A typical bottom hole assembly is depicted in
With reference to
During drilling operations, a delay in the operation of RSS 14 can result in misdirected wellbore. The combination of ambient drilling mud pressure and spring pressure acts on the hydraulic fluid within hydraulic fluid reservoir 22 to maintain a pressure greater than the ambient annulus pressure. Accordingly, performance of RSS 14 depends upon the action of drilling mud pressure and spring pressure on the hydraulic fluid within reservoir 22 to ensure that an adequate supply of hydraulic fluid is available at hydraulic pump 20.
Unfortunately, this configuration allows for the introduction of mud particles and other wellbore debris into fluid passageway 28. Overtime, the debris will reduce the reaction time of compensation piston 26 due to increased friction within passageway 28. Eventually, the accumulation of mud debris on the whole side of compensation piston 26 will freeze compensation piston 26. As a result, actuation of RSS 14 steering arms will be delayed due to an inadequate supply of hydraulic fluid resulting in a poorly drilled wellbore.
As depicted in
As depicted in
For proper operation, oil reservoir 65 must be maintained at a pressure greater than ambient pressure. To provide for this necessity, shaft lubricating block 60 includes passageways 74 and 76. Passageways 74 and 76 are divided into downhole and uphole regions by pistons 78, 80. A port 77 provides fluid communication between the downhole regions of fluid passageways 74 and 76 and the exterior of shaft lubricating block 60. As depicted in
As depicted in
The described configuration balances the pressures experienced by hydraulic block 16 and shaft lubricating block 60. However, overtime the lubricating fluid of shaft lubricating block 60 becomes contaminated with wear particles produced by rotating drive shaft 18. These contaminants will increase friction experienced by floating piston 38 and will lead to delayed movement on the part of floating piston 38 creating an imbalance of pressure between the two operating blocks. This imbalance of pressure could lead to leakage of lubricating fluid from shat lubricating block 60 into hydraulic block 16 contaminating the hydraulic fluid and disrupting steering operations. Additionally, bearings 62, 64 impede the flow of shaft oil from shaft lubricating block 60 to hydraulic block 16 as port 82 is located uphole of bearing 64 while port 85 is located downhole of bearing 62. Thus, shaft oil experiences a constricted flow path as it crosses each bearing. Thus, this configuration does not efficiently transfer hydraulic pressure from shaft lubricating block 60 to floating piston 38. Accordingly, the effective pressure experienced by floating piston 38 is less than expected which can result in a delay of steering arm deployment by the RSS. Any delay in steering arm deployment will increase steering error during drilling operations and increase operational costs.
The following disclosure describes an improved hydraulic block and improved shaft lubricating block. The improvements preclude the contamination of passageway 28 housing the compensation piston 26 with debris carried by the drilling mud. Additionally, the improvements provide for elimination of floating piston 38 from passageway 36.
The present disclosure describes embodiments of an improved pressure compensation system suitable for use as a component of a downhole tool. One improved pressure compensation system includes a main housing supporting a hydraulically actuated tool, a shaft lubricating block, a hydraulic block and a drilling mud access port. A rotatable shaft passes through the main housing. The main housing includes a shaft oil reservoir containing shaft oil, a first bearing supporting the shaft passing through the main housing and a second bearing supporting the shaft passing through the main housing. The first and second bearings are immersed in the shaft oil contained within the shaft oil reservoir. The shaft lubricating block includes at least one shaft lubricating block passageway having an uphole end and a downhole end. Positioned within the shaft lubricating block passageway is a piston positioned. The piston has an uphole side and a downhole side and the piston divides the at least one shaft lubricating block passageway into an uphole region and a downhole region. A first fluid port provides fluid communication between the at least one shaft lubricating block passageway and the shaft oil reservoir. The first fluid port is located downhole of the first bearing. The uphole region of the at least one shaft lubricating block passageway contains shaft oil. Additionally, a spring located in either the uphole region or the downhole region of the at least one shaft lubricating block passageway applies a biasing force against the piston such that the piston applies pressure to shaft oil located within the shaft oil reservoir. The hydraulic block includes a first hydraulic block passageway having an uphole end and a downhole end. Positioned within the first hydraulic block passageway is a piston having an uphole side and a downhole side. The piston divides the first hydraulic block passageway into an uphole region and a downhole region. A second fluid port provides fluid communication between the uphole side of the first hydraulic block passageway and the shaft oil reservoir. The second fluid port is located uphole of the second bearing. The drilling mud access port is in fluid communication with the downhole region of the at least one passageway of the shaft lubricating block.
The present disclosure describes embodiments of an improved pressure compensation system suitable for use as a component of a downhole tool. One improved pressure compensation system includes a main housing supporting a hydraulically actuated tool, a shaft lubricating block, a hydraulic block and a drilling mud access port. A rotatable shaft passes through the main housing. The main housing includes a shaft oil reservoir containing shaft oil, a first bearing supporting the shaft passing through the main housing and a second bearing supporting the shaft passing through the main housing. The first and second bearings are immersed in the shaft oil contained within the shaft oil reservoir. The hydraulic block includes first hydraulic block passageway having uphole end and a downhole end. Positioned within the first hydraulic block passageway is a piston having an uphole side and a downhole side. The piston divides the first hydraulic block passageway into an uphole region and a downhole region. A first fluid port provides fluid communication between the uphole side of the first hydraulic block passageway and the shaft oil reservoir. The first fluid port is located uphole of the second bearing. A spring is located in either the uphole or downhole region of the first hydraulic block passageway. Located within the hydraulic block is a hydraulic fluid reservoir containing hydraulic fluid. A second port provides fluid communication between the hydraulic fluid reservoir and the downhole region of the first hydraulic block passageway. A second hydraulic block passageway houses a hydraulic pump and is in fluid communication with the hydraulic fluid reservoir. A third hydraulic block passageway provides fluid communication between the hydraulic pump and the hydraulically actuated tool. The configuration of the hydraulic block precludes fluid communication between the first, second and third passageways of the hydraulic block and the exterior of the downhole tool.
The present disclosure describes embodiments of an improved pressure compensation system suitable for use as a component of a downhole tool. One improved pressure compensation system includes a main housing supporting a hydraulically actuated tool, a shaft lubricating block, a hydraulic block and a drilling mud access port. A rotatable shaft passes through the main housing. The main housing includes a shaft oil reservoir containing shaft oil, a first bearing supporting the shaft passing through the main housing and a second bearing supporting the shaft passing through the main housing. The first and second bearings are immersed in the shaft oil contained within the shaft oil reservoir. The hydraulic block includes a first hydraulic block passageway having an uphole end and a downhole end. Positioned within the first hydraulic block passageway is a piston having an uphole side and a downhole side. The piston divides the first hydraulic block passageway into an uphole region and a downhole region. A first fluid port provides fluid communication between the uphole side of the first hydraulic block passageway and the shaft oil reservoir. The first fluid port is located whole of the second bearing. A spring is located in either the uphole or downhole region of the first hydraulic block passageway. The whole region of said first hydraulic block passageway contains shaft oil. Located within the hydraulic block is a hydraulic fluid reservoir containing hydraulic fluid. A second port provides fluid communication between the hydraulic fluid reservoir and the downhole region of the first hydraulic block passageway. A second hydraulic block passageway houses a hydraulic pump and is in fluid communication with the hydraulic fluid reservoir. The hydraulic pump divides the second hydraulic block passageway into a downhole region and an whole region. The uphole region of the second hydraulic passageway does not contain a floating piston. A third hydraulic block passageway provides fluid communication between the hydraulic pump and the hydraulically actuated tool.
The invention disclosed herein overcomes the deficiencies of prior art pressure compensation systems through a reconfiguration of the fluid flow passageways of the shaft lubricating block and hydraulic block. As used herein, the term “block” is used generically to designate a component of the bottom hole assembly. The use of the term “block” does not limit the geometric shape of the component. For example, in this instance “block” could also be a tube or other shape capable of being secured to main housing 13.
Through the reconfiguration of the fluid flow passageways, the present invention precludes the introduction of friction inducing debris to the passageways housing pistons necessary for balancing fluid pressures within the hydraulic block and shaft lubricating block. Additionally, the configuration of the improved pressure compensation system 100 provides an additive force to hydraulic fluid housed in hydraulic fluid reservoir 22 by providing a configuration wherein the force of a spring in shaft lubricating block 160 is conveyed to hydraulic block 116. The additive force improves operation of RSS 14 by ensuring a constant supply of hydraulic fluid to hydraulic pump 20.
Additionally, as depicted, in
In one embodiment of improved pressure compensation system 100, placement of plug 119 at the uphole end of passageway 28 precludes mud access through port 77 into passageway 28 of hydraulic block 116. Thus, port 77 provides fluid communication between the interior of shaft lubricating block 160 and the wellbore annulus. In one embodiment of improved pressure compensation system 100, floating piston 38 has been eliminated from the uphole region of hydraulic block passageway 36. In retrofits where port 85 remains open, passageway 36 may be filled with lubricating fluid entering through port 85. In another embodiment of pressure compensation system 100, mud access to hydraulic block 116 has been eliminated, port 32 has been eliminated or plugged and floating piston 38 has been eliminated.
In improved compensation system 100, ambient pressure conveyed by drilling mud enters through port 77 and actuates pistons 78, 80 in passageways 74, 76. The mud pressure in combination with the springs 84, 86, ensures that the oil within oil reservoir 65 is maintained at a pressure between about 10 psi and about 50 psi above ambient pressure with a target pressure of about 30 psi above ambient pressure.
Although the disclosed embodiment of
As depicted in
As noted above, if the unproved pressure compensation system 100 is a retrofit of a prior art system port 32 has been plugged. However, in a newly manufactured pressure compensation system 100, port 32 will be omitted. Thus, port 117 now provides fluid communication between shaft lubricating block 160 and oil reservoir 65 while port 115 provides fluid communication between oil reservoir 65 and hydraulic block 116. In this configuration, oil flows from shaft lubricating block 160 through ports 115 and 117 to hydraulic block 116 and passageway 28 housing compensation piston 26.
In view of the pressure applied to compensation piston 26 by oil in passageway 28, floating piston 38 has been eliminated from passageway 36. Additionally, the modification of the hydraulic block by the addition of plug 119 precludes entry of drilling mud into passageway 28. As a result, the improved pressure compensation system 100 precludes contamination of compensation piston 26 by drilling mud debris. Thus, modified hydraulic block 116 will no longer experience lags in pressure compensation due to drilling mud debris.
As depicted in
As noted above, compensation piston 26 is associated with spring 34 which provides an additional additive force to ensure that compensation pressure applied to hydraulic fluid located within reservoir 22 remains at least about 10 psi to about 50 psi above ambient drilling mud pressure. Accordingly, the improved compensation system operates in a manner where the spring forces provided b springs 84, 86 and 84 are additive when applied to hydraulic fluid reservoir 22. The additive forces ensure a constant, adequate supply of hydraulic fluid to hydraulic pump 20 thereby precluding delayed operation of RSS 14 arms. Thus, improved pressure compensation system 100 enhances the operation of RSS 14.
Additionally, the modified fluid flow path, allows compensation piston 26 to act as a floating piston and as a separation point balancing the pressures of the hydraulic fluid system and the shaft lubricating block fluid system. Thus, elimination of floating piston 38 provides a more efficient and reliable pressure compensation system. The modified pressure compensation system requires drilling mud access to only shaft lubricating block 160 thereby isolating hydraulic block 116 from drilling mud debris. Finally, the elimination of the floating piston 38 from the uphole region of passageway 36 creates a void on the uphole side of hydraulic pump 20. This void may be filled with lubricating fluid, hydraulic fluid or may remain empty.
In the prior art system, the total drag force within pressure compensation system 10 resulting from compensation piston 26, floating piston 38 and pistons 78, 80 was approximately 50% to 71% of the available compensation pressure. Removal of floating piston 38 reduces overall frictional force within improved pressure compensation system 100 thereby reducing the drag force within hydraulic block 116. Further, as discussed below, to the configuration of improved pressure compensation system 100, the forces of springs 84, 86 and 34 are additive thereby providing an increase in compensation pressure available to hydraulic pump 20 within hydraulic block 116.
As discussed above, spring rates for each spring in improved pressure compensation system 100 may range from about 5 psi to about 50 psi. Thus, because of the additive spring forces and reduced drag force resulting from the removal of floating piston 38 resulting drag three within improved pressure compensation system 100 is only about 11% to 17% of available compensation pressure. Thus, improved pressure compensation system 100 preferably operates with about 10% to 35% of available compensation pressure dedicated to operation of compensation piston 26.
The present invention also provides a method. for retrofitting a prior art compensation system to the a hove described improved pressure compensation system 100. The method entails removal of hydraulic block 16 and shaft lubricating block 60 from main housing 13. Following removal of hydraulic block 16, port 32 is plugged using any convenient means and plug 119 inserted in passageway 28 to block mud access from port 77 to passageway 28. Additionally, new port 115 is drilled providing fluid access to passageway 34. A corresponding port 115 is drilled within main housing 13 to provide fluid access to reservoir 65. Optionally, floating piston 38 is removed from passageway 36. Similarly, new port 117 is drilled in shaft lubricating block 60 to provide fluid access to the one or more passageways housing spring actuated pistons in shaft lubricating block 60. A corresponding port is drilled in main housing 13 to provide fluid access to reservoir 65. As discussed above, new port 115 will be uphole of the downhole shaft bearing 62 and new port 117 will be downhole of shaft bearing 64 to provide an unobstructed flow path for lubricating oil within reservoir 65 from the one or more passageways housing spring actuated pistons in shaft lubricating block 60 to passageway 34 of hydraulic block 16.
Other embodiments of the present invention will be apparent to one skilled in the art. As such, the foregoing description merely enables and describes the general uses and methods of the present invention. Accordingly, the following claims define the true scope of the present invention.
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