This disclosure is related to the field of directional drilling wellbores through subsurface formations. More particularly the disclosure relates to methods for directional drilling using “steerable” drilling motors.
U.S. Pat. No. 6,802,378 issued to Haci et al. describes a method and apparatus for directional drilling using “steerable” drilling motors. A drilling motor may be operated by pumping drilling fluid through a drill pipe inserted into a wellbore. The flow of drilling fluid rotates a drill bit at the end of the drill pipe. A steerable drilling motor has a housing with a bend along its longitudinal dimension such that when the drill pipe, and thereby the motor housing, is held rotationally stationary, the trajectory of the wellbore is drilled in the direction of the inside of the bend in the housing. When the entire drill pipe and motor housing are rotated, the drilling of the wellbore trajectory tends to continue along the current orientation of the end of the drill pipe. A method and apparatus as disclosed in the Haci et al. patent includes rotating the drill pipe from the surface back and forth between a first measured torque value and a second measured torque value. The first and second torque values may be empirically determined by measuring the amount of torque needed to rotate the drill pipe at the surface such that the entire drill pipe rotates. The first and second torque values may also be estimated using torque and drag modeling programs known in the art. Such programs may use as input the configuration of the drill string, normally consisting of drill pipe and bottom hole assembly components, one of which is the steerable motor. The trajectory of the well, the casing and open hole information; the type of drill bit; and properties of the drilling fluid. These programs can be used to determine an expected amount of torque needed to cause the drill pipe to rotate as well as an amount of torque that may be applied to the drill pipe without causing rotation of the steerable motor. The latter condition is desirable during “slide” drilling, that is, when it is desired to change the wellbore trajectory by keeping the bend in the steerable motor housing oriented in a selected direction.
An example embodiment of a well drilling system including one possible embodiment of a directional drilling system is shown schematically in
The drilling rig 11 includes a derrick 13 that is supported on the ground surface above a rig floor 15. The drilling rig 11 includes lifting gear, which comprises a crown block 17 mounted to or suspended from the derrick 13, and a traveling block 19. The crown block 17 and the traveling block 19 are interconnected by a cable 21 that is driven by draw works 23 to control upward and downward movement of the traveling block 19 in the derrick 13. The traveling block 19 carries or has affixed thereto a hook 25 from which may be suspended a top drive 27. The top drive 27 supports a drill string, designated generally by reference numeral 31, in a wellbore 33. The top drive 27 may be operated to rotate the drill string 31 in either direction.
In some embodiments, a length of connected drill pipe segments having certain drilling tools at a longitudinal end thereof, collectively, the “drill string” 31, is coupled to the top drive 27. In the present embodiment such connection may be made through an instrumented top sub 29. As will be described in more detail, the instrumented top sub 29 may include sensors that measure torque and axial loading and may receive signals from a communication channel in the drill string 31. In the present example, the drill string 31 may comprise a “wired” drill pipe. Wired drill pipe may include a communication channel comprising at least one or more insulated electrical conductors extending along the lengths of each segment 35 (“joint”) of the drill pipe and electromagnetic couplings at the longitudinal ends of each segment 35 and thus between adjacent pipe segments 35 so that signals may be communicated from proximate the wellbore end of the drill string 31 to the surface, e.g., to the instrumented sub 29, and then to a processor 55 (explained in more detail with reference to
A wired drill pipe as disclosed in the Boyle et al. '434 patent may include one or more signal repeaters 36 disposed at selected positions along the length of the drill string 31. A non-limiting example embodiment of a signal repeater usable with such a wired drill pipe is described in U.S. Pat. No. 7,064,676 issued to Hall et al. The signal repeater(s) 36 may amplify and retransmit signals communicated along the wired drill pipe such that there is sufficient signal amplitude both at the instrumented sub 29 for signals communicated to the surface and at a sensor system (51, described below) at the end of the drill string 31 for signals communicated from the surface. The signal repeater(s) 36 may include sensors therein, for example and without limitation, strain gauges to measure torsion on the drill string 31, strain gauges to measure axial loading on the drill string 31, accelerometers and magnetometers and/or gyroscopes to measure the geodetic (or geomagnetic) direction and inclination of the drill string 31 at any one or more of the repeaters 36, pressure sensors to measure pressure inside and/or outside the drill string 31 at each repeater position and temperature sensors to measure temperature in the wellbore 33 at each repeater 36 position. In other embodiments, the repeater(s) 36 may be substituted by sensor housings having one or more of the above described sensors, although the described types of sensors are not a limitation on the number of and types of sensors that may be used in any particular embodiment. In some embodiments, the instrumented top sub 29 may include a wireless signal transceiver 30 that can transmit the signals generated by each of the sensors in each of the repeaters 36 and a measurement while drilling (MWD) sensor forming part of the sensor system 51 (explained below) to the signal recording and processing unit 32 for further processing by the processor 55 as will be further explained with reference to
The drill string 31 may include a bottom hole assembly (BHA) 37 at its end, which may include stabilizers, drill collars, and a set of (MWD) sensors forming part of the sensor system 51 including, without limitation a directional and inclination sensor, a pressure sensor, a torque sensor and an axial load sensor (not shown separately for clarity). As will be explained in more detail, the directional and inclination (D&I) sensor may generate a signal corresponding to the tool face angle orientation of a steerable drilling motor 41 coupled within the drill string 31.
Drilling fluid is delivered to the drill string 31 by mud pumps 43 through a mud hose 45. During “rotary” drilling, the drill string 31 is rotated within the wellbore 33 by operating the top drive 27 to rotate the drill string 31 connected thereto such that the drill string 31 imparts rotation to a drill bit 40 at the end of the drill string 31. The top drive 27 may be mounted on parallel, vertically extending rails (not shown) to couple reactive torque to the derrick 13 as torque is applied to the drill string 31 by the top drive 27. Rotary drilling is used to extend the length of a bore hole 33.
The bent housing (“steerable”) drilling motor 41 may be connected to the drill string 31 proximate the bottom of BHA 37 and may have the drill bit 40 functionally connected to a rotary output of the steerable drilling motor 41. As is known in the art, by controlling a “tool face angle” (i.e., the orientation of a plane intersecting the largest angle subtended by the bend in the housing) of the steerable motor 41 the trajectory (i.e., azimuth and/or inclination) of the wellbore 33 may be maintained, controlled or changed during “slide” directional drilling, that is, when the drill string (31 in
The drilling rig operator (“driller”) may further operate the top drive 27 to move the tool face angle of the steerable drilling motor 41 to a selected rotational orientation and thereby change the trajectory of the wellbore 33 to a selected orientation. Although a drilling rig having a top drive is illustrated, those skilled in the art will recognize that the present example system may also be used in connection with drilling rigs in which a rotary table and kelly are used to rotate the drill string 31. Drill cuttings produced as the drill bit 40 drills into the formations to extend the wellbore 33 are carried out of wellbore 33 (through an annular space 39 between the wellbore wall and the drill string 31) by the drilling fluid supplied by the mud pumps 43.
Additionally, any one or more of the repeaters 36 may also provide an indication of its tool face position using similar D&I sensors disposed in or proximate to each repeater 36 or a subset thereof in order to detect whether or not any particular repeater 36 is rotating or is rotationally stationary with reference to the axial direction of the wellbore (33 in
The control apparatus may also include a surface drill string torque sensor 53, which provides a measurement corresponding to the torque applied to the drill string (31 in
The output of the respective sensors 51, 36 and 53 may be received as input to the processor 55. The processor 55 may be programmed to process signals received from sensors 51, 36, 53 in a manner to be further explained below. The processor 55 may also receive user input from user input devices, such as a keyboard 57. Other user input devices such as touch screens, keypads, and the like may also be used. The processor 55 may provide signals to a display 59 wherein a visual representation of the various sensor measurements may be observed. The processor 55 also provides output to a drill string rotation controller 61 that operates the top drive (27 in
In some embodiments, the steerable drilling motor 41 may be oriented at a tool face angle selected to attain a desired wellbore trajectory. As the steerable drilling motor 41 is advanced into the wellbore (33 in
As the drill string (31 in
As slide directional drilling progresses, the processor 55 continues to monitor measured drill string torque and rotation at the surface and along the drill string (31 in
In some embodiments, the selected point along the drill string (31 in
It may also be possible in some embodiments to determine distribution of the reactive torque along the length of drill string by observing the measured torque at each repeater 36.
In some embodiments, the selected point (referred to as the “neutral point”) may be determined using measurements from the sensors in the repeaters 36. In some embodiments, measurements of rotary orientation of the drill string at each of the repeaters 36 may be made, and the selected point determined by determining which of the repeaters 36 is not rotated when the drill string is rotated at the surface. In some embodiments, measurements using the D&I sensors in each repeater 36 may be used to infer rotation of the drill string at each repeater 36. In some embodiments, the first torque magnitude may be determined by rotating the drill string in the first direction until slight rotation of the drill string is measured by the D&I sensor in any one of, or the deepest one of the repeaters 36 while measuring torque on at least the surface torque sensor 53. For purposes of the present example embodiment, it may be assumed that the drill string does not rotate below the deepest repeater 36 at which rotation is measured or determined. Rotation of the drill string may be inferred, for example by measurements of acceleration due to gravity along different directions, e.g., three orthogonal directions, indicating a change in the orientation of the drill string with respect to gravity when one or more of the acceleration measurements changes. In other embodiments, rotation may be inferred by measuring directional components of Earth's magnetic field, e.g., along three mutually orthogonal directions, wherein change in orientation may be inferred by changes in the relative magnitude of any one or more of the component measurements. The controller 55 may be programmed to then operate the drill string rotation controller 61 to reverse direction of rotation of the top drive and the drill string. The torque measured by at least the surface sensor may be measured and the drill string rotation stopped when the deepest one of the repeaters 36 detects slight rotation of the drill string.
In some embodiments, measurements of torque and/or rotation at each repeater 36 may be used as an indication that a detrimental drilling situation is occurring such as drill cuttings beginning to accumulate in the wellbore annulus (39 in
In some embodiments, the processor (e.g., 55 in
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By monitoring a distributed set of torque, rotation, and/or axial load sensors a wellbore “efficiency” may be computed that can indicate the amount of friction and torque loss that is being experienced along the wellbore. Determined distribution of friction losses along the length of the drill string may aid in computation of dynamic drill string behavior and in general estimating the drillability of the portion of the wellbore remaining to be drilled. Using distributed torque and axial loading measurements may also enable estimating the coefficients of friction along the length of the drill string and their changes due to dynamic environmental changes, for example and without limitation, cuttings accumulation and movement within the wellbore.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
The present document is based on and claims priority to U.S. Provisional Application Ser. No. 62/064406, filed Oct. 15, 2014, which is incorporated herein by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2015/054136 | 10/6/2015 | WO | 00 |
Number | Date | Country | |
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62064406 | Oct 2014 | US |