U.S. patent application number 13/969576 was filed with the patent office on 2014-03-06 for drilling tool, apparatus and method for underreaming and simultaneously monitoring and controlling wellbore diameter.
The applicant listed for this patent is Wajid Rasheed. Invention is credited to Wajid Rasheed.
Application Number | 20140060933 13/969576 |
Document ID | / |
Family ID | 39683278 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140060933 |
Kind Code |
A1 |
Rasheed; Wajid |
March 6, 2014 |
DRILLING TOOL, APPARATUS AND METHOD FOR UNDERREAMING AND
SIMULTANEOUSLY MONITORING AND CONTROLLING WELLBORE DIAMETER
Abstract
A dynamic position sensing Apparatus or Method is used to
underream an oil or natural gas well with a variable gauge
positioning system incorporating underreamer position or diameter
sensing means.
Inventors: |
Rasheed; Wajid; (Slough,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rasheed; Wajid |
Slough |
|
GB |
|
|
Family ID: |
39683278 |
Appl. No.: |
13/969576 |
Filed: |
August 18, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12966195 |
Dec 13, 2010 |
8511404 |
|
|
13969576 |
|
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Current U.S.
Class: |
175/50 |
Current CPC
Class: |
E21B 47/01 20130101;
E21B 47/08 20130101; E21B 47/00 20130101; E21B 10/322 20130101;
E21B 7/28 20130101; E21B 47/095 20200501; E21B 49/00 20130101; E21B
47/12 20130101; A01N 43/40 20130101; E21B 10/32 20130101; E21B
33/124 20130101; E21B 44/00 20130101; E21B 47/09 20130101; B26B
21/54 20130101; E21B 43/26 20130101; E21B 47/085 20200501; A01N
43/40 20130101; A01N 37/20 20130101; A01N 37/22 20130101; A01N
37/26 20130101; A01N 43/10 20130101; A01N 43/12 20130101; A01N
43/20 20130101; A01N 43/78 20130101; A01N 43/80 20130101; A01N
43/82 20130101; A01N 47/12 20130101; A01N 47/16 20130101; A01N
47/38 20130101; A01N 57/14 20130101; A01N 2300/00 20130101 |
Class at
Publication: |
175/50 |
International
Class: |
E21B 47/08 20060101
E21B047/08 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 27, 2008 |
GB |
0811815.0 |
Jun 27, 2009 |
ES |
PCT/ES2009/070261 |
Claims
1. An apparatus for closed loop underreaming to provide a wellbore
of a predetermined diameter, sensing a position of extendable
blocks using a dynamic position sensor, sensing a property from one
of a group comprising flow, rotation, weight, sound transit time,
density, pressure, and hydraulic force using a properties sensor,
performing the step of comparing block positional data to property
data and using said properties data to check underreaming and
delivery of the predetermined wellbore diameter.
2. An apparatus for oil and gas drilling comprising a variable
gauge reamer with at least one radially extendable block, at least
one dynamic position sensor wherein said sensor indicates a
position of radially extendable cutter block positions selected at
surface.
3. Apparatus of claim 2 further comprising at least one calliper to
determine wellbore diameter.
4. Apparatus of claim 3 further comprising a processor interlinked
to receive positional data and wellbore data and one of the group
from: vibration, rpm, torque, pressure, weight, flow, hydraulic
force.
5. Apparatus of claim 4 further comprising wherein the processor
controls the position of the block according to either calliper
data, vibration data, rpm, torque, pressure, weight, flow,
hydraulic force.
6. The apparatus of claim 2 wherein the detected position is sensed
by analogue, digital, electrical or mechanical means.
7. The apparatus of claim 2 wherein the detected position is based
on a direct or inferred measurement.
8. The apparatus of claim 1 wherein position data is based on
direct or inferred signaling means.
9. The apparatus of claim 1 wherein said cutter block positions are
locatable within at least three known positions.
10. The apparatus of claim 1 wherein sensing or signaling means
indicate the radial position of the cutter block.
11. The apparatus of claim 2 wherein sensing or signaling means
indicate the radial position of the cutter block.
12. The apparatus of claim 1 wherein sensing or signaling means
indicate the diameter of the cutter block relative to the tool.
13. The apparatus of claim 2 wherein sensing or signaling means
indicate the diameter of the cutter block relative to the tool.
14. The apparatus of claim 2 wherein said dynamic sensing detects
reamer diameters
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-and-part of U.S. Ser. No.
12,966,195 granted U.S. Pat. No. 8,511,404 which claims priority
from U.S. Ser. No. 12,966,195 based on WO 156552A1 PCT 2009 and
GB0811815.0 (27.06.2008) granted GB 2460096.
[0002] This application is a continuation-and-part of copending
U.S. patent application Ser. No. 12,966,195 filed Dec. 13, 2010,
and entitled "DRILLING TOOL, APPARATUS AND METHOD FOR UNDERREAMING
AND SIMULTANEOUSLY MONITORING AND CONTROLLING WELLBORE DIAMETER",
which is a continuation-and-part of International Application
number PCT/ES09/70261, filed Jun. 27, 2009 and entitled "DRILLING
TOOL AND METHOD FOR WIDENING AND SIMULTANEOUSLY MONITORING THE
DIAMETER OF WELLS AND THE PROPERTIES OF THE FLUID", and claims
priority to and the benefit of GB 0811815.0, filed Jun. 27, 2008
and entitled "Expansion and Calliper Tool", the entireties of which
applications are hereby incorporated by reference as if fully set
forth herein.
FIELD OF THE INVENTION
[0003] This invention relates to a dynamic sensing underreamer
capable of detecting reamer diameters or positions and the terms
reamer or underreamer are used to designate an expandable tool. In
one embodiment this invention relates to a tool, apparatus and
method capable of enlarging and dynamically sensing positions or
diameters of expandable tools, especially, expandable reamers for
use in wellbores in the oil and gas industry. The expandable blocks
of the tool can be configured with cutting or stabilising elements
locatable in a plurality of known positions that form a variable
gauge expansion tool. Dynamic position sensing means provide data
on the reamer status or diameter and position sensing may be via
analogue or digital means.
[0004] Alternatively or additionally further embodiments of the
invention allow for acoustic sensors or mechanical gauge probes to
measure the underreamed wellbore diameter. Further measurements
where required can be obtained such as formation properties,
vibration, rpm, rotation, flow, hydraulic force, pressure, torque,
temperature.
[0005] Additionally or alternatively pressure or flow indicators
based on the location of the block or the location of a detector
may also be used to sense or indicate or infer or signal the
position of the blocks. Variations in sensors or signals may be
electrical, mechanical or a combination of both. It is not
essential that physical sensors measure the distance in such an
embodiment because the radially extended positions or underreamer
diameters may be sensed by indicative means. Such types of
embodiments may be considered modular as they can be configured in
separate modules or housings yet sharing common features.
[0006] It is to be understood that the term `expansion` as used
herein refers to the capacity of the tool to expand outwardly and
against the interior wall of a passage, such as a borehole,
especially a wellbore, or a tubular used as a casing, and then to
apply pressure or a cutting action against the wall. It is not
always essential that the wall itself be expanded, since the tool
can be used for centralisation or stabilisation or like purposes
without necessarily expanding the passage.
[0007] When constructing an exploration or production well,
numerous downhole operations are conducted to drill and measure the
borehole so that it meets the desired dimensions specified in the
well-plan.
[0008] An underreamer (which covers all manner of reamers,
expandable reamers, extendable reamers and the like) is used to
enlarge the diameter of the borehole beyond its original drilled
size. Enlargement (underreaming or reaming using
expandable/extendable tools) is typically done below a restriction
in the borehole, and the cutting diameter of an underreamer is
always greater than that of the pass-through diameter of the
restriction. Additionally, an underreamer is provided with
activation and deactivation modes and mechanisms for extending and
retracting cutting elements to ensure effective underreaming once
it has passed below the restriction.
[0009] The time-lag associated with the separated operations of
underreaming and measurement leads to uncertainty and unnecessary
cost.
BACKGROUND OF THE INVENTION
[0010] Oil and gas accumulations are found at depth in different
geological basins worldwide. Exploration and production of such
accumulations rely on the construction of a well according to a
well plan.
[0011] Various well types exist and are defined according to usage
such as wildcats or those used in exploration, delineation, and
production and injection. Variations in well profile exist also
according to vertical, slant, directional and horizontal
trajectories. Each well differs according to the oil company's
objectives and the challenges that a given basin presents from the
surface of the earth or the ocean to reaching the hydrocarbon
reservoir at a given underground depth.
[0012] Engineering challenges are related to the location of the
well-site such as onshore or offshore, seawater depths, formation
pressures and temperature gradients, formation stresses and
movements and reservoir types such as carbonate or sandstone. To
overcome these challenges, a highly detailed well plan is developed
which contains the well objective, coordinates, legal, geological,
technical and well engineering data and calculations.
[0013] The data is used to plot the well profile, and plan its
execution using precise bearings, which is designed in consecutive
telescopic sections--surface, intermediate and reservoir. To
deliver the well objective and maintain the integrity and operating
capacity of the well over its lifecycle, a given wellbore with
multiple sections and diameters is drilled from surface. Although
there are many variants, a simple vertical well design could
include the following dimensions: a surface or top-hole diameter of
171/2'' (445 mm), intermediate sections of 135/8'' (360 mm) and
95/8'' (245 mm) narrowing down to a bottom-hole diameter of 81/2''
(216 mm) in the reservoir section.
[0014] Each consecutive section is `cased` with a number of metal
tubes placed into the wellbore with the specified diameter
according to the length of the section. Casing tubes are connected
to each other after which they are cemented into the outer wall of
the well. In this way, a well is constructed in staged sections,
each section dependent on the completion of the previous section
until the well is isolated from the formation in question along the
entire distance from surface to the reservoir.
[0015] Scarcity of oil and gas is driving oil and gas companies to
explore and develop reserves in more challenging basins such as
those in water-depths exceeding 6,000 ft (1800m) or below massive
salt sections. These wells have highly complex directional
trajectories with casing designs including 6 or more well sections.
Known in the art as `designer` or `close tolerance casing` wells,
these wells have narrow casing diameters with tight tolerances and
have created a need to enlarge the wellbore to avoid very narrow
reservoir sections and low production rates.
[0016] Therefore, the bottom-hole assemblies that are needed to
drill these wells routinely include devices to underream the
well-bore below a given casing diameter or other restriction. In
this way, underreaming has become an integral part of well
construction and there is now an increased dependence on
underreaming to meet planned wellbore diameters.
SUMMARY OF THE INVENTION
[0017] The present invention has for a principal object to provide
an improvement on the prior art in wellbore underreaming and
wellbore measurement wherein the actual position of the underreamer
is sensed or indicated.
[0018] Measurement may involve the acquisition and communication to
surface of various types of wellbore data such as azimuth,
inclination and borehole diameter or rugosity, formation types,
dips or bedding angles.
[0019] The present invention seeks to provide certainty of
operation of underreaming and eliminates the need for separate
corrective underreaming runs by providing real-time data which
allows the driller to respond earlier thereby saving time and money
on wellbore operations.
[0020] It is thus an object of the present invention to provide
reaming expansion blocks integrated with position sensing which can
be used to assess the functioning and diameter of the
wellbore-widening operation and, if the position and diameter is
found insufficient or undergauge, to automatically detect and
diagnose the potential faults, and to repeat underreaming until a
satisfactory result is achieved. It is a further embodiment of the
invention that provides the measurement of wellbore diameter as
well as other measurements such as formation characteristics.
[0021] Although underreaming is the principal route to wellbore
diameter enlargement, the invention may be applied to enlargement
means integrated with bicentre bits, fixed wing bits, eccentric
underreamers and expandable bits.
[0022] The tool is principally enabled to detect reamer positions
or reamer diameters. In a separate and further embodiment the tool
can conduct diagnostics according to a logic circuit. In this way,
the user can achieve a planned or desired underreamer activation or
deactivation and at any given time check that the underreamer is
functioning correctly. This reduces downtime and uncertainty.
[0023] In such an embodiment of the invention the tool may be
linked to a micro-processor. Additionally or alternatively the tool
may be further linked to a MWD/LWD. Such types of embodiments may
be considered modular as they can be configured in separate modules
or housings yet sharing common features.
[0024] In this way, different types of modular solutions may be
provided according to the need of the wellbore underreaming
operation. For example, an underreamer with positional sensing
only, an underreamer with positional sensing and other measurements
such as calliper or vibration or underreamer with calliper only.
These solutions can be configured to provide increasing levels of
problem solving according to the application. For example if a
problem occurs and if the corrective steps have been taken and the
underreamer position sensing indicates an undergauge position then
this may solve the problem in certain applications such as swelling
shales or radial shrinkage. For other applications, such as
requiring tight tolerances, a further caliper measurement may
indicate that the desired hole diameter is still not being
delivered a signal may be sent to the rig-surface or to the
location of the operating engineer so that further remedial action
can be taken, according to a logic circuit. This may include
extending cutter blocks in response to caliper data, checking block
positions or any number of logic steps. A memory card may store
sensor information that can be downloaded at surface when the tool
is retrieved, or sent to the surface by telemetry. In this way, the
invention is entirely flexible and configured according to the
application.
[0025] The invention can be configured with a modular processor
which can be linked to a MWD pulser and capable of receiving data
such as azimuth, inclination and borehole diameter or rugosity,
formation dips or bedding angles.
[0026] The tool may also have a built-in link to a mud-pulse
telemetry system to allow real-time monitoring of the under-reaming
operation (cutter-block position, caliper measurements, fluid
properties, pressure, rotation, torque, etc).
[0027] In the underreamer and positional sensor module there may or
may not be a keyway to provide a channel for wiring to and from the
sensors to a processor and MWD when such components are configured.
The wiring can be used to transmit other data retrieved by other
sensors, as well as positional data from the mechanical blocks, to
the processor. The processor can process this data and sends it to
the transponder to be sent to the control system at the surface.
The keyway may be sealed and filled with a means to absorb
vibration such as silicone gel or grease and to maintain wires in
position.
[0028] In the embodiment of the underreamer with positional sensors
the tool itself may communicate to surface by wired or wireless
means. Additionally or alternatively the processor can transmit
data to the surface by means of a mud-pulser which uses a series of
binary codes at a given frequency using drilling fluid as means of
transmission. Other means of wireless transmission can be used,
using radio frequency or electro-magnetic pulses. This allows up
and downlink of the tool in order to receive and transmit data and
commands. The data may be transmitted to the surface for use by the
drilling operator or may be further transmitted by satellite to a
remote operations centre.
[0029] One embodiment of the invention provides for a wellbore
underreaming tool or apparatus, which is particularly applicable in
oil and natural gas wells, arranged for attachment to a rotary
drill-bit and associated drill-pipe, which comprises at least one
radially extendable cutter block (62), at least one positional
sensor (76 or 64-66) to determine the wellbore diameter, to verify
and control a desired underreamer diameter (22).
[0030] The positional sensor may be dynamic and the tool support
may be the drill string but it may also be a length of coiled
tubing.
[0031] The tool body is a cylindrical high grade steel housing
adapted to form part of the bottom-hole assembly by means of a
screw connection arranged at the end of the tool, which is coupled
to the drill bit. The attachment need not be direct, but may be
indirect, depending on the requirements of the different elements
of each drill string and each well. The lower end of the BHA may be
a drill bit, or a bull nose and/or an expandable bit and various
components between the tool there may or may not be a means for
directional control of the wellbore such as a rotary steerable
system.
[0032] In one embodiment of the invention, the expansion operation
is an underreaming application, and expansion elements comprise a
set of cutter blocks optimally configured with cutter inserts and
nozzles. In another embodiment, the expansion elements may comprise
expansion blocks, which may be of similar construction to the
cutter blocks, but having outer surfaces where cutter elements may
be replaced by a hardened material. Such expansion blocks may
simply bear under pressure against the inside of a tubular wall,
with sufficient force to deform it outwardly to a larger diameter.
In yet another embodiment, the same blocks may simply bear against
the underreamed wellbore in order to stabilize the tool within the
wellbore without enlarging the bore. The same blocks maybe received
within an additional section of the tool or a separate steel body
suitably prepared to provide a means of stabilization to the
expansion operation. In a further embodiment, the same blocks maybe
received within an additional section of the tool or a separate
steel body suitably prepared as apparatus to provide a means of
stabilization for underreaming applications.
[0033] In one embodiment where the wellbore expansion activity is
underreaming the cutter blocks are situated within the tool body in
an open chamber, the outer surface of which is composed of a
plurality of high strength cutter elements such as
polydiamondcrystalline inserts arranged externally. The cutter
block is provided with a flow of drilling fluid via an external
nozzle adjacent to the set of cutters which allows drilling fluid
to flow from an internal bore connected to a source of said
drilling fluid.
[0034] In another embodiment, the tool comprises a module that can
be coupled by means of a thread connection to the body of the tool
which comprises expandable stabilizing blocks in order to stabilize
the tool against the wellbore walls during underreaming and
measurement and if so required, increase or expand the diameter of
the metallic tube casing of the well.
[0035] It is to be noted that the description herein of the
expansion blocks is applicable generally, irrespective of the
function of cutting, expansion or stabilization of the drill
string. Thus, the cutter blocks are provided with cutting inserts
or teeth to enable underreaming of the wellbore that may be
replaced by hardened smooth surfaces for expansion operations of an
expandable steel tubular inside the wellbore.
[0036] In yet another embodiment the microprocessor control means
(68) are adapted to receive, during drilling operations,
information from the positional sensors of the extendable cutter
block in order to control the extension and retraction of said
block in order to detect and correct failures in real-time and
achieve the desired wellbore diameter.
[0037] The tool normally comprises a plurality of such cutter
blocks, arranged symmetrically around the tool. Two cutter blocks
would be on opposite sides of the tool, three blocks would be
separated by 120 degrees, four blocks by ninety degrees, and six by
sixty degrees. Or the blocks may simply be housed in separate
housings allowing for a plurality of cutter blocks. In operation,
the tool is typically rotated together with the drill string as
well as being moved axially along the wellbore.
[0038] The tool body is provided with an internal bore for
receiving drilling fluid via a device nozzle adjacent the cutter.
In each case, the nozzles provide a fluid flow that help to keep
the cutters clean and prevent the build-up of clogging debris from
the underreaming operation and provide a cooling and lubricating
function for the cutters. In one embodiment of the present
invention the tool incorporates a non-mechanical means of reamer
position measurement or reamer diameters such as a pressure
measurement. Suitable means for pressure measurements are pulse
heads or flow restrictors such as castellations, turbines or valve
plates which can reciprocate or rotate or vibrate to create a
dynamic pressure signal or a plurality of pressure signals. The
pulse head or flow restrictor may be connected to a mandrel or
travelling lock or sleeve thereby the displacement related to the
movement of the extendable blocks outward. Other restrictors may be
graduated and allow for reduced turbulent flow with less chance of
erosion. In either case treatments such as tungsten carbide, HVOF
etc may be applied.
[0039] In yet another embodiment a bending moment sensor may detect
bending moments on the tool allowing for activation forces to be
optimized by increasing or decreasing activation forces. The
bending moment sensor may show that further activation force is
required or lower force or that parameters should be changed such
as the angle, rop, WOB, FLOW, directional control system blades.
Optimal configurations of the invention are envisaged based on
application needs.
[0040] A pulse head may travel through a number of rings and thus
create a number of pulses related to position. For example, 1 pulse
may be deactivated, 2 pulses 1 inch extended, 3 pulses 2 inches
extended and so on. Additionally or alternatively the reverse is
also possible as is a further embodiment wherein the duration of
the pulse may indicate positional data. For example, a long pulse
indicates activation while a short pulse is deactivated or the
alternate is possible. Further pulse encoding may be planned
dependent on the type of frequency and duration and other pulsers
that may be in the hole as is the case when directional or LWD/MWD
companies are providing such measurements.
[0041] The positional sensing means are generally located in the
tool or cutter block or mandrel in a chamber but in an alternative
configuration of the tool may be placed within the cutter block
itself in the most radially extended zone among the cutting
elements or linked to a nozzle opening to the wellbore. Other
embodiments are for example, a pressure sensor may detect chamber
pressure. Additionally or alternatively the sensing means may be
located below a sealed area or within a seal area.
[0042] In one embodiment, the invention provides for a method of
operating an expansion tool or apparatus to underream a borehole to
a desired dimension below a restriction, which comprises locating
said tool or apparatus in said borehole on drill-pipe below a
restriction, extending a set of cutter blocks to an expansion
diameter greater than the restriction, rotating the tool and moving
it axially along the borehole on the drill string or other support,
sensing the block position by detection means and continuing
underreaming until the desired dimension is achieved.
[0043] In accordance with yet another method of the invention, the
tool may be provided with expandable cutter control means
responsive to dimension data received from positional sensors or
caliper means. In this way, an integrated tool and apparatus which
is capable of diagnosing under-performance and correcting it may be
realized. The dimension data may prompt for tests and checks on the
effective deployment of the expandable blocks, may trigger a
repeated cycle of expansion, or activate a further set of cutters
and may provide data to a surface monitor to signal an opportunity
for operator intervention.
[0044] The processor uses this data to correlate whether the
pre-programmed wellbore diameter is actually being underreamed via
block position sensing. Where the processor detects a fault or
difference between the two minimum measurements it automatically
troubleshoots the fault using a logical procedure.
[0045] The skilled operator will readily appreciate that other
procedures may be implemented by the logic circuit or control
program within the tool's processors, which can be programmed to
cover other scenarios.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] The various embodiments of the invention are illustrated by
way of non-limiting examples in the accompanying drawings, in
which:
[0047] FIG. 1 is a general diagrammatic view of an oil or gas well
showing surface structures and the interior of the underground
wellbore, with a tool in accordance with the invention as part of
the final bottomhole assembly;
[0048] FIG. 2 is a longitudinal section of the tool and apparatus
according to one embodiment showing the expansion elements
constituted by cutter blocks; FIGS. 2a and 2b show the tool of FIG.
2 activated and deactivated respectively and further configured
with a calliper and mud pulser.
[0049] FIG. 2A and FIG. 2B respectively show configuration with
calliper (58) and cutters (62) activated and deactivated.
[0050] FIG. 3 is a cross section of the tool as seen from the drill
bit, showing the diameters of the drill bit, of the pass-through
casing and of the desired underreaming of the wellbore in
accordance with the invention shown in the previous Figures, in the
operative mode of the expanded expansion cutter blocks (activated
operating mode);
[0051] FIG. 4 shows a cross-section of the tool as seen from the
drill bit, showing the diameters of the drill bit, of the casing
and of the desired underreaming of the wellbore, according to the
invention shown in earlier figures in the operative mode of the
retracted expansion cutter blocks (deactivated operating mode);
[0052] FIG. 5 is a general view of the well illustrating telemetry
of the underreaming and drilling data recorded by the tool or
apparatus;
[0053] FIG. 6 corresponds to FIG. 5 but illustrates downlink
telemetry of the data with parameters sent in order to control the
underreaming and drilling by the tool or apparatus; and
[0054] FIG. 7 shows an embodiment of an expansion block configured
with cutters;
[0055] FIG. 8 is a view corresponding to FIG. 7 showing an
alternative construction with external nozzle;
[0056] FIG. 9 is a longitudinal section of one embodiment of the
tool or apparatus showing the expansion elements constituted by a
set of cutter blocks and a further set of cutter blocks in a
deactivated state. Equally the first or second set may be
replaceable with an expandable bit.
[0057] FIG. 10 is longitudinal section of an expandable stabilizer
with a dynamic positional detector means contained therein and with
cutter blocks in a further module.
[0058] FIG. 11 shows a longitudinal section showing two locations
for positional detector means above and below a mud pulser
[0059] FIGS. 12 and 13 show a detail of a dynamic position detector
with and without a pulse head of one embodiment of the tool or
apparatus showing the expansion elements constituted by a set of
cutter blocks and a further expandable bit replacing the second set
of cutter blocks.
[0060] FIGS. 14 and 15 detail a preferred embodiment with two
locations for dynamic position detection contained within and
partly without respectively of expandable cutter assembly.
[0061] FIGS. 16, 17 show different configurations of a dynamic
pulse head for position detection with a spring and
compression/expansion chamber.
[0062] FIG. 18 shows where the pulse head is connected to a mandrel
which moves up or down the housing.
[0063] FIG. 19 shows an embodiment wherein the blocks are connected
to a single chamber
[0064] FIG. 20 shows an embodiment where the dynamic position
detector is placed in a fluid pathway to the annular.
[0065] FIG. 21 shows yet another embodiment leading drilling fluid
from a through passage (90) to an oscillating pulser.
DETAILED DESCRIPTION OF THE INVENTION
[0066] As shown in FIG. 1, an exploration or production rig
comprises a surface structure (10) at the wellhead, a wellbore
(20), a drill string (30) in the wellbore and a bottom-hole
assembly (40) at its lower end where the tool or apparatus (50) may
be configured according to the present invention.
[0067] The tool or apparatus (50) comprises at least one
underreamer module integrated with a sensing means for reamer
position detection or reamer diameter signal, and capable of
connection to a drill-bit.
[0068] Further embodiments can be configured as desired adding or
removing modules: module housing the expandable cutter blocks and
positional sensors, module housing the positional sensors,
callipers, sensors and processors and the module with expandable
stabilizer blocks or expandable blocks to expand a tubular within
the wellbore.
[0069] The signal or position is detected according to the position
so that for a 121/4''-143/4'' tool it could be configurable and
extended to a plurality of radial positions between 121/4'' and
143/4''. Generally such reamer positions are dependent on the pass
through ID of casing and are expressed as increase in diameter
relative to the bit size or reamer body size. Accordingly such
expressions are generally in the order of 1'', 1.25'', 1.375'',
1.5'', 1.875'', 2.5'', 2.75'', 3'', 3.5'', 3.875'' and 4'' and so
on. Other sizes are in the order of 0.5'', 0.75'' and so on.
[0070] Alternatively or additionally the reamer body size or pass
through dimension can be used to denote the expandable ratio or
configured expandable reamer positions. Generally denoted in a such
a manner these would be expressed in the order of 12.25''-14.75'',
14.75''-17'', 16.5''-19.5'', 18.125''-21'', 18.125''.times.22'',
16.5''.times.20'', 14.5''.times.16.5'', 12.25''.times.14.75'',
10.625''.times.12.25'', 8.5''-9.875'', 9.25'' to 10'', 11.25'' to
12.25'', and so on.
[0071] The longitudinal section of the tool illustrated in FIG. 2
comprises a steel tool body with connection (82) provided with an
internal flowbore and if required a wellbore diameter measurement
caliper (76 or 64-66) with the cutter blocks (62). The expandable
cutter (60) is composed of various cutter blocks (62) placed
symmetrically and radially outwards of the tool body (52) as shown
in FIG. 2 in the activated status with the blocks extended outside
the tool.
[0072] In one embodiment the tool may incorporate an acoustic
caliper comprising an acoustic transmitter and receiver which can
be housed within the body of the tool in sealed recesses (64 and 66
or 76). Tool performance is verified using the micro-processor (68)
that compares data recorded by the acoustic receiver (66 or 76)
with the programmed wellbore diameter, thus detecting possible
undergauge hole diameters. The tool is automated according to logic
control sequences stored in each processor (68) to deliver a
desired wellbore diameter and in order to ensure the underreamer is
functioning correctly. Once verification and corrective steps have
been taken, and if the caliper for measuring the underreamed
wellbore diameter (66 or 76) indicates that the required hole
diameter is still not being delivered, a signal is sent via the
mud-pulser (56) to the rig-surface (10) to allow control commands
to be sent by the operator either locally or by remote control.
These control commands adopt the relevant operative and corrective
measures such as modification of the pump flow rate of mud or
drilling fluid, activation of cutter blocks in response to caliper
data, replacement of the bottom-hole assembly etc. The memory card
associated with the processor (68) stores data from the calipers,
fluid properties measurement sensors. The said data is transmitted
in real time in order to be used in the underreaming and drilling
operations (56) or physically downloaded by removing said card when
the tool is retrieved from the well.
[0073] FIGS. 2a and 2b activated and deactivated respectively show
how the tool is provided with a built-in link to the telemetry
system (56) which also serves to monitor performance of the
under-reaming operation, position of expansion blocks (62) and data
recorded by the caliper for measuring the underreamed wellbore
diameter (66 or 76). One or more acoustic sensors (64 or 76) are
placed within the tool body (52) in order to emit a number of sound
waves during a given time period which are reflected back by the
wellbore wall and picked up by the receiver sensors (66 or 76). In
a further embodiment the processor (68) calculates the distance
using transit time and calibrates transit time with data from
further fluid properties sensors to establish the speed of return
of the acoustic waves and wellbore diameter. The processor compares
the measured wellbore diameter to the programmed desired diameter.
If the two measurements match given user-defined tolerances the
tool continues to operate to the total depth of the wellbore
section to be underreamed. Where the measurements do not match the
processor automatically activates a series of logic steps to
troubleshoot the fault.
[0074] As further shown in FIG. 2, a keyway (78) provides a channel
for wiring of the acoustic pulsers or transmitters (64 or 76) and
the acoustic sensor/receivers (66 or 76) to the processor (68), and
also to the transponder (72). The wiring can be used to transmit as
much or as little data required by the configuration of the tool.
For example, this may include acoustic data retrieved by wellbore
calipers and fluid properties sensors as well as positional data
from the cutter and stabilizer blocks to the processors and
transponders. The keyway may be sealed and filled with a means to
absorb vibration such as silicone gel.
[0075] FIG. 2 shows a processor (68) which provides data for
transmission to surface (10) via the mud-pulser (56) FIGS. 2a and
2b which transmits the data to surface using a series of binary
codes at a given frequency using the drilling mud itself as means
of transmission. Other means of wireless data transfer may be used
such as systems using radio frequency or electro-magnetic
pulses.
[0076] FIG. 2 also shows an alternative location for the caliper
for measuring the underreamed diameter which may be a caliper (76)
arranged in an encapsulated recess connected to wiring in keyway
(74) connected to the processor which may also be connected to the
acoustic (transmitter/receiver) calipers (66-64) and a new keyway
connection (78) which may be connected to an alternate processor
(68) for the expandable block (62 or 63). FIG. 1 also shows an
internal flow bore or axial through passage (90) in the tool to
allow mud to flow through the whole bottom-hole assembly (40). The
encapsulated recesses (64, 66 and 76) may also be used to house
other types of sensors such as a vibration sensor to detect
stick-slip conditions.
[0077] FIG. 3 shows an uphole front view of the bit illustrating
the generally designated expandable cutters (60) in the activated
mode, i.e. with cutter blocks (62) expanded outwardly of the tool
body and supported against the underreamed wellbore wall (22) which
arises from the wellbore (20) which has not been underreamed. FIG.
3 shows the arrangement of the drill bit teeth in which there are
ten curved rows of cutters (44), with cutter teeth in each one. A
central drilling fluid outlet (46) indicates where drilling fluid
passes through the internal flowbore (90) in the tool body (52).
The direction of rotation of the bottom-hole assembly and of the
drill bit is shown (124).
[0078] FIG. 4 illustrates the same front view as FIG. 3 with the
expandable cutters (60) in a deactivated condition, i.e. with
cutter blocks (62) retracted within the inner chambers of the tool
body without exceeding the wellbore diameter that has not been
underreamed (20).
[0079] In a further embodiment of the invention, each expandable
block is provided with lines, strips, contacts or sensors to detect
the actual position of the blocks. The signal is measured according
to the position so that for a 123/4''-143/4'' tool it could be
extended to a plurality of radial positions between 123/4'' and
143/4''. Each radial position is capable of being determined and
sensed. In this way, it can be seen whether the block has actually
been extended and determine its extension length and position. This
block positional data is sent to the processor where it is stored,
compared and correlated with the caliper data or data from
vibration, rpm, pressure, hydraulic force, torque, flow sensors to
deliver a desired wellbore diameter and also troubleshoot causes of
failures. It is not necessary for the block positional sensor to be
on the block. In an alternate embodiment the sensor may be on the
housing. In yet a further embodiment the sensor may be on another
tool or may be at surface applicable as the purpose is to establish
the relative position of the block to the tool. Additionally or
alternatively, pressure or flow may be used to lock the radial
position and equally pressure or flow signals may be used to sense
or indicate the block position. Additionally or alternatively it is
not always necessary that a sensor physically measures each radial
position as the groove location serves the same purpose.
[0080] As noted above, the invention provides a method of real-time
drilling operation and control, which uses an extendable tool to
underream the borehole to the desired dimension passing through a
restriction, activating the tool, extending the extendable cutter
block to a diameter greater than that of the restriction, and
locating the extendable block in a predetermined position, rotating
the tool and moving it axially along the borehole, enabling the
simultaneous measurement and calibration of the borehole diameter
by the caliper for measuring the underreamed wellbore diameter.
Microprocessors connected to a control area act in response to data
received from the caliper for measuring the underreamed wellbore
diameter, the fluid properties or the parameters such as pressure,
torque, flow with the objective of achieving the desired wellbore
diameter and eliminate causes of errors or failures and minimizing
drilling time by not tripping in with another caliper or performing
further underreaming corrective runs.
[0081] FIGS. 5 and 6 illustrate how the underreaming tool may
utilize means for communicating data from the tool such as dynamic
positions, calliper for measuring the underreamed wellbore
diameter, the calibration fluid properties sensors, the block
positional sensors or the vibration sensors and control signals
between the tool and a surface interface which may, among other
functions, control the advance and trajectory of drilling during
the underreaming operation.
[0082] As shown in FIGS. 5 and 6, the wellhead surface structure
(10) includes a control and communications system (12) having an
interface for telemetry with downhole instrumentation including a
data processor or data logger (14) and a controller (15) which
decodes binary codes from the mud pulser and may be linked directly
to the user's drilling terminal (16). The decoded data may be yet
further transmitted by satellite (17) beyond the wellhead to a
remote operations centre (18) where another user of the drilling
software may access the data and the control by means of a
telecommunication link (19).
[0083] The tool may be provided with a mud pulser as a standalone
tool or the mud pulser and associated measurements may be provided
by a third party as would be the case when a measurement while
drilling or logging while drilling suite of tools is located in the
BHA. The hard wiring and processor may be configured to make use of
these measurements or they be sent to surface where a user may make
further use of them.
[0084] The apparatus may be directly or indirectly connected to
other components in the drilling or bottom hole assembly.
[0085] FIGS. 7 and 8 show variations in block and according to
these embodiments of the invention, each block is provided with
lines, strips, contacts or sensors that permit the processor to
detect the actual position of the blocks. The signals can be
configured so that they are strongest when the block is fully
extended or strongest when the block is fully retracted or a signal
may simply correspond to a radial position. In this way, it can be
seen whether the block has actually been extended and determine its
extension length and position. This data is sent to the processor
where it is stored and processed.
[0086] Additionally or alternatively to digital or electronic
sensing the positional signal may be generated via analogue
mechanisms. Therefore, sensing means can be any suitable type of
sensor or detector or indicator such as contacts, electrical
sensors, strips, resistive wipers, rheostats, circuit breakers,
proximity sensors, distance sensors, volumetric sensors, volumetric
measurements, valves, induction loops, spirals, coils, wireless and
wired. Others maybe grooves, lines, piston valves, channels,
strips, mechanical, pressure or force related. Further a
combination of both mechanical and electrical sensing mechanisms
can be used to detect the position of the block.
[0087] The sensing means may also serve a number of functions so a
strip may also form part of a seal or serve as a seal so isolating
the block or housing from pressure. Or a pressure sensor may be
used to detect the position of the cutter block. Further the signal
may be defined as a direct or inferred or indicative position. The
signal or a lack of a signal may also be provided to show a status
such as a series of pressure signals according to a series of
variable cutter positions.
[0088] The positional data plus the vibration data provides novel
data which determines vibration as per the underreamer status i.e.
activated/deactivated or in an intermediate or variable gauge
position.
[0089] The underreamer status is generally performed by a position
sensing means which can be a position sensor. Additionally or
alternatively such sensors can be on the block or housing (96, 94)
to determine the actual position of blocks (63,62) and send
corresponding signals back to the surface or processor (68).
Suitable sensor means include any type of known of sensor or
detector for position, respectively on the cutter block and housing
or alternately on solely located on the cutter block or the housing
itself. Additionally or alternatively the block sensing means may
be on another tool or located at surface. Additionally or
alternatively pressure or flow indicators based on the location of
the block in the predetermined groove or location may also be used
to sense or detect or indicate or infer the position of the blocks.
Variations in sensors or signals may be electrical, mechanical or a
combination of both. It is not essential that physical sensors
measure the distance in this embodiment because the radial
positions may be pre-determined by grooves and unlike the prior art
which is only extended or retracted in the present invention there
may be a plurality of known positions according to grooves. The
term groove is used broadly and generally but serves to describe a
locatable position for the cutter block. Other terms may be
channels, positions, locators etc. The importance of the locatable
position is to provide a variable gauge underreamer capable of
being positioned in at least three positions such as open, closed
and intermediate. Additionally or alternatively a further
embodiment would be activated or extended, retracted or deactivated
and an intermediate position in between the former two.
[0090] In another embodiment the block position sensing is not
performed on the block or housing but can be performed on another
tool or performed at surface.
[0091] As shown in FIG. 9 the illustrated example is of an
embodiment of the tool sharing common features which is at least
two sets of expandable blocks and an underreamer that uses a
microprocessor (68) and electronic means to determine and control
block position.
[0092] In one embodiment the position sensing function is performed
by a sensor on the block or housing. The position of the
underreamer is designated by sensing means in a general and broad
way and can clearly use any type of position detectors, position
indicators, position signals, position measurements. Such position
sensing means can be analogue or digital, inferred, observed, or
direct with the importance being a comparative data set relating to
the underreamer status. Therefore, it is not essential that the
position sensing means is contained within the underreamer as it
may be contained within other downhole tools and additionally or
alternatively at the surface.
[0093] The tool or apparatus may be configured with any number of
modules integrated by means of screw connections (65) and (82). The
body of all parts of the tool or apparatus (52) is a cylindrical
high grade steel housing adapted to form part of the bottom-hole
assembly (BHA) (40) via internal screw connections to ensure the
through flow of drilling fluid (90). The connection may be direct
or indirect depending on the needs of the different drilling
components of each BHA and each well. At the leading downhole end
of the BHA there may be a drill-bit or a stabilizer and between
this point and the tool there may be a wellbore directional control
system.
[0094] As shown in FIG. 10, dynamic position sensor means
comprising a pulse head (950) and a spring (960) provide for
pressure signals detected at surface or downhole. FIG. 10 also
shows the stabilizing blocks (63) are constructed identically to
the cutter blocks (62), except that in place of cutter elements
(60) there is a surface which is hard faced (61) or coated with a
hard abrasion-resistant material.
[0095] The hard faced surfaces of the stabilizer expansion blocks
act to stabilize the drill string and eliminate some of the
problems associated with the loss of directional control above the
underreamer when the diameter in said zone is equal to that of the
underreamer or greater than the pilot hole. Likewise, the tool can
be used to expand or enlarge the diameter of metal tubes by
deformation of the latter in the wellbore. In this case, the tool
body facilitates the operation of expanding or enlarging the
diameter of the expandable casing and is connected to the downhole
assembly by means of a screw connection in said body.
[0096] The stabilizer module may be directly or indirectly
connected to the underreamer and hard-wired accordingly (74a) to
send data from the processor (68) to the transponder (72) through
the mud-pulser (56) to surface.
[0097] It is to be noted that the following description of the
cutter means is equally applicable to the structure and function of
the stabilizer and expansion means in the uphole section (61) of
the tool, with due allowance for the absence of cutter elements
(92).
[0098] A set of cutters comprises at least one cutter block (62)
carrying a plurality of cutter elements (92) directed outwardly of
the tool body (52). The cutter block is received within the tool
body in a cutter block chamber (94) having an open mouth, and the
cutter is extendable from the chamber through the chamber mouth
with the cutter elements projecting from the tool body, and
retractable back into the chamber. A seal (104) is provided around
the cutter block at the mouth of the receiving chamber (94).
[0099] As noted above, in one embodiment the tool is provided with
means for extending and retracting the cutter block from and into
the cutter block chamber, such means may comprise a power mechanism
(84) in the tool body in engagement with driven teeth (86) on the
cutter block. Motor means (80) are provided for extending and
retracting the cutter block, and microprocessor control means for
the motor means are both mounted within the tool body. The
microprocessor control means is suitably adapted to receive bore
dimension information from the caliper means (66) and to control
the cutter block extension in response thereto. A mechanical lock
is provided by means of a locking collet finger (96), which can be
located into one of a plurality of retaining lip grooves (98) by
travelling lock (100), which is located by sealing collar (102).
The tool may be activated by means of electronic signal sent by
mud-pulse and decoded or by other means using fiber-optics or
wireless transmission.
[0100] Hydraulic locking means may be provided to resist retraction
of the extended cutter block (62) into the cutter block chamber
(94) when the extension of the cutter block is opposed by external
pressure. This may comprise a port (not shown) open to a source of
drilling fluid (passage 90) onto the travelling lock (100)
immediately behind the cutter block.
[0101] The tool normally comprises a plurality of such cutter
blocks (62), arranged symmetrically around the tool. Two cutter
blocks are on opposite sides of the tool, three blocks are
separated by 120 degrees, four by 90 degrees, and six by 60
degrees. Additionally, a plurality of such cutter blocks are
arranged at longitudinally separated positions so as to provide for
a plurality of cutter block housings further detailed in FIG. 11.
In operation, the underreaming tool (50) is typically rotated on
the drill string as well as being moved axially along the
wellbore.
[0102] In accordance with an embodiment of the invention, shown in
FIG. 9, the cutter block is provided with an internal flowbore
(110) leading drilling fluid from a through passage (90) to an
external nozzle (112) among the cutter elements (92). The source of
drilling fluid may be the rig pumps via the drill-string (30) to
the passage (90) for the flow of drilling fluid from the drill
string to the drill bit. In another embodiment, as shown in FIG.
10, the tool body may be provided with an internal flowbore (114)
leading drilling fluid from passage (90) to an external nozzle
(116) adjacent the set of cutters. In each embodiment, the nozzle
provides an optimized fluid flow that can help to keep the cutters
clean and prevent the build-up of clogging debris from the
underreaming operation, remove such material altogether from the
underreaming zone, and provide a cooling and lubricating function
for the cutters.
[0103] In yet another embodiment FIG. 10 shows an additional or
alternate component a translatable mandrel or axial sleeve with
position sensing (910) which may also have a profile or groove to
engage expandable blocks (62) to act as a seal or lock or simply to
engage expandable blocks and move them radially or laterally
outward and also shows additional or alternate component 115 which
can be an expandable bit configured with or without reaming
capability to reduce downtime and uncertainty.
[0104] In yet another embodiment of FIG. 10 corresponding to
certain components of FIGS. 8 and 9, sealing collar 102 may be used
to house further sensors or the sensors 96a, 98a may be used to
detect the position of the mandrel.
[0105] FIG. 11 shows a further embodiment of the tool wherein a
dynamic positional indicator is placed additionally or
alternatively in a separate module to the set of cutters shown at
the downhole end and a further set of stabilizers are shown at the
uphole end, both sets suitably housed in modules. Such an
embodiment comprises more than one set of expandable cutter blocks
(62 and 62) integrated within independent modules that are screwed
to each other in order to reduce drilling downtime.
[0106] FIGS. 12 and 13 show a detail of a dynamic position detector
with and without a pulse head of one embodiment of the tool or
apparatus showing the expansion elements constituted by a set of
cutter blocks and a further expandable bit replacing the second set
of cutter blocks. The signal or position is detected according to
the position so that for a 143/4''-171/2'' tool it could be
configurable and extended to radial positions between 121/4'' and
143/4''. Generally such reamer positions are dependent on the pass
through ID of casing and are expressed as increase in diameter
relative to the bit size or reamer body size. Accordingly such
expressions are generally in the order of 1'', 1.25'', 1.375'',
1.5'', 1.875'', 2.5'', 2.75'', 3'', 3.5'', 3.875'' and 4'' and so
on. Other sizes are in the order of 0.5'', 0.75'' and so on.
[0107] FIGS. 14 and 15 detail a preferred embodiment with two
locations for dynamic position detection contained within and
partly without respectively of expandable cutter assembly.
[0108] FIGS. 16, 17 show different configurations of a dynamic
pulse head (950) for position detection with a spring (960) and
compression/expansion chamber (980) with valve or pressure sensor
(990). Additionally or alternatively, pressure or flow may be used
to move the pulse head and thus create a series of clear and
detectable pressure or flow signals corresponding to radial
positions which are used to sense or indicate the block
position.
[0109] In yet another embodiment a bending moment sensor may detect
bending moments on the tool allowing for activation forces to be
optimized by increasing or decreasing activation forces. The
bending moment sensor may show that further activation force is
required or lower force or that parameters should be changed such
as the angle, rop, WOB, FLOW, directional control system blades.
Optimal configurations of the invention are envisaged based on
application needs.
[0110] A pulse head may travel through a number of rings and thus
create a number of pulses related to position. For example, 1 pulse
may be deactivated, 2 pulses 1 inch extended, 3 pulses 2 inches
extended and so on.
[0111] Additionally or alternatively the reverse is also possible
as is a further embodiment wherein the duration of the pulse may
indicate positional data. For example, a long pulse indicates
activation while a short pulse is deactivated or the alternate is
possible. Further pulse encoding may be planned dependent on the
type of frequency and duration and other pulsers that may be in the
hole as is the case when directional or LWD/MWD companies are
providing such measurements.
[0112] A series of pulses configurable by the user may be
advantageous in detection and can be configurable to avoid
interference with other signals in the mud column. Additionally or
alternatively the interference may be electronic in which case
means are provided to avoid such interference. Such means can be
based on shielding, noise cancellation, circuitry configuration or
component selection, frequency modulation, amplitude modulation,
carrier waves, electro magnetic, sonic, etc.
[0113] FIG. 18 shows where the pulse head is connected to a mandrel
which moves up or down the housing (975) which may if required be
further contained within the body of the tool. In yet another
embodiment of FIG. 18, the mandrel may have a profile to engage
with the expandable block, or a profile to engage with body or may
simply engage with the expandable block.
[0114] FIG. 19 shows an embodiment wherein the blocks are connected
to a chamber and dynamic position indicator (910) and further
additional or alternate position sensing means located as (98) and
(96) in relation to (910). The positional sensing means are
generally located in the tool or cutter block or mandrel in a
chamber but in an alternative configuration of the tool may be
placed within the cutter block itself in the most radially extended
zone among the cutting elements or linked to a nozzle opening to
the wellbore. Other embodiments are for example, a pressure sensor
may detect chamber pressure. Additionally or alternatively the
sensing means may be located below a sealed area or within a seal
area.
[0115] As shown in FIG. 20 and yet another embodiment leading
drilling fluid from a through passage (90) to an external flow path
(970) wherein a pulse head (950) may be driven by a solenoid or
motor powered. The source of drilling fluid may be the rig pumps
via the drill-string (30) to the passage (90) for the flow of
drilling fluid from the drill string to the drill bit.
[0116] As shown in FIG. 21 and yet another embodiment leading
drilling fluid from a through passage (90) to an oscillating pulser
(990) wherein one or more discs (991) may be driven by fluid flow,
a solenoid or motor powered to dynamically create pressure pulses
to detect, monitor or indicate radial or longitudinal positional
status. The discs may be open, close, partially open or closed and
configured to operate at the desired flow, rpm or oscillation with
the objective of providing positional indication. The source of
drilling fluid may be the rig pumps via the drill-string (30) to
the passage (90) for the flow of drilling fluid from the drill
string to the drill bit.
[0117] Those skilled in the art will appreciate that the examples
of the invention given by the specific illustrated and described
embodiments show a novel underreaming tool and apparatus integrated
with a caliper and accompanied by a method for underreaming
verification and measuring underreamed wellbore diameter
measurements using calibrated downhole fluid property measurements
for accurate wellbore diameter measurements. A further embodiment
includes a sensor for measuring the position of extendable blocks.
While a further embodiment incorporates a vibration measurement
sensor. Consequently, numerous variations are possible to achieve
the purpose of the invention which is to improve drilling
efficiency and provide certainty whenever a desired underreamed
wellbore diameter is required. These embodiments are not intended
to be limiting with respect to the scope of the invention.
Substitutions, alterations and modifications not limited to the
variations suggested herein may be made to the disclosed
embodiments while remaining within the purpose and scope of the
invention.
* * * * *