Sucker rod connectors and tool fittings with polycrystalline diamond elements

Abstract

This disclosure includes a sucker rod string, a tubing protector, and a tool joint with a polycrystalline diamond element positioned thereon for mating with other surfaces in downhole applications. The polycrystalline diamond element can be positioned on the sucker rod guide, sucker rod connector, tubing protector, and tool joint.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 083,252 (pending), filed September 25, 2020, entitled “Sucker Rod Couplings with Polycrystalline Diamond Elements,” the entire contents of which are incorporated herein by reference. This application is also a partial continuation of U.S. Patent Application No. 16 / 529,310 (pending), filed August 1, 2019, entitled “Polycrystalline Diamond Tubular Protection,” which itself claims the benefit of U.S. Provisional Patent Application No. 62 / 713,681 (expired), filed August 2, 2018, entitled “Polycrystalline Diamond Tubular Protection,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to polycrystalline diamond elements used as protection between tubular components that are movably joined to each other; to devices and systems including the devices; and to methods of manufacturing, assembling, and using them. Background Technology

[0004] Several downhole well constructions and production applications involve relatively small-diameter tubular components that are movably connected (e.g., internally) to relatively large-diameter tubular components (e.g., through sliding, rotating, and / or reciprocating engagement). These applications include, but are not limited to, drill pipe strings operating within casing and sucker rod strings operating within production tubing.

[0005] Wear on the relatively large inner diameter of the outer tubing and the relatively small outer diameter of the inner tubing, particularly at the upset joints or connections of the inner tubing or sucker rod, is often problematic. These wear problems are accelerated in directional drilling, where gravity causes the inner tubing and its connections to engage and "ride" against the inner lower side of a larger diameter tubing (e.g., casing or production tubing). Furthermore, wells with relatively high deviation variations create friction points at the interface between the inner and outer tubing.

[0006] During drilling operations, this wear can lead to drill string failure and subsequent loss. Due to casing wear, it can also compromise well integrity. In production operations, this wear can cause sucker rod string failure or production tubing wear. Production tubing failure forces operators to repair the well prematurely, increasing costs and reducing production.

[0007] Over time, techniques have been developed to reduce contact and wear at the interface between the inner and outer tubular sections by periodically attaching sacrificial protectors or guides around the outer surface of the inner tubular section. In drilling applications, these sacrificial protectors or guides are commonly referred to as "pipe protectors." In production applications, they are commonly referred to as "rod guides." In both drilling and production applications, these sacrificial protectors or guides are typically made of molded rubber, nylon, plastics, polymers, polyurethane, synthetic polyamides, or polyetheretherketone (PEEK). Pipe protectors are typically mounted on a metal frame. Rod guides can be molded directly along the length of the rod and may or may not include a metal frame. For any material currently used for sacrificial protectors or guides, relatively high temperatures lead to an increased abrasive wear rate.

[0008] Replacing drill pipe, sucker rod string, and / or production tubing is both expensive and time-consuming. In production applications, avoiding wear issues involves workovers on the wellhead to replace guides and remove debris from the production tubing. In so-called unconventional wells, workovers to replace sucker rod guides can occur as frequently as every three months.

[0009] What is needed is a technology to extend the life of pipe protectors and rod guides without increasing or significantly increasing the coefficient of friction at the interface between the protector / guide and the outer tubular component.

[0010] Previously, polycrystalline diamond components were prohibited from being bonded to the inner surfaces of casings or production tubing. Without theoretical constraints, polycrystalline diamond, including thermally stable polycrystalline diamond and polycrystalline diamond composites, has been considered unsuitable for bonding with ferrous metals and other metals, metal alloys, composites, hardfaces, coatings, or platings containing trace amounts of diamond solvent-catalysts (including cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, or tantalum). Furthermore, this previous taboo on the use of polycrystalline diamond extended to so-called “superalloys,” including iron-based, cobalt-based, and nickel-based superalloys containing trace amounts of diamond solvent-catalysts. Typically, the surface velocities used to machine such materials are typically in the range of approximately 0.2 m / s to approximately 5 m / s. Although these surface velocities are not particularly high, the loads and accompanying temperatures generated at the cutting tip often exceed the graphitization temperature of diamond (i.e., approximately 700°C), which, in the presence of diamond solvent-catalysts, can lead to rapid wear and failure of components such as diamond-tipped tools. Without being bound by theory, the specific failure mechanism is considered to be caused by the chemical interaction between the carbon-containing diamond and the carbon-absorbing material being processed. U.S. Patent No. 3,745,623 is an exemplary reference to the contraindications of polycrystalline diamond in processing metals or alloys containing diamond solvent-catalysts. The contraindication of polycrystalline diamond in processing materials containing diamond solvent-catalysts has long led to the avoidance of its use in all applications involving contact with such materials. Summary of the Invention

[0011] Some embodiments of this disclosure include a sucker rod assembly. The assembly includes production tubing positioned within a wellbore. The production tubing has an internal cavity wall defining a cavity. The internal cavity wall is a metal surface comprising a diamond solvent-catalyst at least 2 wt.% (wt%) of the total weight of the metal. A sucker rod string is positioned within the cavity of the production tubing. The sucker rod string includes a first sucker rod, a second sucker rod, and a sucker rod connector. The first sucker rod is connected to a first end of the sucker rod connector, and the second sucker rod is connected to a second end of the sucker rod connector. A plurality of polycrystalline diamond elements are connected to the sucker rod connector. Each polycrystalline diamond element has a polycrystalline diamond mating surface. The polycrystalline diamond mating surfaces are positioned along the sucker rod string to mate the metal surface of the sucker rod string with that of the production tubing.

[0012] Some embodiments of this disclosure include a method for engaging a sucker rod string and a production tubing. The method includes providing a sucker rod string having a first sucker rod, a second sucker rod, and a sucker rod connector. The first sucker rod is connected to a first end of the sucker rod connector, and the second sucker rod is connected to a second end of the sucker rod connector. The method includes positioning a plurality of polycrystalline diamond elements on the sucker rod connector. Each polycrystalline diamond element has a polycrystalline diamond engagement surface. The method includes providing a production tubing positioned within a wellbore. The production tubing has an internal cavity wall defining a cavity. The internal cavity wall is a metal surface comprising a metal containing at least 2 wt.% diamond solvent-catalyst based on the total weight of the metal. The method includes positioning the sucker rod string within the cavity of the production tubing such that the engagement surfaces of the polycrystalline diamonds are positioned along the sucker rod string to engage the metal surfaces of the sucker rod string and the production tubing.

[0013] Some embodiments of this disclosure include a downhole tubular assembly. The assembly includes a tubular member having a first end, a second end, and a tool connector at the second end. A plurality of polycrystalline diamond elements are coupled to the tool connector. Each polycrystalline diamond element has a polycrystalline diamond mating surface. The assembly includes a casing in a wellbore. The casing has an inner wall with a metallic surface. The metallic surface comprises a metal containing at least 2 wt.% diamond solvent-catalyst based on the total weight of the metal. The tubular member is positioned within the casing such that the mating surfaces of the polycrystalline diamonds are positioned to engage the tool connector with the inner wall of the casing.

[0014] Some embodiments of this disclosure include a method for engaging a docking tool connector and a casing. The method includes providing a tubular member having a first end, a second end, and a tool connector at the second end. The method includes coupling a plurality of polycrystalline diamond elements to the tool connector. Each polycrystalline diamond element has a mating surface of polycrystalline diamond. The method includes providing a casing in a wellbore. The casing has an inner wall having a metallic surface. The metallic surface comprises a metal containing at least 2 wt.% diamond solvent-catalyst based on the total weight of the metal. The method includes positioning the tubular member within the casing such that the mating surfaces of the polycrystalline diamonds are positioned for engagement between the docking tool connector and the inner wall of the casing. Attached Figure Description

[0015] To gain a more detailed understanding of the features and advantages of the systems, devices, and / or methods of this disclosure, a more specific description, briefly summarized above, can be obtained by referring to the embodiments shown in the accompanying drawings, which form part of this specification. However, it should be noted that the drawings illustrate only various exemplary embodiments and should not be considered as limiting of the disclosed concepts, as they may include other effective embodiments.

[0016] Figure 1A This is a side view of a tubular joint interface, which includes a polycrystalline diamond element extending above the joint surface of the body of the tubular joint interface.

[0017] Figure 1B This is a side view of a tubular joint interface, which includes a polycrystalline diamond element flush with the joint surface of the body of the tubular joint interface.

[0018] Figure 1C This is a side view of a tubular joint interface, which includes a polycrystalline diamond element positioned below the joint surface of the body of the tubular joint interface.

[0019] Figure 1D It is a top view of the interface of the tubular components including polycrystalline diamond elements.

[0020] Figure 2A It is a three-dimensional view of a hollow tubular component;

[0021] Figure 2B yes Figure 2A End view of the hollow tubular component.

[0022] Figure 2C It is a diameter smaller than Figure 2A A three-dimensional view of a hollow tubular component.

[0023] Figure 2D It is a three-dimensional view of a solid tubular component;

[0024] Figure 2E It is a perspective view of a relatively small diameter tubular member movably joined within a relatively large diameter tubular member, wherein the joint interface of the tubular member is connected to and mats with the relatively large diameter tubular member.

[0025] Figure 2F It is a perspective view of a relatively small diameter tubular member movably joined within a relatively large diameter tubular member, wherein the joint interface of the tubular member is connected to and mats with the relatively small diameter tubular member.

[0026] Figure 3A This is a side view of a tubular joint interface prior to wear, which includes a polycrystalline diamond element positioned below the joint surface of the body of the tubular joint interface.

[0027] Figure 3B This is a side view of a tubular joint interface, which includes a polycrystalline diamond element flush with the joint surface of the body of the tubular joint interface, wherein the polycrystalline diamond element is positioned within a socket in the body.

[0028] Figure 3C This is a side view of a tubular joint interface, which includes a polycrystalline diamond element extending above the joint surface of the body of the tubular joint interface, wherein the polycrystalline diamond element is positioned within a recess in the body.

[0029] Figure 3D It is after wear and tear. Figure 3A Side view of the interface of the tubular fitting.

[0030] Figure 4A It is a perspective view of a sucker rod and sucker rod guide with polycrystalline diamond elements on it.

[0031] Figure 4B yes Figure 4A Side view of the sucker rod and sucker rod guide.

[0032] Figure 4C yes Figure 4A A top view of the sucker rod and sucker rod guide.

[0033] Figure 4D It is located inside the production oil pipeline. Figure 4A A top view of the sucker rod and sucker rod guide.

[0034] Figure 5 This is a side view of another sucker rod guide with polycrystalline diamond elements on it.

[0035] Figure 6 This is a partial perspective view of the drill pipe protector frame with polycrystalline diamond elements on it.

[0036] Figure 7A This is a side view of the pipe protector on the drill pipe, which includes a polycrystalline diamond element.

[0037] Figure 7B yes Figure 7A End view of the pipe protector and drill pipe.

[0038] Figure 7C It is positioned inside the well casing. Figure 7A End view of the pipe protector and drill pipe.

[0039] Figure 8 This is a cross-sectional view of a drill pipe protector with polycrystalline diamond elements on it.

[0040] Figure 9 This is another perspective view of a drill pipe protector with polycrystalline diamond elements on it.

[0041] Figure 10 The sucker rod is described.

[0042] Figure 11The sucker rod connector is described.

[0043] Figure 12 This is an end view of the sucker rod connector located inside the production tubing.

[0044] Figure 13 It is a cross-sectional view of the sucker rod string located inside the production tubing.

[0045] Figure 14 It depicts the isolation from the production pipeline. Figure 13 The sucker rod string.

[0046] Figure 15A A tubular member positioned in a sleeve is depicted, wherein the tubular member has a tool connector for a polycrystalline diamond element.

[0047] Figure 15B Depicting Figure 15A A tubular component in which a polycrystalline diamond element is bonded to the surface of a sleeve. Detailed Implementation

[0048] Some embodiments of this disclosure include polycrystalline diamond elements used as protection between tubular elements movably joined to each other; protectors or guides including the polycrystalline diamond elements; tubular assemblies including protectors or guides; apparatus and systems including the tubular assemblies; and methods of manufacturing, assembling, and using polycrystalline diamond elements, protectors or guides, tubular assemblies, and apparatus and systems.

[0049] Joint interface

[0050] Some embodiments of this disclosure include a mating interface configured to engage two different tubular members. (See also...) Figure 1A-1D An exemplary bonding interface is shown. The bonding interface 10 includes a body 12. The body 12 may be or include materials such as metals (e.g., steel) or polymers (e.g., rubber or plastic). Some exemplary polymers of the body 12 may be or include nylon, polyurethane, polyamide (e.g., synthetic polyamide), or polyetheretherketone (PEEK). The body 12 is not limited to being or including any of these specific materials.

[0051] The bonding interface 10 includes a plurality of polycrystalline diamond elements 14. Each polycrystalline diamond element 14 is coupled to the body 12. For example, each polycrystalline diamond element 14 may be embedded within or otherwise coupled to the body 12. In embodiments where the body 12 is a polymer body, the body 12 may be molded on, over, or together with the polycrystalline diamond elements 14 via a polymer molding process. For example, Figure 1B and Figure 1CA variation of the polycrystalline diamond element 14 embedded in a body 12 is shown, wherein the body 12 is molded over the polycrystalline diamond element 14. In embodiments where the body 12 is a metal body, the polycrystalline diamond element 14 may be attached to the body 12, for example, attached to a surface of the body 12 or attached to a machined recess in the body 12. For example, Figure 1A A polycrystalline diamond element 14 is shown attached to the top of the body 12. In some embodiments, the polycrystalline diamond element 14 is static relative to the body 12.

[0052] The body 12 includes a body bonding surface 16, and each polycrystalline diamond element 14 includes a diamond bonding surface 18. For example... Figure 1A As shown, in some embodiments, the polycrystalline diamond element 14 extends above the body bonding surface 16, such that the diamond bonding surface 18 is positioned at a first distance 20 above the body bonding surface 16. In other embodiments, such as Figure 1B As shown, the diamond bonding surface 18 is flush with the body bonding surface 16, such that the diamond bonding surface 18 and the body bonding surface 16 are located in the same plane 24 (i.e., coplanar with the body bonding surface 16). In other embodiments, such as Figure 1C As shown, the main engagement surface 16 extends over the diamond engagement surface 18, such that the main engagement surface 16 is positioned at a second distance 22 above each diamond engagement surface 18. As used herein, "engagement surface" refers to a surface of a material (e.g., polycrystalline diamond, polymer, or steel) positioned and arranged within an assembly (e.g., within a tubular assembly) such that, during operation of the assembly, the engagement surface comes into a mating contact between the two tubular members of the tubular assembly. Those skilled in the art will understand that the diamond engagement surfaces and / or main engagement surfaces are not limited to being constantly engaged with opposing engagement surfaces. Rather, the diamond engagement surfaces and / or main engagement surfaces are positioned such that one or both of the diamond engagement surfaces and / or main engagement surfaces will engage with opposing engagement surfaces prior to direct surface-to-surface engagement between the two tubular members.

[0053] The engagement interface 10 can provide protection at the interface of two different tubular members that are movably (e.g., slidably and / or rotatably) engaged with each other. In some embodiments, the engagement interface 10 is a drill pipe protector. In other embodiments, the engagement interface 10 is a sucker rod guide. Although drill pipe protectors and sucker rod guides are shown and described herein, the engagement interface disclosed herein is not limited to drill pipe protectors or sucker rod guides, and can be another structure capable of engaging with a tubular member and aligning a movable engagement between that tubular member and another tubular member. In some embodiments, the engagement interface is not coupled to a tubular member, but is integral with the tubular member. In some embodiments, the engagement interface is static relative to one tubular member (i.e., the tubular member to which the engagement interface is coupled) and movable relative to another tubular member (i.e., movably engaged with another tubular member).

[0054] tubular components

[0055] Some embodiments include a tubular assembly that includes a mating interface disclosed herein, the mating interface being positioned for engagement between the tubular members of the tubular assembly. (Refer to...) Figures 2A-2F The diagram illustrates a first tubular component and a second tubular component. The first and second tubular components can be, for example, but not limited to, pipes, casings, rods, tubes, downhole tools, or other tubular components.

[0056] The tubular member 30 is a hollow tubular member having an inner wall 32 that defines a cavity 34, such as a pipe or other conduit, passing through it. The tubular member 30 has an outer wall 36. The tubular member 30 has an outer diameter 38 defined by the outer wall 36 and an inner diameter 31 defined by the inner wall 32.

[0057] In some embodiments, such as Figure 2C As shown, the tubular member 40 is a hollow tubular member such as a pipe or other conduit, having an inner wall 42 defining a cavity 44 passing through it. In other embodiments, such as Figure 2D As shown, the tubular member 40 is a solid tubular member such as a rod, without a cavity or conduit defined therethrough. The tubular member 40 has an outer wall 46 that defines the outer diameter 48 of the tubular member 40.

[0058] The outer diameter 48 of the tubular member 40 and the inner diameter 31 of the tubular member 30 are designed such that the tubular member 40 can be at least partially connected or joined within the cavity 34 of the tubular member 30, such as... Figure 2E As shown. That is to say, tubular component 30 is a tubular component with a relatively large diameter, and tubular component 40 is a tubular component with a relatively small diameter, such that the outer diameter 48 of tubular component 40 is smaller than the inner diameter 31 of tubular component 30.

[0059] like Figure 2E and 2FAs shown, tubular component assemblies 100a and 100b each include tubular components 30 and 40 that are movably engaged with each other. Tubular component 40 is slidably engaged within tubular component 30, such that one or both of tubular components 30 and 40 can move along one or both directions 50 and 52. As used herein, “slidably engaged” means an engagement between at least two tubular components that allows at least one tubular component to slide relative to the other. For example, tubular component 40 can slide within tubular component 30 along one or both directions 50 and 52, tubular component 30 can slide about tubular component 40 along one or both directions 50 and 52, or a combination thereof.

[0060] Tubular member 40 is rotatably engaged within tubular member 30, such that one or both of tubular members 30 and 40 can rotate in one or both directions 54 and 56 (e.g., Figure 2B (As shown). As used herein, "rotatably engaged" means an engagement between at least two tubular members that allows at least one tubular member to rotate relative to the other tubular member. For example, tubular member 40 may rotate within tubular member 30 in one or both directions 54 and 56, tubular member 30 may rotate about tubular member 40 in one or both directions 54 and 56, or a combination thereof.

[0061] Therefore, tubular member 40 is movably engaged within tubular member 30, such that one or both of tubular members 30 and 40 are movable relative to the other tubular member. As used herein, "movably engaged" refers to engaged tubular members, meaning an engagement between at least two tubular members that allows at least one tubular member to move relative to the other. For example, tubular member 40 may move relative to tubular member 30 (e.g., slide and / or rotate), tubular member 30 may move relative to tubular member 40, or a combination thereof.

[0062] The mating interface 10 can be positioned on and connected to a larger diameter tubular member to mate with a smaller diameter tubular member, or the mating interface 10 can be positioned on and connected to a smaller diameter tubular member to mate with a larger diameter tubular member. Figure 2E In this configuration, the mating interface 10 is positioned on and connected to the tubular member 30, and engages with the opposing mating surface of the tubular member 40, namely the outer wall 46. Figure 2F In the middle, the joint interface 10 is positioned on the tubular member 40 and connected to the tubular member 40, and is engaged with the opposite joint surface of the tubular member 30, namely the inner wall 32.

[0063] As used herein, “opposite tubular member” means a tubular member movably engaged with different tubular members, wherein the different tubular members have at least one engagement interface connected thereto for engaging with the opposite tubular member.

[0064] Mounting and wear characteristics of polycrystalline diamond components

[0065] Reference Figures 3A-3D The mounting of polycrystalline diamond elements is shown and described. The bodies 12a-12c of the mating interfaces 10a-10c can each be a body or part of a drill pipe protector or sucker rod guide, and can be attached to or integrated with the drill pipe protector or sucker rod guide. They are depicted as having three polycrystalline diamond elements 14a, 14b, and 14c with different mountings, respectively as shown... Figure 3A , 3B As shown in 3C.

[0066] The polycrystalline diamond element 14a is an example of an "underexposed" polycrystalline diamond element, such that the polycrystalline diamond element is positioned below the plane 24a defined by the body bonding surface 16a. Therefore, in operation, the polycrystalline diamond element 14a will be bonded to another tubular component after the body bonding surface 16a has been worn down to expose the diamond bonding surface 18a of the polycrystalline diamond element 14a, as... Figure 3D As shown, Figure 3D The mating interface 10a after wear is depicted. Figure 3D It is described as 60. Therefore, in Figure 3A In this configuration, the diamond bonding surface 18a is positioned within plane 23a, while the main bonding surface 16a is positioned within plane 24a above plane 23a and is closer to the opposing tubular surface during operation. However, after a sufficient amount of wear 60, the main body 12a wears down to the point that plane 24a is coplanar with plane 23a; or to the point that plane 24a is lower than plane 23a, and during operation, plane 23a is equal to or closer to the opposing tubular surface.

[0067] like Figure 3B As shown, the polycrystalline diamond element 14b is an example of a "flush-mounted" polycrystalline diamond element, such that the diamond bonding surface 18b resides in the plane 24b defined by the body bonding surface 16b of the body 12b. That is, the plane defined by the diamond bonding surface 18b (i.e., plane 23b) is coplanar with the plane defined by the body bonding surface 16b (i.e., plane 24b). Therefore, in operation, the polycrystalline diamond element 14b will engage with the opposing tubular member, while the body bonding surface 16b engages with the opposing tubular member.

[0068] like Figure 3CAs shown, the polycrystalline diamond element 14c is an example of an "exposed" polycrystalline diamond element, such that the polycrystalline diamond element is positioned above and within the plane 24c defined by the body bonding surface 16c of the body 12c. Therefore, in operation, the polycrystalline diamond element 14c will engage with the opposing tubular element prior to engagement between the body bonding surface 16c and the opposing tubular element.

[0069] Therefore, in some embodiments, the polycrystalline diamond elements disclosed herein provide "backup wear resistance" for the associated bonding interfaces. As used herein, "backup wear resistance" refers to the arrangement of the polycrystalline diamond elements relative to the body such that the diamond bonding surfaces only engage with the opposing tubular element after the body has undergone sufficient wear (e.g., as shown in the image). Figure 3A and 3D (As shown). In other embodiments, the polycrystalline diamond elements disclosed herein provide “consistent wear resistance” for associated bonding interfaces. As used herein, “consistent wear resistance” refers to the arrangement of the polycrystalline diamond element relative to the body such that the diamond bonding surface engages with the opposing tubular element when the body is bonded to the opposing tubular element, without requiring wear to occur before the engagement between the diamond bonding surface and the opposing tubular element (e.g., as shown). Figure 3B (As shown). In other embodiments, the polycrystalline diamond element disclosed herein provides “primary wear resistance” for the associated bonding interface. As used herein, “primary wear resistance” refers to the arrangement of the polycrystalline diamond element relative to the body such that the diamond bonding surface engages with the opposing tubular element before the engagement between the body and the opposing tubular element, without requiring wear to occur before the engagement between the diamond bonding surface and the opposing tubular element (e.g., as shown). Figure 3C (As shown). Therefore, polycrystalline diamond elements 14a, 14b, and 14c provide primary wear resistance, consistent wear resistance, and backup wear resistance, respectively, for drill pipe or sucker rod protectors. The joint interfaces disclosed herein are not limited to those that are exposed ( Figure 1A and 3C ), level ( Figure 1B and 3B ) or concave ( Figure 1C and 3A It can be one of the polycrystalline diamond elements installed, or any combination thereof.

[0070] like Figures 3A-3DAs shown, polycrystalline diamond elements 14a-14c can be positioned within or connected to cavities 62a-62c in the bodies 12a-12c. Furthermore, each polycrystalline diamond element 14a-14c includes a support 15a-15c and a diamond layer 17a-17c. The diamond layers 17a-17c can be connected to the support 15a-15c, and the support 15a-15c can be connected to the body 12a-12c. For example, the diamond layers 17a-17c can be or include thermally stable polycrystalline diamond or PDC, and the support can be or include tungsten carbide. In some embodiments, the bonding interface disclosed herein includes a plurality of polycrystalline diamond elements (e.g., PDC), and each polycrystalline diamond element is discrete from another of the plurality of polycrystalline diamond elements.

[0071] Having described the interface, it is now typically time to describe some embodiments thereof and their applications in more detail.

[0072] Sucker rod with guide

[0073] In some embodiments, the engagement interface disclosed herein is provided on a sucker rod guide, for example, for engaging a sucker rod string movably positioned within a production tubing. For example, see reference... Figure 2F The tubular member 40 may be a sucker rod having a mating interface 10, on which at least a portion of a sucker rod guide is formed, and the tubular member 30 may be a production tubing in which the sucker rod is positioned. As those skilled in the art will understand, a sucker rod is a rod (e.g., a steel rod) used to form a mechanical assembly between the surface and downhole components of a rod-pumped oil system. The length of the sucker rod may be 20 to 40 feet, or 24 to 35 feet, or 25 to 30 feet, and may be threaded at each end to allow for easy operation and retrieval of the downhole components. Those skilled in the art should understand that, depending on the specific application, the sucker rod may be of other lengths.

[0074] Reference Figures 4A-4DAn exemplary sucker rod assembly 101a is shown, comprising a sucker rod 102 having a sucker rod guide 104. The sucker rod 102 engages with the sucker rod guide 104. In some embodiments, at least some portions of the sucker rod guide 104 are directly molded onto the sucker rod 102. For example, the body 12 of the sucker rod guide 104 may be or include a moldable material (e.g., a polymer), such as molded rubber, nylon, polyurethane, synthetic polyamide, polyetheretherketone (PEEK), or another plastic or elastomer. This material can be molded onto the sucker rod 102 using any of a variety of polymer molding techniques, such as extrusion molding. The sucker rod 102 may be a metal rod or include a metal rod, such as a steel rod. Therefore, in some embodiments, the sucker rod guide 104 is coupled to the sucker rod 102. In some such embodiments, the sucker rod guide 104 is static relative to the sucker rod 102.

[0075] The body 12 of the sucker rod guide 104 includes a base 13 circumferentially surrounding the sucker rod 102. The body 12 also includes a protrusion 110 extending outward from the base 13 away from the sucker rod 102. In some embodiments, the protrusion 110 is in the form of a peak, leaf, rib, fin, or blade extending outward from the sucker rod 102. The protrusions 110 are radially spaced around the base 13 and the sucker rod 102 such that cavities or valleys 111 are positioned between adjacent protrusions 110. Each protrusion 110 defines a body engagement surface 16 for engagement with, for example, a production tubing, to protect and / or guide the sucker rod 102 during operation.

[0076] At least one polycrystalline diamond element is coupled to the sucker rod guide disclosed herein. For example... Figure 4A As shown, the sucker rod guide 104 includes four protrusions 110, each having two polycrystalline diamond elements 14 thereon. However, the sucker rod guide disclosed herein is not limited to having this number of protrusions or polycrystalline diamond elements, and may include any number of polycrystalline diamond elements arranged in any of a variety of arrangements.

[0077] Each polycrystalline diamond element 14 may be embedded within the body engagement surface 16 or otherwise attached to the sucker rod guide 104, such that the polycrystalline diamond element 14 is positioned to protect and guide the engagement between the sucker rod 102 and, for example, a production tubing. As shown, the polycrystalline diamond element 14 has a protruding engagement surface 18 for engagement with the production tubing and is in the form of an insert inserted into the sucker rod guide 104. However, the polycrystalline diamond elements disclosed herein are not limited to this particular arrangement, shape, or number.

[0078] Figure 4DA tubular assembly 103 is shown, comprising a sucker rod 102 and a sucker rod guide 104 engaged within a production tubing 109. As shown, a diamond mating surface 18 engages the sucker rod 102 with the inner surface o of the production tubing 109.

[0079] Figure 5 Another embodiment of a sucker rod assembly 101b, including a sucker rod 102 and a sucker rod guide 104, is shown, with the same reference numerals indicating the same elements. The sucker rod 102 engages with the sucker rod guide 104, which includes protrusions 110, each having a convex polycrystalline diamond element 14 inserted therein. Figures 4A-4D and Figure 5 The difference lies in the form, shape, arrangement, and positioning of the sucker rod guide 104. Therefore, in Figures 4A-4D and Figure 5 In this paper, the tubular joint interface comprising the main body 12 and the polycrystalline diamond element 14 is in the form of a sucker rod guide, or forms part of a sucker rod guide.

[0080] In some embodiments, the sucker rod guide disclosed herein (e.g., Figures 4A-4D The sucker rod guide is the same or similar to that described in Figures 1-6 of U.S. Patent No. 6,152,223, wherein the polycrystalline diamond element described herein is added.

[0081] drill pipe

[0082] In some embodiments, the engagement interface disclosed herein is provided on a pipe protector of a tube (e.g., drill pipe), for example for engaging the drill pipe and casing during drilling operations in which the drill pipe is movably positioned within the casing. For example, see reference... Figure 2F The tubular member 40 may be a drill pipe having a mating interface 10 that forms at least a portion of a pipe protector, and the tubular member 30 may be a casing in which the drill pipe is positioned.

[0083] Reference Figure 6 and Figure 8 This document describes a drill pipe protector according to the present disclosure. In some embodiments, the disclosed drill pipe protector is consistent with the pipe protector shown and described in U.S. Patent No. 5,833,019, such as shown in Figures 1, 2, and 4 of U.S. Patent No. 5,833,019, wherein the polycrystalline diamond element disclosed herein is added and incorporated into the pipe protector.

[0084] The drill pipe protector 820 includes a body 822, also called a sleeve, which defines a portion of the wear surface or body engagement surface 16. (As...) Figure 6As shown, the frame 200 is embedded within the body 822, forming a cage 222. Furthermore, the inner frame 221 can be embedded within the body 822. The polycrystalline diamond element 14 can be coupled to the frame 222 such that the polycrystalline diamond element 14 is also at least partially embedded within the body 822. The polycrystalline diamond element 14 can be embedded within the body such that the mating surface 18 is flush with the mating surface 16 of the body, recessed relative to the mating surface 16, or extends above the mating surface 16.

[0085] Reference Figure 6 The frame 200 includes a frame body 224 and a protrusion 226. The protrusion 226 extends outwardly from the frame body 224. A polycrystalline diamond element 14 is attached to, embedded in, inserted into, or otherwise engaged with the protrusion 226, positioned to engage, for example, a casing during drilling operations. The frame 200 includes a cavity 228, which is at least partially defined by the frame body 224. (See reference...) Figure 8 A cross-sectional view of the drill pipe protector 820, showing a frame 200 embedded within a body 822. A polycrystalline diamond element 14 is positioned to engage, for example, a casing during drilling operations. The drill pipe can be positioned within an opening 828 such that the body 822 and the drill pipe protector frame 200 are positioned about the drill pipe and between the drill pipe and the casing. For example, as... Figures 7A-7C As shown, drill pipe protector 820 can be arranged around the drill pipe in the same or substantially the same manner as drill pipe protector 722.

[0086] Figure 7A A side view of a tubular assembly 701 is shown, which includes a drill pipe 700 and a drill pipe protector 722 attached around the drill pipe, the drill pipe protector including a polycrystalline diamond element 14. Figure 7B A top view depicting drill pipe 700 and drill pipe protector 722 is shown, illustrating the cavity 702 of drill pipe 700 defined by inner surface 704 of drill pipe 700, and the drill pipe protector 722 connected around outer surface 706 of drill pipe 700. Figure 7C A top view of assembly 703 is depicted, including the tubular component assembly 701 positioned within casing 790. As shown, drill pipe 700 and drill pipe protector 722 are positioned within cavity 794 of casing 790. The polycrystalline diamond element 14 mating may occur during operation between drill pipe 700 and casing 790 and inner wall 791.

[0087] Reference Figure 9The image shows a drill pipe protector 920, which includes a drill pipe protector body 922, which can be formed of any material, such as molded rubber, nylon, plastic, polymer, polyurethane, synthetic polyamide, or polyetheretherketone (PEEK). The drill pipe protector body 922 includes a base 924 and a protrusion 926 extending outwardly from the base 924. A polycrystalline diamond element 14 is attached to, embedded in, or inserted into the protrusion 926, and is positioned to engage, for example, a casing during drilling operations. The drill pipe can be positioned within an opening 928 such that the drill pipe protector body 922 is positioned about the drill pipe and between the drill pipe and the casing.

[0088] Figure 9 The drill pipe protector 920 is a wedge-shaped lifting drill pipe protector. As those skilled in the art will understand, the drill pipe protector 920 can be coupled to the drill pipe via a latching pin, such that the drill pipe is positioned within an opening 928. The drill pipe protector 920 can slidably engage with the drill pipe, such that the drill pipe protector 920 can move axially along the length of the drill pipe during drill pipe operation. During drilling, the drill pipe rotates within and relative to the drill pipe protector 920. A protrusion 926 of the drill pipe protector 920 extends outward from the drill pipe by a distance sufficient to prevent engagement of the drill bit, bottoms drill assembly, and other parts of the drill string with the casing. That is, the protrusion 926 extends outward from the drill pipe such that the protrusion 926 and / or the polycrystalline diamond element 14 thereon engage with the casing while keeping the drill bit, bottoms drill assembly, and other parts of the drill string spaced apart from the casing. For example, in the case where the drill pipe is engaged with a downhole tool such as a drill bit, the drill pipe typically includes threads for engagement with the tool. The threaded portion of the drill pipe is typically thicker than the rest of the drill pipe to compensate for metal loss due to the presence of the threads. This thicker portion of the drill pipe, referred to as the "upset," has a larger outer diameter due to the additional thickness. In this embodiment, the protrusion 926 extends outward and away from the drill pipe at a distance sufficient to prevent the upset from engaging with the casing. Therefore, during operation, when the drill pipe deviates from the center of the casing or wellbore, the drill pipe protector disclosed herein contacts the inner diameter of the well (e.g., the casing) to protect the casing or wellbore from contact with the drill pipe or its portion during drill pipe rotation. In some embodiments, the drill pipe protector disclosed herein is the drill pipe protector of Figure 7 according to U.S. Patent No. 6,378,633, with the polycrystalline diamond element disclosed herein added.

[0089] Polycrystalline diamond

[0090] The technology of this application preferably employs convex polycrystalline diamond elements, preferably polished polycrystalline diamond compact (PDC) elements, to provide primary, concurrent, or backup wear resistance to the protectors of drill pipes or sucker rods. However, the polycrystalline diamond elements of this technology can alternatively be planar surfaces with rounded or highly rounded edges. The polycrystalline diamond elements of this application can be, for example, thermally stable polycrystalline diamond or PDC. In some embodiments, the polycrystalline diamond elements are, for example, backed by tungsten carbide (e.g., supported) or unbacked (e.g., unsupported). As those skilled in the art will understand, the polycrystalline diamond elements disclosed herein can all be non-immersion, immersion, immersion and backfill, or coated (e.g., by CVD) using methods known in the art.

[0091] In some embodiments, the polycrystalline diamond elements disclosed herein may have diameters ranging from, for example, as small as 3 mm (approximately 1 / 8 inch) to as large as 75 mm (approximately 3 inches), depending on the application and the construction and diameter of the mating surfaces. Some polycrystalline diamond elements disclosed herein will have diameters ranging from 8 mm (approximately 5 / 16 inch) to 25 mm (approximately 1 inch). Those skilled in the art will understand that polycrystalline diamond elements are not limited to these specific sizes and may vary in size and shape depending on the specific application.

[0092] In some applications, the polycrystalline diamond elements disclosed herein have an increased cobalt content transition layer between the outer polycrystalline diamond surface and the supporting tungsten carbide block. In some applications, the polycrystalline diamond elements disclosed herein may not be supported by tungsten carbide and may be substantially “freestanding,” discrete polycrystalline diamond bodies directly mounted (e.g., on a tubular member). In embodiments where the polycrystalline diamond element is a planar or domed polycrystalline diamond element, the polycrystalline diamond element can be mounted in a manner that allows the polycrystalline diamond element to rotate about its own axis. Reference is made to U.S. Patent No. 8,881,849 to Shen et al. as a non-limiting example of a method for providing a polycrystalline diamond element that provides rotation about its own axis while in contact with a diamond reactive material surface.

[0093] Although the most common shape for polycrystalline diamond elements is cylindrical, it should be understood that the techniques of this application can be practiced with polycrystalline diamond elements of square, rectangular, elliptical, any shape described herein with reference to the accompanying drawings, or any other suitable shape known in the art.

[0094] In some embodiments, the polycrystalline diamond element undergoes edge radius treatment. In some embodiments of the present application employing flat or concave polycrystalline diamond elements, edge radius treatment is preferably applied to such polycrystalline diamond elements. One purpose of edge radius treatment is to reduce or avoid the possibility of cutting or scribing at the outer edge of a given polycrystalline diamond element at the outer boundary of the linear engagement area with an opposing tubular member (e.g., a curved surface).

[0095] The polycrystalline diamond elements of this application can be deployed in a manner that preferably excludes any edge or sharp contact between the polycrystalline diamond elements and the iron-containing material to which they are slidably bonded (e.g., iron-containing casing or production tubing). Exclusion of edge contact overcomes the machinability of the iron-containing material and the chemical interaction between the diamond and the iron-containing material.

[0096] Installation of polycrystalline diamond

[0097] In some embodiments, the polycrystalline diamond element of this application may be mounted on a metal frame and overmolded from a thermoplastic material or other common materials used for protectors. The polycrystalline element of this application may be underexposed, flush-mounted, or exposed relative to the protector or guide.

[0098] In some embodiments, the polycrystalline diamond element of this application can be directly molded into and held therein by a protective material. This molding can occur directly on the mother tube or separately from the mother tube, and the molded component can then be attached in a separate step. Alternatively, the socket can be molded into a thermoplastic material or an alternative body material, and the polycrystalline diamond element can then be mounted using adhesive bonding, threading, or other methods known in the art. In some embodiments, the polycrystalline diamond element can be mounted on a connector of a sucker rod assembly. In yet another alternative, the polycrystalline diamond element of this application can be attached to a metal frame that is not overmolded but serves as the main frame, providing substantially all the wear resistance and spacing of the protector. In yet another alternative embodiment, as known in the art, the polycrystalline diamond element of the present technology can be mounted in a sub-assembly that allows the polycrystalline diamond element to rotate about its own axis.

[0099] Current technology allows polycrystalline diamond elements to be recycled from used protectors or guides and reused in newly molded or deployed protectors or guides. This ability to recycle and reuse polycrystalline diamond elements reduces the ultimate cost of using this technology.

[0100] Grinding or polishing

[0101] In some applications, polycrystalline diamond elements, or at least their mating surfaces, are ground or polished, optionally highly ground or highly polished. As used herein, a surface is defined as “highly ground” if its surface finish (Ra) is 20 μRa or about 20 μRa, for example, if its surface finish (Ra) is in the range of about 18 μin Ra to about 22 μin Ra. As used herein, a surface is defined as “polished” if its surface finish (Ra) is less than about 10 μin Ra, or from about 2 μin Ra to about 10 μin Ra. As used herein, a surface is defined as “highly polished” if its surface finish (Ra) is less than about 2 μin Ra, or from about 0.5 μin Ra to less than about 2 μin Ra. In some embodiments, the surface finish (Ra) of the mating surfaces ranges from 0.5 μin Ra to 40 μin Ra, or from 2 μin Ra to 30 μin Ra, or from 5 μin Ra to 20 μin Ra, or from 8 μin Ra to 15 μin Ra, or less than or equal to 32 μin Ra, or less than 20 μin Ra, or less than 10 μin Ra, or less than 2 μin Ra, or any range therebetween. The coefficient of friction for polycrystalline diamond polished to a surface finish (Ra) of 0.5 μin Ra is approximately half that of standard ground polycrystalline diamond with a surface finish of 20–40 μin Ra. U.S. Patents 5,447,208 and 5,653,300 to Lund et al. provide disclosures relating to polycrystalline diamond polishing. As those skilled in the art will understand, surface finish can be measured using a profilometer or atomic force microscope. Surface finish can be determined according to ASME B46.1-2009.

[0102] Diamond active materials

[0103] In some embodiments, the opposing tubular element or at least its surface is or comprises a diamond reactive material. As used herein, “diamond reactive material” is a material containing more than trace amounts of diamond solvent-catalyst. As used herein, a diamond reactive material containing more than “trace amounts” of diamond solvent-catalyst contains at least 2 wt.% diamond solvent-catalyst based on the total weight of the diamond reactive material. In some embodiments, the diamond reactive material disclosed herein comprises 2 wt.% to 100 wt.%, or 5 wt.% to 95 wt.%, or 10 wt.% to 90 wt.%, or 15 wt.% to 85 wt.%, or 20 wt.% to 80 wt.%, or 25 wt.% to 75 wt.%, or 25 wt.% to 70 wt.%, or 30 wt.% to 65 wt.%, or 35 wt.% to 60 wt.%, or 40 wt.% to 55 wt.%, or 45 wt.% to 50 wt.%. Examples of known diamond solvent catalysts (also known as "diamond catalysts", "diamond solvents", "diamond catalyst-solvent", "catalyst-solvent", or "solvent-catalyst") are disclosed in: U.S. Patent No. 6,655,845; U.S. Patent No. 3,745,623; U.S. Patent No. 7,198,043; U.S. Patent No. 8,627,904; U.S. Patent No. 5,385,715; U.S. Patent No. 8,485,284; U.S. Patent No. 6,814,775; U.S. Patent No. 5,271,749; U.S. Patent No. 5,948,541; U.S. Patent No. 4,906,528; U.S. Patent No. 7,737,377; U.S. Patent No. 5,011,515; U.S. Patent No. 3,650,714; U.S. Patent No. 2,947,609; and U.S. Patent No. 8,764,295. As understood by those skilled in the art, a diamond solvent-catalyst is a chemical element, compound, or material (e.g., a metal) capable of reacting (e.g., catalytically and / or dissolving) with polycrystalline diamond, thereby causing graphitization of the polycrystalline diamond, for example, under load and at temperatures reaching or exceeding the graphitization temperature of diamond (i.e., approximately 700°C). Therefore, diamond reactive materials include materials that, under load and at temperatures reaching or exceeding the graphitization temperature of diamond, can cause wear, sometimes rapid wear, and failure of components formed from polycrystalline diamond, such as diamond-tipped tools. Diamond solvent-catalysts include, but are not limited to, iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, and tantalum.

[0104] Diamond reactive materials include, but are not limited to, metals, metal alloys, and composite materials containing trace amounts of diamond solvent-catalyst. In some embodiments, the diamond reactive material is in the form of a hard surface, coating, or plating. For example, but not limited to, the diamond reactive material may comprise ferrous, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, tantalum, or alloys thereof. In some embodiments, the diamond reactive material is steel or cast iron. In some embodiments, the diamond reactive material is a superalloy, including but not limited to iron-based superalloys, cobalt-based superalloys, and nickel-based superalloys. In some embodiments, the opposing bonding surface (i.e., the surface bonded to the polycrystalline diamond bonding surface) is a metallic surface. As used herein, a metallic surface, by weight percentage, is the surface of a material that is predominantly metallic. In some embodiments, the opposing bonding surfaces comprise 2 wt.% to 100 wt.%, or 5 wt.% to 95 wt.%, or 10 wt.% to 90 wt.%, or 15 wt.% to 85 wt.%, or 20 wt.% to 80 wt.%, or 25 wt.% to 75 wt.%, or 25 wt.% to 70 wt.%, or 30 wt.% to 65 wt.%, or 35 wt.% to 60 wt.%, or 40 wt.% to 55 wt.%, or 45 wt.% to 50 wt.%. In some embodiments, the opposing bonding surfaces comprise 2-100 wt%, or 5-95 wt%, or 10-90 wt%, or 15-85 wt%, or 20-80 wt%, or 25-75 wt%, or 25-30 wt%, or 30-65 wt%, or 35-60 wt%, or 40-55 wt%, or 45-50 wt% of iron, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, titanium, or tantalum. In some embodiments, the opposing bonding surfaces comprise at least 50 wt.%, at least 55 wt.%, at least 60 wt.%, at least 65 wt.%, at least 70 wt.%, at least 75 wt.%, at least 80 wt.%, at least 85 wt.%, at least 90 wt.%, at least 95 wt.%, or 100 wt.% of a metal, wherein the metal is a diamond reactive material.

[0105] In some embodiments, the opposing tubular element, or at least its surface, is not and / or does not include (i.e., specifically excludes) so-called “superhard materials.” As understood by those skilled in the art, a “superhard material” is a class of materials defined by material hardness, which can be determined according to the Brinell, Rockwell, Knoop, and / or Vickers scales. For example, superhard materials include materials with a hardness value exceeding 40 gigapascals (GPa) as measured by a Vickers hardness test. As used herein, superhard materials include materials that are at least as hard as tungsten carbide bricks and / or sintered tungsten carbide, such materials being determined, for example, according to one of these hardness scales, such as the Brinell scale. Those skilled in the art will understand that Brinell scale testing can be performed, for example, according to ASTM E10-14; Vickers hardness testing can be performed, for example, according to ASTM E384; Rockwell hardness testing can be performed, for example, according to ASTM E18; and Knoop hardness testing can be performed, for example, according to ASTM E384. The “superhard materials” disclosed herein include, but are not limited to, tungsten carbide for ceramic tiles (e.g., ceramic tiles or cement), tungsten carbide-infiltrated matrices, silicon carbide, silicon nitride, cubic boron nitride, and polycrystalline diamond. Therefore, in some embodiments, the opposing tubular member is partially or entirely composed of one or more materials (e.g., metals, metal alloys, composites) that are softer (lower hardness) than the superhard material, such as having a lower hardness than tungsten carbide (e.g., ceramic tiles or cement), as determined according to one of these hardness tests (e.g., a Brinell hardness tester). As those skilled in the art will understand, hardness can be determined using the Brinell scale, for example, according to ASTM E10-14. As those skilled in the art will understand, a “high-temperature alloy” is a high-strength alloy capable of withstanding high temperatures. In some embodiments, the opposing tubular member, or at least its surface, is not and / or does not contain (i.e., specifically excludes) diamond.

[0106] The examples disclosed herein that may be diamond reactive materials or surfaces including diamond reactive materials are as follows: Figure 2A , 2B The inner wall 32 shown in 2E and 2F; Figure 2A and 2B The outer wall shown is 36; Figure 2C-2F The outer wall shown is 46; Figure 2C The inner wall 42 is shown. Figure 4D The inner surface 107 is shown. Figure 7A and 7B The outer surface shown is 706; Figure 7C The inner wall 791 is shown. Figure 12 and 13 The opposing mating surfaces 1121 are shown; and the inner wall is shown in FIG15.

[0107] Rod connector with polycrystalline diamond

[0108] In some embodiments, the engagement interface disclosed herein is located on a connector of a tubular member, such as a rod (e.g., a sucker rod), rather than on a guide of the tubular member (e.g., a rod) or in any other way besides on a guide of the tubular member (e.g., a rod). In some such embodiments, the sucker rod connector is an engagement interface or includes an engagement interface. The engagement interface on the connector can mat between sucker rod strings movably positioned within a production tubing. A sucker rod is a rod (e.g., a steel rod) used to form a mechanical assembly between the surface and downhole components of a rod-pumped oil system. A sucker rod string or assembly may include a plurality of sucker rods joined together. In some embodiments, the plurality of sucker rods are threaded together. For example, a rod connector may be connected to a first sucker rod and a second sucker rod such that the first sucker rod and the second sucker rod are joined together via the rod connector. Exemplary sucker rods may be 20 to 40 feet, or 24 to 35 feet, or 25 to 30 feet in length, and may be threaded at each end to allow engagement with a rod connector.

[0109] Reference Figure 10-14 The diagram shows and describes a sucker rod connector having a polycrystalline diamond bonding surface thereon. Figure 10 A sucker rod 1002 is shown. The sucker rod 1002 includes a rod body 1004. The rod body 1004 may be a metal body such as steel. The rod body 1004 has a first end 1006 and a second end 1008. At each end of the rod body 1004, the sucker rod 1002 includes threaded ends 1010a and 1010b. The threaded ends 1010a and 1010b allow the sucker rod 1002 to be threadedly connected to other components such as other sucker rods. Although the sucker rods disclosed herein are shown to include threaded ends, they are not limited to threaded connections. Although some embodiments of the sucker rods disclosed herein are shown to include threaded ends at both ends, they only include a threaded connector (or other connector) at one end of the rod body. Although the threaded ends 1010a and 1010b of some embodiments of the sucker rods disclosed herein are shown as external threads, they include internal threads.

[0110] Figure 11 A sucker rod connector 1102 is shown. The sucker rod connector 1102 includes a connector body 1104. The connector body 1104 may be a metal body such as steel. The sucker rod connector 1102 includes threads 1110a and 1110b formed on the inner diameter of the connector body 1104 at each end 1106 and 1108. Threads 1110a and 1110b allow the sucker rod connector 1102 to be threadedly engaged with two different sucker rods, such that the sucker rod connector 1102 connects two different sucker rods together. That is, the thread on the first sucker rod can be threadedly engaged with thread 1110a, and the thread on the second sucker rod can be threadedly engaged with thread 1110b. For example, with... Figure 10 The two identical sucker rods 1002 shown can be threadedly connected to the sucker rod connector 1102. It should be noted that... Figure 10 sucker rod and Figure 11 The sucker rod connectors in this document are not drawn to scale relative to each other. Although the sucker rod connectors disclosed herein are shown to include threaded ends, they are not limited to threaded connectors. Although threads 1110a and 1110b are shown as internal threads, some embodiments of the sucker rod connectors disclosed herein include external threads.

[0111] The sucker rod connector 1102 includes a plurality of polycrystalline diamond elements 1114 on a connector body 1104. The polycrystalline diamond elements 1114 may be the same as or similar to those throughout this disclosure, including those referenced. Figure 1A-9 Those described. For example... Figure 11 As shown, the polycrystalline diamond element 1114 includes polycrystalline diamond 1116 supported on a support 1118 (e.g., a tungsten carbide support). The sucker rod connector disclosed herein is not limited to including polycrystalline diamond elements supported on a support, and may include unsupported polycrystalline diamond elements. Each polycrystalline diamond 1116 has a mating surface 1120. In some embodiments, the mating surface 1120 is dome-shaped, curved, or has other contours. The mating surface 1120 may be convex. In some embodiments, the curvature of the mating surface 1120 matches or is less than the curvature of the connector body 1104. For example, refer to... Figure 12 The outer surface of the connector body 1104 is shown to have curvature. The mating surface 1120 may have the same surface curvature as the connector body 1104. In other embodiments, the surface curvature of the mating surface 1120 is less than the surface curvature of the connector body 1104. In some embodiments, the mating surface 1120 is flush with the outer surface of the connector body 1104. In some embodiments, the mating surface 1120 is raised above the outer surface of the connector body 1104 (as shown). In some embodiments, the mating surface 1120 is recessed below the outer surface of the connector body 1104. Figure 12 As shown, the connector body 1104 (and the sucker rod attached to the connector body) may be hollow, including a cavity 1107 that defines a flow path for fluid through it. Figure 12In this configuration, the sucker rod connector 1102 and the attached sucker rod (not shown) are positioned within the production tubing 1111. During operation, if the sucker rod string (i.e., a plurality of threaded sucker rods and the sucker rod connector) engages with the production tubing 1111, a mating surface 1120 will abut this engagement. Specifically, the mating surface 1120 will engage with the opposing mating surface 1121 of the production tubing (i.e., the inner diameter of the production tubing). Therefore, the mating surface 1120 will prevent or at least reduce engagement between the outer surface of the sucker rod body or the outer surface of the sucker rod connector body and the production tubing 1111. This prevents or reduces wear on the outer surface of the sucker rod body or the outer surface of the sucker rod connector body due to engagement with the production tubing. Correspondingly, wear on the inner surface of the production tubing is prevented or reduced.

[0112] Figure 13 A sucker rod string 1300 is shown, comprising two sucker rods 1002a and 1002b, each threadedly engaged with a sucker rod connector 1102. The sucker rod string 1300 is positioned within a production tubing 1111. A mating surface 1120 is raised above the outer surfaces of the sucker rod connector body 1104 and the sucker rod bodies 1004a and 1004b, such that the mating surface 1120 is positioned and arranged to engage any connection between the sucker rod string 1300 and the production tubing 1111. In some embodiments, the opposing mating surfaces 1121 are diamond reactive materials such as steel. Figure 14 A sucker rod string 1300 isolated from the production tubing is shown. Those skilled in the art will understand that a sucker rod string typically includes more than two separate sucker rod sections and more than one sucker rod connector, and simplification is used to explain the connection between two adjacent sucker rod sections. Figure 13 and 14 The embodiment shown. Figure 10-14 The embodiments shown illustrate that polycrystalline diamond elements can be directly mounted onto the sucker rod connector. In some embodiments, refer to Figure 10-14 The described concept can be combined with the concept described herein with reference to Figures 1-5, wherein the sucker rod guide is provided with a polycrystalline diamond element serving as a mating interface. In some embodiments, adding a sucker rod guide to the sucker rod string strengthens the sucker rod string, supplementing the protection provided to the string by the PDC on the sucker rod guide. In such embodiments, the sucker rod guide may also include a PDC thereon, or it may not have a PDC. When the sucker rod string includes a sucker rod guide, the diameter of the guide may be smaller than that of a conventional rod guide. In other embodiments, a sucker rod string with a polycrystalline diamond element on the sucker rod connector lacks an additional sucker rod guide because the sucker rod connector itself provides the dual functions of a sucker rod connector and a sucker rod guide (rod stabilizer).

[0113] Tubular connectors with polycrystalline diamond

[0114] In some embodiments, the tubular components disclosed herein include connectors for connection to other components, such as other tubular components or to tools (e.g., tool connectors). Figure 15A A tubular member with a connector is depicted, on which a polycrystalline diamond element is positioned. In Figure 15, a tube 1502, which may be a drill pipe, is positioned within a tube 3111, which may be a casing in a wellbore. The tube 3111 has an inner wall 3121. The tubular member 1502 includes a body 1504 that expands at a body section 1506 into a connector section 1508 of a larger diameter. The connector section 1508 includes threads 1511 on its inner diameter, which allow the tubular member 1502 to be connected to tools, other tubular members, or other components. As shown, the connector section 1508 is connected to a tool 1510 (only a portion of it is shown). The tool 1510 may be, for example, a drill bit.

[0115] Multiple polycrystalline diamond elements 1114 are positioned on the connector section 1508 such that the mating surface 1120 aligns with the engagement between the tube 1502 and the opposite mating surface 1321. Figure 15B Depicting Figure 15A The tubular member 1502 is positioned at an angle within the tube 3111. With the tubular member 1502 positioned at an angle within the tube 3111, at least some of the mating surfaces 1120 engage with the inner wall 3121 of the tube 3111. Therefore, the mating surfaces 1120 of the plurality of polycrystalline diamond elements 1114 engage with the tube 3111, but not with other parts of the tubular member 1502. (e.g., sucker rod string) Figure 13 The mating surfaces of the sucker rod (1300) shown in the diagram function in essentially the same way, such that when the sucker rod is at an angle within the production tubing, the mating surfaces of the multiple polycrystalline diamond elements thereon will engage with the production tubing, rather than with other parts of the sucker rod.

[0116] Therefore, in some embodiments, the PDC element disclosed herein is positioned on a tool connector. The tool connector may be located at one end of a drill pipe, for example, a drill pipe that includes threads and has an outer diameter (OD) larger than the rest of the drill pipe. In some embodiments, the tubular member having such a tool connector (e.g., connector segment 1508) does not have features such as Figure 10-14 The connector shown is integrated with the tubular part because the tool fitting for connection with other components is integral. Therefore, some embodiments provide positioning of the PDC element on and / or around such a tool fitting.

[0117] As can be readily understood from the description and figures provided above, the technology of this application can be used in a wide range of applications, including those in downhole environments. Furthermore, the technology provided herein has broad applications in other industrial applications. Those skilled in the art will understand that this disclosure is not limited to use with drill pipe and sucker rod, or even to use in downhole applications, and that the concepts disclosed herein can be applied to the joints between any surfaces.

[0118] Although the embodiments and advantages have been described in detail, it should be understood that various changes, substitutions, and modifications can be made therein without departing from the spirit and scope of this disclosure. Furthermore, the scope of this application is not limited to the specific embodiments of the processes, machines, manufactures, material compositions, means, methods, and steps described in the specification. As will be readily understood by those skilled in the art from the disclosure, based on this disclosure, currently existing or future processes, machines, manufactures, material compositions, means, methods, or steps that perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein can be utilized. Therefore, the appended claims are intended to include such processes, machines, manufactures, material compositions, means, methods, or steps within their scope.

Claims

1. A sucker rod assembly, the assembly comprising: A production tubing located within a wellbore, the production tubing having an internal cavity wall defining a cavity of the production tubing, wherein the internal cavity wall includes a metal surface, the metal surface including at least 2 wt.% of a diamond solvent-catalyst based on the total weight of the metal; A sucker rod string, the sucker rod string being positioned within the cavity of the production tubing, the sucker rod string including a first sucker rod connected to a second sucker rod via a sucker rod connector; The sucker rod connector includes polycrystalline diamond elements, each having a polycrystalline diamond mating surface, and wherein the polycrystalline diamond mating surface is positioned along the sucker rod string to mate the metal surfaces of the sucker rod string and the production tubing. The outer surface of the sucker rod connector has a first curvature, the polycrystalline diamond bonding surface has a second curvature, and the second curvature is equal to or less than the first curvature.

2. The component according to claim 1, characterized in that, The first sucker rod and the second sucker rod are threadedly connected to the sucker rod connector.

3. The component according to claim 1, characterized in that, The second curvature is smaller than the first curvature.

4. The component according to claim 1, characterized in that, The second curvature is equal to the first curvature.

5. The component according to claim 1, characterized in that, The polycrystalline diamond bonding surface has a surface finish of up to 32 μinRa.

6. The component according to claim 1, characterized in that, The diamond solvent-catalyst includes iron, titanium, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, tantalum and their alloys.

7. The component according to claim 6, characterized in that, The metal is an iron-based high-temperature alloy, a cobalt-based high-temperature alloy, or a nickel-based high-temperature alloy.

8. The component according to claim 1, characterized in that, The metal comprises 45 wt.% to 100 wt.% of the diamond solvent-catalyst based on the total weight of the metal.

9. The component according to claim 1, characterized in that, The metal is softer than tungsten carbide.

10. A method for connecting a sucker rod string and a production tubing, the method comprising: A sucker rod string is provided, the sucker rod string including a first sucker rod connected to a second sucker rod via a sucker rod connector. A polycrystalline diamond element is positioned on the sucker rod connector, wherein the polycrystalline diamond element has a polycrystalline diamond bonding surface; The sucker rod string is positioned within the cavity of the production tubing such that the polycrystalline diamond bonding surface is positioned along the sucker rod string to mate the metal surfaces of the sucker rod string and the production tubing, wherein the metal surfaces comprise a metal comprising at least 2 wt.% diamond solvent-catalyst based on the total weight of the metal, and The polycrystalline diamond bonding surface of the polycrystalline diamond element is provided with a curvature equal to or less than that of the outer surface of the sucker rod connector.

11. The method according to claim 10, characterized in that, Providing the sucker rod string includes threading the first sucker rod and the second sucker rod to the sucker rod connector.

12. The method according to claim 10, characterized in that, It also includes providing a curvature to the polycrystalline diamond bonding surface of the polycrystalline diamond element that is less than the curvature of the outer surface of the sucker rod connector.

13. The method according to claim 10, characterized in that, It also includes providing a curvature to the polycrystalline diamond bonding surface of the polycrystalline diamond element that is equal to the curvature of the outer surface of the sucker rod connector.

14. The method according to claim 10, characterized in that, The diamond solvent-catalyst includes iron, titanium, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, or tantalum.

15. The method according to claim 10, characterized in that, The metal comprises 45 wt.% to 100 wt.% of the diamond solvent-catalyst based on the total weight of the metal.

16. The method according to claim 10, characterized in that, The metal is softer than tungsten carbide.

17. A downhole tubular component assembly, the assembly comprising: A tubular component, the tubular component including a first end, a second end, and a tool connector at the second end; A polycrystalline diamond element, wherein the polycrystalline diamond element is connected to the tool connector, and wherein the polycrystalline diamond element has a polycrystalline diamond bonding surface; A casing in a wellbore, the casing having an inner wall having a metal surface, the metal surface comprising a metal comprising at least 2 wt.% of a diamond solvent-catalyst based on the total weight of the metal; The tubular component is positioned within the sleeve, such that the polycrystalline diamond bonding surface of the polycrystalline diamond element is positioned to mate with the tool connector and the metal surface of the inner wall of the sleeve. Wherein, the outer diameter of the tubular member at the tool joint is greater than the diameter of the tubular member between the tool joint and the first end.

18. The component according to claim 17, characterized in that, The tubular component is a drill pipe.

19. The component according to claim 17, characterized in that, It also includes a drill bit that is connected to the tool joint.

20. The component according to claim 17, characterized in that, The polycrystalline diamond bonding surface of the polycrystalline diamond element has a surface finish of up to 32 μin Ra.

21. The component according to claim 17, characterized in that, The diamond solvent-catalyst is made of iron, titanium, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, or tantalum.

22. The component according to claim 21, characterized in that, The metal includes iron-based superalloys, cobalt-based superalloys, or nickel-based superalloys.

23. The component according to claim 17, characterized in that, The metal comprises 45 wt.% to 100 wt.% of the diamond solvent-catalyst based on the total weight of the metal.

24. The component according to claim 17, characterized in that, The metal is softer than tungsten carbide.

25. A method for engaging a tool connector and a sleeve, the method comprising: A tubular component is provided, the tubular component including a first end, a second end, and a tool connector at the second end; A polycrystalline diamond element is connected to the tool connector, wherein the polycrystalline diamond element has a polycrystalline diamond bonding surface; The tubular component is positioned within a casing within the wellbore such that the polycrystalline diamond mating surface of the polycrystalline diamond element is positioned to engage with the metal surfaces of the tool joint and the inner wall of the casing, wherein the metal surfaces comprise a metal comprising at least 2 wt.% diamond solvent-catalyst based on the total weight of the metal, and The outer diameter of the tubular member at the tool joint is greater than the diameter of the tubular member between the tool joint and the first end.

26. The method according to claim 25, characterized in that, The tubular component is a drill pipe, and the method includes connecting a drill bit to the tool joint and drilling a hole in the wellbore.

27. The method of claim 25, characterized in that, The diamond solvent-catalyst is made of iron, titanium, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, or tantalum.

28. The method according to claim 25, characterized in that, The metal comprises 45 wt.% to 100 wt.% of the diamond solvent-catalyst based on the total weight of the metal.

29. The method according to claim 25, characterized in that, The metal is softer than tungsten carbide.

30. A tubular assembly, the assembly comprising: A first tubular member is positioned within a wellbore. The first tubular member has an internal cavity wall defining a cavity of the first tubular member, wherein the internal cavity wall includes a metal surface, the metal surface including a metal comprising at least 2 wt.% of iron, titanium, cobalt, nickel, ruthenium, rhodium, palladium, chromium, manganese, copper, tantalum, or a combination thereof based on the total weight of the metal. A second tubular member is positioned within the cavity of the first tubular member; A polycrystalline diamond element coupled to the second tubular member, wherein the polycrystalline diamond element has a polycrystalline diamond bonding surface, and wherein the polycrystalline diamond bonding surface is positioned along the second tubular member to mate the bonding between the second tubular member and the metal surface, and The outer surface of the second tubular member has a first curvature, the polycrystalline diamond bonding surface has a second curvature, and the second curvature is equal to or less than the first curvature.

31. The component according to claim 30, Its features are, The first tubular component includes a production oil pipe; The second tubular component includes a sucker rod string, which includes a first sucker rod connected to a second sucker rod via a sucker rod connector; and The polycrystalline diamond element is connected to the sucker rod connector.

32. The component according to claim 30, Its features are, The first tubular component includes a sleeve; The second tubular component includes a first end, a second end, and a tool connector at the second end; The polycrystalline diamond element is connected to the tool connector; and The second tubular member is positioned inside the sleeve, such that the polycrystalline diamond bonding surface is positioned to engage the tool connector with the metal surface.

33. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% iron based on the total weight of the metal.

34. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% titanium based on the total weight of the metal.

35. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% cobalt based on the total weight of the metal.

36. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% nickel based on the total weight of the metal.

37. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% ruthenium based on the total weight of the metal.

38. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% rhodium based on the total weight of the metal.

39. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% palladium based on the total weight of the metal.

40. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% chromium based on the total weight of the metal.

41. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% manganese based on the total weight of the metal.

42. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% copper based on the total weight of the metal.

43. The component according to claim 30, characterized in that, The metal comprises at least 2 wt.% tantalum based on the total weight of the metal.

44. The component according to claim 30, characterized in that, The metal in question is steel.

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