Expansion and sensing tool

• US 8,235,144 B2
• Filed: 06/16/2011
• Issued: 08/07/2012
• Est. Priority Date: 06/27/2008
• Status: Active Grant

• Current Assignee: Smart Reamer Drilling Systems Ltd
• Original Assignee: Wajid Rasheed
• Inventors: Rasheed, Wajid
• Primary Examiner(s): GAY, JENNIFER HAWKINS
• Application Number:
  US13/161,806
• Publication Number:
  US 20110247878A1
• Time in Patent Office: 418 Days
• Field of Search: 175/5, 175/24, 175/40, 175/57, 175/263, 731/520.3, 731/524.6
• US Class Current: 175/57
• CPC Class Codes: A01N 2300/00 Combinations or mixtures of active ingredients covered by classes A01N27/00 - A01N65/48 with other active or formulation relevant ingredients, e.g. specific carrier materials or surfactants, covered by classes A01N25/00 - A01N65/48
• CPC Class Codes: A01N 37/20 containing the group , wherein Cn means a carbon skeleton not containing a ring; Thio analogues thereof
• CPC Class Codes: A01N 37/22 the nitrogen atom being directly attached to an aromatic ring system, e.g. anilides
• CPC Class Codes: A01N 37/26 containing the group; Thio analogues thereof
• CPC Class Codes: A01N 43/10 with sulfur as the ring hetero atom
• CPC Class Codes: A01N 43/12 condensed with a carbocyclic ring
• CPC Class Codes: A01N 43/20 three- or four-membered rings
• CPC Class Codes: A01N 43/40 six-membered rings
• CPC Class Codes: A01N 43/78 1,3-Thiazoles; Hydrogenated 1,3-thiazoles
• CPC Class Codes: A01N 43/80 five-membered rings with one nitrogen atom and either one oxygen atom or one sulfur atom in positions 1,2
• CPC Class Codes: A01N 43/82 five-membered rings with three ring hetero atoms
• CPC Class Codes: A01N 47/12 containing a —O—CO—N< group, or a thio analogue thereof, neither directly attached to a ring nor the nitrogen atom being a member of a heterocyclic ring
• CPC Class Codes: A01N 47/16 the nitrogen atom being part of a heterocyclic ring
• CPC Class Codes: A01N 47/38 containing the group >N—CO—N< where at least one nitrogen atom is part of a heterocyclic ring; Thio analogues thereof
• CPC Class Codes: A01N 57/14 containing aromatic radicals
• CPC Class Codes: B26B 21/54 Razor-blades B26B21/4006 takes precedence
• CPC Class Codes: E21B 10/32 with expansible cutting tools
• CPC Class Codes: E21B 33/124 Units with longitudinally-spaced plugs for isolating the intermediate space
• CPC Class Codes: E21B 44/00 Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
• CPC Class Codes: E21B 47/013 Devices specially adapted for supporting measuring instruments on drill bits
• CPC Class Codes: E21B 47/08 : Measuring diameters or related dimensions at the borehole
• CPC Class Codes: E21B 47/085 : using radiant means, e.g. acoustic, radioactive or electromagnetic
• CPC Class Codes: E21B 47/09 : Locating or determining the position of objects in boreholes or wells , e.g. the position of an extending arm; Identifying the free or blocked portions of pipes
• CPC Class Codes: E21B 47/095 : by detecting an acoustic anomalies, e.g. using mud-pressure pulses
• CPC Class Codes: E21B 47/12 : Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
• CPC Class Codes: E21B 49/00 : Testing the nature of borehole walls; Formation testing; Methods or apparatus for obtaining samples of soil or well fluids, specially adapted to earth drilling or wells
• CPC Class Codes: E21B 7/28 : Enlarging drilled holes, e.g. by counterboring

Abstract

An expansion and sensing tool (50) comprising a tool body, cutter blocks and sensors which permit simultaneous underreaming and measurement of the diameter of a wellbore (40) drilled by an oil and gas rig (10). Radially extendable cutter blocks (62) incorporating positional sensors (80) contained on the block or within the body measure the position of the cutter block relative to the tool, and a vibration sensor (76) measures vibration and underreaming wellbore dimensions in real-time. Receivers, sensors and microprocessors deliver a desired wellbore depth both simultaneously comparing and correlating measured vibration data and optimizing underreaming parameters. The tool may be optionally configured with a caliper or a stabilizer.

Claims

1. A tool comprising a tool body, at least one radially extendable cutter block, each of the at least one cutter block radially movable from a retracted position substantially within the tool body to an extended position radially outward of the tool body, the tool attached to and rotatable by a drilling support to underream, and a position sensor comprising a strip and a sensor to measure a position of the at least one cutter block relative to the tool body, the tool further comprising:

the at least one radially extendable cutter block supporting one of the strip and the sensor, and the tool body supporting the other of the strip and the sensor to measure the position of the at least one cutter block relative to the tool body, a vibration sensor to measure vibration of the tool, and the position sensor and the vibration sensor being in communication with a microprocessor to optimize drilling dynamics by comparing position sensor data and vibration signal data.

2. The tool of claim 1, wherein said microprocessor compares position sensor data to other data and stores position sensor data in memory.

3. The tool of claim 1, wherein the vibration sensor measures stick/slip data and the microprocessor optimizes drilling dynamics by comparing stick/slip data with other data.

4. The tool of claim 3, wherein said microprocessor stores stick/slip data in memory.

5. The tool of claim 3, further comprising:

a telemetry system for communicating said sensor data and other control signals between the tool and a surface interface in real-time so as to optimize drilling performance.

6. The tool of claim 1, further comprising:

the microprocessor receiving vibration data from the vibration sensor to detect vibration in real-time.

7. The tool of claim 1, further comprising:

a telemetry system for communicating sensor data between the tool and a surface interface in real-time to optimize drilling performance.

8. An apparatus, comprising:

at least one expansion elements housed in a first tool body, the at least one expansion element radially movable from a retracted position substantially within the first tool body to an extended position radially outward from the first tool body to underream the wellbore; and

at least one expandable stabilizer block supported in a second tool body, the at least one stabilizer block movable from a retracted position substantially within the second tool body to an extended position radially outward from the second tool body to stabilize the apparatus in the wellbore;

one or more sensing elements each supported on a third tool body connected to the second tool body, adapted wherein the one or more sensing elements measure drilling dynamics;

a calliper element for measuring wellbore diameter; and

data from the calliper element is compared with data from the one or more sensing elements.

9. The apparatus as claimed in claim 8, wherein the at least one expansion element is provided with cutter inserts, and the apparatus is provided with a through passage for the flow of drilling fluid which exits the tool from a nozzle adjacent the at least one expansion element.

10. The apparatus as claimed in claim 8, wherein the at least one expandable stabilizer block is provided with stabilizing surface, and apparatus is provided with a through passage for the flow of drilling fluid to the expansion elements.

11. A method of operating an expansion tool to enlarge a borehole or tubular or like passage to a target dimension beyond a restriction, comprising:

locating a tool body in a borehole on a support below a restriction;

providing at least one cutter block radially movable from a retracted position substantially within the tool body to an expanded positioning radially outward of the tool body;

extending at least one cutter block to an expansion diameter greater than the restriction;

rotating the tool while moving the tool axially along the borehole on the support;

measuring a position of the at least one cutter block;

measuring vibration with a vibration sensor;

measuring wellbore diameter with a calliper element;

data from the calliper element is compared with data from the vibration sensor and block positional.

12. The method as claimed in claim 11, further comprising:

forwarding data using at least one mud pulse to a surface interface, wherein the surface interface controls movement of the drill string.

13. The method of claim 11, further comprising:

recording the position of the at least one cutter block.

14. The method of claim 11, further comprising:

providing a rotary steerable device for directional control of the drill string.

15. A tool, comprising:

at least one expandable stabilizer block housed in a tool body, the at least one expandable stabilizer block, radially movable from a retracted position substantially within the body to an extended position radially outward from the body;

the at least one expandable stabilizer block supporting one of a strip and a position sensor, and the tool body supporting the other of the strip and the position sensor to sense a position of the at least one stabilizer block relative to the tool body;

one or more sensing elements each supported on a sensing body connected to the expandable stabilizer body, the at least one expandable stabilizer block adapted to stabilize the tool in the wellbore; and

wherein the one or more sensing elements measure drilling dynamics; and

a calliper element for measures wellbore diameter; and

data from the calliper element is compared with data from a vibration sensor and block positional data.

16. A tool of claim 15, wherein:

the at least one expandable stabilizer block housed in a tool stabilizer body and radially movable from a retracted position substantially within the expansion body to an extended position radially outward from the expansion body to stabilize the tool in the wellbore;

the one or more sensing elements each supported on- a sensing body connected to the stabilizer body, and the one or more sensing elements sense drilling dynamics.

17. A tool, comprising:

at least one movable expandable stabilizer block;

each of the at least expandable stabilizer block radially movable from a retracted position substantially within the tool body to an extended position radially outward of the tool body;

the tool attached to and rotatable by a drilling support to underreaming;

a position sensor comprising a strip and a sensor, one of the strip and the sensor supported on the expandable stabilizer block, the position sensor to sensing a position of the at least one radially extendable cutter block relative to the tool body; and

a vibration sensor to measure vibration of the tool, and the position sensor and the vibration sensor being in communication with a microprocessor to optimize drilling dynamics by comparing data.

18. A method of operating an expandable apparatus in a well to enlarge a borehole to a target dimension below a restriction, comprising:

locating a tool body in the borehole on a support below the restriction;

providing at least one cutter block radially movable from the retracted position substantially within the tool body to an expanded positioning radially outward of the tool body;

extending the at least one cutter block to an expansion diameter greater than the restriction;

rotating the apparatus while moving the apparatus axially along the borehole on the support while;

sensing a position of the at least one cutter block; and

measuring vibration with a vibration sensor; and

measuring wellbore diameter with a calliper element;

wherein block positional data is compared with data from the vibration sensor and data from the calliper element to optimize drilling.

19. The method of claim 18, further comprising:

recording the position of the at least one cutter block.

20. The method of claim 18, further comprising:

forwarding data using at least one mud pulse to a surface interface wherein the surface interface controls movement of the drill sting.

21. The method of claim 18, wherein the position sensor includes a strip and a sensor, one of the strip and the sensor supported on the cutter blade and the other of the strip and the sensor supported on the tool body.