Lead the bit rotary steerable tool

Abstract

A drilling assembly comprises a drill bit that includes a bit body intermediate a working face and a shank. An indenting member adapted to guide the drill bit protrudes from the working face. A flexible portion is disposed above the bit body.

Description

BACKGROUND OF THE INVENTION

This invention relates to the field of tools used in directional drilling. More specifically, the invention includes a flexible portion disposed in a drill string to facilitate drilling inclined wellbores. The prior art includes several methods for steering a tool string. An embodiment of a bent sub system is generally depicted in FIG. 1a. In this embodiment, a drill string 2000 comprises a bent sub 2050 above the drill bit 2051. A hydraulic motor housed within a bore of a drill string component rotates the drill bit 2051 below the bent sub 2050. As drilling mud is passed through the drill string 2000, the motor turns in response to the flow and rotates a portion 2052 of the drill string 2000 below the bent sub 2050. A portion 2053 of the drilling string 2000 above the bent sub 2050 does not rotate from the motor, but slides through the wellbore as the drill bit 2051 advances into the earth. The bent sub 2050 directs the trajectory of the drill string 2000 in relation to an angle of the bent sub 2050.

An embodiment of a push-the-bit system is generally depicted in FIG. 1b. In this embodiment of a drill string 2100, an extendable pad 2150 is located above the drill bit 2151. Typically, there is more than one extendable pad oriented around an outer surface of the drill string 2100 near the drill bit 2151 that are timed together so as to extend at the same azimuth with relation to the well bore while the drill string 2100 is rotating. Each time an extendable pad 2150 extends, it pushes the drill bit 2151 off course and may be used to control the trajectory of the drill string 2100.

Yet another embodiment for steering a bit includes point-the-bit systems where a drill bit is actively positioned from further up a drill string.

Variations of these systems are disclosed in the following prior art documents. U.S. Pat. No. 5,529,133 to Eddison, which is hereby incorporated by reference for all that it contains, discloses a steerable rotary drilling tool that includes a drill bit mounted on the lower end of a housing by a drive shaft having an articulative coupling that allows the bit's rotation axis to be inclined relative to the rotation axis of the housing, an eccentric weight in the housing that maintains the bit axis pointed in only one direction in space as the bit is turned by the housing, and a clutch system that allows such direction to be changed downhole. A measuring-while-drilling tool is included to allow the progress of the drilling to be monitored at the surface and to allow changing the bit axis or toolface by a selected amount.

U.S. Pat. No. 5,078,650 to Foote which is herein incorporated by reference for all that it contains discloses a universal joint arrangement that includes a first adapter having two projecting support formations; a drive plate having a first pair of matching depressions or pockets is seated with these depressions on the projecting support formations of the first adapter and the drive plate has a second pair of pockets for the projecting support formations of a respective second adapter.

U.S. Pat. No. 7,188,685 to Downton which is herein incorporated by reference for all that it contains discloses a bottom hole assembly that is rotatably adapted for drilling directional boreholes into an earthen formation. It has an upper stabilizer mounted to a collar, and a rotary steerable system. The rotary steerable system has an upper section connected to the collar, a steering section, and a drill bit arranged for drilling the borehole attached to the steering section. The steering section is joined at a swivel with the upper section. The steering section is actively tilted about the swivel. A lower stabilizer is mounted upon the steering section such that the swivel is intermediate the drill bit and the lower stabilizer.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the present invention, a drilling assembly includes a drill bit body disposed intermediate a working face and a shank. The shank may be attached to a drill string. The working face comprises an indenting member protruding from the working face, the indenting member being adapted to guide the drill bit. A flexible portion is disposed above the bit body to allow angular deflection of the bit with respect to the drill string.

The flexible portion may comprise upper and lower segments, and may be disposed intermediate, or between, the bit body and the shank or may be disposed intermediate, or between, the shank and an adjacent drill string component. The lower segment of the flexible portion may comprise an extension with a generally spherical distal end, and a corresponding spherical recess may be disposed in the upper segment. Bearing balls adapted to transfer torque may be retained in recesses and/or grooves in the spherical portions of the upper and lower segments. In another embodiment, the flexible portion may comprise one or more universal joints. The flexible portion may comprise a compliant segment. The flexible portion may comprise a joint with laterally sliding surfaces.

The indenting member may be rotatable with respect to the bit body. A shaft may be disposed internal to the bit body and intermediate the indenting member and a rotating element such as a fluid-driven turbine, mud motor, or an electric motor. The shaft may be flexible, and may comprise a compliant portion, one or more universal joints, or a constant velocity joint.

The indenting member may comprise asymmetrical geometry on a distal end and a polycrystalline diamond cutting element. The polycrystalline diamond cutting element may comprise a pointed geometry.

The drilling assembly may comprise a mechanism adapted to selectively prevent movement of the flexible portion for drilling straight wellbores. The mechanism may be adapted to selectively limit angular deflection of the flexible portion, and may self-align the flexible portion to a position of zero angular deflection.

The drilling assembly may comprise a wiper seal disposed intermediate moveable sections of the flexible portion. The drilling assembly may also comprise a bellows-type seal disposed exterior to the flexible portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a cross-sectional view of an embodiment of the prior art.

FIG. 1 b is a cross-sectional view of another embodiment of the prior art.

FIG. 1 c is a cross-sectional view of an embodiment of a drill string suspended in a borehole.

FIG. 2 is a cross-sectional view of an embodiment of a drilling assembly.

FIG. 3 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 4 is a different cross-sectional view of the embodiment of a drilling assembly in FIG. 3.

FIG. 5 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 6 is a perspective view of an embodiment of a universal joint.

FIG. 7 a is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 7 b is a different cross-sectional view of the embodiment of a drilling assembly in FIG. 7a.

FIG. 8 a is a perspective view of an embodiment of an indenting member.

FIG. 8 b is a perspective view of another embodiment of an indenting member.

FIG. 8 c is a perspective view of another embodiment of an indenting member.

FIG. 8 d is a perspective view of another embodiment of an indenting member.

FIG. 9 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 10 a is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 10 b is another cross-sectional view of the embodiment of a drilling assembly in FIG. 10a.

FIG. 10 c is a detailed view of the embodiment of a drilling assembly in FIG. 10a.

FIG. 11 a is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 11 b is another cross-sectional view of the embodiment of a drilling assembly in FIG. 11a.

FIG. 12 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 13 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 14 is a cross-sectional view of another embodiment of a drilling assembly.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

FIG. 1 c discloses a drill string 100 suspended in a borehole 103 by a derrick 101. A drilling assembly 102a is connected to the end of the drill string 100 and comprises a drill bit 104a. As the drill bit 104a rotates the drill string 100 advances in the formation 105a. The drill string 100 may comprise one or more flexible portions 209a to allow directional drilling.

FIG. 2 discloses an embodiment of a drilling assembly 102b. The drilling assembly 102b may comprise a drill bit 104b with a working face 106a, an indenting member 107a protruding from the working face 106a, and a shank 108a. A compliant segment 113 may be disposed intermediate, or between, the shank 108 and a portion of the drill string 109a. The compliant segment 113 may comprise a portion of reduced cross-section 110 to provide elastic angular deflection with respect to an axial centerline of the portion of the drill string 109a. Cross-sectional area may be reduced by a taper, a series of circumferential or axial grooves, or one or more helical grooves or via a more elastic material. The compliant segment 113 may be constructed from any material with sufficient strength and suitable elastic modulus, such as high-strength steel or other metal or metal alloy. The drilling assembly 102b may comprise a shaft 111a intermediate, or between, the indenting member 107a and a rotating element 114a such as a fluid powered turbine, mud motor or an electric motor. The shaft 111a may comprise a compliant portion 112a to allow deflection in the shaft 111a corresponding to the deflection in the compliant segment 113.

The indenting member 107a may be asymmetric such that as it indents into the formation it leads the drill bit 104b away from a straight trajectory. The rotating element 114a above may be used to position an apex of the indenting member 107a at a desired azimuth for the drill string 109a to follow. In such a manner, the driller may control the trajectory of the drill string 109a. In some embodiments, it may be desirable for the drill string 109a to drill in a straight trajectory; in such cases, the indenting member 107a may be randomly or otherwise rotated such that it leads the drill bit 104b in a straight direction.

The ability of the indenting member 107a to steer depends on the ability of the asymmetric indenting member 107a to push off of the formation. In soft formations, the formation may push back on the indenting member 107a less. Thus, the compliant portion 112a may lower the amount of formation side push back on the indenting member 107a required to alter the path of the drill bit 104b.

FIG. 3 discloses a drilling assembly 102b according to the present invention. The drilling assembly 102b may comprise a drill bit 104c with a working face 106b, an indenting member 107b protruding from the working face 106b, and a shank 108b. The shank 108b is connected to a flexible portion 209a. The flexible portion 209a comprises an upper segment 210a and a lower segment 211a, the lower segment 211a comprising an extension 212a with a generally spherical portion 213. The upper segment 210a comprises a generally spherical recess 214 corresponding to the generally spherical portion 213 of the lower segment 211a. The generally spherical portion 213 is moveably retained in the generally spherical recess 214. The generally spherical recess 214 comprises a plurality of reliefs 215 which hold a plurality of bearing balls 216. The generally spherical portion 213 of the lower segment 211a comprises a plurality of grooves 217, the bearing balls 216 extending into the grooves 217. The bearing balls 216 are free to slide or rotate in the grooves 217 and reliefs 215, thus allowing angular deflection of the lower segment 211a with respect to the upper segment 210a, while providing torque transmission through the flexible portion 209a as the drilling assembly 102b rotates. The bearing balls 216 may be retained in a bearing cage. The bearing balls 216 may be constructed from high strength steel and may be case hardened, heat treated, or otherwise processed to provide sufficient strength. Other suitable materials such as other metals, metal alloys, or ceramic may be used. The reliefs 215 and grooves 217 that retain the bearing balls 216 may also be heat treated, case hardened, or otherwise processed to mitigate abrasive wear.

The upper segment 210a may comprise a mechanism that selectively prevents movement of the lower segment 211a with respect to the upper segment 210a. In this embodiment, a plurality of stops 219a are disposed inside the upper segment 210a and may be brought into contact with the lower segment 211a, thus preventing angular deflection of the flexible portion 209a and allowing the drilling assembly 102b to drill a straight borehole. The plurality of stops 219a may be actuated by a mechanical, hydraulic, or electronic system or combinations thereof.

The upper segment 210a of the flexible portion 209a comprises a face 220 with a convex, generally spherical geometry, and the lower segment 211a comprises a face 221 with a concave, generally spherical geometry. The faces 220, 221 on the upper segment 210a and the lower segment 211a, respectively, have a common, substantially constant radius of curvature, with a center of curvature in the same location as a center of curvature of the generally spherical portion 213 and the generally spherical recess 214. The faces 220 and 221 are in slideable contact, thus allowing angular deflection of the lower segment 211a with respect to the upper segment 210a. The faces 220 and 221 may be heat treated, case hardened, or coated with a wear resistant material such as polycrystalline diamond, a low-friction material such as PTFE, or other wear resistant and/or low friction coating.

The drilling assembly 102b may also comprise a shaft 111b intermediate, or between, the indenting member 107b and a rotating element 114b, such as a fluid-powered turbine or electric motor. The shaft 111b may comprise a compliant portion 112b to allow deflection corresponding to the deflection of the flexible portion 209a.

Referring now to FIG. 4, the plurality of stops 219a are removed from contact with the lower segment 211a, thus allowing greater angular deflection 401 of the lower segment 211a with respect to the upper segment 210a. The indenting member 107b may comprise an asymmetrical geometry 402 on a distal end 803a. As the drilling assembly 102b rotates, the rotating element 114b rotates the shaft 111b with an angular velocity having the same magnitude but opposite direction of the angular velocity of the drilling assembly 102b. Thus, the indenting member 107b has zero angular velocity with respect to the formation 105b, and the asymmetrical geometry 402 on the distal end 803a guides the drill bit 104c through the formation 105b in an azimuth direction determined by the orientation of the indenting member 107b.

In some embodiments the flexible portion 209a is moved passively in consequence of the deflections caused by the indenting member 107b.

The plurality of stops 219 may selectively constrain the angular deflection 401 of the flexible portion 209a to any angle in an interval including zero angle, or non-deviated drilling, to the maximum angle attainable by the flexible portion 209a.

FIG. 5 discloses another embodiment of a drilling assembly 102c according to the present invention. In this embodiment, the drilling assembly 102c comprises a drill bit 104d comprising a working face 106c and a shank 108c. A flexible portion 209b is disposed intermediate, or between, the working face 106c and the shank 108c. The shank 108c is connected to a drill string 501.

FIG. 6 discloses an embodiment of a universal joint 601. The universal joint 601 comprises an inner portion 602 and an outer portion 603. The inner portion 602 is attached to the outer portion 603 by a spider 604a comprising bearing carriers 605a.

Referring now to FIG. 7a, a drilling assembly 102d comprises a drill bit 104e with a working face 106d and a shank 108d. The drill bit 104e comprises a flexible portion 209c intermediate, or between, the working face 106d and the shank 108d. The flexible portion 209c comprises an upper portion 701 and a lower portion 702, the lower portion 702 comprising an extension 703. A universal joint spider 604b comprises generally cylindrical bearing carriers 605b and is disposed such that an axial centerline 606 of the bearing carriers 605b intersects a center of curvature of a generally spherical interface 704. The bearing carriers 605b are held in bushings or bearings 607 in the upper portion 701 of the flexible portion 209c.

FIG. 7 b discloses the same embodiment as FIG. 7a, with the drilling assembly 102d rotated 90 degrees. The universal joint spider 604b comprises generally cylindrical bearing carriers 608, an axial centerline 609 of which intersects the center of curvature of the generally spherical interface 704. Bearing carriers 608 extend into bushings or bearings 610 disposed in the extension 703 of the lower portion 702. The bushings 607 and 610 may be made from any suitable material including bronze, steel, Babbitt metal, or a polymer.

FIG. 8 a discloses an embodiment of an indenting member 107c. In this embodiment, a polycrystalline diamond compact 801a is brazed or otherwise affixed to a distal end 803b of a shank 802a. The polycrystalline diamond compact 801a may be disposed coaxial to the shank 802a, and the polycrystalline diamond compact 801a may comprise pointed geometry 805. The shank 802a may be constructed from a steel alloy, and may be case hardened, heat treated, or otherwise processed to improve abrasion resistance. The shank 802a may comprise hard-facing.

FIG. 8 b discloses another embodiment of an indenting member 107d. In this embodiment, a polycrystalline diamond compact 801b is brazed or otherwise affixed to a distal end 803c of a shank 802b. An axial centerline of the polycrystalline diamond compact 801b and an axial centerline of the shank 802b may be offset.

FIG. 8 c discloses another embodiment of an indenting member 107e. A shank 802c comprises a distal end 803d which may be cast, machined, forged, or otherwise formed into a generally polygonal shape 820. The generally polygonal shape 820 may be asymmetric with respect to an axial centerline of the shank 802c.

FIG. 8 d discloses another embodiment of an indenting member 107f. In this embodiment, the indenting member 107f comprises a shank 802d and a distal end 803e. The distal end 803e may comprise generally conical geometry 825, and may be asymmetric with respect to an axial centerline of the shank 802d. The distal end 803e may comprise hard-facing or other material or treatment intended to reduce abrasive wear.

FIG. 9 discloses another embodiment of a drilling assembly 102e according to the present invention. Drilling assembly 102e comprises a flexible portion 209d disposed intermediate, or between, a drill bit 104f and a portion of drill string 109b. The flexible portion 209d comprises an interface 901 intermediate, or between, an upper segment 210b and a lower segment 211b. The interface 901 may be protected from abrasion and wear by a bellows-type cover 902. The cover 902 may be made from electron-beam welded sheet metal or another material.

The interface 901 may comprise a seal 903 disposed intermediate the upper segment 210b and the lower segment 211b. The seal 903 may comprise an o-ring or wiper seal, and may be adapted to retain lubrication on the interface 901. The interface 901 may be sealed from contact with drilling fluid or may be open to the drilling fluid.

A shaft 111b may be disposed intermediate an indenting member 107g and a rotating element 114c. In this embodiment, the shaft 111b comprises two universal joints 904 adapted to allow the shaft 111b to deflect according to the deflection of the flexible portion 209d.

FIG. 10 a discloses another embodiment of a drilling assembly 102f. In this embodiment, the drilling assembly 102f comprises a flexible portion 209e and includes a sliding collar 1001 comprising ports 1002. Fluid passages 1003 are in communication with a plurality of pistons 1004. The plurality of pistons 1004 are attached to mechanical stops 219b.

Referring now to FIG. 10b, the ports 1002 in the sliding collar 1001 are now in communication with a plurality of fluid passages 1003. Drilling fluid 1005 is diverted into and creates fluid pressure in passages 1003.

Referring now to FIG. 10c, which is a detailed view of FIG. 10b, drilling fluid 1005 creates fluid pressure in the passages 1003 that forces the plurality of pistons 1004 and mechanical stops 219b inward to contact a lower segment 211c of the flexible portion 209e. Flexible portion 209e is thus immobilized to allow drilling of straight wellbores.

FIG. 11 a discloses another embodiment of a drilling assembly 102g. In this embodiment, a lower segment 211d of a flexible portion 209f comprises a threaded sleeve 1101 engaged with a threaded collar 1102. The threaded sleeve 1101 is free to rotate on an extension 212b of a lower segment 211d of the flexible portion 209f. An electric motor 1103 rotates the threaded sleeve 1101, and alignment pins 1104 prevent the rotation of the threaded collar 1102. As the electric motor 1103 rotates the threaded sleeve 1101, the non-rotating threaded collar 1102 moves upward. Maximum angular deflection of the flexible portion 209f can be controlled by adjusting the position of the threaded collar 1102, and as the threaded collar 1102 moves upward it aligns the flexible portion 209f to a position of zero angular deflection.

Referring now to FIG. 11b, the threaded collar 1102 is engaged with the rotatable threaded sleeve 1101. The threaded collar 1102 is in its maximum upward position, effectively immobilizing the flexible portion 209f to allow for straight drilling.

FIG. 12 discloses another embodiment of a drilling assembly 102h. In this embodiment, a collar 1201 comprises a distal end 1202 with a generally conical geometry 1203. A flexible portion 209g comprises a lower segment 211e with an extension 212c, which also comprises generally conical geometry 1204. The collar 1201 may be movable in a direction coaxial with an axial centerline 1205a of the drilling assembly 102h. The position of the collar 1201 determines the maximum angular deflection of the lower portion 211e of the flexible portion 209g. The position of the collar 1201 may be controlled by a mechanical, electronic, hydraulic, or other system, or combinations thereof. As the collar 1201 moves toward the lower portion 211e of the flexible portion 209g, the generally conical geometries 1203 and 1204 are brought into mechanical contact and the lower portion of the joint 211e self-aligns with the collar 1201 and the flexible portion 209g reaches a position of zero angular deflection.

FIG. 13 discloses another embodiment of a drilling assembly 102i. A drill bit 104g comprises a plurality of grooves 1301 intermediate, or between, a working face 106e and a shank 108e. The grooves 1301 may be circumferential, helical, or otherwise oriented and may be machined, forged, cast, or otherwise formed in the drill bit 104g. The grooves 1301 allow for elastic, angular deflections in the drill bit 104g.

FIG. 14 discloses another embodiment of a drilling assembly 102j. A flexible portion 209h is disposed intermediate, or between, a drill bit 104h and a portion of a drill string 109c. The flexible portion 209h comprises a compliant segment 1401 and an outer sleeve 1402. A collar 1403 is moveable in a direction coaxial to an axial centerline 1205b of the drilling assembly 102j. Mechanical stops 1404 are disposed internal to the outer sleeve 1402. The collar 1403 may selectively be brought into mechanical contact with the stops 1401, thus limiting or disallowing angular deflection of the compliant segment 1401 and the drill bit 104h.

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.

Claims

1. A drilling assembly, comprising: a drill string component; and,a drill bit positioned adjacent the drill string component, the drill bit including: a working face;a shank;a bit body between the working face and the shank;an indenting member protruding from the working face, the indenting member being adapted to guide the drill bit;a flexible portion disposed above the bit body between the shank and the adjacent drill string component; and,at least one of an o-ring disposed between the flexible portion and the bit body, a wiper seal disposed between the flexible portion and the bit body, and a bellows-type seal disposed exterior to the flexible portion.

2. The drilling assembly of claim 1, wherein the flexible portion comprises at least one of a compliant segment, a reduced cross-section, and a joint with laterally sliding surfaces.

3. The drilling assembly of claim 1, wherein the indenting member is rotatable with respect to the bit body.

4. The drilling assembly of claim 1, wherein the indenting member comprises an asymmetrical geometry on a distal end of the indenting member.

5. The drilling assembly of claim 1, wherein the indenting member comprises a polycrystalline diamond cutting element.

6. The drilling assembly of claim 5 wherein the polycrystalline diamond cutting element comprises pointed geometry.

7. The drilling assembly of claim 1, further comprising a locking mechanism adapted to selectively prevent movement of the flexible portion.

8. A drilling assembly, comprising: a drill bit that includes: a working face;a shank;a bit body between the working face and the shank;an indenting member protruding from the working face, the indenting member being adapted to guide the drill bit; and,a flexible portion disposed above the bit body, the flexible portion including: a lower segment that includes an extension with a generally spherical geometry on a distal end; and,an upper segment that includes a generally spherical recess that corresponds with the generally spherical geometry of the lower segment.

9. The drilling assembly of claim 8, wherein at least one of the generally spherical geometry and the generally spherical recess include at least one of a recess and a groove, and wherein bearing balls adapted to transfer torque are disposed in at least one of the recess and the groove.

10. A drilling assembly, comprising: a fluid-driven turbine; and,a drill bit that includes: a working face;a shank;a bit body between the working face and the shank;an indenting member protruding from the working face, the indenting member being adapted to guide the drill bit; and,a flexible portion that includes a shaft disposed internal to the bit body and between the indenting member and the fluid-driven turbine.

11. The drilling assembly of claim 10, wherein the shaft is flexible.

12. The drilling assembly of claim 10, wherein the shaft comprises at least one of a universal joint, a compliant portion, and a constant-velocity joint.

13. A drilling assembly, comprising: a drill bit that includes: a working face;a shank;a bit body between the working face and the shank;an indenting member protruding from the working face, the indenting member being adapted to guide the drill bit; and,a flexible portion disposed above the bit body, the flexible portion including: a lower segment;an upper segment; and,an interface between the lower and the upper segment, the interface including at least one of an o-ring and a wiper seal to create a seal.

14. The drilling assembly of claim 13, wherein the lower segment further comprises an extension with a generally spherical geometry on a distal end and the upper segment further comprises a generally spherical recess that corresponds with the generally spherical geometry of the lower segment.

15. A drilling assembly, comprising: a drill bit that includes: a working face;a shank;a bit body between the working face and the shank;an indenting member protruding from the working face, the indenting member being adapted to guide the drill bit; and,a flexible portion disposed above the bit body, the flexible portion including: a lower segment;an upper segment;an interface between the lower and the upper segment; and,a bellows-type cover disposed exterior to the flexible portion.