U.S. patent application number 13/170954 was filed with the patent office on 2013-01-03 for control of downhole safety devices.
This patent application is currently assigned to BAKER HUGHES INCORPORATED. Invention is credited to Harald Grimmer, Volker Krueger.
Application Number | 20130000981 13/170954 |
Document ID | / |
Family ID | 47389447 |
Filed Date | 2013-01-03 |
United States Patent
Application |
20130000981 |
Kind Code |
A1 |
Grimmer; Harald ; et
al. |
January 3, 2013 |
CONTROL OF DOWNHOLE SAFETY DEVICES
Abstract
A drilling system for drilling a borehole includes a drill
string including a bottom hole assembly and a telemetry system
coupled together and a communication device coupled to the
drillstring configured to transmit sensor data to and receive
control data from a control unit located at a surface location
through the telemetry system. The system also includes a sensor
coupled to the drillstring, the sensor providing the sensor data to
the communication device and a downhole safety device coupled to
the drill string and in operable communication with the
communication device, the downhole safety device configured to
actuate after receiving an activation signal initiated by the
control unit.
Inventors: |
Grimmer; Harald;
(Lachendorf, DE) ; Krueger; Volker; (Celle,
DE) |
Assignee: |
BAKER HUGHES INCORPORATED
Houston
TX
|
Family ID: |
47389447 |
Appl. No.: |
13/170954 |
Filed: |
June 28, 2011 |
Current U.S.
Class: |
175/45 ;
175/55 |
Current CPC
Class: |
E21B 47/10 20130101;
E21B 47/12 20130101 |
Class at
Publication: |
175/45 ;
175/55 |
International
Class: |
E21B 47/02 20060101
E21B047/02; E21B 7/04 20060101 E21B007/04 |
Claims
1. A drilling system for drilling a borehole comprising: a drill
string including a bottom hole assembly and a telemetry system
coupled together; a communication device coupled to the drillstring
configured to transmit sensor data to and receive control data from
a control unit located at a surface location through the telemetry
system 1; a sensor coupled to the drillstring, the sensor providing
the sensor data to the communication device; and a downhole safety
device coupled to the drill string and in operable communication
with the communication device, the downhole safety device
configured to actuate after receiving an activation signal
initiated by the control unit.
2. The drilling system of claim 1, wherein the sensor senses one
of: formation pressure of a formation surrounding the borehole, mud
flow, and mud composition, or combinations thereof.
3. The drilling system of claim 1, wherein the downhole safety
device includes a blowout preventer.
4. The drilling system of claim 1, wherein the activation signal is
automatically initiated.
5. The drilling system of claim 1, wherein the activation signal is
initiated relative to a second signal that causes another portion
of the drilling system to vary its operation, wherein the
activation signal is created based on the sensor data.
6. The drilling system of claim 5, wherein the activation signal
and the second signal are initiated in a predetermined coordinated
way.
7. The drilling system of claim 5, wherein the other portion is a
drill string actuator.
8. The drilling system of claim 5, wherein the other portion is a
surface blowout preventer.
9. A method of actuating a downhole safety device in a drilling
system, the method comprising: collecting information indicative of
borehole conditions at a downhole location; transmitting the
information to a surface control unit; determining that the
downhole safety device should be actuated; sending an actuation
signal through a telemetry system to the downhole safety device;
and actuating the downhole safety device using the actuation
signal.
10. The method of claim 9, wherein the downhole safety device is a
blowout preventer.
11. The method of claim 9, further comprising: sending a variation
signal to another portion of the drilling system that causes the
other portion to vary its operation, the variation signal being
sent relative to the actuation signal.
12. The method of claim 11, wherein the variation signal and the
actuation signal are initiated in a predetermined coordinated
way
13. The method of claim 11, wherein the other portion is a drill
string actuator.
14. The method of claim 11, wherein the other portion is a surface
blowout preventer.
15. The system of claim 1, wherein the telemetry system includes a
plurality of joined wired pipe segments.
Description
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention generally relates drilling and, in
particular, to activation of downhole safety devices.
[0003] 2. Description of the Related Art
[0004] Boreholes are drilled deep into the earth for many
applications such as carbon sequestration, geothermal production,
and hydrocarbon exploration and production. In all of the
applications, the boreholes are drilled such that pass through or
can allow for access to a material (e.g., a gas or fluid) contained
in a formation located below the earth's surface. Many different
types of tools and instruments may be disposed in the boreholes to
perform various tasks and some of these can be utilized to take
measurements of various values while the borehole is being
drilled.
[0005] One disadvantageous phenomenon that can arise while drilling
is referred to as "drilling kick" or simply "kick." Kick generally
refers to the condition where a formation fluid or formation gas
flows from the formation into the borehole while drilling. Kick can
occur when formation pressure exceeds the hydrostatic pressure
exerted on the formation by drilling mud utilized in drilling the
borehole. This type of kick is generally referred to as
"underbalanced kick." Another type of kick referred to as "induced
kick" can occur when movement of the drill sting or casing causes
the pressure in the borehole to fluctuate.
[0006] Regardless of the cause, the kick can, in extreme cases,
result in an uncontrolled flow of formation fluid or gases into the
atmosphere at the surface in a phenomenon referred to as "blowout."
To prevent blowout, a blowout preventer is typically installed in
the space between the drill pipe and the casing at the surface. The
blowout preventer is activated when a kick is detected and seals
off the annulus between the drill pipe and the casing to prevent
the fluid or gasses from escaping. Early detection of a kick is
required to effectively operate the blowout preventer and typically
includes visual observation of bubbles in the drilling mud at the
surface.
BRIEF SUMMARY
[0007] Disclosed is a drilling system for drilling a borehole that
includes a drill string including a bottom hole assembly and a
telemetry system coupled together. The system also includes a
communication device coupled to the drillstring configured to
transmit sensor data to and receive control data from a control
unit located at a surface location through the telemetry system and
a sensor coupled to the drillstring, the sensor providing the
sensor data to the communication device. The system also includes a
downhole safety device coupled to the drill string and in operable
communication with the communication device, the downhole safety
device configured to actuate after receiving an activation signal
initiated by the control unit.
[0008] Also disclosed is a method of actuating a downhole safety
device in a drilling system that includes collecting information
indicative of borehole conditions at a downhole location;
transmitting the information to a surface control unit; determining
that the downhole safety device should be actuated; sending an
actuation signal through a telemetry system to the downhole safety
device; actuating the downhole safety device using the actuation
signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0010] FIG. 1 illustrates a drilling system in which embodiments of
the present invention may be implemented; and
[0011] FIG. 2 is flow chart illustrating a method according to one
embodiment of the present invention.
DETAILED DESCRIPTION
[0012] A detailed description of one or more embodiments of the
disclosed apparatus and method presented herein is by way of
exemplification and not limitation with reference to the
Figures.
[0013] FIG. 1 illustrates FIG. 1 is a schematic diagram of an
exemplary drilling system 100 that includes a drill string having a
drilling assembly attached to its bottom end that can be operated
according to the exemplary methods apparatus disclosed herein. FIG.
1 shows a drill string 120 that includes a drilling assembly or
bottomhole assembly ("BHA") 190 conveyed in a borehole 126. The
drilling system 100 includes a conventional derrick 111 erected on
a platform or floor 112 which supports a rotary table 114 that is
rotated by a prime mover, such as an electric motor (not shown), at
a desired rotational speed. A tubing (such as drill pipe) 122
having the drilling assembly 190 attached at its bottom end extends
from the surface to the bottom 151 of the wellbore 126. The tubing
122 is so-called wired pipe in one embodiment and allows for
high-speed bi-directional communication through it.
[0014] A drill bit 150, attached to drilling assembly 190,
disintegrates the geological formations when it is rotated to drill
the borehole 126. The drill string 120 is coupled to a drawworks
130 via a Kelly joint 121, swivel 128 and line 129 through a
pulley. Drawworks 130 is operated to control the weight on bit
("WOB"). The drill string 120 can be rotated by a top drive (not
shown) instead of by the prime mover and the rotary table 114. The
prime mover/rotary table 114 combination or a top drive or any
other means of turning drill string 120 shall be referred to as
drill string actuator herein. The operation of the drawworks 130 is
known in the art and is thus not described in detail herein.
[0015] A suitable drilling fluid 131 (also referred to as "mud")
from a source 132 thereof, such as a mud pit, is circulated under
pressure through the drill string 120 by a mud pump 134. The
drilling fluid 131 passes from the mud pump 134 into the drill
string 120 via a de-surger 136 and the fluid line 138. The drilling
fluid 131 discharges at the borehole bottom 151 through openings in
the drill bit 150. The returning drilling fluid 131b circulates
uphole through the annular space 127 between the drill string 120
and the borehole 126 and returns to the mud pit 132 via a return
line 35 and drill cutting screen 185 that removes the drill
cuttings 186 from the returning drilling fluid 131b.
[0016] In some applications, the drill bit 150 is rotated by
rotating the drill pipe 122. However, in other applications, a
downhole motor 155 (mud motor) disposed in the drilling assembly
190 also rotates the drill bit 150. The rate of penetration ("ROP")
for a given drill bit and BHA largely depends on the WOB or the
thrust force on the drill bit 150 and its rotational speed.
[0017] A surface control unit or controller 140 receives signals
from downhole sensors and devices and processes such signals
according to programmed instructions provided from a program to the
surface control unit 140. The surface control unit 140 displays
desired drilling parameters and other information on a
display/monitor 141 that is utilized by a human operator to control
the drilling operations. The surface control unit 140 can be a
computer-based unit that can include a processor 142 (such as a
microprocessor), a storage device 144, such as a solid-state
memory, tape or hard disc, and one or more computer programs 146 in
the storage device 144 that are accessible to the processor 142 for
executing instructions contained in such programs to perform the
methods disclosed herein. The surface control unit 140 can process
data relating to the drilling operations, data from the sensors and
devices on the surface, and data received from downhole and can
control one or more operations of the downhole and surface
devices.
[0018] The drilling assembly 190 also contains formation evaluation
sensors or devices (also referred to as measurement-while-drilling,
"MWD," or logging-while-drilling, "LWD," sensors) determining
borehole pressure, formation pressure, resistivity, density,
porosity, permeability, acoustic properties, nuclear-magnetic
resonance properties, corrosive properties of the fluids or
formation downhole, salt or saline content, and other selected
properties of the formation 195 surrounding the drilling assembly
190. Such sensors are generally known in the art and for
convenience are generally denoted herein by numeral 165 and can
include, for example, resistivity sensors, density sensors,
porosity sensors, permeability sensors, temperature sensors,
pressure sensors, vibration sensors, bending moment sensors,
rotation sensors, orientation sensors and shear sensors. The
drilling assembly 190 can further include a variety of other
sensors and communication devices 159 for controlling and/or
determining one or more functions and properties of the drilling
assembly (such as velocity, vibration, bending moment,
acceleration, oscillations, whirl, stick-slip, etc.) and drilling
operating parameters, such as weight-on-bit, fluid flow rate,
pressure, temperature, rate of penetration, azimuth, tool face,
drill bit rotation, etc.
[0019] A suitable telemetry sub (communication device) 180 using,
for example, two-way telemetry, is also provided as illustrated in
the drilling assembly 190 and provides information from the various
sensors to the surface control unit 140 through the wired pipe 122.
The telemetry sub 180 can also provide control or activation data
received from the control unit 140 to the sensors or other devices
located at or near the BHA 190. In one embodiment, the telemetry
sub 180 provides activation signals to downhole safety devices
167.
[0020] Still referring to FIG. 1, the drill string 120 further
includes an energy conversion device 160. In an aspect, the energy
conversion device 160 is located in the BHA 190 to provide an
electrical power or energy, such as current, to sensors 165 and/or
communication devices 159. Energy conversion device 160 can include
a battery or an energy conversion device that can for example
convert or harvest energy from pressure waves of drilling mud which
are received by and flow through the drill string 120 and BHA 190.
Alternately, a power source at the surface can be used to power the
various equipment downhole.
[0021] The drill string 120 further includes one or more downhole
safety devices 167. These safety devices 167 can include, for
example, blowout preventers (BOPs). The BOPs, as is known in the
art, are operated to seal incoming fluid from the formation 169
from traversing up the annulus between the drill pipe 122 and the
borehole 126. It shall be understood that the safety devices 167
can receive an activation signal from the control unit 140 through
the telemetery sub 180. In some cases, a surface BOP can also be
provided that seals fluid from escaping into the atmosphere.
[0022] According to one embodiment of the present invention, the
sensors 165 can sense one or more of formation pressure, flow rate
of the drilling mud and composition of the drilling mud.
Information collected by the sensors 165 is provided to the
controller 140 through wired pipe 122. At the controller 140 it is
determined if a kick is about to or has occurred. The determination
can be automatic or based on analysis of the data by an operator.
If kick has or is about to occur, the controller 140 can transmit a
signal through the wired pipe 122 to safety devices 167 that cause
them to activate.
[0023] In prior art applications, after detection of a kick at the
surface, an activation of the safety devices 167 has heretofore
been initiated manually with significant time delay from surface by
dropping a ball or the like or sending a downlink. In either case,
the safety devices 167 are actuated independent of the other
portions of the drilling system 100. Such activation, while
suitable for reducing or eliminating the effects of kick, is not
very effective due to the time delay and can create additional
problems. For instance, if the safety device 167 is activated
before the rotary table 114 is stopped, the drill string 120 could
be damaged. In some cases a blow-out will not be even recognized
(underground blow-out) at surface.
[0024] By making the determination of a kick condition based on
downhole information at the surface, other related systems can be
stopped or altered in the correct order. For instances, if the
sensors detect conditions indicative of kick, the rotary table 114
could be stopped, a surface BOP (not shown) activated, and then the
controller 140 could then transmit the signal to cause the safety
devices 167 to actuate. In short, due to the high speed
communication capabilities of e.g. wired pipe, the correct
sequencing of a kick related shut-down can be controlled from the
surface in real-time.
[0025] Such safety device can also be used in case of mud losses to
shut-in the annulus and prevent an underbalanced condition causing
borehole instability or a kick initiation.
[0026] FIG. 2 is a flow chart showing a method according to one
embodiment. At process 200 current drilling conditions are
monitored by sensors located on or near the BHA of a drill string.
The conditions can include, for example, the flow rate or
composition of the drilling mud and hydrostatic pressure of the
formation to name but a few. At process 202 the drilling conditions
are transmitted to the surface. At the surface, the drilling
conditions are provided to a control unit as indicated at process
204. It shall be understood that the control unit can be located at
the same location as or remote from the location where the drilling
is being conducted. That is, the control unit could be remote from
the drilling rig in one embodiment.
[0027] Regardless of where the control unit is located, at block
206 a determination is made that a downhole safety device located
along the drill string needs to be actuated. This determination can
be made either by an operator, fully automatically by the control
unit using an expert system approach, or combinations of operator
determined and automatic control. At process 208 at least one other
portion of the drilling system (e.g., the rotary table) is provided
a command to cause it vary its operation (e.g., stop). After
process 208 is completed, at process 210, an activation command is
sent to from the control unit to the downhole safety device. In
some instances, downhole conditions are further monitored to
determine is the activation command achieved the desired result or
if further safety devices need to be actuated or other actions
taken.
[0028] Elements of the embodiments have been introduced with either
the articles "a" or "an." The articles are intended to mean that
there are one or more of the elements. The terms "including" and
"having" are intended to be inclusive such that there may be
additional elements other than the elements listed. The conjunction
"or" when used with a list of at least two terms is intended to
mean any term or combination of terms. The terms "first," "second,"
and "third" are used to distinguish elements and are not used to
denote a particular order.
[0029] It will be recognized that the various components or
technologies may provide certain necessary or beneficial
functionality or features. Accordingly, these functions and
features as may be needed in support of the appended claims and
variations thereof, are recognized as being inherently included as
a part of the teachings herein and a part of the invention
disclosed.
[0030] While the invention has been described with reference to
exemplary embodiments, it will be understood 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 will be appreciated to adapt a particular
instrument, 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.
* * * * *