Pulsed electric rock drilling apparatus

• US 7,416,032 B2
• Filed: 08/19/2005
• Issued: 08/26/2008
• Est. Priority Date: 08/20/2004
• Status: Active Grant

• Current Assignee: SDG, LLC
• Original Assignee: Tetra Corporation
• Inventors: Moeny, William M., Hill, Gilman
• Primary Examiner(s): DANG, HOANG C
• Application Number:
  US11/208,671
• Publication Number:
  US 20060037779A1
• Time in Patent Office: 1,103 Days
• Field of Search: 175/16, 299/14
• US Class Current: 175/16
• CPC Class Codes: B02C 2019/183 Crushing by discharge of high electrical energy
• CPC Class Codes: B23H 1/08 Working media
• CPC Class Codes: E21B 10/00 Drill bits specially adapted for deflecting the direction of boring E21B7/064; with means for collecting substances E21B27/00
• CPC Class Codes: E21B 7/00 Special methods or apparatus for drilling
• CPC Class Codes: E21B 7/15 of electrically generated heat
• CPC Class Codes: E21C 37/18 by electricity
• CPC Class Codes: H01B 3/20 liquids, e.g. oils silicone oils H01B3/46

Abstract

The present invention provides for pulsed powered drilling apparatuses and methods. A drilling apparatus is provided comprising a bit having one or more sets of electrodes through which a pulsed voltage is passed through a mineral substrate to create a crushing or drilling action.

Claims

1. A pulsed power drilling apparatus for passing a pulsed electrical current through a substrate, the apparatus comprising:

a drill bit;

at least one set of at least two electrodes disposed on said drill bit defining therebetween at least one electrode gap, said electrodes of each said set oriented substantially along a face of said drill bit to pass current through the substrate;

a high-voltage pulsed power generator linked to said drill bit, delivering a pulsed current between said electrodes and through the substrate;

an electrical power source powering said pulsed power generator;

an electrical conduction conduit sending high-voltage pulses from said high-voltage pulse generator to said drill bit; and

an insulating drilling fluid having a dielectric strength of at least 300 kV/cm (1 μ

sec).

2. The apparatus of claim 1 wherein at least one of said electrodes is compressible toward said drill bit.

3. The apparatus of claim 1 wherein said drill bit is rotatable.

4. The apparatus of claim 1 further comprising a plurality of mechanical teeth disposed on at least one of said electrodes.

5. The apparatus of claim 1 wherein said insulating drilling fluid has an electrical conductivity less than approximately 10⁻

5 mho/cm.

6. The apparatus of claim 1 wherein said insulating drilling fluid comprises

a dielectric constant of at least approximately 6.

7. The apparatus of claim 1 wherein at least one of said electrode sets is arranged on said bit in a configuration that is asymmetric relative to an axis of rotational symmetry of said bit.

8. The apparatus of claim 1 wherein at least one of said electrode sets is arranged on said bit in a configuration that is symmetric relative to an axis of rotational symmetry of said bit.

9. The apparatus of claim 1 wherein at least one of a first of said electrode sets is arranged on said bit in a configuration that is asymmetric relative to an axis of rotational symmetry of said bit and at least one of a second of said electrode sets is arranged on said bit in a configuration that is symmetric relative to an axis of rotational symmetry of said bit.

10. The apparatus of claim 1 further comprising a control system that varies or changes either or both a pulse repetition rate and a pulse energy on at least one asymmetric electrode as a function of azimuthal angle as it rotates to change a direction of drilling.

11. The apparatus of claim 1 further comprising a control system that varies or changes either or both a pulse repetition rate and a pulse energy among separate sets of electrodes to change a direction of drilling.

12. The apparatus of claim 1 further comprising a reamer and a reamer drag bit disposed in a drill string so that said reamer and said drill bit operate in conjunction with said drill string.

13. The apparatus of claim 12 wherein said reamer comprises a plurality of mechanical cutting teeth arranged on a reamer housing a geometry selected from the group consisting of a substantially conical shape, a substantially cylindrical shape, and a combination thereof.

14. The apparatus of claim 1 wherein at least one set of electrodes is disposed so that it touches the substrate and another of said electrodes is disposed so that it functions in close proximity to, or touches, the substrate for current to pass through the substrate.

15. The apparatus of claim 1 wherein said pulsed power generator is disposed on or near said drill bit for providing electrical current to said drill bit.

16. The apparatus of claim 1 wherein said pulse generator delivers high voltage pulses of at least approximately 100 kV.

17. The apparatus of claim 1 wherein said pulse generator comprises a capacitor bank utilizing at least one switch selected from the group consisting of a spark gap switch, a thyratron switch, a vacuum gap switch, a pseudo-spark switch, a mechanical switch, a solid state switch and a combination thereof.

18. The apparatus of claim 1 further comprising passages disposed in said bit and in which a flow of fluid is disposed for flushing debris.

19. The apparatus of claim 1 comprising a plurality of electrode sets arranged in an array.

20. The apparatus of claim 19 further comprising a steering device, steering said array by varying a repetition rate or pulse energy of some of said electrode sets relative to other said drill bits in said array.

21. The apparatus of claim 12 further comprising at least one component disposed in said drill string selected from the group consisting of a pulsed power supply, a generator to power said pulsed power, a gearbox to drive said generator, a rotating interface, a mud motor to drive said generator gearbox, a mud motor to rotate said bit, a rotating interface, a non-rotating drill pipe, a rotating rigid drill pipe, a downhole mud motor, a mud turbine, and a combination thereof.

22. The apparatus of claim 12 further comprising at least one component disposed in said drill string and selected from the group consisting of a continuous mud pipe, a rigid multi-section pipe, a rigid multi-section pipe with conductors buried in a wall of said pipe, and a rotating magnetic interface.

23. The apparatus of claim 1 wherein said bit comprises a shape selected from the group consisting of a substantially conical shape, a substantially conical shape with a plurality of conical angles, a truncated conical shape, a substantially cylindrical shape, a substantially radiused shape, and a substantially planar shape.

24. The apparatus of claim 1 wherein at least one of said electrodes comprises a shape selected from the group consisting of a radiused face where said electrode contacts the substrate, a completed circle shape, a partial circle shape, a complete ellipse shape, a partial ellipse shape, a complete parabola shape, and a partial parabola shape.

25. A pulsed power drilling apparatus for passing a pulsed electrical current through a substrate, the apparatus comprising:

a drill bit;

at least one set of at least two electrodes disposed on said drill bit defining therebetween at least one electrode gap, said electrodes of each said set oriented substantially along a face of said drill bit to pass current through the substrate;

a high-voltage pulsed power generator linked to said drill bit, delivering a pulsed current between said electrodes and through the substrate;

an electrical power source powering said pulsed power generator; and

an electrical conduction conduit sending high-voltage pulses from said high-voltage pulse generator to said drill bit, wherein at least one of a first of said electrode sets is arranged on said bit in a configuration that is asymmetric relative to an axis of rotational symmetry of said bit and at least one of a second of said electrode sets is arranged on said bit in a configuration that is symmetric relative to an axis of rotational symmetry of said bit.

26. The apparatus of claim 25 wherein at least one of said electrodes is compressible toward said drill bit.

27. The apparatus of claim 25 wherein said drill bit is rotatable.

28. The apparatus of claim 25 comprising a plurality of drill bits arranged in an array.

29. The apparatus of claim 25 further comprising a control system that varies or changes either or both a pulse repetition rate and a pulse energy on at least one asymmetric electrode as a function of azimuthal angle as it rotates to change a direction of drilling.

30. The apparatus of claim 25 further comprising a control system that varies or changes either or both a pulse repetition rate and a pulse energy among separate sets of electrodes to change a direction of drilling.

31. A pulsed power drilling apparatus for passing a pulsed electrical current through a substrate, the apparatus comprising:

a drill bit;

at least one set of at least two electrodes disposed on said drill bit defining therebetween at least one electrode gap, said electrodes of each said set oriented substantially along a face of said drill bit to pass current through the substrate;

a high-voltage pulsed power generator linked to said drill bit, delivering a pulsed current between said electrodes and through the substrate;

an electrical power source powering said pulsed power generator;

an electrical conduction conduit sending high-voltage pulses from said high-voltage pulse generator to said drill bit; and

a control system that varies or changes either or both a pulse repetition rate and a pulse energy on at least one asymmetric electrode as a function of azimuthal angle as it rotates to change a direction of drilling.

32. The apparatus of claim 31 wherein at least one of said electrodes is compressible toward said drill bit.

33. The apparatus of claim 31 wherein said drill bit is rotatable.

34. The apparatus of claim 31 wherein at least one of a first of said electrode sets is arranged on said bit in a configuration that is asymmetric relative to an axis of rotational symmetry of said bit and at least one of a second of said electrode sets is arranged on said bit in a configuration that is symmetric relative to an axis of rotational symmetry of said bit.

35. The apparatus of claim 31 comprising a plurality of electrode sets arranged in an array.

36. A pulsed power drilling apparatus for passing a pulsed electrical current through a substrate, the apparatus comprising:

a drill bit;

at least one set of at least two electrodes disposed on said drill bit defining therebetween at least one electrode gap, said electrodes of each said set oriented substantially along a face of said drill bit to pass current through the substrate;

a high-voltage pulsed power generator linked to said drill bit, delivering a pulsed current between said electrodes and through the substrate;

an electrical power source powering said pulsed power generator;

an electrical conduction conduit sending high-voltage pulses from said high-voltage pulse generator to said drill bit; and

a control system that varies or changes either or both a pulse repetition rate and a pulse energy among separate sets of electrodes to change a direction of drilling.

37. The apparatus of claim 36 wherein at least one of said electrodes is compressible toward said drill bit.

38. The apparatus of claim 36 wherein said drill bit is rotatable.

39. The apparatus of claim 36 wherein at least one of said electrode sets is arranged on said bit in a configuration that is asymmetric relative to an axis of rotational symmetry of said bit.

40. The apparatus of claim 36 wherein at least one of said electrode sets is arranged on said bit in a configuration that is symmetric relative to an axis of rotational symmetry of said bit.

41. The apparatus of claim 36 comprising a plurality of electrode sets arranged in an array.

42. A pulsed power drilling apparatus for passing a pulsed electrical current through a substrate, the apparatus comprising:

a drill bit;

at least one set of at least two electrodes disposed on said drill bit defining therebetween at least one electrode gap, said electrodes of each said set oriented substantially along a face of said drill bit to pass current through the substrate;

a high-voltage pulsed power generator linked to said drill bit, delivering a pulsed current between said electrodes and through the substrate;

an electrical power source powering said pulsed power generator;

an electrical conduction conduit sending high-voltage pulses from said high-voltage pulse generator to said drill bit; and

a plurality of electrode sets arranged in an array.

43. The apparatus of claim 42 further comprising a steering device, steering said array by varying a repetition rate or pulse energy of some of said electrode sets relative to other said electrode sets in said array.

44. The apparatus of claim 42 wherein at least one of said electrodes is compressible toward said drill bit.

45. The apparatus of claim 42 wherein said drill bit is rotatable.