Expandable Borehole Reamer with Debris Removal
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Solution Overview
Problem
Conventional methods for enlarging subterranean boreholes often result in narrowing the diameter, limiting production flow rates and requiring additional casing installations, which restricts further drilling and hydrocarbon extraction efficiency.
Innovation Solution
An expandable apparatus with a tubular body and retractable members that can be extended by drilling fluid pressure, allowing for a greater than 20% increase in borehole diameter, utilizing a push sleeve and traveling sleeve mechanism to activate and deactivate the expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If additional casing is installed to increase borehole depth, then the borehole can reach greater depths, but the borehole diameter is narrowed
Solution Approach 1:
The reamer blades are designed to be movable between retracted and extended positions. During drilling, the blades remain retracted to maintain a compact profile that can pass through existing casing. When reaming is required, the blades extend radially outward to enlarge the borehole diameter, thus dynamically adapting the tool configuration to different operational requirements.
Solution Approach 2:
The reamer assembly is segmented into a tubular body and multiple independent reamer blades that can be individually positioned. This segmentation allows the blades to be retracted during drilling operations and extended during reaming operations, resolving the contradiction between maintaining small diameter for depth and enlarging diameter for production.
2Area of stationary object
If conventional reamer blades are used, then borehole enlargement is achieved, but debris accumulates near the blade openings causing operational issues
Solution Approach 1:
A debris removal element is provided that actively removes or extracts debris from the area near the reamer blade openings. This element may include features such as scraping surfaces or airflow channels that prevent debris accumulation and eliminate the harmful effects of debris buildup during reaming operations.
3Area of stationary object
If the expandable apparatus is activated, then borehole diameter increases by greater than 20%, but drilling fluid flow rate must be increased
Solution Approach 1:
The reamer blades are actuated using hydraulic pressure from drilling fluid. The apparatus includes fluid communication channels that direct drilling fluid to push against the reamer blades, forcing them from retracted to extended positions. This hydraulic actuation mechanism allows controlled expansion using the existing drilling fluid system, minimizing additional energy requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient enlargement of boreholes without the limitations of traditional casing installations, enhancing production flow rates and allowing for larger diameter passages for further drilling and hydrocarbon extraction.
Implementation Method 1
At least one member positioned within the at least one opening in the wall of the tubular body and configured to move between a retracted position and an extended position. A push sleeve disposed within the longitudinal bore and coupled to the at least one member. The push sleeve configured to move the at least one member from the retracted position to the extended position responsive to a flow rate of drilling fluid passing through the longitudinal bore.
Implementation Method 2
At least one of the yoke and the tubular body comprises at least one surface having a central portion comprising an apex for removing debris proximate to the at least one opening in the wall of the tubular body.
Data Source
AI summary
Expandable apparatus for use in subterranean boreholes include at least one member configured to move between a retracted position and an extended position. Components of the expandable apparatus may include at least one surface for removing debris proximate to the tubular body. Components of the expandable apparatus may be configured to enable the expandable apparatus to increase a diameter of a subterranean borehole by greater than twenty percent. Components of the expandable apparatus may be configured to restrict fluid flow to nozzle assemblies. The expandable apparatus may include a protect sleeve having a push sleeve disposed therein. Methods of operating an expandable apparatus may include removing debris with a surface of the expandable apparatus. Methods of operating an expandable apparatus may also include selectively flowing fluid to nozzle assemblies.