Reamer with polycrystalline diamond compact inserts
View Patent ↗Reamers for use in core-sample drilling include PDC inserts. Such reamers with PDC inserts may be used to maintain borehole diameters, reduce deviation, and/or stabilize drill strings used in core sample drilling. The PDC inserts may be of different sizes and shapes and may be arranged around the reamers in various ways.
1. A reaming shell for use in core sample drilling comprising:
a cylindrical, steel body used in core sample drilling, the body including:
an upper connector configured to couple an upper end of the body to another drilling component,
a lower connector configured to couple a lower end of the body to an additional drilling component, and
a length extending from the upper connector to the lower connector, the length having a substantially uniform outer diameter and a consistent outer surface; and
a plurality of polycrystalline diamond compact (PDC) inserts secured directly to the body and arranged around the body;
wherein the PDC inserts maintain a diameter of a borehole previously drilled.
2. The reaming shell as recited in claim 1 , wherein the PDC inserts are mechanically attached to the body.
3. The reaming shell as recited in claim 2 , wherein the PDC inserts are threadably attached to the body.
4. The reaming shell as recited in claim 1 , wherein the body includes a plurality of recesses defined therein to receive at least a portion of the PDC inserts.
5. The reaming shell as recited in claim 1 , wherein one or more of the upper connector and the lower connector is a threaded connector.
6. The reaming shell as recited in claim 1 , wherein one of the PDC inserts differs from another of the PDC inserts in size.
7. The reaming shell as recited in claim 1 , wherein each of the PDC inserts includes a polycrystalline diamond compact layer bonded to a backing substrate.
8. The reaming shell as recited in claim 7 , wherein the backing substrate comprises steel.
9. The reaming shell as recited in claim 1 , wherein one or more of the PDC inserts have a domed outer surface.
10. A core drilling system, comprising
a drilling component including:
a cylindrical, steel body configured to be used in core sample drilling, the body having a substantially uniform outer diameter and a consistent outer surface,
a connector configured to couple the body to another drilling component;
a first plurality of polycrystalline diamond compact (PDC) inserts attached directly to the body and arranged around the body at a first distance from the connector,
at least a second plurality of PDC inserts attached directly to the body and arranged around the body at a second distance from the connector; and
a core drill bit.
11. The system as recited in claim 10 , wherein the drilling component is a reamer.
12. The system as recited in claim 11 , wherein the PDC inserts are mechanically attached to the body.
13. The system as recited in claim 11 , wherein the reamer is disposed in a core barrel assembly.
14. The system as recited in claim 11 , wherein one of the PDC inserts differs in shape from another of the PDC inserts.
15. The system as recited in claim 11 , wherein each of the PDC inserts includes a polycrystalline diamond compact layer bonded to a backing substrate.
16. The system as recited in claim 15 , wherein the backing substrate comprises steel.
17. The system as recited in claim 11 , wherein one or more of the PDC inserts has a domed outer surface.
18. A drilling method comprising:
securing an upper connector of a reamer to a first drill string component of a drill string;
securing a lower end of the reamer to a second drill string component of the drill string, wherein a cylindrical, steel body with a substantially uniform outer diameter and a consistent outer surface extends from the upper connector to the lower connector;
securing a core drill bit to an end of the drill string;
advancing the drill string into an earthen formation whereby the core drill bit drills a borehole with a diameter, and whereby a plurality of polycrystalline diamond compact (PDC) inserts arranged around, and fastened directly to the body of the reamer, maintain the diameter of the borehole drilled by the core drill bit; and
retrieving a core sample.
19. The method as recited in claim 18 , further comprising replacing at least one of the PDC inserts with a new PDC insert.
20. The method as recited in claim 18 , further comprising unscrewing the at least one PDC insert from the body.
21. The method as recited in claim 18 , wherein the drill component is disposed in a core barrel assembly.
22. The method as recited in claim 18 , wherein the PDC inserts comprise a polycrystalline diamond layer bonded to a backing substrate.
23. The method as recited in claim 22 , wherein the backing substrate comprises a ceramic.
24. The method as recited in claim 23 , wherein one or more of the PDC inserts have a domed outer surface.
25. A drilling method comprising:
securing a connector of a steel drilling component to a drill string, the drilling component being cylindrical and having (i) a substantially uniform outer diameter and a consistent outer surface, (ii) a first plurality of polycrystalline diamond compact (PDC) inserts attached to, and arranged around, the outer surface at a first distance from the connector, and (iii) at least a second plurality PDC inserts attached to, and arranged around, the outer surface at a second distance from the connector;
securing a drill bit to an end of the drill string;
advancing the drill string into an earthen formation whereby the drill bit drills a borehole with a diameter, and whereby the first plurality of PDC and the at least a second plurality of PDC inserts maintain the diameter of the borehole drilled by the drill bit;
retrieving a core sample; and
un-securing at least one PDC insert from the drilling component.
26. The method as recited in claim 25 , wherein the drilling component is an adaptor or locking coupling.
27. The method as recited in claim 25 , wherein the drilling component is a reamer.
28. The method as recited in claim 25 , wherein the plurality of PDC inserts are configured to be selectively removable from the drilling component.