ROTARY DRILL BITS AND SYSTEMS FOR INSPECTING ROTARY DRILL BITS

• US 20090320584A1
• Filed: 09/03/2009
• Published: 12/31/2009
• Est. Priority Date: 04/17/2006
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Sullivan, Eric C., Lund, Jeffrey B., Lyons, Nicholas J., Watts, Terry D.
• Granted Patent: US 7,954,380 B2
• Time in Patent Office: Days
• US Class Current: 73/152.58
• CPC Class Codes: G01N 2291/044 Internal reflections (echoes), e.g. on walls or defects
• CPC Class Codes: G01N 2291/045 External reflections, e.g. on reflectors
• CPC Class Codes: G01N 2291/101 one transducer
• CPC Class Codes: G01N 2291/2634 cylindrical from outside
• CPC Class Codes: G01N 2291/2636 cylindrical from inside
• CPC Class Codes: G01N 2291/267 Welds
• CPC Class Codes: G01N 2291/2698 Other discrete objects, e.g. bricks
• CPC Class Codes: G01N 29/04 Analysing solids using acoustic emission techniques G01N29/14
• CPC Class Codes: G01N 29/265 by moving the sensor relative to a stationary material
• CPC Class Codes: G01N 29/27 by moving the material relative to a stationary sensor
• CPC Class Codes: G01N 29/275 by moving both the sensor and the material
• CPC Class Codes: G01N 29/28 providing acoustic coupling , e.g. water impedance matching G10K11/02

Abstract

A method for conducting nondestructive internal inspection of a rotary drill bit used for drilling subterranean formations comprises communicating ultrasonic waves into a drill bit and detecting ultrasonic waves that are reflected by at least a portion of the drill bit. In some embodiments, the waves may be directed into the drill bit from within a longitudinal bore thereof. Reflected waves also may be detected from within the bore. The methods may be used to develop threshold acceptance criteria for classifying drill bits as acceptable or unacceptable to prevent catastrophic failures of drill bits during use. Systems and apparatuses are disclosed for conducting nondestructive ultrasonic inspection of a drill bit used for drilling subterranean formations. The systems and apparatuses may comprise an ultrasonic probe configured for insertion within an internal longitudinal bore of a drill bit. Drill bits are disclosed that are configured to facilitate nondestructive ultrasonic inspection thereof.

Claims

1. A system for ultrasonically inspecting a drill bit for subterranean drilling comprising:

an ultrasonic probe including at least one ultrasonic transducer configured for at least one of emitting ultrasonic waves and detecting ultrasonic waves, the ultrasonic probe being configured for insertion within an internal longitudinal bore of an earth-boring rotary drill bit;

a longitudinal probe-positioning mechanism operably coupled with the ultrasonic probe and configured for changing a longitudinal position of the ultrasonic probe relative to the earth-boring rotary drill bit;

a rotational probe-positioning mechanism operably coupled with the ultrasonic probe and configured for changing a rotational position of the ultrasonic probe relative to the earth-boring rotary drill bit; and

a computer device for receiving data acquired from the ultrasonic probe.

2. The system of claim 1, wherein the rotational probe-positioning mechanism is configured to rotate the rotary drill bit about the ultrasonic probe.

3. The system of claim 2, wherein the rotational probe-positioning mechanism comprises a rotary table configured to support and rotate the rotary drill bit about the ultrasonic probe.

4. The system of claim 3, further comprising a rotary drill bit aligning structure for substantially aligning a longitudinal axis of the internal longitudinal bore of the rotary drill bit with an axis of rotation of the rotary table.

5. The system of claim 1, wherein the rotational probe-positioning mechanism is configured to rotate the ultrasonic probe within the internal longitudinal bore of the rotary drill bit.

6. The system of claim 1, wherein the longitudinal probe-positioning mechanism comprises:

a fixed member disposed outside the longitudinal bore of the rotary drill bit, the fixed member extending generally parallel to the longitudinal axis of the internal longitudinal bore of the rotary drill bit; and

a cantilevered support member moveably coupled to the fixed member, the cantilevered support member comprising;

a first portion movably coupled to the fixed member and extending laterally from the fixed member; and

a second portion extending generally perpendicularly relative to the first portion and having a free end coupled to the Ultrasonic probe.

7. The system of claim 1, further comprising an additional ultrasonic probe including at least one ultrasonic transducer configured for at least one of emitting ultrasonic waves and detecting ultrasonic waves, the additional ultrasonic probe being configured to be positioned on the exterior of the earth-boring rotary drill bit and for communicating ultrasonically with the ultrasonic probe configured for insertion within the internal longitudinal bore of the earth-boring rotary drill bit.

8. An ultrasonic inspection apparatus for inspecting a drill bit for subterranean drilling comprising:

an ultrasonic probe support structure for supporting an ultrasonic probe, the ultrasonic probe support structure comprising a portion thereof configured to be positioned within an internal longitudinal bore of the rotary drill bit;

an ultrasonic probe structurally coupled to the portion of the support structure, the ultrasonic probe configured for positioning within the internal longitudinal bore of the rotary drill bit;

a longitudinal probe-positioning mechanism configured for changing a longitudinal position of the ultrasonic probe relative to the rotary drill bit; and

a rotational probe-positioning mechanism configured for changing a rotational position of the ultrasonic probe relative to the rotary drill bit.

9. The apparatus of claim 8, wherein the ultrasonic probe support structure comprises a member for attaching the ultrasonic probe support structure to the rotary drill bit.

10. The apparatus of claim 8, wherein the longitudinal probe-positioning mechanism comprises one of a mechanical device, an electro-mechanical device, a pneumatic device, and a hydraulic device.

11. The apparatus of claim 8, wherein the rotational probe-positioning mechanism comprises one of a mechanical device, an electro-mechanical device, a pneumatic device, and a hydraulic device.

12. The apparatus of claim 8, further comprising an angle-adjustment mechanism configured for changing an angle of the ultrasonic probe relative to the rotary drill bit.

13. A matrix-type rotary drill bit for drilling subterranean formations comprising a bit body defining an internal longitudinal bore therein, the bit body comprising:

a steel blank; and

a bit body matrix coupled to the steel blank, the bit body matrix adjoining the steel blank along an interface comprising a chamfer region, the steel blank being configured to provide a continuous path through the steel blank between the internal longitudinal bore and the chamfer region.

14. The drill bit of claim 13, further comprising a removable erosion and abrasion-resistant liner configured for insertion within the internal longitudinal bore of the bit body.

15. A drill bit for drilling subterranean formations comprising a bit body defining an internal longitudinal bore therein, the bit body comprising:

an inner surface within the internal longitudinal bore; and

at least one reference feature in the inner surface of the bit body within the longitudinal bore, the at least one reference feature being structured to facilitate substantially repeatable positioning of an ultrasonic probe within the longitudinal bore.

16. The drill bit of claim 15, wherein the at least one reference feature comprises a landing pad cavity.

17. The drill bit of claim 15, wherein the bit body further comprises:

a steel blank; and

a bit body matrix, the landing pad cavity being formed in the steel blank of the bit body.

18. The drill bit of claim 15, wherein the bit body further comprises:

a steel blank; and

a bit body matrix, the landing pad being formed in the bit body matrix.

19. The drill bit of claim 15, further comprising a removable erosion and abrasion-resistant liner configured for insertion within the internal longitudinal bore of the bit body.