This invention relates to an apparatus for adjusting the orientation of a tubular. More specifically, but not by way of limitation, this invention relates to an adjustable bent housing apparatus, and a method of using the bent housing.
In the search for hydrocarbon deposits, operators have found it desirable to drill deviated and horizontal wells. As those of ordinary skill in the art will recognize, there are numerous advantages to being able to drill directional wells. For instance, an operator may drill a horizontal well for hundreds of feet within a subterranean reservoir, thus enabling high rates of production of hydrocarbons once completed. Additionally, an operator may wish to drill several lateral wells from a single surface location. This list is meant to be illustrative.
In order to obtain the angle of inclination necessary to drill these wellbores, numerous types of directional drilling apparatuses have been developed. One prior art technique includes use of a bent housing as part of the downhole mud motor. However, prior art downhole mud motors suffer from many deficiencies. For instance, some prior art devices require that the entire bent housing section be replaced if the operator wishes to adjust the drill bit axis relative to the bore hole.
Therefore, an object of the present invention is an adjustable bent housing apparatus that can be adjusted on the drilling rig without the need to have a large inventory of bent housing sections at the drilling rig site. Another object of the present invention includes an apparatus that is durable and can withstand the tremendous stress placed on downhole equipment in the drilling process. Yet another object is the development of a system that accurately adjust the drill bit axis relative to the work string. These and many other objects will become apparent upon a reading of the following description.
An apparatus for controlling the direction of drill bit within a wellbore is disclosed, and wherein the drill bit has as a drill bit axis and the drill bit is connected to the apparatus. In one embodiment, the apparatus comprises a first housing with a first housing axis therein, and wherein the first housing has a first threaded opening having a first threaded opening axis. The first housing has a helical end. A second housing is included, and the second housing contains a second housing axis, and a second threaded opening having a second threaded opening axis configured to engage with the first threaded opening, and wherein the second housing has an end surface.
The apparatus further includes a collar having a radial collar end and a partial helical collar end, and wherein the radial collar end engages the end surface and the helical collar end engages the helical end, and wherein the partial helical collar end is configured reciprocal to the helical end, and rotational displacement of the first housing relative to the collar will angularly displace the first threaded opening axis from the second threaded opening axis so that the inclination of the bit axis is changed. The apparatus may further include means for locking the collar in place relative to the first and second housing.
In one embodiment, the locking means includes a reciprocal set of splines. The splines may also be referred to as teeth, keys, or teeth or key like projections. The splines may also be referred to as a mechanical interlocking mechanism. More specifically, in one preferred embodiment, the locking means comprises a male set of splines formed on an inner portion of the collar and a female set of splines formed on an inner portion of the first housing. In another embodiment, the locking means comprises a female set of splines formed on an inner portion of the collar and a male set of splines formed on an inner portion of the second housing. Additionally, in one preferred embodiment, the first threaded opening is configured perpendicular to the helical end and the second threaded opening is configured perpendicular to the end surface.
The first housing may have disposed therein an output shaft of a drilling motor, and the second housing may have disposed therein a drive shaft of the drilling motor, and wherein the drive shaft is connected to the drill bit. In one preferred embodiment, the helical collar end has a slope between 0.1 degrees and 10 degrees, and the helical end has a complimentary slope.
A method of drilling a well with a drill bit is also disclosed. The method comprises providing a drill assembly within the well, with the drill assembly being connected to the drill bit via a drive shaft. The assembly comprises a first housing with a first housing axis therein, with the first housing having a first threaded opening having a first threaded opening axis, and wherein the first housing has a helical end. The tool further includes a second housing having a second housing axis, with the second housing having a second threaded opening having a second threaded opening axis configured to engage with the first threaded opening, and wherein the second housing having an end surface. The housing also includes a collar having a radial collar end and a helical collar end, and wherein the radial collar end engages the end surface and the helical collar end engages the helical end, and wherein the helical collar end is at a reciprocal angle to the helical end. The method further includes drilling the well with the drill bit at a first angle of inclination.
The method further comprises retrieving the drill assembly from the well, unscrewing the first housing from the second housing, and rotating the collar relative to the first housing hence axial displacing the radial end surface of the collar to the first housing. The method further includes adjusting the collar's axial position relative to the first housing and the second housing, by rotationally moving the collar relative to the first housing and therefore displacing the first housing relative to the collar in order to angularly displace the drill bit at a second angle of inclination. Next, the first housing is locked with the second housing. The method includes running into the well with the drill bit and drilling the well at the second angle of inclination.
In one preferred embodiment, the step of locking the first housing with the collar includes engaging a spline located on said collar with a spline located on the first housing.
In another preferred embodiment, the step of locking the first housing with the second housing includes engaging a thread connection located on the first housing with a thread connection located on the second housing.
In one preferred embodiment, the step of adjusting the axial inclination includes rotational displacement of the first housing relative to the collar in order to align the first housing axis with the second housing axis. In another preferred embodiment, the step of adjusting the axial inclination includes rotational displacement of the first housing relative to the collar so that the first housing axis and the second housing axis is angularly displaced. In yet another embodiment, the step of adjusting the collar's axial position includes rotation displacement of the first housing relative to the collar so that the radial end surface of the collar is axially displaced.
In another preferred embodiment, an apparatus for controlling the direction of a tubular is disclosed. In this embodiment, the apparatus comprises a first housing with a first housing axis therein, with the first housing having a first threaded opening having a first threaded opening axis offset from the first housing axis, and wherein the first housing has a helical end. The apparatus includes a second housing having a second housing axis, with the second housing having a second threaded opening having a second threaded opening axis offset from the second housing axis and wherein the second threaded opening is configured to engage with the first threaded opening, and wherein the second housing has an end surface.
Additionally, this embodiment includes a collar having a radial collar end and a helical collar end, and wherein the radial collar end engages the end surface and the helical collar end engages the helical end, and wherein the helical collar end is configured reciprocal to the helical end. In a first position, rotational displacement of the first housing relative to the collar will align the first housing axis with the second housing axis and in a second position, rotational displacement of the first housing relative to the collar will deviate the first housing axis relative to the second housing axis. Means for locking the collar in place relative to the first and second housing may also be included.
An advantage of the present invention is that angular adjustments can be made to the downhole motor assembly without the need for spare inventory at the rig site. The collar can be adjusted in the field. Another advantage is that the driller on the drill rig floor can make accurate changes to the orientation of the drill bit axis for precision geo-steering. Yet another advantage is that the driller can quickly make angular adjustments to the drill bit axis.
Yet another advantage is that the apparatus can be used for controlling the direction of a tubular, wherein the tubular can be used in applications wherein it is necessary to change and/or adjust the orientation of the tubular i.e. when a bend is needed in a tubular.
A feature of the present invention is the first and second housing that share a common axis, and wherein this common axis is offset from the axis of the threaded openings contained within the first and second housing. Another feature is a collar that contains a helical end profile that mates with a reciprocal profile end face on one of the housings. Yet another feature is the splines on the collar and the mating splines of the housing which allow for locking the desired angular displacement into the drilling assembly.
Referring now to
Extending from the surface 6 will be the threaded opening seen generally at 12, sometimes referred to as the pin connection 12. The threaded opening 12 includes the outer cylindrical surface 14 that extends to the outer spline members seen generally at 16 which in turn extends to the indentation 18. The splines are teeth-like projections extending from the pin connection 12. As seen in
Referring now to
Referring now to
The numeral angle 98 would be the sum of the tilted box angle 58 and the first housing angle 99 (angle between item 10 and item 22 seen in
As oriented in
Referring now to
As mentioned earlier, the adjustable bent sub 68 will be part of a downhole mud motor assembly used in drilling subterranean reservoirs. Referring now to
As seen in
Although the invention has been described in terms of specified embodiments which are set forth in detail, is should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and cooperating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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Number | Date | Country | |
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20090159339 A1 | Jun 2009 | US |