The present invention relates to the field of downhole oil, gas, and/or geothermal exploration and more particularly to the field of drill bits for tool strings of such exploration.
Since the beginning of downhole drilling, a lot of time and resources have been invested in developing an optimal drill bit for a downhole tool string. Because of the enormous expense associated with running a drill rig, the operational quality of a drill bit may provide substantial economic benefits.
Today's drill bits generally serve at least two purposes. Using rotary energy provided by the tool string they bore through downhole formations, thus advancing the tool string further into the ground. They also function to dispense drilling mud pumped through the tool string that lubricates parts and washes cuttings and formation material to the surface.
The prior art contains references to drill bits with sensors or other apparatus for data retrieval. For example, U.S. Pat. No. 6,150,822 to Hong, et al discloses a microwave frequency range sensor (antenna or wave guide) disposed in the face of a diamond or PDC drill bit configured to minimize invasion of drilling fluid into the formation ahead of the bit. The sensor is connected to an instrument disposed in a sub interposed in the drill stem for generating and measuring the alteration of microwave energy.
U.S. Pat. No. 6,814,162 to Moran, et al discloses a drill bit, comprising a bit body, a sensor disposed in the bit body, a single journal removably mounted to the bit body, and a roller cone rotatably mounted to the single journal. The drill bit may also comprise a short-hop telemetry transmission device adapted to transmit data from the sensor to a measurement-while-drilling device located above the drill bit on the drill string.
U.S. Pat. No. 6,913,095 to Krueger discloses a closed-loop drilling system utilizes a bottom hole assembly (“BHA”) having a steering assembly having a rotating member and a non-rotating sleeve disposed thereon. The sleeve has a plurality of expandable force application members that engage a borehole wall. A power source and associated electronics for energizing the force application members are located outside of the non-rotating sleeve.
In one aspect of the invention, a drill bit assembly has a body portion intermediate a shank portion and a working portion. The working portion has at least one cutting element. The drill bit assembly also has a shaft with an end substantially coaxial to a central axis of the assembly. The second end of the shaft protrudes from the working portion, and at least one downhole logging device is disposed within the shaft.
The logging device of the drill bit assembly may engage a downhole formation. The logging device may also be in communication with a downhole network. In some embodiments, the drill bit assembly comprises a plurality of logging devices disposed within the shaft. At least a portion of the shaft may be electrically isolated from the body portion when resistivity or similar parameters are being sensed. The logging device may comprise a resistivity sensor, an acoustic sensor, hydrophone, an annular pressure sensor, formation pressure sensor, a gamma ray sensor, density neutron sensor, a geophone array, or an accelerometer, directional drilling sensor, an inclination system that may include a gyroscopic device, a drilling dynamics sensor, another system that may be used to evaluate formation properties, an active sensor, a passive sensor, a nuclear source, a gamma source, a neutron source, an electrical source, an acoustic wave source, a seismic source, a sonic source, or combinations thereof
In another aspect of the invention, a method of downhole data retrieval includes the steps of providing a drill bit assembly having a body portion intermediate a shank portion and a working portion and providing a shaft comprising an end substantially protruding from the working portion, the shaft having at least one downhole logging device. The method includes the additional step of relaying data from the downhole logging device to tool string control equipment.
In an additional step, the method may include engaging a downhole formation with the end of the shaft. The data may be relayed from the downhole logging device to the tool string control equipment through a downhole network and/or logged by a downhole processing element. The method may also include the step of steering the drill bit assembly based on data received from the logging device.
In still another aspect of the invention, a drill bit assembly has a body portion intermediate a shank portion and a working portion. The working portion has at least one cutting element. A shaft has a first end disposed within the body portion and a second end which is substantially coaxial to a central axis of the assembly. The second end of the shaft substantially protrudes from the working portion, and at least one downhole logging device is in communication with the shaft.
The shaft of the drill bit assembly may engage a downhole formation. The downhole logging device may be disposed within the body portion, the working portion, or another area of a tool string. The sensor may be in communication with a downhole network.
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The drill bit assembly further comprises a shaft 125 having a first end 135 disposed within the body portion and a second end 130 which is substantially coaxial to a central axis 140 of the assembly 100. The second end 130 of the shaft 125 substantially protrudes from the working portion 115. In some embodiments, of the present invention, the shaft may simply be a protrusion formed in the working portion of the drill bit assembly. Fluid channels 165 may allow drilling mud or another fluid to pass through the drill bit assembly 100.
The '022, '391, and '307 U.S. Patent Applications to David Hall previously cited in the cross reference to related applications section and incorporated into this disclosure, teach many of the mechanical merits of a shaft 125 extending from the working portion 115 of the drill bit assembly 100. For example, working in conjunction with cutting elements 120, the shaft 125 may help to break up rock formations and increase the rate of formation penetration by the drill bit assembly 100. The shaft 125 may also be used to help steer the assembly 100. In addition to these mechanical benefits, considerable data logging benefits may also be realized from the use of a shaft 125 protruding from the working portion 115 of the drill bit assembly 100. This is because the shaft 125 may enable measuring certain attributes of a downhole formation 155 because of its location and because it physically engages the formation 155. The present invention is believed to improve the ability to take downhole measurements, such measurements include at least formation resistivity, salinity, neutron or sonic porosity, natural gamma, pH, formation density, formation pressure, annular pressure, gas, oil or other fluid detection, lithology identification, clay analysis, depth, temperature, formation fracture detection, borehole stability, formation velocity or slowness, or nuclear magnetic resonance NMR.
The shaft 125 may comprise an energy source 145. The energy source may be used in conjunction with a corresponding energy receiver 150 located at a different point on the drill bit assembly 100 or along the tool string. The energy source 145 may be an electric terminal configured to pass a current or a voltage into the downhole formation 155 as it engages the downhole formation 155. The electric current or voltage may then be received at the corresponding energy receiver 150. By regulating the distance between the energy source 145 and the energy receiver 150 and by applying either the current or voltage between the energy source and the receiver, valuable resistivity measurements may be made on the downhole formation 155. In some embodiments, the energy source 145 may be electrically isolated from the energy receiver 150 by a special dielectric layer 125. In other embodiments it may be feasible to electrically isolate the energy source 145 from the energy receiver by electrically isolating the energy receiver 150. The energy source 145 and receiver 150 may function together as a sensor.
In other embodiments, the energy source 145 may be a radioactive source, an emitting device, an acoustic source, passive source, an active source or combinations thereof In other embodiments of the invention, the shaft comprises or is in communication with a sensor a resistivity sensor system, an acoustic sensor system, hydrophone system, an annular pressure sensor system, formation pressure sensor system, a gamma ray sensor system, density neutron sensor system, a geophone array system, or an accelerometer system, directional drilling system, an inclination sensor system that may include a gyroscopic device, a drilling dynamics system, another system that may be used to evaluate formation properties, an active sensor, a passive sensor, or combinations thereof.
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In this embodiment, the shaft 125 comprises a sensor 405. While the sensor 405 shown is an induction-type resistivity sensor, in other embodiments the sensor 405 may be a laterolog resistivity sensor, a short normal resistivity sensor, an electromagnetic wave resistivity tool, a nuclear sensor, an acoustic sensor, or a pressure sensor. It is believed that an elongated shaft 125 as shown in this figure may substantially engage the downhole formation 155 and provide data that more accurately represents the characteristics of the formation 155 being drilled.
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One advantage of such a configuration is that under circumstances in which the shaft 125 engages a downhole formation, the energy emitted from the energy source 145 almost entirely passes through the formation 155 and minimize interference from drilling fluids and other materials used in drilling. The energy source 145 may also be used in conjunction with additional receivers 150 situated further up the downhole tool string 160.
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In other embodiments an acoustic signal may be generated downhole through acoustic sources disposed in the drill bit assembly 100 or other locations on the tool string 160. The acoustic signal may also come from another well bore, or in some embodiments, the acoustic signal may be generated by the vibrations in the earth generated as the drill bit assembly advances in the earth. In yet another embodiment, the acoustic signal may be generated by the process of pressurizing and fracturing the formation along weakness in the formation. In such an embodiment, the bore hole may be pressurized to an extent that the formation breaks at its weakest points. The vibrations generated by the fracturing of the formation may be recorded by the sensors 405. The sensors 405 may be in communication with a local storage module 905 that may log their data and/or provide them with electrical power. The control module 905 may communicate with tool string control equipment to assist in planning the trajectory of the tool string 160.
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A drill bit assembly 100 according to the present invention may be in communication with one or more tools in a network. Referring now to
The tool string 160 may be suspended by a derrick 1301. Data may be transmitted along the tool string 160 through techniques known in the art. A preferred method of downhole data transmission using inductive couplers disposed in tool joints is disclosed in the U.S. Pat. No. 6,670,880 to Hall, et al, which is herein incorporated by reference for all it discloses. An alternate data transmission path may comprise direct electrical contacts in tool joints such as in the system disclosed in U.S. Pat. No. 6,688,396 to Floerke, et al., which is herein incorporated by reference for all that it discloses. Another data transmission system that may also be adapted for use with the present invention is disclosed in U.S. Pat. No. 6,641,434 to Boyle, et al., which is also herein incorporated by reference for all that it discloses. In some embodiments, of the present invention alternative forms of telemetry may be used to communicate with the drill bit assembly, such as telemetry systems that communicate through the drilling mud or through the earth. Such telemetry systems may use electromagnetic of acoustic waves. The alternative forms of telemetry may be the primary telemetry system for communication with the drill bit assembly or they may be back-up systems designed to maintain some communication if the primary telemetry system fails.
A data swivel 1302, or a wireless top-hole data connection may facilitate the transfer of data between the rotatable tool string 160 and the stationary surface equipment 1303. Downhole tool string components 1305 may comprise drill pipes, jars, shock absorbers, mud hammers, air hammers, mud motors, turbines, reamers, under-reamers, fishing tools, steering elements, MWD tools, LWD tools, seismic sources, seismic receivers, pumps, perforators, packers, other tools with an explosive charge, and mud-pulse sirens.
Having a network 1300 in the tool string 160 may enable high-speed communication between each device connected to it and facilitate the transmission and receipt of data between sensors 405, energy sources 145, and energy receivers 150 in the shaft 125 of the drill bit assembly 100.
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The method 1500 may include the step of engaging a downhole formation with the end of the shaft. This may provide optimal measurements and/or data from the sensor disposed within the shaft. The data may be relayed 1515 from the sensor to tool string control equipment such as downhole intelligent steering equipment or surface control equipment through a downhole network. The tool string control equipment may then change drilling parameters according to the data received to optimize drilling efficiency. For example, the drill bit assembly may be steered according to data received from the sensor.
The data may also be logged in a local storage module for later retrieval or delayed transmission to tool string control equipment.
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The method 1600 may also include the step of engaging a downhole formation with the end of the shaft. The portion of the emitted energy received 1620 in the downhole tool may be used to sense parameters of the formation, such as resistivity, composition, physical dimensions, and other properties. The portion of emitted energy received 1620 may also be logged as data and be stored in a local storage module such as a processing element. Other properties of the energy received 1620 may also be logged as data such as distortions or transformations in waveforms.
The data may be sent to tool string control equipment through a downhole network. As in the method 1500 of
Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.
This application is a continuation in part of U.S. application Ser. No. 11/277,380 filed Mar. 24, 2006 entitled “A Drill Bit Assembly Adapted to Provide Power Downhole”, The U.S. application Ser. No. 11/277,380 is a continuation-in-part of U.S. patent application Ser. No. 11/306,976 which was filed on Jan. 18, 2006 and entitled “Drill Bit Assembly for Directional Drilling.” U.S. patent application Ser. No. 11/306,976 is a continuation-in-part of 11/306,307 filed on Dec. 22, 2005, entitled Drill Bit Assembly with an Indenting Member. U.S. patent application Ser. No. 11/306,307 is a continuation-in-part of U.S. patent application Ser. No. 11/306,022 filed on Dec. 14, 2005, entitled Hydraulic Drill Bit Assembly. U.S. patent application Ser. No. 11/306,022 is a continuation-in-part of U.S. patent application Ser. No. 11/164,391 filed on Nov. 21, 2005, which is entitled Drill Bit Assembly. All of these applications are herein incorporated by reference in their entirety.
Number | Date | Country | |
---|---|---|---|
Parent | 11277380 | Mar 2006 | US |
Child | 11277394 | Mar 2006 | US |
Parent | 11306976 | Jan 2006 | US |
Child | 11277380 | Mar 2006 | US |
Parent | 11306307 | Dec 2005 | US |
Child | 11306976 | Jan 2006 | US |
Parent | 11306022 | Dec 2005 | US |
Child | 11306307 | Dec 2005 | US |
Parent | 11164391 | Nov 2005 | US |
Child | 11306022 | Dec 2005 | US |