Navigable downhole drilling system

• US 5,269,383 A
• Filed: 01/15/1992
• Issued: 12/14/1993
• Est. Priority Date: 01/15/1992
• Status: Expired due to Term

• Current Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Original Assignee: Drilex Systems, Inc. (Baker Hughes Company)
• Inventors: Forrest, John
• Primary Examiner(s): NOVOSAD, STEPHEN
• Application Number:
  US07/822,359
• Time in Patent Office: 699 Days
• Field of Search: 175/107, 175/104, 175/106, 175/101, 175/92, 175/95, 175/45, 175/40, 175/26, 415/122.1, 418/48
• US Class Current: 175/26
• CPC Class Codes: E21B 4/02 Fluid rotary type drives
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: E21B 44/005 Below-ground automatic control systems
• CPC Class Codes: E21B 47/022 of the borehole, e.g. using geomagnetism
• 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 navigable downhole drilling system incorporating a drilling motor having a system of sensors and information processors for determining the depth, inclination, direction and thrust of the drilling motor. Accordingly, the drilling operation can be continuously monitored and adjusted to ensure desired directional drilling. A programmed processor may be incorporated into the drilling system to guide the drilling motor along a predetermined course. A generator assembly provides power to the processors and sensors as a result of the precessional rotation of the rotor within the stator of the drilling motor. The overall length of the drilling system is minimized by piggybacking the thrust bearings with the power generation unit and siamesing the transmission assembly for the drilling motor with the power section of the motor. As a result, a downhole drilling system of navigable length is created which can be readily directed along the desired course.

Claims

1. A downhole drilling system for drilling a borehole along a predetermined trajectory, said drilling system connected to a drill string, said drilling system comprising:

a drilling motor for operating a drill bit independent of the drill string, said drilling motor including a stator and a rotor operatively displaceable within said stator, said drill bit drivably connected to said rotor;

means for measuring the operating parameters of said drilling system to ensure drilling along the predetermined trajectory; and

power generation means drivably connected to said rotor of said drilling motor for supplying power to said measuring means of said drilling system.

2. The drilling system as defined in claim 1 and further comprising an information processing unit mounted within said drilling system in electrical communication with said measuring means and said power generation means, said generation means supplying power to operate said processing unit and said unit processing information communicated by said measuring means.

3. The drilling system as defined in claim 2 wherein said processing unit alters the trajectory of said drilling system in accordance with information communicated by said measuring means.

4. The drilling system as defined in claim 2 wherein said processing unit intermittently communicates a signal to the surface in accordance with information communicated by said measuring means.

5. The drilling system as defined in claim 1 wherein said power generation means is drivably connected to said rotor by a crankshaft which translates the precessional motion of said rotor to said power generation means, said crankshaft being connected to an upper end of said rotor.

6. The drilling assembly as defined in claim 5 and further comprising a transmission assembly axially below said drilling motor for transmitting the displacement motion of said rotor within said stator to said drill bit, said transmission assembly operatively connected to said upper end of said rotor by an output shaft and including a transmission shaft connected to said drill bit.

7. The drilling system as defined in claim 6 and further comprising a thrust bearing assembly contained within a sealed housing axially above said drilling motor, said thrust bearing assembly mounted to said crankshaft extending from said drilling motor.

8. The drilling assembly as defined in claim 7 wherein said upper end of said rotor, said crankshaft and said output shaft are connected by a single coupling such that thrust loads transmitted through said drill bit and output shaft are absorbed by said thrust bearing assembly.

9. The drilling assembly as defined in claim 6 wherein said measuring means includes first sensors proximate said transmission shaft for measuring forces acting upon said drill bit and second sensors proximate said drilling motor for measuring inclination of said drilling system along the trajectory.

10. The drilling assembly as defined in claim 9 wherein said transmission shaft is radially supported by joinal bearings, said first sensors mounted within said bearings to determine the location of said transmission shaft relative to said joinal bearings, said first sensors determining the radial and longitudinal displacement of said transmission shaft relative to said joinal bearings.

11. The drilling assembly as defined in claim 6 wherein said transmission assembly includes a transmission joint translating the eccentric motion of said output shaft to a rotary motion in said transmission shaft.

12. A downhole drilling system for drilling a borehole along a predetermined trajectory, said drilling system connected to a drill string, said drilling system comprising:

a positive displacement drilling motor for operating a drill bit independent of the drill string, said drilling motor including a stator, said drill bit drivably connected to said rotor by an output shaft;

means for measuring the operating parameters of said drilling system to ensure drilling along the predetermined trajectory;

power generation means drivably connected to said rotor of said drilling motor by a crankshaft whereby operation of said drilling motor drives said generation means, said generation means supplying power to said measuring means of said drilling system; and

a thrust bearing assembly contained within a sealed- housing axially above said drilling motor, said thrust bearing assembly mounted to said crankshaft to absorb thrust loads associated with drilling.

13. The drilling system as defined in claim 12 and further comprising an information processing unit mounted within said drilling system in electrical communication with said measuring means and said power generation means, said generation means supplying power to operate said processing unit and said unit processing information communicated by said measuring means.

14. The drilling system as defined in claim 12 and further comprising a transmission assembly axially below said drilling motor for transmitting the displacement motion of said rotor to said drill bit, said transmission assembly including a transmission joint operatively connected to an upper end of said rotor by an output shaft of said drilling motor and to a transmission shaft connected to said drill bit.

15. The drilling system as defined in claim 14 wherein said measuring means includes first sensors proximate said transmission shaft for measuring forces acting upon said drill bit and second sensors proximate said drilling motor for measuring inclination of said drilling system along the predetermined trajectory.

16. The drilling system as defined in claim 15 wherein said first sensors include proximity sensors disposed within joinal bearings radially supporting said transmission shaft, said proximity sensors measuring radial and longitudinal displacement of said transmission shaft thereby determining forces acting on said drill bit.

17. The drilling system as defined in claim 14 wherein said upper end of said rotor, said output shaft of said drilling motor and said crankshaft are interconnected by a coupling.

18. A downhole drilling system for drilling a borehole along a predetermined trajectory, said drilling system connected to a drill string, said drilling system comprising:

a positive displacement drilling motor for operating a drill bit independent of the drill string, said drilling motor including a stator and a rotor operatively displaceable within said stator;

a transmission assembly axially below said drilling motor for transmitting the displacement motion of said rotor within said stator to said drill bit, said transmission assembly operatively connected to said drilling motor by an output shaft;

sensor means disposed within said drilling system for measuring the operating parameters of said drilling system to ensure drilling along the predetermined trajectory;

power generation means drivably connected to said rotor of said drilling motor by a crankshaft, whereby said drilling motor drives said generation means, said generation means supplying power to operate said sensor means of said drilling system; and

a thrust bearing assembly contained within a sealed housing axially above said drilling motor, said sealed thrust bearing assembly mounted to said crankshaft to absorb the thrust loads associated with drilling.

19. The drilling system as defined in claim 18 and further comprising an information processing unit mounted within said drilling system, said generation means supplying power to operate said processing unit and said unit processing information communicated by said sensor means to ensure drilling along the predetermined trajectory.

20. The drilling system as defined in claim 18 wherein said output shaft of said drilling motor and said crankshaft are drivably connected to an upper end of said rotor by a coupling.

21. A downhole drilling system for drilling a borehole along a predetermined trajectory, said drilling system connected to a drill string, said drilling system comprising:

a positive displacement drilling motor for operating a drill bit independent of the drill string, said drilling motor including a stator and a rotor operatively displaceable with said stator, said rotor having a first shaft extending upwardly therefrom above said drilling motor;

a transmission assembly axially below said drilling motor for transmitting the displacement motion of said rotor within said stator to said drill bit, said transmission assembly operatively connected to said rotor of said drilling motor by an output shaft; and

a thrust bearing assembly contained within a sealed housing axially above said drilling motor, said thrust bearing assembly connected to said first shaft extending upwardly from said rotor of said drilling motor such that said thrust bearing assembly and said first shaft are connected to an upper end of said rotor whereby thrust loads associated with drilling are absorbed by said thrust bearing assembly.

22. A downhole drilling system for drilling a borehole along a predetermined trajectory, said drilling system connected to a drill string, said drilling system comprising:

a positive displacement drilling motor for operating a drill bit independent of the drill string, said drilling motor including a stator and a rotor operatively displaceable within said stator;

a transmission assembly axially below said drilling motor for transmitting the displacement motion of said rotor within said stator to said drill bit, said transmission assembly operatively connected to said drilling motor by an output shaft and including a transmission shaft connected to said drill bit;

first sensors proximate said transmission shaft for measuring and communicating forces acting upon said drill bit;

second sensors mounted within said drilling system for measuring and communicating inclination of said drilling system along the trajectory;

third sensors proximate said drilling motor for measuring and communicating operating parameters of said drilling motor;

power generation means drivably connected to said rotor of said drilling motor by a crankshaft whereby precession motion of said rotor within said drilling motor is transmitted through said crankshaft to drive said generation means said generation means supplying power to operate said sensors.