RU2817840C1 - Expander (versions) - Google Patents

Abstract

FIELD: oil and gas industry.

SUBSTANCE: group of inventions relates to versions of a expander, including those for increasing the borehole diameter. Expander comprises: a housing comprising a flow tube passing through the center of the inner part of the housing, and a plurality of holes from the inner part of the body to the outer part of the body; first expander unit in the inner part of the housing, wherein the first expander unit comprises a first front wall, a first inner wall and a first rear wall, wherein the first rear wall and the first inner wall comprise a first recess; a second expander unit in the inner part of the housing, the second expander unit comprising a second front wall, a second inner wall and a second rear wall, wherein the first front wall is inserted into the second recess in the retracted configuration; and a third expander unit in the inner part of the housing, wherein the third expander unit comprises a third front wall, a third inner wall and a third rear wall, wherein the third rear wall and the third inner wall comprise a third recess, and the second front wall is inserted into the third recess in the retracted configuration, and the third front wall is inserted into the first recess in the retracted configuration. A line drawn perpendicular to the longitudinal axis of the housing, which passes along the longitudinal axis, crosses, in order, across the expander, first expander unit, flow tube, second front wall of second expander unit, third rear wall of third expander unit in retracted configuration and housing.

EFFECT: reduced number of passes with the help of expander.

16 cl, 5 dwg

Description

State of the art

Well bores can be drilled deep into a location on the surface or deep into the seabed for a variety of exploration or production purposes. For example, a wellbore may be drilled to access fluids, such as liquid and gaseous hydrocarbons, that are contained in subterranean formations and to extract fluids from the formations. Wellbores used to produce or extract fluids may be lined with casing around the walls of the wellbore. A variety of drilling techniques can be used depending in part on the characteristics of the formation through which the wellbore is being drilled.

Initially, a wellbore with a first diameter may be drilled. Part of the wellbore can be expanded using an expander. In some embodiments, the reamer may be located uphole from the bit in the same bottom hole assembly. In some embodiments, the reamer may increase the diameter of the wellbore after drilling a pilot hole. Some reamers may contain expander blocks that can be selectively expanded to increase the diameter of the wellbore.

Thus, from US 2014/0182940 A1 an expander for increasing the diameter of the hole is known. Such an expander includes a substantially cylindrical body having an axial opening therein. A mandrel may extend axially through the axial hole. One or more cutting blocks are movably connected to the body. The ratio of cutting unit height to body diameter is from about 0.35:1 to about 0.50:1.

However, the known expander does not allow obtaining a high gear ratio.

The purpose of the present invention was to create an expander that makes it possible to obtain a high gear ratio.

The essence of the invention

According to the invention, there has been proposed an expander comprising a housing having a flow pipe extending through the interior of the housing and a plurality of openings from the interior of the housing to the exterior of the housing. A first expander block is located in an interior portion of the housing, the first expander block comprising a first front wall and a first rear wall, the first rear wall including a first recess. A second expander block is located in the interior of the housing, the second expander block comprising a second front wall and a second rear wall, the second rear wall including a second recess, the first front wall being inserted into the second recess in a retracted position.

In other embodiments, the expander includes a housing having a longitudinal axis; flow pipe coaxial with the longitudinal axis of the housing. A plurality of expander blocks are arranged radially around the flow pipe and are retractable and extendable relative to the housing. The secondary flow pipe is located radially outward from the flow pipe and between two expander blocks of the plurality of expander blocks.

In still other embodiments, the expander includes a housing including an opening from an interior portion of the housing to an exterior portion of the housing, and an expander block. The expander block contains a front wall, a rear wall and a radial perimeter. In the retracted configuration the coverage to exposure ratio is less than 1.00.

Thus, according to the first aspect of the present invention, there is provided an expander comprising:

a housing comprising a flow pipe extending through the center of an interior portion of the housing and a plurality of openings from an interior portion of the housing to an exterior portion of the housing;

a first expander block in an interior portion of the housing, the first expander block comprising a first front wall, a first inner wall, and a first rear wall, wherein the first rear wall and the first inner wall comprise a first recess;

a second expander block in an interior portion of the housing, the second expander block comprising a second front wall, a second inner wall, and a second rear wall, the first front wall being inserted into the second recess in a retracted configuration, and

a third expander block in an interior portion of the housing, the third expander block comprising a third front wall, a third interior wall, and a third rear wall, the third rear wall and the third interior wall comprising a third recess, and the second front wall being inserted into the third recess in a retracted configuration, and a third front wall is inserted into the first recess in a retracted configuration;

wherein a line drawn perpendicular to the longitudinal axis of the housing, which extends along the longitudinal axis, intersects, in order across the expander, the first expander unit, the flow pipe, the second front wall of the second expander unit, the third rear wall of the third expander unit in a retracted configuration, and the housing.

Preferably, the first front wall has a height that is greater than the height of the first rear wall.

Preferably, the first inner wall of the first expander block and the second inner wall of the second expander block are concave.

Preferably, the flow pipe is coaxial with the longitudinal axis of the housing.

Preferably, the first inner wall of the first expander block and the second inner wall of the second expander block are shaped to complement the flow pipe.

Preferably, the first inner wall has a shape complementary to the flow pipe for a wall arc angle greater than 90°.

Preferably, the first reamer block is located uphole from the second reamer block, and the second reamer block is located uphole from the third reamer block.

Preferably, the expander has a coverage to exposure ratio of less than 1.00.

According to the second aspect of the present invention, an expander is provided containing:

a body with a body around a longitudinal axis, the body forming an internal channel;

a flow pipe passing through the internal channel of the housing along the longitudinal axis of the housing;

a plurality of expander blocks arranged radially around the flow pipe and configured to expand and retract relative to the housing; And

a secondary flow pipe extending within the internal bore of the housing and radially outward from the flow pipe, the secondary flow pipe being located between two expander blocks of the plurality of expander blocks in a retracted configuration.

Preferably, the expander includes a flow diverter, the flow diverter comprising a primary port in fluid communication with the flow pipe and a secondary port in fluid communication with the secondary flow pipe.

Preferably, the secondary flow pipe extends along the length of the plurality of expander blocks.

Preferably, the expander includes an elastic element located around the secondary flow pipe.

According to a third aspect of the present invention, an expander is provided comprising:

a housing comprising an opening from an interior portion of the housing to an exterior portion of the housing;

expander unit containing:

- a front wall, wherein the height of the front wall exceeds the radius of the body;

- back wall; And

- radial perimeter;

wherein the expander block is configured into a retracted configuration and an expanded configuration, wherein when the expander block is in a retracted configuration, the radial perimeter is located in a radial direction inward from the outer surface of the housing, and when the expander block is in an expanded configuration, the radial perimeter is located in a radial direction outward from the outer surface of the housing, wherein the exposure is the distance from the outer surface of the housing, the coverage is the length of contact of the front wall with the housing, and the ratio of coverage to exposure is less than 1.00.

Preferably, the expansion ratio is greater than 2.00.

Preferably, the height of the front wall is greater than the height of the rear wall.

Preferably, the expander block is a first expander block, and the front wall is a first front wall, wherein the first expander block includes a recess in the rear wall of the first expander block, and there is a second expander block containing a second front wall, wherein the second front wall is inserted into the recess.

This summary section presents a selection of concepts that are further described in the detailed description. This summary of the invention is not intended to define key or significant distinguishing features of the claimed subject matter of the invention, nor is it intended to be used to limit the scope of the claimed subject matter of the invention. Additional features and aspects of embodiments of the present invention will be set forth herein and, in part, will be apparent from the description or may be learned by practice of such embodiments.

Brief description of drawings

To describe the method in which the above and other features of the present invention can be obtained, more specific description will be given with reference to the specific embodiments contained therein, which are illustrated in the accompanying drawings. For better understanding, like elements are designated by like reference numerals in the various accompanying figures. Although some of the graphics may be presented schematically or enlarged to illustrate concepts, at least some of the graphics may be shown to scale. While the drawings depict certain exemplary embodiments, the embodiments will be described and explained in further specificity and detail in the accompanying drawings, in which:

fig. 1 illustrates a drilling system in accordance with at least one embodiment of the present invention;

fig. 2-1 is a perspective view of an expander in an expanded configuration in accordance with at least one embodiment of the present invention;

fig. 2-2 is a longitudinal sectional view of the expander shown in FIG. 2-1, in retracted configuration;

fig. 2-3 is a longitudinal sectional view of the expander shown in FIG. 2-1, in extended configuration;

fig. 2-4 are cross-sectional views of the expander shown in FIG. 2-1, in retracted configuration;

fig. 2-5 are cross-sectional views of the expander shown in FIG. 2-1, in advanced configuration;

fig. 3 is a perspective view of an expander unit in accordance with at least one embodiment of the present invention;

fig. 4-1 is a cross-sectional view of a dilator in a retracted configuration in accordance with at least one embodiment of the present invention;

fig. 4-2 is a cross-sectional view of the expander shown in FIG. 4-1, in advanced configuration; And

fig. 5 is a cross-sectional view of a dilator in accordance with at least one embodiment of the present invention.

Detailed Description of the Invention

This invention generally relates to devices, systems and methods for operating high ratio expandable expanders. In some embodiments, the expander blocks of the expander in question may have an internal surface that can be inserted into a portion of a circumferentially adjacent expander block. This may allow the expander blocks to have greater exposure, which may increase the diameter of the expandable barrel. This can allow for larger bores to be drilled, thereby potentially preventing further trips in the well with a different reamer, allowing for larger tools and fluid flows in the wellbore.

In some embodiments, the expander blocks of the expander in question may have an internal surface that can be inserted into a portion of a circumferentially adjacent expander block. This may make it possible to increase the height of the expander blocks. This inner surface may allow the diameter of the reamer block to be reduced, allowing running and recovery operations to occur through a tighter restriction in the wellbore.

In well drilling operations, reamers can be used to increase the diameter of the wellbore. In some embodiments, the reamer may be located on the same bottom hole assembly (BHA) as the bit. Thus, when the bit crushes a formation with the diameter of the bit, the reamer can follow the bit and crush the formation with the diameter of the reamer. This can enable larger boreholes to be drilled in a single pass or a run-up operation in the borehole. In other words, the pilot hole can be drilled immediately when the wellbore is reamed. In some embodiments, an reamer may be run into an existing wellbore to increase the diameter of the existing wellbore in a pass or run-in operation other than a bit operation. In other words, a pilot hole may be drilled before introducing the reamer into the wellbore.

A plurality of expander blocks may extend from the housing to fracture the formation. In some embodiments, the expander may be an expandable expander. The expandable extender can have an extended configuration and a retracted configuration. In the retracted configuration, the cutting surface of the expander blocks is located radially inward from the outer surface of the housing. Thus, when lowering the reamer into the wellbore, the reamer blocks may not contact or destroy sections of the wellbore wall. In an expanded configuration, the reamer blocks are radially expanded from the housing such that the cutting surface is located radially outward from the housing. Thus, as the reamer rotates, the reamer can erode portions of the borehole wall and increase diameter along portions of the borehole.

The expander can be expanded using any expansion force. For example, the expander can be expanded using a hydraulic pressure difference between the inside of the housing and the outside of the housing. The flow pipe can pass through the body and behind the expanders. The flow tube may include one or more ports in the piston chamber. The piston can be configured to move longitudinally and connect to the piston chamber. As the pressure of the drilling fluid on the piston increases, said piston can move in the longitudinal direction. The piston can press on the expander blocks, which can slide along the guides. The guides may be inclined radially outward such that the piston moves the expander blocks longitudinally, the expander blocks may be moved radially outward into an expanded configuration. The elastic element can be pressed against the expander blocks by an elastic force that counteracts the force applied by the piston. Thus, when the hydraulic pressure on the piston exceeds the elastic force, the expander blocks can be moved outward into an expanded configuration. Thus, the expander may be a hydraulically driven expander. In other words, to activate the reamer, the pressure of the drilling fluid passing through the flow pipe can be increased.

The expander has a diameter in the expanded position (eg, the diameter of a circle circumscribed around the outer wall of the expander blocks in the expanded configuration) and a diameter in the retracted position (eg, the diameter of the circle described around the outer surface of the housing in the retracted configuration). The expansion ratio is the ratio between the diameter in the expanded position and the diameter in the retracted position. In some embodiments, the expansion ratio may be in a range having an upper value, a lower value, or an upper and lower value, including any of the values 2.5, 2.4, 2.3, 2.2, 2.1, 2.0 , 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1 or any value in between. For example, the expansion ratio may be greater than 1.1. In another example, the expansion ratio may be less than 2.5. In still other examples, the expansion ratio may be any value in the range of 1.1 to 2.5. In some embodiments, it may be critical that the expansion ratio be greater than 2.0 to sufficiently expand the wellbore diameter.

The expander blocks extend from the housing in such a way that the cutting elements of the expander block are located at a distance from the housing. This distance may represent the exposure of the expander. In other words, the exposure may be half the difference in diameter in the expanded position of the expander compared to the diameter in the retracted position of the expander.

The expander block has an outer surface, a front wall, a rear wall and an inner wall. The outer wall contains one or more cutting elements. The front wall is the side surface of the expander block that faces in the direction of rotation (eg, the side surface that first engages the formation during rotation). The rear wall is the side surface of the expander block facing the direction of rotation. The front wall and rear wall engage with guides in the housing to guide the expander block radially outward. The inner wall is opposite the outer wall and is adjacent to both the front wall and the rear wall.

As the reamer rotates, the leading edge of the reamer block may engage the formation. This may force the expander block against the rear edge of the housing opening through which the expander block is expanded. As the outer wall extends beyond the housing, the reamer block may tend to rotate depending on the shear forces from the cutting elements on the outer wall and trailing edge of the bore. Rotation of the expander block can be prevented by contact with the front wall at the leading edge of the hole. The radial extent of the front wall contact at the leading edge of the hole represents the reach of the expander block.

Coverage to exposure ratio is the ratio of coverage to exposure. The coverage to exposure ratio is a measure of the maximum expansion of the expander. In some embodiments, the coverage-to-exposure ratio may be in a range having an upper value, a lower value, or an upper and lower value, including any of the values 0.50, 0.60, 0.70, 0.75, 0.80, 0 .85, 0.90, 0.95, 1.00, 1.05, 1.10, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7 , 1.8, 1.9, 2.0 or any value in between. For example, the coverage-to-exposure ratio may be greater than 0.50. In another example, the coverage to exposure ratio may be less than 2.0. In still other examples, the coverage-to-exposure ratio may be any value in the range of 0.50 to 2.0. In some embodiments, it may be critical that the sweep to exposure ratio be less than 1.00 to sufficiently increase the wellbore diameter. A lower sweep-to-exposure ratio is an indication that the reamer can have a greater increase in borehole diameter. In some embodiments, each expander unit may have the same coverage to exposure ratio. In some embodiments, different expander units may have different coverage to exposure ratios.

In some embodiments, the exposure may be in a range having an upper value, a lower value, or an upper and lower value, including any of 1.5 inches (3.8 cm), 1.6 inches (4.1 cm), 1. 7" (4.3cm), 1.8" (4.6cm), 1.9" (4.8cm), 2.0" (5.1cm), 2.1" (5.3cm) cm), 2.2" (5.6 cm), 2.3" (5.8 cm), 2.4" (6.1 cm), 2.5" (6.4 cm), 3.0 inch (7.62 cm), 4.0 inch (10.16 cm), 5.0 inch (12.7 cm), 6.0 inch (15.24 cm), 8.0 inch (20.32 cm ), 10.0 inches (25.40 cm), 12.0 inches (30.48 cm), 15.0 inches (38.10 cm), 18.5 inches (46.99 cm), or anything in between. For example, the exposure may be more than 1.5 inches (3.8 cm). In another example, the exposure may be less than 18.5 cm (46.99 cm). In yet other examples, the exposure may be any value in the range of 1.5 inches (3.8 cm) to 18.5 cm (46.99 cm). In some embodiments, it may be critical that the exposure be greater than 2.0 inches (5.1 cm) to sufficiently increase the wellbore diameter. In some embodiments, each expander block may have the same exposure. In some embodiments, different expander blocks may have different exposures.

In some embodiments, the coverage may be in a range having an upper value, a lower value, or an upper and lower value, including any of 1.0 inches (2.5 cm), 1.5 inches (3.8 cm), 1. 6" (4.1cm), 1.7" (4.3cm), 1.8" (4.6cm), 1.9" (4.8cm), 2.0" (5.1cm) cm), 2.1" (5.3 cm), 2.2" (5.6 cm), 2.3" (5.8 cm), 2.4" (6.1 cm), 2.5 inch (6.4 cm), 3.0 inch (7.62 cm), 4.0 inch (10.16 cm), 5.0 inch (12.7 cm), 6.0 inch (15.24 cm) cm), 8.0 inches (20.32 cm), 10.0 inches (25.40 cm) or any value in between. For example, the coverage may be more than 1.0 inches (2.5 cm). In another example, the coverage may be less than 10.0 (25.4 cm). In still other examples, the coverage may be any value in the range of 1.0 inches (2.5 cm) to 10.0 inches (25.4 cm). In some embodiments, it may be critical that the span be greater than 1.8 inches (4.6 cm) to support the expander assembly. Increasing the coverage can result in greater stability of the expander block. In addition, the increased coverage can increase the strength of the expander, thereby reducing the likelihood of breakage of the expander assembly during expansion operations. In some implementations, each expander block may have the same coverage. In some embodiments, different extender blocks may have different spans.

The front wall has a front wall height, which is the distance from the outer wall to the inner wall along the front wall. In some embodiments, the front wall height is the sum of exposure and coverage. In some embodiments, the height of the front wall exceeds the sum of exposure and coverage. The back wall has a back wall height, which is the distance from the outer wall to the inner wall along the back wall. In some embodiments, the height of the front wall is greater than the height of the rear wall. This may ensure that the front wall has increased coverage against the leading edge of the housing opening and/or that the expander block extends further from the housing. This may increase the stability and/or strength of the expander block during expansion. The ratio of the front wall height to the rear wall height is the wall height ratio. In some embodiments, the wall height ratio may be in a range having an upper value, a lower value, or an upper and lower value, including any of the values 1.0, 1.1, 1.2, 1.3, 1.4, 1, 5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.5, 3.0 or any value in between. For example, the wall height ratio may be greater than 1.0. In another example, the wall height ratio may be less than 3.0. In yet other examples, the wall height ratio may be any value in the range of 1.0 to 3.0. In some embodiments, it may be critical that the wall height ratio be greater than 1.2 to increase the coverage and exposure of the expander block. In addition, a wall height ratio greater than 1.2 can enable circumferentially adjacent expander blocks to be inserted into each other. In some embodiments, each expander block may have the same wall height ratio. In some embodiments, different expander blocks may have different wall height ratios.

In some embodiments, the height of the front wall may be greater than the radius of the housing. In other words, the height of the front wall may be more than half the diameter in the retracted position. The front wall has a height to diameter ratio in the retracted position. In some embodiments, the height to diameter ratio in the retracted position may be in a range having an upper value, a lower value, or an upper and lower value, including any of 0.45, 0.5, 0.55, 0.6, 0, 65, 0.70, 0.75 or any value in between. For example, the height to diameter ratio in the retracted position may be greater than 0.45. In another example, the height to diameter ratio in the retracted position may be less than 0.75. In yet other examples, the height to diameter ratio in the retracted position may be any value in the range of 0.45 to 0.75. In some embodiments, it may be critical that the height-to-diameter ratio in the retracted position be greater than 0.5 to increase exposure and reduce coverage-to-exposure ratio. In some embodiments, each expander block may have the same height to diameter ratio in the retracted position. In some embodiments, different expander blocks may have different height to diameter ratios in the retracted position.

In some embodiments, the expander unit housing includes a recess in the rear wall. The inner edge of the front wall may be suitably sized and configured to be inserted into the recess. Thus, the front wall of the first expander block can be inserted into the rear wall of an adjacent expander block. This may allow the expander unit to be retracted further into the interior of the housing, thereby providing increased exposure and a reduced coverage-to-exposure ratio. In some embodiments, the recess is located at the intersection of the interior wall and the rear wall. In other words, the angle between the inner wall and the rear wall may be completely or partially removed to form a recess.

For example, the first expander unit has a first front wall and a first rear wall. The first front wall may have a height of the first front wall that is greater than the height of the first rear wall. The first rear wall may comprise a first recess. The second expander block has a second front wall and a second rear wall. The second expander block may be circumferentially adjacent (eg, positioned as a next expander block following the expander circumference) with the first expander block in the direction of rotation. The second rear wall may include a second recess. The first front wall (eg, the inner edge of the first front wall) may be inserted into the second recess in a retracted position. Likewise, the third expander block may include a third front wall and a third rear wall. The third expander block may be circumferentially adjacent to the second expander block in the direction of rotation, and the first expander block may be circumferentially adjacent to the second expander block in the direction of rotation. The third rear wall may comprise a third recess. The second front wall of the second expander unit may be inserted into the third recess. Likewise, a third front wall of the third expander block may be inserted into the first recess. Thus, the expander blocks of said expander can be inserted into circumferentially adjacent expander blocks. In this way, the expander blocks can be retracted further into the interior of the housing. This can increase exposure and provide a reduced sweep to exposure ratio of each reamer block, resulting in a greater increase in the diameter of the wellbore being expanded by the reamer.

In some embodiments, as discussed above, the expander may comprise three expander blocks. In some embodiments, the expander may comprise more or less than three expander blocks. For example, an expander may contain two, three, four, five, six or more expander units. Regardless of the number of expander blocks, each expander block may include a recess, and a front wall of a circumferentially adjacent expander block may extend into a recess of a rear wall of a circumferentially adjacent expander block.

In some embodiments, the recess may extend the entire length of the expander block. In some embodiments, the recess may extend less than the entire length of the expander block. One or both of the front wall and the rear wall of the expander block may comprise a sliding ramp. When the expander block moves between the expanded configuration and the retracted configuration, the expander block may slide along the sliding ramp. The recess can extend along the rear wall only as far as the lower edge of the front wall extends until it reaches the sliding ramp. In some embodiments, the recess may begin between the top end and the bottom end of the expander block. This may allow the outer wall to extend all the way to the top end of the expander block.

In some embodiments, the recess is the depth of a recess into the expander block housing. This can be visualized as the extent that the front wall of the circumferentially adjacent expander block extends into the expander block body. The depth of the recess may be a percentage of the recess from the width of the expander body. In some embodiments, the percentage of recess may be greater than 5%, greater than 10%, greater than 15%, greater than 20%, greater than 25%, greater than 30%, greater than 35%, greater than 40%, greater than 45%, greater than 50%, or anything in between. meaning. In some embodiments, it may be critical that the percentage of recess is greater than 10% to allow circumferentially adjacent expander blocks to fit into each other. In some embodiments, each expander block may have the same percentage of recess. In some embodiments, different expander blocks may have different percentages of recess.

In some embodiments, the inner wall may include a surface that is not planar. For example, the inner wall may include a curved surface. In some embodiments, the inner wall may be shaped to complement or partially complement the flow tube. For example, the flow tube may have a circular cross-sectional shape and the inner wall may have a circular or partially circular cross-sectional shape. The inner wall may have a circular cross-section. In some embodiments, the inner wall may complement the flow pipe for the wall arc angle. In some embodiments, the wall arc angle may be in a range having an upper value, a lower value, or an upper and lower value, including any of 45°, 60°, 75°, 80°, 85°, 90°, 95°, 100 °, 105°, 120° or any value in between. For example, the wall arc angle may be greater than 45°. In another example, the wall arc angle may be less than 120°. In yet other examples, the wall arc angle may be any value in the range of 45° to 120°. In some embodiments, it may be critical that the wall arc angle be greater than 90° to insert the inner wall in the direction of the flow pipe, increasing exposure and decreasing the coverage-to-exposure ratio. In some embodiments, in the retracted position, the inner wall of the expander block may contact or surround the flow pipe portion in the retracted position. In some embodiments, the inner wall of the expander block may be slightly or moderately offset relative to the flow pipe. In some embodiments, the inner wall is concave, or at least a portion of the inner wall is concave. In some embodiments, the inner walls of all expander blocks may surround (eg, enclose, contact, cover) all or approximately (eg, nearly) the entire outer circumference of the flow tube. In other words, the sum of all wall arc angles for the first expander block, the second expander block and the third expander block may be 360°.

In some embodiments, the flow pipe may extend through the center of the housing. In some embodiments, the flow tube may be coaxial (eg, have the same longitudinal axis) with the housing. Thus, each expander block can have the same wall arc angle. In some embodiments, different expander blocks may have different wall arc angles.

In some embodiments, a line drawn through the longitudinal axis and perpendicular to the longitudinal axis of the housing may contact two or more expander units in a retracted configuration. In some embodiments, a line drawn through the longitudinal axis of the housing may contact all three expander blocks. For example, a line drawn through the longitudinal axis may be parallel to the transverse axis of the block. This line may contact a first expander block in the housing of the first expander block, a second expander block at the inner edge of the front wall, and a third expander block in a recess of the rear wall.

The expander block has a transverse axis of the expander block, which is an axis between the outer wall and the inner wall. In some embodiments, a transverse block axis of one or more expander blocks may extend through a longitudinal axis of the housing. In some embodiments, the transverse block axis of one or more expander blocks may be offset relative to the longitudinal axis of the housing. In some embodiments, the transverse block axis of one or more expander blocks may be offset relative to the longitudinal axis of the housing in the direction of rotation of the expander. In some embodiments, the transverse block axis of one or more expander blocks may be offset relative to the longitudinal axis of the housing opposite to the direction of rotation of the expander. Offsetting the transverse axis of the block may allow the expander blocks to be inserted deeper into each other, thereby allowing the expander blocks to have increased exposure and/or a lower coverage-to-exposure ratio.

In some embodiments, the transverse axis of the block may be offset relative to the longitudinal axis of the expander by a percentage of the offset, which is the length of the offset relative to the diameter of the body. In some embodiments, the percentage offset may be in a range having an upper value, a lower value, or an upper and lower value, including any of 1%, 2.5%, 5%, 7.5%, 10%, 12.5% , 15%, 20%, 25% or any value in between. For example, the percentage offset may be greater than 1%. In another example, the percentage offset may be less than 25%. In yet other examples, the percentage offset may be any value in the range of 1% to 25%. In some implementations, it may be critical that the offset percentage be greater than 1% to increase exposure and/or decrease coverage-to-exposure ratio. In some embodiments, each expander block may have the same percentage of offset. In some embodiments, different expander blocks may have different offset percentages.

In some embodiments, the expander may include one or more secondary flow tubes. Secondary flow pipes may be located in the outer part of the housing between two circumferentially adjacent expander blocks. The housing may include an external space defined by a front wall of the first expander unit, a rear wall of the second expander unit, and an interior wall of the housing when the expander is in a retracted configuration. The flow pipe may be located in the external space and extend along the length of the expander blocks. Adding a flow pipe to the external space can increase the flow area through which fluid flows. This may increase the volumetric flow rate of the fluid for a given fluid pressure. This may make it possible to use a variety of downhole tools in conjunction with the reamer, thereby increasing the versatility of the reamer.

In some embodiments, a resilient member may be positioned around one or more secondary flow tubes to provide a resilient force to counteract the engagement force from the piston. Thus, when the hydraulic pressure presses on the piston, the piston presses on the expander blocks with an interlocking force, thereby causing them to move in the longitudinal direction. This engagement force is counteracted by the elastic force of the elastic elements. Thus, when the engagement force exceeds the elastic force, the expander blocks are pressed in the longitudinal direction. When the expander blocks move longitudinally, guides in the housing bore guide the expander blocks radially outward.

In some embodiments, the elastic element is a coil spring wound around the secondary flow tubes. In some embodiments, each secondary flow tube includes a resilient element. In some embodiments, not all secondary flow tubes include a resilient element. For example, in some embodiments, one or two (of three) secondary flow tubes may include a resilient element.

Drilling fluid flowing through the body can be directed into the flow pipe and secondary flow pipes using a flow diverter. The flow diverter can direct the flow into the flow pipes. For example, the flow diverter may include a primary port. The primary port may be in fluid communication with the primary flow pipe. In some examples, the flow diverter may include one or more secondary ports in fluid communication with the secondary flow pipes. Thus, as fluid flows through the housing, the flow diverter can divert flow into the primary flow pipe through the primary port and into the secondary flow pipes through the secondary ports.

In some embodiments, the uphole end of the flow diverter extends upstream of the wellbore. This may enable the flow diverter to have a reduced flow deflection angle. A small flow deflection angle can reduce wear on the flow diverter due to high-speed fluid flow and particles in the fluid flow. In some embodiments, the flow deflection angle may be in a range having an upper value, a lower value, or an upper and lower value, including any of 0.5°, 1.0°, 1.5°, 2.0°, 2. 5°, 3.0°, 3.5°, 4.0º, 4.5º, 5.0º, 6.0º, 7.0º, 8.0º, 9.0º, 10.0º or any value in between. For example, the flow deflection angle may be more than 0.5º. In another example, the flow deflection angle may be less than 10.0º. In still other examples, the flow deflection angle may be any value in the range of 0.5° to 10.0°. In some embodiments, it may be critical that the flow deflection angle be less than 2.0º to reduce wear on the flow diverter.

In some embodiments, the flow diverter extends beyond the uphole end of the reamer housing. Thus, the flow diverter may extend into the downhole end of a tubular member, sub, downhole tool, or other housing connected to the uphole end of the reamer housing.

In some embodiments, the expander blocks may be located in the same longitudinal location on the expander body. This may reduce the length of the extender. In some embodiments, the expander blocks may be longitudinally offset. In other words, the downhole end of the first reamer block may be located uphole from the uphole end of the second reamer block, and the downhole end of the second reamer block may be located upstream from the uphole end of the second reamer block. along the wellbore of the end of the third expander block. In this embodiment, the central flow pipe may be removed and the expander blocks may extend through the interior of the housing such that the interior wall is positioned behind the longitudinal axis of the housing. This can further increase the expander's exposure. Fluid may flow through the expander through secondary flow pipes in the open space between circumferentially adjacent expander blocks.

With reference to the figures below, FIG. 1 illustrates one example of a drilling system 100 for drilling into an earth formation 101 to form a wellbore 102. The drilling system 100 includes a drilling rig 103 used to rotate a drilling tool assembly 104 that extends down into the wellbore 102 . The drilling tool assembly 104 may include a drill string 105, a bottom hole assembly (BHA) 106, and a bit 110 attached to a downhole end of the drill string 105.

Drill string 105 may include multiple drill pipe joints 108 connected end-to-end by tool joints 109. Drill string 105 transmits drilling fluid through a central channel and transmits torque from drilling rig 103 to BHA 106. In some embodiments, drill string 105 further includes additional components such as subs, stubs, etc. Drill pipe 108 provides a hydraulic passage through which drilling fluid is pumped from the surface. Drilling fluid is discharged through nozzles, nozzles, or other openings of a selected size in the bit 110 for the purposes of cooling the bit 110 and cutting structures thereon, as well as for transporting cuttings from the wellbore 102 as it is drilled.

The BHA 106 may include a bit 110 or other components. The exemplary BHA 106 may include additional or different components (eg, coupled between the drill string 105 and the bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement while drilling (MWD) tools, logging while drilling (LWD) tools, downhole motors, expandable reamers, sectional cutters, hydraulic release devices, drill jars, vibrating or damping tools, other components or combinations of the above. The BHA 106 may additionally include a rotary steerable system (RSS). The RSS may include directional drilling tools that change the direction of the bit 110 and thus the trajectory of the wellbore. At least a portion of the RSS may maintain a geostationary position relative to an absolute reference frame, such as gravity, magnetic north, and/or true north. Using measurements obtained from the geostationary position, the RSS can locate the bit 110, change the course of the bit 110, and direct the directional drilling tools along a predetermined path.

In general, the drilling system 100 may include other drilling components and accessories, such as special valves (eg, kelly check valves, blowout preventers, and relief valves). Additional components included in the drilling system 100 may be considered part of the drilling tool assembly 104, the drill string 105, or the BHA 106 depending on their location in the drilling system 100.

The bit 110 in the BHA 106 may be any type of bit suitable for grinding downhole materials. For example, the bit 110 may be a drill bit suitable for drilling into the earth formation 101. Exemplary types of drill bits used for drilling into earth formations are pressed polycrystalline diamond bits or carbide blade bits. In other embodiments, the bit 110 may be a cutter or cutter used to remove metal, composite, elastomer, other downhole materials, or combinations thereof. For example, bit 110 may be used with a whipstock to mill casing 107 surrounding wellbore 102. The bit 110 may also be a loosening cutter used to mill tools, plugs, cement, other materials within the wellbore 102, or combinations thereof. Metal filings or other metal shavings generated by the cutter can rise to the surface or can, if necessary, fall deeper into the hole.

In fig. 2-1 is a perspective view of expander 212 in an expanded configuration in accordance with at least one embodiment of the present invention. The reamer 212 includes a housing 214. The housing 214 includes a plurality of openings 215. The reamer block 216 extends from each opening 215. The reamer block 216 includes a plurality of cutting elements 217. Thus, when the reamer 212 rotates, the cutting elements 217 can crush the wall of the wellbore, thus expanding the diameter of the wellbore.

In fig. 2-2 is a cross-sectional view of the expander 212 shown in FIG. 2-1, in a retracted configuration in accordance with at least one embodiment of the present invention. In the retracted configuration, the reamer block 216 is retracted under the outer surface 218 of the housing 214. In other words, the radial perimeter 220 of the reamer block 216 is located radially inward to the outer surface 218 of the housing 215. Thus, the reamer 212 in the retracted position cannot cut the formation or casing or engage them, for example, when the reamer 212 is lowered into the wellbore.

The expander 212 includes a flow pipe 222 that may extend through the center of an interior portion 224 of the housing 214. The flow pipe 222 may extend through a longitudinal axis 223 of the housing 214. The flow of a fluid, such as drilling fluid, flows through the flow pipe from left to right in the illustrated embodiment. Fluid flow may enter the piston chamber 225. The pressure difference between the piston chamber 225 and the outer portion 226 of the housing 214 may apply an expansion force to the piston 228 in the piston chamber 225. The piston 228 may apply an expansion force to the bottom plate 229, which may transmit the expansion force to reamer block 216, thereby pushing reamer block 216 higher up the wellbore. The elastic element 230 applies an elastic force to the top plate 231. The top plate 231 transmits an elastic force to the reamer block 216, thereby pushing the reamer block 216 down the wellbore. In the retracted configuration shown in FIG. 2-2, the elastic force is greater than the expansion force, and therefore the expander block 216 is located in the wellbore in a retracted configuration.

In fig. 2-3 is a cross-sectional view of the expander 212 shown in FIG. 2-1, in an expanded configuration in accordance with at least one embodiment of the present invention. In an expanded configuration, the radial perimeter 220 of the reamer block 216 extends beyond the outer surface 218 of the housing 214. Thus, as the reamer 212 rotates, the cutting elements on the reamer block 216 can engage and crush the formation, thereby increasing the diameter of the wellbore.

To move between the stowed configuration shown in FIG. 2-2 and the expanded configuration shown in FIG. 2-3, the pressure difference between the piston chamber 225 and the outer portion 226 of the housing 214 is increased, for example, by increasing the volumetric flow rate of fluid through the flow tube 222. This will increase the expansion force on the expander block 216 due to the piston 228 and the bottom plate 229. When the force expansion becomes greater than the elastic force on the top plate 231 created by the elastic element 230, the expander block 216 can move higher in the wellbore relative to the housing. One or more guides (eg, racks) in the housing (not shown in FIGS. 2-3) may guide the reamer block 216 radially outward as the reamer block 216 moves longitudinally up the wellbore.

In fig. 2-4 are cross-sectional views of the expander 212 shown in FIG. 2-3, in a retracted configuration in accordance with at least one embodiment of the present invention. In the illustrated embodiment, expander 212 includes three expander blocks (collectively designated 216), a first expander block 216-1, a second expander block 216-2 circumferentially adjacent in the direction of rotation 237 to the first expander block 216-1, and a third block expander 216-3, circumferentially adjacent in the direction of rotation 237 with the second expander block 216-2 and circumferentially adjacent in the opposite direction of rotation 237 with the first expander block 216-1. The expander blocks 216 have a radial perimeter 220, a front wall (collectively designated 232), a rear wall (collectively designated 234), and an inner wall (collectively designated 236). The front wall 232 is the side wall of the reamer block 216 that first contacts the wellbore formation during rotation of the reamer 212. In other words, the front wall 232 is the side wall of the reamer block facing the direction of rotation 237 (clockwise in the view shown). reamer 212. Back wall 234 is the side wall of reamer block 216 that last contacts the wellbore formation (if at all) during rotation of the wellbore. In other words, the rear wall 234 is the side wall of the expander block 216 facing away from the direction of rotation 237.

The rear wall 234 includes a recess (collectively designated 238). The recess 238 is located at the rear inner edge 239 of the rear wall 234. In other words, the recess 238 is located at the intersection between the rear wall 234 and the inner wall 236. Thus, the inner wall 236 can be considered to include a recess 238. The recess 238 is shaped such that to receive a portion of the front wall 232 of the circumferentially adjacent expander block 216. In the retracted configuration shown in FIG. 2-4, the radial perimeter 220 of the expander block 216 is located within the outer surface 218 of the housing 214. Thus, the first recess 238-1 receives the leading inner edge 240 of the third front wall 232-3 such that the leading inner edge 240 of the third front wall 232- 3 is inserted (eg, placed) into the first recess 238-1. This recess 238-1 may allow the third expander block 216-3 to be retracted further into the interior 224 of the housing 214. As discussed below, nested arrangements of the expander blocks 216 may increase the exposure of the third expander block 216-3 and reduce the coverage-to-exposure ratio.

Each of the first expander block 216-1, the second expander block 216-2, and the third expander block 216-3 includes a recess 238. In some embodiments, the recess 238 may be a pocket, an opening, a recess, a receptacle, a notch, any other section, and the same. combinations. Thus, all expander blocks 216 are inserted into each other. In other words, the front wall 232 is inserted (eg, placed) into the recess 238 of the circumferentially adjacent (in the direction of rotation 237) expander block 216. Thus, the second expander block 216-2 includes a second recess 238-2 in the second rear wall 234-2, and the first front wall 232-1 is inserted (eg, positioned) into the second recess 238-2. Likewise, the third expander block 216-3 includes a third recess 238-3 in the third rear wall 234-3, and a second front wall 232-2 is inserted (eg, positioned) into the third recess 238-3. The first expander block 216-3 includes a first recess 238-1 in the first rear wall 234-1, and a third front wall 232-3 is inserted (e.g., positioned, at least partially enclosed, the front inner edge 240 mating with the recess 238) into the third recess 238-3.

In the illustrated embodiment, the inner wall 236 of the expander blocks is not flat. For example, the inner wall 236 partially complements the flow tube 222. The flow tube 222 is cylindrical, meaning that it has a circular cross-sectional shape. The inner wall 236 has a partially cylindrical surface, which means that the inner wall 236 has a partially circular cross-sectional shape. Thus, the inner wall 236 at least partially complements the flow pipe 222. Thus, in the retracted position shown in FIG. 2-4, the inner wall of the expander block contacts or covers the flow pipe section in the retracted position. In the embodiment shown in FIG. 2-4, the inner wall is concave and the inner walls of all expander blocks surround (eg, enclose, contact, cover) all or approximately (eg, almost) the entire outer circumference of the flow tube. In some embodiments, the inner wall 236 may be flat, and the inner wall 236 may extend at an angle from the rear wall 234 to the front wall 232.

The circular portion of the inner wall 236 complements the flow pipe for the wall arc corner 241. In some embodiments, wall arc angle 241 may be within a range having an upper value, a lower value, or an upper and lower value, including any of 45°, 60°, 75°, 80°, 85°, 90°, 95°, 100°, 105°, 120° or any values in between. For example, the wall arc angle 241 may be greater than 45°. In another example, the wall arc angle 241 may be less than 120°. In yet other examples, the wall arc angle 241 may be any value in the range from 45° to 120°. In some embodiments, it may be critical that the wall arc angle 241 be greater than 90° to insert the inner wall toward the flow tube, increasing exposure, and decreasing the coverage-to-exposure ratio.

The recess 238 is recessed 233 deep into the expander block 216 housing. This can be visualized as the extent that the front wall 232 of the circumferentially adjacent expander block 216 extends into the housing of the expander block 216. The depth 233 of the recess may be a percentage of the recess from the width of the expander block 216. In some embodiments, the percentage of depression may be greater than 0%, greater than 5%, greater than 10%, greater than 15%, greater than 20%, greater than 25%, greater than 30%, greater than 35%, greater than 40%, greater than 45%, greater than 50 % or any value in between. In some embodiments, it may be critical that the percentage of recess is greater than 10% to allow circumferentially adjacent expander blocks 216 to fit into each other.

In the embodiment shown in FIG. 2-4, a line 235 drawn through the longitudinal axis 223 of the housing 214 and perpendicular to the longitudinal axis 223 contacts two or more expander blocks 216 in a retracted configuration. In the embodiment shown, line 235 contacts all three expander blocks 216. The line contacts the first expander block 216-1 in the housing of the first expander block 216-1, the second expander block 216-2 on the inner edge of the second front wall 232-2, and the third expander block 216-3 in the third recess 238-3 of the third rear wall 234 -3. This is a measure of how deeply the expander blocks 216 are recessed into the interior 224 of the housing 214. In some embodiments, the expander 212 may contain any number of expander blocks 216, including 2, 3, 4, 5, 6, 7, 8, 9, 10, or more expander blocks.

In fig. 2-5 are cross-sectional views of the expander 212 shown in FIG. 2-1, in an expanded configuration in accordance with at least one embodiment of the present invention. In an expanded configuration, the radial perimeter 220 of the expander block 216 extends beyond the outer surface 218 of the housing 214. The height to which the radial perimeter 220 extends beyond the outer surface 218 is the exposure 242.

The expander has a diameter of 243 in the retracted position and a diameter of 244 in the extended position. The retracted diameter 243 is the retracted diameter of the retracted circle 245 described around the housing 214. The expanded diameter is the expanded diameter of the expanded circle 246 described around the expander blocks 216 in the expanded configuration. Thus, exposure 242 is half the difference between the diameter in the expanded position and the diameter in the retracted position or the difference between the radius of the circle 246 in the expanded position and the radius 245 in the retracted position.

The expansion ratio is the ratio between the diameter in the expanded position and the diameter in the retracted position. In some embodiments, the expansion ratio may be in a range having an upper value, a lower value, or an upper and lower value, including any of the values 2.5, 2.4, 2.3, 2.2, 2.1, 2.0 , 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1 or anything in between. For example, the expansion ratio may be greater than 1.1. In another example, the expansion ratio may be less than 2.5. In still other examples, the expansion ratio may be any value in the range of 1.1 to 2.5. In some embodiments, it may be critical that the expansion ratio be greater than 2.0 to sufficiently expand the wellbore diameter.

During rotation, the radial perimeter 220 contacts the formation (eg, the wall of the wellbore). This applies an expanding force to the expander block 216 opposite to the direction of rotation 237. The expanding force is counteracted by the side wall of the opening 215 in the housing 214, which contacts the rear wall 234 (eg, where the recess 238 is located). As the expander block 216 extends beyond the outer surface 218 of the housing 214, the expansion force may cause the expander block 216 to rotate. This may cause the front wall 232 to be pushed against the side wall of the opening 215 in the housing 214. The length of contact between the front wall 232 and the housing 214 is the span 248. The torque from the expanding force near the leading edge 240 of the expander block 216 may be greater than the average point of the rear wall 234 of the expander block 216. Accordingly, the length of the front wall 232 may be greater than the length of the rear wall 234 of the expander block 216.

Coverage to Exposure Ratio 248 242 is the coverage to exposure ratio. The coverage to exposure ratio is a measure of the maximum expansion of the expander. In some embodiments, the coverage-to-exposure ratio may be in a range having an upper value, a lower value, or an upper and lower value, including any of the values 0.50, 0.60, 0.70, 0.75, 0.80, 0 .85, 0.90, 0.95, 1.00, 1.05, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8 , 1.9, 2.0 or any value in between. For example, the coverage-to-exposure ratio may be greater than 0.50. In another example, the coverage to exposure ratio may be less than 2.00. In still other examples, the coverage-to-exposure ratio may be any value in the range of 0.50 to 2.00. In some embodiments, it may be critical that the sweep to exposure ratio be less than 1.00 to sufficiently increase the wellbore diameter. A lower sweep-to-exposure ratio is an indication that the reamer can have a greater increase in borehole diameter.

In some embodiments, exposure 242 may be in a range having a high value, a low value, or a high and low value, including any of 1.5 inches (3.8 cm), 1.6 inches (4.1 cm), 1 .7" (4.3 cm), 1.8" (4.6 cm), 1.9" (4.8 cm), 2.0" (5.1 cm), 2.1" (5. 3 cm), 2.2 inches (5.6 cm), 2.3 inches (5.8 cm), 2.4 inches (6.1 cm), 2.5 inches (6.4 cm), 3, 0" (7.62cm), 4.0" (10.16cm), 5.0" (12.7cm), 6.0" (15.24cm), 8.0" (20.32cm) cm), 10.0" (25.40 cm), 12.0" (30.48 cm), 15.0" (38.10 cm), 18.5" (46.99 cm) or any value in between . For example, exposure 242 may be over 1.5 inches (3.8 cm). In another example, exposure 242 may be less than 18.5 inches (46.99 cm). In yet other examples, exposure 242 may be any value in the range from 1.5 inches (3.8 cm) to 18.5 inches (46.99 cm). In some embodiments, it may be critical that the exposure 242 be greater than 2.0 inches (5.1 cm) to sufficiently increase the wellbore diameter.

In some embodiments, coverage 248 may be in a range having an upper value, a lower value, or an upper and lower value, including any of 1.0 inches (2.5 cm), 1.5 inches (3.8 cm), 1 .6" (4.1 cm), 1.7" (4.3 cm), 1.8" (4.6 cm), 1.9" (4.8 cm), 2.0" (5. 1 cm), 2.1 inches (5.3 cm), 2.2 inches (5.6 cm), 2.3 inches (5.8 cm), 2.4 inches (6.1 cm), 2, 5" (6.4 cm), 3.0" (7.62 cm), 4.0" (10.16 cm), 5.0" (12.7 cm), 6.0" (15. 24 cm), 8.0 inches (20.32 cm), 10.0 inches (25.40 cm) or anything in between. For example, the coverage 248 may be more than 1.0 inches (2.5 cm). In another example, the coverage 248 may be less than 10.0 inches (25.4 cm). In still other examples, coverage 248 may be any value in the range of 1.0 inches (2.5 cm) to 10.0 inches (25.4 cm). In some implementations, it may be critical that the span 248 be greater than 1.8 inches (4.6 cm) to support the expander block. Increased coverage 248 may result in greater stability of the expander block. In addition, the increased reach 248 may increase the strength of the expander, thereby reducing the likelihood of breakage of the expander assembly during expansion operations.

The front wall 232 of the expander block 216 has a front wall height 249, and the rear wall 234 of the expander block has a rear wall height 250. The front wall height 249 is the distance between the radial perimeter 220 and the inner wall 236 along the front wall 232. The rear wall height 250 is the distance between the radial perimeter 220 and the inner wall 236 along the rear wall. In the embodiment shown in FIG. 2-5, the height 249 of the front wall is greater than the height 250 of the rear wall. The ratio of the front wall height to the rear wall height is the wall height ratio. In some embodiments, the wall height ratio may be in a range having an upper value, a lower value, or an upper and lower value, including any of the values 1.0, 1.1, 1.2, 1.3, 1.4, 1, 5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.5, 3.0 or any value in between. For example, the wall height ratio may be greater than 1.0. In another example, the wall height ratio may be less than 3.0. In yet other examples, the wall height ratio may be any value in the range of 1.0 to 3.0. In some embodiments, it may be critical that the wall height ratio be greater than 1.2 to increase the coverage and exposure of the expander block. In addition, a wall height ratio greater than 1.2 can enable circumferentially adjacent expander blocks to be inserted into each other.

In the embodiment shown in FIG. 2-5, the front wall height 249 may be greater than the radius of the housing 214. In other words, the front wall height 249 may be greater than half the retracted diameter of the circle 245 in the retracted position. The front wall 232 has a height to diameter ratio in the retracted position. In some embodiments, the height to diameter ratio in the retracted position may be in a range having an upper value, a lower value, or an upper and lower value, including any of 0.45, 0.5, 0.55, 0.6, 0, 65, 0.70, 0.75 or any value in between. For example, the height to diameter ratio in the retracted position may be greater than 0.45. In another example, the height to diameter ratio in the retracted position may be less than 0.75. In yet other examples, the height to diameter ratio in the retracted position may be any value in the range of 0.45 to 0.75. In some embodiments, it may be critical that the height-to-diameter ratio in the retracted position be greater than 0.5 to increase exposure and reduce coverage-to-exposure ratio.

The expander block 216 has a spreader block transverse axis 252 that is an axis between the radial perimeter 220 and the inner wall 236. In the embodiment shown, the expander block transverse axis 252 of the expander blocks 216 extends through the longitudinal axis 223 of the housing 214. In some embodiments, the expander block transverse axis 252 of the expander blocks 216 extends through the longitudinal axis 223 of the housing 214. In some embodiments, the expander block transverse axis 252 of the expander blocks 216 extends through the longitudinal axis 223 of the housing 214. the expander block of one or more expander blocks 216 may be offset relative to the longitudinal axis 223 of the housing 214. In some embodiments, the transverse axis 252 of the expander block of the one or more expander blocks 216 may be offset relative to the longitudinal axis 223 of the housing in the direction of rotation 237 of the expander 212. In some In embodiments, the expander block transverse axis 252 of one or more expander blocks 216 may be offset relative to the longitudinal axis 223 of the housing 214 opposite to the direction of rotation 237 of the expander 212. Offset of the expander block transverse axis 252 may allow the expander blocks 216 to be inserted deeper into each other, thereby allowing the blocks 216 expander to have increased exposure 242 and/or a lower coverage to exposure ratio.

In some embodiments, the transverse axis 252 of the expander assembly may be offset relative to the longitudinal axis of the expander by an offset percentage, which is the length of the offset relative to the diameter of the housing 214. In some embodiments, the offset percentage may be in a range having an upper value, a lower value, or upper and lower values, including any of 1%, 2.5%, 5%, 7.5%, 10%, 12.5%, 15%, 20%, 25%, or any value in between. For example, the percentage offset may be greater than 1%. In another example, the percentage offset may be less than 25%. In yet other examples, the percentage offset may be any value in the range of 1% to 25%. In some implementations, it may be critical that the offset percentage be greater than 1% to increase exposure 242 and/or decrease the coverage-to-exposure ratio.

In fig. 3 is a perspective view of expander block 316 as viewed on interior surface 336, in accordance with at least one embodiment of the present invention. The expander block 316 includes a front wall 332 and a rear wall 334. The rear wall 334 includes a recess 338 into which the front wall 332 of the circumferentially adjacent expander block 316 can be inserted or positioned. In some embodiments, the front wall 332 and/or the rear wall 334 may include one or more slats that engage an opening in the housing to help guide the expander block 316 during expansion and support the expander block 316 during operation. In the view shown, the inner surface 336 includes a curved portion 354 and a recess portion 356, wherein the recess portion 356 is part of the recess 338. In the view shown, the recess 338 extends toward the top surface 358 of the expander 316. The recess 338 does not extend the entire distance to the bottom surface 360 of the expander 316. In some embodiments, the recess 338 may extend the entire distance between the top surface 358 and the bottom surface 360. In other embodiments, the recess 338 begins and ends between the top surface 358 and the bottom surface. When the recess 338 begins between the top surface 358 and the bottom surface 360, the top wall 320 can extend the entire distance to the top surface 358, thereby allowing more cutting elements to be placed on the top wall 320.

In fig. 4-1 is a cross-sectional view of the dilator 412 in a retracted configuration in accordance with at least one embodiment of the present invention; Expander 412 contains a plurality of expander blocks (collectively designated 416). A primary flow pipe 422 extends through the center of the housing 414. A plurality of secondary flow pipes (collectively designated 462) extend through the interior housing portion 424 in a radial direction outward from the primary flow pipe 422. The secondary flow pipes 462 are located between circumferentially adjacent expander blocks 416 and adjacent the inner wall of the housing 414. In other words, the first secondary flow pipe 462-1 is located between the first front wall 432-1 of the first expander block 416-1 and the second rear wall 434-2 of the second expander block. The second secondary flow pipe 462-2 is located between the second front wall 432-2 of the second expander block 416-2 and the third rear wall 434-3 of the third expander block 416-3. The third secondary flow pipe 462-3 is located between the third front wall 432-3 of the third expander block 416-3 and the first rear wall 434-1 of the first expander block 416-1. Secondary flow pipes 462 can allow a higher volumetric flow rate of drilling fluid to pass through the body 414 at the same drilling pressure. This may allow more downhole tools to be used while the reamer 412 is in use, thereby increasing the versatility of the reamer 412.

In fig. 4-2 is a longitudinal sectional view of the expander 412 shown in FIG. 4-1, in a retracted configuration in accordance with at least one embodiment of the present invention. In the illustrated embodiment, the resilient member 430 is shown to be positioned around the secondary flow pipe 462. The resilient member 430 is pushed against the top plate 431 to prevent expansion of the expander block 416. In the illustrated embodiment, three resilient members 430 are arranged around three secondary flow tubes 462. This can provide sufficient resilient force to be applied to the top plate 431. The resilient members 430 shown are coil springs.

The flow diverter 464 directs flow into the primary flow pipe 422 and the secondary flow pipes 462. The uphole end of the flow diverter 464 extends up the wellbore from the extension block 416. This may allow the flow diverter 464 to have a reduced flow deflection angle 466. A small flow deflection angle 466 can reduce wear on the flow diverter 464 due to high velocity fluid flow and particles in the fluid flow. In some embodiments, flow deflection angle 466 may be within a range having an upper value, a lower value, or an upper and lower value, including any of 0.5°, 1.0°, 1.5°, 2.0°, 2 .5°, 3.0°, 3.5°, 4.0º, 4.5º, 5.0º, 6.0º, 7.0º, 8.0º, 9.0º, 10.0º or any value in between. For example, the flow deflection angle 466 may be greater than 0.5º. In another example, the flow deflection angle 466 may be less than 10.0º. In yet other examples, flow deflection angle 466 may be any value in the range of 0.5° to 10.0°. In some embodiments, it may be critical that the flow deflection angle 466 be less than 2.0º to reduce wear on the flow diverter. In the illustrated embodiment, flow diverter 464 extends beyond the uphole end of expander 412. Thus, flow diverter 464 may extend into the downhole end of a tubular member, sub, downhole tool, or other housing connected to the uphole end. wells with the end of the expander housing.

In fig. 5 is a cross-sectional view of the expander 512 in a retracted configuration in accordance with at least one embodiment of the present invention. In the illustrated embodiment, the expander blocks (collectively designated 516) are offset in the longitudinal direction. In other words, the downhole end of the first reamer block 516-1 is located upstream of the uphole end of the second reamer block 516-2, and the downhole end of the second reamer block 516-2 may be located uphole from the uphole end of the third expander block 516-3. In this embodiment, the primary flow tube (e.g., primary flow tube 422 in FIG. 4-1) may be removed and expander blocks 516 may extend through the interior of the housing such that one or more interior walls extend radially through the longitudinal axle 523 housing. This can further increase the expander's exposure. Fluid may flow through the expander through secondary flow tubes (eg, secondary flow tubes 462 in FIG. 4-1) between circumferentially adjacent and longitudinally offset expander blocks 516.

Embodiments of a high ratio reamer have been generally described with reference to wellbore drilling operations; The high ratio reamer described herein may be used in applications other than wellbore drilling. In other embodiments, a high ratio reagent in accordance with the present invention may be used outside a wellbore or other downhole environment used for exploration or production of natural resources. For example, the high ratio reamer of this invention may be used in a wellbore used to accommodate power lines. Accordingly, the terms “wellbore,” “well,” and the like should not be construed as limiting the tools, systems, arrangements, or methods of the present invention to any particular industry, area, or environment.

This document describes one or more specific embodiments of the present invention. These described embodiments are examples of currently disclosed techniques. Additionally, in an attempt to provide a concise description of these embodiments, not all features of the actual embodiment may be described in the description. It should be appreciated that in the development of any such actual implementation, as in any engineering or development work, numerous implementation-specific decisions will be made to achieve the developers' specific objectives, such as satisfying system-related and business-related constraints , which will vary depending on the implementation option. Moreover, it should be understood that such development work may be complex and time consuming, but will nevertheless be common practice in the design, manufacture and production of those skilled in the art taking advantage of the present invention.

In addition, it should be understood that references to “one embodiment” or “embodiment” of the present invention are not intended to be construed as excluding the existence of additional embodiments that also include the present features. For example, any element described in connection with an embodiment herein may be combined with any element of any other embodiment described herein. Numbers, percentages, ratios or other values stated herein are intended to include this value as well as other values that are "about" or "about" close to the stated value as will be understood by one skilled in the art covered by the embodiments of the present invention. Therefore, the stated value should be interpreted broadly enough to cover values that are at least sufficiently close to the stated value to perform the required function or achieve the required result. Stated values include at least the expected variations in a suitable manufacturing or manufacturing process and include values that are within 5%, within 1%, within 0.1% or within 0.01% of the stated value.

In view of the present invention, one skilled in the art will understand that equivalent constructions do not depart from the spirit and scope of the present invention, and that various changes, substitutions and amendments may be made herein without departing from the spirit and scope of the present invention. Equivalent designs, including functional "means and function" claims, are intended to cover the designs described herein as performing the stated function, including both design equivalents that operate in the same manner and equivalent designs that provide that function. same function. Applicant expressly intends not to refer to “means and function” or other functional requirements for any claim, except for claims in which the words “means for...” appear together with a related function. Every addition, deletion, and modification of embodiments that falls within the meaning and scope of the claims shall be covered by the claims.

The terms "about", "about" and "substantially" as used herein represent an amount close to the specified amount that is within standard manufacturing or processing tolerances or that still performs the required function or achieves the desired result. For example, the terms "about", "about" and "substantially" can refer to an amount that is less than 5%, less than 1%, less than 0.1% and less than 0.01% of declared quantity. In addition, it should be understood that any directions or coordinate systems in the foregoing description are simply relative directions or displacements. For example, any mention of the words "up" and "down" or "above" or "below" simply describes the relative position or movement of related elements.

The present invention may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments should be considered illustrative and not restrictive. Therefore, the scope of the present invention is indicated by the appended claims and not by the foregoing description. Modifications that fall within the meaning and range of equivalence of the claims must be included within their scope.

Claims (31)

1. Expander containing: a housing comprising a flow pipe extending through the center of an interior portion of the housing and a plurality of openings from an interior portion of the housing to an exterior portion of the housing; a first expander block in an interior portion of the housing, the first expander block comprising a first front wall, a first inner wall, and a first rear wall, wherein the first rear wall and the first inner wall comprise a first recess; a second expander block in the interior of the housing, the second expander block comprising a second front wall, a second inner wall, and a second rear wall, the first front wall being inserted into the second recess in a retracted configuration; And a third expander block in an interior portion of the housing, the third expander block comprising a third front wall, a third interior wall, and a third rear wall, the third rear wall and the third interior wall comprising a third recess, and the second front wall being inserted into the third recess in a retracted configuration, and a third front wall is inserted into the first recess in a retracted configuration; wherein a line drawn perpendicular to the longitudinal axis of the housing, which extends along the longitudinal axis, intersects, in order across the expander, the first expander unit, the flow pipe, the second front wall of the second expander unit, the third rear wall of the third expander unit in a retracted configuration, and the housing. 2. The expander according to claim 1, in which the first front wall has a height that is greater than the height of the first rear wall. 3. The expander according to claim 1, wherein the first inner wall of the first expander block and the second inner wall of the second expander block are concave. 4. Expander according to claim 1, in which the flow pipe is coaxial with the longitudinal axis of the housing. 5. The expander of claim 1, wherein the first inner wall of the first expander block and the second inner wall of the second expander block are shaped to complement the flow pipe. 6. The expander according to claim 5, wherein the first inner wall is shaped to complement the flow pipe for a wall arc angle greater than 90°. 7. The expander according to claim 1, in which the first expander block is located upstream from the second expander block, and the second expander block is located upstream from the third expander block. 8. The expander of claim 1, having a coverage to exposure ratio of less than 1.00. 9. Expander containing: a body with a body around a longitudinal axis, the body forming an internal channel; a flow pipe passing through the internal channel of the housing along the longitudinal axis of the housing; a plurality of expander blocks arranged radially around the flow pipe and configured to expand and retract relative to the housing; And a secondary flow pipe extending within the internal bore of the housing and radially outward from the flow pipe, the secondary flow pipe being located between two expander blocks of the plurality of expander blocks in a retracted configuration. 10. The expander of claim 9, comprising a flow diverter, the flow diverter comprising a primary port in fluid communication with the flow pipe and a secondary port in fluid communication with the secondary flow pipe. 11. The expander of claim 9, wherein the secondary flow pipe extends along the length of the plurality of expander blocks. 12. The expander according to claim 9, containing an elastic element located around the secondary flow pipe. 13. Expander containing: a housing comprising an opening from an interior portion of the housing to an exterior portion of the housing; expander unit containing: - front wall, where the height of the front wall exceeds the radius of the body; - back wall; And - radial perimeter; wherein the expander block is configured into a retracted configuration and an expanded configuration, wherein when the expander block is in a retracted configuration, the radial perimeter is located in a radial direction inward from the outer surface of the housing, and when the expander block is in an expanded configuration, the radial perimeter is located in radially outward from the outer surface of the housing, wherein the exposure is the distance from the outer surface of the housing, the coverage is the length of contact of the front wall with the housing, and the ratio of coverage to exposure is less than 1.00. 14. The expander according to claim 13, wherein the expansion ratio is greater than 2.00. 15. Expander according to claim 13, in which the height of the front wall exceeds the height of the rear wall. 16. The expander of claim 13, wherein the expander block is a first expander block, and the front wall is a first front wall, wherein the first expander block includes a recess in the rear wall of the first expander block, and there is a second expander block comprising a second front wall. wall, while the second front wall is inserted into the recess.