1. Field of the Invention
The present invention relates to a directional rotary drilling method and apparatus; specifically, to a method and apparatus for moving a drill bit in a desired path by selectively adjusting a portion of drilling fluid flow through orifices located adjacent a drill bit body to apply a lateral hydraulic force and minimize contact with a bore hole with mechanical guides.
2. Related Art
All methods known to applicant use some manner of mechanical contact with the well bore to achieve the desired steering of the drilling tool, or as in the case of point-the-bit methods, the steering is achieved by offsetting the angle of the drill bit axis relative to the rest of the drill tool. Fluid pressure necessary to cause fluid flow through changing flow geometries (orifices, bends, narrow passages, conduits, etc.) commonly described as pressure loss is typically considered a negative effect of changing flow conditions because it often requires alternative design requirements. That same changing fluid flow conditions is used in the described method and apparatus to create a pressure differential between the two sides of the drilling tool and thereby achieve a desired lateral force on the drilling tool useable for steering the tool in the given direction. There have been attempts to use changing directional fluid flows that are different than this invention and not intended to use the hydraulic pressure difference around the drilling tool for steering the tool in the preferred direction. See U.S. Pat. No. 4,836,301 as an example of these types of fluid directing systems, which uses changing direction of drilling fluid flow inside the drilling tool to generate a hydrodynamic force to tilt the drill bit axis in a given direction using a point-the-bit steering method and system.
A method for hydraulic steering of a drill bit is described which provides the steps of setting an angular direction from a longitudinal axis of a bottom hole assembly providing the drill bit; and, opening one or more lateral orifices at a selected interval to divert drilling fluid from the drill bit to provide motive hydraulic force in an angular direction opposite the angular direction required for forward progress of the drill bit toward the set direction. The method can further comprise adjusting a gap between a distal tip of the orifices and a universal joint sleeve to increase a force applicable to move the bottom hole assembly in an opposite direction.
This method can further provide for determining a direction for forward progress of a drill bit and directing the flow of drilling fluid from the orifices toward a lateral face of a well bore in a manner currently practiced in directional drilling programs.
Where the point-the-bit directional drilling apparatus is used, this method can include determining a direction for forward progress of a drill bit and directing the flow of drilling fluid from the orifices to a universal joint sleeve connected to a drill bit to move the drill bit in set direction. Since the lateral hydraulic force exerted by the drilling fluid flow through the lateral orifices is a function of the distance from the distal tip of the orifice to the opposing well bore face, this method can also provide the steps of adjusting a gap between a distal tip of the orifices and a well bore face to increase a hydraulic force applicable to move the bottom hole assembly in an opposite direction, or diverting a portion of drilling fluid through a lateral pad of a rotary steerable drill bit system to direct additional force against a lateral bore hole wall.
A directional drilling bottom hole assembly used to practice the method of this invention is a bottom hole assembly having one or more lateral orifices circumferentially spaced around said bottom hole assembly, and activation valves to selectively open and close said lateral orifices to provide lateral hydraulic force on said directional drilling bottom hole assembly. The directional drilling bottom hole assembly can further provide in the bottom hole assembly a drill bit and a control unit for sensing and controlling drilling fluid flow through the lateral orifices which control the movement of the assembly while drilling. This may be controlled either from the surface by the collection and transmission of data or using auto-steering techniques to control the direction based upon sensor input.
The directional drilling bottom hole assembly can be entirely located in a control unit located adjacent a drilling motor. Alternatively, the directional drilling bottom hole assembly can be adapted to a standard push-the-bit drilling assembly by providing orifices in each control pad to selectively and lateral forcefully move drilling fluid against the borehole thereby minimizing wear on the pads to achieve directional control.
The method can additionally further comprise diverting a portion of drilling fluid through a lateral pad of a rotary steerable drill bit system to direct additional force against a lateral bore hole wall or diverting a portion of drilling fluid through one or more lateral orifices to direct the drill bit and the entire drilling BHA straight ahead along the longitudinal axis of the drilling BHA. This method can further be accomplished by using a control module/unit to measure and process drilling parameters, direction and orientation of the BHA, and using that information to control opening and closing of said lateral orifices to achieve the desired drilling direction.
The present invention also encompasses a directional drilling bottom hole assembly comprising: a bottom hole assembly; one or more lateral orifices circumferentially spaced around said bottom hole assembly; and, activation valves to selectively open and close said lateral orifices to provide lateral hydraulic force on said directional drilling bottom hole assembly. This embodiment can also be realized wherein the bottom hole assembly comprises a drill bit and a control unit or wherein the bottom hole assembly comprises a control unit located adjacent a drilling motor or wherein the lateral orifices are located in the drill bit body.
The apparatus of this embodiment can also provide the lateral orifices either located in the hole gauge section of the drill bit assembly, or in a separate BHA section between the drill bit an the control unit or in a section that is integral part of a control unit. Additionally, this apparatus can provide the lateral orifices inside a universal joint sleeve connected to a drill bit in a point-the-bit drilling assembly thereby permitting the hydraulic pressure to move the sleeve in the desired direction. The directional drilling bottom hole assembly can be accomplished wherein the bottom hole assembly comprises a push-the-bit drilling assembly and wherein the lateral orifices are in a control pad or wherein the bottom hole assembly comprises a mechanism for adjusting a gap between a distal tip of the lateral orifices and a well bore face or a universal joint sleeve to increase a force applicable to move the bottom hole assembly in an opposite direction.
The directional bottom hole assembly apparatus of this invention can also provide the bottom hole assembly which provides a mechanism for diverting a portion of drilling fluid through lateral orifices to direct the drill bit and the entire drilling BHA straight ahead along the longitudinal axis of the drilling BHA. Finally, the bottom hole assembly of this invention can comprise a control module/unit to measure and process drilling parameters, direction and orientation of the BHA, and uses that information to control opening and closing of said lateral orifices to achieve the desired drilling direction.
Possible benefits/advantages of the proposed drilling tool steering method and apparatus are:
The steering of the drilling tool is achieved by applying hydraulic forces to one side of the tool, thus achieving the steering of the tool in the opposite side direction. A portion of drilling fluid (mud) is diverted through a number of lateral orifices and through a narrow gap between the tool steering section and the bore hole. Only orifices on one side of the tool are opened at a time to provide a pressure differential in the tool-borehole annulus between that and the opposite side of the tool, thus creating a side hydraulic force on the tool, which steers the tool in the opposite side direction. The pressure differential is achieved mainly by the pressure needed to push a certain amount (flow rate) of drilling fluid through the fight gap between the tool and the borehole. The pressure needed to push the fluid through the narrow tool-borehole gap is provided by the pressure difference between the inside and the outside of the drilling tool. The new approach requires a controlled flow of part of drilling mud through the steering system and out into the tool-borehole annulus through the narrow annular gap.
As shown in
As the entire drilling BHA is rotated during drilling, including the lateral orifices, one or more lateral orifices are open only when they are approximately opposite to the desired change in drilling direction, while all other lateral orifices are closed until they get approximately opposite to the desired change in drilling direction as the entire BHA rotates around its longitudinal axis. The corresponding opening and closing of the lateral orifices, or opening and closing of the drilling fluid paths to these orifices, can be achieved and controlled by using existing methods for opening and closing fluid paths to the steering pads of a traditional bias or steering unit and controlling the process with a traditional control unit that performs necessary measurements and provides control and steering functions. For example, a counter-rotating valve that rotates at the same rotational speed as the drilling BHA but in the opposite direction can be used to open and close the drilling fluid path to the lateral orifices, thus keeping the fluid flow through the lateral orifices geo-stationary, i.e. in the same relative direction/orientation to the earth, while the rest of the drilling BHA rotates relative to the earth. The drilling fluid flow through the lateral orifices is kept geo-stationary in the lateral direction that is opposite to the desired change in drilling direction.
The desired opening and closing of the lateral orifices or the fluid paths to these orifices also can be achieved by other means, such as a piston or valve mechanism controlled from the control unit that measures the relative BHA position and orientation in real time, or by other means.
The described methods and mechanisms can also be used to direct the drilling BHA to drill straight ahead in a straight line along its longitudinal axis. For example, the rotary valve described above can be used to direct the drilling fluid flow to one or more lateral orifices to achieve the desired lateral hydraulic force and the corresponding drill bit movement in the opposite direction. When the rotary valve is not kept geo-stationary but instead it is rotated fully or partially with the rest of the BHA, or partially counter rotated relative to the BHA, the drilling fluid is effectively directed to the lateral orifices while they are in various orientations to the earth, thus applying the lateral hydraulic force in all directions around the bore hole and thus directing the drilling BHA straight ahead along its longitudinal axis. Another way of directing the BHA to drill straight ahead is to open all the lateral orifices at the same time, or to close all lateral orifices while drilling straight and switch back to the steering mode when the BHA starts to deviate from the straight path.
In another embodiment as shown in
Current directional drilling systems use a down hole mud motor with a bend sub or a rotary steerable system (RSS) with a steering section to create a 2-D or a 3-D well bore trajectory. RSS systems have many advantages over mud motor systems and are used for most drilling applications today. The current RSS systems use push-the-bit or point-the-bit approaches to achieve the desired steering of the drilling tool.
Most of the today's drilling market is covered by systems using the push the bit technology, which uses mechanical pads 200, an example of which is partially shown in
Pressure drop test data show that a large pressure differential and thus a large lateral force could be achieved with the currently used pressure difference between the inside and the outside of the drilling tool and with a fraction of the current overall flow rate of the drilling fluid.
Steering of the drilling tool or drill bit can be achieved by applying hydraulic forces to one side of the tool, thus achieving the steering of the tool in the opposite direction. The concept of the proposed invention can be explained by using
In another embodiment the lateral discharge of portion of the drilling fluid Qs can be forced into an even tighter annular gap h between the bit hole gauge section 10 and the bore hole 100 on an adjacent lateral side of the drill bit 50 as shown in
The proposed method also can be used with the existing drilling tool designs to minimize the abrasion wear and tool shocks and vibrations as shown in
Estimates of the lateral hydraulic forces associated with the steering method described herein are shown in
As can be seen from
Additionally, to achieve a higher pressure in the annular gap h and, consequently, higher lateral force Fs for hydraulic steering of the drilling tool, the geometry of the annular flow can be changed so that a higher pressure drop is achieved in the annular gap both near and away from the lateral orifice, for the same nominal annular gap h and the same lateral fluid flow rate Qs. For example, the lateral flow can be discharged in the localized annular gap at multiple points in different directions to create a higher pressure drop and a higher pressure in a larger annular gap area, producing a larger lateral force (e.g. multiple lateral flows in the same annular gap would flow against each other, thus possibly creating a higher pressure drop before the fluid exits the annular gap area). Other ways, for example without limitation include changing the flow and tool geometries, fluid properties, and pressure differentials can be substituted for a more optimized hydraulic lateral forces on the drilling tool thereby providing adequate steering with a minimum disruption to the fluid flow through the drill bit.
Numerous embodiments and alternatives thereof have been disclosed. While the above disclosure includes the best mode belief in carrying out the invention as contemplated by the named inventors, not all possible alternatives have been disclosed. For that reason, the scope and limitation of the present invention is not to be restricted to the above disclosure, but is instead to be defined and construed by the appended claims.