The present invention is directed to a suppression module, a suppression assembly, and a drilling tool. More particularly, the present invention is directed to fixed rate suppression modules, a variable rate suppression assembly formed from the fixed rate suppression modules, and a drilling tool including the variable rate suppression assembly.
Commercial drilling applications, such as rock drilling for oil and gas typically use elongated drillstrings having a drill bit attached thereto. During drilling the drillstrings often experience vibrations, such as self-excited vibrations (chatter) in the longitudinal direction (axial chatter), rotational vibration and bit whirl. The vibrations in the bit of a drillstring may produce an undulated surface in the rock and/or cause failure of the cutter portion. In particular, failures of Polycrystalline Diamond Compact (“PDC”) cutters and damage to the bottom hole assembly are of concern.
Even though there are many types of vibrations encountered during drilling, chatter is considered to be one of the main causes of failure in PDC bits, particularly in hard rock formations such as Sierra White Granite (“SWG”). When the PDC bits fail a new bit must be installed, requiring removal of the drillstring from the drilling hole. Removing the drillstring halts drilling, which increases operational cost and repair time.
It has been shown that the proper combination of weight on bit (“WOB”), rotating speed, and bit design reduces the axial chatter. However, the bit design is not adjustable or variable under field conditions and poor surface telemetry with bottom hole conditions often results in the actual downhole dynamic conditions being incorrectly diagnosed. This is particularly important as the dynamics of drillstrings are constantly varying with the drilling depth. Moreover, rock properties vary and unexpected variations in rock hardness is common. Sudden changes in load as the bit transitions a soft-to-hard rock boundary is often sufficient to induce drillstring instability.
A suppression assembly and drilling tool for suppressing drilling vibrations that do not suffer from one or more of the above drawbacks would be desirable in the art.
In an embodiment, a suppression module includes a spindle having a first end and a second end, an ear plate slideably disposed between the first end and the second end, a spring positioned between the ear plate and the first end, and an activation mechanism coaxially disposed around the second end of the spindle. The activation mechanism engages the ear plate, activating the spring, or disengages the ear plate, deactivating the spring.
In another embodiment, a suppression assembly includes at least two suppression modules, each suppression module comprising a spindle having a first end and a second end, an ear plate slideably disposed between the first end and the second end, a spring positioned between the ear plate and the first end, and an activation mechanism coaxially disposed around the second end of the spindle; and a processor. The activation mechanism engages the ear plate, activating the spring, or disengages the ear plate, deactivating the spring. The suppression modules are activated or deactivated by the processor, each of the suppression modules being activated or deactivated independent of the other suppression modules.
In another embodiment, a drilling tool includes a drill pipe, a drill bit, a variable stiffness suppression assembly between the drill pipe and the drill bit, the variable stiffness suppression assembly including at least two suppression modules, each of the suppression modules having a prescribed stiffness, a processor coupled to the variable stiffness suppression assembly, and a vibration sensor coupled to the processor, the vibration sensor arranged and disposed to determine vibration in the drilling tool. The suppression modules are activated or deactivated by the processor, each of the suppression modules being activated or deactivated independent of the other suppression modules to vary the stiffness of the suppression module in response to the vibration in the drilling tool.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.
Provided are a suppression module, a suppression assembly, and a drilling tool. Embodiments of the present disclosure, in comparison to similar tools and methods that fail to include one or more of the features of the present disclosure, for example, decrease drillstring vibration, increase drilling efficiency, increase drilling rate, decrease drill bit wear, permit remote activation and deactivation of suppression modules, permit remote variation of a suppression assembly stiffness, or a combination thereof.
The drilling tool 112 includes a drillstring 120 having a drill pipe 121 and a bottom hole assembly 123 coupled to the drill pipe 121. The bottom hole assembly 123 includes a drill bit 125 coupled to a drill collar 127 coupled to a shock assembly 129 coupled to the drill pipe 121. In another embodiment, the bottom hole assembly 123 may include one or more subassemblies 129. The drill collar 127 provides weight to the drill bit 125. The drillstring 120 is rotated by the rotary table 117, which is rotated by any suitable mechanism, such as, but not limited to, a motor 119. The rotation of the drillstring 120 rotates the drill bit 125, drilling a bore hole 105 extending from a surface 107.
As the drilling tool 112 advances in the bore hole 105, each of the modules 300 may be independently activated or deactivated to increase or decrease the overall stiffness of the shock assembly 129, respectively. The activation and deactivation of a module is discussed below. The individual modules 300 provide a variable stiffness to the shock assembly 129, which reduces transmissibility of longitudinal vibrations into the drillstring 120. In one embodiment, the variable stiffness of the shock assembly 129 absorbs and decreases or eliminates vibration during drilling to stabilize the drilling tool 112 at near-zero vibration levels. Additionally, the variable stiffness increases stability of the drillstring 120 by changing the dynamic compliance of the drillstring 120 supporting the drill bit 125. For example, the modules 300 may be activated or deactivated in response to contact with surfaces having different hardness values.
A spindle 303 is movably positioned at least partially within the enclosure. The spindle 303 includes a base portion 308 and an elongated portion 312. The elongated portion 312 extends away from the base portion 308, terminating in a distal end 314. The distal end 314 is configured to slide through an aperture in the top plate 323 when the spindle 303 is moved axially between the top plate 323 and the bottom plate 301. In this exemplary embodiment, the spindle 303 includes posts 304 secured to the base portion 308. The posts 304 are configured to extend through corresponding apertures in the bottom plate 301, aligning the spindle 303 and reducing or eliminating rotation of the spindle 303 with respect to the bottom plate 301. Additionally, the posts 304 extend through corresponding apertures in the top plate 323 of any suppression module 300 positioned adjacent to bottom plate 301. The posts 304 reduce or eliminate rotation of the suppression modules 300 with respect to each other. In another embodiment, the posts 304 may be attached to another component. In this exemplary embodiment, the spindle 303 is fitted within the side portion 302. In another embodiment, the spindle 303 is keyed to a shaft and/or the side portion 302 is keyed to the suppression assembly 200 to reduce or eliminate rotation of the spindle 303 within the suppression module 300 and/or rotation of the suppression module 300 within the suppression assembly 200, respectively.
As illustrated in
The retaining ring 311 is axially fixed on the spindle 303, and provides a stop for an ear plate 309 movably positioned between the retaining ring 311 and the base portion 308. The ear plate 309 may be keyed to the spindle 303, such as, for example, with a projection and mating recess, to reduce or eliminate rotation of the ear plate 309 with respect to the spindle 303. Any suitable spring 307 or other force providing member is positioned between the ear plate 309 and the base portion 308. For example, in one embodiment, as illustrated in
Both the ear plate 309 and the spring 307 may be coaxially positioned around the elongated member 312. The spring 307 extends towards distal end 314, positioning the ear plate 309 adjacent to, and/or in contact with, the retaining ring 311. The ear plate 309 is configured to engage the spring 307, such that when the ear plate 309 is engaged, as discussed in detail below, the ear plate 309 compresses the spring against the base portion 308. In one embodiment, the suppression module 300 includes a spacer 305 positioned between the spring 307 and the base portion 308. In another embodiment, the spacer 305 decreases the length between the ear plate 309 and the base plate 308. As best illustrated in
An activation mechanism 313 is positioned within the enclosure, the activation mechanism 313 including any suitable mechanism for engaging or disengaging the ear plate 309 as the spindle 303 moves between the top plate 323 and the bottom plate 301. Suitable mechanisms include, but are not limited to, an engagement spline, a mechanical lock, or a combination thereof. An axial opening in the activation mechanism 313 permits the elongated portion 312 of the spindle 303 to pass therethrough. In one embodiment, the activation mechanism 313 is directly or indirectly coupled to the top plate 323. In another embodiment, the activation mechanism 313 is movable with respect to the enclosure, the spindle 303, and/or the ear plate 309. For example, as illustrated in
Additionally, each of the suppression modules 300 includes an actuator 317. The actuator 317 includes any suitable actuator for moving and/or rotating the activation mechanism 313 between an active configuration (shown in
In
In
Selectively activating and deactivating the suppression modules comprising the drilling assembly allows the preferred compliance or spring rate to be introduced to the bottom hole assembly to reduce the impact of damaging vibrations produced by the drilling process. The effective stiffness of the tool can be tailored by preferential activation and deactivation of the individual suppression modules to produce a spring rate that is neither too soft nor too stiff for the drilling conditions encountered.
When the suppression modules 300 are positioned in series, as in the suppression assembly 200 (see
The spindles 303 of the suppression modules 300 form a load path through the suppression assembly 200, with the individual suppression modules 300 acting in parallel to support a thrust through the suppression assembly 200. In one embodiment, the drill bit 125 directly or indirectly contacts the base portion 308 of the spindle 303 in the first suppression module 300a. When the drill bit 125 axially thrusts against the suppression assembly 200, it moves the spindles 303 of the first suppression module 300a and any adjacent suppression modules 300. The springs 307 of any activated suppression modules 300 absorb the thrust independent of the enclosures of each suppression module 300, supporting the thrust through the suppression assembly 200 and changing the compliance through the rest of the drillstring 120.
A total stiffness (e.g., spring rate) of the suppression assembly 200 is a sum of the individual stiffness values of the activated suppression modules 300. Although the spring 307 in each of the suppression modules 300 includes a prescribed stiffness, the total stiffness of the suppression assembly 200 is varied by activating and deactivating the individual suppression modules 300. The stiffness of the spring 307 may be the same in each of the suppression modules 300, or may differ between one or more of the suppression modules 300. For example, the stiffness of the spring 307 may differ by varying amounts between each of the suppression modules 300, may be stepped between suppression modules 300, may include a binary escalating sequence such that each successive suppression module 300 includes a stiffness that is half the stiffness of the suppression module 300 after it and twice the stiffness of the suppression module 300 before it, or a combination thereof.
By actuating combinations of springs 307 in the suppression modules 300 the stiffness may be changed between suppression modules 300 having similar springs 307. Activating and deactivating different combinations of suppression modules 300 provides different total stiffness values of the suppression assembly 200. For example, a suppression assembly 200 having three suppression modules with spring rates of 400,000 lbs/in, 200,000 lbs/in, and 100,000 lbs/in is capable of providing total stiffness values of 100,000 lbs/in, 200,000 lbs/in, 300,000 lbs/in (200,000+100,000), 400,000 lbs/in, 500,000 lbs/in (400,000+100,000), 600,000 lbs/in (400,000+200,000), and 700,000 lbs/in (400,000+200,000+100,000). As will be understood by one skilled in the art, these values are examples only, and are not necessarily representative of the spring rates or total stiffness values used during drilling.
Control features within and/or coupled to the drilling tool 112 are configured to activate and/or deactivate the individual suppression modules 300. The control features include, but are not limited to, a processor, one or more individual controllers, or a combination thereof. Each of the one or more individual controllers is coupled to one of the individual suppression modules 300. The processor provides commands to the one or more individual controllers, selectively activating or deactivating each of the individual suppression modules 300.
In one embodiment, the processor is coupled to an input device, such as a keypad and/or a touch screen positioned at the surface 107. The processor receives input provided to the input device at the surface 107, and provides commands to the one or more individual controllers to remotely activate and/or deactivate the individual suppression modules 300. In another embodiment, the drilling tool 112 includes one or more vibration sensors configured to measure vibration levels in the drillstring 120. The one or more vibration sensors are coupled to the processor (e.g., integral with, hard wired, wireless) and include, but are not limited to, an accelerometer, a linear variable differential transformer, or a combination thereof. The processor develops autonomous control commands in response to the vibration levels indicated by the vibration sensor(s), then provides the autonomous control commands to the individual controllers. The individual controllers receive the autonomous control commands and activate and/or deactivate the individual suppression modules 300 to vary the total stiffness of the suppression assembly 200. For example, in response to increased vibration, the control features may deactivate suppression modules 300 using the latching mechanism 321, rotating the activation mechanism 313 to the inactive position. Alternatively, in response to decreased vibration, the control features may activate additional suppression modules 300 by electrically heating the SMA actuator 317 to rotate the activation mechanism 313 and engage the spring 307. Any suitable combination of suppression modules 300 having the same or different springs 307, stiffness values, actuators 317, and/or activation mechanisms 313 may be used.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
This application claims priority to provisional patent applications U.S. Ser. No. 62/219,481, entitled “Drilling System Vibration Suppression Systems and Methods,” by Raymond et al., filed Sep. 16, 2015, the disclosure of which is incorporated herein by reference in its entirety.
This invention was developed under Contract DE-AC04-94AL85000 between Sandia Corporation and the United States Department of Energy. The U.S. Government has certain rights in this invention.
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