Patent Application
20240141779
The present disclosure relates generally to a device, system, and methods for controlling a drill bit, and in particular to a device, system and related methods for controlling the drill bit with a rotary pulser having regenerative power control.
In underground drilling, such as gas, oil or geothermal drilling, a bore is drilled through a formation deep in the earth. Such bores are formed by connecting a drill bit to sections of long pipe, referred to as a “drill pipe,” so as to form an assembly commonly referred to as a “drill string” that extends from the surface to the bottom of the bore. The drill bit is rotated so that it advances into the earth, thereby forming the bore. In rotary drilling, the drill bit is rotated by rotating the drill string and/or the drill bit. In order to lubricate the drill bit and flush cuttings from its path, pumps on the surface pump a high-pressure fluid, referred to as “drilling mud,” through an internal passage in the drill string and out through the drill bit. The drilling mud then flows to the surface through the annular passage formed between the drill string and the surface of the bore.
The distal end of a drill string, which includes the drill bit, is referred to as the “bottom hole assembly.” In “measurement while drilling” (MWD) applications, sensing modules in the bottom hole assembly provide information concerning the direction of the drilling. This information can be used, for example, to control the direction in which the drill bit advances in a steerable drill string. Such sensors may include a magnetometer to sense azimuth and accelerometers to sense inclination and tool face, among other sensors that measure other parameters.
Technologies are disclosed for a drill string device configured to operate at a down hole location in a well bore toward a location proximate the surface of an earthen formation. The drill string device may comprise one or more motors and/or a capacitor bank.
The drill string device may comprise a control processor. The control processor may be configured to control operation of a first motor of the one or more motors, perhaps for example as part of processing a drilling fluid. The control processor may be configured to provide a first electrical energy to the first motor, perhaps for example at least as the first motor operates. The control processor may be configured to receive a signal to stop the first motor. The control processor may be configured to stop the first motor. The control processor may be configured to control receipt of a second electrical energy from the first motor, perhaps for example at least as the first motor stops. The control processor may be configured to direct at least some of the second electrical energy to the capacitor bank.
In one or more scenarios, the first motor may be a direct current (DC) motor. In one or more scenarios, the second electrical energy may be produced by the DC Motor, perhaps for example as the DC Motor stops, among other scenarios.
In one or more scenarios, the control processor may be configured to determine that the received second electrical energy is substantially equivalent to a motor energy threshold, above the motor energy threshold, or below the motor energy threshold. The control processor may be configured to switch the second electrical energy to the capacitor bank, perhaps for example upon a determination that the received second electrical energy is substantially equivalent to the motor energy threshold, or above the motor energy threshold.
In one or more scenarios, the control processor may be configured to determine an electrical energy level of the capacitor bank is substantially equivalent to a capacitor energy threshold, above the capacitor energy threshold, or below the capacitor energy threshold. In one or more scenarios, the control processor may be configured to charge the capacitor bank with the second electrical energy, perhaps for example at least upon a determination that the electrical energy level of the capacitor bank is below the capacitor energy threshold.
In one or more scenarios, the control processor may be configured to determine an electrical energy level of the capacitor bank is at least one of: substantially equivalent to a capacitor energy threshold, above the capacitor energy threshold, or below the capacitor energy threshold. The control processor may be configured to provide the first electrical energy to the first motor from the capacitor bank, perhaps for example upon a determination that the electrical energy level of the capacitor bank is substantially equivalent to the capacitor energy threshold, or above the capacitor energy threshold.
In one or more scenarios, the control processor may be configured to determine an electrical energy level of the capacitor bank is substantially equivalent to a capacitor energy threshold, above the capacitor energy threshold, or below the capacitor energy threshold. The control processor may be configured to provide the first electrical energy to the first motor from the capacitor bank, perhaps for example upon a determination that the electrical energy level of the capacitor bank is substantially equivalent to the capacitor energy threshold, or above the capacitor energy threshold.
In one or more scenarios, the drill string device may comprise a battery module. The control processor may be configured to determine an electrical energy level of the capacitor bank is substantially equivalent to a capacitor energy threshold, above the capacitor energy threshold, or below the capacitor energy threshold. The control processor may be configured to provide the first electrical energy to the first motor from the battery module, perhaps for example upon a determination that the electrical energy level of the capacitor bank is below the capacitor energy threshold.
In one or more scenarios, the drill string device may comprise a rotary pulser. The control processor may be configured to provide the first electrical energy to the first motor at least for operation of the first motor in one or more pulses of the rotary pulser.
In one or more scenarios, the control processor may be configured to produce one or more pulses of the rotary pulser. The control processor may be configured to receive one or more pressure pulses produced by the rotary pulser. The control processor may be configured to determine one or more parameters of the one or more pressure pulses.
In one or more scenarios, the one or more parameters of the one or more pressure pulses may include one or more of an amplitude of the one or more pressure pulses, a duration of the one or more pressure pulses, a shape of the one or more pressure pulses, or a frequency of the one or more pressure pulses, for example, among other parameters. In one or more scenarios, the control processor may be configured to interpret one or more characteristics of a drilling operation from the one or more parameters of the pressure pulses, for example.
In one or more scenarios, the DC motor may be a brushless DC motor, an un-commutated DC motor, a permanent magnet DC motor, and/or a wound-stator DC motor.
The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings. The drawings show illustrative embodiments of the disclosure. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown.
For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the examples illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended.
Operation of the downhole motor causes the drill bit 15 to rotate along with or without rotation of the drill string 6. Accordingly, both the surface motor and the downhole motor can operate during the drilling operation to define the well 2. During the drilling operation, a pump 17 pumps drilling fluid downhole through an internal passage (not shown) of the drill string 6 out of the drill bit 15 and back to the surface 4 through an annular passage 13 defined between the drill string 6 and well wall. The drilling system 1 can include a casing 19 that extends from the surface 4 and into the well 2. The casing 19 can be used to stabilize the formation near the surface. One or more blowout preventers can be disposed at the surface 4 at or near the casing 19.
Continuing with
A mud pump pumps drilling fluid downward through the drill string 6 and into the drill bit 15. The drilling fluid flows upward to the surface through the annular passage 13 between the bore hole and the drill string 6, where, after cleaning, it is recirculated back down the drill string 6 by the mud pump. Also, in MWD and LWD systems, sensors, such as those of the types discussed above, are located in the bottom hole assembly portion of the drill string. The pulser 10 is located in the drill collar of the bottom hole assembly 11 so that drilling fluid flows through the pulser 10. By generating encoded pressure pulses, the pulser transmits information, such as information from the sensors, to the surface.
As discussed in U.S. Pat. No. 6,714,138 (Turner et al.) and U.S. Pat. No. 7,327,634 (Perry et al.), incorporated by reference above and providing mechanical details concerning the construction of a pulser, on one side of the pressure housing 26 is a gas-filled chamber in which the motors 16 and 18 are located, whereas an oil-filled chamber is formed on the other side of the pressure housing. The inner shaft 42 is supported on bearings 44 and 46 and drives rotation of a first rotor 50.
As shown in
Continuing with
As shown in
The pulsers according to an embodiment of present disclosure need not utilize a stationary stator. Specifically, the first and second rotors 50 and 52 are arranged adjacent to each other so that the blades of each rotor can at least partially, and in some cases almost fully, block the flow of drilling fluid through the passages in the adjacent rotor when the blades are circumferentially aligned with the passages. Furthermore, the pulser 10 could include at least two rotors that are similar to each other. For instance, the first and second rotor could be similar to rotor 50 illustrated in
The first and second motors 16 and 18 are separately controlled by a controller, such as by the controller (not shown) shown in
According to an embodiment, a pressure pulse is created in the drilling fluid whenever the one or both of the rotors rotate from a relative circumferential orientation in which the rotor blades of one rotor are not aligned with the passages in the other rotor and, therefore, do not obstruct the passages in the other rotor as shown in
The rotary pulser as described herein provides flexibility in terms of the operating mode of the pulser. In operation, one or both of the rotors 50 and 52 can be rotated continuously in the same or opposite directions, or both of the rotors can be oscillated, or one of the rotors can oscillate while the other rotates continuously in one direction. Further, one rotor can be rotated while the other rotor remains stationary, so that the stationary rotor acts as a stator. Alternatively, one rotor can be operated at a constant rotary speed, thereby generating a carrier wave within the drilling fluid, while the other rotor can rotate at a different constant rotary speed in the same direction so as to impart a phase shift in the carrier wave that is used to transmit information.
In one or more scenarios, the rotors can be rotated in the same direction or in opposite directions. The pulser has one or more clearing operating modes when debris jams or plugs the pulser 10 such that one or both rotors 50 and 52 can be rotated as necessary to clear the debris. For example, one clearing operating mode is where one rotor rotates in a first direction while the other rotor remains stationary. In another example of a clearing operating mode is where a first rotor rotates in a first direction while the second rotor rotates in a second direction that is opposite to the first direction. In yet another example of a clearing operating mode, the first rotor remains stationary and the second rotor rotates.
Technologies that may provide for electrical energy to operate, at least partially, one or more motors of a drill string beyond, and/or in addition to, a battery/battery back system of a drill string could be useful. Further, technologies that may provide for charging/recharging and/or replenishment of electrical energy to/for such sources of electrical energy could be useful.
Without the capabilities, techniques, methods, and/or devices described herein, the skilled artisan would not appreciate how to provide electrical energy for at least partial operation of one or more motors of a drill string other than a battery/battery back system, where such technologies may provide for charging/recharging and/or replenishment of electrical energy to/for such sources of electrical energy.
The motor driver 80 receives power 107 from the power source 64 and directs power 108 to a switching device 90. The switching device 90 transmits power 111 to the appropriate windings of the motor 82 so as to effect rotation of the rotor 36 in either a first (e.g., clockwise) or opposite (e.g., counterclockwise) direction so as to generate pressure pulses 112 that are transmitted through the drilling mud 182. The pressure pulses 112 are sensed by the sensor at the surface and the information is decoded and directed to a data acquisition system for further processing, as is conventional. The pressure pulses 112 generated at the down hole pulser 62 may have an amplitude. The shape of the pulses may be less distinct and/or noise may be superimposed on the pulses.
In one or more scenarios, a down hole static pressure sensor 29 may be incorporated into the drill string to measure the pressure of the drilling mud in the vicinity of the pulser 62. As shown in
In one or more scenarios, the down hole pulser 62 may include a down hole dynamic pressure sensor 28 that senses pressure pulsations in the drilling mud (not shown) in the vicinity of the pulser 62. The pressure pulsations sensed by the sensor 28 may be the pressure pulses generated by the down hole pulser 62 or the pressure pulses generated by the surface pulser. In either case, the down hole dynamic pressure sensor 28 transmits a signal 115 to the controller 76 containing the pressure pulse information, which may be used by the controller in generating the motor control signals 106. The down hole pulser 62 may also include an orientation encoder 95 suitable for high temperature applications, coupled to the motor 82. The orientation encoder 95 directs a signal 114 to the controller 76 containing information concerning the angular orientation of the rotor 36, which may also be used by the controller in generating the motor control signals 106. The orientation encoder 95 is of the type employing a magnet coupled to the motor shaft that rotates within a stationary housing in which Hall effect sensors are mounted that detect rotation of the magnetic poles.
The memory 420 can store information about the pulses which were received and generated by the controller. This information could consist of the time, speed, pulse width and braking information which could be used for diagnostics if required.
The high current switches 440 will be able to control the flow of electrical energy both to the motor and to the capacitors.
The switches 440 and A/D converter 430 will provide the means to read in from the resolver in order for the processor 410 to measure the rotational position of the rotor in relation to the passages.
In one or more scenarios, a drill string device may be configured to operate at a down hole location in a well bore toward a location proximate the surface of an earthen formation. The drill string device may comprise one or more motors and/or a capacitor bank.
The drill string device may comprise a control processor. The control processor may be configured to control operation of a first motor of the one or more motors, perhaps for example as part of processing a drilling fluid. The control processor may be configured to provide a first electrical energy to the first motor, perhaps for example at least as the first motor operates. The control processor may be configured to receive a signal to stop the first motor. The control processor may be configured to stop the first motor. The control processor may be configured to control receipt of a second electrical energy from the first motor, perhaps for example at least as the first motor stops. The control processor may be configured to direct at least some of the second electrical energy to the capacitor bank.
In one or more scenarios, the first motor may be a direct current (DC) motor. In one or more scenarios, the second electrical energy may be produced by the DC Motor, perhaps for example as the DC Motor stops, among other scenarios.
In one or more scenarios, the control processor may be configured to determine that the received second electrical energy is substantially equivalent to a motor energy threshold, above the motor energy threshold, or below the motor energy threshold. The control processor may be configured to switch the second electrical energy to the capacitor bank, perhaps for example upon a determination that the received second electrical energy is substantially equivalent to the motor energy threshold, or above the motor energy threshold. In one or more scenarios, the motor energy threshold will be in the range of 2 to 3 amps peak, for example.
In one or more scenarios, the control processor may be configured to determine an electrical energy level of the capacitor bank is substantially equivalent to a capacitor energy threshold, above the capacitor energy threshold, or below the capacitor energy threshold. In one or more scenarios, the control processor may be configured to charge the capacitor bank with the second electrical energy, perhaps for example at least upon a determination that the electrical energy level of the capacitor bank is below the capacitor energy threshold. In one or more scenarios, the capacitor energy threshold may be in the range of 2 to 3 amps, for example.
In one or more scenarios, the control processor may be configured to determine an electrical energy level of the capacitor bank is at least one of: substantially equivalent to a capacitor energy threshold, above the capacitor energy threshold, or below the capacitor energy threshold. The control processor may be configured to provide the first electrical energy to the first motor from the capacitor bank, perhaps for example upon a determination that the electrical energy level of the capacitor bank is substantially equivalent to the capacitor energy threshold, or above the capacitor energy threshold.
In one or more scenarios, the control processor may be configured to determine an electrical energy level of the capacitor bank is substantially equivalent to a capacitor energy threshold, above the capacitor energy threshold, or below the capacitor energy threshold. The control processor may be configured to provide the first electrical energy to the first motor from the capacitor bank, perhaps for example upon a determination that the electrical energy level of the capacitor bank is substantially equivalent to the capacitor energy threshold, or above the capacitor energy threshold.
In one or more scenarios, the drill string device may comprise a battery module. The control processor may be configured to determine an electrical energy level of the capacitor bank is substantially equivalent to a capacitor energy threshold, above the capacitor energy threshold, or below the capacitor energy threshold. The control processor may be configured to provide the first electrical energy to the first motor from the battery module, perhaps for example upon a determination that the electrical energy level of the capacitor bank is below the capacitor energy threshold.
In one or more scenarios, the drill string device may comprise a rotary pulser. The control processor may be configured to provide the first electrical energy to the first motor at least for operation of the first motor in one or more pulses of the rotary pulser.
In one or more scenarios, the control processor may be configured to produce one or more pulses of the rotary pulser. The control processor may be configured to receive one or more pressure pulses produced by the rotary pulser. The control processor may be configured to determine one or more parameters of the one or more pressure pulses.
In one or more scenarios, the one or more parameters of the one or more pressure pulses may include one or more of an amplitude of the one or more pressure pulses, a duration of the one or more pressure pulses, a shape of the one or more pressure pulses, or a frequency of the one or more pressure pulses, for example, among other parameters. In one or more scenarios, the control processor may be configured to interpret one or more characteristics of a drilling operation from the one or more parameters of the pressure pulses, for example.
In one or more scenarios, the DC motor may be a brushless DC motor, an un-commutated DC motor, a permanent magnet DC motor, and/or a wound-stator DC motor.
Referring now to
At 302, the process may start or restart. At 304, the drill string device may operate a first motor of the one or more motors as part of processing the drilling fluid. At 306, the drill string device may provide a first electrical energy to the first motor at least as the first motor is operating.
At 308, the drill string device may receive a signal to stop the first motor. At 310, the drill string device may stop the first motor. At 312, the drill string device may receive a second electrical energy from the first motor at least as the first motor is stopping. At 314, the drill string device may direct at least some of the second electrical energy to the capacitor bank. At 316, the process may stop or restart.
Referring now to
At 512, when the motor decelerates, its rotational energy generates electricity required to recharge the capacitors. Thereafter, at 514, the switches are opened from the capacitor source after completion of motion. Finally, at 516, the pulser control processor stops until the next signal is received and restarts at step 502.
Those skilled in the art will appreciate that the disclosed subject matter improves upon methods and/or apparatuses for supplying electrical energy to one or more motors of a drill string, such as a pulser motor, for example. A burden on a drill string battery/battery back system may be reduced and/or the service time of the battery/battery back system may be increased by providing electrical energy to one or more drill string motors from a capacitor bank and/or recharging/replenishing the capacitor bank electrical energy from a braking/stopping motor of the drill string.
The subject matter of this disclosure, and components thereof, can be realized by instructions that upon execution cause one or more processing devices to carry out the processes and/or functions described herein. Such instructions can, for example, comprise interpreted instructions, such as script instructions, e.g., JavaScript or ECMAScript instructions, or executable code, and/or other instructions stored in a computer readable medium.
Implementations of the subject matter and/or the functional operations described in this specification and/or the accompanying figures can be provided in digital electronic circuitry, in computer software, firmware, and/or hardware, including the structures disclosed in this specification and their structural equivalents, and/or in combinations of one or more of them. The subject matter described in this specification can be implemented as one or more computer program products, e.g., one or more modules of computer program instructions encoded on a tangible program carrier for execution by, and/or to control the operation of, data processing apparatus.
A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, and/or declarative or procedural languages. It can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, and/or other unit suitable for use in a computing environment. A computer program may or might not correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs and/or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, and/or in multiple coordinated files (e.g., files that store one or more modules, sub programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that may be located at one site or distributed across multiple sites and/or interconnected by a communication network.
The processes and/or logic flows described in this specification and/or in the accompanying figures may be performed by one or more programmable processors executing one or more computer programs to perform functions by operating on input data and/or generating output, thereby tying the process to a particular machine (e.g., a machine programmed to perform the processes described herein). The processes and/or logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) and/or an ASIC (application specific integrated circuit).
Computer readable media suitable for storing computer program instructions and/or data may include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices (e.g., EPROM, EEPROM, and/or flash memory devices); magnetic disks (e.g., internal hard disks or removable disks); magneto optical disks; and/or CD ROM and DVD ROM disks. The processor and/or the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
While this specification and the accompanying figures contain many specific implementation details, these should not be construed as limitations on the scope of any invention and/or of what may be claimed, but rather as descriptions of features that may be specific to described example implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in perhaps one implementation. Various features that are described in the context of perhaps one implementation can also be implemented in multiple combinations separately or in any suitable sub-combination. Although features may be described above as acting in certain combinations and/or perhaps even (e.g., initially) claimed as such, one or more features from a claimed combination can in some cases be excised from the combination. The claimed combination may be directed to a sub-combination and/or variation of a sub-combination.
While operations may be depicted in the drawings in an order, this should not be understood as requiring that such operations be performed in the particular order shown and/or in sequential order, and/or that all illustrated operations be performed, to achieve useful outcomes. The described program components and/or systems can generally be integrated together in a single software product and/or packaged into multiple software products.
Examples of the subject matter described in this specification have been described. The actions recited in the claims can be performed in a different order and still achieve useful outcomes, unless expressly noted otherwise. For example, the processes depicted in the accompanying figures do not require the particular order shown, and/or sequential order, to achieve useful outcomes. Multitasking and parallel processing may be advantageous in one or more scenarios.
While the present disclosure has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain examples have been shown and described, and that all changes and modifications that come within the spirit of the present disclosure are desired to be protected.
