Energy Storage Drill Pipe

BACKGROUND

Oil wells are created by drilling a hole into the earth, in some cases using a drilling rig that rotates a drill string (e.g., drill pipe) having a drill bit attached thereto. In other cases, the drilling rig does not rotate the drill bit. For example, the drill bit can be rotated down-hole. The drill bit, aided by the weight of pipes (e.g., drill collars) cuts into rock within the earth. Drilling fluid (e.g., mud) is pumped into the drill pipe and exits at the drill bit. The drilling fluid may be used to cool the bit, lift rock cuttings to the surface, at least partially prevent destabilization of the rock in the wellbore, and/or at least partially overcome the pressure of fluids inside the rock so that the fluids do not enter the wellbore. Other equipment can also be used for evaluating formations, fluids, production, other operations, and so forth.

SUMMARY

Aspects of the disclosure can relate to a bottom hole assembly that includes a pipe having a pipe wall with an external surface and an internal surface and defining a longitudinal passage therethrough. The bottom hole assembly also includes an energy storage device in the pipe wall between the external surface and the internal surface and extending from a first end of the pipe wall. The bottom hole assembly further includes a second device to connect to the pipe. The bottom hole assembly also includes a connector for connecting the energy storage device to the second device. The connector facilitates energy transfer between the energy storage device and the second device.

Other aspects of the disclosure can relate to a pipe that includes a pipe wall having an external surface and an internal surface and defining a longitudinal passage therethrough. The pipe also includes an energy storage device in the pipe wall between the external surface and the internal surface. The pipe further includes a connector for connecting the energy storage device to a second device, wherein the connector facilitates energy transfer between the energy storage device and the second device.

Also, aspects of the disclosure can relate to a method including forming a pipe wall having an external surface and an internal surface and defining a longitudinal passage therethrough. The method also includes positioning an energy storage device in the pipe wall between the external surface and the internal surface. The method further includes forming a connector for connecting the energy storage device to a second device. The connector facilitates energy transfer between the energy storage device and the second device.

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 limiting the scope of the claimed subject matter.

FIGURES

Embodiments of energy storage drill pipe are described with reference to the following figures. The same numbers are used throughout the figures to reference like features and components.

FIG. 1 illustrates an example system in which embodiments of energy storage pipe can be implemented;

FIG. 2 illustrates an example energy storage pipe in accordance with one or more embodiments;

FIG. 3 is a cross-sectional side view of an example energy storage pipe, such as the energy storage pipe illustrated in FIG. 2, in accordance with one or more embodiments;

FIG. 4 illustrates another example energy storage pipe in accordance with one or more embodiments;

FIG. 5 is a cross-sectional side view of an example energy storage pipe, such as the energy storage pipe illustrated in FIG. 4, in accordance with one or more embodiments;

FIG. 6 illustrates a further example energy storage pipe in accordance with one or more embodiments;

FIG. 7 is a cross-sectional side view of an example energy storage pipe, such as the energy storage pipe illustrated in FIG. 6, in accordance with one or more embodiments;

FIG. 8 illustrates an example energy storage pipe in accordance with one or more embodiments;

FIG. 9 is a block diagram illustrating an example energy storage pipe in accordance with one or more embodiments;

FIG. 10 is a block diagram illustrating a connector for an energy storage pipe, such as the energy storage pipe illustrated in FIG. 9, in accordance with one or more embodiments;

FIG. 11 is a block diagram illustrating an energy storage device for an energy storage pipe, such as the energy storage pipe illustrated in FIG. 9, in accordance with one or more embodiments;

FIG. 12 illustrates an example method of forming an energy storage pipe in accordance with one or more embodiments; and

FIG. 13 is a cross-sectional end view of an example energy storage pipe, such as the energy storage pipe illustrated in FIG. 8, in accordance with one or more embodiments.

DETAILED DESCRIPTION

FIG. 1 depicts a wellsite system 100 in accordance with one or more embodiments of the present disclosure. The wellsite can be onshore or offshore. A borehole 102 is formed in subsurface formations by directional drilling. A drill string 104 extends from a drill rig 106 and is suspended within the borehole 102. In some embodiments, the wellsite system 100 implements directional drilling using a rotary steerable system (RSS). For instance, the drill string 104 is rotated from the surface, and down-hole devices move the end of the drill string 104 in a desired direction. The drill rig 106 includes a platform and derrick assembly positioned over the borehole 102. In some embodiments, the drill rig 106 includes a rotary table 108, kelly 110, hook 112, rotary swivel 114, and so forth. For example, the drill string 104 is rotated by the rotary table 108, which engages the kelly 110 at the upper end of the drill string 104. The drill string 104 is suspended from the hook 112 using the rotary swivel 114, which permits rotation of the drill string 104 relative to the hook 112. However, this configuration is provided by way of example and is not meant to limit the present disclosure. For instance, in other embodiments a top drive system is used.

As described herein, drilling applications are provided by way of example and are not meant to limit the present disclosure. In other embodiments, systems, techniques, and apparatus as described herein can be used with other down-hole operations, such as with equipment for applications including, but not necessarily limited to: well testing, simulation, completion, and so forth.

In embodiments of the disclosure, the drill string 104 includes a number of drill pipes 120 that extend the bottom hole assembly 116 into subterranean formations. Drilling fluid (e.g., mud) 122 is stored in a tank and/or a pit 124 formed at the wellsite. The drilling fluid can be water-based, oil-based, and so on. A pump 126 displaces the drilling fluid 122 to an interior passage of the drill string 104 via, for example, a port in the rotary swivel 114, causing the drilling fluid 122 to flow downwardly through the drill string 104 as indicated by directional arrow 128. The drilling fluid 122 exits the drill string 104 via ports (e.g., courses, nozzles) in the drill bit 118, and then circulates upwardly through the annulus region between the outside of the drill string 104 and the wall of the borehole 102, as indicated by directional arrows 130. In this manner, the drilling fluid 122 cools and lubricates the drill bit 118 and carries drill cuttings generated by the drill bit 118 up to the surface (e.g., as the drilling fluid 122 is returned to the pit 124 for recirculation).

In some embodiments, the bottom hole assembly 116 includes a logging-while-drilling (LWD) module 132, a measuring-while-drilling (MWD) module 134, a rotary steerable system 136, a motor, and so forth (e.g., in addition to the drill bit 118). The logging-while-drilling module 132 can be housed in a drill collar and can contain one or a number of logging tools. It should also be noted that more than one LWD module and/or MWD module can be employed (e.g. as represented by another logging-while-drilling module 138). In embodiments of the disclosure, the logging-while drilling modules 132 and/or 138 include capabilities for measuring, processing, and storing information, as well as for communicating with surface equipment, and so forth.

The measuring-while-drilling module 134 can also be housed in a drill collar, and can contain one or more devices for measuring characteristics of the drill string 104 and drill bit 118. The measuring-while-drilling module 134 can also include components for generating electrical power for the down-hole equipment. This can include a mud turbine generator (also referred to as a “mud motor”) powered by the flow of the drilling fluid 122. However, this configuration is provided by way of example and is not meant to limit the present disclosure. In other embodiments, other power and/or battery systems can be employed. The measuring-while-drilling module 134 can include one or more of the following measuring devices: a weight-on-bit measuring device, a torque measuring device, a vibration measuring device, a shock measuring device, a stick slip measuring device, a direction measuring device, an inclination measuring device, and so on.

In embodiments of the disclosure, the wellsite system 100 is used with controlled steering or directional drilling. For example, the rotary steerable system 136 is used for directional drilling. As used herein, the term “directional drilling” describes intentional deviation of the wellbore from the path it would naturally take. Thus, directional drilling refers to steering the drill string 104 so that it travels in a desired direction. In some embodiments, directional drilling is used for offshore drilling (e.g., where multiple wells are drilled from a single platform). In other embodiments, directional drilling enables horizontal drilling through a reservoir, which enables a longer length of the wellbore to traverse the reservoir, increasing the production rate from the well. Further, directional drilling may be used in vertical drilling operations. For example, the drill bit 118 may veer off of a planned drilling trajectory because of the unpredictable nature of the formations being penetrated or the varying forces that the drill bit 118 experiences. When such deviation occurs, the wellsite system 100 may be used to guide the drill bit 118 back on course.

FIGS. 2 through 9 depict pipes 200 that can be used with, for example, a wellsite system (e.g., the wellsite system 100 described with reference to FIG. 1). For instance, one or more pipes 200 can be used with a bottom hole assembly suspended at the end of a drill string (e.g., in the manner of the bottom hole assembly 116 suspended from the drill string 104 depicted in FIG. 1). For example, a pipe 200 can be used as a drill collar. In some embodiments, a bottom hole assembly is implemented using a drill bit. However, this configuration is provided by way of example and is not meant to limit the present disclosure. In other embodiments, different working implement configurations are used. Additionally, one or more pipes 200 can be used to suspend a bottom hole assembly at the end of a drill string (e.g., in the manner of drill pipe 120 for the drill string 104 depicted in FIG. 1). Pipes 200 can also be used as testing string pipe, completion pipe, and so forth. It should also be noted that pipes 200 in accordance with the present disclosure are not limited to wellsite systems described herein. Pipes 200 can be used in other various applications, including but not necessarily limited to: cutting and/or crushing applications, testing applications, simulation applications, measurement applications, and so forth.

Modern oil and gas exploration increasingly uses electronic devices in the borehole to provide measurements, and for control and operational optimization. When operating electronics as part of a drill string and/or other down-hole equipment and/or strings (e.g., for well testing, well simulation, well monitoring, formation evaluation, etc.), available power in the borehole may be limited near a bottom hole assembly. In some cases, electrical power can be generated by turbines while fluids are pumped into and/or out of a well, but this technique may not be efficient when there is little or no movement of fluids. Batteries can also be installed in electronic equipment to provide electrical power in a borehole, but batteries have a finite energy storage capacity, which limits the amount of time the equipment can be operated. In some cases, larger batteries may be used, but the amount of space available in the borehole is also finite, limiting the size of such batteries. In other cases, higher power density batteries may be used, but such batteries may be more prone to failure (e.g., in the high temperature operating conditions present down-hole).

Systems and techniques described herein can be used to increase the volume available for batteries and/or other energy storage devices (e.g., with respect to batteries and/or energy storage devices that can be deployed within a borehole). For instance, a pipe 200 includes a pipe wall 202 having an external surface 204 and an internal surface 206, where the pipe 200 defines a longitudinal passage 208, e.g., within the pipe 200 and proximate to the internal surface 206. As describe herein, the volume available for energy storage devices 210 (e.g., batteries) within the pipe 200 can be extended by positioning one or more energy storage devices 210 longitudinally within the pipe wall 202 between the external surface 204 and the internal surface 206 (e.g., axially with respect to, for example, a borehole). In this manner, pipes used to perform other functions, such as drill pipe, drill collar, and so forth, can also be used to store energy. Thus, using the systems, techniques, and apparatus of the present disclosure, a larger volume can be provided to store energy within a borehole, and constrictions on energy density can be lessened. However, it should be noted that although energy storage devices are described herein with some specificity, such energy storage devices are provided by way of example and are not meant to limit the present disclosure. Thus, in other embodiments, different down-hole equipment can be positioned within the pipe 200, including, but not necessarily limited to: electronics, sensors, gauges, and so forth. In embodiments of the disclosure, these devices can be positioned within the pipe wall 202 between the external surface 204 and the internal surface 206 (e.g., in addition to the one or more energy storage devices 210 or in place of the one or more energy storage devices 210).

In some embodiments, the pipe 200 is implemented as a drill collar or another component of a drill string that provides weight on a drill bit for drilling. For example, a pipe 200 can be a thick-walled tubular piece machined from a solid bar of steel (e.g., plain carbon steel, a nonmagnetic nickel-copper alloy, another nonmagnetic alloy, and so on). The bar of steel can be drilled from end to end to form a longitudinal passage 208 for pumping drilling fluid through the pipe 200. In some embodiments, the external surface 204 of the pipe 200 may be machined for roundness and/or may be machined with helical grooves (spiral collars). Then, threaded connections (e.g., a male connection on one end and a female connection on the other end) can be cut so that multiple collars can be screwed together along with other down-hole tools to form a bottom hole assembly. For example, with reference to FIG. 9, one or more pipes 200 can be suspended from a pipe 212. When deployed, gravity can act on the large mass of a pipe 200 to provide downward force for drill bits to efficiently break rock. However, a drill collar is provided by way of example and is not meant to limit the present disclosure. As previously described, a pipe 200 can also be used as a drill pipe, a testing string pipe, a completion pipe, and so forth.

Referring to FIGS. 2, 3, and 8 through 10, a pipe 200 includes one or more connectors 214 (e.g., electrical contacts) for connecting an energy storage device 210 to another device, such as additional pipes 200-2, one or more powered devices 216 of a bottom hole assembly, and so forth. For example, in some embodiments, a pipe 200 includes a connector 214 at one end of the pipe 200. In other embodiments, a pipe 200 includes two connectors 214 (e.g., at opposite ends of the pipe 200). However, two connectors 214 are provided by way of example and are not meant to limit the present disclosure. In other embodiments, a pipe 200 can have more than two connectors (e.g., three connectors, four connectors, and so forth). In some embodiments, a pipe 200 includes multiple connectors 214 at a single end of the pipe 200. In other embodiments, a pipe 200 includes multiple connectors 214 at both ends of the pipe 200. When multiple connectors 214 are used, each connector 214 can be connected to a separate energy storage device 210. Further, multiple energy storage devices 210 can be connected to a single connector 214 and/or multiple connectors 214 can be connected to a single energy storage device 210. Still further, multiple energy storage devices 210 can be connected to one another (e.g., in series and/or parallel), e.g., using connectors 214 and/or other connectors. In some embodiments, a feed-through connector 214 is coupled with an energy storage device 210 using another connector 215 (e.g., as shown in FIG. 8).

The connectors 214 facilitate energy transfer between energy storage devices 210 and other devices and/or energy storage devices 210. With reference to FIG. 10, a connector 214 can be an inductor 218 used to establish an inductive connection between an energy storage device 210 and a pipe 200-2, a powered device 216, another energy storage device 210, and so forth. However, inductive coupling is provided by way of example and is not meant to limit the present disclosure. In other embodiments, a connector 214 can be an exposed electrical contact 220. In further embodiments, a connector 214 can be an electrical contact 220 that can be covered by a biased cover (e.g., a spring-loaded sleeve), where the electrical contact 220 is exposed when the pipe 200 contacts a pipe 200-2, a powered device 216, and so on. As described herein, a powered device 216 can comprise a bottom hole assembly tool (e.g., a drill bit, a sensor, a measuring device, a rotary steerable system, a motor, etc.) suspended from a drill string. For example, the powered device 216 includes electronic equipment configured to measure and/or control the rate and/or direction of the drill string, such as sensors to sense formation types, sensors to prevent kick (out of control behavior), and so forth. However, a bottom hole assembly tool is provided by way of example and is not meant to limit the present disclosure. For example, in other embodiments, the tool can comprise a sub suspended from a drill string.

In the case of an inductor 218, a system can include an energy storage device 210 coupled with a primary inductor 218. The system can also include a pipe 200-2, a powered device 216, a sub, and/or another energy storage device 210 comprising a secondary inductor for connecting the energy storage device 210 when an inductive connection is established between the primary inductor 218 and the secondary inductor. Once the inductive connection is established, energy can be transferred between the energy storage device 210 and the pipe 200-2, the powered device 216, the sub, and/or another energy storage device 210. For example, one or more energy storage devices 210 can be used to power a powered device 216. In some embodiments, an energy storage device 210 can be chargeable (e.g., rechargeable) by a pipe 200-2, a powered device 216, a sub, and/or another energy storage device 210 when an inductive connection is established between a primary inductor and a secondary inductor. For instance, the pipe 200 can comprise another inductor (e.g., a secondary inductor) for receiving energy from another pipe 200-2, where the additional pipe 200-2 also includes a primary inductor for connecting the pipe 200-2 to the pipe 200 (e.g., when an inductive connection is established between the primary inductor of the pipe 200-2 and the secondary inductor of the pipe 200). In this manner, energy can be transferred between the pipe 200-2 and the pipe 200 and/or a sub or a powered device 216. A pipe 200-2 can be used to charge (e.g., recharge) one or more energy storage devices 210 of the pipe 200, furnish energy to a sub and/or a powered device 216 along with the pipe 200 (e.g., in series with the pipe 200, in parallel with the pipe 200, and so on), directly furnish energy to a sub and/or a powered device 216 (e.g., bypassing the pipe 200), and so forth.

Referring now to FIG. 11, in some embodiments, an energy storage device 210 is implemented as a battery 222 (e.g., one or more battery cells of a primary battery and/or one or more battery cells of a secondary battery, etc.) that provides current, such as direct current (DC). However, a battery 222 is provided by way of example and is not meant to limit the present disclosure. For example, in some embodiments, the energy storage device 210 comprises a capacitor 224, a super-capacitor 226, and so on. To supply an induction connector with alternating current (AC) (e.g., to induce current through an inductor on the other side of the connector), an alternator (e.g., configured as a DC/AC converter) can be used. The current induction can function in a similar manner as in an electrical transformer, transferring energy from one inductor to another. In some embodiments, energy to a powered device 216 (e.g., a down-hole tool) is supplied in a DC format to power electronics. In such cases, a rectifier (e.g., an AC/DC converter) can be used on the powered device side of the connector.

To avoid unnecessary discharge of a battery 222 during transportation and/or storage, a switch can be used to keep the battery 222 or another energy storage device 210 disconnected from the rest of the system when not in use. In some embodiments, an activation solenoid can be used to activate one or more switches to connect to an energy storage device 210. In this example, the same inductive connector can be used to activate such a switch. In some embodiments, a bi-stable switch can be used. In other embodiments, an energy storage device 210 can be used to store mechanical energy. For example, an energy storage device 210 is implemented as a storage device that employs compressed gas 228, a biasing member 230 (e.g., a spring), and so forth. Then, once a connection is established between the energy storage device 210 and a pipe 200-2, a powered device 216, a sub, and/or another energy storage device 210, mechanical energy can be transferred between the devices.

In some embodiments, the pipe wall 202 defines an annular cavity for the energy storage device 210. For example, with reference to FIG. 3, a first (inner) pipe (e.g., sub-pipe 232) can be inserted into a second (outer) pipe (e.g., sub-pipe 234) to form a pipe 200 defining an annular cavity between the sub-pipe 232 and the sub-pipe 234. In this example, the interior surface of the sub-pipe 232 forms the interior surface 206 of the pipe 200, and the exterior surface of the sub-pipe 234 forms the exterior surface 204 of the pipe 200. In this configuration, the energy storage device 210 can be an annular device disposed between the sub-pipe 232 and the sub-pipe 234. In some embodiments, a seal member 236 can be used to contain one or more energy storage devices 210 (e.g., between inner and outer pipes), to prevent fluids from penetrating into and/or out of the pipe wall 202, and so forth. In embodiments employing connectors 214, one or more connectors 214 can extend through the seal member 236.

Referring now to FIGS. 4 through 8, and 13 a pipe wall 202 can define one or more longitudinal cavities for an energy storage device 210. For instance, holes 238 can be extended (e.g., drilled, machined) into the pipe wall 202 (e.g., with reference to FIGS. 4 and 5). With reference to FIGS. 6 through 8, a first (inner) pipe (e.g., sub-pipe 240) can be inserted into a second (outer) pipe (e.g., sub-pipe 242) to form a pipe 200 defining longitudinal cavities (e.g., holes 238) between the sub-pipe 240 and the sub-pipe 242. In this example, the interior surface of the sub-pipe 240 forms the interior surface 206 of the pipe 200, and the exterior surface of the sub-pipe 242 forms the exterior surface 204 of the pipe 200. Further, the exterior surface of the sub-pipe 240 and/or the interior surface of the sub-pipe 242 can be machined (e.g., grooved) to form the holes 238. For example, with reference to FIG. 7, the exterior surface of the sub-pipe 240 and the interior surface of the sub-pipe 242 can be grooved to form holes 238. With reference to FIGS. 8 and 13, the exterior surface of the sub-pipe 240 can be grooved to form holes 238. In these configurations, an energy storage device 210 can be a longitudinal device (e.g., having a generally circular cross-section) disposed between the sub-pipe 240 and the sub-pipe 242.

In some embodiments, a seal member can be used to contain one or more energy storage devices 210 (e.g., between inner and outer pipes). In embodiments employing connectors 214, one or more connectors 214 can extend through the seal members (e.g., as previously described with reference to FIG. 3). It should also be noted that in embodiments employing multiple sub-pipes (e.g., sub-pipe 232 and sub-pipe 234 and/or sub-pipe 240 and sub-pipe 2420), additional features can be machined into the sub-pipes to locate the holes 238, prevent slipping and/or rotation of sub-pipes with respect to one another, and so forth. Further, while generally circular holes 238 are illustrated in the accompanying figures, this configuration is provide by way of example and is not meant to limit the present disclosure. Thus, in other embodiments, differently shaped cavities (e.g., having rectangular cross-sections, hexagonal cross-sections, octagonal cross-sections, and so forth) can be used. It should also be noted that cross-sectional areas, shapes, dimensions and so forth, can be selected to maintain the structural integrity of the pipe 200. Further, in some embodiments, the pipe 200 can be strengthened to compensate for the presence of one or more cavities within the pipe wall 202. For example, the diameter of the pipe 200 can be increased and/or the pipe 200 can be formed using stronger materials. Additionally, the pipe 200 can be rated for a maximum load based upon its structural characteristics. This maximum load rating can be modified to compensate for the presence of cavities (e.g., holes 238) within a pipe wall 202.

Referring now to FIG. 12, a procedure 1200 is described in an example embodiment in which an energy storage pipe (e.g., pipe 200) is formed. At block 1210, a pipe wall, such as pipe wall 202, if formed. The pipe wall has an external surface, such as external surface 204, and an internal surface, such as internal surface 206, and defines a longitudinal passage, such as longitudinal passage 208. At block 1220, an energy storage device, such as energy storage device 210, is positioned in the pipe wall between the external surface and the internal surface. At block 1230, a connector, such as connector 214, is formed for connecting the energy storage device to a second device, such as pipe 200-2, powered device 216, another energy storage device 210, and so forth. The connector facilitates energy transfer between the energy storage device and the second device.

Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from energy storage drill pipe. Features shown in individual embodiments referred to above may be used together in combinations other than those which have been shown and described specifically. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.

Energy Storage Drill Pipe

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CPC

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