DRILLING COMPONENTS AND SYSTEMS TO DYNAMICALLY CONTROL DRILLING DYSFUNCTIONS AND METHODS OF DRILLING A WELL WITH SAME

• US 20080164062A1
• Filed: 01/07/2008
• Published: 07/10/2008
• Est. Priority Date: 01/08/2007
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Pastusek, Paul E., Brackin, Van J.
• Granted Patent: US 7,921,937 B2
• Time in Patent Office: Days
• US Class Current: 175/24
• CPC Class Codes: E21B 21/103 Down-hole by-pass valve arrangements, i.e. between the inside of the drill string and the annulus valves specifically for maintaining circulation of drilling fluid while connecting or disconnecting tubular joints E21B21/019
• CPC Class Codes: E21B 44/005 Below-ground automatic control systems

Abstract

Drilling tools that may detect and dynamically adjust drilling parameters to enhance the drilling performance of a drilling system used to drill a well. The tools may include sensors, such as RPM, axial force for measuring the weight on a drill bit, torque, vibration, and other sensors known in the art. A processor may compare the data measured by the sensors against various drilling models to determine whether a drilling dysfunction is occurring and what remedial actions, if any, ought to be taken. The processor may command various tools within the bottom hole assembly (BHA), including a bypass valve assembly and/or a hydraulic thruster to take actions that may eliminate drilling dysfunctions or improve overall drilling performance. The processor may communicate with a measurement while drilling (MWD) assembly, which may transmit the data measured by the sensors, the present status of the tools, and any remedial actions taken to the surface.

Claims

1. A downhole drilling assembly for controlling a manner of engagement of a drill bit with a subterranean formation, comprising:

a bottom hole assembly comprising a drill bit including at least one cutting structure thereon and a component configured to adjust at least one aspect of operation of the downhole drilling assembly that affects at least one of a force and a speed with which the at least one cutting structure may engage a subterranean formation being drilled by the drill bit;

at least one sensor configured to measure at least one downhole drilling parameter, and;

a processor operably coupled to the at least one sensor and the component to cause the component to adjust the at least one aspect of operation of the downhole drilling assembly responsive to input from the at least one sensor.

2. The downhole drilling assembly of claim 1, further comprising:

a downhole motor having a power section adapted to convert energy from drilling fluid passing through the bottom hole assembly to rotate the drill bit, and;

wherein the component comprises a bypass valve assembly configured to divert from energy-conversion passage through the power section of the downhole motor at least a portion of a drilling fluid flowing through the bottom hole assembly.

3. The downhole drilling assembly of claim 1, further comprising at least one memory storage device.

4. The downhole drilling assembly of claim 3, wherein the memory storage device is configured to store data from the at least one sensor.

5. The downhole drilling assembly of claim 3, wherein the memory storage device is configured to store a computer program for operation of the processor.

6. The downhole drilling assembly of claim 1, wherein the at least one sensor comprises at least one of an RPM sensor, a torque sensor, an axial force sensor, and a shock sensor.

7. The downhole drilling assembly of claim 2, wherein the bypass valve comprises a valve configured for response to commands from the processor.

8. The downhole drilling assembly of claim 7, wherein the valve configured for response to commands from the processor further comprises a route to divert drilling fluid to flow from an interior of the downhole bottom hole assembly to an annulus between a wellbore wall and an exterior of the bottom hole assembly.

9. The downhole drilling assembly of claim 7, wherein the valve configured for response to commands from the processor further comprises a route to divert drilling fluid to flow through an interior bore in a rotor of the downhole motor.

10. The downhole drilling assembly of claim 1, further comprising a hydraulic thruster configured to adjust a force applied along an axis of the bottom hole assembly to the drill bit.

11. The downhole drilling assembly of claim 10, further comprising a valve configured for response to commands from the processor comprising a route for at least partially restricting a flow of a fluid from a first reservoir of the hydraulic thruster to a second reservoir of the hydraulic thruster.

12. The downhole drilling assembly of claim 1, further comprising a device for communicating with at least one of another component in the bottom hole assembly and a surface system.

13. The downhole drilling assembly of claim 12, wherein the device for communicating with at least one of another component in the bottom hole assembly and a surface system further comprises at least one of an electromagnetic telemetry device, a pressure modulating device, and an electrical connecting device.

14. A method of drilling a well, comprising, while drilling:

measuring a value of at least one downhole drilling performance parameter associated with operation of a downhole drilling assembly having a drill bit at a distal end thereof;

analyzing the at least one downhole drilling performance parameter value;

adjusting at least a valve in the downhole drilling assembly in response to the analyzed at least one downhole drilling parameter value to alter at least one aspect of operation of the downhole drilling assembly; and

;

repeating the measuring, analyzing, and adjusting until a desired downhole drilling performance parameter value is achieved.

15. The method of claim 14, wherein measuring the value of at least one downhole parameter associated with operation of the downhole drilling assembly is conducted at the drill bit.

16. The method of claim 14, wherein adjusting at least a valve in the downhole drilling assembly comprises adjusting at least a valve to alter a flow path of at least a portion of drilling fluid flowing through the downhole drilling assembly.

17. The method of claim 14, wherein altering the at least one aspect of operation of the downhole drilling assembly comprises altering the at least one aspect of operation responsive to the analyzing the at least one downhole performance parameter value indicating a type of subterranean formation being drilled.

18. The method of claim 14, wherein analyzing the at least one downhole drilling performance parameter value further comprises comparing the at least one measured downhole drilling performance parameter value to at least one drilling performance model.

19. The method of claim 18, wherein the at least one drilling performance model comprises performance models for different types of subterranean formations and the analyzing includes determining at least one characteristic of a type of subterranean formation being drilled, and wherein adjusting at least a valve is effected to alter at least one aspect of operation of the downhole drilling assembly to enhance performance of the downhole drilling assembly responsive to the determined at least one characteristic.

20. The method of claim 14, wherein repeating the measuring, analyzing, and adjusting until a desired drilling performance parameter value is achieved further comprises repeating the measuring, analyzing, and adjusting until at least one of an optimal rate of penetration, optimal wear rate, an optimal depth of cut of at least one of a cutting element on a drill bit, and an optimal drilling cost is achieved.

21. The method of claim 20, wherein repeating the measuring, analyzing, and adjusting until at least one of an optimal rate of penetration, optimal wear rate, and optimal drilling cost is achieved further comprises repeating the measuring, analyzing, and adjusting until at least one of a maximum rate of penetration, minimal wear rate, and a minimal drilling cost is achieved.

22. The method of claim 14, further comprising communicating at least one of the measured downhole drilling performance parameter value, the analyzed downhole drilling parameter value, and a status of the at least a valve to at least one of another component in a bottom hole assembly and a surface system.

23. The method of claim 14, wherein measuring of the at least one downhole drilling performance parameter comprises measuring at least one of a bit RPM, a turbine revolutions per minute, a downhole torque, an axial force, and a shock.

24. A method of drilling a well, comprising:

flowing drilling fluid through a bottom hole assembly including a drilling-fluid driven downhole motor and a drill bit;

diverting substantial drilling fluid flow away from driving the downhole motor;

engaging a formation to be drilled with the drill bit; and

ceasing at least a portion of the diversion of drilling fluid flow.

25. The method of claim 24, further comprising:

sensing a WOB after the formation is engaged by the drill bit; and

ceasing the at least a portion of the diversion of drilling fluid flow after the sensed WOB reaches a selected magnitude.