Expandable Reamer and Stabilizer for Borehole Enlargement
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Solution Overview
Problem
The existing drilling technologies face challenges in enlarging subterranean boreholes beyond previously installed casing without narrowing the borehole diameter, which restricts production flow rates of hydrocarbons.
Innovation Solution
The use of an actuatable expandable reamer and an actuatable expandable stabilizer, where the reamer and stabilizer blades and pads are movable from a refracted to an extended position, allowing for increased borehole diameter while maintaining stability through controlled actuation by electronic signals and hydraulic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If additional smaller diameter casing is installed to reach greater depths, then the borehole can reach greater depths, but the borehole diameter is narrowed which restricts production flow rates
Solution Approach 1:
The patent employs an expandable reamer with movable blades that can dynamically change the borehole diameter from a smaller initial size to a larger final size. The blades are positioned in a retracted state during initial drilling to allow passage through smaller casing, then extended to enlarge the borehole for increased production flow rates, thus dynamically resolving the contradiction between depth access and diameter requirement
Solution Approach 2:
The expandable reamer is designed to be inserted within the previously installed smaller diameter casing. The reamer blades are initially retracted to fit within the casing inner diameter, then extended outward to cut and enlarge the borehole beyond the original casing diameter, effectively nesting the enlargement tool within the existing casing structure
2Area of stationary object
If expandable reamer blades are extended to enlarge borehole diameter, then production flow rate is improved, but lateral vibrational loads and instability increase
Solution Approach 1:
The patent introduces an expandable stabilizer as an intermediary component located above the expandable reamer. The stabilizer includes bearing pads that contact the borehole wall to provide mechanical support and reduce lateral vibrations. This intermediary stabilizing mechanism allows the reamer blades to extend and enlarge the borehole while maintaining drilling stability through the stabilizer's vibration-dampening contact with the borehole wall
3Stability of the object's composition
If fixed stabilizer pads are used to improve stability, then drilling stability is improved, but the stabilizer cannot adapt to enlarged borehole diameter
Solution Approach 1:
The patent employs an expandable stabilizer with bearing pads that can dynamically change their radial position. The bearing pads are initially in a retracted position for stability during initial drilling, then extend outward to contact the enlarged borehole wall after the reamer has increased the diameter. This dynamic adjustment allows the stabilizer to maintain contact and stability throughout the borehole enlargement process, adapting to the changing borehole diameter
Data Source
AI summary
A drilling assembly for drilling a subterranean wellbore includes an expandable reamer and an expandable stabilizer. The expandable reamer and the expandable stabilizer each have a tubular body with a longitudinal axis and a drilling fluid flow path extending therethrough. A plurality of blades is carried by the reamer and a plurality of bearing pads is carried by the stabilizer. The blades and bearing pads are outwardly movable from a retracted position to an extended position with respect to the longitudinal axes of the reamer and stabilizer, respectively. The reamer and stabilizer each include an actuation device for moving the blades and bearing pads, respectively, from the retracted position to the extended position.