Drilling assembly with a steering device for coiled-tubing operations

Information

  • Patent Grant
  • 6609579
  • Patent Number
    6,609,579
  • Date Filed
    Monday, March 18, 2002
    22 years ago
  • Date Issued
    Tuesday, August 26, 2003
    20 years ago
Abstract
A drilling assembly for drilling deviated wellbores includes a drill bit and a drilling motor that provides rotary power to the drill bit. A steering device integrated into drilling motor assembly contains a plurality of force application members. In one embodiment, each force application member is adapted to exert an adjustable amount of force on the wellbore interior. A separate or common power unit at or uphole of the drilling motor provides power to the force application members. A control device and control circuit can cooperate to independently operate each of the force application members. An inductive transmission device can be used to transmit electrical signals and/or power between rotating and non-rotating section of the drilling motor. During drilling of a wellbore, the force application members are operated to adjust the force on the wellbore to drill the wellbore in the desired direction.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




This invention relates generally to drill strings for drilling boreholes for the production of hydrocarbons and more particularly to a drilling assembly which utilizes a downhole controllable steering device for relatively accurate drilling of short-radius to medium-radius boreholes. The drilling assembly of the present invention is particularly useful with coiled-tubing operations.




2. Description of the Related Art




To obtain hydrocarbons such as oil and gas, boreholes or wellbores are drilled by rotating a drill bit attached to a drill string end. A large proportion of the current drilling activity involves directional drilling, i.e., drilling deviated and horizontal boreholes, to increase the hydrocarbon production and/or to withdraw additional hydrocarbons from the earth's formations. More recently, demand for drilling short to medium radius wellbores has been increasing. The term “short radius wellbores” generally means wellbores with radii between 12 and 30 meters, while the term “medium radius wellbores” generally means wellbores with radii between 30 and 300 meters.




Modern directional drilling systems generally employ a drilling assembly that includes a drill bit at its bottom end, which is rotated by a drill motor (commonly referred to as the “mud motor”) in the drilling assembly. The drilling assembly is conveyed into the wellbore by a coiled tubing. A fluid (“mud”) under pressure is injected into the tubing which rotates the drilling motor and thus the drill bit. The state-of-the-art coiled-tubing drill conveyed drilling assemblies usually contain a drilling motor with a fixed bend and an orienting tool to rotate the high side of the drilling motor downhole in the correct direction. The currently available coiled-tubing drilling assemblies (systems) with such orienting tools are typically more than sixteen (16) meters long. Tools of such length are difficult to handle and difficult to trip into and out of the wellbore. Furthermore, such tools require long risers at the surface. Such orienting tools require relatively high power to operate due to the high torque of the drilling motor and the friction relating to the orienting tool.




To drill a short radius or medium radius wellbore it is highly desirable to be able to drill such wellbores with relative precision along desired or predetermined wellbore paths (“wellbore profiles”), and to alter the drilling direction downhole without the need to retrieve the drilling assembly to the surface. Drilling assemblies for use with coiled tubing to drill short-radius wellbores in the manner described above need a dedicated steering device, preferably near the drill bit, for steering and controlling the drill bit while drilling the wellbore. The device needs to be operable during drilling of the wellbore to cause the drill bit to alter the drilling direction.




The present invention provides drilling assemblies that address the above-noted needs. In one embodiment, the drilling assembly includes a steering device in a bearing assembly which is immediately above the drill bit. The steering device may be operated to exert radial force in any one of several directions to articulate the drill bit along a desired drilling direction. The steering assembly may be disposed at other locations in the drilling assembly for drilling medium radius wellbores. Devices and/or sensors are provided in the drilling assembly to continuously determine the drilling assembly inclination, azimuth and direction. Other measurement-while-drilling (“MWD”) devices or sensors may be utilized in the drilling assembly, as is known in the drilling industry.




SUMMARY OF THE INVENTION




The present invention provides a drilling assembly for drilling deviated wellbores. The drilling assembly contains a drill bit at the lower end of the drilling assembly. A motor provides the rotary power to the drill bit. A bearing assembly disposed between the motor and the drill bit provides lateral and axial support to the drill shaft connected to the drill bit. A steering device integrated into the drilling motor, preferably in the bearing assembly provides direction control during the drilling of the wellbores. The steering device contains a plurality of ribs disposed at an outer surface of the bearing housing. Each rib is adapted to move between a normal position or collapsed position in the housing and a radially extended position. Each rib exerts force on the wellbore interior when in the extended position. Power units to independently control the rib actions are disposed in the bearing assembly. An electric control unit or circuit controls the operation of the power units in response to certain sensors disposed in drilling assembly. Sensors to determine the amount of the force applied by each of the ribs on the wellbore are provided in the bearing section. The electric control circuit may be placed at a suitable location above the drilling motor or in the rotating section of the drilling motor.




For drilling short radius wellbores, a knuckle joint or other suitable device may be disposed uphole of the steering device to provide a desired bend in the drilling assembly above the steering device. Electrical conductors are run from a power source above the motor to the various devices and sensors in the drilling assembly.




During drilling of a wellbore, the ribs start in their normal or collapsed positions near the housing. To alter the drilling direction, one or more ribs are activated, i.e., extended outwardly with a desired amount of force on each such rib. The amount of force on each rib is independently set and controlled. The rib force produces a radial force on the drill bit causing the drill bit to alter the drilling direction.




Examples of the more important features of the invention thus have been summarized rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject of the claims appended hereto.











BRIEF DESCRIPTION OF THE DRAWINGS




For detailed understanding of the present invention, 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:





FIGS. 1A-1B

show a cross-sectional view of a portion of the drilling assembly with the steering device and the control device disposed in the bearing assembly of the drilling assembly.





FIG. 1C

shows a rib of the steering device of in

FIG. 1A

in an extended position.





FIG. 1D

is a schematic view cross-sectional side view of an alternate embodiment of a power unit for a pump.





FIG. 2

is a schematic view of an alternative embodiment of a drilling assembly with steering members in the bearing assembly of the mud motor and the power and control devices for operating the steering members disposed above the mud motor.





FIG. 3

is a schematic view of an alternative embodiment of a drilling assembly with steering members and the power and control devices for operating the steering members disposed above the mud motor.





FIG. 4

is a schematic view of a configuration of the steering members disposed around a non-rotating housing for use in the steering device of

FIGS. 1-3

.





FIG. 5

is a schematic view of an alternative configuration of the steering members disposed around a non-rotating housing for use in the steering devices of

FIGS. 1-3

.





FIG. 6

is a schematic drawing of an embodiment of the drilling assembly according to the present invention.











DESCRIPTION OF THE PREFERRED EMBODIMENT




In general, the present invention provides a drilling assembly for use with coiled tubings to drill wellbores. The drilling assembly includes a drilling motor having a power section and a bearing assembly that provides radial and axial support to the drill bit. A steering device integrated into the bearing assembly provides directional control in response to one or more downhole measured parameters. The steering device included a plurality of independently controlled force application members, which are preferably controlled by a control unit or processor in response to one or more downhole measured parameters and predetermined directional models provided to the control unit.





FIGS. 1A-1B

show a schematic diagram of a steering device


30


integrated into a bearing assembly


20


of a drilling motor


10


. The drilling motor


10


forms a part of the drilling assembly


100


(FIG.


2


). The drilling motor


10


contains a power section


12


and the bearing assembly


20


. The power section


12


includes a rotor


14


that rotates in a stator


16


when a fluid


52


under pressure passes through a series of openings


17


between the rotor


14


and the stator


16


. The fluid


52


may be a drilling fluid or “mud” commonly used for drilling wellbores or it may be a gas or a liquid and gas mixture. The rotor


14


is coupled to a rotatable shaft


18


for transferring rotary power generated by the drilling motor


10


to the drill bit


50


.




The bearing assembly


20


has an outer housing


22


and a through passage


24


. A drive shaft


28


disposed in the housing


22


is coupled to the rotor


14


via the rotatable shaft


18


. The drive shaft


28


is connected to the drill bit


50


at its lower or downhole end


51


. During drilling of the wellbores, drilling fluid


52


causes the rotor


14


to rotate, which rotates the shaft


18


, which in turn rotates the drive shaft


28


and hence the drill bit


50


.




The bearing assembly


20


contains within its housing


22


suitable radial bearings


56




a


that provide lateral or radial support to the drive shaft


28


and the drill bit


50


, and suitable thrust bearings


56




b


to provide axial (longitudinal or along wellbore) support to the drill bit


50


. The drive shaft


28


is coupled to the shaft


18


by a suitable coupling


44


. The shaft


18


is a flexible shaft to account for the eccentric rotation of the rotor


14


. Any suitable coupling arrangement may be utilized to transfer rotational power from the rotor


14


to the drift shaft


28


. During the drilling of the wellbores, the drilling fluid


52


leaving the power section


12


enters the through passage


24


of the drive shaft


28


at ports or openings


46


and discharges at the drill bit bottom


53


. Various types of bearing assemblies are known in the art and are thus not described in greater detail here.




In the preferred embodiment of

FIGS. 1A-1B

, a steering device, generally represented by numeral


30


is integrated into the housing


22


of the bearing assembly


20


. The steering device


30


includes a number of force application members


32


. Each force application member is preferably placed in a reduced diameter section


34


of the bearing assembly housing


22


. The force application members may be ribs or pads. For the purpose of this invention, the force application members are generally referred herein as the ribs. Three ribs


32


, equispaced around or in the outer surface of the housing


22


, have been found to be adequate for properly steering the drill bit


50


during drilling operations. Each rib


32


is adapted to be extended radially outward from the housing


22


.

FIG. 1C

shows a rib


32


in its normal position


32




a


(also referred to as the “retracted” or “collapsed” position) and in fully extended position


32




b


relative to the wellbore inner wall


38


.




The operation of each steering rib


32


is independently controlled by a separate piston pump


40


. For short radius drilling assemblies, each such pump


40


is preferably an axial piston pump


40


disposed in the bearing assembly housing


22


. In one embodiment the piston pumps


40


are hydraulically operated by the drill shaft


28


utilizing the drilling fluid


52


flowing through the bearing assembly


20


. A control valve


33


is disposed between each piston pump


40


and its associated steering rib


32


to control the flow of the hydraulic fluid from such piston pump


40


to its associated steering rib


32


. Each control valve


33


is controlled by an associated valve actuator


37


, which may be a solenoid, magnetostrictive device, electric motor, piezoelectric device or any other suitable device. To supply the hydraulic power or pressure to a particular steering rib


32


, the valve actuator


37


is activated to provide hydraulic power to the rib


32


. If the valve actuator


37


is deactivated, the check valve is blocked, and the piston pump


40


cannot create pressure in the rib


32


. During drilling, all piston pumps


40


are operated continuously by the drift shaft


28


. In one method, the duty cycle of the valve actuator


37


is controlled by processor or control circuit


80


disposed at the suitable place in the drilling assembly


100


.

FIG. 1A

shows the control circuit


80


placed in the rotor


14


to conserve space. The control circuit may be placed at any other location, including at a location above the power section


12


. Referring now to

FIG. 1D

, instead of using the hydraulic power to operate the pumps


40


, each pump


40


may be operated by electric motors


41


suitably disposed in the bearing assembly


20


. A separate electric motor


41


may be operably connected to each pump


40


. Each of the electric motors can be configured to control a linear motion of pump to move the rib between a normal or collapsed position


32




a


and an extended position


32




b.






Still referring to

FIGS. 1A-1B

, it is known that the drilling direction can be controlled by applying a force on the drill bit


50


that deviates from the axis of the borehole tangent line. This can be explained by use of a force parallelogram depicted in FIG.


1


A. The borehole tangent line is the direction in which the normal force (or pressure) is applied on the drill bit


50


due to the weight on bit, as shown by the arrow WOB


57


. The force vector that deviates from this tangent line is created by a side force applied to the drill bit


50


by the steering device


30


. If a side force such as that shown by arrow


59


(Rib Force) is applied to the drilling assembly


100


, it creates a force


54


on the drill bit


50


(Bit Force). The resulting force vector


55


then lies between the weight on bit force line (Bit Force) depending upon the amount of the applied Rib Force.




In the present invention, each rib


32


can be independently moved between its normal or collapsed position


32




a


and an extended position


32




b.


The required side force on the drilling assembly is created by activating one or more of the ribs


32


. The amount of force on each rib


32


can be controlled by controlling the pressure on the rib


32


. The pressure on each rib


32


is preferably controlled by proportional hydraulics or by switching to the maximum pressure (force) with a controlled duty cycle. The duty cycle is controlled by controlling the operation of the valve actuator


37


by any known method.




The use of axial piston pumps


40


enables disposing such pumps


40


in the bearing assembly and relatively close to the ribs


30


. This configuration can reduce the overall length of the drilling assembly. Placing the ribs


32


in the housing


22


of the bearing assembly


20


aids in drilling relatively shorter radius boreholes. The above-described arrangement of the steering device


30


and the ability to independently control the pressure on each rib


32


enables steering the drill bit


12


in any direction and further enables drilling the borehole with a controlled build-out rate (deviation angle). Preferably a separate sensor


39


is provided in the bearing assembly


20


to determine the amount of force applied by each rib


32


to the borehole interior


38


. The sensor


39


may be a pressure sensor, a position measuring sensor or a displacement sensor. The processor


80


processes the signals from the sensor


39


and in response thereto and stored information or models controls the operation of each rib


32


and thus precisely controls the drilling direction.




To achieve higher build-up rates (“BUR”), such as rates of more than 60°/100 feet, a knuckle joint


60


may be disposed between the motor power section


14


and the steering devices


30


. The knuckle joint


60


is coupled to the bearing assembly


20


at the coupling


44


and to the shaft


28


with a coupling joint


45


. The knuckle joint


60


can be set at one or more bent positions


62


to provide a desired bend angle between the bearing assembly


20


and the motor power section


14


. The use of knuckle joints


60


is known in the art and thus is not described in detail herein. Any other suitable device for creating the desired bend in the drilling assembly


100


may be utilized for the purpose of this invention.




Electric conductors


65


are run from an upper end


11


or drilling motor


10


to the bearing assembly


20


for providing required electric power to the valve actuators


39


and other devices and sensors in the drilling motor


10


and to transmit data and signals between the drilling motor


10


and other devices in the system. The rotor


14


and the shaft


28


may be hollow to run conductors


65


therethrough. Appropriate feed-through connectors or couplings, such as coupling


63


, are utilized, where necessary, to run the electric conductors


65


though the drilling motor


10


. An electric slip ring


70


in the bearing assembly


20


and a swivel (not shown) at the top of the power section


12


is preferably utilized to pass the conductors


65


to the non-rotating parts in the bearing assembly


20


. Electric swivel and slip rings may be replaced by an inductive transmission device. The devices and sensors such as pressure sensors, temperature sensors, sensors to provide axial and radial displacement of the drill shaft


28


are preferably included in the drilling motor


10


to provide data about selected parameters during drilling of the boreholes.





FIG. 2

is a schematic view of an alternative embodiment of a drilling assembly


100


with steering members


30


in the bearing assembly


20


of the mud motor


10


and the power and control devices


90


for operating the steering members


30


disposed above the power section


12


of the mud motor


10


. In this configuration the rotor


14


is coupled to the drill shaft


28


by a suitable coupling or flexible shaft


19


. A common housing


92


with or without connection joints


93


may be used to house the stator


16


, coupling


19


and the bearing assembly


20


. A separate fluid line


91


is run from a source of hydraulic power in section


90


to each of the individual force application members


30


through the housing


92


. The section


90


contains the pumps and the control valves and the required control circuits to independently control the operation of each of the ribs


30


. This configuration is simpler than the configuration that contains the power and/or control devices in the mud motor


10


, more reliable as it does not require using mechanical and electrical connections inside the bearing housing


22


. It also enables building reduced overall length mud motors


10


compared to the configuration shown in FIG.


1


. The configuration of

FIG. 2

allows drilling of the wellbores with a higher build up rate compared due the proximity of the ribs


30


near the drill bit


50


and the shorter length of the drilling motor


10


. A stabilizer


83


is provided at a suitable location uphole of the ribs


30


to provide lateral stability to the drilling assembly


100


. Alternatively, a second set of ribs


30


may be incorporated into the drilling assembly as described below.





FIG. 3

is a schematic view of drilling assembly configuration wherein the ribs


30


are placed above the mud motor


10


and the power unit and the control devices to control the operation of the ribs is disposed in a suitable section above the mud motor


10


. A hydraulic line


93


provides the fluid to the ribs


30


. The operation of the steering devices shown in FIG.


2


and

FIG. 3

are similar to the operation of the embodiment of

FIGS. 1A-1C

. In yet another configuration, the ribs


30


may be placed in the bearing assembly


20


as show in FIG.


2


and also above the motor


10


as shown in FIG.


3


. In such a configuration, a separate line is run for each of the ribs. A common control circuit and a common hydraulic power unit may be used for all the ribs with each rib having a separate associated control valve. This configuration allows control of the drilling direction at multiple locations on the drilling assembly.





FIG. 4

is a schematic view of a configuration showing three force application members


32




a


-


32




c


disposed around the non-rotating housing


22


of the bearing assembly


20


of

FIGS. 1-3

. The configuration of

FIG. 4

shows three force application members


32




a


-


32




c


placed spaced apart around the periphery of the bearing assembly housing


22


. The force application members


32




a


-


32




c


are identical and thus the configuration and operation thereof is described with respect to only the member


32




a


. The force application member


32




a


includes a rib member


102




a


that is radially movable as shown by the arrows


110




a


. A hydraulically-operated piston


104




a


in a chamber


106




a


acts on the rib member


102




a


to moves the rib member


102




a


outward to cause it to apply force to the wellbore. The fluid is supplied to the chamber


106




a


from its associated power source via a port


108




a


. As described earlier, each force application member is independently operated to control the amount of the force exerted by such member to the wellbore inside, which allows precisely controlling the drilling direction of the wellbore. The force application members


32




b


and


32




c


respectively include pistons


104




b


and


104




c


, chambers


106




b


and


106




c


and inlet ports


108




b


and


108




c


and they move in the directions shown by the arrows


110




b


and


110




c


.

FIG. 5

is a schematic view of an alternative configuration of the steering members. This configuration differs from the configuration of

FIG. 4

in that it does not have the rib members. The pistons


112




a


-


112




c


directly apply the force on the wellbore walls the pistons are extended outward.





FIG. 6

shows a configuration of a drilling assembly


100


utilizing the steering device


30


(see

FIGS. 1A-1B

) of the present invention in the bearing assembly


20


coupled to a coiled tubing


202


. The drilling assembly


100


has the drill bit


50


at the lower end. As described earlier, the bearing assembly


20


above the drill bit


50


carries the steering device


30


having a number of ribs that are independently controlled to exert desired force on the drill bit


50


during drilling of the boreholes. An inclinometer (z-axis)


234


is preferably placed near the drill bit


50


to determine the inclination of the drilling assembly. The mud motor


10


provides the required rotary force to the drill bit


50


as described earlier with reference to

FIGS. 1A-1B

. A knuckle joint


60


may be provided between the bearing assembly


20


and the mud motor


10


. Depending upon the drilling requirements, the knuckle joint


60


may be omitted or placed at another suitable location in the drilling assembly


100


. A number of desired sensors, generally denoted by numerals


232




a


-


232




n


may be disposed in a motor assembly housing


15


or at any other suitable place in the assembly


100


. The sensors


232


-


232




n


may include a resistivity sensor, a gamma ray detector, and sensors for determining borehole parameters such as temperature and pressure, and drilling motor parameters such as the fluid flow rate through the drilling motor


10


pressure drop across the drilling motor


10


, torque on the drilling motor


10


and speed of the motor


10


.




The control circuit


80


may be placed above the power section


12


to control the operation of the steering device


30


. A slip ring transducer


221


may also placed in the section


220


. The control circuits in the section


220


may be placed in a rotating chamber which rotates with the motor. The drilling assembly


100


may include any number of other devices. It may include navigation devices


222


to provide information about parameters that may be utilized downhole or at the surface to control the drilling operations and/or devices to provide information about the true location of the drill bit


50


and/or the azimuth. Flexible subs, release tools with cable bypass, generally denoted herein by numeral


224


, may also be included in the drilling assembly


100


. The drilling assembly


100


may also include any number of additional devices known as the measurement-while-drilling devices or logging-while-drilling devices for determining various borehole and formation parameters, such as the porosity of the formations, density of the formation, and bed boundary information. The electronic circuitry that includes microprocessors, memory devices and other required circuits is preferably placed in the section


230


or in an adjacent section (not shown). A two-way telemetry


240


provides two-way communication of data between the drilling assembly


100


and the surface equipment. Conductors


65


placed along the length of the coiled-tubing may be utilized to provide power to the downhole devices and the two-way data transmission.




The downhole electronics in the section


220


and/or


230


may be provided with various models and programmed instructions for controlling certain functions of the drilling assembly


100


downhole. A desired drilling profile may be stored in the drilling assembly


100


. During drilling, data/signals from the inclinometer


234


and other sensors in the sections


222


and


230


are processed to determine the drilling direction relative to the desired direction. The control device, in response to such information, adjusts the force on force application members


32


to cause the drill bit


50


to drill the wellbore along the desired direction. Thus, the drilling assembly


100


of the present invention can be utilized to drill short-radius and medium radius wellbores relatively accurately and, if desired, automatically.




The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention. It is intended that the following claims be interpreted to embrace all such modifications and changes.



Claims
  • 1. A method of drilling a wellbore, comprising:(a) providing a drilling assembly having a drilling motor operated by a drilling fluid; (b) providing a plurality of force application members arranged around a section of the drilling motor, each force application member extending radially outward from the drilling motor to apply force to the wellbore inside, upon the application of power thereto; (c) providing a separate power unit operably coupled to each force application member, the separate power units being disposed in the drilling motor and supplying power to an associated force application member; and (d) operating the power units to separately operate the force application members.
  • 2. The method according to claim 1, wherein each power unit includes a pump for supply pressurized fluid to the force application members.
  • 3. The method according to claim 1, wherein each power unit includes a separate electric motor associated with a separate control device for controlling the supply of the power to the force application members, each electric motor controlling a linear motion of its control device to move the force application member between a normal position and an extended position.
  • 4. The method according to claim 3, further comprising controlling the operation of the control devices with a control circuit.
  • 5. The method according to claim 4, further comprising placing the control circuit in a rotating part of the drilling motor.
  • 6. The method according to claim 3, wherein each control device is a fluid control valve.
  • 7. The method according to claim 6, further comprising controlling the operation of the control valve with a valve actuator.
  • 8. The method according to claim 7, wherein the valve actuator is selected from a group consisting of (a) magnetostrictive device; (b) an electric motor; and (c) a piezoelectric device.
  • 9. The method according to claim 8, further comprising duty cycling the valve actuator to control the supply of a pressurized fluid to its associated force application member.
  • 10. The method according to claim 1, further comprising providing the drilling motor with a power section and a bearing assembly; and integrating the force application devices into the bearing assembly.
  • 11. The method according to claim 1, supplying a pressurized fluid to each of the force application members to move each force application member between a normal position and a radially-extended position.
  • 12. The method according to claim 1, further comprising operating each power unit by one of (a) a rotating shaft associated with the drilling motor, and (b) an electric motor.
  • 13. The method according to claim 1, wherein the drilling fluid is selected from a group of fluids consisting of a (i) gas, and (ii) liquid-gas mixture.
  • 14. The method according to claim 1, supplying a pressurized fluid to each force application member, the force application members each including a piston that radially moves a rib member of the force application member upon receiving the pressurized fluid from each power unit.
  • 15. The method according to claim 1, further comprising providing a sensor for each force application member; and providing signals indicative of the position of each such force application member relative to a reference position.
  • 16. The method according to claim 15, further comprising controlling independently the operation of each force application member in response to the measurements of the sensors and according to instructions provided thereto.
  • 17. A coiled tubing conveyed drilling assembly for use in drilling of a wellbore, comprising:(a) a drilling motor for generating a rotary force in response to the flow of a drilling fluid through the drilling motor; and (b) a steering device integrated into the drilling motor for controlling the drilling direction of the drilling assembly, said steering device including: (i) a plurality of force application members arranged around and extending radially outward from a section of the drilling motor, each said force application member adapted to apply an adjustable amount of force to the wellbore inside, upon the application of power thereto; (ii) a common power unit operably coupled to said force application members, said common power unit being disposed uphole of said drilling motor and supplying power to an associated said force application members; and (iii) a separate control device associated with each said force application member for controlling the power provided to each associated said force application member.
  • 18. The drilling assembly according to claim 17, wherein said power unit includes a pump for supplying pressurized fluid to said force application members.
  • 19. The drilling assembly according to claim 17, further comprising a control circuit for controlling the operation of said control devices.
  • 20. The drilling assembly according to claim 17, wherein said drilling motor includes a power section and a bearing assembly and wherein said steering device is integrated in said bearing assembly.
  • 21. The drilling assembly according to claim 17, wherein said power unit includes a pump for supplying a pressurized fluid to each of said force application members to move each said force application member between a normal position and a radially-extended position.
  • 22. The drilling assembly according to claim 17, wherein each said control device is a fluid control valve.
  • 23. The drilling assembly according to claim 22, further comprising a valve actuator for each said control valve for controlling the operation of such control valve.
  • 24. The drilling assembly according to claim 23, wherein said valve actuator is selected from a group consisting of (a) a magnetostrictive device; (b) an electric motor; and (c) a piezoelectric device.
  • 25. The drilling assembly according to claim 23, wherein said valve actuator is duty cycled to control the supply of a pressurized fluid to its said associated force application member.
  • 26. The drilling assembly according to claim 17, wherein said power unit is operated by one of (a) a rotating shaft associated with the drilling motor, an (b) and electric motor.
  • 27. The drilling assembly according to claim 17, wherein said drilling fluid is selected from a group of fluids consisting of a (i) gas, and (ii) liquid-gas mixture.
  • 28. The drilling assembly according to claim 17, wherein said power unit supplies a pressurized fluid, and wherein each force application member includes a piston that radially moves a rib member of the force application member to exert an adjustable amount of force on the wellbore inside upon receiving the pressurized fluid from said power unit.
  • 29. The drilling assembly according to claim 17, further comprising a sensor associated with each force application member for providing signals indicative of the force applied by each force application member.
  • 30. The drilling assembly according to claim 29 wherein each said separate control device independently controls the operation of each said force application member in response to the measurements of said sensors and according to instructions provided thereto.
  • 31. The drilling assembly according to claim 17 wherein said control device controls a pressure provided to each said associated force application member by one of proportional hydraulics and controlled duty cycle.
  • 32. A method of drilling a wellbore, comprising:(a) providing a drilling motor for generating a rotary force in response to the flow of a drilling fluid through the drilling motor; and (b) providing a plurality of force application members arranged around and extending radially outward from a section of the drilling motor, each force application member adapted to apply an adjustable amount of force to the wellbore inside, upon the application of power thereto; (c) operating the force application members with a common power unit disposed uphole of the drilling motor and by supplying power to an associated force application member; and (d) controlling the power provided to each associated force application member with a separate control device associated with each force application member.
  • 33. The drilling method according to claim 32, further comprising supplying pressurized fluid to the force application members.
  • 34. The drilling method according to claim 32, further comprising controlling the operation of the control devices with a control circuit.
  • 35. The drilling method according to claim 32, further comprising providing the drilling motor with a power section and a bearing assembly; and integrating the force application devices into the bearing assembly.
  • 36. The drilling method according to claim 32, further comprising providing the power unit with a pump for supplying a pressurized fluid to each of the force application members to move each force application member between a normal position and a radially-extended position.
  • 37. The drilling method according to claim 32, wherein each control device is a fluid control valve.
  • 38. The drilling method according to claim 37, further comprising controlling the operation of each control valve with a valve actuator.
  • 39. The drilling method to claim 38, wherein the valve actuator is selected from a group consisting of (a) a magnetostrictive device; (b) an electric motor; and (c) a piezoelectric device.
  • 40. The drilling method according to claim 38, further comprising duty cycling the valve actuator to control the supply of a pressurized fluid to its associated force application member.
  • 41. The drilling method according to claim 32, wherein the drilling fluid is selected from a group of fluids consisting of a (i) gas, and (ii) liquid-gas mixture.
  • 42. The drilling method according to claim 32, further comprising supplying a pressurized fluid to the force application members using the power unit; providing each force application member with a piston that radially moves a rib member of the force application member to exert an adjustable amount of force on the wellbore inside upon receiving the pressurized fluid from the power unit.
  • 43. The drilling method according to claim 32, further comprising providing signals indicative of the force applied by each force application member.
  • 44. The drilling method according to claim 43, wherein each separate control device independently controls the operation of each force application member in response to the measurements of the sensors and according to instructions provided thereto.
  • 45. The drilling method according to claim 32, further comprising controlling the pressure provided to each associated force application member by one of proportional hydraulics and a controlled duty cycle.
  • 46. The drilling method according to claim 32, further comprising operating the power unit by one of (a) a rotating shaft associated with the drilling motor, and (b) an electric motor.
  • 47. A coiled tubing conveyed drilling assembly for use in drilling of a wellbore, comprising:(a) a drilling motor for generating a rotary force in response to the flow of a drilling fluid through the drilling motor; and (b) a steering device integrated into the drilling motor for controlling the drilling direction of the drilling assembly, said steering device including: (i) a plurality of force application members arranged around and extending radially outward for a non-rotating section of the drilling motor, each said force application member adapted to apply force to the wellbore inside, upon the application of power thereto; (ii) a separate power unit operably coupled to each one of said force application members for supplying power to said force application members; (iii) a control device associated with each said force application member for controlling the power provided to each associated said force application member; and (iv) an inductive transmission device for transferring one of electrical power and electrical signals between a rotating section and said non-rotating section of said drilling motor.
  • 48. The drilling assembly according to claim 47 further comprising a control circuit for controlling the operation of said control device, said control circuit being placed in said rotating section of said drilling motor.
  • 49. The drilling assembly according to claim 47 further comprising a sensor associated with each force application member for providing signals indicative of the position of each said force application member relative to a reference position.
  • 50. The drilling assembly according to claim 49, wherein said control devices independently control the operation of each said force application member in response to the measurements of said sensors and according to instructions provided thereto.
  • 51. The drilling assembly according to claim 47 wherein said control devices control a pressure provided to each said associated force application member by one of proportional hydraulics and a controlled duty cycle.
  • 52. A method for drilling a wellbore, comprising:(a) providing a drilling motor for generating a rotary force in response to the flow of a drilling fluid through the drilling motor; and (b) providing a plurality of force application members arranged around and extending radially outward from a non-rotating section of the drilling motor, each force application member adapted to apply force to the wellbore inside, upon the application of power thereto; (c) coupling a separate power unit to each one of the force application members to supply power to the force application members; (d) controlling the power provided to each force application member with a control device; and (e) transferring one of electrical power and electrical signals between a rotating section and the non-rotating section of the drilling motor with an inductive transmission device.
  • 53. The drilling method according to claim 52 further comprising controlling the operation of the control device with a control circuit placed in the rotating section of the drilling motor.
  • 54. The drilling method according to claim 52 further comprising providing signals indicative of the position of each force application member relative to a reference position using a sensor associated with each force application member.
  • 55. The drilling method according to claim 54 further comprising independently controlling the operation of each force application member in response to the measurements of the sensors and according to instructions provided thereto.
  • 56. The drilling method according to claim 52 further comprising controlling a presssure provided to each associated force application member by one of proportional hydraulics and a controlled duty cycle.
CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of co-pending application Ser. No. 09/711,213 filed Nov. 9, 2000, which is a continuation of Ser. No. 09/015,848, filed on Jan. 29, 1998, now abandoned, which claimed benefit of provisional U.S. patent application Ser. No. 60/036,572, filed on Jan. 30, 1997.

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Provisional Applications (1)
Number Date Country
60/036572 Jan 1997 US
Continuations (2)
Number Date Country
Parent 09/711213 Nov 2000 US
Child 10/100671 US
Parent 09/015848 Jan 1998 US
Child 09/711213 US