AUTOMATED STEERABLE HOLE ENLARGEMENT DRILLING DEVICE AND METHODS

Abstract

A bottomhole assembly (BHA) coupled to a drill string includes a steering device, one or more controllers, and a hole enlargement device that selectively enlarges the diameter of the wellbore formed by the drill bit. In an automated drilling mode, the controller controls drilling directing by issuing instructions to the steering device. In one arrangement, the hole enlargement device is integrated into a shaft of a drilling motor that rotates the drill bit. The hole enlargement device includes an actuation unit and an electronics package that cooperate to translate extendable cutting elements between a radially extended position and a radially retracted position. The electronics package may be responsive to a signal that is transmitted from a downhole and/or a surface location. The hole enlargement device may also include one or more position sensors that transmit a position signal indicative of a radial position of the cutting elements.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

For detailed understanding of the present disclosure, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals and wherein:

FIG. 1 illustrates a drilling system made in accordance with one embodiment of the present disclosure;

FIG. 2 illustrates an exemplary bottomhole assembly made in accordance with one embodiment of the present disclosure; and

FIG. 3 illustrates an exemplary hole enlargement device made in accordance with one embodiment of the present disclosure.

Claims

1. An apparatus for forming a wellbore in an earthen formation, comprising: (a) a drill string having a drill bit at an end thereof;(b) a steering device steering the drill bit in a selected direction; and(c) a hole enlargement device positioned adjacent the drill bit, the hole enlargement device having at least one selectively extendable cutting element that enlarges the diameter of the wellbore formed by the drill bit.

2. The apparatus according to claim 1, further comprising a controller operatively coupled to the steering device, the controller controlling the steering device to steer the drill bit in the selected direction.

3. The apparatus according to claim 2, wherein the controller is programmed with instructions for controlling the steering device in response to a measured parameter of interest selected from one of (i) drilling direction parameter, (ii) a formation parameter and (iii) an operating parameter.

4. The apparatus according to claim 1, wherein the hole enlargement device is integrated into one of (i) the drill bit; and (ii) a shaft of a drilling motor rotating the drill bit.

5. The apparatus according to claim 1, wherein the at least one selectively extendable cutting element moves between an extended position and a retracted position in response to a signal transmitted from one of (i) a downhole location and (ii) a surface location.

6. The apparatus according to claim 1, further comprising a communication link between the hole enlargement device and a surface location.

7. The apparatus according to claim 6, wherein the communication link is selected from one of: (i) a data signal transmitted via a conductor, (ii) an optical signal transmitted via a conductor, (iii) an electromagnetic signal, (iv) a pressure pulse, and (v) an acoustic signal.

8. The apparatus according to claim 1 further comprising a conductor operatively coupled to the hole enlargement device, the conductor providing data communication between the hole enlargement device and a surface device.

9. The apparatus according to claim 1, wherein the conductor is selected from one of: (i) at least one conductive element formed along a drilling tubular, and (ii) at least one conductive element positioned adjacent a coiled tubing.

10. The apparatus according to claim 1, wherein the hole enlargement device is operatively connected to the steering device.

11. The apparatus according to claim 10 wherein the operative connection is one of: (i) a hydraulic connection, and (ii) an electrical connection.

12. The apparatus according to claim 1 further comprising a drilling motor coupled to and rotating the drill bit, wherein the drill string is substantially rotationally stationary while the drill bit is rotating.

13. A method for forming a wellbore in an earthen formation, comprising: (a) drilling the wellbore with a drill bit coupled to an end of a drill string;(b) steering the drill bit in a selected direction with a steering device; and(d) enlarging the diameter of the wellbore formed by the drill bit with a hole enlargement device positioned adjacent the drill bit.

14. The method according to claim 13 further comprising controlling the steering device with a controller operatively coupled to the steering device;

15. The method according to claim 14 further comprising controlling the steering device in response to a measured parameter of interest selected from one of (i) a drilling direction parameter, (ii) an operating parameter, and (iii) a formation parameter.

16. The method according to claim 13 further comprising transmitting the signal from one of (i) a downhole location and (ii) a surface location to move the at least one selectively extendable cutting element moves between an extended position and a retracted position.

17. The method according to claim 13 further comprising rotating the drill bit with a drilling motor while the drill string is substantially rotationally stationary.

18. The method according to claim 13 further comprising communicating with the hole enlargement device using one of: (i) a data signal transmitted via a conductor, (ii) an optical signal transmitted via a conductor, (iii) an electromagnetic signal, and (iv) a pressure pulse.

19. The method according to claim 13 further comprising communicating with the hole enlargement device using one of: (i) at least one conductive element formed along a drilling tubular, and (ii) at least one conductive element positioned adjacent a coiled tubing.

20. An system for forming a wellbore in an earthen formation, comprising: (a) a drill string having a drill bit at an end thereof;(b) a steering device steering the drill bit in a selected direction;(c) a controller operatively coupled to the steering device, the controller controlling the steering device to steer the drill bit in the selected direction;(d) a hole enlargement device positioned adjacent the drill bit, the hole enlargement device having at least one extendable cutting element that enlarges the diameter of the wellbore formed by the drill bit; and(e) at least one data conductor coupling the hole enlargement device to a surface location and providing data communication therebetween.