Adjustable Bent Drilling Tool Having in situ Drilling Direction Change Capability

• US 20130153297A1
• Filed: 06/20/2012
• Published: 06/20/2013
• Est. Priority Date: 06/20/2011
• Status: Active Grant

• Current Assignee: David L. Abney, Inc.
• Original Assignee: David L. Abney, Inc.
• Inventors: Abney, David, Crow, Morgan, Muse, Anthony C., Orban, Andre, Weise, Stan
• Granted Patent: US 9,038,747 B2
• Time in Patent Office: Days
• US Class Current: 175/45
• CPC Class Codes: E21B 7/04 Directional drilling
• 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

Abstract

An adjustable bent drilling tool capable of changing in situ drilling direction to facilitate horizontal drilling. The drilling tool may be controlled from the surface and eliminates the need to bring the tool to the surface for reconfiguration. In one embodiment, the drilling tool utilizes a communications module to communicate with upstream sections of the tool. The communications module is connected to a programmable electronic control module which controls an electric motor. A hydraulic valve assembly follows the control module, which receives input signals and controls a pilot piston between two fixed points of a mid-assembly typically located adjacent to and downstream of the hydraulic valve assembly on the drill tool. A lower assembly is attached to the drill tool immediately following the mid-assembly, and provides both a safety release sub-assembly as well as a bendable sub-assembly which directs the adjustable drill tool to change drilling angle and direction.

Claims

1. An adjustable drilling tool assembly comprising:

a startup and communications module;

an electronics module for providing information to the drilling tool;

a piston operably attached to a J-slot assembly;

a hydraulic valve assembly for providing a hydraulic fluid to a mid-assembly, the hydraulic valve assembly adapted to supply hydraulic pressure alternately to a first side and a second side of the piston, the hydraulic pressure for reciprocating the piston;

a mid-assembly comprising the J-slot assembly, the J-slot assembly incrementally rotatable in response to the reciprocation of the piston, the rotational position of the J-slot assembly determining the drilling angle of the drilling tool; and

,

an adjustable lower assembly for adjusting the angle of the drilling tool, an upstream end of the adjustable lower assembly engaged to the J-slot assembly, the adjustable lower assembly comprising a flex nipple with a plurality of laterally oriented cavities disposed therein and a bent nipple that selectively bends depending on the rotational position of the J-slot assembly.

2. The drilling tool assembly of claim 1 further comprising a transition sub-assembly for interconnecting the hydraulic valve assembly and mid-assembly.

3. The drilling tool assembly of claim 1 further comprising a safety release sub-assembly for connecting the mid-assembly with the adjustable lower assembly.

4. The drilling tool assembly of claim 1 wherein the J-slot assembly comprises a series of longitudinal slots parallel to the axis of rotation of the drilling tool assembly and interconnected by angular channels in sequential increments.

5. The drilling tool assembly of claim 4 wherein the J-slot assembly is engaged by a guide pin extending from the mid-assembly.

6. The drilling tool assembly of claim 4 wherein the J-slot assembly facilitates angular adjustment of the bent nipple incrementally from 1 to 3 degrees.

7. The drilling tool assembly of claim 4 wherein the J-slot assembly facilitates angular adjustment of the bent nipple between 1, 1.5, and 3 degrees.

8. The drilling tool assembly of claim 1 wherein the J-slot orientation is controlled by a magnetic assembly.

9. The drilling tool assembly of claim 1 wherein the flex nipple is formed from a single contiguous material.

10. The drilling tool assembly of claim 1, the laterally oriented cavities of the flex nipple selectively interconnected by a plurality of lateral channels, the flex nipple able to be bent in the region containing the lateral cavities and channels.

11. The drilling tool assembly of claim 1 wherein the electronics module further comprises a magnetic sensor, a processor in communication with a memory, and a battery.

12. The drilling tool assembly of claim 1 wherein the startup module, electronics module, hydraulic valve assembly and adjustable bent lower assembly are interconnected in sequence.

13. A method for adjusting the drilling direction of a drilling tool assembly in situ comprising:

receiving a first hydraulic signal from an upstream source, activating an electronics module for controlling a hydraulic valve assembly;

reciprocating a hydraulically operated piston to rotate a J-slot assembly contained in a mid-assembly, the J-slot assembly rotatable in predetermined increments; and

,

bending a bendable sub-assembly to a predetermined angular position by bending a flex nipple based upon the rotational position of the J-slot assembly;

14. The method of claim 13, the drilling tool assembly controllable by the upstream source and able to send feedback information to the upstream source.

15. The method of claim 13 wherein the J-slot assembly comprises a series of longitudinal slots parallel to the axis of rotation of the drilling tool assembly and interconnected by angular channels in a sequential direction.

16. The method of claim 13 wherein the J-slot assembly is engaged by a pin extending from the mid-assembly, the pin engaging the longitudinal slots of the J-slot assembly as the J-slot assembly rotates in sequential increments.

17. The method of claim 13 wherein the rotational position of the J-slot assembly determines the drilling angle of the flex nipple incrementally from 1 to 3 degrees.

18. The method of claim 13 wherein the current rotational position of the J-slot assembly is determined by a magnetic assembly.

19. The method of claim 13 wherein the adjustable bent lower assembly further comprises a flex nipple form from a single contiguous part.

20. The method of claim 13 wherein the electronics module further comprises a magnetic sensor, a processor in communication with a memory, and a battery.

21. The method of claim 13 wherein the startup module, electronics module, hydraulic valve assembly and adjustable bent lower assembly are interconnected in sequence.

22. A coupling assembly for non-rotatably coupling two sections of a drill tool, comprising:

a first cylindrical section having an annular cavity located concentrically within the first section, and a slot adjacent a first end of the first section;

a second cylindrical section having a circumferential groove disposed coaxially on the outer surface of the second section and adjacent a first annular end of the second section, the first end of the second section having a diameter smaller than the diameter of the cavity;

a pin hole located in the circumferential groove; and

,

a semi-circular key, the key having a pin located at an end thereto;

wherein the first end of the second section is inserted into the annular cavity of the first section such that the pin hole is aligned with the slot, the semi-circular key used to operatively couple the first and second cylindrical sections together.

23. The coupling assembly of claim 22 wherein the pin of the key is inserted into the pin hole and the second section is rotated relative to the first section such that the key is secured into an annular space formed between the first and second sections.