Patent Grant
9976360
Underground drilling, such as gas, oil, or geothermal drilling, generally involves drilling a bore through a formation deep in the earth. Such bores are formed by connecting a drill bit to long sections of pipe, referred to as a “drill pipe,” so as to form an assembly commonly referred to as a “drill string.” The drill string extends from the surface to the bottom of the bore.
The drill bit is rotated so that the drill bit advances into the earth, thereby forming the bore. In rotary drilling, the drill bit is rotated by rotating the drill string at the surface. Piston-operated pumps on the surface pump 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 lubricates the drill bit, and flushes cuttings from the path of the drill bit. In the case of motor drilling, the flowing mud also powers a drilling motor which turns the bit, whether or not the drill string is rotating. The drilling mud then flows to the surface through an annular passage formed between the drill string and the surface of the bore.
The drilling environment, and especially hard rock drilling, can induce substantial vibration and shock into the drill string. Vibration also can be introduced by factors such as rotation of the drill bit, the motors used to rotate the drill string, pumping drilling mud, imbalance in the drill string, etc. Such vibration can result in premature failure of the various components of the drill string. Substantial vibration also can reduce the rate of penetration of the drill bit into the drilling surface, and in extreme cases can cause a loss of contact between the drill bit and the drilling surface.
Operators usually attempt to control drill string vibration by varying one or both of the following: the rotational speed of the drill bit, and the down-hole force applied to the drill bit (commonly referred to as “weight-on-bit”). These actions are frequently in reducing the vibrations. Reducing the weight-on-bit or the rotary speed of the drill bit also usually reduces drilling efficiency. In particular, drill bits typically are designed for a predetermined range of rotary speed and weight-on-bit. Operating the drill bit away from its design point can reduce the performance and the service life of the drill bit.
So-called “shock subs” are sometimes used to dampen drill string vibrations. Shock subs, however, typically are optimized for one particular set of drilling conditions. Operating the shock sub outside of these conditions can render the shock sub ineffective, and in some cases can actually increase drill string vibrations. Moreover, shock subs and isolators usually isolate the portions of the drill string up-hole of the shock sub or isolator from vibration, but can increase vibration in the down-hole portion of the drill string, including the drill bit.
One approach that has been proposed is the use of a damper containing a magnetorheological (hereinafter “MR”) fluid valve. The viscosity of MR fluid can be varied in a down-hole environment by energizing coils in the valve that create a magnetic field to which the MR fluid is subjected. Varying the viscosity of the MR fluid allows the damping characteristics to be optimized for the conditions encountered by the drill bit. Such an approach is disclosed in U.S. Pat. No. 7,219,752, entitled System And Method For Damping Vibration In A Drill String, issued May 22, 2007, hereby incorporated by reference in its entirety.
The aforementioned U.S. Pat. No. 7,219,752 discloses an MR valve using a mandrel to hold the coils that is made of 410 martensitic stainless steel. Prior art embodiments of similar MR valves have used coil holders made of 12L14 low carbon steel (which has a saturation magnetization of about 14,000 Gauss, a remanent magnetization of 9,000 to 10,000 Gauss, and a coercivity of about 2 to 8 Oersteds) and 410/420 martensitic stainless steel. The shafts in such embodiments have been made of 410 stainless steel, which can have a relative magnetic permeability of 750 Gauss and a coercivity of 6 to 36 Oe. Unfortunately, the inventors have found that the minimum level of damping achievable using such MR valves is compromised by the fact that energizing the coil can result in a low level of permanent magnetization of the valve components. Although this residual, or remanent, magnetization is considerably below that normally used to provide effective damping, it reduces the range of the MR fluid viscosity at the lower end and, therefore, the minimum damping that can be obtained. In prior art MR valves, the problem of remanent magnetization has been addressed by demagnetizing components of the valve that had become permanently magnetized by supplying to the coils current of alternating polarity and decreasing amplitude in a stepwise fashion.
A problem experienced by prior art MR valves is that using a coil to maintain the magnetic field requires a considerable amount of electrical energy. Consequently, turbine alternators, which are expensive and costly to maintain, are typically required to power the coils. An ongoing need, therefore, exists for a MR fluid damping system that can dampen drill-string vibrations, and particularly vibration of the drill bit, throughout a range of operating conditions, including high and low levels of damping, that does not require large amounts of electrical energy.
Moreover, in order to most efficiently operate the MR valve, it would be desirable to determine the current to be applied to the MR valve that is necessary to achieve the desired magnetic field, given the magnetization history of the MR valve. While technique have been proposed to model the magnetic field based on the history of the magnetization in Jian Guo Zhu's PhD thesis entitled “Numerical Modeling Of Magnetic Materials For Computer Aided Design Of Electromagnetic Devices,” Chapter 2, “Modeling of Magnetic Hysteresis” (1994), such techniques have not been applied to the operation of MR valves. Further it would be desirable to increase the speed at which calculations of the magnetic field based on the magnetization history can be performed.
In one embodiment, the invention is applied to a damping system for damping vibration in a down hole portion of a drill string in which the damping system comprises an MR valve containing an MR fluid subjected to a magnetic field created by at least one coil. In this embodiment, the invention includes a method of operating the MR valve comprising the steps of: (a) energizing the coil of the MR valve for a first period of time so as to create a first magnetic field that alters the viscosity of the MR fluid, the first magnetic field being sufficient to induce a first remanent magnetization in at least one component of the MR valve, the first remanent magnetization being at least about 12,000 Gauss; (b) substantially de-energizing the coil for a second period of time so as to operate the MR valve using the first remanent magnetization in the at least one component of the MR valve to create a second magnetic field that alters the viscosity of the MR fluid; (c) subjecting the at least one component of the MR valve to a demagnetization cycle over a third period of time so as to reduce the first remanent magnetization of the at least one component of the MR valve to a second remanent magnetization; and (d) operating the MR valve for a third period of time after the demagnetization cycle in step (c). Preferably, the magnetic field associated with the first remanent magnetization is sufficient to magnetically saturate the MR fluid. The value of the remanent magnetization can be measured using a sensor and the coil re-energized when the value drops below a specified minimum.
In another embodiment, the invention is a method of damping vibration in a down hole portion of a drill string drilling into an earthen formation that comprises the steps of: (a) providing a magnetorheological (MR) valve having at least one coil and containing an MR fluid that flows through a passage formed in the MR valve, the MR valve having associated therewith a limiting hysteresis loop relating the strength of the magnetic field in the valve to the current supplied to the coil; (b) supplying a varying current to the coil so as to subject the MR fluid in the MR valve to a varying magnetic field created by the coil; (c) determining the magnetization history of the MR valve as the current supplied to the coil varies by measuring the varying current and calculating the strength of the magnetic field created by the varying current, the strength of the magnetic field determined using information representative of the limiting hysteresis loop associated with the MR valve; and (d) determining the current to be supplied to the coil that will result in a desired magnetic field using the magnetization history of the MR valve determined in step (c); and (e) supplying the current determined in step (d) to the coil so as to obtain the desired magnetic field. According to one aspect of this embodiment, the magnetization history of the MR valve comprises a first stack of first sets of data points, each the first sets of data points comprising a first data point that is representative of a current that was supplied to the coil and a second data point that is representative of the magnetic field that resulted from the supply of the current. In connection with this aspect, determining the current to be supplied to the coil in step (d) comprises the further steps of: (f) copying the first stack of first data points so as to create a second stack of data points; (g) adding one or more second sets of data points to the second stack of data points, each of the second sets of data points added to the second stack comprising a selected test current and the magnetization expected to result if the test current were supplied to the coil; and (h) performing a binary search of the data points in the second stack after the one or more second sets of data points have been added to the second stack so as to determine the current to be supplied to the coil that will result in the desired magnetic field. In a preferred version of this embodiment, the current that was supplied to the coil of which each of the first data points is representative is the current at which the change in current supplied to the coil reversed direction.
In another embodiment, the invention concerns a MR valve assembly for damping vibration of a drill bit for drilling into an earthen formation that comprises: (a) at least one coil and an MR fluid that flows through a passage formed in the MR valve proximate the coil; (b) memory means in which is stored information representative of the limiting hysteresis loop relating the strength of the magnetic field in the MR valve to the current supplied to the coil; (c) current control means for controlling the current supplied to the coil so as to vary the current and subject the MR fluid in the MR valve to a varying magnetic field created by the coil; and (d) history determining means for determining the magnetization history of the MR valve as the current supplied to the coil varies by measuring the varying current and calculating the strength of the magnetic field created by the varying current, the strength of the magnetic field determined using the information representative of the limiting hysteresis loop stored in the memory means; (e) current determining means for determining the current to be supplied to the coil that will result in a desired magnetic field using the magnetization history of the MR valve.
The foregoing summary, as well as the following detailed description of a preferred embodiment, are better understood when read in conjunction with the appended diagrammatic drawings. For the purpose of illustrating the invention, the drawings show embodiments that are presently preferred. The invention is not limited, however, to the specific instrumentalities disclosed in the drawings. In the drawings the Z arrow indicates the downhole direction or the bore hole, which may or may not be vertical, i.e., perpendicular to the Earth's surface.
The figures depict a preferred embodiment of a vibration damping system 10. As shown in
The downhole portion of the drill string 8 includes a power module 14. The vibration damping system 10 comprises a torsional bearing assembly 22 and a spring assembly 16, each of which is discussed more fully in the aforementioned U.S. Pat. No. 7,219,752. In addition, located between the spring assembly 16 and the power module 14 is a magnetorheological (“MR”) valve assembly 18. The MR valve assembly 18 and the spring assembly 16 can produce axial forces that dampen vibration of the drill bit 13. The magnitude of the damping force can be varied by the MR valve assembly 18 in response to the magnitude and frequency of the drill bit vibration after the drill bit has temporarily ceased operation, for example during the incorporation of an additional section of drill pipe. In another embodiment, the magnitude of the damping force can be varied by the MR valve assembly 18 in response to the magnitude and frequency of the drill bit vibration on an automatic and substantially instantaneous basis while the drill bit is in operation.
The vibration damping assembly 10 is mechanically coupled to the drill bit 13 by a mandrel 15 that runs through the torsional bearing assembly 22 and spring assembly 16. Power module 14 provides power to the MR valve assembly 18 and may also provide power to other components of the drill string, such as an MWD system. In one embodiment, the power module 14 is a turbine alternator as discussed more fully in the aforementioned U.S. Pat. No. 7,219,752. In another embodiment, the power module 14 contains a battery pack. The controller 134 for the MR valve assembly may also be housed in the power module 14.
Preferably, the MR valve assembly 18 is located immediately down-hole of the power module 14 and uphole of the spring assembly 16, as shown in
The MR valve assembly 18 is shown in
At the downhole end 123 of the MR valve assembly 18, the coil mandrel 100 is secured by a coupling 119 to the mandrel 15 that extends through the torsional bearing assembly 22 and spring assembly 16 so that the coil mandrel 100 rotates, and translates axially, with the drill bit 13.
An uphole housing 102 encloses the uphole end of the coil mandrel 100. A coupling 104 on the uphole end of the uphole housing 102 is connected to the outer casing of the power module 14 so that the drilling torque from the surface is transferred through power module 14 to the uphole housing 102. The uphole housing 102 transmits the drilling torque to the outer casing of the spring assembly 16 and torsional bearing 22 via the MR valve casing 122, which is connected at its up hole end to the downhole end of the up hole housing 102, and at its downhole end 130 to the other casing of the spring assembly 16. The uphole housing 102 therefore rotates, and translates axially, with the outer casing of the torsional bearing 22 and spring assembly 16.
As shown in
As shown in
As shown in
The first and second chambers 128, 129 are filled with a MR fluid. MR fluids typically comprise non-colloidal suspensions of ferromagnetic or paramagnetic particles. The particles typically have a diameter greater than approximately 0.1 microns. The particles are suspended in a carrier fluid, such as mineral oil, water, or silicon. Under normal conditions, MR fluids have the flow characteristics of a conventional oil. In the presence of a magnetic field, however, the particles suspended in the carrier fluid become polarized. This polarization cause the particles to become organized in chains within the carrier fluid. The particle chains increase the fluid shear strength (and therefore, the flow resistance or viscosity) of the MR fluid. Upon removal of the magnetic field, the particles return to an unorganized state, and the fluid shear strength and flow resistance returns to its previous value. Thus, the controlled application of a magnetic field allows the fluid shear strength and flow resistance of an MR fluid to be altered very rapidly. MR fluids are described in U.S. Pat. No. 5,382,373 (Carlson et al.), which is incorporated by reference herein in its entirety. An MR fluid suitable for use in the valve assembly 16 is available from the Lord Corporation of Indianapolis, Ind.
The coil mandrel 100 reciprocates within the MR valve housing 122 and valve cylinders 124, 132 in response to vibration of the drill bit 13. This movement alternately decreases and increases the respective volumes of the first and second chambers 128, 129. In particular, movement of the mandrel 100 in the up-hole direction (to the right in
The flow resistance of the MR fluid causes the MR valve assembly 18 to act as a viscous damper. In particular, the flow resistance of the MR fluid causes the MR fluid to generate a force (opposite the direction of the displacement of the coil mandrel 100 in relation to the valve housing 122) that opposes the flow of the MR fluid between the first and second chambers 128, 129. The MR fluid thereby resists the reciprocating motion of the coil mandrel 100 in relation to the housing 122. This resistance can dampen axial vibration of the drill bit 13. Also, as discussed more fully in the aforementioned U.S. Pat. No. 7,219,752, the torsional bearing assembly 22 converts at least a portion of the torsional vibration of the drill bit 13 into axial vibration of the mandrel 100. Thus, the MR valve assembly 18 is also capable of damping torsional vibration of the drill bit 13.
The magnitude of the damping force generated by the MR fluid is proportional to the flow resistance of the MR fluid and the frequency of the axial vibration. The flow resistance of the MR fluids, as noted above, can be increased by subjecting the MR fluid to a magnetic field. Moreover, the flow resistance can be altered by varying the magnitude of the magnetic field.
The coils 150 are positioned so that the lines of magnetic flux generated by the coils cut through the MR fluid located in the first and second chambers 128, 129 and the gap 152. The current supplied to the coils 150, and thus the magnitude of the magnetic flux, preferably varies during drilling and is controlled by a controller 134, which may be located in the power module 14, as shown in
The LVDT 110 provides a signal in the form of an electrical signal indicative of the relative axial position, velocity, and acceleration between the uphole housing 102, and hence the MR valve housing 122, and the coil mandrel 100, which is connected to the drill bit 13. Hence, the output of the LVDT 110 is responsive to the magnitude and frequency of the axial vibration of the drill bit 13. In one embodiment, the LVDT 110 sends information concerning the vibration of the drill bit 13 to the surface for analysis. Based on this information, the drill rig operator can determine whether a change in the damping characteristics of the MR valve 18 is warranted during the next stoppage of the drill bit 13. If so, the operator will send a signal to the controller 134 during the stoppage instructing it to change the power supplied to the coils 150 and thereby alter the magnetic field to which the MR fluid is subjected and the dampening provided by the MR valve 10.
In another embodiment, the controller 134 preferably comprises a computing device, such as a programmable microprocessor with a printed circuit board. The controller 134 may also comprise a memory storage device, as well as solid state relays, and a set of computer-executable instructions. The memory storage device and the solid state relays are electrically coupled to the computing device, and the computer-executable instructions, including those for performing the method described in the flow charts in
The LVDT 110 is electrically connected to the controller 134. The computer executable instructions include algorithms that can automatically determine the optimal amount of damping at a particular operating condition, based on the output of the LVDT 100. The computer executable instructions also determine the desired magnetic field to be produced by the coils and/or the electrical current that needs to be directed to the coils 150 to provide the desired magnetic field, for example by employing the method described in the flow charts in
Preferably, the damping force prevents the drill bit 13 from losing contact with the drilling surface due to axial vibration. The controller 134 preferably causes the damping force to increase as the drill bit 13 moves upward, to help maintain contact between the drill bit 13 and the drilling surface. (Ideally, the damping force should be controlled so the weight-on-bit remains substantially constant.) Moreover, it is believed that the damping is optimized when the dynamic spring rate of the vibration damping system 10 is approximately equal to the static spring rate. (More damping is required when the dynamic spring rate is greater than the static spring rate, and vice versa.)
In any event, whether done during periodic stoppages of the drill bit 13 or automatically on an essentially instantaneous basis, the ability to control vibration of the drill bit 13, it is believed, can increase the rate of penetration of the drill bit, reduce separation of the drill bit 13 from the drilling surface, lower or substantially eliminate shock on the drill bit, and increase the service life of the drill bit 13 and other components of the drill string. Moreover, the valve assembly and the controller can provide optimal damping under variety of operating conditions, in contra-distinction to shock subs. Also, the use of MR fluids to provide the damping force makes the valve assembly 14 more compact than otherwise would be possible.
Operation of the MR valve 10 by energizing the coils 150 whenever an increase in damping is necessary beyond that provided by the MR fluid that is not subjected to a magnetic field requires a relatively large amount of electrical power since the dc current supplied to the coils may be in excess of 2 amps. At such power levels, battery packs typically used in downhole systems, such as for an MWD system, would only last about twelve hours. Therefore, operation in such a manner is typically done using a turbine alternator as the power module, as discussed in aforementioned U.S. Pat. No. 7,219,752.
According to the invention, the need for continuous electrical power is eliminated by fabricating portions of the MR valve—in one embodiment, the coil holders 146, shaft 100 and end cap 142—from a material that will, overtime, become somewhat essentially “permanently” magnetized to a substantial degree—that is, as a result of being subjected to the magnetic field of the coils 150, they will maintain their magnetism after the magnetic field has been removed. Thus, when the coils 150 are de-energized to a very low state, or turned off completely, the coil holders 146, shaft 100 and end cap 142 may retain a remanent degree of magnetization that will generate a magnetic field maintaining a relatively high viscosity of the MR fluid. Whether or not they become magnetized, portions of the valve that are not proximate the gap 152 through which the MR fluid flows will have little effect on the performance of the damper. The materials for these portions are chosen based on their structural, rather than magnetic properties.
According to the invention, the MR valve 10 is constructed so that some or all of the components of the valve are made from a material having sufficient residual magnetization so that the strength of the residual magnetic field generated by the components is still relatively high when the electrical field inducing the magnetic field, as a result of the dc current through the coils 150, is eliminated. In other words, according to one aspect of the invention, the residual magnetism phenomenon, which in prior art MR valves created a problem that required a demagnetization cycle to avoid, is intentionally enhanced. When, during initial operation of the MR valve 10, it is desired to increase the damping beyond that afforded by the MR fluid subjected to zero magnetic field, the batteries will supply a current of, for example, 2.5 amps, for a period of time preferably only sufficiently long to create the desired residual magnetization in the valve components, typically less than about 100 milliseconds. After this period of time, the coils 150 are energized to a lower value and the residual magnetic field of the MR valve components is primarily used to create the necessary damping thereafter. Preferably, the coils 150 are completely de-energized and the residual magnetic field of the MR valve components is solely used to create the necessary damping thereafter. According to one aspect of the invention, the materials from which the valve components are made, as discussed further below, are selected so that the remanent magnetic field is at least about 12,000 Gauss.
If, after a period of time operating at this level of damping, it were determined by the operator or the controller 134 that additional damping was required, the coils 150 would be energized at a higher current than that previously used, for a period of time sufficient to magnetically saturate the parts. This higher current will result in higher residual magnetism in the MR valve components that is then used to provide the additional damping after the coils 150 were again de-energized.
If, still later, it were determined by the operator or the controller 134 that less damping was required, the MR valve components would be subjected to a demagnetization cycle, discussed below, to reduce the residual magnetic field to approximately zero. If the new desired amount damping was less than that resulting from the residual magnetism of the MR valve, but greater than that afforded by the MR fluid at zero magnetic field, the coils 150 would then be temporarily energized as they were during the initial operation to create the desired degree of residual magnetization in the valve components. The coils 150 would then be partially or completely de-energized and the MR valve operated primarily or solely using the residual magnetism of the valve components.
According to one embodiment of the current invention, when desired, this permanent magnetization is removed by periodically using the coils 150 to subject the coil holders 146, shaft 100 and end cap 142, as well as any other MR valve components subject to being permanently magnetized, to a demagnetization cycle. According to one embodiment, the controller 134 includes circuitry, shown in
As shown in
To control the voltage in a stepwise fashion a process known as Pulse Width Modulation is used (PWM). To accomplish this, the switch pairs are switched on and off very fast, typically operating at several hundred to several thousand hertz. The percentage of on-time versus off-time essentially scales the voltage by that percentile. For example, if the supply voltage is 40 VDC and the duty cycle is 50% the effective voltage on the coil is 20 VDC. The electronics and the coil inductance filter the modulated signal and smooth out the pulses to a steady DC at a lower value than the supply. This allows the gradually scaling down of the supply voltage from full-on (i.e., 100% duty cycle, switches always on) to near zero (i.e., 5% duty cycle, switch on for a very short time but off for the majority of the time).
A typical prior art demagnetization cycle is shown in
In one typical embodiment, the duration of each step in the demagnetization cycle is about 0.06 second and the time between initiations of each step is about 0.1 second so that there is a slight “rest” period between each polarity reversal. The total number of steps is typically about sixteen so that the total time required for the demagnetization cycle is less than about two seconds. However, as will be apparent to those skilled in the art, other demagnetization cycles could also be utilized, provided the number and length of the steps is sufficient to reduce the remanent field to a low value, preferably, essentially zero. After demagnetization, completely de-energizing the coils will result in obtaining the minimum damping associated with non-magnetized MR fluid.
Although the use of current of alternating polarity and decreasing amplitude in a stepwise fashion in order to demagnetize the valve components is described above, other demagnetization methodologies could also be utilized, as discussed further below.
Operation of the MR valve 18 according to the invention is illustrated in
If, at time T2 it is determined that less damping is required, a demagnetization cycle is initiated. At the completion of the demagnetization at time T3, the coils are energized to current I2 so as to generate a magnetic field having strength B3 for a period of time sufficient to induce a remanent magnetic field of strength B4 in one or more components of the MR valve. Thereafter, the coils are de-energized at time T4 and the MR valve operated using the remanent magnetic field of strength B4 from the components of the MR valve. Significantly, no electrical power is supplied to the coils 150 between T1 and T2 and subsequent to T4.
Alternatively, the demagnetization cycle shown in
In the embodiment operated as illustrated in
According to one embodiment of the invention, a feedback loop is incorporated to monitor the strength of the magnetic field in order to determine when the strength of the magnetic field drops below a value specified by the drill rig operator, or determined by the controller 134 if the MR valve is under the automatic control, thereby indicating the need to reenergize the coils 150. A circuit for measuring the strength of the magnetic field in the valve using one or more Hall effect sensors 304, such as Honeywell SS495A, located on the MR valve is shown in
As shown in
The signal from the Hall effect sensor 304 is fed into the operational amplifier 305, which acts as a buffer with unity gain (R1=1K Ohm, R2=0 Ohm, and R3=infinite resistance). Alternatively, R2 and R3 could be used to boost the voltage by changing the resistance values but would not generally be required due to the stable output of the Hall effect sensor 304. The operational amplifier 305 allows the outputs from all seven circuits to be tied together so only a single signal goes back to the controller 134, thus saving valuable pins in the connector structure of the tool and utilizing only one of the few available A/D inputs to the microprocessor.
The purpose of the demultiplexor 302 is first to minimize the number of pins and Analog to digital (A/D) inputs required to feed back to the microprocessor (three digital outputs and one analog input, as opposed to five A/D inputs to look at individual hall effect sensors), and also to minimize the power draw. The power draw for Hall effect sensors 304 may be relatively very high—in one embodiment, 7 to 8 mAmps each. The maximum power draw for the demultiplexor 302 in this embodiment is 160 uAmps. As a result, there is a power savings of 4,400%, which allows the battery powering the circuit to last forty four times longer. The five distributed circuits in total draw 1/10 the power of a single Hall effect sensor. Thus the Hall effect sensors are only powered up briefly and only when the microprocessor is making a reading, also only one Hall effect sensor is on at a time so the power draw is minimized.
In operation, the controller 134 is programmed to poll the Hall effect sensors 304 one at a time, get an average value representative of the strength of the magnetic field in the MR valve, and compare it to the value specified by the operator or controller 134. The controller 134 is programmed to reenergize the coils 150 so as to re-magnetize the valve if this comparison indicates that the strength of the measured magnetic field deviates from the specified value by more than a predetermined amount. The controller 134 is programmed to perform this polling approximately every minute or so, unless the information received from the LVDT dictated a change in strength of the magnetic field, in which case the Hall effect sensors would be polled again after the magnetic field has been readjusted to determine if the magnetization was at the proper power.
As used herein (i) “saturation magnetization” refers to the maximum magnetic flux density of the material such that any further increase in the magnetizing force produces no significant change in the magnetic flux density, measured in Gauss; (ii) “remanent” or “residual” magnetization or magnetic field refers to the magnetic flux density remaining in the material after the magnetizing force has been reduced to zero, measured in Gauss; (iii) “maximum remanent” magnetization refers to the remanent magnetization of a material after it has experienced saturation magnetization; (iv) “coercivity” refers to the resistance of the material to demagnetization, measured in Oersteds (Oe) and is related to the coercive force, which is the value of the magnetic force that must be applied to reduce the residual magnetization to zero; and (v) magnetic permeability refers to the “conductivity” of magnetic flux in a material, it is expressed as relative magnetic permeability, which is the ratio of the permeability of the material to the permeability of a vacuum.
To facilitate operation as described above, components of the MR valve 18 that are intended to create the remanent magnetic field—in one embodiment, the coil holders 146 and the end cap 142—are made from a material having a maximum remanent magnetism that is substantially greater than that of the 12L14 low carbon steel and 410/420 martensitic stainless steel used in prior art MR valves so that the maximum damping achieved at zero power to the coils 150 is relatively high. Preferably, the material should have a maximum remanent magnetization that is at least 12,000 Gauss. Optimally, the material has a maximum remanent magnetization that is sufficient to saturate the MR fluid—that is, that the magnetic field applied to the MR fluid by the remanent magnetization of the material is such that any further increase in the magnetic field would cause no further increase in the viscosity of the MR fluid—so as to achieve the maximum range of operation possible using remanent magnetization. Ideally, the material should have a high remanent magnetization relative to the saturation magnetization. Preferably the maximum remanent magnetization should be at least about 50%, and more preferably at least about 70%, of the saturation magnetization. Preferably, the material should also have a relatively low coercivity so that power necessary to demagnetize the components is relative low but not so low that the material will become easily unintentionally demagnetized during operation. Preferably, the material should have a coercivity in the range of at least about 10 Oe but not more than about 20 Oe, and most preferably about 15 Oe. The material should also have good corrosion resistance.
Grade 1033 mild steel, preferably with minimal impurities, which has a saturation magnetization of about 20,000 Gauss, a maximum remanent magnetization of about 13,000 to 15,000 Gauss, and a coercivity of about 10 to 20 Oe, is one example of a material suitable for use in the components of the MR valve intended to be operated as described above using primarily remanent magnetization. Ferritic chrome-iron alloys are another example of suitable materials. Examples of such ferritic chrome alloys are described in U.S. Pat. No. 4,994,122 (DeBold et al), hereby incorporated by reference in its entirety. Carpenter Chrome Core 8 alloy, available from Carpenter Technology Corporation, which has a saturation magnetization of 18,600 Gauss, a maximum remanent magnetization of 13,800 Gauss (74% of saturation) and a coercivity of 2.5 Oe may also be a suitable material for many MR valves. Other materials, also available from Carpenter Technology Corporation, that may be used are Hiperco 50A, having a relative permeability of 4000, a saturation magnetization of 23,400 Gauss, a maximum remanent magnetization of 15,000 Gauss (64% of saturation) and a coercivity of 2.3 Oe, and Hiperco 27, having a relative permeability of 2000, a saturation magnetization of 23,400 Gauss, a maximum remanent magnetization of 18,000 Gauss (77% of saturation) and a coercivity of 1.9. Oe. Silicon iron C, which has a relative permeability of about 4,000, a saturation magnetization of about 20,000 Gauss, a maximum remanent magnetization of 4000 Gauss (20% of saturation) and a coercivity of about 0.6 Oe, could also be used in some applications.
Preferably, the components of the MR valve made from the materials described above are capable of applying a magnetic field to the MR fluid, solely as a result of remanent magnetization, that is of sufficient strength to magnetically saturate the MR properties of the particular fluid.
Preferably, the shaft 100 is made at least in part from a material having a high permeability so as to facilitate magnetic flux through the MR valve. Preferably the material has a relative permeability of at least about 7000. It is also desirable for the material to have a low coercivity, preferably less than 1.0, so that it can be easily demagnetized and remagnetized as it moves within the magnetic field without creating a sufficiently strong magnetic field to demagnetize other portions of the valve. As shown in
Although as shown in the drawings, the coil 150 is mounted in the casing 122 that transmits the drilling torque, the invention could also be practice by mounting the coils in the shaft 100. In that arrangement, at least a portion of the shaft 100 would be made from a material having a remenant magnetization of at least 12,000 Gauss and at least a portion of the casing 122 would be made from a material having a high permeance, such as Permalloy, as discussed further below.
In many instances, it would be desirable to take into account the magnetization history of the MR valve in determining the amplitude of the current to be applied to the coils in order to achieve the desired strength of the magnetic field produced by the coils and, therefore, the amount of damping achieved by the MR valve. According to one embodiment of the invention, the current to be applied to the coils is determined by a method that uses the limiting hysteresis data for the MR valve and the history of the magnetization state of the MR valve. The current supplied to the coils is measured downhole by a conventional current measuring device, such as an analog to digital converter. Although the magnetization of the MR valve could be measured directly downhole, preferably the magnetization state of the valve for each value of the current applied to the coils is tracked by the downhole firmware to predict the needed new current for new levels of magnetization.
The limiting hysteresis data for the MR valve is preferably measured directly before placing the valve in service. Preferably, a current is applied to the coils 150 and the strength of the resulting magnetic field is measured at the circumferential gap 152—that is, location at which the field is used to control the MR fluid. Preferably, the strength of the magnetic field is measured as the current is slowly raised to its maximum—that is, the current is raised until further increases in current do not result in further magnetization, in other words the current is raised until saturation is reached. The current at which this occurs is the saturation current. The current is then lowered back to zero and the polarity of the current reversed, and then again raised until magnetic saturation is reached, after which the current is again returned to zero, all the while measuring the strength of the resulting magnetic field. These measurements represent the entire limiting hysteresis loop for the MR valve.
The data collected from the first pass through this limiting hysteresis loop should not be trusted due to the unknown initial conditions of the magnetic material. However, if current is again applied to the coils in the same manner so as to make a second pass through this loop, the resulting magnetic field will follow the limiting hysteresis loop so that reliable data can be obtained. The process of raising and lowering the current while measuring the resulting magnetic field is preferably repeated several times to create a statistical average of the limiting hysteresis loop, which is made up of a series of current versus magnetization data points. Preferably, the data representative of the average limiting hysteresis loop is stored in flash memory, for example, in a memory device of the controller 134, as a permanent characteristic of the MR valve.
The second factor used to determine the current to be applied to obtain a desired magnetization in the MR valve is based on the history of magnetization state of the MR valve. This is a property that is tracked in the operation of the MR valve and can be reduced to a “stack” of “reversal points.” A reversal point occurs when the direction of the change of the magnetic field has reversed—that is, the direction of strength of the magnetic field reverses from increasing to decreasing or from decreasing to increasing. This kind of reversal point need not involve changing the polarity of the applied magnetic field, only the direction in which the magnetic field is changing. Preferably, the current and magnetization of the reversal point during the operation of the MR valve are stored in a memory device in the controller 134.
The initial data set shows the valve began operation from a degaussed state and current was then increased to 3 amps, which resulted in 50 k Gauss. The second data set shows that the current was later increased to 4 amps, resulting in 60 k Gauss. Since the current continued to increase, no “reversal point” was created. The third data set shows that the current was later decreased to 3 amps, resulting in 50 k Gauss. This means that the 4 amp/60 k Gauss point now constitutes a reversal point and so is added to the “history stack” shown on the right. The remaining sets show the effect of continued operation and the fact that, after the current associated with a prior reversal point is exceeded, the prior reversal point is eliminated from the stack, indicated by the strike through. Thus, increasing the current to 5 amps in the sixth data set results in the elimination of the 4 amp reversal point from the history stack. As previously discussed, the sets of data points of current and magnetization that make up history stack, both the “real” and “what if” history stacks, are stored in memory for use in determining the current necessary to achieve a desired magnetization, as discussed below.
According to the current invention, preferably two magnetization history stacks and variables are utilized along with the limiting hysteresis loop data. The first stack, referred to as the “real” history stack, keeps track of the state of the actual MR valve in the form of reversal points, as explained above.
The method for updating the “real” history stack as the current supplied to the coils varies during operation of the MR valve is shown in the flowchart in
In step 482, the direction of the change from the existing current IE to the last current IL, PC2, is compared to the direction of the change in current, PC1, that was last used to calculate a magnetization for the MR valve. For example, if the last prior two currents that were applied to the coils were 0 amps and 2 amps, the old direction was increasing; then if the new current was 1 amp, the change from 2 amps to 1 amp is decreasing, giving a reversal or change in direction of the change in current.
If a reversal of the direction of change of current has occurred, the old current and magnetization ML and IL are pushed onto the top of the real history stack in step 483. Step 484 determines whether the new magnetization ME, calculated as explained above, has gone past the value of MREV, the magnetization on the top of the “real history” stack, and closed a loop by being greater than MREV if the current is increasing and less than MREV if the current is decreasing. If it has, then in step 485, the last two reversal points are removed from the “real” history stack. By continually performing the method discussed above, the real history stack reflects the magnetization history of the MR valve as the current varies during operation.
The second stack is used as a “what if” stack to test predictions of the magnetization that will result from new currents. As discussed more fully below, incremented values of a “test current” are used in the calculation of the current necessary to result in a desired magnetization. For each succeeding valve of the test current, the “what if” stack is initially set to be the “real” history stack. The “what if” stack is then updated to include a test current and its resulting calculated magnetization if the test current creates a reversal point. There are also both “real” and “what if” variables to keep track of support parameters like the last current used to calculate a magnetization, and the last magnetization calculation result. All variables are initialized to 0 before starting this system. When a new magnetization state is desired, a “binary search” of possible currents to achieve the new magnetization is conducted, which includes copying the “true” history stack to the “what if” history stack. When the system first starts, the data for the measured limiting hysteresis has been stored in a memory device, preferably in permanent memory, and all stacks and variables are cleared to zero. As discussed above, the current being applied to the MR valve coil is continually measured and monitored. Any changes in current triggers the calculation of a new magnetization using the “real” stack and variables. This calculation compares the new current with the existing current to determine the direction of change of the current. This direction of change is then compared with the last direction of change of current to determine how the new magnetization is to be computed. If the present change of current is the same as the previous change of current, no new reversal point is created. If no direction reversals have occurred, the calculated magnetization will still be the initial magnetization. The new magnetization for the new current is then calculated according to the present direction of change of current, and the last reversal point, if any. These calculations are done using the “real” stack and variables so that those values will always represent the “starting point” for any desired changes in magnetization.
When the rig operator or the controller 134, or other control system, determines the need of a change in magnetization, the method of the current invention determines the best current for achieving the desired magnetization using a binary search. First the direction of the desired change is determined A current is chosen which is half way between the present current and maximum possible current in the desired direction. The change in current required to achieve this “half way” point is called the “incremental current” and can be either positive or negative. The current needed for this “half way” point is called the “Test Current.” Then the “real” stack and variables are copied to the “what if” stack and variables. Then the magnetization calculations are performed using these “what if” variables. This involves making a predicting for “what if we change the magnetization from its present operating current to a current at the half way point or test current.” The resultant magnetization is then compared with the desired magnetization, and the “incremental current” is cut in half. If the resultant magnetization did not achieve the desired magnetization, this new “incremental current” is added to the Test Current. If the resultant magnetization went beyond the desired magnetization, this new “incremental current” is subtracted from the Test Current. The “real” stack and variables are again copied to the “what if” stack and variables to “reset” the start conditions for making the prediction. The magnetization calculations are performed again using the revised Test Current and the reset “what if” stack and variables. Again the resultant magnetization is compared with the desired magnetization, and the “incremental current” is cut in half. This search process is preferably repeated until the incremental current is divided below the resolution of the system for measuring current, or either the “incremental current” or the difference between the result and desired magnetization fall below a predetermined error limit.
The method for determining the new magnetization depends on the polarity of both the “old” and “new” current, and the direction of change of current both now and in the past. These factors are stored in variables called either “real” or “what if”, but the method for computing the magnetization is the same for both kinds of variables. In a preferred embodiment, the new magnetization is computed using a method described by Jian Guo Zhu, M. Eng. Sc., B.E. (Elec.) University of Technology, Sydney, July, 1994, in his thesis “Numerical Modelling Of Magnetic Materials For Computer Aided Design Of Electromagnetic Devices,” hereby incorporated by reference herein in its entirety. However, it is also possible to compute this magnetization with other methods, though those other methods may call for different variables to be separated as “real” and “what if” to implement the binary search method described above.
The method for determining the current required to achieve a desired magnetization, which is preferably implemented in software stored in a processor in the controller 134, will now be explained by reference to the flow charts illustrated in
In step 508, a test current IT is determined by adding the current increment Ii to the existing current IE. In step 510, the “real” hysteresis stack, created as discussed above, is copied to a “what if” hysteresis stack that is used in performing this test. In step 512, the method moves to the flow chart shown in
If a reversal of the direction of change of current has occurred, the old current and magnetization are pushed onto the top of the “what if” history stack in step 608.
Step 610 determines whether the test current IT is positive. If it is, then F(c), which can be referred to as the first partial change in the field, and Fm(c), which can be referred to as the second partial change in the field, are determined from the data from the limiting hysteresis loop using the equations indicated in step 612. If the test current is negative, then F(c) and Fm(c) are determined by inverting the data representing the limiting hysteresis loop and using the equations indicated in step 614. In connection with the equations in steps 612 and 614, Mdown(c) is the value of the magnetization of the upper curve of the limiting hysteresis loop (which is traversed when the current is going down) at the test current IT, and Mup(c) is the magnetization of the lower curve of the limiting hysteresis loop (which is traversed when the current is going up) at the test current IT.
Step 616 determines if there are any reversal points on the “what if” history stack. If step 616 determines that there are no reversals in the “what if” history stack, then the method is continued based on the flow chart shown in
As shown in
Mup(c) and Mdown(c)=the value of the magnetization while current is increasing and decreasing, respectively, stored in permanent memory for the current c.
Note that Mup and Mdown are lists of numbers stored in permanent memory as a characteristic of the tool. The terms “c” or “REV” denote the current for which we wish to fetch this value. In one embodiment these lists have 1024 elements each. The current of 0-4 amps is converted to a number 0-1023 by multiplying it by 256. This then becomes the index into the arrays Mup and Mdown.
Step 806 determines whether the new magnetization MN, calculated as explained above, has gone past the value of MREV, and closed a loop by being greater than MREV if the current is increasing and less than MREV if the current is decreasing. If it has, then in step 808, the last two reversal points are removed from the “what if” history stack. The method then returns to the main flow chart shown in
If in step 616 of the flow chart shown in
Following steps 704 or 706, the method then returns to the main flow chart shown in
Upon return to the main flow chart shown in
Step 522 determines whether the new incremental current Ii is greater than a selected error amount. The error amount can be selected in various ways depending on the precision desired. As one example, if the values of current are represented by integers from 0 to 1023, then the error value may be set at 1/1023. In any event, if the incremental current is greater than the error value, then step 510 and the succeeding steps are repeated using the new value of test current IT calculated in steps 518 or 520. If the incremental current is less than the error value, then the new value for the current to be supplied to the coils IN in order to obtain the desired magnetization MD is set as the new value of test current IT calculated in steps 518 or 520. This value of the current could either be reported to the rig operator for manual adjustment by the operator or the current to the coils could be automatically adjusted by the controller 134. If the new value of the current represents a reversal point, it is added to the “real” history stack when that new current is realized by the hardware.
Using the method described in the flow charts in
If the desired magnetization MD is not greater than the maximum remanent magnetization MRM, meaning that operation solely on remanent magnetization is possible, then the “remanent” current Irem is set to zero in step 902, since no current will be necessary to achieve the desired magnetization once the appropriate amount of remanent magnetization has been induced. If the desired magnetization MD is greater than the maximum remanent magnetization MRM, meaning that operation solely on remanent magnetization is not possible, then the “remanent” current Irem necessary to achieve the desired magnetization MD is determined in step 904 as the current associated with the desired magnetization on the upper curve of the limiting hysteresis loop, which is the limiting hysteresis of the downward trajectory (or the limiting hysteresis when the current is decreasing).
In step 906, a determination is made as to whether the newly desired magnetic field MD is greater than, less than, or equal to, the existing magnetic field ME that results from the existing current IE being applied to the coils, which will be zero if the MR valve were being operated using only remenant magnetization. If it is determined in step 906 that the desired magnetic field is neither greater than nor less than—in other words, is equal to—the existing magnetic field, then the method returns in step 912 because no change in current is required. Otherwise, in steps 908 or 910 a current increment Ii is selected given the direction of the change between the existing magnetization ME and the desired magnetization MD. Specifically, Ii is set half way between (i.e., the average of) the existing current IE and the maximum current, in either positive or negative polarity (as determined in step 906), that the power source for the MR valve is capable of generating.
In step 914, a test current IT is determined by adding the current increment Ii to the existing current IE. In step 916, the “real” hysteresis stack, created as discussed above, is copied to a “what if” hysteresis stack that is used in determining the new current for the desired magnetization. The method then continues at A in
The value of the current to be used in the succeeding calculations is then set at Irem, as reflected in step 920, and the method described in the flow charts illustrated in
In step 930, the value of the incremental current Ii is halved. Step 932 then determines whether the calculated value of remanent magnetization Mrem is greater than the desired magnetization MD. If it is, then a new test current IT is determined in step 934 by subtracting the new incremental current Ii from the previous test current. If the new magnetization Mrem is not greater than the desired magnetization MD, then the new test current IT is determined in step 936 by adding the new incremental current Ii to the previous test current.
Step 938 determines whether the new incremental current Ii is greater than a selected error amount. If the incremental current is greater than the error value, then step 938 and the succeeding steps are repeated using the new value of test current IT calculated in steps 934 or 936. If the incremental current is less than the error value, then the test current IT represents the current to be initially supplied to the coils so that, after a sufficient period of time, the current can be reduced to Irem and the MR valve operated at current Irem, which may be zero if operation solely on remanent magnetization is possible but, in any event, will be less than if the MR valve had been completely demagnetized before adjusting the current to the achieve the newly desired magnetization.
Operation of an MR valve using the method described above is depicted in
If, after further operation, it were desired to operate at 1000 Gauss, demagnetization would be required. The method discussed above would determine that the test current IT to which the current should initially be set would be a “discharging current” of −0.11 amps, which resulted in a magnetization of 356 Gauss (indicated as point #3), followed by a reduction in the current to the value of the remanent current Irem of 0 amps, which would allow the MR valve to operate at point #4 at which the remanent magnetization is 1000 Gauss, as desired.
Operation using the method described above ensures that full advantage is made of remanent magnetization since the MR valve is preferably only demagnetized to the extent necessary to achieve the desired magnetization. If the desired magnetization is less than the existing remanent magnetization will permit, this method avoids fully demagnetizing the valve and then increasing the current to the value necessary to achieve the desired magnetization without the benefit of remenant magnetization. Rather, according to the method described above, operation relying solely on remanent is still achieved by directly reducing the amount of remanent magnetization.
Although the invention has been described with reference to a drill string drilling a well, the invention is applicable to other situations in which it is desired to control damping. Accordingly, the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
This application is a continuation-in-part of U.S. application Ser. No. 12/398,983, now U.S. Pat. No. 8,087,476, entitled System and Method for Damping Vibration in a Drill String Using a Magnetorheological Damper, filed Mar. 5, 2009, the contents of which is hereby incorporated by reference in its entirety.
Pursuant to 35 U.S.C. § 202(c), it is acknowledged that the U.S. government may have certain rights to certain aspects of the invention described herein, which was made in part with funds from the Deep Trek program of the U.S. Department of Energy National Energy Technology Laboratory, Grant Number DE-FC26-02NT41664.
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