Method and apparatus for automatic closed loop drilling system

• US 5,332,048 A
• Filed: 10/23/1992
• Issued: 07/26/1994
• Est. Priority Date: 10/23/1992
• Status: Expired due to Term

• Current Assignee: Halliburton Company
• Original Assignee: Halliburton Company
• Inventors: Underwood, Lance D., Dewey, Charles H., Johnson, Harold D.
• Primary Examiner(s): Bui, Thuy M.
• Assistant Examiner(s): TSAY, FRANK
• Application Number:
  US07/965,200
• Time in Patent Office: 641 Days
• Field of Search: 175/61, 175/76, 175/73, 175/321, 175/325.4, 175/26
• US Class Current: 175/26
• CPC Class Codes: E21B 44/005 Below-ground automatic control systems
• 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

An automatic closed loop drilling system is disclosed for providing automatic directional drilling capabilities in a bottomhole assembly. The drilling system includes at least one adjustable stabilizer that varies in response to formational and drilling conditions encountered downhole. A microcontroller is preprogrammed with a desired range of formation characteristics or with a desired inclination or target area. The microcontroller compares actual sensed data with the desired data and adjusts the position of the stabilizer blades to vary the direction of drilling.

Claims

1. A drilling system for a bottomhole assembly, comprising:

a drill bit;

a first stabilizer positioned near said drill bit, said first stabilizer having a generally tubular configuration with a particular cross-sectional diameter;

a second stabilizer positioned in the bottom hole assembly a predetermined distance above said first stabilizer, said second stabilizer having a generally tubular configuration with a particular cross-sectional diameter,

wherein the diameter of at least one of said first or second stabilizers is adjustable, between a retracted position and a plurality of extended positions, in response to a position control signal;

sensors for determining formation properties and for generating signals indicative thereof;

a microcontroller receiving the signals from said sensors, said microcontroller being located in said bottomhole assembly and being preprogrammed to respond to the signals from said sensor;

said microcontroller generating the position control signal when the sensed formation properties are outside a predetermined range;

wherein said position control signal from said microcontroller is used to adjust the diameter of the first or second stabilizer to alter the inclination angle at which said drill bit is drilling.

2. A system as in claim 1, wherein the diameter of said first stabilizer is adjustable between the retracted position and the plurality of extended positions.

3. A system as in claim 1, wherein the diameter of said second stabilizer is adjustable between the retracted position and the plurality of extended positions.

4. A system as in claim 3, further comprising a downhole motor positioned between said first stabilizer and said second stabilizer.

5. A closed loop drilling system for providing inclination control to a bottomhole assembly, comprising:

a drill bit;

a first stabilizer positioned in said bottomhole assembly near said drill bit;

a second stabilizer positioned in said bottomhole assembly a predetermined distance above said first stabilizer,

wherein both the first stabilizer and the second stabilizer have an effective cross-sectional diameter, and

wherein the diameter of at least one of said first or second stabilizers is adjusted to control the inclination at which the bottomhole assembly drills, and includes;

a plurality of stabilizer blades that are adjustable between a retracted position and an extended position to change the effective diameter of the stabilizer;

means for positioning said plurality of stabilizer blades;

means for controlling the operation of said closed loop drilling system, said means for controlling located in said bottomhole assembly and being programmed to drill at a desired inclination, and including means for measuring the actual inclination of the bottomhole assembly and producing an electrical output signal indicative of the actual inclination;

said means for controlling also including means for comparing the electrical output signal indicative of actual inclination with the desired inclination;

said comparing means generating a position control signal that is transmitted to said positioning means to set the diameter of said stabilizer blades.

6. A system as in claim 5, wherein said means for positioning includes:

means for driving the blades outwardly; and

means for limiting the outward expansion of said blades.

7. A system as in claim 6, wherein said positioning means receives said control signal and adjusts the means for limiting to limit the outward expansion of said blades.

8. A system as in claim 5, wherein said first stabilizer is adjustable and includes a plurality of stabilizer blades that adjust between a fully retracted position and a plurality of extended positions.

9. A system as in claim 5, wherein said second stabilizer is adjustable and includes a plurality of stabilizer blades that adjust between a fully retracted position and a plurality of extended positions.

10. A system as in claim 9, further comprising a downhole motor positioned between said first stabilizer and said second stabilizer.

11. An automatic drilling system, comprising:

a drill bit located at the end of a drill string;

a stabilizer positioned in the drill string above said drill bit;

sensors for sensing parameters downhole and generating a signal indicative thereof, said sensor being located in said drill string; and

means for transmitting said signal indicative of said sensed parameters;

a controller for receiving the signal from said transmitting means and for comparing said signal indicative of downhole parameters with predetermined data reflecting desired parameters, and generating a position control signal if the desired parameters differ from the sensed parameters;

wherein said stabilizer is adjustable and comprises;

a generally tubular housing with a plurality of openings;

a plurality of blades, each blade movably mounted within a respective opening to extend from a first retracted position to a plurality of positions extending at different radial distances from said housing; and

positioning means for setting the radial extent of said blades, and wherein said positioning means receives said control signal from said control means and varies the position of the blades to change the inclination angle at which the drilling system drills.

12. A system as in claim 11 further comprising a near bit stabilizer positioned in the drill string between said adjustable stabilizer and said drill bit.

13. A system as in claim 12, wherein the near bit stabilizer has a diameter that also is adjustable.

14. A system as in claim 12, further comprising a drill collar between said near bit stabilizer and said adjustable stabilizer, and wherein the drilling system operates in a rotary mode.

15. A system as in claim 12, wherein said near bit stabilizer comprises an azimuth control device.

16. A system as in claim 11 further comprising a second stabilizer positioned in the drill string a predetermined distance above said adjustable stabilizer.

17. A system as in claim 16, wherein the second stabilizer has a diameter that also is adjustable.

18. A system as in claim 14, wherein at least one of the sensors is located in said drill collar.

19. A method for automatically controlling the direction in which a bottomhole assembly drills, said bottomhole assembly including a stabilizer with blades that adjust between a retracted position and a plurality of extended positions, comprising the steps of:

(a) setting the position of the blades of said stabilizer to a particular diameter;

(b) operating a drill bit to drill into a downhole formation;

(c) measuring the actual inclination of the bottomhole assembly;

(d) comparing, in a downhole controller, the actual inclination with a planned inclination;

(e) generating in the downhole controller a position control signal if the actual inclination deviates significantly from planned inclination; and

(f) altering the position of the blades in response to said position control signal to provide a real-time change to the inclination of said bottomhole assembly.

20. A method as in claim 19, wherein the signal generated in step (e) indicates whether inclination is too high.

21. A method as in claim 20, wherein the position of the blades in step (f) is expanded.

22. A method as in claim 19, wherein the signal generated in step (e) indicates whether inclination is too low.

23. A method as in claim 22, wherein the position of the blades in step (f) is retracted.

24. A method for automatically controlling the inclination at which a bottomhole assembly drills a formation, said bottomhole assembly including a stabilizer with blades that adjust between a retracted position and a plurality of extended positions, comprising the steps of:

(a) setting the position of the blades;

(b) rotating a drill bit to drill into the downhole formation;

(c) determining the characteristics of the formation in which the bottomhole assembly is drilled;

(d) comparing the characteristics of the formation being drilled with a range of predetermined characteristics for a desired formation;

(e) generating a control signal if the characteristics of the formation being drilled are outside the range of the predetermined characteristics; and

(f) altering the position of the blades in response to said control signal to change the inclination at which the bottomhole assembly drills.

25. A method as in claim 24, wherein the range of predetermined characteristics are set before the bottomhole assembly begins drilling.

26. A method as in claim 24, wherein the range of predetermined characteristics are communicated from the surface to the bottom hole assembly through a telemetry means after a desired formation has been entered by the bottomhole assembly.