Drilling apparatus and method

• US 8,322,461 B2
• Filed: 11/04/2008
• Issued: 12/04/2012
• Est. Priority Date: 11/03/2008
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Hay, Richard T., Botterell, Paul, Schroter, Terence, Strilchuk, Nathan
• Primary Examiner(s): Andrews, David
• Application Number:
  US12/264,827
• Publication Number:
  US 20100108383A1
• Time in Patent Office: 1,491 Days
• Field of Search: 175/26, 175/45, 175/61, 175/74
• US Class Current: 175/45
• CPC Class Codes: E21B 47/024 of devices in the borehole determining slope or direction of the borehole E21B47/022
• 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 drilling apparatus includes an upper drill string, a lower drill string including a rotary drilling motor, an orientable rotatable connection between the drill strings, a reactive torque control device associated with the orientable rotatable connection, an orientation sensing device for providing a sensed actual orientation of the lower drill string, and a feedback control system configured to actuate the control device in response to the sensed actual orientation to achieve a target orientation of the lower drill string. A drilling method includes actuating the control device to prevent relative rotation of the drill strings, providing a sensed actual orientation of the lower drill string, comparing the sensed actual orientation with a target orientation of the lower drill string, actuating the control device to allow the lower drill string to rotate to provide the target orientation, and actuating the control device to prevent relative rotation of the drill strings.

Claims

1. An apparatus for use in drilling a borehole, the apparatus comprising:

(a) an upper assembly which is connectable with a drilling string;

(b) a lower assembly comprising a rotary drilling motor such that the lower assembly is subjected to a reactive torque during drilling as a result of the operation of the drilling motor;

(c) an orientable rotatable connection between the upper assembly and the lower assembly;

(d) a reactive torque control device associated with the orientable rotatable connection, wherein the reactive torque control device is actuatable to selectively allow rotation of the lower assembly relative to the upper assembly or prevent rotation of the lower assembly relative to the upper assembly, wherein the reactive torque control device is comprised of a pump and wherein the pump is driven by relative rotation between the lower assembly and the upper assembly;

(e) an orientation sensing device for providing a sensed actual orientation of the lower assembly;

(f) a feedback control system associated with the reactive torque control device and the orientation sensing device, for actuating the reactive torque control device in response to the sensed actual orientation of the lower assembly in order to achieve a target orientation of the lower assembly, wherein the feedback control system is a component of one of the upper assembly and the lower assembly; and

(g) at least one parameter sensing device, for sensing a parameter other than the actual orientation of the lower assembly and for providing a sensed parameter value relating to the parameter.

2. The apparatus as claimed in claim 1 wherein the feedback control system is comprised of a feedback processor for processing the sensed actual orientation of the lower assembly in order to generate a feedback actuation instruction for actuating the reactive torque control device in order to achieve the target orientation of the lower assembly.

3. The apparatus as claimed in claim 2 wherein the feedback control system is further comprised of a reactive torque control device controller for receiving the feedback actuation instruction and for actuating the reactive torque control device in order to implement the feedback actuation instruction.

4. The apparatus as claimed in claim 3 wherein the feedback control system is further comprised of a feedback communication link between the orientation sensing device and the feedback processor, for transmitting the sensed actual orientation of the lower assembly from the orientation sensing device to the feedback processor.

5. The apparatus as claimed in claim 4 wherein the lower assembly provides a toolface orientation for facilitating directional drilling.

6. The apparatus as claimed in claim 5 wherein the toolface orientation is provided by a bend associated with the lower assembly.

7. The apparatus as claimed in claim 5 wherein the orientation sensing device is comprised of an orientation sensor associated with the lower assembly such that the orientation sensor is a component of the lower assembly.

8. The apparatus as claimed in claim 7 wherein the feedback processor is associated with the upper assembly such that the feedback processor is a component of the upper assembly.

9. The apparatus as claimed in claim 8 wherein the feedback communication link is comprised of a wireline between the orientation sensor and the feedback processor.

10. The apparatus as claimed in claim 9 wherein the feedback communication link is further comprised of a rotatable signal coupler between the orientation sensor and the feedback processor.

11. The apparatus as claimed in claim 10 wherein the rotatable signal coupler is comprised of a slip ring.

12. The apparatus as claimed in claim 8 wherein the reactive torque control device controller is associated with the upper assembly such that the reactive torque control device controller is a component of the upper assembly.

13. The apparatus as claimed in claim 5 wherein the reactive torque control device is further comprised of a loop containing a pumping fluid, wherein the relative rotation between the lower assembly and the upper assembly causes the pump to pump the pumping fluid around the loop, wherein the loop is comprised of a pumping resistance, and wherein the pumping resistance loads the pump and thereby impedes the relative rotation between the lower assembly and the upper assembly.

14. The apparatus as claimed in claim 13 wherein the pumping resistance is adjustable.

15. The apparatus as claimed in claim 13 wherein the pumping resistance is comprised of a flow restrictor positioned in the loop.

16. The apparatus as claimed in claim 15 wherein the flow restrictor is adjustable.

17. The apparatus as claimed in claim 16 wherein the flow restrictor is adjustable by the reactive torque control device controller.

18. The apparatus as claimed in claim 13 wherein the loop may be selectively blocked in order to prevent the pumping fluid from being pumped around the loop by the pump.

19. The apparatus as claimed in claim 13 wherein the reactive torque control device is further comprised of a valve positioned in the loop and wherein the valve may be actuated between an open position and a closed position in which the loop is blocked in order to prevent the pumping fluid from being pumped around the loop by the pump.

20. The apparatus as claimed in claim 19 wherein the valve is actuatable by the reactive torque control device controller.

21. The apparatus as claimed in claim 13 wherein the pump is a swash plate pump.

22. The apparatus as claimed in claim 13 wherein the reactive torque control device is further comprised of a brake associated with the loop, wherein the brake is comprised of a first brake part associated with the upper assembly and a second brake part associated with the lower assembly, and wherein the brake is actuated by a fluid pressure in the loop.

23. The apparatus as claimed in claim 22 wherein the first brake part and the second brake part are urged into engagement with each other as a result of the fluid pressure in the loop, thereby providing an engagement force between the first brake part and the second brake part which impedes the relative rotation between the lower assembly and the upper assembly, and wherein the engagement force between the first brake part and the second brake part increases as the fluid pressure in the loop increases.

24. The apparatus as claimed in claim 23 wherein the pumping resistance is comprised of a first flow restrictor positioned in the loop on an upstream side of the brake and a second flow restrictor positioned in the loop on a downstream side of the brake.

25. The apparatus as claimed in claim 23 wherein the reactive torque control device is further comprised of a first valve positioned in the loop on an upstream side of the brake and a second valve positioned in the loop on a downstream side of the brake, and wherein the first valve and the second valve may each be actuated between an open position and a closed position in which the loop is blocked between the first valve and the second valve in order to maintain the engagement force between the first brake part and the second brake part.

26. The apparatus as claimed in claim 25 wherein the loop is comprised of a pressure relief bypass line positioned in the loop for bypassing the first valve and the second valve when the fluid pressure in the loop exceeds a bypass pressure as determined by the pressure relief bypass line.

27. The apparatus as claimed in claim 26 wherein the loop is further comprised of a dump valve for releasing an amount of the pumping fluid from the loop when the fluid pressure in the loop exceeds a dump pressure as determined by the dump valve.

28. The apparatus as claimed in claim 27 wherein the reactive torque control device is further comprised of an accumulator in communication with the loop, for supplying additional pumping fluid to the loop when the fluid pressure in the loop is below an accumulator threshold pressure as determined by the accumulator.

29. The apparatus as claimed in claim 25 wherein the first valve and the second valve are both actuatable by the reactive torque control device controller.

30. The apparatus as claimed in claim 5 wherein the orientation sensing device is comprised of an orientation sensor associated with the upper assembly such that the orientation sensor is a component of the upper assembly and such that the orientation sensor provides a sensed actual orientation of the upper assembly.

31. The apparatus as claimed in claim 30 wherein the orientation sensing device is further comprised of a referencing device for providing a reference orientation between the upper assembly and the lower assembly so that the sensed actual orientation of the lower assembly can be obtained from the sensed actual orientation of the upper assembly.

32. The apparatus as claimed in claim 31 wherein the feedback processor is associated with the upper assembly such that the feedback processor is a component of the upper assembly.

33. The apparatus as claimed in claim 32 wherein the reactive torque control device controller is associated with the upper assembly such that the reactive torque control device controller is a component of the upper assembly.

34. The apparatus as claimed in claim 5 wherein the feedback control system is further comprised of a memory for storing the target orientation of the lower assembly.

35. The apparatus as claimed in claim 5, further comprising a surface communication link between a surface location and the feedback control system, for communicating a downlink instruction from the surface location to the feedback control system.

36. The apparatus as claimed in claim 35 wherein the surface communication link communicates an uplink communication from the feedback control system to the surface location.

37. The apparatus as claimed in claim 35 wherein the surface communication link is comprised of a measurement-while-drilling telemetry system.

38. The apparatus as claimed in claim 35 wherein the surface communication link is comprised of a pressure pulse telemetry system.

39. The apparatus as claimed in claim 35 wherein the surface communication link is comprised of a fluid flowrate telemetry system comprising a turbine and a rotation sensor for sensing a rotational speed of the turbine.

40. The apparatus as claimed in claim 35 wherein the feedback control system is further comprised of a memory for storing the downlink instruction.

41. The apparatus as claimed in claim 40 wherein the downlink instruction is comprised of the target orientation of the lower assembly.

42. The apparatus as claimed in claim 5 wherein the drilling string is comprised of a coiled tubing and wherein the upper assembly is connected with the coiled tubing.

43. The apparatus as claimed in claim 5 wherein the upper assembly is comprised of an upper section, a lower section adjacent to the orientable rotatable connection, and a swivel connection between the upper section and the lower section so that the upper section is rotatable relative to the lower section.

44. The apparatus as claimed in claim 43 wherein the lower section of the upper assembly is comprised of a rotation restraining device for restraining the lower section of the upper assembly from rotating relative to the borehole.

45. The apparatus as claimed in claim 5 wherein the reactive torque control device is actuatable between a first position which provides a minimum resistance to rotation of the lower assembly relative to the upper assembly and a second position which provides a maximum resistance to rotation of the lower assembly relative to the upper assembly, wherein rotation of the lower assembly relative to the upper assembly is allowed when the reactive torque control device is actuated to the first position, and wherein rotation of the lower assembly relative to the upper assembly is prevented when the reactive torque control device is actuated to the second position.

46. The apparatus as claimed in claim 45 wherein the reactive torque control device is actuatable to at least one intermediate position between the first position and the second position, which intermediate position provides an intermediate resistance to rotation of the lower assembly relative to the upper assembly.

47. The apparatus as claimed in claim 45 wherein the reactive torque control device is actuatable to a plurality of intermediate positions between the first position and the second position in order to provide a variable intermediate resistance to rotation of the lower assembly relative to the upper assembly.

48. The apparatus as claimed in claim 1 wherein the at least one parameter sensing device is associated with the feedback control system so that the feedback control system actuates the reactive torque control device in response to the sensed parameter value.

49. The apparatus as claimed in claim 1 wherein the reactive torque control device is actuatable to selectively allow rotation of the lower assembly relative to the upper assembly in order to facilitate non-directional drilling, and wherein the reactive torque control device is actuatable to selectively prevent rotation of the lower assembly relative to the upper assembly in order to facilitate directional drilling.

50. A method of directional drilling of a borehole using an apparatus comprising an upper assembly connected with a drilling string, a lower assembly comprising a rotary drilling motor such that the lower assembly is subjected to reactive torque during drilling as a result of the operation of the drilling motor, an orientable rotatable connection between the upper assembly and the lower assembly, and a reactive torque control device associated with the orientable rotatable connection, wherein the reactive torque control device is actuatable to selectively allow rotation of the lower assembly relative to the upper assembly or prevent rotation of the lower assembly relative to the upper assembly, wherein the reactive torque control device is comprised of a pump, and wherein the pump is driven by relative movement between the lower assembly and the upper assembly, the method comprising the following:

(a) actuating the reactive torque control device to prevent rotation of the lower assembly relative to the upper assembly;

(b) providing a sensed actual orientation of the lower assembly to a feedback control system, wherein the feedback control system is a component of one of the upper assembly and the lower assembly;

(c) comparing the sensed actual orientation of the lower assembly with a target orientation of the lower assembly;

(d) actuating the reactive torque control device with the feedback control system to allow the lower assembly to rotate relative to the upper assembly;

(e) operating the drilling motor in order to provide the target orientation of the lower assembly; and

(f) actuating the reactive torque control device with the feedback control system to prevent rotation of the lower assembly relative to the upper assembly.

51. The method as claimed in claim 50 wherein the lower assembly provides a toolface orientation for facilitating the directional drilling.

52. The method as claimed in claim 51 wherein the toolface orientation is provided by a bend associated with the lower assembly.

53. The method as claimed in claim 51 wherein the upper assembly is comprised of an upper section, a lower section adjacent to the orientable rotatable connection, and a swivel connection between the upper section and the lower section so that the upper section is rotatable relative to the lower section, further comprising rotating the upper section of the upper assembly while operating the drilling motor.

54. The method as claimed in claim 53, further comprising restraining the lower section of the upper assembly from rotating relative to the borehole.

55. The method as claimed in claim 51, further comprising communicating a downlink instruction to the apparatus, wherein the downlink instruction is comprised of the target orientation of the lower assembly.

56. The method as claimed in claim 55 wherein the target orientation of the lower assembly is comprised of an updated target orientation of the lower assembly.

57. The method as claimed in claim 55 wherein the downlink instruction is comprised of a sequence of target orientations of the lower assembly.

58. The method as claimed in claim 51, further comprising repeating (b) through (f) while the directional drilling is being performed.

59. The method as claimed in claim 58, further comprising communicating a downlink instruction to the apparatus, wherein the downlink instruction is comprised of the target orientation of the lower assembly.

60. The method as claimed in claim 58, further comprising communicating a downlink instruction to the apparatus periodically while the directional drilling is being performed, wherein the downlink instruction is comprised of the target orientation of the lower assembly.

61. The method as claimed in claim 60 wherein the target orientation of the lower assembly is an updated target orientation of the lower assembly.

62. The method as claimed in claim 60 wherein the downlink instruction is comprised of a sequence of target orientations of the lower assembly.

63. The method as claimed in claim 62 wherein (b) through (f) are repeated using an updated target orientation of the lower assembly, further comprising generating the updated target orientation of the lower assembly.

64. The method as claimed in claim 63 wherein the updated target orientation of the lower assembly is generated using data from at least one sensing device associated with the apparatus.

65. The method as claimed in claim 64 wherein the updated target orientation of the lower assembly is generated by the feedback control system.

66. The method as claimed in claim 51 wherein the sensed actual orientation of the lower assembly is provided by obtaining a sensed actual orientation of the upper assembly and a reference orientation between the upper assembly and the lower assembly.

67. The method as claimed in claim 51, further comprising communicating an uplink communication from the apparatus, wherein the uplink communication is comprised of the sensed actual orientation of the lower assembly.

68. The method as claimed in claim 67, further comprising communicating a downlink instruction to the apparatus, wherein the downlink instruction is comprised of the target orientation of the lower assembly.

69. The method as claimed in claim 51 wherein the reactive torque control device is actuatable between a first position which provides a minimum resistance to rotation of the lower assembly relative to the upper assembly and a second position which provides a maximum resistance to rotation of the lower assembly relative to the upper assembly and wherein actuating the reactive torque control device to prevent rotation of the lower assembly relative to the upper assembly is comprised of actuating the reactive torque control device to the second position.

70. The method as claimed in claim 69 wherein the reactive torque control device is actuatable to at least one intermediate position between the first position and the second position, which intermediate position provides an intermediate resistance to rotation of the lower assembly relative to the upper assembly, and wherein actuating the reactive torque control device to allow the lower assembly to rotate relative to the upper assembly is comprised of actuating the reactive torque control system to the intermediate position.

71. The method as claimed in claim 69 wherein the reactive torque control device is actuatable to a plurality of intermediate positions between the first position and the second position in order to provide a variable intermediate resistance to rotation of the lower assembly relative to the upper assembly, and wherein actuating the reactive torque control device to allow the lower assembly to rotate relative to the upper assembly is comprised of actuating the reactive torque control device to one of the intermediated positions.