% of the length of the first portion of the tube and the second portion of the upset tubular having a length of between 25% - 75% of the length of the second portion of the tube, processing the first portion and the second portion of the upset tubular to form integral connector ends; and processing the central portion of the upset tubular to form a predetermined outer profile, the central portion of the upset tubular being processed to have at least one integral wear pad.
providing a unitary tubular blank having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion being adjacent the first end, the second portion being adjacent the second end and the central portion being positioned between the first portion and the second portion;
upsetting the first portion of the tube and the second portion of the tube to form an upset tubular having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion of the upset tubular having a length of between 25% - 75% of the length of the first portion of the tube and the second portion of the upset tubular having a length of between 25% - 75% of the length of the second portion of the tube, processing the first portion and the second portion of the upset tubular to form integral connector ends; and processing the central portion of the upset tubular to form a predetermined outer profile, the central portion of the upset tubular being processed to have at least one integral wear pad.
43. The method of claim 42, wherein the first integral connector end of the upset tubular is processed to have a box connection
44. The method of claims 42 or 43, wherein the second integral connector end of the upset tubular is processed to have a pin connection.
45 The method of claims 42 or 43, wherein the second integral connector end of the upset tubular is processed to have a box connection
46. The method of claim 42 or 43, wherein the first integral connector end of the upset tubular is processed to have a pin connection.
47. The method of any one of claims 42 to 46, wherein one of the at least one integral wear pads is centrally located on the central portion of the upset tubular.
48 The method of any one of claims 42 to 47, wherein at least one of the at least one integral wear pad is a fluted wear pad
49 The method of any one of claims 42 to 47, wherein at least one of the at least one integral wear pad is a bladed wear pad.
50 The method of any one of claims 42 to 47, wherein at least one of the at least one integral wear pad is a ribbed wear pad.
51 A method of manufacturing a drilling tubular, comprising the steps of:
providing a unitary tubular blank having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion being adjacent the first end, the second portion being adjacent the second end and the central portion being positioned between the first portion and the second portion, upsetting the first portion of the tube and the second portion of the tube to form an upset tubular having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion of the upset tubular having a length of between 25%-75% of the length of the first portion of the tube and the second portion of the upset tubular having a length of between 25%-75% of the length of the second portion of the tube;
processing the outer wall of the upset tubular to form a predetermined outer profile;
attaching a tool joint to the first end, and attaching a tool joint to the second end.
providing a unitary tubular blank having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion being adjacent the first end, the second portion being adjacent the second end and the central portion being positioned between the first portion and the second portion, upsetting the first portion of the tube and the second portion of the tube to form an upset tubular having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion of the upset tubular having a length of between 25%-75% of the length of the first portion of the tube and the second portion of the upset tubular having a length of between 25%-75% of the length of the second portion of the tube;
processing the outer wall of the upset tubular to form a predetermined outer profile;
attaching a tool joint to the first end, and attaching a tool joint to the second end.
52 The method of claim 51, wherein the predetermined outer profile is substantially cylindrical and uniform.
53. The method of claim 51, wherein the predetermined outer profile has at least one integral wear pad.
54. The method of claim 53, wherein at least one of the at least one integral wear pad is a fluted wear pad.
55. The method of claim 53, wherein at least one of the at least one integral wear pad is a bladed wear pad.
56. The method of claim 53, wherein at least one of the at least one integral wear pad is a ribbed wear pad
57. The method of any one of claims 53 to 56, wherein one of the at least one integral wear pads is centrally located on the central portion of the upset tubular.
58 A drill string comprising one or more of the integral tubular members of any one of claims 1 to 28
59. The integral tubular member of any one of claims 18 to 28, wherein the at least one wear pad is formed on the tube body without redistributing material of the tubular blank
60. The method of any one of claims 42 to 50 and 53 to 57, wherein the wear pad is formed without redistributing material of the tubular blank.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA3003991A CA3003991C (en) | 2018-05-04 | 2018-05-04 | Integral tubular member and methods of manufacturing the same |
| US16/403,267 US20190338603A1 (en) | 2018-05-04 | 2019-05-03 | Integral Tubular Member and Methods of Manufacturing Same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA3003991A CA3003991C (en) | 2018-05-04 | 2018-05-04 | Integral tubular member and methods of manufacturing the same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA3003991A1 CA3003991A1 (en) | 2018-08-01 |
| CA3003991C true CA3003991C (en) | 2019-02-19 |
Family
ID=63036945
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA3003991A Active CA3003991C (en) | 2018-05-04 | 2018-05-04 | Integral tubular member and methods of manufacturing the same |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US20190338603A1 (en) |
| CA (1) | CA3003991C (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2023230402A1 (en) * | 2022-05-26 | 2023-11-30 | National Oilwell Varco, L.P. | Wear resistant tubular members and systems and methods for producing the same |
-
2018
- 2018-05-04 CA CA3003991A patent/CA3003991C/en active Active
-
2019
- 2019-05-03 US US16/403,267 patent/US20190338603A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| CA3003991A1 (en) | 2018-08-01 |
| US20190338603A1 (en) | 2019-11-07 |
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