U.S. patent application number 12/663039 was filed with the patent office on 2010-11-11 for wired smart reamer.
This patent application is currently assigned to HALLIBURTON ENERGY SERVICES, INC.. Invention is credited to Kevin Glass, Christopher A. Maranuk, Terence Allan Schroter.
Application Number | 20100282511 12/663039 |
Document ID | / |
Family ID | 40093958 |
Filed Date | 2010-11-11 |
United States Patent
Application |
20100282511 |
Kind Code |
A1 |
Maranuk; Christopher A. ; et
al. |
November 11, 2010 |
Wired Smart Reamer
Abstract
A wired reamer for use on a downhole drillstring is disclosed.
In some embodiments, the reamer includes a reamer body comprising a
pathway therethrough and wiring located within the pathway for
transmitting at least one of power or communications. In other
embodiments, the reamer includes a reamer body comprising a pathway
enclosed within the reamer body, wiring located within the pathway
for transmitting at least one of power or communications, a sensor
and a processor located within the reamer body. The sensor is
connected with the wiring for transmitting data measured by the
sensor through the wiring, and the processor is connected with the
wiring for receiving the data from the sensor.
Inventors: |
Maranuk; Christopher A.;
(Houston, TX) ; Schroter; Terence Allan;
(Edmonton, CA) ; Glass; Kevin; (Spring,
TX) |
Correspondence
Address: |
CONLEY ROSE, P.C.;David A. Rose
PO BOX 3267
HOUSTON
TX
77253-3267
US
|
Assignee: |
HALLIBURTON ENERGY SERVICES,
INC.
Houston
TX
|
Family ID: |
40093958 |
Appl. No.: |
12/663039 |
Filed: |
June 5, 2007 |
PCT Filed: |
June 5, 2007 |
PCT NO: |
PCT/US07/70396 |
371 Date: |
February 11, 2010 |
Current U.S.
Class: |
175/40 ;
175/344 |
Current CPC
Class: |
E21B 47/08 20130101;
E21B 47/12 20130101; E21B 47/01 20130101; E21B 10/32 20130101 |
Class at
Publication: |
175/40 ;
175/344 |
International
Class: |
E21B 47/12 20060101
E21B047/12; E21B 10/32 20060101 E21B010/32 |
Claims
1. A reamer for use on a downhole drillstring, comprising: a reamer
body comprising a pathway therethrough; and wiring located within
the pathway for transmitting at least one of power or
communications.
2. The reamer of claim 1, wherein the reamer body pathway comprises
a flowbore extending through the reamer body.
3. The reamer of claim 2, further comprising a feed through
assembly, the feed through assembly surrounding at least a portion
of the wiring.
4. The reamer of claim 1, wherein the reamer body further comprises
a wall surrounding a flowbore extending through the reamer body and
wherein the pathway extends through the wall.
5. The reamer of claim 1, further comprising a sensor located
within the reamer body, the sensor being connected with the wiring
for transmitting data measured by the sensor through the
wiring.
6. The reamer of claim 5, wherein the sensor is selected from the
group consisting of: a vibration sensor, a weight-on-bit sensor, a
torque-on-bit sensor, a temperature sensor, a
pressure-while-drilling sensor, a resistivity sensor, a nuclear
sensor, an acoustic sensor, a nuclear magnetic resonance sensor,
and a formation evaluation sensor.
7. The reamer of claim 5, wherein the reamer body further comprises
a cutting structure and wherein a location of the sensor is
selected from the group consisting of: above the cutting structure,
below the cutting structure, and on the cutting structure.
8. The reamer of claim 5, further comprising the sensor being
wirelessly connected with the wiring.
9. The reamer of claim 5, further comprising a processor connected
with the wiring for receiving data from the sensor.
10. The reamer of claim 9, wherein the sensor is wirelessly
connected with the wiring.
11. The reamer of claim 9, wherein the processor is positioned at a
location, the location selected from the group consisting of:
within the reamer body, at the surface, and on another downhole
tool.
12. The reamer of claim 1, further comprising: wherein the reamer
is an adjustable blade reamer comprising adjustable blades; an
actuator operatively connected with the adjustable blades to adjust
the position of the adjustable blades; and a controller operatively
connected with the actuator for controlling the position of the
adjustable blades.
13. The reamer of claim 12, wherein the controller is configured to
change the cutting diameter of the adjustable blades.
14. The reamer of claim 12, wherein the actuator is selected from
the group consisting of: an electric actuator, a mechanical
actuator, and a hydraulic actuator.
15. The reamer of claim 12, further comprising a processor
connected with the controller for transmitting a signal to the
controller, the signal directing the controller to actuate the
actuator.
16. The reamer of claim 15, wherein the processor is positioned at
a location, the location selected from the group consisting of:
within the reamer body, at the surface, and on another downhole
tool.
17. The reamer of claim 12, further comprising: a sensor located
within the reamer body, the sensor being connected with the wiring
for transmitting data measured by the sensor through the wiring;
and a processor being connected with the wiring for receiving the
data from the sensor and with the controller for transmitting a
signal to the controller, the signal directing the controller to
actuate the actuator.
18. The reamer of claim 17, wherein the controller is configured to
change the cutting diameter of the adjustable blades.
19. The reamer of claim 17, wherein the actuator is selected from
the group consisting of: an electric actuator, a mechanical
actuator, and a hydraulic actuator.
20. The reamer of claim 17, wherein the processor is positioned at
a location, the location selected from the group consisting of:
within the reamer body, at the surface, and on another downhole
tool.
21. The reamer of claim 17, wherein the processor generates the
signal as a function of the data received from the sensor.
22. A reamer for use on a downhole drillstring, comprising: a
reamer body comprising a pathway extending through at least a
portion of the reamer body; and wiring located within the pathway
for transmitting at least one of power or communications to or from
the reamer.
23. The reamer of claim 22, wherein the reamer body pathway
comprises a portion of a flowbore extending through the reamer
body.
24. The reamer of claim 23, further comprising a feed through
assembly, the feed through assembly surrounding at least a portion
of the wiring.
25. The reamer of claim 22, wherein the reamer body further
comprises a wall surrounding a flowbore extending through the
reamer body and wherein the pathway extends through a portion of
the wall.
26. The reamer of claim 22, further comprising a sensor located
within the reamer body, the sensor being connected with the wiring
for transmitting data measured by the sensor through the
wiring.
27. The reamer of claim 26, wherein the reamer body further
comprises a cutting structure and wherein a location of the sensor
is selected from the group consisting of: above the cutting
structure, below the cutting structure, and on the cutting
structure.
28. The reamer of claim 26, further comprising the sensor being
wirelessly connected with the wiring.
29. The reamer of claim 26, further comprising a processor
connected with the wiring for receiving data from the sensor.
30. The reamer of claim 29, wherein the sensor is wirelessly
connected with the wiring.
31. The reamer of claim 29, wherein the processor is positioned at
a location, the location selected from the group consisting of:
within the reamer body, at the surface, and on another downhole
tool.
32. The reamer of claim 22, further comprising: wherein the reamer
is an adjustable blade reamer comprising adjustable blades; an
actuator operatively connected with the adjustable blades to adjust
the position of the adjustable blades; and a controller operatively
connected with the actuator for controlling the position of the
adjustable blades.
33. The reamer of claim 32, wherein the controller is configured
change the cutting diameter of the adjustable blades.
34. The reamer of claim 32, wherein the actuator is selected from
the group consisting of: an electric actuator, a mechanical
actuator, and a hydraulic actuator.
35. The reamer of claim 32, further comprising a processor
connected with the controller for transmitting a signal to the
controller, the signal directing the controller to actuate the
actuator.
36. The reamer of claim 35, wherein the processor is positioned at
a location, the location selected from the group consisting of:
within the reamer body, at the surface, and on another downhole
tool.
37. The reamer of claim 32, further comprising: a sensor located
within the reamer body, the sensor being connected with the wiring
for transmitting data measured by the sensor through the wiring;
and a processor connected with the wiring for receiving the data
from the sensor and the controller for transmitting a signal to the
controller, the signal directing the controller to actuate the
actuator.
38. The reamer of claim 37, wherein the controller is configured to
change the cutting diameter of the adjustable blades.
39. The reamer of claim 37, wherein the actuator is selected from
the group consisting of: an electric actuator, a mechanical
actuator, and a hydraulic actuator.
40. The reamer of claim 37, wherein the processor is positioned at
a location, the location selected from the group consisting of:
within the reamer body, at the surface, and on another downhole
tool.
41. The reamer of claim 37, wherein the processor generates the
signal as a function of the data received from the sensor.
42. A reamer for use on a downhole drillstring, comprising: a
reamer body comprising a pathway enclosed within the reamer body;
wiring located within the pathway for transmitting at least one of
power or communications; a sensor located within the reamer body,
the sensor being connected with the wiring for transmitting data
measured by the sensor through the wiring; and a processor located
within the reamer body and connected with the wiring for receiving
the data from the sensor.
43. The reamer of claim 42, wherein the reamer body pathway
comprises a flowbore extending through the reamer body.
44. The reamer of claim 43, further comprising a feed through
assembly, the feed through assembly surrounding at least a portion
of the wiring.
45. The reamer of claim 42, wherein the reamer body further
comprises a wall surrounding a flowbore extending through the
reamer body and wherein the pathway extends through the wall.
46. The reamer of claim 42, wherein the reamer body further
comprises a cutting structure and wherein a location of the sensor
is selected from the group consisting of: above the cutting
structure, below the cutting structure, and on the cutting
structure.
47. The reamer of claim 42, wherein the sensor is wirelessly
connected with the wiring.
48. The reamer of claim 42, further comprising: wherein the reamer
is an adjustable blade reamer comprising adjustable blades; an
actuator operatively connected with the adjustable blades to adjust
the position of the adjustable blades; and a controller operatively
connected with the actuator for controlling the position of the
adjustable blades.
49. The reamer of claim 48, wherein the controller is configured
change the cutting diameter of the adjustable blades.
50. The reamer of claim 48, wherein the actuator is selected from
the group consisting of an electric actuator, a mechanical
actuator, and a hydraulic actuator.
51. The reamer of claim 48, wherein the processor is connected with
the controller for transmitting a signal to the controller, the
signal directing the controller to actuate the actuator.
52. The reamer of claim 51, wherein the processor generates the
signal as a function of the data received from the sensor.
Description
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] Not applicable.
BACKGROUND
[0002] In the drilling of oil and gas wells, it is frequently
necessary or desirable to "ream" a borehole that has been
previously created by a drill bit or other cutting tool so as to
ream out ledges, remove sloughed areas and key seats, straighten
the borehole, stabilize the drill string, and enlarge the borehole.
For those reasons, a reamer may be positioned behind a drill bit,
or other cutting structure, on the drilling assembly so as to ream
the hole after the bit has formed the borehole. It is sometimes
preferred that such a reaming step be performed as the bit is being
withdrawn from the borehole, that process being referred to as
"backreaming." Also, it is sometimes necessary to run a reamer on a
subsequent trip to straighten or clean up the borehole. In casing
drilling applications, the reamer is needed to drill the primary
hole before the casing string.
[0003] When drilling oil and gas wells using a rotary steerable
tools, it is desirable to ream the borehole as close to the bit as
possible so as to minimize the distance between the bit borehole
and the reamer borehole. Because rotary steerable tools commonly
need to communicate with the measurement-while-drilling (MWD)
system, it is important for all tools located between the rotary
steerable tool and the MWD telemetry system to allow the
transmission of power and communications through the tool.
[0004] There are three main categories of reamers. Fixed blade
reamers, including near bit reamers, have fixed blades that do not
move or expand. A fixed blade reamer cuts a larger bore because it
has a larger outer diameter than the pilot bit. The fixed blade
reamer can be used to enlarge a borehole by a relatively small
amount. Since the reamer blade is fixed, the borehole opening is at
the surface or adjacent a larger hole section. A fixed blade reamer
can be used to ream out ledges, straighten boreholes, remove key
seats and remove sloughed areas. Roller reamers have roller cutters
that are mounted to a main body and can be used to enlarge the
bore, ream out ledges, straighten boreholes, remove key seats and
sloughed areas, as well as stabilize a drilling string and reduce
the overall torque of the drill string. Extendable blade or
expandable reamers, including underreamers, have arms that may be
extended on surface or downhole to a predetermined diameter to cut
a larger bore. An extendable blade reamer can be used to enlarge
the bore by a substantial amount, ream out ledges, straighten
boreholes, and remove key seats and sloughed areas.
[0005] Conventional underreamers are typically used in conjunction
with a pilot drill bit which is positioned below or downstream of
the underreamer. A underreamer can be used to drill and expand the
borehole below a cased section or, as in casing drilling
applications, can be used to drill the well bore from the surface
or below a larger cased section. In casing drilling applications, a
drilling assembly including at least a bit and reamer are used to
open the borehole below the casing string. The casing string is
used as a replacement for the drill pipe, transferring fluid and
torque down to the drilling assembly. After the borehole is
completed, the underreamer arms are retracted and the drilling
assembly is recovered to surface.
[0006] The underreamers usually have hinged arms with roller cones
and PDC cutters attached thereto. The arms are actuated by
mechanical or hydraulic forces acting on the arms, causing the arms
to pivot at an end opposite the cutting end of the arms and thereby
extend or retract. These arms can be forced out against the
formation by a piston or driving arm. In conventional operations,
the arms of the underreamer are retracted to allow the tool to pass
through a smaller hole section or cased hole section. Once the tool
has passed through the smaller hole or cased hole section, the
underreamer arms are extended. The pilot bit drills the borehole,
while at the same time, the underreamer enlarges the borehole
formed by the bit. Typical examples of these types of underreamers
are found in U.S. Pat. Nos. 3,224,507, 3,425,500 and 4,055,226.
[0007] In casing drilling applications, the underreamer is opened
on surface with a casing string connected behind the reamer. The
casing string is used as a replacement for conventional drill pipe.
The underreamer needs to be able to close back to a size that will
allow the drilling assembly to be removed from the well bore. The
drilling assembly may need to be removed if a portion of the
assembly fails or if the well bore is completed.
[0008] Conventional reamers have several disadvantages. If a
reamer's cutting structure experiences wear, the hole geometry may
not be opened to the desired size. Also, the reamer's cutting
structure may not be selected correctly to properly stabilize a
drilling assembly. Moreover, a conventional underreamer may fail to
deploy fully or retract fully. A conventional underreamer typically
has rotary cutter pocket recesses formed in the body for storing
the retracted arms and roller cone cutters when the tool is in a
closed state. The pocket recesses tend to fill with debris from the
drilling operation, which hinders collapsing of the arms. If the
arms do not fully collapse, the drill string may easily hang up in
the borehole when an attempt is made to remove the string from the
borehole. In casing drilling applications, if the reamer arms do
not collapse, the underreamer may hang up on the casing string.
[0009] The activation and deactivation method of the arms of an
underreamers may also create drilling operational limitations. Some
underreamers use a ball to assist with the activation and
deactivation of the reamer arms. Although a ball drop can be used
to lock the reamer arm position, the underreamer cannot be used
below tools that have no throughbore to permit passage of the ball.
In addition, there may be a limitation to the number of cycles that
the reamer arms can be activated and deactivated. Moreover, some
underreamers are designed to automatically expand when drilling
fluid is pumped through the drill string. Underreamers that actuate
in response to flow alone are very sensitive to the flow. Thus,
these underreamers may open and close every time the pumps are
turned on or off. The primary operational limitation may be the
ability to maintain the full deployment of the reamer arms under
the required flow rate needed for drilling. Many underreamers have
limited or no indication provided at the surface that the
underreamer is in the fully-expanded or collapsed position. Thus,
in some applications, it may be desirable to control when the
underreamer expands or collapses regardless of the flow, rather
than rely on automatic expansion in response to the drilling fluid.
It may also be desirable to vary the size of the hole being opened
downhole depending on the well bore location.
[0010] Another method for enlarging a borehole below a previously
cased borehole section includes using a winged reamer behind a
conventional drill bit. In such an assembly, a conventional pilot
drill bit is disposed at the lowermost end of the drilling assembly
with a winged reamer disposed at some distance behind the drill
bit. The winged reamer generally comprises a tubular body with one
or more longitudinally extending "wings" or blades projecting
radially outwardly from the tubular body. Once the winged reamer
has passed through any cased portions of the wellbore, the pilot
bit rotates about the centerline of the drilling axis to drill a
lower borehole on center in the desired trajectory of the well
path, while the eccentric winged reamer follows the pilot bit and
engages the formation to enlarge the pilot borehole to the desired
diameter.
[0011] Yet another method for enlarging a borehole below a
previously cased borehole section includes using a bi-center bit,
which is a one-piece drilling structure that provides a combination
underreamer and pilot bit. The pilot bit is disposed on the
lowermost end of the drilling assembly, and the eccentric
underreamer bit is disposed slightly above the pilot bit. Once the
bi-center bit has passed through any cased portions of the
wellbore, the pilot bit rotates about the centerline of the
drilling axis and drills a pilot borehole on center in the desired
trajectory of the well path, while the eccentric underreamer bit
follows the pilot bit and engages the formation to enlarge the
pilot borehole to the desired diameter. The diameter of the pilot
bit is made as large as possible for stability while still being
capable of passing through the cased borehole. Examples of
bi-center bits may be found in U.S. Pat. Nos. 6,039,131 and
6,269,893.
[0012] As described above, winged reamers and bi-center bits
include underreamer portions that are eccentric. A number of
disadvantages are associated with this design. Due to directional
tendency problems, the eccentric underreamer portions have
difficulty reliably underreaming the borehole to the desired
diameter. The bore geometry has a large amount of spiralization
which increases the borehole torque and axial friction. With
respect to a bi-center bit, the eccentric underreamer bit tends to
cause the pilot bit to wobble and undesirably deviate off center,
thereby pushing the pilot bit away from the preferred trajectory of
drilling the well path. A similar problem is experienced with
respect to winged reamers, which only underream the borehole to the
desired diameter if the pilot bit remains centralized in the
borehole during drilling.
[0013] In the oil and gas industry, it is desirable to detect and
control the operational forces that act on a tool in order to
determine whether a tool has sustained damaged, to limit the damage
that the tool may experience, and/or to ensure that a particular
operation is performed correctly. Sensors to detect vibration,
axial forces, torsional forces, and bending forces, and to transmit
that data real-time to the surface, can be used to identify when a
drilling tool is experiencing forces that exceed its operational
parameters. Drilling operations may then be modified to prevent or
limit damage to the tool and/or to correct an ongoing
operation.
[0014] To optimize the drilling operation and/or wellbore
placement, it is desirable to be provided with information
concerning the operational parameters of the drill string and the
environmental conditions of the surrounding formation being
drilled. For example, it is often necessary to frequently adjust
the direction of the borehole while drilling, either to accommodate
a planned change in direction, or to compensate for unintended and
unwanted deflection of the borehole. In addition, it is desirable
that the information concerning tool operation, the drilling
environment, and formation type or characteristics be provided to
the operator on a real time basis. The ability to obtain real time
data measurements while drilling permits a relatively more
economical and more efficient drilling operation. Therefore, it is
important that any tool located between the MWD or LWD sensors and
the MWD telemetry system allow the transmission of power and/or
communications through the tool.
[0015] To obtain real time data while drilling, a collection of
drilling tools and measurement devices commonly known as the bottom
hole assembly (BHA) are positioned at the downhole end of the drill
string. Typically, the BHA includes the drill bit, any directional
or formation evaluation tools, deviated drilling mechanisms, mud
motors, and weighted collars that are used in the drilling
operation. A measurement while drilling (MWD) or logging while
drilling (LWD) collar is often positioned just above the drill bit
to take measurements relating to the borehole direction or
formation properties of the borehole as it is being drilled.
Measurements recorded from MWD and LWD systems may be transmitted
to the surface in real-time using a variety of methods known to
those skilled in the art. Once received, these measurements will
enable those at the surface to make decisions concerning the
drilling operation. Due to the limitations in transmitting
information, it is common for the more detailed information or the
tool reliability information to be stored for download when the
tool is recovered on the surface.
[0016] Accordingly, various systems have been developed that permit
downhole sensors to measure real time drilling parameters and to
transmit the resulting information or data to the surface
substantially instantaneously with the measurements. For example,
mud pulse telemetry systems transmit signals from an associated
downhole sensor to the surface through the drilling mud in the
drill string. As another example, drill pipe with built-in
telemetry, or hard wired pipe, transmits signals from the downhole
sensor to the surface through wiring contained within the drill
pipe wall. These telemetry systems and associated sensors may be
located a significant distance from the drilling bit. The
environmental information measured by the system may not
necessarily correlate with the actual conditions surrounding the
drill bit. Rather, the system is responding to conditions that are
substantially spaced from the drilling bit. For instance, a
conventional telemetry system may have a depth lag of up to or
greater than 60 feet. As a result of this information delay, it is
possible to drill out a hydrocarbon producing formation before
detecting the exit, resulting in the need to drill several feet of
borehole to get back into the pay zone. In response to this
undesirable information delay or depth lag, various near bit sensor
systems or packages have been developed which are designed to be
placed adjacent or near the drilling bit. However, such near bit
sensors continue to be located a spaced distance from the drill bit
assembly that still introduces a lag in determining formation
changes.
[0017] In order to use a near bit sensor system and permit real
time monitoring and adjustment of drilling parameters, a system or
method must be provided for transmitting the measured data or
sensed information from the downhole sensor either directly to the
surface or to a further telemetry system for subsequent
transmission to the surface. Similarly, a system or method may need
to be provided for transmitting the required electrical power to
the downhole sensor system from the surface or some other power
source. As a result, all of the tools in the directional BHA need
the ability to transfer power and communications through their
body, or the tools need to be located above the telemetry system.
Conventional reamers available today do not have the ability to
transmit power and communications through their body, and as a
result, the placement of the underreamers has been a significant
distance from the bit. In casing drilling applications, this means
that the directional BHA below the casing string is very long and
prone to operational issues, such as debris buildup and
vibration.
[0018] Various systems have been developed for communicating or
transmitting the information directly to the surface, for example,
through an electrical line, wireline or cable to the surface. These
hard-wire connectors provide a hard-wire connection from near the
drilling bit to the surface; however, a wireline or cable must be
installed in or otherwise attached or connected to the drill
string. This wireline or cable is subject to wear and tear during
use and thus may be prone to damage or even destruction during
normal drilling operations. The drilling assembly may not be
particularly suited to accommodate such wirelines, with the result
that the wireline sensors may not be able to be located in close
proximity to the drilling bit. Wirelines and wireline connectors by
their very nature create blockages in the drillpipe, thus
precluding some types of reamer activation mechanisms.
[0019] Systems have also been developed for the transmission of
acoustic or seismic signals or waves through the drill string or
surrounding formation. The acoustic or seismic signals are
generated by a downhole acoustic or seismic generator. However, a
relatively large amount of power is typically required downhole in
order to generate a sufficient signal such that it is detectable at
the surface. A relatively large power source must be provided
downhole or repeaters used at intervals along the string to boost
the signal as it propagates along the drill string.
[0020] Further, systems have been developed which require the
transmission of electromagnetic signals through the surrounding
formation. Electromagnetic transmission of the sensed information
often involves the use of a toroid positioned adjacent the drilling
bit for generation of an electromagnetic wave through the
formation. As with acoustic and seismic signal transmission, the
transmission of electromagnetic signals through the formation
typically requires a relatively large amount of power, particularly
where the electromagnetic signal must be detectable at the surface.
Further, attenuation of the electromagnetic signals as they are
propagated through the formation is increased with an increase in
the distance over which the signals must be transmitted.
[0021] Hardwired drillpipe has also been developed which allows
significant amounts of data to be transferred from downhole to the
surface. These systems require that the hardwire be run the length
of the drillstring and communicate with the drilling BHA.
Communications across connections can be problematic, and given the
large number of connections in a typical drill string, these
systems can be prone to reliability and maintenance issues.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] For a detailed description of the preferred embodiments of
the invention, reference will now be made to the accompanying
drawings in which:
[0023] FIG. 1 is a representative schematic of a wired reamer with
power and/or communications wiring through the reamer flowbore in
accordance with the present invention;
[0024] FIG. 2 shows the wired reamer of FIG. 1 with the power
and/or communications wiring through the reamer body;
[0025] FIG. 3 is a representative schematic of a wired, adjustable
blade reamer with power and/or communications wiring through the
reamer flowbore in accordance with the present invention;
[0026] FIG. 4 shows the wired reamer of FIG. 3 with the power
and/or communications wiring through the reamer body;
[0027] FIG. 5 shows the wired reamer of FIG. 1 with the power
and/or communications wiring to the reamer flowbore;
[0028] FIG. 6 shows the wired reamer of FIG. 2 with the power
and/or communications wiring to the reamer body;
[0029] FIG. 7 shows the wired reamer of FIG. 1 with the power
and/or communications wiring contained within the reamer
flowbore;
[0030] FIG. 8 shows the wired reamer of FIG. 2 with the power
and/or communications wiring contained within the reamer body;
[0031] FIG. 9 shows the wired reamer of FIG. 1 with sensors;
[0032] FIG. 10 shows the wired reamer of FIG. 2 with sensors;
[0033] FIG. 11 shows the wired reamer of FIG. 3 with sensors;
[0034] FIG. 12 shows the wired reamer of FIG. 4 with sensors;
[0035] FIG. 13 shows the wired reamer of FIG. 1 with wireless
sensors;
[0036] FIG. 14 shows the wired reamer of FIG. 2 with wireless
sensors;
[0037] FIG. 15 shows the wired reamer with sensors of FIG. 9 with
access to a processor;
[0038] FIG. 16 shows the wired reamer with sensors of FIG. 5 with
sensors and access to a processor;
[0039] FIG. 17 shows the wired reamer of FIG. 7 with sensors and a
processor;
[0040] FIG. 18 shows the wired reamer of FIG. 1 with controllers
and actuators;
[0041] FIG. 19 shows the wired reamer of FIG. 2 with controller and
actuators;
[0042] FIG. 20 shows the smart reamer of FIG. 15 with controllers
and actuators;
[0043] FIG. 21 shows the smart reamer of FIG. 16 with controller
and actuators;
[0044] FIG. 22 shows the smart reamer of FIG. 20 with controllers
and actuators; and
[0045] FIG. 23 shows the smart reamer of FIG. 21 with controller
and actuators.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] The following discussion is directed to various embodiments
of the invention. 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. In addition, one skilled in the art will understand
that the following description has broad application, and the
discussion of any embodiment is meant only to be exemplary of that
embodiment, and not intended to intimate that the scope of the
disclosure, including the claims, is limited to that
embodiment.
[0047] Certain terms are used throughout the following 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. The drawing FIGS. are not
necessarily to scale. Certain features and components herein may be
shown exaggerated in scale or in somewhat schematic form and some
details of conventional elements may not be shown in interest of
clarity and conciseness.
[0048] In the following 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. Thus, if a first device
couples to a second device, that connection may be through a direct
connection, or through an indirect connection via other devices and
connections.
[0049] A wired reamer permits power and/or communications through
the reamer to other downhole tools, to equipment on the surface, or
to the reamer itself. The ability to pass power and/or
communications through the reamer overcomes some limitations
regarding where the reamer may be placed in a drilling BHA.
Furthermore, positioning sensors on the reamer permits the
collection of data relating to the tool operation, borehole
geometry, drilling environment, and evaluation of the surrounding
formations being drilled. The data may be transmitted to the
surface or other telemetry tool using the through-tool
communications and used to optimize the drilling operation, or
stored inside the tool for later download. Moreover, data measured
by the sensors may be transmitted to a processor located at the
surface, on another downhole tool, or on the reamer itself. In such
configurations, the reamer is "smart", meaning the reamer
communicates with a processor for deciphering data collected by the
sensors.
[0050] Furthermore, locating controllers and actuators on the
reamer permits control of the reamer during drilling operations
through direct command or feedback from algorithms developed as a
function of the data measured by the sensors. Direct commands or
feedback may be transmitted using the through-tool communications
to the controllers, directing the controllers to actuate the
actuators, as needed to optimize the drilling operation. For
example, controllers on the reamer may extend or retract the reamer
arms, or otherwise reconfigure the reamer to limit forces
experienced by the reamer.
[0051] Monitoring the performance of the reamer may help to
determine when the reamer experiences a physical failure, such as
excessive cutting structure wear, failed roller bearings, broken
reamer arms, or when the reamer arms are not fully extended or
retracted. Monitoring of the performance of the drilling parameters
may help to determine whether the weight on the reamer arms is too
high or too low, the vibration of the reamer is in an unacceptable
range, or the torque through the reamer arms is in an unacceptable
range.
[0052] The wired reamer may be located between a measurement while
drilling (MWD) telemetry system and an instrumented bit, rotary
steerable, or logging while drilling (LWD) sensor. In rotary
steerable drilling bottom hole assemblies (BHAs), a wired reamer
may allow the reamer to be located closer to the bit, reducing the
rat hole created. In casing drilling applications, a wired reamer
may allow a shorter stick out of the straight or directional
BHA.
[0053] In some embodiments of a wired reamer, power and/or
communications are provided through the bore of the reamer or the
body of the reamer to the tools located downhole of the reamer or
to the reamer itself. The communication path may be through the
reamer bore or embedded in the reamer body. Also, the short hop
power and/or communication path may be a conductive wire,
conductive rod, fiber optic line, sonic or acoustic path, vibration
path, electromagnetic (EM) signal, or wireless transmission. In the
case of a conductive wire or rod, the conductor may be insulated
from the reamer housing.
[0054] FIG. 1 is a schematic of a representative embodiment of a
wired reamer that permits power and/or communications through the
reamer. Wired reamer 100 comprises a body 105 with a flowbore 110
therethrough and a cutting structure 113 along the outer surface of
the body 105. A feedthrough assembly 115 extends through the
flowbore 110. The feedthrough assembly 115 further comprises a
protected pathway 120 surrounding at least a portion of the power
and/or communications wiring 125. The wiring 125 permits power
and/or communications to and/or from other tools positioned uphole
or downhole of the reamer 100.
[0055] In this representative embodiment, the pathway 120 for the
power and/or communications wiring 125 extends through the flowbore
110 of the wired reamer 100. In other embodiments, the pathway 120
for the wiring 125 may extend through the reamer body 105, rather
than the flowbore 110. FIG. 2 shows the wired reamer 100, depicted
in FIG. 1, with the pathway 120 for the power and/or communications
wiring 125 extending through the body 105 of the reamer 100.
Because the pathway 120 is located within the body 105, there is no
need for a feedthrough assembly to house and protect the wiring
125, as depicted in FIG. 1.
[0056] Moreover, the representative embodiment depicted in FIG. 1
is a fixed blade reamer. In other embodiments, the reamer 100 may
be another type of reamer, including an adjustable blade reamer.
FIG. 3 is a schematic of a representative embodiment of a wired,
adjustable blade reamer. Thus, the reamer 100 further comprises
arms 130 that may retract and extend. As shown, the arms 130 open
from the right, which corresponds to the downhole end of the reamer
100. Alternatively, the arms 130 may open from the left, or the
uphole end of the reamer 100, or bow out from the center of the
reamer 100. The arms 130 further comprise cutting structures 113.
Although depicted in FIG. 3 as positioned on the arms 130, the
cutting structures 113 may alternatively, or additionally, be
positioned on the reamer body 105 uphole or downhole of the arms
130.
[0057] As described above, the pathway 120 for the wiring 125 may
extend through the reamer body 105, rather than through the
flowbore 110. FIG. 4 shows the reamer 100, depicted in FIG. 3, with
the pathway 120 for power and/or communications wiring 125
extending through the body 105 of the reamer 100. Because the
pathway 120 is located within the body 105, there is no need for a
feedthrough assembly to house and protect the wiring 125, as
depicted in FIG. 3.
[0058] Power and/or communications need not be contiguous through a
reamer, as they are depicted in FIGS. 1 through 4. Instead, power
or communications may be provided through the reamer. Also, power
and/or communications need not pass through the reamer, but instead
may only be provided to the reamer. FIG. 5 shows the wired reamer
100, depicted in FIG. 1, with the pathway 120 for the power and/or
communications wiring 125 extending to, but not through, the
flowbore 110 of the reamer 100. Similarly, FIG. 6 shows the wired
reamer 100, depicted in FIG. 2, with the pathway 120 for the power
and/or communications wiring 125 extending to, but not through, the
body 105 of the reamer 100. Moreover, power and/or communications
need not pass through or to the reamer, but instead may be
contained entirely within the reamer. FIG. 7 shows the wired reamer
100, depicted in FIG. 1, with the pathway 120 for the power and/or
communications wiring 125 contained within the flowbore 110 of the
reamer 100. Similarly, FIG. 8 shows the wired reamer 100, depicted
in FIG. 2, with the pathway 120 for the power and/or communications
wiring 125 contained within the body 105 of the reamer 100.
[0059] To optimize a drilling operation and/or formation
evaluation, it is desirable to be provided with information
relating to the operational parameters of the reamer as well as
formation data from the surrounding formation being drilled.
Therefore, in some embodiments, the instrumented, wired reamer is
fitted with sensors to collect such information. These embodiments
may be applicable to all three types of reamers, fixed blade,
adjustable, and expandable. Power for operation of the sensors may
be provided by a power source connected to the reamer, such as a
downhole power generator or battery pack, or from the surface via
wireline or hard wired tubulars. Alternatively, the power source
may be located on the wired reamer itself.
[0060] Sensors may be positioned within the reamer as well as on
its outer surface, including the arms. For instance, some sensors
measuring formation data, are optimized by contact of the wellbore
wall, where as other sensors work best centralized in the borehole.
Sensors may be positioned on the reamer outer surface below or
above the reamer arms and/or on the reamer arms. Other sensors can
be used to monitor drilling or environmental data. For instance, to
monitor the gauge and the potential smoothness of the borehole,
sensors, specifically hole calipers, can be positioned above the
arms, in the arms, or below the arms. The hole caliper sensors may
be simple mechanical sensors such as a spring sensor, or more
complex acoustic calipers which depend on pulse-echo, pitch/catch,
or other data acquisition techniques. In measuring the caliper,
mechanical sensors are best situated in the arms while acoustic
sensors are best positioned in the body of the reamer. Sensors may
be positioned on the reamer to monitor and report other
information, such as the positioning, e.g. open, closed, and
partially open, of the reamer arms and forces that act on the tool,
such as vibration, weight on the reamer arms, torque on the reamer
arms, rpm of the tool, temperature, pressure and/or stress/strain
across the tool.
[0061] Certain types of formation evaluation sensors may be better
suited to placement on the body of the reamer versus the reamer
arms. For instance, certain resistivity sensors are better suited
being placed on the arms of the reamer versus the body of the
reamer, whereas other types of resistivity devices work best
centered in the borehole and thus on the reamer body. This is not
to say, however, that these sensors will only work in these
locations. Other formation evaluation sensors that may be
positioned in the reamer include nuclear porosity, sonic, magnetic
imaging and formation testing type sensors.
[0062] Information collected from the sensors may be stored in a
memory chip located in the reamer. The information may be retrieved
using an external port or wireless communication at the surface
when the reamer is removed from downhole to the surface.
Additionally or alternatively, the information collected may be
transmitted using the through-tool communications to another
storage device, whether located on another downhole tool or at the
surface. Intertool communications are done either electrically
through a hardwire connection or via other communications
techniques such as short hop EM or acoustic transmission.
Transmitting the information to the surface may be done real time
using various communications techniques such as a mud pulse
telemetry, acoustic telemetry, electro-magnetic induction,
wireline, fiber optics, or hard wired tubulars.
[0063] FIG. 9 shows the wired reamer 100 of FIG. 1 with sensors for
data collection. Wired reamer 100 further comprises sensors 140
located along the reamer 100. As shown, the sensors 140 are
positioned on the outer surface of reamer 100, uphole of the
cutting structure 113, downhole of the cutting structure 113, and
on the cutting structure 113. The wired reamer 100 further
comprises a cross-over 145, which permits data collected by sensors
140 to be communicated to the power and/or communications wiring
125, which, in this embodiment, extends through the feedthrough
assembly 115 inserted through in the reamer flowbore 110.
[0064] Similarly, FIG. 10 shows the wired reamer 100 of FIG. 2 with
sensors for data collection. In this embodiment, the pathway 120
for the power and/or communications wiring 125 passes through the
reamer body 105. Because the wiring 125 passes through the reamer
body 105, rather than the reamer flowbore 110, a cross-over between
the sensors 140 and the wiring 125 is not necessary.
[0065] FIG. 9 and FIG. 10 depict fixed blade reamers. As discussed
above, the reamer may be another type of reamer, including an
adjustable blade reamer. Moreover, a wired, adjustable blade
reamer, such as those depicted in FIG. 3 and FIG. 4, may be
configured with sensors for data collection. FIG. 11 and FIG. 12
depict the wired, adjustable blade reamer 100 of FIG. 3 and FIG. 4,
respectively, with sensors 140 positioned on the reamer 100 and, in
the case of FIG. 11, the cross-over 145 coupled to the sensors 140
and the wiring 125.
[0066] The embodiments exemplified by FIG. 9 and FIG. 11 comprise a
hard-wired connection, namely the cross-over 145, between the
sensors 140 and the power and/or communications wiring 125. In
other embodiments, this connection may be wireless, instead of
hard-wired. For example, FIG. 13 shows the wired reamer 100 with
sensors 140, depicted in FIG. 9, with a wireless connection 150, in
place of the cross-over 145, between the sensors 140 and the wiring
125. The wireless connection 150 further comprises a source 155 and
a receiver 160 for transmitting and receiving, respectively, data
collected by the sensors 140 from the sensors 140 to the wiring
125.
[0067] Similarly, the hard-wired connection between the sensor(s)
140 located on the cutting structure 113 and the power and/or
communications wiring 125 extending through the reamer body 105 of
the embodiments exemplified by FIG. 10 and FIG. 12 may be replaced
by a wireless connection. For example, FIG. 14 shows the wired
reamer 100 with sensors 140, depicted in FIG. 10, with a wireless
connection 150, in place of a hard-wired connection, between the
sensor(s) 140 located on the cutting structure 113 and the wiring
125. As previously described, the wireless connection 150 further
comprises the source 155 and the receiver 160 for transmitting and
receiving, respectively, data collected by the sensors 140 from the
sensors 140 to the wiring 125.
[0068] Power and/or communications need not be contiguous through a
reamer, as they are depicted in FIGS. 9 through 14. Instead, power
or communications may be provided through the reamer. Also, power
and/or communications need not pass through the reamer, but instead
may only be provided to the reamer, as depicted in FIG. 5 and FIG.
6. Moreover, power and/or communications need not pass through or
to the reamer, but instead may be contained entirely within the
reamer, as shown in FIG. 7 and FIG. 8.
[0069] A processor may be used to collect, process, analyze and
store information measured by downhole sensors. Therefore, in some
embodiments, the wired reamer with sensors is provided with access
to a processor via its through-tool communications. In such
embodiments, the reamer is referred to as "smart". The processor
may be positioned on the surface, located on another downhole tool,
or in the smart reamer itself.
[0070] Data collected by the sensors located on the smart reamer is
transmitted to the processor via the through-tool communications.
Data collected by sensors located on other downhole tools may also
be transmitted to the processor via the through-tool communications
of the reamer. Alternatively, information collected from the
sensors, including those located on the reamer and other downhole
tools, may be stored in a memory chip located in the reamer. The
information may be retrieved from this memory chip using an
external port or wireless communication at the surface or when the
reamer is removed from downhole to the surface. Additionally or
alternatively, the information collected may be transmitted using
the thru-tool communications to another storage device, whether
located on the surface or on another downhole tool. Inter-tool
communications may be accomplished either electrically through a
hardwire connection or via other communications techniques, such as
short hop EM or acoustic transmission. Transmitting the information
to the surface may be done real-time using various communications
techniques, such as mud pulse telemetry, acoustic telemetry,
electro-magnetic induction, wireline, fiber optics, or hard-wired
tubulars. However the data may be retrieved from the sensors, the
data is ultimately transferred to the processor for processing and
analysis.
[0071] FIG. 15 shows the wired reamer with sensors of FIG. 9 with
access to a processor via the through-tool communications of the
reamer. As previously described, wired reamer 100 comprises the
flowbore 110 therethrough, the cutting structure 113 along the
outer surface of the body 105, and the sensors 140 also positioned
along the reamer 100. The feedthrough assembly 115 extends through
the flowbore 110. The feedthrough assembly 115 further comprises
the pathway 120 surrounding at least a portion of the power and/or
communications wiring 125. The wiring 125 permits power and/or
communications to and/or from other tools positioned uphole or
downhole of the reamer 100, including a processor 165. The
processor 165 may be located at the surface or on another downhole
tool. Data collected by sensors 140 on the reamer 100 and sensors
located on other downhole tools with connectivity to the power
and/or communications wiring 125 of the reamer 100 is transmitted
to the processor 165 via the power and/or communications wiring
125.
[0072] FIG. 16 shows the wired reamer of FIG. 7 with sensors and
access to a processor via the through-tool communications of the
reamer. The sole distinction between FIG. 15 and FIG. 16 relates to
the power and/or communications wiring 125 of the reamer 100. In
FIG. 15, the wiring 125 extends through the reamer 100, whereas in
FIG. 16, the wiring 125 extends to, but not through, the reamer
100. In contrast to both FIG. 15 and FIG. 16, FIG. 17 shows the
wired reamer of FIG. 5 with sensors and a processor. The
embodiments exemplified by FIG. 17 comprise the power and/or
communications wiring 125 contained within the reamer 100, rather
than extending through or to the reamer 100. Thus, in the
embodiments exemplified by FIG. 17, the processor 165 is
necessarily located within the reamer 100.
[0073] As with previously described embodiments, power and/or
communications need not be contiguous through the smart reamer, as
they are depicted in FIG. 15. Instead, power or communications may
be provided through the smart reamer. Also, power and/or
communications need not pass through the smart reamer, but instead
may only be provided to the reamer, as depicted in FIG. 16.
Moreover, power and/or communications need not pass through or to
the smart reamer, but instead may be contained entirely within the
reamer, as depicted in FIG. 17. Also, as with previously described
embodiments, the smart reamer may be a fixed blade reamer, as
illustrated in FIGS. 15 through 17, an adjustable blade reamer, or
another type of reamer. In embodiments of the smart reamer having
communications through or to the reamer, the processor may be
located at the surface, on another downhole tool, or on the reamer
itself. In embodiments of the smart reamer having communications
contained within the reamer, the processor is necessarily located
on the reamer itself.
[0074] To optimize a drilling operation and/or wellbore placement,
it is desirable to control the operation of the reamer. Therefore,
in some embodiments of the wired reamer, controllers and actuators
are positioned in the reamer. The controllers and actuators may be
electrical, hydraulic, mechanical, or other suitable type known in
the industry. A signal may be sent to a controller, causing the
controller to actuate an actuator, thereby controlling the
operation of the reamer. For example, a signal may be sent to a
controller, causing the controller to actuate an actuator to
extend, retract, and/or lock the reamer arms.
[0075] In some embodiments, the signal may be a direct command
originating from an operator at the surface. The direct command may
be sent to a controller located on the reamer through any number of
communication techniques, such as mud pulse, EM, acoustic, or
hard-wired tubulars. Upon receipt of the direct command, the
controller may actuate an actuator, also located on the reamer,
causing the actuator to react in a desired manner, e.g. to retract
the reamer arms.
[0076] The various means for actuating the actuators include, but
are not limited to, electric motors, internally isolated hydraulic
actuators, borehole fluid driven actuators, pressure actuated
devices, or drill string driven actuator devices. For example, the
reamer arms may be activated using hydraulic flow or pressure
against an internal piston, which in turn drives the reamer arms
out. Moreover, a ball drop device may be used to assist with
opening, closing or locking the position of the reamer arms. As
another example, an electric actuator may be used to limit the
movement of the reamer arms and to lock the reamer in an open,
closed or partially open position. The electrical actuator may be a
solenoid, switch, or circuit. As still another example, the reamer
arms may be actuated using an electric motor. A sensor may be used
to determine the position of the reamer arms to confirm proper
operation of the tool. As another alternative, electrical valves
may be used to change the piston area of the reamer, thus changing
the activation flow or pressure needed to engage the reamer arms.
As still another alternative, a swash plate pump may be used to
activate the reamer arms. Electrical valves may control the
activation of the pump or the release of the pressure against the
reamer arms or a piston connected to the reamer arms. Lastly, the
reamer arms may be activated by temporarily connecting a motor
drive rod to the reamer arms.
[0077] FIG. 18 shows the wired reamer 100 of FIG. 1 with
controllers and actuators for changing the position of the reamer
cutting structures. Wired reamer 100 further comprises
controller-actuator assemblies 170 positioned between the reamer
body 105 and the cutting structures 113. Each controller-actuator
assembly 170 further comprise a controller and an actuator, where
the controller, upon receiving a signal via the power and/or
communications wiring 125, actuates the actuator to modify the
position of the cutting structures 113, for example, to retract the
cutting structures 113 to reduce the borehole diameter or to expand
the cutting structures 113 to increase the borehole diameter.
[0078] Similarly, FIG. 19 shows the wired reamer 100 of FIG. 2 with
controller and actuators for changing the position of the reamer
cutting structures. In this embodiment, the pathway 120 for the
power and/or communications wiring 125 passes through the reamer
body 105. Because the wiring 125 passes through the reamer body
105, rather than the reamer flowbore 110, a cross-over between the
controller-acutator assemblies 170 and the wiring 125 is not
necessary.
[0079] As with previously described embodiments, power and/or
communications need not be contiguous through a reamer, as they are
depicted in FIGS. 18 and 19. Instead, power or communications may
be provided through the reamer. Also, power and/or communications
need not pass through the reamer, as depicted in FIGS. 18 and 19,
but instead may only be provided to the reamer or contained
entirely within the reamer. Also, as with previously described
embodiments, the wired reamer may be a fixed blade reamer, as
depicted in FIGS. 18 and 19, an adjustable blade reamer, or another
type of reamer.
[0080] In other embodiments of the wired reamer with controllers
and actuators, the controllers may actuate the actuators upon
receiving a signal that originates from a processor. As described
above, a wired reamer with sensors and access to a processor via
its through-tool communications is a "smart reamer". In some
embodiments of a smart reamer, controllers and actuators may be
positioned on the reamer, and the controllers may be actuated by a
direct command originating from the processor.
[0081] The direct command may originate from the operator of the
smart reamer. Alternatively, the direct command may be a signal or
feedback generated by an algorithm developed as a function of
measured data and stored on the processor. Sensors located on other
downhole tools may measure data, in particular, data relating to
the operational parameters of the reamer and the formation
characteristics of the surrounding formation being drilled. The
measured data may be transmitted to the processor for use as input
to the algorithm. Upon receiving the measure data, the processor
may then execute the algorithm to generate feedback based on the
measured data. The feedback may be transmitted in the form of a
signal to the smart reamer via its thru-tool communications. The
signal may direct a controller on the smart reamer to actuate an
actuator, causing the smart reamer to react in a desired
manner.
[0082] FIG. 20 shows the smart reamer 100 of FIG. 15 with
controllers and actuators for changing the position of the reamer
cutting structures. Smart reamer 100 further comprises
controller-actuator assemblies 170 positioned between the reamer
body 105 and the cutting structures 113. Each controller-actuator
assembly 170 further comprise a controller and an actuator, where
the controller, upon receiving a signal from the processor 165 via
the power and/or communications wiring 125, actuates the actuator
to modify the position of the cutting structures 113, for example,
to retract the cutting structures 113 to reduce the borehole
diameter or to expand the cutting structures 113 to increase the
borehole diameter.
[0083] Similarly, FIG. 21 shows the wired reamer 100 of FIG. 16
with controller and actuators for changing the position of the
reamer cutting structures. In this embodiment, the pathway 120 for
the power and/or communications wiring 125 passes through the
reamer body 105. Because the wiring 125 passes through the reamer
body 105, rather than the reamer flowbore 110, a cross-over between
the controller-actuator assemblies 170 and the wiring 125 is not
necessary.
[0084] As with previously described embodiments, power and/or
communications need not be contiguous through a reamer, as they are
depicted in FIGS. 20 and 21. Instead, power or communications may
be provided through the reamer. Also, power and/or communications
need not pass through the reamer, as depicted in FIGS. 20 and 21,
but instead may only be provided to the reamer or contained
entirely within the reamer. Also, as with previously described
embodiments, the wired reamer may be a fixed blade reamer, as
depicted in FIGS. 20 and 21, an adjustable blade reamer, or another
type of reamer. In embodiments of the smart reamer having
communications through or to the reamer, the processor may be
located at the surface, on another downhole tool, or on the reamer
itself. In embodiments of the smart reamer having communications
contained within the reamer, the processor is necessarily located
on the reamer itself.
[0085] As yet another alternative, the direct command may be a
signal or feedback generated by an algorithm developed as a
function of data measured by sensors located on the smart reamer.
In these embodiments, control of the smart reamer components is
actuated in response to sensor data in a closed loop fashion. The
components may be such devices as adjustable stabilization pads
(located before and after the reamer blades), subs to control
excessive torque applied to the reamer cutters, axial force applied
to the reamer cutters or control of the tool rpm. Sensors monitor
conditions of the reamer such as, for example, the vibration,
torque on bit, weight on bit, formation characteristics, and rpm
and a controller and actuator may activate the appropriate
stabilizer or sub to control (limit or regulate) the forces on the
tool. For example, the controller and actuator may extend or
retract the stabilizer pad to minimize the vibration of the tool.
As another example, the controller and actuator may permit a clutch
to allow the string to spin, or a spring sub to temporarily absorb
the high torque, in the situations where the reamer experiences
high torque or rpm. As yet another example, the controller and
actuator may cause a sub to extend or retract in order to modify
the weight on the reamer cutters. As still another example, in
response to data from an imaging device on a reamer arm indicating
the reamer cutters are not cutting the formation wall, the
controller and actuator may cause the reamer arm to apply more
pressure on the surrounding formation at the cutters.
[0086] FIG. 22 shows the smart reamer 100 of FIG. 20, wherein the
data measured by the sensors 140 is used as input to an algorithm
stored and executed by the processor 165 to generate feedback or a
signal. The signal is subsequently transmitted to the
controller-actuator assemblies 170 of the smart reamer 100,
directing the controller-actuator assemblies 170 to modify the
position of the cutting structures 113. In this manner, the
position of the cutting structures 113 is controlled, even
optimized, in a closed-loop fashion.
[0087] Similarly, FIG. 23 shows the smart reamer 100 of FIG. 21,
also operating in a closed-loop fashion to control the position of
the cutting structures 113. In this embodiment, the pathway 120 for
the power and/or communications wiring 125 passes through the
reamer body 105. Because the wiring 125 passes through the reamer
body 105, rather than the reamer flowbore 110, a cross-over between
the controller-actuator assemblies 170 and the wiring 125 is not
necessary.
[0088] As with previously described embodiments, power and/or
communications need not be contiguous through a reamer, as they are
depicted in FIGS. 22 and 23. Instead, power or communications may
be provided through the reamer. Also, power and/or communications
need not pass through the reamer, as depicted in FIGS. 22 and 23,
but instead may only be provided to the reamer or contained
entirely within the reamer. Also, as with previously described
embodiments, the wired reamer may be a fixed blade reamer, as
depicted in FIGS. 22 and 23, an adjustable blade reamer, or another
type of reamer. In embodiments of the smart reamer having
communications through or to the reamer, the processor may be
located at the surface, on another downhole tool, or on the reamer
itself. In embodiments of the smart reamer having communications
contained within the reamer, the processor is necessarily located
on the reamer itself.
[0089] While preferred embodiments have been shown and described,
modifications thereof can be made by one skilled in the art without
departing from the scope or teachings herein. The embodiments
described herein are exemplary only and are not limiting. Many
variations and modifications of the system and apparatus are
possible and are within the scope of the invention. For example,
the relative dimensions of various parts, the materials from which
the various parts are made, and other parameters can be varied.
Accordingly, the scope of protection is not limited to the
embodiments described herein, but is only limited by the claims
that follow, the scope of which shall include all equivalents of
the subject matter of the claims.
* * * * *