Steerable drilling system and method

• US 20060266555A1
• Filed: 07/24/2006
• Published: 11/30/2006
• Est. Priority Date: 12/21/1998
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Rao, M. Vikram, Gleitman, Daniel D., Walker, Colin, Boulton, Roger, Hardin, John R. Jr., Gaynor, Thomas M., Chen, Chen-Kang D.
• Granted Patent: US 7,621,343 B2
• Time in Patent Office: Days
• US Class Current: 175/61
• CPC Class Codes: E21B 47/013 Devices specially adapted for supporting measuring instruments on drill bits
• CPC Class Codes: E21B 7/067 with means for locking sections of a pipe or of a guide for a shaft in angular relation, e.g. adjustable bent sub
• CPC Class Codes: E21B 7/068 drilled by a down-hole drilling motor down-hole drives per se E21B4/00, E21B7/067 takes precedence

Abstract

A bottom hole assembly 10 for drilling a deviated borehole includes a positive displacement motor (PDM) 12 or a rotary steerable device (RSD) 110 having a substantially uniform diameter motor housing outer surface without stabilizers extending radially therefrom. In a PDM application, the motor housing 14 may have a fixed bend therein between an upper power section 16 and a lower bearing section 18. The long gauge bit 20 powered by the motor 10 may have a bit face 22 with cutters 28 thereon and a gauge section 24 having a uniform diameter cylindrical surface 26. The gauge section 24 preferably has an axial length at least 75% of the bit diameter. The axial spacing between the bit face and the bend of the motor housing preferably is less than twelve times the bit diameter. According to the method of the present invention, the bit may be rotated at a speed of less than 350 rpm by the PDM and/or rotation of the RSD from the surface.

Claims

1-101. -101. (canceled)

102. A bottom hole assembly including a bit, comprising:

a rotary shaft of a rotary steerable device rotatable from the surface with respect to a housing at least partially enclosing the rotary shaft, the rotary shaft capable of being deflected with respect to the housing by a transverse force acting on the rotary shaft to steer the bit;

the bit rotatable with the rotary shaft, the bit having a bit face, the bit face having a bit full cutting diameter; and

a gauge section above the bit face, such that an axial length from the bit full cutting diameter to a top of the gauge section is at least 75% of the bit full cutting diameter.

103. A bottom hole assembly of claim 102, wherein the rotary shaft is deflected while drilling the well by applying the transverse force to the rotary shaft in a controllable direction.

104. A bottom hole assembly of claim 102, wherein the bottom hole assembly further comprises:

an anti-rotation device coupled to the housing.

105. A bottom hole assembly of claim 102, wherein the bottom hole assembly further comprises:

a mechanical member for deflecting the rotary shaft.

106. A bottom hole assembly of claim 102, further comprising:

means for deflecting the rotary shaft at one or more points.

107. A bottom hole assembly of claim 102, wherein the gauge section comprises a stabilizer coupled to the bit.

108. A bottom hole assembly of claim 102, wherein a portion of the axial length of the gauge section which is substantially gauge is at least 50% of the gauge section axial length.

109. A bottom hole assembly of claim 102, wherein the axial length between the bit full cutting diameter and the top of the gauge section is at least 90% of the bit full cutting diameter.

110. A bottom hole assembly of claim 102, wherein the top of the gauge section which is substantially the bit full cutting diameter is smaller than the bit full cutting diameter by less than about ¼

″

.

111. A bottom hole assembly of claim 102, further comprising:

a positive displacement motor above the rotary steerable device.

112. A bottom hole assembly of claim 102, wherein the bit is a long gauge bit supporting the gauge section.

113. A bottom hole assembly of claim 102, wherein a stabilizer rotatably fixed to the bit provides at least a portion of the gauge section.

114. A bottom hole assembly of claim 102, wherein at least 50% of the length of an outer surface of the gauge section includes a first diameter and one or more additional diameters, the first diameter and the one or more additional diameters each being no larger than the bit full cutting diameter, and smaller than the bit full cutting diameter by less than about ¼

″

.

115. A bottom hole assembly of claim 102, wherein the housing has a substantially uniform diameter outer surface.

116. An apparatus for use with drill string in drilling a well, comprising:

a rotary steerable device, comprising;

a) a rotary shaft capable of being rotatably driven by the drill string, the rotary shaft at least partially disposed in a housing; and

b) an anti-rotation device coupled to the housing to limit the rotation of the housing, the housing having an upper axis, at least a portion of the shaft capable of rotating about the upper axis, and

c) a deflecting device to deflect at least a portion of the shaft from rotation about the upper axis while drilling the well, to rotation about a second rotational axis, the deflecting device applying an off axis force in a controllable direction;

a bit below the rotary steerable device, the bit having a bit face, the bit face having a bit full cutting diameter; and

a gauge section at a location above the bit face such that an axial length from the bit face to a top of the gauge section is at least 75% of the bit full cutting diameter.

117. An apparatus of claim 116, wherein the bit is coupled to the rotary shaft to drill the deviated borehole;

and

the gauge section includes a stabilizer coupled to the bit.

118. An apparatus of claim 116, wherein the housing has a substantially uniform diameter outer surface.

119. An apparatus of claim 116, wherein a stabilizer rotatably fixed to the bit includes at least a portion of the gauge section.

120. An apparatus of claim 116, wherein at least 50% of the length of an outer surface of the gauge section includes a first diameter and one or more additional diameters, the first diameter and the one or more additional diameters each being no larger than the bit full cutting diameter, and smaller than the bit full cutting diameter by less than about ¼

″

.

121. An apparatus of claim 116, wherein the top of the gauge section which is substantially the bit full cutting diameter is smaller than the bit full cutting diameter by less than about ¼

″

.

122. An apparatus of claim 116, wherein the axial length between the bit full cutting diameter and a top of the gauge section is at least 90% of the bit full cutting diameter.

123. A method, comprising:

drilling a deviated borehole using a bottom hole assembly while rotating a drill string from the surface, the bottom hole assembly having a rotary shaft of a rotary steerable device, the rotary shaft capable of being deflected;

deflecting the rotary shaft by a transverse force acting on the rotary shaft;

using a bit coupled to the rotary shaft to drill the deviated borehole, the bit having a bit face, the bit face having a bit full cutting diameter; and

using a gauge section above the bit face, such that an axial length between the bit full cutting diameter and a top of the gauge section is at least 75% of the bit full cutting diameter.

124. A method of claim 123, further comprising:

coupling an anti-rotation device to a housing of the rotary steerable device.

125. A method of claim 123, wherein deflecting the rotary shaft comprises temporarily bending the rotary shaft using the transverse force.

126. A method of claim 123, wherein using a bit coupled to the rotary shaft to drill the deviated borehole comprises drilling the deviated borehole with a bottom hole assembly including a stabilizer coupled to the bit.

127. The method of claim 126, further comprising:

supporting at least a portion of the gauge section on the stabilizer.

128. A method of claim 123, further comprising:

rotatably fixing a stabilizer to the bit, the stabilizer providing at least a portion of the gauge section.

129. A method of claim 123, further comprising:

rotating the bit at a speed of less that 350 rpm to form a curved section of the borehole.

130. A method of claim 123, wherein rotary shaft deflection is adjustable while drilling the well by applying the transverse force to the rotary shaft in a controllable direction.

131. A method of claim 123, wherein a portion of the axial length of the gauge section which is substantially gauge is at least 50% of the gauge section axial length.

132. A method of claim 123, wherein the axial length between the bit full cutting diameter and the top of the gauge section is at least 90% of the bit full cutting diameter.

133. A method of claim 123, wherein at least 50% of the length of an outer surface of the gauge section includes a first diameter and one or more additional diameters, the first diameter and the one or more additional diameters each being no larger than the bit full cutting diameter, and smaller than the bit full cutting diameter by less than about ¼

″

.

134. The method of claim 123, wherein the top of the gauge section which is substantially the bit full cutting diameter is smaller than the bit full cutting diameter by less than about ¼

″

.

135. A method of claim 123, wherein the housing has a substantially uniform diameter outer surface.

136. A method of claim 123, further comprising:

providing a positive displacement motor above the rotary steerable device; and

using the positive displacement motor to increase the rotary speed of the bit above the rotary speed of the drill string.

137. A method of directionally drilling a borehole with a drill string, the method comprising:

using the drill string to rotate a rotary shaft of a rotary steerable tool, the rotary shaft at least partially disposed in a housing of the rotary steerable tool and coupled to the housing with one or more bearings, the housing having coupled thereto an anti-rotation device to limit the rotation of the housing, the housing having an upper axis, at least a portion of the shaft capable of rotating about the upper axis, and at least a portion of the shaft capable of being deflected from rotation about the upper axis to rotation about a second rotational axis by a radial force acting on the rotary shaft below at least one of the one or more bearings;

using a bit below the rotary steerable tool, the bit having a bit face, the bit face having a bit full cutting diameter, and using a gauge section above the bit face, such that the distance from the bit face to a top of the gauge section is at least 75% of the bit full cutting diameter; and

deflecting the rotary shaft while drilling the well by applying the radial force to the rotary shaft in a controllable direction.

138. A method of claim 137, wherein the radial force is applied in a controllable magnitude.

139. A method of claim 137, wherein the rotary shaft deflection directs the bit to a controllable toolface related to the controllable direction.

140. A method of claim 137, wherein the gauge section comprises a stabilizer coupled to the bit.

141. A method of claim 137, wherein at least 50% of the length of an outer surface of the gauge section includes a first diameter and one or more additional diameters, the first diameter and the one or more additional diameters each being no larger than the bit full cutting diameter, and smaller than the bit full cutting diameter by less than about ¼

″

.

142. A method of claim 137, wherein the top of the gauge section which is substantially the bit full cutting diameter is smaller than the bit full cutting diameter by less than about ¼

″

.

143. A method of claim 137, further comprising:

rotating the bit at a speed of less that 350 rpm to form a curved section of the borehole.

144. A method of claim 137, wherein the axial length between the bit full cutting diameter and the top of the gauge section is at least 90% of the bit full cutting diameter.

145. A method of claim 137, wherein using a gauge section above the bit face comprises drilling the borehole with a bottom hole assembly including a stabilizer coupled to the bit.

146. The method of claim 145, further comprising:

supporting at least a portion of the gauge section on the stabilizer.

147. A method for directionally drilling a deviated borehole using a bottom hole assembly while rotating a drill string from the surface, the bottom hole assembly comprising:

a bit having a bit face, the bit face having a bit full cutting diameter;

a gauge section above the bit, the gauge section having a top end;

a rotary shaft above the gauge section, the rotary shaft having an upper central axis;

a housing for a rotary steerable device, the housing having a longitudinal axis;

a lower portion of the rotary shaft extending from the housing, the lower portion of the shaft having a lower central axis offset from the upper central axis when drilling a deviated borehole;

wherein the method comprises;

drilling with the bit, wherein an axial length from the bit full cutting diameter to the top end of the gauge section is at least 75% of the bit full cutting diameter.

148. A method of claim 147, further comprising:

rotating the bit at a speed of less than 350 rpm to form a curved section of the borehole.

149. A method of claim 147, wherein the gauge section comprises a stabilizer coupled to the bit.

150. A method of claim 147, wherein a stabilizer rotatably fixed to the bit provides at least a portion of the gauge section.

151. A method of claim 147, wherein at least 50% of the length of an outer surface of the gauge section includes a first diameter and one or more additional diameters, the first diameter and the one or more additional diameters each being no larger than the bit full cutting diameter, and smaller than the bit full cutting diameter by less than about ¼

″

.

152. A method of claim 147, wherein the top of the gauge section which is substantially the bit full cutting diameter is smaller than the bit full cutting diameter by less than about ¼

″

.

153. A method of claim 147, wherein the housing has a substantially uniform diameter outer surface.

154. A method of claim 147, wherein the axial length between the bit full cutting diameter and the top of the gauge section is at least 90% of the bit full cutting diameter.

155. A method of claim 147, wherein drilling with the bit comprises drilling the deviated borehole with a bottom hole assembly including a stabilizer coupled to the bit.

156. The method of claim 155, further comprising:

supporting at least a portion of the gauge section on the stabilizer.

157. A method of using a drill string and a bit having a bit face and a bit full cutting diameter to drill a borehole, comprising:

providing a stabilizer above the bit, the stabilizer having a gauge section, a portion of which is substantially the bit full cutting diameter, and wherein an axial length between the bit full cutting diameter and a top of the stabilizer gauge portion is at least 75% of the bit full cutting diameter;

providing a rotary steerable device with a shaft; and

using the rotary steerable device to directionally steer the bit while rotating the drill string from surface.

158. A method of claim 157, wherein the stabilizer gauge section portion which is substantially the bit full cutting diameter is smaller than the bit full cutting diameter by less than about ¼

″

.

159. A method of claim 157, further comprising:

coupling the stabilizer to rotate with the bit.

160. A method of claim 157, wherein the rotary steerable device includes a housing, and the method comprises using an anti-rotation device coupled to the housing to engage the borehole wall.

161. A method of claim 157, wherein the rotary steerable device includes a housing and the shaft is rotatable within at least a portion of the housing.

162. A method of claim 161, wherein the rotary steerable device includes a mechanism for deflecting a portion of the shaft within the housing, and the method further comprises deflecting the shaft to steer the bit.

163. A method of claim 162, wherein the deflection of the shaft is in a controlled direction and steers the bit in the direction opposite the controlled direction.

164. A method of claim 157, further comprising:

providing a positive displacement motor above the rotary steerable device; and

using the positive displacement motor to increase the rotary speed of the bit above the rotary speed of the drill string.

165. A method of claim 157, further comprising:

using the rotary steerable device to steer the bit to drill a curve in a portion of the borehole and to drill straight in another portion of the borehole.

166. A method of claim 157, wherein the axial length between the bit full cutting diameter and the top of the gauge section is at least 90% of the bit full cutting diameter.

167. A method of claim 157, wherein the housing has a substantially uniform diameter outer surface.

168. A method of claim 157, further comprising:

rotating the bit at a speed of less that 350 rpm to form a curved section of the borehole.

169. A method to use a drill string and a bit having a bit face and a bit full cutting diameter to drill a borehole, comprising:

providing a stabilizer coupled above the bit, the stabilizer having a gauge section, a portion of which is substantially the bit full cutting diameter, and wherein an axial length between the bit full cutting diameter and a top of the stabilizer gauge portion is at least 75% of the bit full cutting diameter;

providing above the bit a rotary steerable device comprising a shaft and a housing, the shaft to rotate with respect to the housing, the rotary steerable device including a deflection device to deflect the shaft, and the shaft rotated from above the rotary steerable device; and

using the rotary steerable device to directionally steer the bit while the shaft is rotated from above the rotary steerable device to drill the borehole.

170. A method of claim 169, wherein the shaft is rotated by coupling the shaft to a rotatable drill string.

171. A method of claim 169, wherein the shaft is rotated by a positive displacement motor above the shaft.

172. A method of claim 169, wherein the axial length between the bit full cutting diameter and the top of the gauge section is at least 90% of the bit full cutting diameter.

173. A method of claim 169, wherein the housing has a substantially uniform diameter outer surface.

174. A method of claim 169, further comprising:

rotating the bit at a speed of less that 350 rpm to form a curved section of the borehole.

175. A method of claim 169, wherein the stabilizer gauge section portion which is substantially the bit full cutting diameter is smaller than the bit full cutting diameter by less than about ¼

″

.

176. A method to drill a borehole and produce formation evaluation logs, comprising:

directionally drilling a deviated borehole using a bottom hole assembly (BHA) comprising (a) a bit having a bit face and a bit full cutting diameter;

(b) a gauge section having a top, the gauge section spaced above the bit face, wherein an axial spacing between the bit face and the top of the gauge section which is substantially the bit full cutting diameter is at least 75% of the bit full cutting diameter; and

(c) a rotary steerable device above the gauge section to steer the bit while the drill string rotates;

providing a measurement while drilling (MWD) system within the BHA including one or more sensors to sense one or more of borehole or formation parameters;

producing a log representing one or more of the borehole or formation parameters.

177. A method of claim 176, wherein the rotary steerable device supports one or more sensors.

178. A method of claim 177, wherein the one or more sensors includes one or more of an RPM sensor, an inclinometer, or a vibration sensor.

179. A method of claim 176, further comprising:

adjusting drilling in response to at least one of the sensed borehole or formation parameters.

180. A method of claim 179, wherein the adjusting comprises adjusting one or more of weight on bit and rotary RPM.

181. A method of claim 176, further comprising:

transmitting signals to surface relating to one or more of the borehole or formation parameters.