Active controlled bottomhole pressure system & method

• US 7,114,581 B2
• Filed: 02/20/2004
• Issued: 10/03/2006
• Est. Priority Date: 07/15/1998
• Status: Expired due to Term

• Current Assignee: DEEP Vision, LLC
• Original Assignee: DEEP Vision, LLC
• Inventors: Fincher, Roger, Aronstam, Peter, Krueger, Volker, Watkins, Larry, Grimmer, Harald, Krueger, Sven, Fontana, Peter
• Primary Examiner(s): Tsay, Frank
• Application Number:
  US10/783,471
• Publication Number:
  US 20040206548A1
• Time in Patent Office: 956 Days
• Field of Search: 175/57, 175/65, 175/7, 175/5, 175/25, 175/48, 175/38, 175/217, 175/393, 175/339, 175/324, 166/368
• US Class Current: 175/57
• CPC Class Codes: B63B 21/502 by means of tension legs
• CPC Class Codes: E21B 17/206 with conductors, e.g. electrical, optical
• CPC Class Codes: E21B 19/002 specially adapted for underwater drilling E21B19/09, E21B19/143 take precedence
• CPC Class Codes: E21B 19/09 specially adapted for drilling underwater formations from a floating support using heave compensators supporting the drill string
• CPC Class Codes: E21B 19/22 Handling reeled pipe or rod units, e.g. flexible drilling pipes lifting or hauling appliances using two or more cooperating endless chains B66D3/003
• CPC Class Codes: E21B 21/08 Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure valve arrangements therefor E21B21/10
• CPC Class Codes: E21B 21/085 Underbalanced techniques, i.e. where borehole fluid pressure is below formation pressure
• CPC Class Codes: E21B 33/076 specially adapted for underwater installations
• CPC Class Codes: E21B 4/006 Mechanical motion converting means, e.g. reduction gearings E21B4/10 takes precedence
• CPC Class Codes: E21B 4/02 Fluid rotary type drives
• CPC Class Codes: E21B 7/002 Drilling with diversely driven shafts extending into the borehole ⁠ E21B7/001 takes precedence
• CPC Class Codes: E21B 7/128 from floating support with independent underwater anchored guide base
• CPC Class Codes: E21B 7/28 Enlarging drilled holes, e.g. by counterboring

Abstract

A wellbore drilling system has an umbilical that carries a drill bit in a wellbore. Drilling fluid pumped into the umbilical discharges at the drill bit bottom and returns through an annulus between the umbilical and the wellbore carrying entrained drill cuttings. An active differential pressure device (APD device), such as a jet pump, turbine or centrifugal pump, in fluid communication with the returning fluid creates a differential pressure across the device, which alters the pressure below or downhole of the device. The APD device can be driven by a positive displacement motor, a turbine, an electric motor, or a hydraulic motor. A controller controls the operation of the APD device in response to programmed instructions and/or one or more parameters of interest detected by one or more sensors. A preferred system is a closed loop system that maintains the wellbore at under-balance condition, at-balance condition or over-balance condition.

Claims

1. A drilling system for drilling a wellbore, comprising:

(a) a drill string;

(b) a source of drilling fluid supplying drilling fluid under pressure into the drill string (a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

); and

(c) an active pressure differential device (“

APD Device”

) associated with the return fluid to create a pressure drop across said APD Device to reduce pressure in the annulus around the drill string downhole of said APD Device.

2. The drilling system of claim 1, wherein said APD Device is selected from one of (a) a positive displacement pump, (b) a centrifugal type pump, and (c) a Moineau-type pump.

3. The drilling system of claim 1 further comprising:

a drive assembly coupled to said APD Device and energizing said APD Device.

4. The drilling system of claim 3, wherein said drive assembly is selected from one of (a) a positive displacement drive, (b) a turbine drive, (c) an electric motor, (d) a hydraulic motor, (e) a Moineau-type motor, and (f) a rotating drill string.

5. The drilling system of claim 3 further comprising a speed converter interposed between said drive assembly and said APD device, said speed converter being adapted to convert a first speed associated with said drive assembly to a selected second speed associated with said APD device.

6. The drilling system of claim 5, wherein said speed converter is selected from a group consisting of (i) a gear drive, (ii) a hydrostatic drive, and (iii) a hydrodynamic drive.

7. The drilling system of claim 3 further comprising a bypass selectively diverting fluid around said drive assembly.

8. The drilling system of claim 1 further comprising a bypass selectively diverting fluid around said APD device.

9. The drilling system of claim 1 further comprising an annular seal disposed around said APD device, said annular seal causing the return fluid to flow into said APD device and allowing said APD device to create a differential pressure thereacross.

10. The drilling system of claim 1 further comprising a controller operatively connected to said APD Device, the controller controlling the operation of said APD Device.

11. The drilling system of claim 10, wherein said controller is located at one of:

(i) at the surface;

(ii) in a drilling assembly attached to the drill string; and

(iii) adjacent said APD Device.

12. The drilling system of claim 10, wherein said controller controls said APO Device in response to one of:

(i) a parameter of interest;

(ii) programmed instructions provided to said controller;

(iii) instructions from a remote location; and

(iv) a downhole measured parameter.

13. The drilling system of claim 10, wherein said controller includes one of (a) a microprocessor and a memory, and (b) a hydro-mechanical device.

14. The drilling system of claim 10, wherein said controller is positioned in the wellbore;

and further comprises a telemetry system for transmitting signals to said controller.

15. The drilling system of claim 10, wherein said controller controls the operation of said APD Deviee to control the pressure in the wellbore to one of:

(i) maintain the wellbore boftomhole pressure at a predetermined value;

(ii) maintain the wellbore bottomhole pressure within a selected range;

(iii) maintain an at-balance condition; and

(iv) maintain an under-balance condition.

16. The drilling system of claim 1 further comprising a blocking device downhole of said APD Device that blocks the return fluid flow when the drilling fluid supply is interrupted or stopped.

17. The drilling system of claim 1, wherein said APD device is attached to one of (a) said drill string, (b) a location stationary relative to said drill string, (c) the annulus, and (d) a riser.

18. A drilling system for drilling a wellbore, comprising:

(a) a drill string;

(b) a source of drilling fluid supplying drilling fluid under pressure into the drill string (a “

supply fluid”

) the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

);

(c) an active pressure differential device (“

APD Device”

) associated with the return fluid to create a pressure drop across said APD Device to reduce pressure in the annulus around the drill string downhole of said APD Device; and

(d) a comminution device positioned downhole of said APD device, said comminution device configured to reduce the size of cuttings entrained in the return fluid.

19. The drilling system of claim 18, wherein said comminution device includes a shaft coupled to a rotor associated with said APD Device and a conical head mounted on an end thereof, said shaft having a radial motion corresponding to an eccentric motion of said rotor, said conical head thereby engaging and reducing the size of the cuttings.

20. The drilling system of claim 18, wherein said APD Device comprises a centrifugal type pump and said comminution device comprises a shearing member configured as a stage in said centrifugal type pump.

21. A drilling system for drilling a wellbore, comprising:

(a) a drill string;

(b) a source of drilling fluid supplying drilling fluid under pressure into the drill string(a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

); and

(c) an active pressure differential device (“

APD Device”

) associated with the return fluid to create a pressure drop across said APD Device to reduce pressure in the annulus around the drill string downhole of said APD Device; and

(d) sensor for detecting a parameter of interest.

22. The drilling system of claim 21, wherein said sensor detects a parameter selected from a group consisting of (i) drilling parameters, (ii) drilling assembly parameters, and (iii) formation evaluation parameters.

23. The drilling system of claim 21, wherein said sensor is positioned at a predetermined location selected from a group consisting of (i) a surface location, (ii) at said APD Device, (iii) at wellhead equipment, (iv) in the supply fluid, (v) along said drill stung, (vi) at a drilling assembly connected to said drill string, (vii) in the return fluid upstream of said APD device, and (viii) in the return fluid downstream of said APD device.

24. A drilling system for drilling a wellbore, comprising

(a) a drill string;

(b) a source of drilling fluid supplying drilling fluid under pressure into the drill string (a “

usupply fluid”

), said drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

);

(c) an active pressure differential device (“

APD Device”

) placed in the annulus to create a pressure drop across said APD Device to reduce pressure in the wellbore downhole of said APD Device, said APD Device in fluid communication with the return fluid; and

(d) an electric drive assembly being substantially isolated from the supply fluid.

25. The drilling system of claim 24, wherein said electric drive assembly is disposed in a location selected from (a) in housing that substantially isolates said electric drive assembly from the supply fluid, and (b) on the outside of said drill string.

26. The drilling system of claim 24 further comprising a speed converter interposed between said drive assembly and said APD device, said speed converter adapted to convert a first speed associated with said drive assembly to a selected second speed associated with said APD device.

27. The drilling system of claim 26, wherein said speed converter is selected from a group consisting of (i) a gear drive, (ii) a hydrodynamic drive, and (iii) a hydrostatic drive.

28. The drilling system of claim 24 further comprising a comminution device positioned downhole of said APD device, said comminution device configured to reduce the size of particles entrained in said drilling fluid.

29. The drilling system of claim 28, wherein said comminution device is coupled to said drive assembly and energized thereby.

30. The drilling system of claim 28, wherein said comminution device comprises a shearing member configured as a stage in a centrifugal type pump associated with said APD Device.

31. The drilling system of claim 24 further comprising an annular seal disposed around said APD device, said annular seal causing drilling fluid to flow into said APD device.

32. The drilling system of claim 24, wherein said APD Device includes one of:

(i) a turbine; and

(ii) a centrifugal pump.

33. A method for drilling a wellbore, comprising:

(a) providing a drill string;

(b) supplying drilling fluid under pressure into the drill string (a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

); and

(c) positioning an active pressure differential device (“

APD Device”

) in fluid communication with the return fluid to create a pressure drop across the APD Device to reduce pressure in the annulus around the drill string downhole of the APD Device.

34. The method of claim 33, wherein said APD Device is selected from one of (a) a positive displacement pump, (b) a centrifugal type pump, and (c) a Moineau-type pump.

35. The method of claim 33, further comprising coupling a drive assembly to the APD Device for energizing said APD Device.

36. The method of claim 35, wherein said drive assembly is operated by one of (a) a positive displacement drive, (b) a turbine drive, (c) an electric motor, (d) a hydraulic motor, (e) a Moineau-type pump, and (f) rotation of the drill string.

37. The method of claim 35, further comprising selectively diverting fluid around the drive assembly.

38. The method of claim 33 further comprising disposing an annular seal around the APD device, the annular seal causing the return fluid to flow into the APD device and allowing the APD device to create a differential pressure.

39. The method of claim 33 further comprising controlling the operation of the APD Device with a controller that is operatively coupled to the APD Device.

40. The method of claim 39 further comprising positioning the controller at one of:

(i) at the surface;

(ii) in a drilling assembly attached to the drill string; and

(iii) adjacent the APD Device.

41. The method of claim 39, wherein the controller controls the APO Device in response to one of:

(i) a parameter of interest;

(ii) programmed instructions provided to the APD Device;

(iii) instructions provided to the APD Device from a remote location; and

(iv) a downhole detected parameter.

42. The method of claim 39 further comprising positioning the controller in the wellbore;

and transmitting signals to the controller via a telemetry system.

43. The method of claim 39, wherein the controller controls the operation of the APD Device to control the pressure in the wellbore to one of:

(i) maintain the wellbore bottomhole pressure at a predetermined value;

(ii) maintain the wellbore bottomhole pressure within a selected range;

(iii) maintain an at-balance condition; and

(iv) maintain an under-balance condition.

44. The method of claim 33 further comprising attaching the APD device to one of (a) the drill string, (b) a location stationary relative to the drill string, (c) the annulus, and (d) a riser.

45. The method of claim 33, further comprising selectively diverting fluid around the APD Device.

46. A method for drilling a wellbore, comprising:

(a) providing a drill string;

(b) supplying drilling fluid under pressure into the drill string (a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

);

(c) positioning an active pressure differential device (“

APD Device”

) in fluid communication with the return fluid to create a pressure drop across the APD Device to reduce pressure in the annulus around the drill string downhole of the APD Device; and

(d) positioning a comminution device downhole of the APD device, the comminution device configured to reduce the size of cuttings entrained in the return fluid.

47. The method of claim 46, wherein the comminution device includes a shaft coupled to a rotor associated with the APD Device and a conical head mounted on an end thereof, the shaft having a radial motion corresponding to an eccentric motion of the rotor, the conical head thereby engaging and reducing the size of the cuttings.

48. The method of claim 46, wherein the APD Device comprises a centrifugal type pump and the comminution device comprises a shearing member configured as a stage in the centrifugal type pump.

49. A method for drilling a wellbore, comprising:

(a) providing a drill string;

(b) supplying drilling fluid under pressure into the drill string (a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

);

(c) positioning an active pressure differential device (“

APD Device”

) in fluid communication with the return fluid to create a pressure drop across the APD Device to reduce pressure in the annulus around the drill string downhole of the APD Device; and

(d) detecting a parameter of interest with a sensor.

50. The method of claim 49, wherein the sensor detects a parameter selected from a group consisting of (i) drilling parameters, (ii) drilling assembly parameters, and (iii) formation evaluation parameters.

51. The method of claim 49 further comprising positioning the sensor at a predetermined location selected from a group consisting of (i) a surface location, (ii) at the APD Device, (iii) at wellhead equipment, (iv) in the supply fluid, (v) along the drill string, (vi) at a drilling assembly connected to the drill string, (vii) in the return fluid upstream of the APD device, and (viii) in the return fluid downstream of the APD device.

52. A method for drilling a wellbore, comprising

(a) providing a drill string;

(b) supplying drilling fluid under pressure into the drill string (a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

);

(c) placing an active pressure differential device (“

APD Device”

) in the annulus to create a pressure drop across the APD Device to reduce pressure in the wellbore downhole of the APD Device, the APD Device in fluid communication with the return fluid; and

(d) driving the APD device with an electric drive assembly that is substantially isolated from the supply fluid.

53. The method of claim 52 further comprising disposing the electric drive assembly in a location selected from (a) in a housing that substantially isolates the electric drive assembly from the supply fluid, and (b) on the outside of the drill string.

54. The method of claim 52 further comprising positioning a comminution device downhole of the APD device, the comminution device configured to reduce the size of particles entrained in the return fluid.

55. The method of claim 52 further comprising disposing an annular seal around the APD device, the annular seal causing drilling fluid to flow into the APD device and providing a pressure differential across the APD device.

56. The method of claim 52, wherein said APD Device includes one of:

(i) a turbine; and

(ii) a centrifugal pump.

57. A drilling system for drilling a wellbore, comprising

(a) a drill string having a drill bit at an end thereof;

(b) a source of drilling fluid supplying drilling fluid under pressure into the drill string (a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

);

(c) an active pressure differential device (“

APD Device”

) associated with the return fluid to create a pressure drop across said APD Device to reduce pressure in the annulus around the drill string downhole of said APD Device, the APD Device operating substantially independently of rotation of the drill bit.

58. A method for drilling a wellbore, comprising

(a) conveying a drill string having a drill bit into the wellbore;

(b) supplying drilling fluid under pressure into the drill string (a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

);

(c) positioning en active pressure differential device (“

APD Device”

) in fluid communication with the return fluid;

(d) operating the APD Device to create a pressure drop across the APD Device to reduce pressure in the annulus around the drill string downhole of the APD Device; and

(d) rotating the drill bit substantially independently of operating the APD Device.

59. A drilling system for drilling a wellbore, comprising:

(a) a drill string;

(b) a source of drilling fluid supplying drilling fluid under pressure into the drill string (a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

); and

(c) an active pressure differential device (“

APD Device”

) associated with the return fluid to control pressure in the annulus around the drill string downhole of said APD Device to at least partially offset an equivalent circulating density associated with the flowing drilling fluid.

60. A method for drilling a wellbore, comprising:

(a) conveying a drill string into the wellbore;

(b) supplying drilling fluid under pressure into the drill string (a “

supply fluid”

), the drilling fluid returning uphole via an annulus around the drill string (a “

return fluid”

);

(c) positioning an active pressure differential device (“

APD Device”

) in fluid communication with the return fluid; and

(d) operating the APD Device to at least partially offset an equivalent circulating density associated with the flowing drilling fluid.