Patent Grant
10443307
The present application claims the benefit of the Chinese patent application No. 201711044207.9, filed on Oct. 31, 2017 before the Chinese Patent Office, entitled “Static Internal Pushing Hinged-Type High-Deflecting-Rate Rotary Guiding Tool and Control Method”, the contents of which are incorporated herein by reference in their entirety.
The present invention mainly belongs to the technical field of rotary steerable systems, and particularly relates to a static push-the-bit articulated high-built-rate rotary steerable tool and a control method thereof.
Rotary steerable technology belongs to the field of directional drilling, and is mainly used for drilling three trajectory wells such as directional wells, horizontal wells and extended reach wells, etc. Relying on a high-precision servo control mechanism and high-precision D&I measurement sensors, it can accurately control the drilling direction of a drill bit in real time, and thereby controls a wellbore trajectory. Existing conventional low-built-rate (6.5°/30 m) rotary steerable tools can't meet the requirements for drilling directional shale gas wells and offshore or land high-DLS wells anymore.
The AutoTrak Curve rotary steerable tool from Baker Hughes Incorporated employs three sets of hydraulic push-the-bit cylinders and their auxiliary ribs to push against the well wall. Under the pushing forces, the upper portion of the steerable tool is bent and deformed integrally, so that a fixed angle is formed between the axial direction of the wellbore trajectory and the axial direction of the steerable tool, and thereby a building angle is created. A disadvantage of such a structure is that bending the upper portion of the steerable tool consumes the pushing forces, and the bending caused by the pushing forces aggravates the bending stress in the drilling stem at the upper portion. Consequently, in a large-curvature wellbore, the drilling tool at the upper portion is prone to have alternating fatigue damages. As a result, there is a high requirement for the strength of the metal material of the drilling tool at the upper portion. It is hard for the steerable system to achieve a higher built rate, because the entire tool system is deformed integrally in the wellbore. Moreover, the ribs of the rotary steerable tool from Baker Hughes Incorporated suffer severe abrasion, since they push against the well wall.
The PD Archer rotary steerable tool from Schlumberger Limited employs a structure in which the main body of a measurement and control unit is articulated with the main body of a universal mechanism, four sets of pushing pistons located at the lower end of the main body of the measurement and control unit push against the inner wall of a steering sleeve around the main body of the universal mechanism at the lower portion, and thereby the direction of the drill bit is controlled. Since the tool system employs a full-rotary design concept and utilizes mud pressure to drive the pistons, the steering sleeve around the main body of the universal mechanism bears high force, may be worn out more easily in a rotation state, and has a short service life. Furthermore, the pistons are hard to seal and may have a shortened service life because the mud contains sand. Consequently, the entire rotary steerable tool system has a short overall service life and involves a higher maintenance and service cost.
In view of the above-mentioned technical problems, the present invention provides a static push-the-bit articulated high-built-rate rotary steerable tool, and a method for controlling a rotary steerable system. The static push-the-bit articulated high-built-rate rotary steerable tool in the present invention employs a static push-the-bit articulated design concept in which the main body of a non-rotary measurement and control unit is articulated with the main body of a non-rotary actuator, rather than employs an integral structure. Owing to a fact that the drilling tool is easy to bend in a wellbore, the bending stress in an upper portion of the steerable tool is low, and the consumption of the pushing force for bending deformation of the drilling tool is minimized; since the steering sleeve around the main body of a load-bearing actuator only slides along the well wall in an axial direction without rotational friction there-between, the service life of the steering sleeve is long. Besides, since hydraulic pressure is used instead of pressure difference of mud to act on the pistons to form the pushing force, the pushing force is greatly improved, and the sealing life of the pistons is longer. Therefore, the apparatus in the present invention can achieve a higher built rate easily, and has an advantage of longer drilling service life.
The object of the present invention is attained with the following technical scheme:
A static push-the-bit articulated high-built-rate rotary steerable tool, comprising a rotary mandrel, a drill bit shaft, a universal joint connecting the rotary mandrel with the drill bit shaft, and a first non-rotary steering sleeve and a second non-rotary steering sleeve that are disposed around the rotary mandrel, wherein, the universal joint is disposed inside the second non-rotary steering sleeve; the first non-rotary steering sleeve (4) is supported on the mandrel (7) by means of a lower mud bearing (5) and an upper mud bearing (6). A stator coil in a non-contact electric power transmission assembly (3) is mounted inside the first non-rotary steering sleeve (4), and a rotor coil of the non-contact electric power transmission assembly (3) is positioned on the mandrel (7) and rotates together with the mandrel (7). A central control circuit (2) is also mounted inside the inner hole of the first non-rotary steering sleeve (4). For the convenience of maintenance and service, three sets of independent motor pump hydraulic modules (1) are secured to the first non-rotary steering sleeve (4) by bolts.
The rotary mandrel is articulated with the universal joint, so as to transmit drilling pressure and torque for drilling to a drill bit and realize universal articulation of the first non-rotary steering sleeve and the second non-rotary steering sleeve as well;
The first non-rotary steering sleeve and the second non-rotary steering sleeve are isolated from the rotation of the rotary mandrel by means of an upper mud bearing, a lower mud bearing and a near-bit-end mud bearing, so that the first non-rotary steering sleeve and the second non-rotary steering sleeve are kept in a quasi-stationary or non-rotary state with respect to the ground.
Furthermore, the first non-rotary steering sleeve is positioned in axial direction and radial location by means of the upper mud bearing and the lower mud bearing, and is isolated from the rotational movement of the rotary mandrel, so that the first non-rotary steering sleeve is kept in a quasi-stationary or non-rotary state with respect to the ground.
Furthermore, the second non-rotary steering sleeve is positioned in axial direction and radial location by means of the near-bit-end mud bearing, and is isolated from the rotational movement of the drill bit shaft, so that the second non-rotary steering sleeve is kept in a non-rotary quasi-stationary state in a wellbore.
Furthermore, a bow spring device is mounted on the first non-rotary steering sleeve, and is retained on the first non-rotary steering sleeve by a retaining cover; the outer diameter of the bow spring device is greater than the diameter of the wellbore, and the bow spring device abuts against the well wall by virtue of its compressive spring force in the wellbore to prevent the first non-rotary steering sleeve from rotating quickly incurred by a friction force of the mud bearings, and thereby keeps the first non-rotary steering sleeve in the quasi-stationary state.
Furthermore, wear-resistant ribs are mounted outside the second non-rotary steering sleeve; the outer circumference of each of the wear-resistant ribs has zigzag structures, and several hard alloy blocks for improving wear resistance are inlaid among the zigzag structures; and the wear-resistant ribs are evenly distributed on the outer circumference of the second non-rotary steering sleeve.
Furthermore, the rotary steerable tool further comprises a centering connecting shaft, a first circuit disposed on the rotary mandrel, a central control circuit, and three sets of independent motor pump hydraulic modules; and each set of motor pump hydraulic modules comprises at least one set of pushing pistons; and
electric power and communication signals from a MWD are transferred to the first circuit via the centering connecting shaft, the first circuit transfers the electric power subjected to high-frequency modulation and the signals subjected to carrier modulation to the central control circuit via a non-contact electric power transmission assembly, motor controllers in the central control circuit drive the three sets of independent motor pump hydraulic modules, hydraulic systems in the motor pump hydraulic modules generate high-pressure oil sources and feed high-pressure oil into the pushing pistons, and vector resultants of three coplanar concurrent force systems are formed by separately controlling the oil pressure acting on each set of pushing pistons, so as to form a resultant force vector, which acts on the inner wall of the second non-rotary steering sleeve so that the drill bit shaft is deflected around an articulation point defined by the universal joint and thereby forms an angle with respect to the axis of the rotary steerable tool; and by controlling the magnitude and direction of the resultant force vector, a lateral force acting on the drill bit is controlled accurately, and thereby the drilling direction of the drill bit is controlled.
Furthermore, the first circuit is sealed in a cavity in an upper portion of the rotary mandrel by a sealing cover plate; and the first circuit is electrically connected with the centering connecting shaft via a connector.
Furthermore, the three sets of independent motor pump hydraulic modules are fixed on the first non-rotary steering sleeve by screws.
Furthermore, a mud turbine generator for supplying electric power is disposed on the rotary steerable tool, positioned at an inner shoulder of a sub of a drill collar, and connected with an upper-end interface of the rotary steerable tool via a lower-end interface of the mud turbine generator by insertion, so that the sub of the drill collar with the generator is electrically connected with the rotary steerable tool; and
a guiding connection base is provided on a lower portion of the mud turbine generator, an electrical connector is provided in the guiding connection base, and the mud turbine generator is pushed into the guiding connection base in an axial direction, so as to realize positioning and transfer electric power from of the mud turbine generator to the first circuit via the electrical connector as well.
A method for controlling a static push-the-bit articulated high-built-rate rotary steerable tool, comprising:
receiving a current target tool face as a target execution instruction, by a central control circuit;
acquiring signals from sensors and calculating a current tool face, by the central control circuit;
calculating a target steering force vector according to the target tool face, and decomposing the target steering force vector into three separate hydraulic pressures, by a central control circuit system;
transmitting hydraulic pressure commands to three sets of independent motor controllers, which drive three sets of independent motor pump hydraulic modules respectively, and acquiring operating pressures of hydraulic systems and controlling the operating pressures by closed-loop control in real-time at high precision, so that the current steering force vector approaches to the target steerable force vector and is maintained at the target steering force vector all the time;
acquiring and monitoring a current gravitational tool face value in real time, by the central control circuit system, and, if the current gravitational tool face value varies, recalculating the target steering force vector and decomposing the recalculated target steering force vector into three separate hydraulic pressures, by the central control circuit system; and
driving the three sets of independent motor pump hydraulic modules respectively by the three sets of independent motor controllers, and acquiring the operating pressures of the hydraulic systems and controlling the operating pressures by closed-loop control in real time at high precision, so that the current steering force vector approaches to the reassigned target steering force vector and is maintained at the target steering force vector all the time; and controlling a drill bit under the action of the target steering force vector all the time to drive a well according to a required wellbore trajectory.
The Present Invention has Advantageous Technical Effects:
The rotary steerable tool in the present invention employs a static push-the-bit articulated design concept in which the main body of a non-rotary measurement and control unit is articulated with the main body of a non-rotary actuator, rather than employs an integral structure. Owing to a fact that the drilling tool is easy to bend in a wellbore, the bending stress in an upper portion of the steerable tool is low, and the consumption of the pushing force for bending deformation of the drilling tool is minimized; since the steering sleeve around the main body of a load-bearing actuator only slides along the well wall in an axial direction without rotational friction there-between, the service life of the steering sleeve is long. Besides, since hydraulic pressure is used instead of pressure difference of mud to act on the pistons to form the pushing force, the pushing force is greatly improved, and the sealing life of the pistons is longer. Therefore, the apparatus in the present invention can achieve a higher built rate easily, and has an advantage of longer drilling service life.
1—motor pump hydraulic module; 2—central control circuit; 3—non-contact electric power transmission assembly; 4—first non-rotary steering sleeve; 5—lower mud bearing; 6—upper mud bearing; 7—rotary mandrel; 8—sealing cover plate; 9—first circuit; 10—far-bit-end centralizer; 11—centering connecting shaft; 11.1—lower electrical connector; 12—second non-rotary steering sleeve; 12.1—wear-resistant rib; 12a—zigzag structure of wear-resistant rib of non-rotary steering sleeve at lower portion; 13—universal joint; 14—near-bit-end mud bearing; 15—drill bit shaft; 16—pushing piston; 16.1—first set of pushing pistons; 16.2—second set of pushing pistons; 17—drill collar for generator; 18—mud turbine generator; 18.1—electric connector at lower portion of generator; 19—bow spring device; 20—retaining cover; 21—connecting base; 21.1—electrical connector; 22—motor pump valve assembly; 23—fixing screw
Hereunder the present invention will be further detailed in embodiments with reference to the accompanying drawings, to make the object, technical scheme, and advantages of the present invention understood more clearly. It should be understood that the embodiments described here are only provided to explain the present invention, but shall not be deemed as constituting any limitation to the present invention.
Rather, the present invention is intended to encompass any alternation, modification, equivalent method or scheme worked out without departing from the spirit and scope of the present invention as defined by the claims. Furthermore, some specific details are described in at large in the following detailed description of the present invention, to enable the public to understand the present invention better. However, those skilled in the art can fully understand the present invention even without the description of those details.
In this embodiment, a static push-the-bit high-built-rate rotary steerable tool is provided. The static push-the-bit articulated high-built-rate rotary steerable tool comprise a rotary mandrel 7, a drill bit shaft 15, a universal joint 13 connecting the rotary mandrel 7 with the drill bit shaft 15, a first non-rotary steering sleeve 4 and a second non-rotary steering sleeve 12; as shown in
The second non-rotary steering sleeve 12 is isolated from the rotational movement of the drill bit shaft 15 by means of the near-bit-end mud bearing 14, so that the second non-rotary steering sleeve 12 is kept in a non-rotary state in the wellbore. At the same time, the second non-rotary steering sleeve 12 is positioned in axial direction and radial location, and can bear bidirectional force in the axial direction.
The first circuit 9 mainly comprises a communication circuit and an electric power carrier modulation circuit. The mandrel is designed with a far-bit-end centralizer 10 at its upper portion to inhibit radial vibration of the drilling tool and provide protection for the first circuit 9 in the vibration process of well drilling. The first circuit 9 is sealed inside a cavity in the upper portion of the rotary mandrel 7 by the sealing cover plate 8. In comparison with a built-in instrument compartment structure, that feature has advantages including less axial space occupation and convenient maintenance and service, etc. An electrical interface in the first circuit 9 is electrically connected to the centering connecting shaft 11 via a connector. Electric power and communication signals from a MWD are transferred via the centering connecting shaft 11 to the first circuit 9 of the rotary mandrel, the carrier modulation circuit in the first circuit 9 modulates the electric power by high-frequency modulation and modulates the signals by carrier modulation, and then transfers the modulated electric power and signals via a non-contact power transmission transformer 3 to the central control circuit 2, motor controllers in the central control circuit 2 drive the three sets of independent motor pump hydraulic modules 1, and hydraulic systems generate high-pressure oil sources and feed high-pressure oil via oil circuits in the hydraulic modules to three sets of pistons 16 inside the second non-rotary steering sleeve 12. In this embodiment, three sets of independent motor pump hydraulic modules 1 are used, and the motor pump hydraulic modules 1 are fixed to the first non-rotary steering sleeve 4 by several screws 23. Therefore, the motor pump hydraulic modules 1 are kept in a quasi-stationary state with respect to the ground.
Vector resultants of three coplanar concurrent force systems are formed by controlling the oil pressure acting on each set of pistons respectively, and thereby a resultant force vector is formed. The resultant force vector acts on the inner wall of the second non-rotary steering sleeve 12, so that the drill bit shaft is deflected around an articulation point defined by the universal joint 13, and forms an included angle with respect to the axis of the rotary steerable tool. At this point, the resultant force vector acting on the hydraulic piston and the lateral force on the drill bit establish a level force equilibrium, with the articulation point defined by the universal joint as a fulcrum. By controlling the magnitude and direction of the resultant force vector, a lateral force acting on the drill bit is controlled accurately, and thereby the drilling direction of the drill bit is controlled.
As describe above, in this embodiment, the first non-rotary steering sleeve 4 and the second non-rotary steering sleeve 12, on which the motor pump hydraulic modules 1 are mounted, are isolated from the rotation of the rotary mandrel by means of the upper mud bearing 6, the lower mud bearing 5, and the near-bit-end mud bearing 14, so that the first non-rotary steering sleeve 4 and the second non-rotary steering sleeve 12 are kept in a quasi-stationary or non-rotary state with respect to the ground. The stationary or non-rotary state constitutes a main feature of the static push-the-bit design of the rotary steerable tool in this embodiment.
In this embodiment, a static push-the-bit articulated high-built-rate rotary steerable tool in a sub of drill collar with a generator is provided, wherein the static push-the-bit articulated high-built-rate rotary steerable tool is the same as that in the embodiment 1, and this embodiment is specifically implemented as follows:
As shown in
As shown in
A guiding connection base is provided on a lower portion of the mud turbine generator 18 for supplying electric power, an electrical connector 21.1 is provided in the guiding connection base 21 and generator 18 positioned on a shoulder of an inner hole in the upper portion of the rotary mandrel by insertion in the axial direction, so as to realize positioning and transfer the electric power of the generator to the first circuit 9 via the electrical connector as well. Since the mud turbine generator 18 is directly positioned inside the drill collar 7 of the rotary mandrel of the rotary steerable tool, an electrical interface is reduced, and the apparatus provided in the present invention has characteristics such as compact structure and high reliability, etc.
In this embodiment, a single-piston hydraulic push-the-bit assembly is further provided. As shown in 6-8, the electric power supplied by the turbine generator 18 is used to drive the hydraulic systems in the hydraulic modules via the central control circuit 2. Since a hydraulic scheme is employed, the pushing pistons provide higher output, and thereby the drill bit obtains higher lateral cutting force, and achieves a higher built rate. The three sets of motor pump hydraulic modules 1 are fixed on the first non-rotary steering sleeve 4 by several bolts 23, so that they are kept in a stationary state with respect to the ground. The hydraulic modules 1 contain motors, pumps, and valve assemblies 22, and contain a first set of pushing pistons 16.1 as well. The first set of pushing piston 16.1 is of a bulb structure. The high-pressure oil produced by the hydraulic systems flows into the first set of pushing pistons 16.1 through high-pressure oil passages in the hydraulic modules 1. The pushing force of the first set of pushing pistons 16.1 acts on the inner wall of the second non-rotary steering sleeve 12.
In addition, a dual-piston hydraulic push-the-bit assembly is further provided. The specific implementation of the dual-piston hydraulic push-the-bit assembly is shown in
In this embodiment, a static push-the-bit high-built-rate rotation steerable tool is provided. The difference of this embodiment from the embodiment 1 is that a structure of the second non-rotary steering sleeve 12 is further provided in this embodiment to increase the rotary friction resistance between the second non-rotary steering sleeve and the well wall, so as to keep the second non-rotary steering sleeve in a quasi-stationary all the time. As shown in
The second non-rotary steering sleeve 12 is provided with wear-resistant ribs 12.1, which are straight wings. The outer circumference of each of the wear-resistant ribs has zigzag structures, and several hard alloy blocks are inlaid among the zigzag structures to improve wear resistance of the wear-resistant ribs 12.1. Besides, the wear-resistant ribs 12.1 may be three, four, or six sets of wear-resistant ribs, which are evenly distributed on the outer circumference of the second non-rotary steering sleeve 12, in the specific form as shown in
In this embodiment, a method for controlling a static push-the-bit articulated high-built-rate rotary steerable tool is provided. The specific implementation of the method is shown in
A central control circuit 2 receives an instruction for current target tool face and deflection level, and takes the instruction as a target execution instruction. A target instruction always includes target tool face and deflection level. The central control circuit 2 acquires signals from a three-axis acceleration sensor and a fluxgate sensor, and calculates a current gravitational or magnetic tool face. If the well deflection is smaller than 5°, a magnetic tool face angle is calculated with the signal from the fluxgate sensor; if the well deflection is greater than 5°, a gravitational tool face angle is calculated with the signal from the three-axis acceleration sensor. The central control circuit 2 calculates a target steering force vector, which contains an instruction for target tool face and deflection level, according to the target tool face. Then, the central control circuit 2 decomposes the target steering force vector into three separate hydraulic pressures. Hydraulic pressure commands are transmitted through a communication bus to the three sets of independent servo motor controllers, which drive three sets of independent hydraulic modules respectively. The three sets of hydraulic modules provide high-pressure oil sources for three sets of pistons (a first set of pistons, a second set of pistons, and a third set of pistons) corresponding to them to drive the pistons to work. Each set of servo motor controllers acquires the operating pressure in each piston chamber at high precision in real time, provides a feedback and control the operating pressure by closed-loop control in real time, so that the current resultant force vector approaches to the target force vector and is kept at the target force vector all the time. The central control circuit 2 acquires and monitors the current gravitational tool face value in real time. If the current gravitational tool face value varies, the central control circuit system decomposes the resultant force vector into three separate hydraulic pressures again, so as to ensure that the tool face angle defined by the resultant force vector is consistent with the target tool face angle. The three sets of independent servo motor controllers drive the corresponding hydraulic modules according to the obtained recalculated resultant force vector, acquire the operating pressure in each hydraulic piston chamber and control the operating pressure by closed-loop control at high precision in real time, so that the current force vector approaches to the reassigned force vector and is kept at the reassigned force vector all the time. The drill bit is controlled under the action of the target steering force vector all the time to drive a well according to a required wellbore trajectory.
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