Directional wellbore operations, such as directional drilling, involve varying or controlling the direction of a downhole tool (e.g., a drill bit) in a wellbore to direct the tool towards a desired target destination. Various techniques have been used for adjusting the direction of a tool string in a wellbore. Slide drilling employs a downhole motor and a bent housing to deflect the wellbore. In slide drilling, the direction of the wellbore is changed by using the downhole motor to rotate the bit while drill string rotation is halted and the bent housing is oriented to deflect the bit in the desired direction.
Embodiments are described with reference to the following figures. The same numbers are used throughout the figures to reference like features and components. The features depicted in the figures are not necessarily shown to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form, and some details of elements may not be shown in the interest of clarity and conciseness.
The drill bit 14 is just one piece of a bottom-hole assembly 24 that includes a mud motor and one or more “drill collars” (thick-walled steel pipe) that provide weight and rigidity to aid the drilling process. Some of these drill collars include built-in logging instruments to gather measurements of various drilling parameters such as location, is orientation, weight-on-bit, wellbore diameter, etc. The tool orientation may be specified in terms of a tool face angle (rotational orientation), an inclination angle (the slope), and compass direction, each of which can be derived from measurements by magnetometers, inclinometers, and/or accelerometers, though other sensor types such as gyroscopes may alternatively be used. For example, the tool may include a 3-axis fluxgate magnetometer and a 3-axis accelerometer. As is known in the art, the combination of those two sensor systems enables the measurement of the tool face angle, inclination angle, and compass direction. Such orientation measurements can be combined with gyroscopic or inertial measurements to accurately track tool position.
The bottom-hole assembly 24 may also include a device for measuring formation resistivity, a gamma ray device for measuring formation gamma ray intensity, devices for measuring the inclination and azimuth of the drill string 8, pressure sensors for measuring wellbore pressure, temperature sensors for measuring wellbore temperature, etc. Also included in bottom-hole assembly 24 is a telemetry sub that maintains a communications link with the surface. Mud pulse telemetry is one common telemetry technique for transferring tool measurements to surface receivers and receiving commands from the surface, but other telemetry techniques can also be used. For some techniques (e.g., through-wall acoustic signaling) the drill string 8 includes one or more repeaters 30 to detect, amplify, and re-transmit the signal. At the surface, transducers 28 convert signals between mechanical and electrical form, enabling a network interface module 36 to receive the uplink signal from the telemetry sub and (at least in some embodiments) transmit a downlink signal to the telemetry sub.
A computer system 50 located at the surface receives a digital telemetry signal, demodulates the signal, and displays the tool data or well logs to a user. Although
The drill string shown in
For drill strings capable of varying the angle of the bent sub, the sub is set to a desired angle and direction while the drill string is maintained at a desired fixed azimuthal orientation, with the drill bit being driven by the downhole motor. This is sometimes referred to as “slide drilling” or “sliding” as the drill string slides through the wellbore without rotating. For example,
The bent housing 260 is a tubular section of the drilling assembly 226 and includes a first, upper section that may receive the motor (i.e. motor section) 262 and a second, lower section 264 that may receive or at least orient the rotational axis of the bit 214, with a bend 266 between the upper section 262 and lower section 264. The angle of the bend is exaggerated in
The fluid-driven motor 270 rotates the drill bit 214 to form the wellbore through the formation. The fluid-driven motor 270 is coupled to the bent housing 260 and is a turbine motor with a stator 272 and a rotatable blade-bearing rotor 274 disposed inside the stator 272. Pressurized drilling fluid that is bypassed into the fluid-driven motor imparts a force on the angled rotor blades causing the rotor 274 to rotate within the stator 272. A drive shaft 276 is coupled to the rotor 272 and configured to output the rotational drive forces generated by the fluid-driven motor 270. The drive shaft 276 is coupled to the drill bit 214 and powers the rotation of the drill bit 2014.
The drill bit 214 is coupled to a lower end of the bent housing 260 and is used to crush or cut through the formation and form the wellbore. The drill bit 214 may be a roller-cone bit, a polycrystalline diamond compact (PDC) drill bit, or any other suitable drill bit. Positioning the housing 260 at a fixed azimuthal orientation allows the drill bit 214 to advance the wellbore in the direction of the bend 266 relative to the longitudinal axis 280 of the motor section 262.
The adjustable pads 282 are movable so that they can be alternately extended from or retracted towards the exterior of the housing 260 in response to controlled fluid pressure, to engage or disengage the wellbore wall to adjust the angle of the drill bit 214 and thus the direction of the drill bit 214 relative to the wellbore. Any one or more of the adjustable pads 282 may be extended to engage the wellbore to adjust the direction of the drill bit based on the displacement of the adjustable pad 282 from the exterior of the housing 260. The adjustable pads 282 may be axially and/or azimuthally spaced along the drilling assembly housing 260 to facilitate directional drilling. As shown in
A fluid control system for extending or retracting the pads according to this disclosure may include any number of elements that collectively or cooperatively control fluid to the pads that are responsive to applied fluid pressure. Such a fluid control system may include, at least, a valve of some type involved in controlling the application of fluid directly or indirectly to control movement of the pads. Fluid control may include delivering fluid pressure to the pads to actively extend the pads when so desired. Fluid control may further include adjusting fluid flow or pressure to forcibly retract the pads. Fluid control may alternatively involve allowing the pads to passively retract, such as by releasing fluid pressure delivered to the pads so the pads may easily retract in response to forces applied by the wellbore wall. As an example,
The orientation of the sealing element 288 may be adjusted via a motor assembly 310 or any other suitable device capable of rotating the sealing element to the orientation desired to set the displacement of the respective adjustable pad 282. The motor assembly 310 includes a fluid-driven motor 312, an electric generator 314, a controller 316, and an electric motor 318. The fluid-driven motor 312 may be a turbine motor, similar to that of the fluid-driven motor 270 of
It should be appreciated that the sealing element 288 may be oriented via any other suitable device. For instance, the sealing element 288 may be oriented via a device that is responsive to pressure pulses transmitted along the drill string through the drilling fluid. The sealing element 288 may also be oriented by sending darts or plugs into the bore of the drill string to actuate a device that can rotate the sealing element 288. It should also be appreciated that the drilling assembly 226 may include any number of valves 284 operably coupled to the adjustable pads 282 axially spaced along the drilling assembly 282 as depicted in
The sealing element 288 is shaped to form two flow paths 292, 294 through the bore of the valve body 286. The upper flow path 292 of
The adjustable pads and valve system described herein thus enable variability in the bend angle of the drilling assembly. The adjustable pads also enable varying the forces applied to the drilling assembly via the pad-wellbore contact and the time interval of the force. Therefore, the adjustable pads provide for far more control of directional change and tortuosity than with a conventional motor application.
The adjustable pads also enable reducing the bend angle of the drilling assembly. This can be used to reduce the stress levels encountered by the fluid-driven motor which may improve motor reliability and performance improvements. Less stress on the fluid-driven motor provides less risk of the fluid-driven motor overheating, which in turn reduces the risk of motor chunking. Less stress on the fluid-driven motor also improves operational life and reduces replacement and maintenance costs. Reducing the bend angle of the drilling assembly may also enable the drill bit to rotate at higher RPMs relative to a high bend setting. The high bend setting can restrict the RPM output of the drill bit. With a higher drill bit RPM, the lower bend setting also enables an increased weight-on-bit (WOB) applied to the drilling assembly from the surface before the drill bit is overloaded. Reducing the bend angle of the drilling assembly may also enable the drilling assembly to be rotated at higher RPMs during rotary drilling (not sliding). Higher RPMs of the drilling assembly with larger bend settings increase the fatigue on and around the bend as a result of cyclic stress loading. Reducing the bend with the adjustable pads would allow the application of higher RPMs from the surface, reducing cyclic stress and enabling an increased WOB and rate of penetration through the formation.
The adjustable pads also provide directional drilling that respond to formations that are prone to hole enlargement. Such formations may increase in hole size restricting the bend angle of the drilling assembly without an adjustable pad. The adjustable pad can offset these formation types by extending the adjustable pad as the hole size increases.
In addition to the embodiments described above, many examples of specific combinations are within the scope of the disclosure, some of which are detailed below:
A drilling assembly for drilling a wellbore comprising a wall, comprising:
The drilling assembly of example 1, wherein the fluid control system comprises a valve comprising a sealing element rotatable on an axis of the bent housing, the sealing element rotatable to seal off fluid communication between the bore and the adjustable pad.
The drilling assembly of example 1, wherein the adjustable pad is positioned below the bend.
The drilling assembly of example 1, wherein the adjustable pad is positioned above the bend.
The drilling assembly of example 1, further comprising an additional adjustable pad in fluid communication with the fluid control system.
The drilling assembly of example 1, wherein the additional adjustable pad is azimuthally spaced from the adjustable pad.
The drilling assembly of example 1, further comprising an additional adjustable pad in fluid communication with an additional fluid control system and axially spaced from the adjustable pad.
The drilling assembly of example 7, wherein the additional adjustable pad is positioned below the bend.
The drilling assembly of example 7, wherein the additional adjustable pad is positioned above the bend.
The drilling assembly of example 1, wherein the additional adjustable pad is radially extendable in an opposite direction from that of the adjustable pad.
A method of directional drilling a wellbore with a wall, comprising:
The method of example 11, wherein radially extending the adjustable pad comprises rotating a valve on an axis of the bent housing to adjust a drilling direction of the drilling assembly.
The method of example 11, wherein the adjustable pad is located below the bend of the housing.
The method of example 11, wherein the adjustable pad is located above the bend of the housing.
The method of example 11, further comprising radially extending an additional adjustable pad from the exterior of drilling assembly to engage or disengage the wellbore wall to adjust the drilling direction of the bit.
The method of example 11, wherein the additional adjustable pad is extendable in an opposite direction from that of the adjustable pad.
A system, comprising:
The system of example 17, wherein the fluid control system comprises a valve comprising a sealing element rotatable on an axis of the bent housing, the sealing element rotatable to seal off fluid communication between the bore and the adjustable pad.
The system of example 17, wherein the drilling assembly further comprises an additional adjustable pad in fluid communication with the fluid control system.
The system of example 17, wherein the drilling assembly further comprises an additional adjustable pad in fluid communication with an additional fluid control system and axially spaced from the adjustable pad.
This discussion is directed to various embodiments of the present disclosure. The drawing figures are not necessarily to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. It is to be fully recognized that the different teachings of the embodiments discussed may be employed separately or in any suitable combination to produce desired results. In addition, one skilled in the art will understand that the description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.
Certain terms are used throughout the description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function, unless specifically stated. In the discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. In addition, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. The use of “top,” “bottom,” “above,” “below,” and variations of these terms is made for convenience, but does not require any particular orientation of the components.
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Although the present disclosure has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the disclosure, except to the extent that they are included in the accompanying claims.
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