In borehole geophysics, a wide range of parametric borehole measurements can be made, including chemical and physical properties of the formation penetrated by the borehole, as well as properties of the borehole and material therein. Measurements are also made to determine the path of the borehole during drilling to steer the drilling operation or after drilling to plan details of the borehole. To measure parameters of interest as a function of depth within the borehole, a drill string can convey one or more logging-while-drilling (LWD) or measurement-while-drilling (MWD) sensors along the borehole so measurements can be made with the sensors while the borehole is being drilled.
As shown in
Surface equipment 22 having an uphole telemetry unit (not shown) can obtain sensor responses from one or more sensors in the assembly's instrument section 70. When combined with depth data, the sensor responses can form a log of one or more parameters of interest. Typically, the surface equipment 22 and electronics section 50 transfer data using telemetry systems known in the art, including mud pulse, acoustic, and electromagnetic systems.
Shown in more detail in
Mud flows from the drill string 30, through the electronic section 50, through the connectors 42/44 and to the mud motor 50, which has a rotor 64 and a stator 62. The downhole flowing drilling fluid rotates the rotor 64 within the stator 62. In turn, the rotor 64 connects by a flex shaft 66 to a drive shaft 72 supported by bearings 68. The flex shaft 66 transmits power from the rotor 64 to the drive shaft 72.
Disposed below the mud motor 60, the instrument section 70 has one or more sensors 74 and electronics 76 to control the sensors 74. A power supply 78, such as a battery, can power the sensors 74 and electronics 76 if power is not supplied from sources above the mud motor 60. The drill bit (34;
Because the instrument section 70 is disposed in the bottom hole assembly 40 below the mud motor 60, the rotational nature of the mud motor 60 presents obstacles for connecting to the downhole sensors 74. As shown, the sensors 74 are hard wired to the electronics section 50 using conductors 46 disposed within the rotating elements of the mud motor 60. In particular, the conductors 46 connect to the sensor 74 and electronics 76 at a lower terminus 48a and extend up through the drive shaft 72, flex shaft 66, and rotor 64. Eventually, the conductors 46 terminate at an upper terminus 48b within the mud motor connector 44. As with the lower terminus, this upper terminus 48b rotates as do the conductors 46.
Running conductors 46 through the flex shaft 66 creates difficulties with sealing and can be expensive to implement.
The flex shaft 66 is elongated and has downhole and uphole adapters 69a-b disposed thereon. The shaft 66 and adapters 69a-b each define the bore 67 so the conductors 46 used for power and/or communications can pass through them. The adapters 69a-b typically shrink or press with an interference fit to the ends of the shaft 66.
Down flowing drilling fluid from the stator 62 and rotor 64 passes in the annular space around the shaft 66 and adapters 69a-b. The shrink fitting of the adapters 69a-b to the shaft 66 creates a fluid tight seal that prevents the drilling fluid from passing into the shaft's bore 67 at the adapters 69a-b. A port 69c toward the downhole adapter 69a allows the drilling fluid to enter a central bore 73 of the drive shaft 72 so the fluid can be conveyed to the drill bit (not shown).
The flex shaft 66 has to be long enough to convert the orbital motion of the rotor 64 into purely rotational motion for the drive shaft 72 while being able to handle the required torque, stresses, and the like. Moreover, the flex shaft 66 has to be composed of a strong material having low stiffness in order to reduce bending stresses (for a given bending moment) and also to minimize the side loads placed on the surrounding radial bearings 68. For this reasons, the elongated flex shaft 66 is typically composed of titanium and can be as long as 4.5 to 5 feet. Thus, the shaft 66 can be quite expensive and complex to manufacture. Moreover, the end adaptors 69a-b shrink fit onto ends of the shaft 66 to create a fluid tight seal to keep drilling fluid out of the internal bore 67 in the shaft 66. Although the shrink fit of the adapters 69a-b avoids sealing issues, this arrangement can be expensive and complex to manufacture and assemble.
The subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.
A bottom hole assembly for a drill string has a mud motor, a mandrel, and a transmission section. The mud motor has a rotor and a stator, and the rotor defines a rotor bore for passage of one or more conductors. The mandrel has a bore for passage of the conductors and for drilling fluid, and rotation of the mandrel rotates a drill bit. Drilling fluid pumped down the drill string passes through the mud motor and causes the rotor to orbit within the stator. The drilling fluid passes the transmission section and enters a port in the mandrel bore so the drilling fluid can be delivered to drill bit on the mandrel.
A shaft in the transmission section has a bore and coverts the orbital motion at the mud motor to rotational motion at the mandrel. The shaft couples at a first end to the rotor with a first universal joint and couples at a second end to the mandrel with a second universal joint. An inner conduit or beam disposes in the shaft's bore. The shaft can be composed of alloy steel, while the inner conduit or beam can be composed of titanium.
This inner beam has an internal passage therethrough for communicating the conductors between opposing ends. These opposing ends seal inside passages of the universal joints. In particular, seal caps dispose on each of the ends of the inner beam and seal inside the passages of the universal joints. In this way, drilling fluid passing from the mud motor and around the transmission shaft is sealed from communicating in the bore of the shaft around the inner beam having the conductors.
For their part, the universal joints can each have a joint member coupled to the rotor and can have a socket receiving an end of the shaft therein. At least one bearing disposes in a bearing pocket in the end of the shaft, and at least one bearing slot in the socket receives the at least one bearing. To hold the bearing, a retaining ring can dispose about the end of the shaft adjacent the socket in the joint member.
The mandrel below the motor section can have an electronic device, such as a sensor, associated therewith. The conductors electrically couple to the electronic device and pass from the bore of the mandrel, through the inner passage of the inner beam, and to the bore of the rotor. For example, the conductors can pass from a sensor disposed with the mandrel to a sonde disposed above the mud motor. The sensor can be a gamma radiation detector, a neutron detector, an inclinometer, an accelerometer, an acoustic sensor, an electromagnetic sensor, a pressure sensor, or a temperature sensor. The conductors can be one or more single strands of wire, a twisted pair, a shielded multi-conductor cable, a coaxial cable, and an optical fiber.
The foregoing summary is not intended to summarize each potential embodiment or every aspect of the present disclosure.
A bottom hole assembly 100 according to the present disclosure conceptually illustrated in
The electronics section 50 is similar to that described previously and includes an electronics sonde 52 having a power supply 54, sensors 56, and a downhole telemetry unit 58. Disposed below the electronics section 50, the mud motor section 110 has a stator 112 and a rotor 114. Drilling fluid from the drill string 30 flows through the downhole telemetry connector 42 and the mud motor connector 44 to the mud motor section 110. Here, the downhole flowing drilling fluid rotates the rotor 114 within the stator 112. In turn, the rotor 114 connects by a transmission shaft 130 to a mandrel or drive shaft 170 supported by bearings 174, and the transmission shaft 130 transmits power from the rotor 114 to the drive shaft 170.
The instrument section 70 is disposed below the transmission section 120. The instrumentation section 70 is also similar to that described previously and includes one or more sensors 74, an electronics package 76, and an optional power supply 78. (Because a conductor conduit 108 has conductors that can provide electrical power, the power source 78 may not be required within the instrument section 70.) The one or more sensors 74 can be any type of sensing or measuring device used in geophysical borehole measurements, including gamma radiation detectors, neutron detectors, inclinometers, accelerometers, acoustic sensors, electromagnetic sensors, pressure sensors, temperature sensors, and the like.
The one or more sensors 74 respond to parameters of interest during drilling. For example, the sensors 74 can obtain logging and drilling parameters, such as direction, RPM, weight/torque on bit and the like as required for the particular drilling scenario. In turn, sensor responses are transferred from the sensors 74 to the downhole telemetry unit 58 disposed above the mud motor section 60 using the conductor conduit 108. A number of techniques can be used to transmit the sensor responses across the connectors 42/44, including techniques disclosed in U.S. Pat. No. 7,303,007, which is incorporated herein by reference in its entirety. In turn, the sensor responses are telemetered uphole by the unit 58 to the surface, using mud pulse, electromagnetic, or acoustic telemetry. Conversely, information can be transferred from the surface through an uphole telemetry unit and received by the downhole telemetry unit 58. This “down-link” information can be used to control the sensors 40 or to control the direction in which the borehole is being advanced.
Because the instrument section 70 is disposed in the bottom hole assembly 100 below the mud motor section 110, the rotational nature of the mud motor section 110 presents obstacles for connecting the telemetry unit 58, power supply 54, and the like to the downhole sensors 74 below the mud motor section 110.
To communicate sensor response, convey power, and the like, the conductor conduit 108 disposes within the rotating elements of the bottom hole assembly 100 and has one or more conductors that connect the sonde 52 to the instrument section 70 and to other components. As shown in
The conductor conduit 108 extends from the lower terminus 48a and pass through the mandrel or drive shaft 170, the transmission section 120, and the motor section's rotor 114. Eventually, the conductor conduit 108 terminates at an upper terminus 48b within the mud motor connector 44. As with the lower terminus, this upper terminus 48b rotates as does the conductor conduit 108. Various fixtures, wire tensioning assemblies, rotary electrical connections, and the like (not shown) can be used to support the conductor conduit 108 and their passage through the bottom hole assembly 100.
As shown in
Further details of the transmission section 120 are best shown in
The conductor conduit 108 passes from the uphole components (e.g., telemetry unit, power supply, etc.), through the rotor 114, through the arrangement of upper universal joint 140b, transmission shaft 130, lower universal joint 140a, and to the drive shaft 170. The conductor conduit 108 continues through the bore 172 of the drive shaft 170 to downhole components (e.g., sensors, electronics, etc.).
Downhole flowing fluid rotates the rotor 114 within the stator 112. In turn, the rotor 114 connects to the transmission shaft 130, which transfers the orbital motion at the rotor 114 to rotational motion at the mandrel or drive shaft 170. At the downhole end of the assembly 100, a bearing assembly 174 supports the drive shaft 170. The bearing assembly 174 provides radial and axial support of the drive shaft 170. As shown in
After passing the rotor 114 and stator 112, the downward flowing fluid passes around the transmission shaft 130 and universal joints 140a-b. An end connector 176 connects the drive shaft 170 to the lower universal joint 140a. This connector 176 has ports 177 that let the drilling fluid from around the transmission shaft 130 to pass into the drive shaft 170, where the fluid can continue on to the drill bit (not shown). A flow restrictor 106 disposes around this connector 176 in the space with the transmission housing 106 to restrict flow between the transmission section 120 and the bearing assembly 174.
Discussion now turns to
During rotation, the universal joint adapters 140a-b transfer rotation between the transmission shaft 130 and the rotor 114 and the mandrel or drive shaft 170. Yet, the universal joint adapters 140a-b allow the connection with the transmission shaft's ends 134a-b to articulate during the rotation. In this way, the transmission shaft 130 can convert the orbital motion at the rotor 114 into purely rotational motion at the drive shaft 170.
To convey the conductor conduit (108) from the rotor 114 to the instrumentation section below the drive shaft 170, the transmission shaft 130 defines a through-bore 132. To deal with fluid sealing at the connection of the shaft's ends 134a-b to the universal joint adapters 140a-b, an inner shaft or beam 150 having its own bore 152 installs in the transmission shaft's bore 132. As described below, the beam 150 helps seal passage of the conduit (108) through the universal joint adapters 140a-b, and the beam 150 flexes to compensate for eccentricity of the power section and any bend of the drilling motor.
To prepare the transmission section 120, operators mill the bore 132 through the transmission shaft 130. Operators then run the inner beam 150 down the bore 132 for sealing purposes. This inner beam 150 can be composed of alloy steel or titanium. Seal caps 160a-b dispose on opposing ends of the inner beam 150 and seal the connection between the adapters 140a-b and the inner beam 150. O-rings or other forms of sealing can be used on the seal caps 160a-b to seal against the shaft's bore 132 and the beam 150.
In later stages of assembly, operators run the conductor conduit (108) through this inner beam 150 and the seal caps 160a-b. Ultimately, the arrangement seals fluid from communicating through the bore 132 of the shaft 130. Although fluid may still pass through bore 152 of the beam 150 (e.g., up through connector 176), the shaft 130 and end caps 160a-b prevent fluid flow from the universal joints 140a-b from passing into the bore 132 and around the conductor conduit (108), which could damage the conduit (108).
The seal caps 160a-b can affix in the intermediate passages in the joint members 142 in a number of suitable ways. As shown, for example, the seal caps 160a-b can thread into the intermediate passages and can include O-rings or other seal elements. An internal ledge or shoulder in the seal cap 160a-b can retain the ends of the inner beam 150. As shown, the inner beam 150 preferably has an outer diameter along most of its length that is less than the inner diameter of the shaft's bore 132. This may allows for some flexure and play in the assembly. The ends of the inner beam 150, however, may fit more snuggly in the bore 132 to help with sealing.
Rather than transferring torque through interference fits, the universal joint adapters 140a-b transfer torque through their universal joint connections to the ends 134a-b of the transmission shaft 130. The inner beam 150 seals the passage 152 and bore 132 for the conductor conduit (108) from the drilling fluid. The outer transmission shaft 130 can be much smaller than the conventional flex shaft composed of titanium used in the art. Because the transmission section 120 has internal and external shafts 130/150 that rotate and orbit along their lengths during operation, the seal caps 160a-b handle issues with axial movement of the inner beam 150 at the seal caps 160a-b relative to the adapter socket members 142.
As opposed to the more expensive titanium conventionally used, the transmission shaft 130 can be composed of alloy steel or other conventional metal for downhole use, although the shaft 130 could be composed of titanium if desired. Moreover, the transmission shaft 130 can be shorter than the conventional length used for a flex shaft with shrunk fit adapters. In particular, the universal joint adapters 140a-b and their ability to convert the orbital motion of the rotor 114 into pure rotation at the drive shaft 170 enables the transmission shaft 130 to be shorter than conventionally used. In fact, in some implementations for a comparable motor application, the transmission shaft 130 can be about 2 to 3 feet in length as opposed to the 4 to 5 feet length required for a titanium flex shaft with shrunk fit adapters of the prior art. In addition to the shorter length, the transmission shaft can be composed of materials other than the conventional titanium. For example, the transmission shaft 130 can be composed of more conventional materials (e.g., alloy steel) and still be able to handle the torque and other forces experienced during operation.
As disclosed above, the transmission section 120 having external and internal shafts 130/150 and universal joints 140a-b can be used for a downhole mud motor to pass conductor conduit 108 to electronic components near the drill bit. Yet, the transmission section 120 can also find use in other applications. In one example, the inner beam 150 sealed inside the transmission shaft 130 and universal joints 140a-b can be used to convey any number of elements or components other than wire conductor conduit in a sealed manner between uphole and downhole elements of a bottom hole assembly. In fact, the transmission shaft 130 with its sealed inner beam 150 can allow fluid to communicate alternatively outside the external shaft 130 or inside the inner beam 150 in a sealed manner when communicated between a mud motor and a drive shaft. Thus, the disclosed arrangement of transmission shaft, inner conduit, and universal joint adapters can be useful for these and other applications.
The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.