System for directional control of drilling

• US 6,109,370 A
• Filed: 01/20/1999
• Issued: 08/29/2000
• Est. Priority Date: 06/25/1996
• Status: Expired due to Fees

• Current Assignee: Ian Gray
• Original Assignee: Ian Gray
• Inventors: Gray, Ian
• Primary Examiner(s): TSAY, FRANK
• Application Number:
  US09/011,999
• Time in Patent Office: 587 Days
• Field of Search: 175/61, 175/24, 175/27, 175/45, 175/38, 175/324, 175/215
• US Class Current: 175/61
• CPC Class Codes: E21B 21/10 Valve arrangements in drilling-fluid circulation systems
• 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 7/065 using oriented fluid jets
• 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 drill bit (6) is equipped with one or more fluid jets (7) that are activated during a portion of the rotational movement of the drill bit (6). A processor (41) located with other down-hole sensors (33-38), is programmed with parameters defining the desired path of the borehole (8). The sensors (33-38) determine the actual spatial location of the drill bit (6) and provide the processor (41) with corresponding information. The processor (41) compares the actual drilling path to the desired path, and if a correction is required, a switching module (3) allows a pressurized drill fluid to be sequentially switched to selected jets (7) during rotation of the drill bit (6) to thereby erode the formation in a direction toward the desired path. With this arrangement, the problems of directional control by surface-located equipment are overcome.

Claims

1. A bottom-hole assembly for controlling the direction of a path of a borehole during formation thereof, comprising:

a port in said assembly for receiving a pressurized fluid;

a rotating fluid carrying mechanism operable for changing the direction of the drilling path,

an electrically operated fluid switch for selectively controlling coupling of said pressurized fluid to said fluid carrying mechanism to change the path of the borehole;

one or more sensors for sensing a rotational position as said bottom-hole assembly rotates; and

a programmed processor responsive to said rotational sensor for controlling activation of said electrical fluid switch at different times during each rotation of said bottom-hole assembly so that the pressurized fluid can be switched to said mechanism to control the direction of the drilling path.

2. An assembly according to claim 1, wherein said processor is programmed with a profile of a desired path to be taken to form said borehole, and programmed to compare the parameters of an actual location with the profile of the desired path, and programmed to actuate said fluid switch based on a difference found in said comparison.

3. An assembly according to claim 1, wherein said fluid carrying mechanism comprises at least one nozzle for providing a jet of said pressurized fluid.

4. An assembly according to claim 1, wherein said electrically operated fluid switch selectively controls at least one nozzle which controls the path direction by exerting a force in a direction opposite to a direction of an intended path.

5. An assembly according to claim 4, wherein said electrically operated fluid switch is included in a bi-stable fluidic switching system that has plural stages for successively increasing the fluid power in the bottom-hole assembly.

6. An assembly according to claim 1, further including a fluidic amplifier means coupled to said fluid carrying mechanism for increasing a quantity of fluid passing thereto.

7. An assembly according to claim 6, including at least a pair of nozzles, and a bi-stable fluidic switching system having a primary fluid duct controlled by a pair of inlet fluid channels, each fluid channel for controlling the flow of fluid to a respective said nozzle.

8. An assembly according to claim 7, wherein said bi-stable fluidic switching system includes a spool valve having two stable positions controlled by respective channels of the fluidic amplifier.

9. An assembly according to claim 1, wherein said fluid switch comprises an electromagnetic fluid switch to divert fluid flow between at least two channels by electromagnetically displacing an obturating device to close one channel at a time.

10. An assembly according to claim 1, wherein said fluid carrying mechanism comprises a mechanical assembly for changing by fluid controls an angular build characteristic of the bottom-hole assembly including a down-hole fluid operated motor.

11. An assembly according to claim 1, wherein said fluid carrying mechanism comprises a clutch which selectively rotationally disengages a lower part of the bottom-hole assembly that includes a down-hole motor and a bent sub, from the upper part and which permits reactive torque to change a tool face angle of said lower part of the bottom hole assembly so as to effect controllable change of the tool face angle and hence a preferred direction of drilling.

12. An assembly according to claim 1, further including a device to detect an angular position of a rotating bottom hole assembly utilizing an electrical output of an electromagnetic coil attached to and rotating with the bottom hole assembly and excited by the magnetic field of the earth.

21. The method according to claim 12, wherein the information from the borehole collar is transmitted down-hole by means of pulses.

13. A method of controlling the path of an underground borehole during formation thereof, comprising the steps of:

advancing in the earth a pressurized fluid conveyor with a bottom-hole assembly incorporating at least one fluid jet nozzle, an electrical fluid switch and a programmed processor for controlling said electrical fluid switch, and a positional sensor for sensing an arcuate position during rotation of said bottom-hole assembly;

providing arcuate position data to said programmed processor;

causing electrical signals to be generated by said processor in response to said arcuate position data, so that said electrical fluid switch is both electrically activated and deactivated at least once for each revolution of said bottom-hole assembly; and

controlling said electrical fluid switch for switchably coupling the pressurized fluid from said fluid conveyor to said fluid jet nozzle by said processor to control the direction of the path of the borehole.

14. The method according to claim 13, wherein at least one fluid jet nozzle is utilized to form the borehole by directional erosion, and a different fluid jet nozzle is selectively switched for directional control.

15. The method according to claim 13, comprising the steps of:

coupling a fluid-controlled clutch to a mechanism for controlling an angular build rate of the bottom-hole assembly; and

using a fluid switching system to switchably control said clutch to adjust the angular build characteristics of the bottom-hole assembly.

16. The method according to claim 13, further including increasing the fluid power available to the bottom-hole assembly by using a down-hole fluidic amplifier.

17. The method according to claim 16, further including using a spool valve driven by the fluidic amplifier to divert fluid flow to actuate adjustments in the angular build characteristics of the bottom-hole assembly.

18. The method according to claim 13, including using a fluidic amplifier switching system having multiple stages.

19. The method of claim 13, further including transmitting information from surface located equipment to the bottom-hole assembly by utilizing negative or positive fluid pulses.

20. The method of claim 13, further including obtaining information from angular position sensors contained within the bottom-hole assembly and combining said information with information transmitted from a borehole collar to the bottom-hole assembly to thereby compute the physical location of the bottom hole assembly.