MX2011005675A - Real time dull grading. - Google Patents

Abstract

A method of monitoring the wear of drill bits for drilling wells in earth formations, several embodiments of an improved drill bit for drilling a well in an earth formation, and methods of manufacture. In one embodiment, the bit is assembled by forming the bit, including a bit body and a plurality of cutting components; introducing a wear detector into the bit; and providing a module to monitor the wear detector and generate an indication of bit wear. The wear detector may be one or more electrical circuits that may experience a change in resistance or conductivity due to wear of the bit. The module may determine wear by detecting an open circuit. The wear detector may be introduced during or after formation of the bit. The bit wear may be displayed for an operator.

Description

INDICATION OF LACK OF FILO IN REAL TIME DESCRIPTION OF THE INVENTION The inventions described and taught herein are generally related to drill bits for drilling wells; and more specifically, they are related to monitoring the wear of drill bits for drilling wells in land reservoirs.

US Patent No. 4, 655, 300 teaches a "method and apparatus for detecting excessive wear of a rotating auger used for drilling In particular, the apparatus can detect caliber loss or bearing failure in an auger. The method is achieved by connecting restriction means in the drill bit that can be manipulated to reduce the flow of drilling fluid through at least one port in the drill bit, a cable is connected between a sensor which detects the wear and restriction means to cause the restriction means to reduce the flow of drilling fluid and thus reducing flow is a signal on the surface as an indicator of wear. " U.S. Patent No. 4,694,686 teaches a "method and apparatus by means of which the degree of wear and life limitations of an auger, spike mill or other types of tooling can be detected. removal of metal. The method is based on the short circuit cover, open circuit voltage and / or the energy generated during the removal of metals through the use of a rotating insulating tool to which the electrical contact is made by means of a non-conducting conductor. rotary and an insulating or non-insulating work piece, with an external circuit that connects the tool and the work piece through a measuring device. The current, voltage or energy generated, show an increase or change in slope with considerable wear of the tool and / or at the point of failure ".

U.S. Patent No. 4,785,894 teaches a "ground drill bit incorporating an auger wear indicator." The auger wear indicator includes: a sensor for detecting wear at a selected point of the auger, a device for altering resistance of the auger to receive the drilling fluid from the drill string, and a tensioned connection extending between the wear sensor and the flow resistance alteration means.When detecting a predetermined degree of wear, the wear sensor releases the tension in the tensioned connection.This activates the flow resistance alteration device, causing the flow rate and / or pumping pressure of the drilling fluid to change.This serves as a signal that a predetermined wear condition has been reached. The bit wear indicator can be adapted to monitor many different types of bit wear, including bearing wear in tapered roller bits and wear of gauges in all types of bit. " U.S. Patent No. 4, 785, 895 teaches a "ground-boring drill bit incorporating a tensed connection-type drill wear indicator." A tensioned connection extending through the drill bit between a wear sensor and a tampering device. the resistance of the auger to receive the drilling fluid from the drill string.When detecting a predetermined degree of wear, the wear sensor releases the tension in the tensioned connection.This activates the flow resistance alteration device, causing the flow rate and / or the pumping pressure of the drilling fluid to change The tensioned connection passes through two intercepting passages in the auger A guiding element is inserted at the intersection of the two intersecting passages The guiding element directs the tensioned connection between the two passages. " U.S. Patent No. 4,786,220 teaches a "method and apparatus by means of which the degree of wear and life-limitation of a auger, dowel drill or other types of metal removal tools. The method is based on the short circuit cover, open circuit voltage and / or the energy that is generated during the removal of metals by means of the use of an insulating rotating tool auger to which the electrical contact is made by means of a non-rotating conductor and an insulating or non-insulating work piece, with an external circuit that connects the tool and the work piece through a measuring device. The current, voltage or energy generated show an increase or change in slope with the considerable wear of the tool and / or the point of failure ".

U.S. Patent No. 4,928,521 teaches a "method that is provided to determine the wear state of a multiple cone drilling bit." The vibrations generated by the operation of the drill bit are detected and converted into an oscillatory time signal to From which a frequency spectrum is derived The periodicity of the frequency spectrum is extracted The rotation speed of at least one cone is determined from the periodicity and the state of wear of the drill bit is derived from of the rotation index of the cone The oscillating signal represents the variation in amplitude of the vertical or torsional force applied to the drill bit. periodicity, a set of harmonies in the frequency spectrum is given importance by calculating the cepstrum of the frequency spectrum or by means of obtaining an improved spectrum by harmony. The fundamental frequency in the harmony set is determined and the rate of rotation of the cone is derived from the fundamental frequency ".

U.S. Patent No. 5,216,917 teaches "a new model describing the process of drilling a drill bit and relating it to a method for determining the drilling conditions associated with drilling a borehole through underground reservoirs, each corresponding to a particular lithology, the borehole that is drilled with a drill or rotary drive, the method comprising the steps of: measuring the weight W applied to the auger, "the torque of the auger T, the angular rotation speed O of the auger and the penetration index N of the auger to obtain the data sets (Wi, 'i, Ni, O ^) that correspond to different depths, calculate the specific energy Ei and the perforation resistance Si from the data (Wi, Ti, Ni, üi); At least one linear group of values (Ei, Si), the group that corresponds to a particular lithology, and determine the drilling conditions from the linear group.The slope of the linear group is determined, from the estimate of the angle of internal friction F of the deposit. The specific intrinsic energy E of the deposit and the drilling efficiency are also determined. The change in lithology, the wear of the bit and the caking of the bit can be detected. " US Patent No. 6,631,772 teaches a "system and method for detecting the wear of a roller auger bearing between a roller borer body and a roller borer rotatably connected to the roller borer body. A valve male is placed between the roller auger body and the roller auger so that the valve male is removably fitted in a drilling fluid outlet of the roller borer body, and the male valve extends to a channel in the roller auger where uneven rotation or vibration of the roller auger causes the valve tap to impact the sides of the channel which removes the valve tap from the fluid outlet perforation, which causes the drilling fluid to flow through the drilling fluid outlet.The drop in drilling fluid pressure n flowing through the fluid outlet drill bit indicates that the roller is worn and may fail ".

U.S. Patent No. 6,634,441 teaches a "system and method for detecting the wear of a roller auger bearing on a roller auger body where the roller element has a plurality of cutting elements and which is rotatably joined to the drill bit body of In the invention, a rotation impediment is located between the roller element and the roller drill bit body and by the uneven rotation of the roller element, which indicates that the bearing of the roller element can fail, the rotation stop prevents rotation of the roller element The operator of the surface drilling rig can stop the drilling operations when it is detected that the roller element has stopped rotating. in an outlet of the drilling fluid and cause a detectable loss in the drilling fluid pressure when it travels for stop the rotation of the roller drill bit ".

The inventions described and taught herein are directed to an improved method for monitoring the wear of drill bits for drilling wells in land deposits.

The invention relates to a method for monitoring the wear of drill bits for drilling wells in land deposits, various modalities of an improved drill bit for drilling a well in a land deposit, and manufacturing methods. In one embodiment, the auger is assembled to form the auger, including a auger body and a plurality of cutting components; introduce a wear detector in the auger; and provide a module to monitor the wear detector and generate an indication of wear of the auger. The wear detector may be one or more electrical circuits that may undergo a change in resistance or conductivity due to the wear of the auger. The module can determine wear by detecting an open circuit. The wear detector can be introduced during or after the formation of the auger. The wear of the auger can be deployed for an operator.

A drill bit assembly, according to the present invention, may comprise a drill bit including a bit body and a plurality of cutting components; a wear detector inside the drill bit; and a module to monitor the wear detector and generate an indication of wear of the auger. The wear detector may be one or more electrical circuits that may undergo a change in resistance or conductivity due to the wear of the auger. The module can determine wear by detecting an open circuit. The wear detector can be introduced during or after the formation of the auger. The auger wear can be deployed to an operator on a surface computer.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 illustrates a perspective view of an exemplary drill bit incorporating cutting elements and covering certain aspects of the present inventions; Figure 2 is an enlarged perspective view of an exemplary cutting element embracing certain aspects of the present inventions; Figure 3 illustrates a perspective view of an exemplary impregnated drill bit encompassing certain aspects of the present inventions; Figure 4 is an elevational view in partial section of a blade of a drill bit, a first embodiment of the present inventions; Figure 5 is an elevation view in partial section of a blade of a drill bit, a second embodiment of the present inventions; Figure 6 is an elevation view in partial section of a drill bit blade, a third embodiment of the present inventions; Figure 7 is an elevational view in partial section of a blade of a drill bit, a fourth embodiment of the present inventions; Figure 8 is an elevation view in partial section of a drill bit blade, a fifth embodiment of the present inventions; Figure 9 is an elevational view in partial section of a blade of a drill bit, a 6a. mode of the present inventions; Figure 10 is an elevation view in partial section of a drill bit blade, a seventh embodiment of the present inventions; Figure 11 is an elevation view in partial section of a drill bit blade, an eighth embodiment of the present inventions; Figure 12 is a flow diagram illustrating certain aspects of the present inventions; Figure 13 is an elevation view in partial section of a drill bit blade, a ninth embodiment of the present inventions; Figure 14 illustrates a perspective view of a mill using certain aspects of the present inventions; Figure 15 illustrates a perspective view of a milling cutter showing wear using certain aspects of the present inventions; Figure 16 illustrates another perspective view of a burr showing wear using certain aspects of the present inventions; Figure 17 illustrates a perspective view of a drill bit shaft, an exemplary electronics module, and an end cap that can be part of a bottomhole assembly using certain aspects of the present inventions; Figure 18 illustrates a conceptual perspective view of an exemplary electronics module configured as a flexible circuit board that enables formation in an annular ring suitable for disposition in the shaft of Figure 17; Y Figure 19 illustrates a block diagram of an exemplary embodiment of a data analysis module using certain aspects of the present invention.

The Figures described above and the written description of the specific structures and functions in the following are not presented to limit the scope of what has been invented or the scope of the appended claims. In contrast, the Figures and the described description are provided to teach those skilled in the art to make and use the inventions for which patent protection is sought. Those with experience in the art will appreciate that not all the characteristics of a commercial modality of the inventions are described or shown for purposes of clarity and understanding. Those skilled in the art will also appreciate that the development of a real commercial mode incorporating aspects of the present inventions will require numerous specific implementation decisions to achieve the greatest purpose of the developers for the commercial mode. Such specific implementation decisions may include, and are similarly not limited to, compliance related to the system, business, government and other restrictions, which may vary by specific implementation, location and periodically. While the efforts of a developer can be complex and consume time in an absolute sense, such efforts can be, however, a routine carried out by those with experience in the art who derive benefits from this description. It should be understood that the inventions described and taught herein are susceptible to numerous and various modifications and alternative forms. Finally, the use of a singular term, such as, but not limited to, "a", is not intended as limiting the number of elements. Also, the use of relationship terms, such as, but not limited to, "top", "bottom", "left", "right", "top", "bottom", "bottom", "top" , "lateral", and the like are used in the description described for clarity in specific reference to the Figures and are not intended to limit the scope of the invention or the appended claims.

The particular embodiments of the invention can be described in the following with reference to block diagrams and / or operational illustrations of the methods. In some alternative implementations, the functions / actions / structures observed in the figures may occur outside the order observed in the block diagrams and / or operational illustrations. For example, two operations shown as occurring successively, in fact, may be executed substantially concurrently or the operations may be executed in the reverse order, depending on the functionality / acts / structure involved.

A method has been created to monitor the wear of drill bits for drilling wells in land deposits, various modalities of an improved drill bit for drilling a well in a land deposit, and manufacturing methods. In one embodiment, the auger is assembled to form the auger, including a auger body and a plurality of cutting components; introduce a wear detector in the auger; and provide a module to monitor the wear detector and generate an indication of wear of the auger. The wear detector it can be one or more electrical circuits that can undergo a change in resistance or conductivity due to the wear of the auger. The module can determine wear by detecting an open circuit. The wear detector can be introduced during or after the formation of the auger. The wear of the auger can be deployed for an operator.

FIGURE 1 is an illustration of a drill bit 10 including an auger body 12 having a conventional bolt end 14 to provide a threaded connection to a tubular drilling string attached in a conventional manner rotationally and longitudinally driven by means of of a drilling rig. Alternatively, the drill bit 10 may be connected in a manner known in the art to a bottomhole assembly which, in turn, is connected to a tubular drill string or to an essentially continuous pipeline coil. Such downhole assemblies may include a motor at the bottom of the bore to rotate the drill bit 10 in addition to, or instead of, being rotated by means of a rotary table or a motorized rotating link located on the surface or on a maritime platform (not shown inside the drawings). In addition, the conventional pin end 14 can optionally be replaced with various known alternative connection structures within the technique. In this way, the drill bit 10 can easily be adapted to a wide variety of mechanisms and structures used for drilling the underground deposit.

The drill bit 10 and the selected components thereof are preferably similar to those described in US Patent 7,048,081, which is incorporated herein by reference. In any case, the drilling bit 10 preferably includes a plurality of blades 16, each projecting outwardly from the face 18. The drill bit 10 also preferably includes a row of cutters, or cutting elements 20, secured to each other. the blades 16. The drill bit 10 also preferably includes a plurality of nozzles 22 for distributing the drilling fluid to cool and lubricate the drill bit 10 and remove the sediments from the drill. As is customary in the art, the gauge 24 is the maximum diameter which drill bit 10 should have at its periphery. The caliber 24 will then determine the minimum diameter of the resulting borehole that the drill bit 10 will produce when it is put to work. The 24 gauge of a small drill bit must be as small as a few centimeters and the 24 gauge of an extremely large drill bit can approach a meter, or more. Between each blade 16, the drill bit 10 preferably has fluid slots, or passages 26, into which the drilling fluid is fed by means of the nozzles 22.

An exemplary cutting element 20 of the present invention, as shown in FIGURE 2, includes a super-abrasive cutting table 28 of circular, rectangular or other polygonal, oval, truncated circular, triangular, or other suitable cross section. The super-abrasive table 28 has a circular cross section and a general cylindrical configuration, or shape, which is suitable for a wide variety of drill bits and drilling applications. The super-abrasive table 28 of the cutting element 20 is preferably formed with a conglomerated super-abrasive material, such as a compact polycrystalline diamond (PDC), with an exposed cutting face 30. The cutting face 30 will typically consist of an upper portion 30A and a lateral portion 30B, with a peripheral junction thereof serving as the cutting region of the cutting face 30; and more precisely a cutting edge 30C of the cutting face 30, which is usually the first portion of the cutting face 30 to contact and thus initially "cut" the reservoir according to the drilling bit 10 which retains the cutting element 20 progressively drills a borehole. The edge 30C of Cutting can be relatively sharp about a ninety degree edge, or it can be beveled or rounded. The super abrasive table 28 will also typically consist of a main lower part, or joint, unit interface face during diamond sintering, or super abrasive lid forming the super abrasive table 28 to a support substrate 32 typically formed of a hard and relatively strong material such as a cemented tungsten carbide or other carbide. The substrate 32 can be preformed into a desired shape such that a volume of the diamond particle material can be formed within the polycrystalline or super-abrasive sediment table 28 thereof and simultaneously be strongly bound to the substrate 32 during the sintering techniques. of high pressure at high temperature (HPHT) practiced within the technique. Such strawberries are further described in U.S. Patent No. 6, 401, 844, the disclosure of which is hereby incorporated in its entirety for specific reference. A unitary cutting element 20 is then provided which can be secured to the drill bit 10 by means of brazing or other techniques known in the art.

In accordance with the present invention, the super-abrasive table 28 preferably comprises a heterogeneous conglomerate type of PDC lid or diamond matrix in which the less two different nominal sizes and wear characteristics of super-abrasive particles, such as diamonds of different grains, or sizes, are included to ultimately develop a cutting face 30, of rough or rough cut, particularly with respect to the 30B side of the cutting face and more particularly with respect to the cutting edge 30C. In one embodiment, larger diamonds may vary upwards from approximately 600 μp ?, with a preferred range from approximately 100 μm to approximately 600 μm, and smaller diamonds, or super-abrasive particles, may preferably vary from around 15 μm to around 100 p.m. In another embodiment, the larger diamonds may vary upwards from about 500 p.m., with a preferred range from about 100 p.m. to about 250 p.m., and smaller diamonds, or super-abrasive particles, may preferably vary from about 15 p.m. around 40 pm.

The specific grain size of large diamonds, the specific grain size of small diamonds, the thickness of the 30 cutting face of the 28 super-abrasive table, the amount and type of sintering agent, as well as the fractions and the volume of the large and small diamond respectively, can be adjusted to optimize the cutter 20 to cut particular deposits having a particular hardness and particular abrasive characteristics.

The relative, desirable particle size ratio of large diamonds and small diamonds can be characterized as a trade off between the resistance and aggressiveness of the milling cutter. On the contrary, the desire for the super-abrasive table 28 to be subjected to larger particles during drilling can determine a relatively small difference in average particle size between small and large diamonds. On the contrary, the desire to provide an uneven cutting surface can determine a relatively large difference in the average particle size between small and large diamonds. In addition, the factors immediately above can be adjusted to optimize the mill 20 at the average rotational speed, at which the cutting element 20 will couple the reservoir, as well as for the magnitude of the normal and torsional force at which each bur 20 it will undergo while in operation as a result of the rotational speeds and the amount of weight, or longitudinal force, which will similarly be subjected to the drill bit 10 during drilling.

The blades 16 and / or the auger body 12 can be made from an alloy matrix, such as a matrix of tungsten carbide powder impregnated with a copper alloy binder, during a casting process. For example, the drill bit 10 can be constructed as a matrix style drilling bit using an infiltration melting process where the copper alloy binder is heated beyond its melting temperature and allowed to flow, under the influence of gravity, into a matrix of carbide powder packed inside, formed by means of a graphite mold. The mold preferably contains the shapes of the blades 16 and grooves 26 of the drill bit 10, creating a shape for the drill bit 10. Other features can be made from clay and / or sand and joined to the mold.

Alternatively, bit 10 may be similar to those described in US Patent No. 6,843,333, the disclosure of which is hereby incorporated by reference in its entirety for specific reference. Now with reference to FIGURE 3, the drill 10, is in one embodiment, a diameter of 9 centimeters (8½ inches) and includes a body 12 of matrix type, which has a bore 14 for connection to a drill string (no shown) extending from the same opposite to face 36 of the auger. A plurality of blades 38 extending generally radially outward, linearly to the caliper shoes 40 defining slots 42 for debris therebetween. The auger 10 can employ fluid passages 46 between the blades 38 and that extend to the waste slots 42 to improve the flow of fluid on the auger face 36.

The auger 10 may include impregnated auger cutting structures and / or discrete impregnated cutting structures 44 that comprise posts extending upwardly from the knives 38 on the auger face 36. The cutting structures 44 can be formed as an integral part of the matrix-type blades 38 projecting from the matrix bit body 12 when hand-packing the matrix material impregnated with diamond grain into the mold cavities inside the mold. an auger mold defining the locations of the cutting structures 44 and the blades 38. In this way, each blade 38 and associated cutting structure 44 can define a unitary structure. It is noted that the cutting structure 44 can be placed directly on the bit face 36, dispensing with the knives. It can also be seen that, while discussing terms of being integrally formed with the auger 10, the cutting structures 44 can be formed as discrete individual segments, such as by isostatic heat-tensioning, and subsequently by brazing or baking in the auger 10.

The discrete cutting structures 44 can be mutually separated from each other to promote the flow of drilling fluid around them for a cooling and improved cleaning of the deposit material removed by the diamond grain. The discrete cutting structures 44, may generally be in a round or circular cross section at their substantially flat, outermost ends, but become more oval with the decrease in the distance of the face of the blades 38 and thus provide additional bases. wide or elongated (in the direction of rotation of the auger) for greater strength and durability. As the discrete cutting structures 44 wear out, the exposed cross section of the posts increases, determining a progressive increase in the contact area for the diamond grain with the reservoir material. As the cutting structures wear down, the drill 10 assumes the consideration of a heavy set auger more apt to penetrate the harder, more abrasive deposit. Even if the discrete cutting structures 44 wear out completely, the blades 38 impregnated with diamond will provide some cutting action, reducing the possibility of de-centering and having to take out the bit 10.

Although the cutting structures 44 are illustrated as having circular outer end posts and oval shaped bases, other geometries are also contemplated. For example, the outermost ends of the cutting structures can be configured as ovals having a diameter greater and a smaller diameter. The adjacent base portion of the blade 38 may also be oval, with a larger diameter and a smaller diameter, where the base has a smaller diameter than the larger one at the outermost end of the cutting structure 44. As the cutting structure 44 wears toward the blade 38, the smaller diameter increases, resulting in a larger surface area. In addition, the ends of the cutting structures 44 do not need to be flat, but can use inclined geometry. In other words, the cutting structures 44 can change the cross sections at multiple intervals, and the tip geometry can be separated from the general cross section of the cutting structure. Other forms of geometry can be configured in a similar manner. It should also be noted that the spacing between the individual cutting structures 44, as well as the amount of tapering of the outermost ends of the blades 38, may vary to change the total aggressiveness of the auger 10, or to change the speed at which the bit is transformed from a light set auger to a heavy set auger during operation. Furthermore, it is contemplated that one or more of such cutting structures 44 may be formed to have substantially constant cross sections, if desired, depending on the anticipated application of the bit 10.

The discrete cutting structures 44 may comprise a synthetic diamond grain, such as, for example, DSN-47 Synthetic diamond grain, commercially available from DeBeers of Shannon, Ireland, which has demonstrated superior strength to natural diamond grain. The tungsten carbide matrix material with which the diamond grain is mixed to form the discrete cutting structures 44 and support the blades 38 may desirably include a fine-grained carbide, such as, for example, DM2001 powder commercially available from Kennametal Inc., of Latrobe, Pa. Such carbide powder, when infiltrated, provides increased exposure of diamond grain particles compared to conventional matrix materials because of its relatively soft, abrasive nature. The base of each blade 38 may desirably be formed of, for example, a more durable matrix material 121, obtained from Firth MPD of Houston, Texas. The use of more durable material in this region helps prevent de-centering if all discrete cutting structures 44 corrode and most of each blade 38 wears.

However, it should be noted, that alternative abrasive particle materials can be suitably replaced by those mentioned in the above. For example, discrete cutting structures 44 may include natural diamond bead, or a combination of synthetic and natural diamond bead. Alternatively, the cutting structures may include synthetic diamond posts. Additionally, the abrasive particle material may be coated with a single layer or multiple layers of a refractory material, such as those known in the art and described in U.S. Patent Nos. 4,943,488 and 5,049,164, the descriptions of which are incorporated herein by reference. entirety in the present for reference. Such refractory materials may include, for example, a refractory metal, a refractory metal carbide or a refractory metal oxide. In one embodiment, the coating may have a thickness of about 1 to 10 microns. In another embodiment, the coating may have a thickness of about 2 to 6 microns. In another additional embodiment, the coating may have a thickness of less than 1 micron.

In one embodiment, one or more of the blades 38 carrying cutting elements, such as the PDC burs 20, in conventional orientations, with the cutting faces oriented generally facing the direction of rotation of the auger. In one embodiment, the reamers 20 are located within the cone portion 34 of the auger face 36. The cone portion 34 is the portion of the bit face 36 where the profile is defined as a shaped section generally cone-shaped around the centerline of the intended rotation of the drill bit 10. Alternatively or additionally, the burs 20 may be located along the blades 38 and anywhere in the bit 10.

This cutter design provides improved abrasion resistance to hard and / or abrasive deposits typically drilled by impregnated augers, in combination with improved performance, or penetration rate (ROP), in softer, non-abrasive reservoir layers inter-embedded with such hard deposits. However, it should be noted that alternative milling designs can be implemented. For example, the burs 20 can be configured in various shapes, sizes, or materials as known to those skilled in the art. Also, other types of cutting elements may be formed within the cone portion 34 of, and on either side, of the auger 10 depending on the anticipated application of the auger 10. For example, the cutting elements 20 may include shaped cutters. of thermally stable diamond (TSP) product, natural diamond material, or impregnated diamond.

As shown in FIGURE 4, and as mentioned in the foregoing, the cone section of each blade is preferably a substantially linear section that is extends from a central line near the outer drill 10. Because the cone section is located near the centerline of the drill bit 10, the cone section does not experience as much, or as fast, movement in relation to the earth's deposit. Therefore, it has been found that the cone section commonly experiences less wear than the other sections. In this way, the cone section can maintain an effective and efficient penetration speed with less cutting material. This can be achieved in several ways. For example, the cone section may have fewer cutting structures 44 and / or cutters 20, cutting structures 44 and / or smaller cutters 20, and / or more separation between cutting structures 44 and / or cutters 20. Cone angle for a PDC bit is typically 15-25 °, although, in some embodiments, the cone section is essentially flat, with a cone angle substantially of 0 °.

The tip represents the lowest point of a drill bit. Therefore, the end mill is typically the most forward cutter. The tip section is unequally defined by a tip radius. A longer tip radius provides more area to place strawberries in the tip section. The tip section begins where the cone section ends, where the curvature of the blade begins, and extends to the support section. From More specifically, the tip section extends where the blade profile substantially splices with a circle formed by the radius of the tip. The tip section experiences much more, and faster, relative movement than the cone section. Additionally, the tip section typically bears more weight than other sections, as such, the tip section commonly experiences much more wear than the cone section. Therefore, the tip section preferably has a higher distribution, concentration, or density of the cutting structures 44 and / or the cutters 20.

The support section begins where the blade profile starts from the radius of the tip and continues externally in each blade 18, 38 to a point where a blade inclination is essentially completely vertical, in the section of the gauge. The support section experiences much more and faster, relative movement than the cone section. Additionally, the support section typically assumes the excess abuse of the dynamic dysfunction, such as the rotation of the auger. As such, the support section experiences much more wear than the cone section. The support action also contributes more significantly to the penetration speed and drilling efficiency than the cone section. Therefore, preferably, the support section has one more high distribution, concentration, or density of cutting structures 44 and / or cutters 20. Depending on the application, the tip section or support section may experience the greatest wear, and therefore, either the tip section or the support section may have the highest distribution, concentration, or density of the structures 44 cutting and / or cutters 20.

The gauge section begins where the support section ends. More specifically, the gauge section begins where the inclination of the blade is predominantly vertical. The gauge section continues externally to an outer perimeter or gauge of the drill bit 10. The caliber section experiences the largest, and fastest, relative movement with respect to the Earth's reservoir. However, at least partially due to the high, substantially vertical inclination of the blade 18, 38 in the gauge section, the gauge section typically does not experience as much wear as the support section and / or the tip section. However, the gauge section does typically experience more wear than the cone section. Therefore, the gauge section preferably has a higher distribution of cutting structures 44 and / or cutters 20 than the cone section, but may have a lower distribution of cutting structures 44 and / or cutters 20 that the support section and / or the section of tip As shown in FIGURE 4, according to one embodiment of the present invention, a conductor or cable 50 is embedded within each blade 16. Each cable 50 is preferably pre-positioned in the mold during casting, or forming the auger 10. The cables 50 are preferably located inside the blades 16, just below the cutters 20, above the face 18 of the auger 10. In one embodiment, the cables 50 terminate in an electronics module 52, which can be connected to the surface computer 54 through a communication link 56, such as drilling cable communication, drilling measurement (MWD) and / or wireless. The computer 54 is preferably located on or near the surface of the well being drilled, or on board the drilling rig, and is preferably monitored by a drilling operator or supervisor. Alternatively, the computer 54 may be located away from the well, such as at a central monitoring station.

The module 52 preferably monitors the cable 50, such as by continuously and / or periodically checking the continuity of the cable 50. If the cable 50 is broken, such that continuity is lost, the module 52 notifies the computer 54 of surface through communication link 56. Then an operator is notified in the surface that the bit 10 experiences significant wear and needs to be replaced. This notification may be by means of one or more multiple means, such as an audible alarm, and / or visual indication. In some embodiments, which will be discussed in greater detail in the following, the operator is presented with an image of the auger showing its condition in real time, determined by the module 52 using the cables 50. These advances allow the operator to take better decisions, eliminating unnecessary trips out of the hole, and thus significantly increasing the efficiency of drilling.

More specifically, as the auger 10 is used, the cutters 20 experience wear and eventually fail. The reservoir through which the auger 10 is drilling, then begins to corrode the blades 16. As the blades 16 corrode, the cable 50 is eventually exposed and corrodes as well, thus breaking a circuit formed by the cable 50 and the module 52 The module 52 perceives this open circuit and notifies the surface computer 54 through the communication link 56. In this way, the operator can start the borehole assembly (BHA) or drilling string to the surface and replace the drill 10 only when necessary to prevent de-centering or other wear condition excessive As shown in FIGURE 5, each blade 16 can have multiple cables 50 for a better wear indicator. These cables 50 may be concentric, as shown, and / or may be arranged or routed in different or unique patterns to more fully cover the interior of the blades 16. The concentric cables 50 may be used to better indicate the degree of wear. The cables 50 routed differently can be used to better indicate where wear is occurring. Each of the cables 50 can be connected directly and independently to the module 52, as shown. Additional and / or alternatively, as will be discussed in more detail in the following, the cables 50 may share connections to the module 52.

As shown in FIGURE 6 and FIGURE 7, the cables 50 may comprise multiple individual loops 50a-50d in each blade 16. For example, the cables 50 may comprise a cone loop 50 embedded within the cone section of the cable. blade 16. The wires 50 may comprise a tip loop 50 embedded within the tip section of the blade 16. The wires 50 may comprise a support loop 50c embedded within the support section of the blade 16. The cables 50 may comprise a gauge loop 50 embedded within the section of the blade 16.

As discussed in the above, these loops 50a-50d may have direct and independent connections to the module 52. Additionally and / or alternatively, the loops 50a-50d may share connections to the module 52, as shown. To allow the module 52 and / or the computer 52 to make a difference between them, the loops 50a-50d may include electrical and / or electronic components. For example, the loops 50a-50d may include strong elements 58a-58d. Additionally and / or alternatively, the loops 50a-50d may include capacitive and / or inductive elements. In addition, the loops 50a-50d may include electronic elements, such as microchips that identify each loop to the module 52 and / or the computer 54.

More specifically, as shown in the FIGURE 7, each resistor 58a-58d is initially connected in parallel, resulting in an initial resistance. As one or more of the cables 50 break due to wear, the resistance of the module 52 increases. These changes in resistance can be detected by the module 52. Furthermore, by using resistors 58a-58d with different resistances, the module and / or the computer 54 can determine which loops 50a-50d have been broken, in order to indicate which section of the bit 10 experiences excessive wear, when comparing the initial resistance to the resistance modified using the known resistance values.

Of course, modules 52 can differentiate between loops 50a-50d without discrete electrical and / or electronic components. For example, different lengths of resistant cables can be used like the loops themselves. The module 52 can detect and analyze the capacity between the loops. The module 52 can detect and analyze the inductive coupling between the loops.

As shown in FIGURE 8, a combination of techniques can be used. For example, each section may have multiple loops 50a-50d. These loops 50a-50d can be routed concentrically and / or only to better indicate the wear and / or the exact location of the wear that each section experiences. These loops 50a-50d can have direct and independent connections to the module 52 and / or can share connections to the module 52 using electrical and / or electronic components to allow the module 52 to make a difference between them. For example, the loops of each section may share dedicated connections, such that the module 52 includes a set of connections for each section. The loops 50a-50d, electrical and / or electronic components, and / or the module 52 may collectively be referred to as a circuitry 60.

Although, in one embodiment, drivers 50 are found naked, routed through the non-conductive auger body 12, the blades 16, and / or other components of the auger 10, the conductors 50 can be insulated. This may be of help where various conductors are used in each blade 16 and / or may allow the use of blades 16 and / or a bit body 12 made of conductive material, such as steel. One or more of the cables 50 can also be routed through the cutters 20 and / or the cutting structures 44 themselves, as shown in FIGURE 9. In this case, when the auger 10 loses one of the cutters 20, the Module 52 can detect the open circuit and thus indicate the wear of the auger.

Alternatively and / or additionally, any part of the circuitry described in the foregoing may be provided by the auger body 12, the blades 16 and / or other components of the auger 10 directly. For example, instead of simply passing the wires 50 through the cutters 20, the cutters 20 and / or the cutting structures 44 can be part of the conductivity path 50, as shown in FIGURE 10. The cutters 20 they can be doped with an indicator material 62, such as boron, which can convert the diamond inserts into semiconductors. As the inserts wear out, the conductivity detected by the circuitry 60 may change, resulting in signals to the computer 54 indicating the wear of the auger 10. Alternatively or additionally, the indicator material 62 may be used anywhere within or along the auger 10 and may be used to provide all or portions of the conductivity paths 50, as shown in FIGURE 11. As the indicator material 62 corrodes, the characteristics of the circuitry 60 change, indicating wear.

Beyond only changing the conductivity of the portions of the drill bit 10, the indicator materials can additionally or alternatively change other characteristics of the drill 10. For example, the indicator material can be used to indicate wear by altering a traditional response from auger to acoustic, optical, electrical, magnetic, and / or electromagnetic excitation. Such alternations may preferably change, in response to wear of the auger 10 or a portion thereof.

Also with reference to FIGURE 12, when the drill bit 10 is initially manufactured, on par with the module 52, and / or is put into operation, the module 52 detects the initial characteristic, such as conductivity, resistivity, or capacity , as shown in step 100a. As the drill bit 10 is used, the module 52 continuously or periodically verifies that characteristic, as shown in step 100b. The module 52 compares the most recently detected characteristic with the initial characteristic, as shown in step 100c. As shown in step 100d, if there is a change in the characteristic, the module 52 determines which section or sections experience wear, and how much wear.

For example, resistors of 1000, 2000, 3000 and 4000 ohms are used in the loops 50a-50d of cone, tip, support and gauge, respectively, then the initial resistance detected by the module 52 will be approximately 480 ohms. If the support section experiences a wear corrosion of the support loop 50c, the change in resistance verified by the module 52 will be approximately 571 ohms, indicating the loss of the 3000 ohm resistance caused by the open circuit in the loop 50c of the support. Alternatively, if the tip section were to experience wear corroding the tip loop 50b, the change in resistance verified by the module 52 will be approximately 632 ohms, indicating the loss of the 2000 ohm resistance caused by the open circuit in the 50b loop tip. If the auger 10 experiences more significant wear, both in the tip section and in the support section, the change in resistance verified by the module 52 can be approximately 800 ohms, indicating the loss of the resistances of 2000 and 3000 ohms. caused by the circuits open at the tip and support loops 50b, 50c. In this way, module 52 can determine which section or sections experience wear and how much wear, as shown in step lOOd.

Once wear is detected, by any method, it is reported, as shown in step lOOe. Wear can be reported directly to an operator on the surface. For example, the operator can be shown a representation of the bit 10. The wear can be indicated by the discoloration of the portion of the bit 10 that was determined to experience wear. Alternatively, the portion of the bit 10 that was determined to experience wear can be removed from the screen. How much is removed and / or decolorized may depend on the degree of wear determined by the module 52. This screen may be substantially updated in real time, periodically and / or upon request. Wear can be reported to a control system, which can alert the operator, record the wear report, and / or carry out the corrective action automatically.

Rather than monitor the presence of indicator material 62 in auger 10, auger body 12, knife 16, and / or cutter 20 or cutting structure 44, as discussed above, module 52 and / or computer 54 may perceive the material 62 indicator after it has separated from the auger 10. For example, as shown in FIGURE 13, the indicator material 62 may comprise an isotope, such as uranium or radium, initially embedded in the auger 10, auger body 12, one or more of the blades 16, and / or a or more of the cutters 20 or cutting structures 44. The module 52, and / or one or more of the sensors 64 in communication with the module 52, can be located, positioned and / or configured to detect, or detect a change in an indication of, indicator material, after it has been separated. of the bit 10.

More specifically, as shown in FIGURE 14, the indicator material 62 can be integrated into diamond cutters 20 during hydrostatic pressure. In one embodiment, the indicator material 62 is stratified into substantially equal separations in the Z direction. In this embodiment, and possibly others, the indicator material 62 may be an isotope, such as alpha particles or similar material with a suitable long average life. . The isotope can continuously emit detectable signals.

In an alternative embodiment, as discussed above, the burs are doped with a material such as boron, phosphorus, gallium, or other material, so as to transform the portions of the burs 20 themselves into indicator materials. In one embodiment, diamond cutting tables 28 can be transformed into semiconductors. By way of More specifically, during actual drilling operations, the heat is generated naturally, activating the doping material and transforming the cutting tables doped into semiconductors.

In any case, the cutters 20, according to certain aspects of the present invention, may have a structure similar to a mesh comprising nodes of the isotope or doping material. The module 52 can determine wear by using wired, wireless, acoustic or other sensors to detect the presence or absence of the indicator material 62. The wear can be displayed to the operator on the surface in real time through, for example, a modem, telemetry by means of mud pulses, M-30 bus, or other transmission means. Alternatively or additionally, the wear data can be stored in a memory of the module 52. The screen can show a representation of the actual wear of the auger 10 and / or cutters 20. For example, as shown in FIGURE 15 and FIGURE 16 , if different isotopes are used in different layers, the module 52 may be able to determine which portions of the cutters 20 have experienced the greatest wear, and show a real three-dimensional representation of the wear.

It should be noted that only one blade 16 of a PDC bit is shown in FIGS. 4-11 and 13. It should be appreciated, upon reading this description, that the circuitry The above described can be implemented independently and / or dependently for each blade 16, 38. It should also be appreciated, upon reading this description, that the circuitry described in the foregoing can be implemented in an impregnated bit, as well as in a hybrid bit. In addition, the circuitry described in the foregoing may be implemented in a roll cone auger. In this way, the PDC bit shown in FIGS. 4-11 and 13 is only one example of the possible applications. In this regard, the cutters 20, cutting structures 44, TSP, and / or blades 38 impregnated with diamond, etc., can collectively be referred to as cutting components.

The cables 50, components 58a-d, and a indicator material 62 can be inserted into the auger 10 after substantial fabrication of the auger 10. Alternatively, the cables 50, components 58a-d, and / or indicator material 62 They preferably form during the manufacture of the auger 10. For example, the cables 50, components 58a-d, and / or indicator material 62 can be pre-loaded into the mold during the casting of the auger 10. In any case, the cables 50 , components 58a-d, circuitry 60, and / or indicator material 62 may collectively be referred to as a wear detector and / or components thereof.

The module 52 may be similar to that described in U.S. Patent Application No. 20080060848, the disclosure of which is incorporated herein by reference. For example, FIGURE 17 shows an exemplary embodiment of a bore 210 of a drill bit, such as the drill 10 mentioned above, an end cap 270, and an exemplary embodiment of an electronics module 290. The shaft 210 includes a central hole 280 formed through the longitudinal axis of the shaft 210. In conventional drill bits, this central hole 280 is configured to allow drilling mud to flow through it. In the present invention, a portion of the central hole 280 has a diameter sufficient to accept the electronics module 290 configured in a substantially annular ring, yet without substantially affecting the structural integrity of the shaft 210. In this way, the electronics module 290 can be placed below the central hole 280, around the end cap 270, which extends through the inner diameter of the annular ring of the electronics module 290 to create a narrow annular fluid chamber with the wall of the central hole 280 and sealing the electronics module 290 in place within the shaft 210.

The end cap 270 includes a cap hole 276 formed therethrough, such that the drilling mud can flow through the end cap, a through the central hole 280 of the shaft 210 to the other side of the shaft 210, and then into the body of the drill bit. Further, the end cap 270 includes a first flange 271 including a first sealing ring 272, near the lower end of the end cap 270, and a second flange 273 including a second sealing ring 274, near the upper end of the seal. end cap 270.

The electronics module 290 can be configured as a flexible circuit board, enabling the formation of the electronics module 290 in the annular ring suitable for the arrangement around the end cap 270 and in the central hole 280. This embodiment of the flexible circuit board of the electronics module 290 is shown in a flat unwound configuration in FIGURE 18. The flexible circuit board 292 includes a high strength reinforced main structure (not shown) to provide an acceptable transmissibility of the effects of Acceleration to sensors such as accelerometers. In addition, other areas of the flexible circuit board 292 carrying sensorless electronic components can be attached to the end cap 270 in a manner suitable to at least partially attenuate the acceleration effects experienced with the drill bit 10 during the drilling operations using a material such as a viscoelastic adhesive.

The electronics module 290 can be configured to perform a variety of functions. An exemplary electronics module 290 can be configured as a data analysis module, which is configured to sample the data in different sampling modes, sample the data at different sampling frequencies, and analyze the data.

An exemplary data analysis module 300 is illustrated in FIGURE 19. The data analysis module 300 includes a power supply 310, a processor 320, a memory 330, and at least one sensor 340 configured to measure a plurality of parameters Physical conditions related to the state of the drill bit, which may include the condition of the drill bit, the conditions of the drilling operation, and the environmental conditions close to the drill bit. In the exemplary embodiment of FIGURE 19, sensors 340 may include a plurality of accelerometers 340A, a plurality of magnetometers 340M, and at least one temperature sensor 340T.

The plurality of accelerometers 340A may include three accelerometers 340A configured in the Cartesian coordinate array. Similarly, the plurality of magnetometers 340M may include three magnetometers 340M configured in a Cartesian coordinate arrangement.

Although any coordinate system can be defined within the scope of the present invention, an exemplary Cartesian coordinate system, shown in FIGURE 17, defines a z axis along the longitudinal axis about which the rotating auger rotates. An x axis perpendicular to the z axis, and an axis y perpendicular to both the z axis and the x axis, to form the three orthogonal axes of a typical Cartesian coordinate system. Because the data analysis module 300 can be used while the drill bit is rotating and with the drill bit in other orientations than vertical, the coordinate system can be considered a rotating Cartesian coordinate system with an orientation varied in relation to the fixed surface location of the drilling equipment.

Accelerometers 340A of the embodiment of FIGURE 19, when enabled and sampled, provide a measure of the acceleration, and vibration, of the drill bit along at least one of the three orthogonal axes. The data analysis module 300 may include additional accelerators 340A to provide a redundant system, where various 3 0A accelerometers may be selected or de-selected, in response to the failed diagnostics made by the processor 320.

Magnetometers 340M of the FIGURE mode 19, when activated or sampled, provide a measure of the orientation of the drill bit along at least one of the three orthogonal axes relative to the magnetic field of the earth. The data analysis module 300 may include additional 340M magnetometers to provide a redundant system, where various 340M magnetometers may be selected, or unselected, in response to the failed diagnostics made by the processor 320.

The temperature sensor 340T can be used to collect data related to the temperature of the drill bit, and the nearby temperature of the accelerometers 340A, magnetometers 340M, and other sensors 340. The temperature data can be useful to calibrate the accelerometers 340A and 340M magnetometers to be more accurate at a variety of temperatures.

Other optional sensors 340 may be included as part of the data analysis module 300. Some exemplary sensors that may be useful in the present invention are the strain sensors in various locations of the drill bit, temperature sensors in various locations of the drill bit, mud pressure sensors (drilling fluid) to measure the internal mud pressure to the drill bit, and borehole pressure sensors to measure external hydrostatic pressure to the drill bit. These optional sensors 340 may include sensors 340 that are integrated with and configured as part of the data analysis module 300. These sensors 340 may also include remote optional sensors 340 placed in other areas of the drill bit 10, or on top of the drill bit in the BHA. Optional sensors 340 can communicate using a direct cable connection, or through an optional 360 sensor receiver. The sensor receiver 360 is configured to allow communication of the wireless remote sensor, over limited distances in a drilling environment as is known to those of ordinary skill in the art.

One or more of these optional sensors can be used as a start sensor 370. The start sensor 370 can be configured to detect at least one start parameter, such as, for example, mud turbidity, and generate a signal 372 allowed by energy that responds to at least one start parameter. An intermittent power module 374 coupled between the power supply 310, and the data analysis module 300, can be used to control the application of power to the data analysis module 300, when the signal 372 allowed by energy is secured. The start sensor 370 may have its own independent power source, such as a battery small, to energize the start sensor 370 during the times that the data analysis module 300 is not turned on. As regards other optional sensors 340, some exemplary parameter sensors that can be used to enable power to the data analysis module 300, are the sensors configured for sampling; the deformation in various locations of the drill bit, the temperature in various locations of the drill bit, vibration, acceleration, centripetal acceleration, internal fluid pressure to the drill bit, external fluid pressure to the drill bit, flow of fluid in the drill bit, impediment of the fluid, and turbidity of the fluid. In addition, at least some of these sensors can be configured to generate any energy required for the operation, so that the independent power source is self-generated in the sensor. By way of example, and not limitation, a vibration sensor can generate sufficient energy to sense the vibration and transmit the signal 372 allowed by energy simply from the mechanical vibration.

The memory 330 may be used to store the sensor data, the results of signal processing, long-term data storage, and computer instructions for execution by means of the processor 320.

Portions of the memory 330 may be located external to the processor 320 and the portions may be located within the processor 320. The memory 330 may be a Dynamic Random Access Memory (DRAM), Static Random Access Memory (SRAM), Read Only Memory (ROM), Non-volatile Random Access Memory (NVRAM), such as Flash Memory, Electrically Erasable Programmable ROM (EEPROM), or combinations thereof. In the exemplary embodiment of FIGURE 19, the memory 330 is a combination of SRAM in the processor (not shown), the flash memory 330 in the processor 320, and the external flash memory 330. Flash memory may be desirable for low energy operation and the ability to retain information when no energy is applied to the memory 330.

In one embodiment, the data analysis module 300 uses battery power as the power supply 310. Battery power allows operation without considering the connection to another source of energy while in a drilling environment. However, with battery energy, conservation of energy can become a significant consideration in the present invention. As a result, a low power processor 320 and a low power memory 330 can allow a long battery life. Similarly, other energy conservation techniques can be significant in the present invention.

Additionally, one or more power controllers 316 may be used to control the application of power to the memory 330, the accelerometers 340A, the magnetometers 340M, and other components of the data analysis module 300. Using these power controllers 316, the software used in the processor 320 can administer a power control bus 326 including the control signals to individually enable a voltage signal 314 for each component connected to the power control bus 326. Although the voltage signal 314 shown in FIGURE 19 is shown as a single signal, it should be understood by those of ordinary skill in the art that different components may require different voltages. In this way, the voltage signal 314 can be a bus that includes voltages necessary to energize the different components.

The circuitry 60 described above, or any portion thereof, may be located completely on, in, and / or adjacent the auger 10. Alternatively, some portion, such as the module 52, may be located away from the auger 10. or next to the BHA. For example, the module 52, and / or certain functionality of the module 52, may be combined with the computer 54 at or near the surface. This may not be a preferred modality, some applications, due to the exposure that could result from the cables 50. However, the shielded cable and / or even a wireless communication link can be used to control such risks.

Other additional embodiments and embodiments using one or more aspects of the inventions described in the foregoing, may be conceived without departing from the spirit of the invention. For example, the various methods and embodiments of the drill bit 10 may include, in combination with each other, producing variations of the described methods and embodiments. The discussion of singular elements can include plural elements and vice versa.

The order of the stages can occur in a variety of sequences unless specifically limited in another way. The various steps described herein may be combined with other steps, interspersed with the established steps, and / or divided into multiple stages. Similarly, the elements have been described in a functional manner and may be represented as separate components or may be combined into components having multiple functions.

The inventions have been described in the context of preferred embodiments and other embodiments and each embodiment of the invention has not been described. The modifications and obvious alterations of the described modalities are They are available to those with ordinary experience in the art. The modalities described and not described are not intended to limit or restrict the scope or applicability of the invention, conceived by it, but rather, in accordance with patent laws, are intended to fully protect all modifications and improvements that fall within the scope or margin of the equivalent of the following claims.

Claims (12)

1. A method for assembling a drill bit, such as for drilling in a land deposit, the method characterized in that it comprises the steps of: forming the auger, including a auger body and a plurality of cutting components; introduce a wear detector in the auger; and provide a module to monitor the wear detector and generate an indicator of bit wear.

2. The method in accordance with the claim 1, characterized in that the wear detector comprises at least one electrical circuit.

3. The method according to claim 2, characterized in that the module determines the wear when detecting an open circuit.

4. The method in accordance with the claim 2, characterized in that a resistance of the circuit changes as the auger wears.

5. The method in accordance with the claim 1, characterized in that the wear detector is inserted during the formation of the auger.

6. The method according to claim 1, further characterized by including the step of deploying the wear of the auger to an operator.

7. A drill bit assembly, such as for drilling a land deposit, the assembly characterized in that it comprises: a drill bit including a bit body and a plurality of cutting components; a wear detector inside the drill bit; Y a module to monitor the wear detector and generate an indicator of the wear of the auger.

8. The assembly in accordance with the claim 7, characterized in that the wear detector comprises at least one electrical circuit.

9. The assembly in accordance with the claim 8, characterized in that the module determines the wear when detecting an open circuit.

10. The assembly according to claim 8, characterized in that a resistance of the circuit changes as the auger wears.

11. The assembly according to claim 7, characterized in that the wear detector is embedded within the auger during forming.

12. The assembly according to claim 7, further characterized in that it includes a surface computer configured to display the wear of the auger to an operator.