ROTARY STEERABLE DRILLING APPARATUS

• US 20140131106A1
• Filed: 11/12/2012
• Published: 05/15/2014
• Est. Priority Date: 11/12/2012
• Status: Active Grant

• Current Assignee: APS Technology Inc
• Original Assignee: APS Technology Inc
• Inventors: Coull, David A., Vie, Malcomb George
• Granted Patent: US 9,500,031 B2
• Time in Patent Office: Days
• US Class Current: 175/55
• CPC Class Codes: E21B 17/20 Flexible or articulated drilling pipes , e.g. flexible or articulated rods, pipes or cables
• CPC Class Codes: E21B 7/04 Directional drilling
• CPC Class Codes: E21B 7/062 the tool shaft rotating inside a non-rotating guide travelling with the shaft E21B7/067 and E21B7/068 take precedence
• 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

A rotary steering apparatus for a drill string in which a bending section induces a bend in a portion of the bottom hole assembly of the drill string by using the rotation of the drive shaft that drives the drill bit during normal drilling, while operating at a reduced or zero drilling mud flow rate, to drive a reduction gear that rotates a nut or cam so as to place a tension tube into tension. The tension tube abuts a flexible housing and places the flexible housing in compression. The flexible housing has a local weakening formed in it that causes it to preferentially bend in a predetermined direction. Compression in the flexible housing causes the housing to bend, which bends a portion of the bottom hole assembly so as to alter the direction of drilling. Rotation of the drive shaft at reduced or zero mud flow rate also causes the drive shaft to drive rotation of a second reduction gear the output of which rotates the bent portion of the bottom hole assembly thereby altering its tool face angle.

Claims

1. An apparatus for steering a drill bit used to drill a bore hole in an earthen formation, said apparatus forming a portion of a bottom hole assembly of a drill string to which said drill bit is coupled, said steering apparatus comprising:

(a) a bendable member adapted to be incorporated into said bottom hole assembly, said bendable member having a preferential direction in which said bendable member bends, wherein the amount of bending of said bendable member in said preferential direction determines the degree of change in the direction of said drilling;

(b) means for adjusting in situ the amount of said bending of said bendable member in said preferential direction so as to adjust the degree of directional change in said drilling.

2. The steering apparatus according to claim 1, wherein said bendable member bends in said preferential direction as a result of the application of force to said bendable member.

3. The steering apparatus according to claim 1, wherein said bendable member bends in said preferential direction as a result of the application of a compressive force to said bendable member.

4. The steering apparatus according to claim 3, wherein bendable member comprises at least one weakening feature causing said bendable member to bend in said preferential direction when a force is applied to said bendable member.

5. The steering apparatus according to claim 4, wherein bendable member comprises a flexible housing and wherein said weakening feature comprises at least one cut in said flexible housing extending around a portion thereof.

6. The steering apparatus according to claim 4, wherein said weakening feature comprises an area of locally reduced thickness of said bendable member.

7. The steering apparatus according to claim 3, wherein said means for adjusting in situ said amount of bending of said bendable member comprises means for applying a compressive force to said bendable member.

8. The steering apparatus according to claim 7, wherein said means for applying a compressive force to said bendable member comprises (i) a force applying member in contact with said bendable member and (ii) means for displacing said force applying member relative to said bendable member so that said force applying member applies a compressive force to said bendable member.

9. The steering apparatus according to claim 8, wherein said force applying member comprises a tube placed in tension in order to apply a compressive force to said bendable member.

10. The steering apparatus according to claim 8, wherein rotation of said drill bit is driven by a drive shaft coupled to said drill string, and wherein said means for displacing said force applying member is coupled to and driven by said drive shaft.

11. The steering apparatus according to claim 10, wherein said means for displacing said force applying member is coupled to said drive shaft by a reduction gear.

12. The steering apparatus according to claim 11, wherein said reduction gear comprises a harmonic drive.

13. The steering apparatus according to claim 11, wherein said reduction gear comprises epicyclic gearing.

14. The steering apparatus according to claim 11, wherein said means for displacing said force applying member comprises a threaded member coupling said reduction gear to said force applying member.

15. The steering apparatus according to claim 8, wherein said means for displacing said force applying member comprises a cam follower and a cam surface.

16. The steering apparatus according to claim 1, wherein rotation of said drill bit is driven by a drive shaft coupled to said drill string, and wherein said means for adjusting in situ the amount of said bending of said bendable member is driven by said drive shaft.

17. The steering apparatus according to claim 1, further comprising means for adjusting in situ the tool face angle of said bendable member so as to adjust the direction of said drilling.

18. The steering apparatus according to claim 17, wherein said means for adjusting in situ the tool face angle of said bendable member comprises means for rotating said bendable member with respect to a portion of said drill string uphole of said bendable member.

19. The steering apparatus according to claim 18, wherein rotation of said drill bit is driven by a drive shaft extending through said drill string, and wherein said means for rotating said bendable member is coupled to and driven by said drive shaft.

20. The steering apparatus according to claim 19, wherein said means for rotating said bendable member comprises a reduction gear coupling said bendable member to said drive shaft.

21. The steering apparatus according to claim 20, wherein said reduction gear comprises a harmonic drive.

22. The steering apparatus according to claim 20, wherein said reduction gear comprises epicyclic gearing.

23. The steering apparatus according to claim 17, wherein said means for adjusting in situ the tool face angle of said bendable member comprises (i) means for establishing a reference tool face angle, and (ii) means for rotating said bendable member relative to said means for establishing said reference tool face angle.

24. The steering apparatus according to claim 23, wherein said means for establishing said reference tool face angle comprises an asymmetrically weighted member.

25. An apparatus for steering a drill bit used to drill a bore hole in an earthen formation, said apparatus forming a portion of a bottom hole assembly of a drill string in which said drill bit is coupled to a drive shaft, said steering apparatus comprising:

(a) a bendable member adapted to be incorporated into said bottom hole assembly, said bendable member having a preferential direction in which said bendable member bends when a force is applied to said bendable member, wherein the amount of bending of said bendable member in said preferential direction determines the degree of change in the direction of said drilling; and

(b) a force applying member adapted to be mounted in said bottom hole assembly so as to apply a force to said bendable member that bends said bendable member in said preferential direction, said force applying member coupled to said drive shaft so that rotation of said drive shaft causes said force applying member to apply said force to said bendable member that bends said bendable member in said preferential direction.

26. The steering apparatus according to claim 25, wherein said bendable member comprises a flexible housing adapted to be mounted in said bottom hole assembly uphole of said drill bit.

27. The steering apparatus according to claim 25, wherein said bendable member has at least one weakening feature incorporated therein.

28. The steering apparatus according to claim 27, wherein said weakening feature comprises at least one cut extending around a portion of said bendable member.

29. The steering apparatus according to claim 27, wherein said weakening feature comprises an area of locally reduced thickness of said bendable member.

30. The steering apparatus according to claim 25, wherein said drive shaft is coupled to said force applying member by a reduction gear.

31. The steering apparatus according to claim 30, wherein said reduction gear comprises a harmonic drive.

32. The steering apparatus according to claim 30, wherein said reduction gear comprises epicyclic gearing.

33. The steering apparatus according to claim 25, wherein said bendable member bends in said preferential direction when a compressive force is applied to said bendable member, and wherein said force applying member applies a compressive force to said bendable member.

34. The steering apparatus according to claim 25, wherein said force applying member comprises a tension member that applies a compressive force to said bendable member when placed into tension.

35. The steering apparatus according to claim 34, wherein said tension member comprises a tube arranged approximately coaxially with said bendable member.

36. The steering apparatus according to claim 25, wherein rotation of said drive shaft causes displacement of said force applying member.

37. The steering apparatus according to claim 36, further comprising a threaded member coupling said drive shaft to said force applying member, wherein rotation of said threaded member causes displacement of said force applying member.

38. The steering apparatus according to claim 36, further comprising a cam and a cam surface adapted to cause said displacement of said force applying member.

39. The steering apparatus according to claim 25, further comprising means for adjusting in situ the tool face angle of said bendable member so as to adjust the direction of said drilling.

40. The steering apparatus according to claim 39, wherein said means for adjusting in situ the tool face angle of said bendable member comprises means for rotating said bendable member with respect to a portion of said drill string uphole of said bendable member.

41. The steering apparatus according to claim 40, wherein said means for rotating said bendable member is coupled to and driven by said drive shaft.

42. The steering apparatus according to claim 41, wherein said means for rotating said bendable member comprises a reduction gear coupling said bendable member to said drive shaft.

43. The steering apparatus according to claim 42, wherein said reduction gear comprises a harmonic drive.

44. The steering apparatus according to claim 42, wherein said reduction gear comprises epicyclic gearing.

45. The steering apparatus according to claim 39, wherein said means for adjusting in situ the tool face angle of said bendable member comprises (i) means for establishing a reference tool face angle, and (ii) means for rotating said bendable member relative to said means for establishing said reference tool face angle.

46. The steering apparatus according to claim 45, wherein said means for establishing said reference tool face angle comprises an asymmetrically weighted member.

47. An apparatus for steering a drill bit used to drill a bore hole in an earthen formation, said apparatus forming a portion of a bottom hole assembly of a drill string to which said drill bit is coupled, rotation of said drill bit being driven by a drive shaft coupled to said drill string, said steering apparatus comprising:

(a) a bendable member adapted to be incorporated into said bottom hole assembly, said bendable member having a preferential direction in which said bendable member bends when a force is applied to said bendable member, said preferential direction in which said bendable member bends being angularly oriented at a first tool face angle with respect to a portion of said bottom hole assembly, wherein the amount of bending of said bendable member in said preferential direction determines the degree of change in the direction of said drilling; and

(b) a coupling that couples said drive shaft to said bendable member so that rotation of said drive shaft changes said first tool face angle of said preferential direction in which of said bendable member bends.

48. The steering apparatus according to claim 47, wherein said coupling comprises a reduction gear.

49. The steering apparatus according to claim 48, wherein said reduction gear is a harmonic drive.

50. The steering apparatus according to claim 48, wherein said reduction gear is an epicyclic gear.

51. The steering apparatus according to claim 47, wherein said bendable member comprises a flexible housing adapted to be mounted in said bottom hole assembly uphole of said drill bit.

52. The steering apparatus according to claim 47, wherein said bendable member has at least one weakening feature incorporated therein.

53. The steering apparatus according to claim 47, further comprising an eccentrically weighted member adopted to be rotatably mounted in said bottom hole assembly, wherein said eccentrically weighted member tends to rotate into a circumferential orientation in which said eccentric weight is oriented downward with respect to said earthen formation.

54. The steering apparatus according to claim 53, wherein said drive shaft rotates said bendable member relative to said eccentrically weighted member.

55. A method of steering a drill bit coupled to a drill string having a bottom hole assembly and drilling a bore hole into an earthen formation, said method comprising the steps of:

(a) rotating said drill bit so as to drill said bore hole into said earthen formation in a first direction by rotating a drive shaft coupled to said drill bit while simultaneously pumping a drilling fluid through said drill string at a first flow rate; and

(b) changing the direction in which said drill bit drills said bore hole by bending a bendable portion of said bottom hole assembly in situ in said bore hole.

56. The steering method according to claim 55, wherein said bending of said bendable portion of said bottom hole assembly is effected by rotating said drive shaft while pumping said drilling fluid through said drill string at a second flow rate lower than said first flow rate.

57. The steering method according to claim 56, wherein said second flow rate of drilling fluid is essentially zero.

58. The steering method according to claim 55, wherein said bendable portion of said bottom hole assembly is bent by a bend inducing mechanism disposed in said bottom hole assembly, and wherein said drive shaft drives said bend inducing mechanism through a reduction gear coupling said drive shaft to said bend inducing mechanism.

59. The steering method according to claim 58, wherein said reduction gear is a harmonic drive.

60. The steering method according to claim 58, wherein said reduction gear is an epicyclic gear.

61. The steering method according to claim 58, wherein said driving of said bend inducing mechanism by said drive shaft is effected by biasing a piston coupled to said drive shaft into engagement with said reduction gear.

62. The steering method according to claim 55, wherein said bend inducing mechanism bends said bendable portion of said bottom hole assembly by placing a bendable member mounted in said bottom hole assembly in compression.

63. The steering method according to claim 62, wherein said bendable member is placed in compression by placing a tension member coupled to said bendable member in tension.

64. The steering method according to claim 55, further comprising changing the direction in which said drill bit drills said bore hole by rotating said bendable portion of said bottom hole assembly relative to an uphole portion of said bottom hole assembly in situ in said bore hole.

65. A method of steering a drill bit coupled to a drill string having a bottom hole assembly and drilling a bore hole into an earthen formation, said method comprising the steps of:

(a) rotating said drill bit so as to drill said bore hole into said earthen formation in a first direction by rotating a drive shaft coupled to said drill bit while simultaneously pumping a drilling fluid through said drill string at a first flow rate, at least a first portion of said bottom hole assembly having a bend formed therein;

(b) changing the direction in which said drill bit drills said bore hole, wherein;

(i) said change in the direction in which said drill bit drills said bore hole is effected by rotating said first portion of said bottom hole assembly having said bend formed therein relative to a second portion of said bottom hole assembly disposed uphole of said first portion;

(ii) said first portion of said bottom hole assembly having said bend formed therein is rotated relative to a second portion of said bottom hole assembly using a tool face setting mechanism;

(iii) said relative rotation of first portion of said bottom hole assembly is effected by rotating said drive shaft while pumping said drilling fluid through said drill string at a second flow rate lower than said first flow rate, said rotation of said drill string while pumping drilling fluid at said second flow rate causing said drive shaft to drive said tool face setting mechanism so as to rotate said first portion of said bottom hole assembly relative to said second portion.

66. The steering method according to claim 65, wherein said second flow rate of drilling fluid is essentially zero.

67. The steering method according to claim 65, wherein said drive shaft drives said tool face setting mechanism through a reduction gear coupled between said drive shaft and said tool face setting mechanism.

68. The steering method according to claim 67, wherein said drive shaft is caused to drive said tool face setting mechanism by biasing a piston coupled to said drive shaft into engagement with said reduction gear.