The present disclosure generally relates to tools used to maneuver a drill bit while directional drilling for resource procurement.
This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it may be understood that these statements are to be read in this light, and not as admissions of prior art.
To meet consumer and industrial demand for natural resources, companies often invest significant amounts of time and money in searching for and extracting oil, natural gas, hydrocarbons, and other subterranean resources from the earth. Particularly, once a desired subterranean resource such as oil or natural gas is discovered, drilling and production systems are often employed to access and extract the resource. These systems may be located onshore or offshore depending on the location of a desired resource. Common methods include deploying the drilling and production systems on the surface or on a floating platform disposed above the discovered resources, and drilling a borehole straight down into the surface of the earth to procure the desired resource(s).
However, in some scenarios, desired resources may be located such that it is inconvenient to dispose the drilling and production systems on the surface directly above the resources. In these cases, it may be beneficial to set up the drilling and production systems in a location laterally spaced from the location of the desired resources and employ directional drilling techniques. While employing directional drilling techniques, operators are able to drill straight down below the surface of the earth, and then maneuver the drill bit to curve the drill bit along a prescribed arc to direct the drill bit towards the desired resources. Efforts to improve the efficiency and maneuverability of these drill bits during drilling operations may be advantageous.
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining or limiting the scope of the claimed subject matter as set forth in the claims.
In certain embodiments, a system includes a bottom hole assembly (BHA) that includes a drill bit disposed at a first axial position such that the drill bit is configured to rotate and drill a pilot hole in a subterranean formation, such that the drill bit provides a first point of contact between the BHA and the subterranean formation. Additionally, the BHA includes a steering pad assembly disposed at a second axial position offset from the first axial position, such that the steering pad assembly includes one or more steering pads each configured to move over a path of travel between a retracted position and an extended position to provide a second point of contact between the BHA and the subterranean formation, and a reamer disposed at a third axial position offset from the first and second axial positions, such that the reamer is configured to expand the pilot hole into a borehole, such that the reamer provides a third point of contact between the BHA and the subterranean formation. Further, the system includes a controller of a rotary steerable system (RSS) configured to steer the BHA via the first, second, and third points of contact and adjustments to the second point of contact via control of the steering pad assembly.
In certain embodiments, a system includes a controller of a rotary steerable system (RSS) configured to control a bottom hole assembly (BHA) that includes a drill bit disposed at a first axial position, such that the drill bit is configured to rotate and drill a pilot hole in a subterranean formation, such that the drill bit provides a first point of contact between the BHA and the subterranean formation. Additionally, the BHA includes a steering pad assembly disposed at a second axial position offset from the first axial position, such that the steering pad assembly includes one or more steering pads each configured to move over a path of travel between a retracted position and an extended position to provide a second point of contact between the BHA and the subterranean formation, and a reamer disposed at a third axial position offset from the first and second axial positions, such that the reamer is configured to expand the pilot hole into a borehole, such that the reamer provides a third point of contact between the BHA and the subterranean formation. Additionally, the controller is configured to steer the BHA via the first, second, and third points of contact and adjustments to the second point of contact via control of the steering pad assembly.
In certain embodiments, a method includes controlling steering of a bottom hole assembly (BHA) via a controller of a rotary steerable system (RSS), such that the BHA includes a drill bit disposed at a first axial position, such that the drill bit is configured to rotate and drill a pilot hole in a subterranean formation, such that the drill bit provides a first point of contact between the BHA and the subterranean formation. Additionally, the BHA includes a steering pad assembly disposed at a second axial position offset from the first axial position, such that the steering pad assembly includes one or more steering pads each configured to move over a path of travel between a retracted position and an extended position to provide a second point of contact between the BHA and the subterranean formation, and a reamer disposed at a third axial position offset from the first and second axial positions, such that the reamer is configured to expand the pilot hole into a borehole, such that the reamer provides a third point of contact between the BHA and the subterranean formation. Additionally, the controller is configured to steer the BHA via the first, second, and third points of contact and adjustments to the second point of contact via control of the steering pad assembly.
The subject disclosure is further described in the following detailed description, and the accompanying drawings and schematics of non-limiting embodiments of the subject disclosure. The features depicted in the figures are not necessarily shown to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form, and some details of elements may not be shown in the interest of clarity and conciseness. These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Certain embodiments commensurate in scope with the present disclosure are summarized below. These embodiments are not intended to limit the scope of the disclosure, but rather these embodiments are intended only to provide a brief summary of certain disclosed embodiments. Indeed, the present disclosure may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
As used herein, the term “coupled” or “coupled to” may indicate establishing either a direct or indirect connection (e.g., where the connection may not include or include intermediate or intervening components between those coupled), and is not limited to either unless expressly referenced as such. The term “set” may refer to one or more items. Wherever possible, like or identical reference numerals are used in the figures to identify common or the same elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale for purposes of clarification.
As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “above” and “below”; “inward” and “outward”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.”
Furthermore, when introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment,” “an embodiment,” or “some embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, the phrase A “based on” B is intended to mean that A is at least partially based on B. Moreover, unless expressly stated otherwise, the term “or” is intended to be inclusive (e.g., logical OR) and not exclusive (e.g., logical XOR). In other words, the phrase A “or” B is intended to mean A, B, or both A and B.
Certain terms are used throughout the description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name, but not function.
For decades, humans have relied on resources found below the earth's surface to meet increasing energy demands. These resources include but are not limited to natural gas, coal, hydrocarbons, petroleum, and other materials suitable to generate energy for consumption by humans. As energy demands increase, significant efforts are expended to extract an appropriate supply of energy to meet the increasing demand. Included in these efforts are systems and methods that enable expanded extraction of the resources, increases to the efficiency of the extraction process, and technological advances that permit extraction and exploration in areas that were previously inaccessible for energy production. Recently, one area of exploration that has grown with the advance of energy exploration related technology is the extraction of resources from a portion of the earth's surface where it is not feasible to dispose drilling and production facilities directly above the subterranean resources.
As one might expect, extracting resources from an area below the earth's surface without being able to drill straight down introduces additional challenges that might not necessarily be present when extracting resources from the earth in a conventional manner. For example, operators calculate a location for the drilling and production facilities sufficiently laterally spaced from the resources, and determine an arc profile path that they may then maneuver the drill bit and accompanying drill string along the determined path to approach the desired resources from the side, rather than from above. While traditional resource procurement systems may not require equipment configured to direct the drill bit along an arc-shaped path, directional drilling systems utilize an array of drill bits, valves, actuators, motors, seals, sensors, control systems, and other components that work together to enable the operator to direct the drilling components along the determined path through the subterranean formations. Methods for directional drilling and the arc profile paths taken during operation are constrained by the geometrical aspects of the equipment utilized during the directional drilling process. For example, certain length ratios and diameter ratios that characterize the components of the directional drilling techniques restrict the performance and the shape of the arcs an operator is allowed to chart for a particular directional drilling operation. Components of the directional drilling system that provide for relatively large bore sizes often limit the agility and maneuverability of the system, while alternatively, components that provide for increased agility and maneuverability often restrict the diameter of the borehole. As a result, efforts to improve the maneuverability and agility of the directional drilling system, while simultaneously providing for relatively large borehole sizes to increase production may be advantageous.
The present disclosure relates to a directional drilling system in which a drilling tool provides agile steering performance of a smaller diameter tool, while also configured to drill relatively large boreholes. Present embodiments include a bottom hole assembly (BHA) that includes a rotary steerable system (RSS) drilling tool and a reamer. In the present disclosure, the RSS drilling tool has a comparatively smaller diameter, and by extension, a smaller second moment of area, than traditional RSS drilling tools, thereby enabling the RSS drilling tool to drill a comparatively smaller diameter pilot hole along a tighter curved trajectory, as a result of its geometry. The RSS drilling tool includes a drill bit which provides a first point of contact and an assembly of steering pads which provide a second point of contact. In present embodiments, the RSS drilling tool is attached to the reamer, which is configured to provide a third point of contact in the borehole, which in combination with the first and second points of contact from the drill bit and steering pads, define the arc profile path. Also, the reamer is configured to centralize the tool in the borehole, open the borehole to a larger diameter, and follow the trajectory of the pilot hole cut by the RSS drilling tool. Additionally, present embodiments provide the operator the ability to enjoy the benefits of a more agile, maneuverable directional drilling system configured to drill tighter, more precise arc trajectories while drilling, while still opening up the borehole to a size suitable to maintain relatively high levels of resource production.
Turning to the drawings,
As discussed above, the drilling system 10 may be configured to rotate the drill bit 20 to cut a curved, or an arc shaped path to reach subterranean resources that are not located directly below the drilling and production facilities.
As shown, the drill bit 20 provides a first point of contact 58 with the drilled pilot hole 68, the steering pad assembly 54 provides a second point of contact 60 with the drilled pilot hole 68, and the reamer 50 provides a third point of contact 62 with the borehole 26. Taken together, the three points of contact, 58, 60, 62 define the arc shaped profile 56 of the pilot hole 68 and borehole 26 cut by the drill bit 20 and reamer 50 respectively. As discussed above, the drill bit 20 engages with the subterranean formation 12 to cut the pilot hole 68 and provides the first point of contact 58 of the curved profile path. Additionally, the RSS tool 64 is configured to rotate with the drill string 18 and the drill bit 20, and as the RSS tool 64 rotates, the tool is configured to actuate the steering pad assembly 54 to steer and direct the drill bit 20. The steering pad assembly 54 is configured to radially extend and radially retract individual steering pads of the steering pad assembly 54 as it rotates as part of the RSS tool 64, and as an individual steering pad is radially extended, it contacts a wall of the pilot hole 68 cut by the drill bit 20. This contact between the individual steering pad and the pilot hole 68 acts as the second point of contact 60 defining the arc shaped profile. Additionally, the reamer 50 is configured to follow the path cut by the drill bit 20 and cut the borehole 26 to a larger diameter suitable for producing resources. The reamer 50 engages with the subterranean formation 12 and cuts the production hole and provides the third point of contact 62, that in conjunction with the first point of contact 58 and the second point of contact 60, defines the geometry and path of the arc shaped borehole profile.
In the illustrated embodiment, the three points of contact 58, 60, and 62 are axially spaced apart from one another over a relatively compact axial distance, such as less than or equal to 1, 1.5, 2, 2.5, or 3 meters rather than 4 to 5 meters or more. In other words, the three points of contact 58, 60, and 62 are different axial positions of contact, which span an overall axial distance including a first axial distance between the first and second points of contact 58 and 60 and a second axial distance between the second and third points of contact 60 and 62. By further example, the second point of contact 60 is positioned axially between the first and third points of contact 58 and 62, which are axially spaced less than or equal to 1, 1.5, 2, 2.5, or 3 meters. Thus, the three points of contact 58, 60, and 62 also may be described as axial contact positions, each of which may extend at least partially or entirely around a circumference of the BHA 34. Additionally, the third point of contact 62 is directly at the reamer 50 (e.g., integrated with the reamer 50), rather than relying on a third point of contact axially spaced apart from the reamer 50 at a further distance away from the first and second points of contact 58 and 60 (e.g., not further upstream along the drill string 18). For example, the BHA 34 having the three points of contact 58, 60, and 62 may exclude a stabilizer (e.g., providing a point of contact for the arc shaped profile 56) along the drill string 18 axially spaced further away from the reamer 50, such that the three points of contact 58, 60, and 62 span a shorter axial distance. Thus, the compact axial distance of the three points of contact 58, 60, and 62 enables greater maneuverability of the BHA 34, greater flexibility of the BHA 34, sharper turns or shorter radii of curvature of the arc shaped profile 56, and potentially faster response times when drilling through difficult subterranean formations.
The reamer 50 is coupled to the RSS tool 64 and the drill string 18, wherein the reamer 50 is a cutting structure configured to open or dress the pilot hole 68 into the borehole 26 that is a bit gauge diameter or larger. The reamer 50 may be rotationally coupled or fixed to the drill string 18 and/or the RSS tool 64. Thus, the reamer 50 may be configured to rotate directly with rotation of the drill string 18, and/or the RSS tool 64 may be configured to rotate directly with rotation of the drill string 18. The reamer 50 include a stabilizer portion 52 and a cutter portion 66. In certain embodiments, the reamer 50 may include one or more stabilizer portions 52 at upstream, downstream, and/or intermediate portions of the reamer 50 relative to the cutter portion(s) 66. In some embodiments, the stabilizer portion 52 may be permanently attached to (e.g., welded or integrally formed as one-piece with) the reamer 50, and in other embodiments, the stabilizer portion 52 may be removably coupled to the reamer 50 via one or more fasteners (e.g., screwed in place via threaded fasteners). The stabilizer portion 52 includes an outer circumferential surface (e.g., stabilizer surface) with a smaller diameter than the diameter of the outer circumferential surface (e.g., cutter surface) of the cutter portion 66 of the reamer 50. In other words, the cutter portion 66 radially protrudes relative to the stabilizer portion 52. In certain embodiments, the stabilizer portion 52 includes an annular stabilizer portion having a constant diameter around an annular surface of the reamer 50, a plurality of circumferentially spaced surfaces or ribs (e.g., axial surfaces or ribs, spiral surfaces or ribs, or both) spaced apart by intermediate grooves (e.g., axial and/or spiral grooves), or any combination thereof, with substantially smooth surfaces (e.g., excluding any cutting structures). Additionally, in certain embodiments, the cutter portion 66 may include a plurality of cutting elements made of wear resistant materials, such as diamond, tungsten carbide, or any combination thereof. The cutting elements may include a plurality of cutting projections, such as pointed projections, beads, cones, cylinders, or any combination thereof. For example, the cutter portion 66 may include at least 10 to 100 or more cutting elements. As discussed in further detail below, the reamer 50 may include any number and arrangement of the stabilizer portion 52 and the cutter portion 66; however, the stabilizer portion 52 and the cutter portion 66 may be directly integrated and/or directly adjacent (e.g., axially adjacent) one another in the reamer 50. In certain embodiments, the stabilizer portion 52 may be axially spaced from the cutter portion 66 by an axial distance of less than or equal to 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 30, 40, or 50 centimeters. In certain embodiments, the stabilizer portion 52 may be axially spaced from the cutter portion 66 by an axial distance of less than or equal to a factor of 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5, or 2 times an outer diameter of the stabilizer portion 52. In certain embodiments, the stabilizer portion 52 and the cutter portion 66 are axially adjacent without any discernable axial spacing therebetween.
In the illustrated embodiment, the stabilizer portion 52 of the reamer is configured to prevent deviation from the directed path and maintain the trajectory of the reamer 50, so that it may follow the path of the pilot hole 68. The cutter portion 66 of the reamer 50 includes an outer circumferential surface that includes multiple blades or cutting elements configured to drill the subterranean formation 12. In certain embodiments, the cutter portion 66 of the reamer 50 may include multiple outer circumferential surfaces, each with different diameters. In other embodiments, the cutter portion 66 of the reamer 50 has an outer circumferential surface with a substantially constant diameter. In certain embodiments, the stabilizer portion 52 and the cutter portion 66 of the reamer 50 are fixed together or continuously formed as a one-piece structure, or the stabilizer portion 52 and the cutter portion 66 of the reamer 50 are removably coupled together as a multi-piece structure.
In the illustrated embodiment, the RSS tool 64 includes the steering pad assembly 54. The mud control valves 102 are fluidly coupled to the steering pad assembly 54 by pressurized mud lines 104 (e.g., fluid conduits) that are configured to provide pressurized drilling fluid 28 to the steering pad assembly 54. As discussed in further detail below, the steering pad assembly 54 rotates with the drill bit 20 and is configured to actuate at least one steering pad from the steering pad assembly 54, such that the steering pad may radially extend and radially retract during operation. The mud control valves 102 are configured to provide the drilling fluid 28 to the steering pad assembly 54 via the pressurized mud lines 104, and in certain embodiments, each valve as part of the mud control valves 102 is fluidly connected to a respective steering pad of the steering pad assembly 54 via an individual pressurized mud line 104. In some embodiments, the steering controller 92 outputs instructions to the mud control valves 102 to automatically distribute pressurized drilling fluid 28 through the pressurized mud lines 104. In certain embodiments, the steering controller 92 is configured to control the mud control valves 102 to selectively provide mud to one or more steering pads of the steering pad assembly 54, thereby controlling which steering pad is actuated and a degree of actuation (e.g., radial extension or retraction) of the particular steering pad of the steering pad assembly 54. In this manner, the steering controller 92 is configured to control the second contact point 60 provided by the steering pad assembly 54, such that the steering controller 92 controls the second contact point 60 in combination with the first contact point 58 provided by the drill bit 20 and the third contact point 62 provided by the reamer 50 to define the arc shaped profile 56 for maneuverable directional drilling.
During steering and drilling operations, the steering control unit 90 is configured to receive sensor data 108 from the forward sensor package 106. In certain embodiments, the forward sensor package 106 includes multiple sensors configured to monitor operating parameters of the drilling fluid in the RSS tool (e.g., drilling fluid pressure, drilling fluid flow rate, etc.) during the drilling operation. The steering control unit 90 and the steering controller 92 may receive these operational parameters and output these parameters to the surface 16 via the surface system 94. In certain embodiments, the steering control unit 90 may be configured to automatically adjust the various operating parameters during the drilling operation in order to facilitate the drilling operations.
In certain embodiments, the RSS tool 64 may include or exclude a mud motor 96 and a transmission 100. In the illustrated embodiment, the RSS tool 64 includes the mud motor 96 and the transmission 100. The mud motor 96 may be an electric motor, a fluid-driven motor (e.g., driven by fluid flow of mud), or a combination thereof. In certain embodiments, the mud motor 96 is a fluid-driven motor having a spiral or helical flow path along a shaft (e.g., a helical or spiral shaft). However, a variety of fluid-driven motors may be used for the mud motor 96, and some embodiments of fluid-driven motors may have relatively shorter lengths suitable for reducing an overall length of the BHA 34. The mud motor 96 is configured to provide rotational energy to the drill bit 20 during drilling operations, such that the mud motor 96 can adjust (e.g., increase or decrease) drilling speeds, and also helps to balance the weight transmitted by the reamer 50 to the drill bit 20. In this way, the mud motor 96 enables the drill bit 20 and RSS tool 64 to prevent overloading of the drill bit in situations where the drill bit 20 diameter is significantly smaller than the reamer 50. Additionally or alternatively, the mud motor 96 may couple to the transmission 100, which is configured to receive a rotational energy (e.g., rotational speed RPM and torque, etc.) from the mud motor 96, and output a modified rotational energy to the drill bit 20. For example, if during a portion of the drilling operation a higher relative torque and lower relative rotational speed at the drill bit 20 is advantageous to better cut through the subterranean formation 12, the transmission 100 is configured to receive the rotational energy output from the mud motor 96, and adjust the rotational energy output such that the torque is increased, thereby decreasing the rotational speed at the drill bit 20. Additionally or alternatively, during an additional portion of the drilling operation a relatively higher rotational speed and lower relative torque at the drill bit 20 is advantageous to better cut through the subterranean formation 12, the transmission 100 is configured to receive the rotational energy output from the mud motor 96, and adjust the rotational energy output such that the rotational speed is increased, thereby decreasing the torque at the drill bit 20. The transmission 100 may include a plurality of gears and shafts of varying diameters and configurations, such that when these aforementioned adjustments are desired, the transmission 100 is configured to adjust a configuration of the gears and shafts to manipulate the output rotational energy from the mud motor 96 into an appropriate rotational energy profile at the drill bit 20. In certain embodiments, the mud motor 96 and the transmission 100 are controlled by the surface system 94 such that the user in the drilling and production facilities may output instructions to the mud motor 96 and transmission 100. In other embodiments, the mud motor 96 and transmission may be automatically controlled by the steering controller 92, and the parameters and configurations of the mud motor 96 and the transmission 100 may be dynamically adjusted in response to information from the sensor data 108. However, in certain embodiments, the mud motor 96 and the transmission 100 may be excluded to reduce a length of the BHA 34, thereby helping to improve maneuverability via the RSS tool 64.
In the illustrated embodiment, the reamer 50 includes a pivot joint 98 (e.g., rotational axis crosswise to a longitudinal axis of the drill string 18). The pivot joint 98 is disposed within the reamer 50, axially upstream or above the reamer 50, and/or axially upstream or above the RSS tool 64. For example, in certain embodiments, the pivot joint 98 may be integrally formed or fixed to the reamer 50 as part of a one-piece structure (i.e., unitary self-contained structure), or the pivot joint 98 may be removably coupled directly to the reamer 50. By further example, the pivot joint 98 may be disposed in any suitable location or distance from the reamer 50. During drilling operations, due to the nature of the RSS tool 64 and the reamer 50 cutting a curved borehole, a bending moment may be generated in a portion of the drill string 18 located above the reamer 50. In certain embodiments, the pivot joint 98 may be configured to alleviate such bending moments, and enable the RSS tool 64 and reamer 50 to cut a curved borehole with a tighter radius than otherwise possible. The pivot joint 98 may be configured to mechanically couple the drill string 18 to the reamer 50, while simultaneously enabling the reamer 50 and the RSS tool 64 to pivot in relation to the remainder of the drill string 18. The placement of the pivot joint in relation to the points of contact 58, 60, 62 between the RSS tool 64 and reamer 50 and the pilot hole 68 and borehole 26 respectively determine an effectiveness of the pivot joint in alleviating such bending moments. In the illustrated embodiment, a distance L3118 is defined as the distance between the first contact point 58 axially centered on the drill bit 20 and a fourth contact point 97 axially centered on the pivot joint 98. As the value of L3 increases, the pivot joint 98 is enabled to reduce a greater portion of an associated bending moment generated as a result of the directional drilling operation. Alternatively, as the value of L3 decreases, the pivot joint 98 is enabled to reduce a smaller portion of the associated bending moment generated as a result of the directional drilling operation. In certain embodiments, the length L3118 may be less than or equal to 2, 2.5, 3, 3.5, or 4 meters, wherein an axial distance between the third and fourth points 62 and 97 is less than 0.5, 1, 1.5, or 2 meters. However, in certain embodiments, the length L3 and the axial distance may be greater or lesser than the foregoing examples.
As discussed previously, the drill bit 20, the steering pad assembly 54 and the reamer 50 provide the first, second, and third points of contact 58, 60, 62 along the pilot hole and borehole necessary to define the arc of the curved path cut during the directional drilling operations. As a result, the associated lengths between the drill bit 20, the steering pad assembly 54, and the reamer 50 and the corresponding points of contact determine a radius of curvature of the pilot hole 68 drilled by the drill bit 20, and the associated radius of curvature of the borehole 26 cut by the reamer 50 as it follows the drill bit 20. For example, the length L1114 between the drill bit 20 and the steering pad assembly 54, plays a role in determining the radius of curvature. The smaller the value of L1114, the tighter the radius of curvature of the pilot hole 68 the RSS tool 64 is able to cut. In some embodiments, the steering pad assembly 54 may be disposed directly adjacent to the drill bit 20, thereby reducing the value of L1114 to a value of zero. Additionally or alternatively, as the value of L1114 increases, the value of the corresponding radius of curvature that the RSS tool 64 may cut in the pilot hole 68 increases. In certain embodiments the steering pad assembly 54 may be adjusted axially along the direction of the drill string 18, thereby adjusting the value of L1114 to further adjust the radius of curvature of the pilot hole 68 drilled by the drill bit 20. In certain embodiments, the RSS tool 64 may include an adjustable bend portion configured to help steer the BHA 34. The adjustable bend portion may provide the second point of contact alone or in combination with the steering pad assembly 54.
Furthermore, the length L2116 between the drill bit 20 and the reamer 50 factors into the performance of the RSS tool 64 and the reamer 50. As illustrated, the corresponding length L2116 plays a role in determining the radius of curvature of the pilot hole 68. As the value of L2116 decreases, the RSS tool 64 and drill bit 20 are enabled to drill the pilot hole 68 with a tighter radius of curvature. Additionally or alternatively, as the value of L2116 increases, the RSS tool 64 and the drill bit 20 are enabled to drill the pilot hole 68 with a greater radius of curvature. Further, a ratio between L1114 and L2116 (e.g., ratio of L1/L2) may be established to define a relationship between the multiple points of contact that define the radius of curvature between the components of the RSS tool 64 and the reamer 50. For example, in certain embodiments that may exclude the mud motor 96, the length L2116 may be less than or equal to 1, 1.5, 2, 2.5, or 3 meters rather than 4 to 5 meters or more. In certain embodiments that include the mud motor 96, the length L2 may be longer than 5 meters. In other embodiments, depending on a configuration of the various components discussed above, the length L2116 may be between about 1 to 2.5 meters or 1.5 to 2 meters. By further example, the length L2116 may be less than or equal to a factor of about 4, 5, 6, 7, 8, 9, or 10 times an outer diameter of the reamer 50. In certain embodiments, the ratio of L1/L2 may be less than 0.2, 0.3, 0.4, 0.5, 0.6, or 0.7, and/or the ratio L1/L2 may range between about 0.1 to 0.6 or 0.2 to 0.5. In certain embodiments, the ratio L1/L2 is fixed and thus not adjustable during operation. However, in certain embodiments, the steering control 92 may be configured to control an axial positioner coupled to the steering pad assembly 54, thereby adjusting an axial position of the steering pad assembly 54 and varying the ratio L1/L2 to provide more flexible steering of the BHA 34. In other words, the various examples provided above for lengths L1114, L2116, and L3118 depend on various configurations of the components detailed above. Exclusion of the mud motor 96 may generally result in shorter lengths, whereas inclusion of the mud motor 96 may generally result in longer lengths. Accordingly, in certain embodiments, the lengths L1114, L2116, and L3118 and ratios may be greater or lesser than the foregoing examples.
The steering pad piston-cylinder assembly 142 and the steering pad valve 144 function together to control the actuation of the steering pad 140 along the path and the illustrated direction of movement 146. In a non-limiting embodiment, the steering pad valve 144 is fluidly coupled to a mud control valve via a pressurized mud line. The steering pad valve 144 is configured to receive drilling fluid from the mud control valve and the pressurized mud line, and thereby output the received drilling fluid to the steering pad piston in order to actuate the steering pad 140 along the movement path from a radially retracted position to a radially protruded position. In certain embodiments, the steering pad valve 144 is configured to direct drilling fluid to a first side of a piston of the steering pad piston-cylinder assembly 142 to actuate the piston to push the steering pad 140 into a radially protruded position. Additionally, the steering pad valve 144 is configured to direct drilling fluid to a second side of the piston of the steering pad piston-cylinder assembly 142 to actuate the piston to pull the steering pad 140 into a radially retracted position. In other embodiments, the steering pad valve is configured to receive pressurized oil, and thereby output the received pressurized oil to the steering pad piston in order to actuate the steering pad 140 along the movement path from a radially retracted position to a radially protruded position.
In a non-limiting embodiment, as the steering pad assembly 54 rotates with the drill bit 20 and the RSS tool 64, the steering pad assembly 54 is configured to actuate the steering pad valve 144 and steering pad piston-cylinder assembly 142 to drive the movement of the steering pad 140. For example, the steering pad assembly 54 actuates an individual steering pad 140 to push against the wall of the pilot hole 68 cut by the drill bit 20, thereby causing the drill bit 20 to cut the pilot hole 68 with a determined radius of curvature. As a result, the steering pad assembly 54 actuates the steering pad 140 to protrude and provide the second point of contact 60 between the pilot hole 68 and the RSS tool 64. In a non-limiting embodiment, the steering pad assembly 54 may actuate the steering pad 140 to radially protrude at a point of the rotation, such that the steering pad 140 radially extends at a position opposite of the cutting path of the drill bit 20. In some embodiments, the steering pad assembly 54 may be rotationally decoupled from the drill bit 20 and the RSS tool 64, and the steering pad assembly 54 may be mounted on a rotationally fixed sleeve. In some embodiments, the steering pad assembly 54 may be mounted on a sleeve that is configured to rotate independently from the drill bit 20 and the RSS tool 64.
In a non-limiting embodiment, the fixed diameter reamer 160 includes a pipe thread connection 162 and a bottom connection 168 configured to interface with the RSS tool 64. The pipe thread connection 162 is configured to interface with the drill string 18, and may include pipe threads, or any other suitable coupling interface to couple the fixed diameter reamer 160 to the drill string 18. In certain embodiments, the pipe thread connection 162 is configured to removably couple the fixed diameter reamer 160 to the drill string 18, such that the fixed diameter reamer 160 rotates with the drill string 18. The bottom connection 168 is configured to include pipe threads, or any other suitable coupling interface, to couple the fixed diameter reamer 160 to the RSS tool 64. In some embodiments, the bottom connection 168 is configured to rotatably couple the fixed diameter reamer 160 to the RSS tool 64, thereby enabling the RSS tool 64 to rotate independently of the fixed diameter reamer 160.
In certain embodiments, the staged hole opener 180 is configured to use the first intermediate stabilizer portion 184 and/or the second intermediate stabilizer portion 192 to provide the third point of contact 62, such that the third point of contact 62 is an average or axially central position along the staged hole opener 180. In some embodiments, given that the second intermediate stabilizer portion 192 has a larger diameter than the first intermediate stabilizer portion 184, the second intermediate stabilizer portion 192 may be used to define the third point of contact 62. In either case, the staged hole opener 180 (e.g., reamer 50) defines the third point of contact 62 rather than relying on a separate stabilizer away from the reamer 50.
In a non-limiting embodiment, the staged hole opener 180 includes a pipe thread connection 182 and a bottom connection 188 configured to interface with the RSS tool 64. The pipe thread connection 182 is configured to interface with the drill string 18, and may include pipe threads, or any other suitable coupling interface to couple the staged hole opener 180 to the drill string 18. In certain embodiments, the pipe thread connection 182 is configured to couple the staged hole opener 180 to the drill string 18, such that the staged hole opener 180 rotates with the drill string 18. The bottom connection 188 is configured to include pipe threads, or any other suitable coupling interface, to couple the staged hole opener 180 to the RSS tool 64. In some embodiments, the bottom connection 188 is configured to rotatably couple the staged hole opener 180 to the RSS tool 64, thereby enabling the RSS tool 64 to rotate independently of the staged hole opener 180.
In a non-limiting embodiment, the expandable reamer piston-cylinder assembly 212 and the reamer valve 214 function together to control the actuation of the blade 216 along the path and the illustrated direction of movement 218. In certain embodiments, the reamer valve 214 is fluidly coupled to a mud control valve via a pressurized mud line. The reamer valve 214 is configured to receive drilling fluid from the mud control valve and the pressurized mud line, and thereby output the received drilling fluid to the expandable reamer piston-cylinder assembly 212 in order to actuate the blade 216 along the movement path from a radially retracted position to a radially protruded position. In certain embodiments, the reamer valve 214 is configured to direct drilling fluid to a first side of a piston of the expandable reamer piston-cylinder assembly 212 to actuate the piston to push the blade 216 into a radially protruded position. Additionally, the reamer valve 214 is configured to direct drilling fluid to a second side of the piston of the expandable reamer piston-cylinder assembly 212 to actuate the piston to pull the blade 216 into a radially retracted position.
At block 254, the steering controller may determine, based on the received sensor data, a control signal that is configured to cause a mud control valve to output drilling fluid to a steering pad valve of a steering pad assembly defining the second point of contact 60. For example, if during directional drilling operations, the RSS tool is cutting the curved path at an angle below a particular threshold, the steering controller may output a control signal to increase an operating parameter (e.g., drilling fluid pressure, drilling fluid flow rate, etc.) that the steering controller is outputting to the mud control valves. Additionally or alternatively, if during directional drilling operations, the RSS tool is cutting a curved path at an angle greater than a particular threshold, the steering controller may output a control signal to decrease an operating parameter (e.g., drilling fluid pressure, drilling fluid flow rate, etc.) that the steering controller is outputting to the mud control valves. At block 256, the steering controller may output the determined control signal to the mud control valve. Thus, the method 250 controls the directional steering of the BHA 34 at least by adjusting the second point of contact 60 via the steering pad assembly, defining in part the arc profile path of the BHA 34. In certain embodiments, the method 250 may further control the directional steering of the BHA 34 by adjusting the reamer 50 (e.g., expandable reamer 210) as discussed above with reference to
The technical effect of the disclosed embodiments includes improved steering and maneuvering of a BHA 34 via a compact arrangement of three points of contact 58, 60, and 62 via the drill bit 20, the steering pad assembly 54, and the reamer 50, rather than relying on a third point of contact along the drill string 18 further away from the BHA 34 and the reamer 50. In the illustrated embodiment, the three points of contact 58, 60, and 62 may be within a total axial distance of less than or equal to 1, 1.5, 2, 2.5, or 3 meters. By using the reamer 50 as the third point of contact 62, the BHA 34 can be controlled to turn with sharper turns (e.g., smaller radii of curvature), less time to make changes in direction (e.g., real-time or substantially real-time turning), and more responsive to sensed conditions in the subterranean formations.
The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. Moreover, the order in which the elements of the methods described herein are illustrated and described may be re-arranged, and/or two or more elements may occur simultaneously. The embodiments were chosen and described in order to best explain the principals of the disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the disclosure and various embodiments with various modifications as are suited to the particular use contemplated.
Finally, the techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).
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