CA2024061C - System for drilling deviated boreholes - Google Patents
System for drilling deviated boreholes Download PDFInfo
- Publication number
- CA2024061C CA2024061C CA002024061A CA2024061A CA2024061C CA 2024061 C CA2024061 C CA 2024061C CA 002024061 A CA002024061 A CA 002024061A CA 2024061 A CA2024061 A CA 2024061A CA 2024061 C CA2024061 C CA 2024061C
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- CA
- Canada
- Prior art keywords
- downhole
- drill string
- sensor
- drilling motor
- housing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/04—Directional drilling
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/01—Devices for supporting measuring instruments on drill bits, pipes, rods or wirelines; Protecting measuring instruments in boreholes against heat, shock, pressure or the like
- E21B47/017—Protecting measuring instruments
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/02—Determining slope or direction
- E21B47/022—Determining slope or direction of the borehole, e.g. using geomagnetism
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/12—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
- E21B47/14—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 using acoustic waves
- E21B47/16—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 using acoustic waves through the drill string or casing, e.g. by torsional acoustic waves
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/12—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
- E21B47/14—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 using acoustic waves
- E21B47/18—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 using acoustic waves through the well fluid, e.g. mud pressure pulse telemetry
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/26—Storing data down-hole, e.g. in a memory or on a record carrier
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/04—Directional drilling
- E21B7/06—Deflecting the direction of boreholes
- E21B7/068—Deflecting the direction of boreholes drilled by a down-hole drilling motor
Abstract
Improved techniques are provided for drilling a deviated borehole through earth formations utilizing a rotary bit powered by a drill motor, and for obtaining information regarding the borehole or earth formations while drilling. An inclinometer is positioned below the drill motor and within a sealed cavity of a housing fixed to a drill motor sub, and a transmitter within the sealed cavity forwards acoustic or radial wave signals to a receiver provided in a measurement-whils-drilling tool. The MWD tool may be provided within a non-magnetic portion of the drill string, and further houses an accelerometer for sensing borehole direction. Both borehole inclination and directional signals are transmitted to the surface by the MWD tool, and the drilling trajectory is altered in response to the signals.
Description
- 2 -Background of the Invention 1. Field of the Invention The present invention relates to the drilling of boreholes and to survey and logging techniques used to determine the path and lithology of the drilled borehole.
More particularly, the invention relates to an improved system for sensing the inclination of a borehole formed by a drill bit rotated by a downhole motor, for telemetering borehole inclination and associated logging data to the surface while drilling, and for altering the drilling trajectory in response to the telemetered data.
2 Description of the Background Drilling operators which power a drill bit by rotating the drill string at the surface have previously measured downhole parameters with sensors located closely adjacent the drill bit, and adjusted the drilling trajectory in response to the sensed information. U.S. Patent 4,324,297 discloses strain gages located directly above the drill bit to measure the magnitude and direction of side forces on the bit. The sensed information is transmitted to the surface by an electrical line, and the bit weight and rotational speed of the drill string may be altered in response to the sensed information to vary drilling trajectory.
In recent years, drilling operators have increasingly utilized downhole motors to drill highly deviated wells. ' The downhole motor or "drill motor" is powered by drilling mud pressurized by pumps at the surface and transmitted to the motor through the drill string to rotate the bit. The entire drill string need not be continually rotated during deviated drilling, which has significant advantages over the previously described technique, particularly when drilling highly deviated boreholes. A bent sub or bent housing may be used above the drill motor to achieve the angular displacement between the axis of rotation of the bit and the axis of the drill string, and thereby obtain the bend to effect curved drilling. Alternatively, the angular displacement may be obtained using a bent housing
More particularly, the invention relates to an improved system for sensing the inclination of a borehole formed by a drill bit rotated by a downhole motor, for telemetering borehole inclination and associated logging data to the surface while drilling, and for altering the drilling trajectory in response to the telemetered data.
2 Description of the Background Drilling operators which power a drill bit by rotating the drill string at the surface have previously measured downhole parameters with sensors located closely adjacent the drill bit, and adjusted the drilling trajectory in response to the sensed information. U.S. Patent 4,324,297 discloses strain gages located directly above the drill bit to measure the magnitude and direction of side forces on the bit. The sensed information is transmitted to the surface by an electrical line, and the bit weight and rotational speed of the drill string may be altered in response to the sensed information to vary drilling trajectory.
In recent years, drilling operators have increasingly utilized downhole motors to drill highly deviated wells. ' The downhole motor or "drill motor" is powered by drilling mud pressurized by pumps at the surface and transmitted to the motor through the drill string to rotate the bit. The entire drill string need not be continually rotated during deviated drilling, which has significant advantages over the previously described technique, particularly when drilling highly deviated boreholes. A bent sub or bent housing may be used above the drill motor to achieve the angular displacement between the axis of rotation of the bit and the axis of the drill string, and thereby obtain the bend to effect curved drilling. Alternatively, the angular displacement may be obtained using a bent housing
- 3 -within the drill motor, by using an offset drive shaft axis for the drill motor, or by positioning a non-concentric stabihizer about the drill motor housing. As disclosed in U.S. patent 4,492,276, a relatively straight borehole may be drilled by simultaneously rotating the drill string and actuating the downhole motor, while a curved section of borehole is drilled by activating the downhole motor while the drill string above the. motor is not rotated. U.S.
Patent 4,361,192 discloses a borehole probe positioned within the drill pipe above a drill motor and connected to surface equipment via a wireline. The probe includes magnetometers and accelerometers which measure orientation relative to the earth's magnetic field, and accordingly the probe is constructed of a non-ferromagnetic material.
Significant improvements have occurred in measuring-while-drilling (MWD) technology, which allows downhole sensors to measure desired parameters and transmit data to the surface in real time, i.e., substantially instantaneously with the measurements. MWD mud pulse telemetry systems transmit signals from the sensor package to the surface through the drilling mud in the drill pipe.
Other MWD systems, such as those disclosed in U.S. Patents
Patent 4,361,192 discloses a borehole probe positioned within the drill pipe above a drill motor and connected to surface equipment via a wireline. The probe includes magnetometers and accelerometers which measure orientation relative to the earth's magnetic field, and accordingly the probe is constructed of a non-ferromagnetic material.
Significant improvements have occurred in measuring-while-drilling (MWD) technology, which allows downhole sensors to measure desired parameters and transmit data to the surface in real time, i.e., substantially instantaneously with the measurements. MWD mud pulse telemetry systems transmit signals from the sensor package to the surface through the drilling mud in the drill pipe.
Other MWD systems, such as those disclosed in U.S. Patents
4,320,473 and 4,562,559, utilize the drill string itself as the media for the transmitted signals. U.S. Patent 4,577,701 employs an MWD system in conjunction with a downhole motor to telemeter wellbore direction information to the surface. The telemetered information may be used to determine the duration of drill string rotation required to effect a change in the borehole curvature as previously described.
A downhole MWD tool typically comprises a battery pack or turbine, a sensor package, a mud pulse transmitter, and an interface between the sensor package and transmitter.
When used with a downhole motor, the MWD tool is located above the motor. The electronic components of the tool are spaced substantially from the bit and accordingly are not subject to the high vibration and centrifugal forces acting ,.,...
on the bit. The sensor package may include various sensors, such as gamma ray, resistivity, porosity and temperature sensors for measuring formation characteristics or downhole parameters. In addition, the sensor package typically includes one or more sets of magnetometers and accelerometers for measuring the direction and inclination of the drilled borehole. The tool sensor package is placed in a non-magnetic environment by utilizing monel collars in the drill string both above and below the MWD tool. The desired length of the monel collars will typically be a function of latitude, well bore direction, and local anomalies. As a result of the monel collars and the required length of the downhole motor (including the power section, the bent sub, the bearing assembly), the sensor package for the MWD system is typically located from ten meters to fifty meters from the drill bit.
The considerable spacing between the MWD sensor package and the drill bit has long been known to cause significant problems for the drilling operator, particularly with respect to the measurement of borehole inclination. The operator is often attempting to drill a highly deviated or substantially horizontal borehole, so that the borehole extends over a long length through the formation of interest. The formation itself may be relatively thin, e.g.
only three meters thick, yet the operator is typically monitoring borehole conditions or parameters, such as inclination, thirty meters from the bit. The substantial advantage of a real time MWD system and the flexibility of a downhole motor f or drilling highly deviated boreholes are thus minimized by the reality that the sensors for the MWD
system are responsive to conditions spaced substantially f rom the bi t .
The disadvantages of the prior art are overcome by the present invention. Improved techniques are hereinafter disclosed for more accurately monitoring borehole conditions or parameters, such as borehole inclination, while drilling a deviated borehole utilizing a downhole motor.
= 5 -Summary of the Invention The invention in its broadest aspect relates to a method of drilling a borehole using a drill string having a drill bit at one end and a downhole drilling motor within the drill string for rotating the drill bit, the method comprising detecting a downhole parameter using a sensor fixedly located in the part of the drill string comprising the drill bit, the drilling motor and any components intermediate the drill bit and the drilling motor, transmitting to the surface a signal representative of the detected downhole parameter or of variation of said parameter, and altering the drilling trajectory in response to said transmitted signal.
The invention also broadly relates to apparatus for signalling within a borehole while drilling using a drill string having a drill bit at one end and a downhole drilling motor within the drill string for rotating the drill bit, the apparatus comprising a sensor for location in the part of the drill string comprising the drill bit, the drilling motor and any components intermediate the drill bit and the drilling motor to detect a downhole parameter, a first transmitter for location in said part of the drill string to receive an input from the sensor indicative of the detected downhole parameter or variation of said parameter and to transmit a signal representative of said input, a downhole receiver for location in a portion of the drill string on the opposite axial side of the drilling motor to the drill bit to receive said signal transmitted by the first transmitter, and a second transmitter for location in said portion of the drill string to receive an input from the receiver indicative of said signal and to transmit a signal representative of said input to the surface.
The invention also provides a drill bit or drill bit bearing assembly to be located at one end of the drill string during drilling, the assembly comprising a housing, a sealed cavity within the housing, a sensor within the cavity for detecting a downhole parameter, and a transmitter within the cavity for receiving an input from the sensor indicative of the detected downhole parameter or variation of said parameter and for transmitting a signal representative of said input.
A preferred embodiment of the invention includes an MWD tool, a downhole motor power section having a bent housing, a downhole motor bearing assembly, and a drill bit in descending, order in a drill string. A tool sensor package for the MWD tool includes one or more magneto-meters, and accordingly the tool is positioned within monel collars to minimize magnetic interference. A power pack, an inclination sensor, and a transmitter may each be provided within a sealed cavity within the housing of the downhole motor bearing assembly, and preferably within a lower portion of the bearing housing adjacent the bit box.
The inclinometer senses the angular orientation of the housing and thus the inclination of the well bore at a position closely adjacent the bit. The signal from the inclinometer is transmitted to a receiver in the MWD tool, and borehole inclination data is then transmitted by the MWD system to the surface for computation and display.
The inclination measurements are converted to frequency signals which are transmitted through the motor housing and drill string to the receiver in the MWD tool by a wireless system. Problems associated with power and data transmission wiring extending from the MWD tool to the inclinometer are avoided, yet the drilling operator benefits from inclination data sensed closely adjacent the bit. The motor housing is not rotated by the motor, so that the power pack, inclination sensor, and transmitter provided therein are not subject to continual centrifugal forces. Other conventional downhole sensors may also be provided within the bearing assembly housing closely adjacent the drill bit, and data may be reliably obtained and transmitted to the surface during the drilling mode, thereby saving valuable drilling time. Also, much of the bit chatter is absorbed in the bearing assembly and torque transmission components along the drill motor, so that the sensors are not subject to high vibration although located closely adjacent the drill bit.
According to a preferred method of the present invention, a well bore direction sensor is provided within the MWD tool which is spaced substantially above the drill ,....y bit, while a well bore inclination sensor is positioned closely adjacent the drill bit within the housing of the drill motor bearing assembly. Data from the inclination sensor is transmitted to the MWD tool using a transmitter within the sealed- cavity in the motor housing and a receiver in the MWD tool. Both well bore direction and well bore inclination data may then be transmitted to the surface in real time by mud pulse telemetry. The drilling operator is able to analyze inclination data sensed closely adjacent the bit, and thereby control the operation of the drill motor and the rotation of the drill string in response to this data to better maintain the drilled borehole at its desired inclination.
It is an object of the invention to provide an improved system for enabling a drilling operator to more accurately determine borehole characteristics or formation parameters when drilling a well utilizing a downhole motor and an MWD tool far transmitting sensed information to the surface.
It is another object of the invention to provide sensors positioned closely adjacent the drill box and within a lower portion of the drill motor bearing housing.
Signals from the sensors are transmitted to the MWD tool located above the drill motor utilizing a transmitter within the bearing housing and a receiver in the MWD tool.
The signals are then transmitted to the surface utilizing the MWD tool.
It is a feature of the present invention that electrical conductors are not utilized extending from the MWD tool to the sensors within the lower portion of the bearing housing. The wireless transmission system avoids substantial cost increases for the downhole motor and does not adversely restrict the versatility of the motor.
Yet another feature of the present invention is that sensors are provided within a cavity in the bearing housing, thereby allowing data sensed closely adjacent the drill bit to be transmitted to the surface in real time and without interrupting drilling operations.
2o24os~
_8_ It is an advantage of this invention that a power pack, inclinometer, and transmitter are located within a sealed cavity in .a lower portion of the bearing housing.
These components may be easily serviced or replaced at the rig site. w These and further objects, features and advantages of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
Brief Description of the Drawincts Figure 1 is a simplified pictorial view of a drill string according to the present invention:
Figure 2 is a simplified schematic diagram illustrating the components of a typical drilling and borehole surveying system according to the present invention to sense borehole trajectory and transmit sensed data to the surface far altering the drilling trajectory;
and Figure 3 is an axial section through a lower portion of a drill motor housing according to the present invention schematically showing certain components within a sealed cavity in the motor housing.
Detailed Description of Preferred Embodiments Figure 1 depicts a simplified version of a system 10 according to the present invention for drilling a deviated borehole through earth formations while monitoring borehole characteristics or formation properties. This system includes a drill string 12 comprising lengths of conventional drill pipe extending from the surface 14 through a plurality of earth formations 16, 18. Borehole 20 is drilled by a rotary drill bit 22, which is powered by a fluid driven or mud motor 24 having a bent housing 26.
The motor 24 rotates a drive shaft 28, which is guided at its lower end by radial and thrust bearings (not shown) within a bearing housing 30 affixed to the housing of the mud motor. The motor 24 is driven by drilling mud which is forced by mud pumps 32 at the surface down the drill string 12. The majority of the drill string comprises lengths of - g _ metallic drill pipe, and various downhole tools 34, such as cross-over subs, stabilizer, jars, etc., may be included along.the length of the drill string.
One or more non-magnetic lengths of drill string 36, commonly referred-to as monel collars, may be provided at the lower end of the drill string above the drill motor.
A conventional cross-over 38 preferably interconnects the lower end of a monel collar 36 to a by-pass or dump valve sub 40, and the mud motor 24 is fixedly connected directly to the sub 40. A lower sub 42 is fixedly connected at the lower end of the bearing housing 30, and contains a sealed cavity with electronics, as discussed subsequently. A
rotary bit sub or bit box 44 extends from the lower sub 42, and is rotatable with the drill bit 22.
During straight line drilling, the drill pipe, the mud motor housing, the bearing housing, and any other housings coupled to the mud motor housing are rotated by the rotary table 56, and simultaneously the pumps 32 power the motor 24 to rotate the shaft 28 and the bit 22. During such drilling data representative of various sensed downhole parameters may be transmitted to the surface by an MWD tool 46 within one of the monel collars in the form of pressure pulses in the drilling mud which are received by a near surface sensor 48. The sensed data is then passed by lines 50 to a surface computer 52, which stores and processes the data for the drilling operator. If desired, data may be displayed in real time on a suitable medium, such as paper or a screen 54. When the drilling operator desires to form a deviation or curve in the borehole, the mud motor 24 remains activated while the operator stops rotation of the drill string by the rotary table 56, with the result that the bit is caused to drill at an offset. During this stage of drilling, the MWD system conventionally is not transmitting data to the surface, but data may still be sensed and briefly stored within the MWD tool 46. When the desired offset is drilled, the rotary table 56 is again rotated to drill the borehole at the deviated angle, and during this stage stored data may be transmitted to the '~' 10 - 202 4061 surface by the MWD tool.
According to the present invention, one or more sensors located very near the drill bit 22 and below the power section of the mud motor 24 provide information to a transmitter, which-forwards the information by a wireless system to the MWD tool, which in turn transmits the information to the surface. The significant advantage of this invention is that data may be sensed very near the bit 22, rather than 20 to 100 feet up from the bit where the MWD tool is typically located. This near bit sensing allows more meaningful data to be transmitted to the surface, since the operator would like to know the characteristics of the borehole and/or the formation at a location very near the bit rather than at some location drilled hours previously. In particular, an accelerometer or inclinometer is preferably one of the near bit sensors, since information representing the inclination of the borehole closely adjacent the bit is valuable to the drilling operator. This data cannot be easily transmitted from a near bit location to the MWD tool, however, due to the presence of the intervening mud motor 24. The necessary complexity and desirable versatility of the mud motor are not well suited to accommodate conventional data transmission lines running through the motor. It is therefore preferred that the information is transmitted from a near bit location to the MWD tool by frequency-modulated acoustic signals indicative of the sensed information. However, the information may also be transmitted electro-magnetically, inductively or by mud pulses, for example, and by amplitude or phrase modulation, or by time multiplexity rather than frequency modulation.
Figure 2 generally depicts in block diagram form the primary components of the system according to the present invention, and the same numeral designations will be used for components previously discussed. At the lowermost end of the drill string and moving upward are the drill bit 22, the drill bit box 44 and the drive shaft 28 which extends up to the mud motor 24. The bit, bit box, and drive shaft all rotate with the respect to the remaining components of the drill string. The lower sub 42 is provided above the bit box and includes a sealed cavity which houses an accelerometer 60, a near bit transmitter 62, a power supply 64, and preferably one or more sensors 66 other than an accelerometer. Information from each sensor is transmitted by conventional wiring to the transmitter 62, which then forwards frequency-modulated signals indicative of the sensed information to the MWD receiver in the monel collar 36. A voltage to frequency convertor 63 may be used to convert voltage signals from any sensor to frequency signals. The signals from transmitter 62 pass through the metal housing between the lower sub 42 and an MWD receiver 70 within the monel collar 36. The transmitted signals may be acoustic signals having a frequency in the range of from 500 to 2,000 Hz. Acoustic signals may be efficiently transmitted for a distance of up to 100 feet through either the drilling mud or the metal housings. Alternatively, radio frequency signals of from 30 kilo-Hz to 3,000 mega-Hz may be used as the signals transmitted between the near bit transmitter and the MWD receiver, and these radio frequency signals may require less consumption of energy than acoustic signals.
The lower sub housing 42 may be keyed or otherwise fixed to and may structurally be an integral part of the housing for the bearing pack sub 30. A flexible coupling sub or bent sub 26 houses the drive shaft 28, and is fixedly connected at its lower end to the sub 30 and at its upperend to the drill motor sub 24. Subs 24, 26 and 30 are generally used as an assembly, and drilling operators commonly refer to this entire combination rather than only sub 24 as the downhole motor assembly. Fixed to the upper end of the drill motor sub 24 is by-pass sub 40, which includes conventional outlet ports for dumping excess fluid to the borehole.
Monel collar 36 is fixed to the sub 40, and houses the MWD tool 46 generally shown in Figure 1. Tool 46 includes a magnetometer or other magnetic sensor 66, a downhole data storage device or computer 68, an MWD receiver 70 a power supply 72, and an MWD transmitter 74. Although it is generally preferred that the borehole or formation characteristics be sensed at a location below the drill motor 24, the magnetometer must be magnetically isolated from the metal housings for reasonable accuracy and reliability, and accordingly it is housed within the monel collar 36. If desired, other sensors, such as backup sensors, could also be provided within the monel collar 36, although preferably sensors other than the magnetic sensor are located at the near bit location. In addition to the inclinometer or accelerator 60, near bit sensors provided within the sub 42 may include, for example, a weight on bit sensor, a torque sensor, resistivity sensor, a neutron porosity sensor, a formation density sensor, a gamma ray count sensor, and a temperature sensor. Data from each of these sensors may thus be transmitted by the transmitter 62 to the MWD receiver 70. Since sensor 67 is closely adjacent the downhole computer 68, information from this sensor may be hard-wired directly to the computer 68, while the remaining information is received by the receiver 70 then transmitted to the computer 68.
Computer 68 may include both temporary data storage and data processing capabilities. In particular, information from various sensors may be encoded for each sensor and arranged by the computer so that like signals will be transmitted to the surface, with the signals from each sensor being coded for a particular sensor. Porosity signals, magnetometer signals, resistivity signals, inclination signals and temperature signals may thus be intermittently transmitted to the surface by the MWD
transmitter 74. Transmitter 74 preferably is a mud pulse transmitter, so that the information is passed by the pulse 3 5 waves through the drill ing mud in the drill string . The receiver 70, computer 68, transmitter 74 and any sensors within the monel collar may all be powered by the power supply 72.
.., 202 406 1 Data may be transmitted from the monel collar 36 to the surface receiver 48, and preferably is transmitted through the mud within the drill string 12. The surface computer 52 stores and processes this information, and information may be displayed to the drilling operator on a monitor panel or display 54. Information may be sensed, and data transmitted, processed and displayed in "real time", so that the drilling operator may visually see a representation of borehole or formation characteristics which are being monitored at a position closely adjacent the drill bit and below the drill motor. The information may be obtained and displayed while the drill motor is activated, and the displayed information represents data sensed substantially at the time it is displayed.
Figure 3 depicts the lower end of a suitable lower bearing housing secured to the end of the motor housing 26.
The eccentric or set-off provided by the bent sub allows the reliable drilling of the deviated or curved borehole.
The sub 42 essentially provides a sealed cavity for the components shown in Figure 2 within the sub 42, and may either be part of or attached to the assembly consisting of the mud motor 24 and/or the bearing housing 30, and optionally may also include the motor housing 26. The sealed cavity may be formed by the motor housing 26 and/or the bearing housing 30, although this cavity may be formed in any suitable location below the monel collar 36, and preferably as close as possible to the drill bit 22.
The mud motor 24 may either be a positive displacement motor or a turbine motor, and utilizes pressurized fluid to drive a shaft 20 which is guided by the bearing housing 30.
The bearing housing 30 comprises one or more sleeve-shaped, axially aligned, normally stationary outer subs, which may be threadably connected to the motor housing 26. The bearing housing 30 also includes a mandrel rotated by the drive shaft 28, with the mandrel in turn defining a "full bore" interior fluid passageway for transmitting fluid to cool and clean the drill bit. The annular spacing between the outer subs and the inner mandrel is typically occupied ,,... 202 4061 by a plurality of marine bearings, wear sleeves, thrust bearing assemblies, radial bearings, etc. to guide the rotatable mandrel with respect to the outer subs and absorb some of the thrust load on the drill bit. The bearing housing assembly may be of the type wherein the bearings are lubricated by the drilling mud, or optionally may be sealed from the fluid passing through the mandrel and to the bit.
Figure 3 depicts an embodiment wherein the annular sealed cavity 76 is defined by a lower portion of the bearing housing 30 constituting the lower bearing sub 42.
The lower bearing sub 42 of the housing 30 includes an integral recessed lower body 80 to define cavity 76. The sub 42 comprises an outer sleeve 82 which is threadably connected to body 80, with a fluid-tight seal being formed by O-rings 84, 86 between the radially outwardly projecting legs of the body 80 and the sleeve 82. A wear sleeve 92 and a radial bearing 88 are positioned within the sub 42.
The inner cylindrical surface of the radial bearing 88 is slightly less than the inner diameter of body 80, so that a sleeve extension 90 of a lower spacer sleeve normally engages the radial bearing 88 but not the body 80. The spacer sleeve and thus the extension 90 are attached to mandrel 94, so that the sleeve 90 and mandrel 94 rotate with respect to the body 80. A mandrel ring 96 is attached to mandrel 94 to secure the lower end of the sleeve 90 in place. The mandrel defines a cylindrical full bore 98 for passing the drilling fluid to the bit, and the bit box 44 may be threadably secured directly to the lower end of mandrel 94.
The sealed cavity 76 houses the FM transmitter 62, the accelerometer 60 to monitor borehole inclination, the voltage-to-frequency converter 63, and the power supply 64, which may consist of a lithium battery pack or generator assembly. Any number of additional sensors represented by 66 may be provided within the sealed cavity to monitor near bit information. If desired, a small computer may also be provided within the cavity 76 to provide temporary data 20240fi1 storage functions. The computer may include timing programs or circuitry to regulate the timing for . transmitting FM signals for each of the sensors from the transmitter 62 to the receiver 70. Also, a turbine or eddy current generator' 65 may be provided for generating electrical power to recharge the battery pack 64 or to directly power the sensors, computer and transmitter within the cavity 76. The generator 65 is stationary with respect to the adjoining rotary mandrel 94, and accordingly may be powered by the mandrel driven by the motor 24, so that no additional power supply is required for the generator 65.
Once the electrical components are properly positioned and electrically connected within the cavity 76, a gel sealant 75 may be used to fill voids in the cavity 76 and thus protect the electric components from shock, vibration, etc.
Those skilled in the art should now appreciate the numerous advantages of the system according to the present invention. A fast, accurate, and low cost technique is provided for reliably obtaining and transmitting valuable near bit information past the drilling motor and to the surface. In particular, well bore inclination may be moni-tored at a near bit position, although well bore direction may be reliably sensed and transmitted to the surface from a position above the drill motor. Individual components of the system according to the present invention are commer-cially available, and the equipment is rig site service-able. Complex and unreliable hard-wiring techniques are not required to pass the information by the drill motor.
Although reliable near bit information is obtained, the sensors are not normally rotated during ongoing drilling operations, so that the sensors and electrical components within the sealed cavity 76 are not subject to centrifugal forces caused by a drill bit rotating in the 50 to 600 RPM
range. Moreover, the sub 42 is substantially isolated from the high vibrational forces acting on the drill bit due to the various bearing assemblies within the bearing housing 30. Moreover, the components in the sealed cavity 76 are further cushioned from vibration of the sub 78 due to the 202.4061 encapsulating gel 75. The angular or orientational position of the sensors within the sealed cavity 76 is fixed, and thus the position of any sensor with respect to the sub 42 and thus the drill string 12 may be determined and recorded. w While the invention has been described in connection with certain preferred embodiments, it should be understood that the disclosure of these embodiments is not intended to limit the invention. Dissimilarly, the described method is illustrative, and other methods and procedure variations will be suggested by this disclosure. Accordingly, the invention is intended to cover various alternatives, modifications, and equivalents in the described method and apparatus which are included within the scope of the claims.
A downhole MWD tool typically comprises a battery pack or turbine, a sensor package, a mud pulse transmitter, and an interface between the sensor package and transmitter.
When used with a downhole motor, the MWD tool is located above the motor. The electronic components of the tool are spaced substantially from the bit and accordingly are not subject to the high vibration and centrifugal forces acting ,.,...
on the bit. The sensor package may include various sensors, such as gamma ray, resistivity, porosity and temperature sensors for measuring formation characteristics or downhole parameters. In addition, the sensor package typically includes one or more sets of magnetometers and accelerometers for measuring the direction and inclination of the drilled borehole. The tool sensor package is placed in a non-magnetic environment by utilizing monel collars in the drill string both above and below the MWD tool. The desired length of the monel collars will typically be a function of latitude, well bore direction, and local anomalies. As a result of the monel collars and the required length of the downhole motor (including the power section, the bent sub, the bearing assembly), the sensor package for the MWD system is typically located from ten meters to fifty meters from the drill bit.
The considerable spacing between the MWD sensor package and the drill bit has long been known to cause significant problems for the drilling operator, particularly with respect to the measurement of borehole inclination. The operator is often attempting to drill a highly deviated or substantially horizontal borehole, so that the borehole extends over a long length through the formation of interest. The formation itself may be relatively thin, e.g.
only three meters thick, yet the operator is typically monitoring borehole conditions or parameters, such as inclination, thirty meters from the bit. The substantial advantage of a real time MWD system and the flexibility of a downhole motor f or drilling highly deviated boreholes are thus minimized by the reality that the sensors for the MWD
system are responsive to conditions spaced substantially f rom the bi t .
The disadvantages of the prior art are overcome by the present invention. Improved techniques are hereinafter disclosed for more accurately monitoring borehole conditions or parameters, such as borehole inclination, while drilling a deviated borehole utilizing a downhole motor.
= 5 -Summary of the Invention The invention in its broadest aspect relates to a method of drilling a borehole using a drill string having a drill bit at one end and a downhole drilling motor within the drill string for rotating the drill bit, the method comprising detecting a downhole parameter using a sensor fixedly located in the part of the drill string comprising the drill bit, the drilling motor and any components intermediate the drill bit and the drilling motor, transmitting to the surface a signal representative of the detected downhole parameter or of variation of said parameter, and altering the drilling trajectory in response to said transmitted signal.
The invention also broadly relates to apparatus for signalling within a borehole while drilling using a drill string having a drill bit at one end and a downhole drilling motor within the drill string for rotating the drill bit, the apparatus comprising a sensor for location in the part of the drill string comprising the drill bit, the drilling motor and any components intermediate the drill bit and the drilling motor to detect a downhole parameter, a first transmitter for location in said part of the drill string to receive an input from the sensor indicative of the detected downhole parameter or variation of said parameter and to transmit a signal representative of said input, a downhole receiver for location in a portion of the drill string on the opposite axial side of the drilling motor to the drill bit to receive said signal transmitted by the first transmitter, and a second transmitter for location in said portion of the drill string to receive an input from the receiver indicative of said signal and to transmit a signal representative of said input to the surface.
The invention also provides a drill bit or drill bit bearing assembly to be located at one end of the drill string during drilling, the assembly comprising a housing, a sealed cavity within the housing, a sensor within the cavity for detecting a downhole parameter, and a transmitter within the cavity for receiving an input from the sensor indicative of the detected downhole parameter or variation of said parameter and for transmitting a signal representative of said input.
A preferred embodiment of the invention includes an MWD tool, a downhole motor power section having a bent housing, a downhole motor bearing assembly, and a drill bit in descending, order in a drill string. A tool sensor package for the MWD tool includes one or more magneto-meters, and accordingly the tool is positioned within monel collars to minimize magnetic interference. A power pack, an inclination sensor, and a transmitter may each be provided within a sealed cavity within the housing of the downhole motor bearing assembly, and preferably within a lower portion of the bearing housing adjacent the bit box.
The inclinometer senses the angular orientation of the housing and thus the inclination of the well bore at a position closely adjacent the bit. The signal from the inclinometer is transmitted to a receiver in the MWD tool, and borehole inclination data is then transmitted by the MWD system to the surface for computation and display.
The inclination measurements are converted to frequency signals which are transmitted through the motor housing and drill string to the receiver in the MWD tool by a wireless system. Problems associated with power and data transmission wiring extending from the MWD tool to the inclinometer are avoided, yet the drilling operator benefits from inclination data sensed closely adjacent the bit. The motor housing is not rotated by the motor, so that the power pack, inclination sensor, and transmitter provided therein are not subject to continual centrifugal forces. Other conventional downhole sensors may also be provided within the bearing assembly housing closely adjacent the drill bit, and data may be reliably obtained and transmitted to the surface during the drilling mode, thereby saving valuable drilling time. Also, much of the bit chatter is absorbed in the bearing assembly and torque transmission components along the drill motor, so that the sensors are not subject to high vibration although located closely adjacent the drill bit.
According to a preferred method of the present invention, a well bore direction sensor is provided within the MWD tool which is spaced substantially above the drill ,....y bit, while a well bore inclination sensor is positioned closely adjacent the drill bit within the housing of the drill motor bearing assembly. Data from the inclination sensor is transmitted to the MWD tool using a transmitter within the sealed- cavity in the motor housing and a receiver in the MWD tool. Both well bore direction and well bore inclination data may then be transmitted to the surface in real time by mud pulse telemetry. The drilling operator is able to analyze inclination data sensed closely adjacent the bit, and thereby control the operation of the drill motor and the rotation of the drill string in response to this data to better maintain the drilled borehole at its desired inclination.
It is an object of the invention to provide an improved system for enabling a drilling operator to more accurately determine borehole characteristics or formation parameters when drilling a well utilizing a downhole motor and an MWD tool far transmitting sensed information to the surface.
It is another object of the invention to provide sensors positioned closely adjacent the drill box and within a lower portion of the drill motor bearing housing.
Signals from the sensors are transmitted to the MWD tool located above the drill motor utilizing a transmitter within the bearing housing and a receiver in the MWD tool.
The signals are then transmitted to the surface utilizing the MWD tool.
It is a feature of the present invention that electrical conductors are not utilized extending from the MWD tool to the sensors within the lower portion of the bearing housing. The wireless transmission system avoids substantial cost increases for the downhole motor and does not adversely restrict the versatility of the motor.
Yet another feature of the present invention is that sensors are provided within a cavity in the bearing housing, thereby allowing data sensed closely adjacent the drill bit to be transmitted to the surface in real time and without interrupting drilling operations.
2o24os~
_8_ It is an advantage of this invention that a power pack, inclinometer, and transmitter are located within a sealed cavity in .a lower portion of the bearing housing.
These components may be easily serviced or replaced at the rig site. w These and further objects, features and advantages of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
Brief Description of the Drawincts Figure 1 is a simplified pictorial view of a drill string according to the present invention:
Figure 2 is a simplified schematic diagram illustrating the components of a typical drilling and borehole surveying system according to the present invention to sense borehole trajectory and transmit sensed data to the surface far altering the drilling trajectory;
and Figure 3 is an axial section through a lower portion of a drill motor housing according to the present invention schematically showing certain components within a sealed cavity in the motor housing.
Detailed Description of Preferred Embodiments Figure 1 depicts a simplified version of a system 10 according to the present invention for drilling a deviated borehole through earth formations while monitoring borehole characteristics or formation properties. This system includes a drill string 12 comprising lengths of conventional drill pipe extending from the surface 14 through a plurality of earth formations 16, 18. Borehole 20 is drilled by a rotary drill bit 22, which is powered by a fluid driven or mud motor 24 having a bent housing 26.
The motor 24 rotates a drive shaft 28, which is guided at its lower end by radial and thrust bearings (not shown) within a bearing housing 30 affixed to the housing of the mud motor. The motor 24 is driven by drilling mud which is forced by mud pumps 32 at the surface down the drill string 12. The majority of the drill string comprises lengths of - g _ metallic drill pipe, and various downhole tools 34, such as cross-over subs, stabilizer, jars, etc., may be included along.the length of the drill string.
One or more non-magnetic lengths of drill string 36, commonly referred-to as monel collars, may be provided at the lower end of the drill string above the drill motor.
A conventional cross-over 38 preferably interconnects the lower end of a monel collar 36 to a by-pass or dump valve sub 40, and the mud motor 24 is fixedly connected directly to the sub 40. A lower sub 42 is fixedly connected at the lower end of the bearing housing 30, and contains a sealed cavity with electronics, as discussed subsequently. A
rotary bit sub or bit box 44 extends from the lower sub 42, and is rotatable with the drill bit 22.
During straight line drilling, the drill pipe, the mud motor housing, the bearing housing, and any other housings coupled to the mud motor housing are rotated by the rotary table 56, and simultaneously the pumps 32 power the motor 24 to rotate the shaft 28 and the bit 22. During such drilling data representative of various sensed downhole parameters may be transmitted to the surface by an MWD tool 46 within one of the monel collars in the form of pressure pulses in the drilling mud which are received by a near surface sensor 48. The sensed data is then passed by lines 50 to a surface computer 52, which stores and processes the data for the drilling operator. If desired, data may be displayed in real time on a suitable medium, such as paper or a screen 54. When the drilling operator desires to form a deviation or curve in the borehole, the mud motor 24 remains activated while the operator stops rotation of the drill string by the rotary table 56, with the result that the bit is caused to drill at an offset. During this stage of drilling, the MWD system conventionally is not transmitting data to the surface, but data may still be sensed and briefly stored within the MWD tool 46. When the desired offset is drilled, the rotary table 56 is again rotated to drill the borehole at the deviated angle, and during this stage stored data may be transmitted to the '~' 10 - 202 4061 surface by the MWD tool.
According to the present invention, one or more sensors located very near the drill bit 22 and below the power section of the mud motor 24 provide information to a transmitter, which-forwards the information by a wireless system to the MWD tool, which in turn transmits the information to the surface. The significant advantage of this invention is that data may be sensed very near the bit 22, rather than 20 to 100 feet up from the bit where the MWD tool is typically located. This near bit sensing allows more meaningful data to be transmitted to the surface, since the operator would like to know the characteristics of the borehole and/or the formation at a location very near the bit rather than at some location drilled hours previously. In particular, an accelerometer or inclinometer is preferably one of the near bit sensors, since information representing the inclination of the borehole closely adjacent the bit is valuable to the drilling operator. This data cannot be easily transmitted from a near bit location to the MWD tool, however, due to the presence of the intervening mud motor 24. The necessary complexity and desirable versatility of the mud motor are not well suited to accommodate conventional data transmission lines running through the motor. It is therefore preferred that the information is transmitted from a near bit location to the MWD tool by frequency-modulated acoustic signals indicative of the sensed information. However, the information may also be transmitted electro-magnetically, inductively or by mud pulses, for example, and by amplitude or phrase modulation, or by time multiplexity rather than frequency modulation.
Figure 2 generally depicts in block diagram form the primary components of the system according to the present invention, and the same numeral designations will be used for components previously discussed. At the lowermost end of the drill string and moving upward are the drill bit 22, the drill bit box 44 and the drive shaft 28 which extends up to the mud motor 24. The bit, bit box, and drive shaft all rotate with the respect to the remaining components of the drill string. The lower sub 42 is provided above the bit box and includes a sealed cavity which houses an accelerometer 60, a near bit transmitter 62, a power supply 64, and preferably one or more sensors 66 other than an accelerometer. Information from each sensor is transmitted by conventional wiring to the transmitter 62, which then forwards frequency-modulated signals indicative of the sensed information to the MWD receiver in the monel collar 36. A voltage to frequency convertor 63 may be used to convert voltage signals from any sensor to frequency signals. The signals from transmitter 62 pass through the metal housing between the lower sub 42 and an MWD receiver 70 within the monel collar 36. The transmitted signals may be acoustic signals having a frequency in the range of from 500 to 2,000 Hz. Acoustic signals may be efficiently transmitted for a distance of up to 100 feet through either the drilling mud or the metal housings. Alternatively, radio frequency signals of from 30 kilo-Hz to 3,000 mega-Hz may be used as the signals transmitted between the near bit transmitter and the MWD receiver, and these radio frequency signals may require less consumption of energy than acoustic signals.
The lower sub housing 42 may be keyed or otherwise fixed to and may structurally be an integral part of the housing for the bearing pack sub 30. A flexible coupling sub or bent sub 26 houses the drive shaft 28, and is fixedly connected at its lower end to the sub 30 and at its upperend to the drill motor sub 24. Subs 24, 26 and 30 are generally used as an assembly, and drilling operators commonly refer to this entire combination rather than only sub 24 as the downhole motor assembly. Fixed to the upper end of the drill motor sub 24 is by-pass sub 40, which includes conventional outlet ports for dumping excess fluid to the borehole.
Monel collar 36 is fixed to the sub 40, and houses the MWD tool 46 generally shown in Figure 1. Tool 46 includes a magnetometer or other magnetic sensor 66, a downhole data storage device or computer 68, an MWD receiver 70 a power supply 72, and an MWD transmitter 74. Although it is generally preferred that the borehole or formation characteristics be sensed at a location below the drill motor 24, the magnetometer must be magnetically isolated from the metal housings for reasonable accuracy and reliability, and accordingly it is housed within the monel collar 36. If desired, other sensors, such as backup sensors, could also be provided within the monel collar 36, although preferably sensors other than the magnetic sensor are located at the near bit location. In addition to the inclinometer or accelerator 60, near bit sensors provided within the sub 42 may include, for example, a weight on bit sensor, a torque sensor, resistivity sensor, a neutron porosity sensor, a formation density sensor, a gamma ray count sensor, and a temperature sensor. Data from each of these sensors may thus be transmitted by the transmitter 62 to the MWD receiver 70. Since sensor 67 is closely adjacent the downhole computer 68, information from this sensor may be hard-wired directly to the computer 68, while the remaining information is received by the receiver 70 then transmitted to the computer 68.
Computer 68 may include both temporary data storage and data processing capabilities. In particular, information from various sensors may be encoded for each sensor and arranged by the computer so that like signals will be transmitted to the surface, with the signals from each sensor being coded for a particular sensor. Porosity signals, magnetometer signals, resistivity signals, inclination signals and temperature signals may thus be intermittently transmitted to the surface by the MWD
transmitter 74. Transmitter 74 preferably is a mud pulse transmitter, so that the information is passed by the pulse 3 5 waves through the drill ing mud in the drill string . The receiver 70, computer 68, transmitter 74 and any sensors within the monel collar may all be powered by the power supply 72.
.., 202 406 1 Data may be transmitted from the monel collar 36 to the surface receiver 48, and preferably is transmitted through the mud within the drill string 12. The surface computer 52 stores and processes this information, and information may be displayed to the drilling operator on a monitor panel or display 54. Information may be sensed, and data transmitted, processed and displayed in "real time", so that the drilling operator may visually see a representation of borehole or formation characteristics which are being monitored at a position closely adjacent the drill bit and below the drill motor. The information may be obtained and displayed while the drill motor is activated, and the displayed information represents data sensed substantially at the time it is displayed.
Figure 3 depicts the lower end of a suitable lower bearing housing secured to the end of the motor housing 26.
The eccentric or set-off provided by the bent sub allows the reliable drilling of the deviated or curved borehole.
The sub 42 essentially provides a sealed cavity for the components shown in Figure 2 within the sub 42, and may either be part of or attached to the assembly consisting of the mud motor 24 and/or the bearing housing 30, and optionally may also include the motor housing 26. The sealed cavity may be formed by the motor housing 26 and/or the bearing housing 30, although this cavity may be formed in any suitable location below the monel collar 36, and preferably as close as possible to the drill bit 22.
The mud motor 24 may either be a positive displacement motor or a turbine motor, and utilizes pressurized fluid to drive a shaft 20 which is guided by the bearing housing 30.
The bearing housing 30 comprises one or more sleeve-shaped, axially aligned, normally stationary outer subs, which may be threadably connected to the motor housing 26. The bearing housing 30 also includes a mandrel rotated by the drive shaft 28, with the mandrel in turn defining a "full bore" interior fluid passageway for transmitting fluid to cool and clean the drill bit. The annular spacing between the outer subs and the inner mandrel is typically occupied ,,... 202 4061 by a plurality of marine bearings, wear sleeves, thrust bearing assemblies, radial bearings, etc. to guide the rotatable mandrel with respect to the outer subs and absorb some of the thrust load on the drill bit. The bearing housing assembly may be of the type wherein the bearings are lubricated by the drilling mud, or optionally may be sealed from the fluid passing through the mandrel and to the bit.
Figure 3 depicts an embodiment wherein the annular sealed cavity 76 is defined by a lower portion of the bearing housing 30 constituting the lower bearing sub 42.
The lower bearing sub 42 of the housing 30 includes an integral recessed lower body 80 to define cavity 76. The sub 42 comprises an outer sleeve 82 which is threadably connected to body 80, with a fluid-tight seal being formed by O-rings 84, 86 between the radially outwardly projecting legs of the body 80 and the sleeve 82. A wear sleeve 92 and a radial bearing 88 are positioned within the sub 42.
The inner cylindrical surface of the radial bearing 88 is slightly less than the inner diameter of body 80, so that a sleeve extension 90 of a lower spacer sleeve normally engages the radial bearing 88 but not the body 80. The spacer sleeve and thus the extension 90 are attached to mandrel 94, so that the sleeve 90 and mandrel 94 rotate with respect to the body 80. A mandrel ring 96 is attached to mandrel 94 to secure the lower end of the sleeve 90 in place. The mandrel defines a cylindrical full bore 98 for passing the drilling fluid to the bit, and the bit box 44 may be threadably secured directly to the lower end of mandrel 94.
The sealed cavity 76 houses the FM transmitter 62, the accelerometer 60 to monitor borehole inclination, the voltage-to-frequency converter 63, and the power supply 64, which may consist of a lithium battery pack or generator assembly. Any number of additional sensors represented by 66 may be provided within the sealed cavity to monitor near bit information. If desired, a small computer may also be provided within the cavity 76 to provide temporary data 20240fi1 storage functions. The computer may include timing programs or circuitry to regulate the timing for . transmitting FM signals for each of the sensors from the transmitter 62 to the receiver 70. Also, a turbine or eddy current generator' 65 may be provided for generating electrical power to recharge the battery pack 64 or to directly power the sensors, computer and transmitter within the cavity 76. The generator 65 is stationary with respect to the adjoining rotary mandrel 94, and accordingly may be powered by the mandrel driven by the motor 24, so that no additional power supply is required for the generator 65.
Once the electrical components are properly positioned and electrically connected within the cavity 76, a gel sealant 75 may be used to fill voids in the cavity 76 and thus protect the electric components from shock, vibration, etc.
Those skilled in the art should now appreciate the numerous advantages of the system according to the present invention. A fast, accurate, and low cost technique is provided for reliably obtaining and transmitting valuable near bit information past the drilling motor and to the surface. In particular, well bore inclination may be moni-tored at a near bit position, although well bore direction may be reliably sensed and transmitted to the surface from a position above the drill motor. Individual components of the system according to the present invention are commer-cially available, and the equipment is rig site service-able. Complex and unreliable hard-wiring techniques are not required to pass the information by the drill motor.
Although reliable near bit information is obtained, the sensors are not normally rotated during ongoing drilling operations, so that the sensors and electrical components within the sealed cavity 76 are not subject to centrifugal forces caused by a drill bit rotating in the 50 to 600 RPM
range. Moreover, the sub 42 is substantially isolated from the high vibrational forces acting on the drill bit due to the various bearing assemblies within the bearing housing 30. Moreover, the components in the sealed cavity 76 are further cushioned from vibration of the sub 78 due to the 202.4061 encapsulating gel 75. The angular or orientational position of the sensors within the sealed cavity 76 is fixed, and thus the position of any sensor with respect to the sub 42 and thus the drill string 12 may be determined and recorded. w While the invention has been described in connection with certain preferred embodiments, it should be understood that the disclosure of these embodiments is not intended to limit the invention. Dissimilarly, the described method is illustrative, and other methods and procedure variations will be suggested by this disclosure. Accordingly, the invention is intended to cover various alternatives, modifications, and equivalents in the described method and apparatus which are included within the scope of the claims.
Claims (80)
1. A method of signalling within a borehole having therein a drill string with a drill bit at a lower end thereof, a downhole drilling motor being positioned within said drill string, said downhole drilling motor having a power assembly operable for rotating said drill bit, said method comprising:
rotating said drill bit with said downhole drilling motor at a bit rotation speed in revolutions per minute with respect to said borehole;
supporting at least one sensor at a location below said power assembly of said downhole drilling motor such that said at least one sensor does not rotate at said bit rotation speed; and detecting a downhole parameter with said at least one sensor.
rotating said drill bit with said downhole drilling motor at a bit rotation speed in revolutions per minute with respect to said borehole;
supporting at least one sensor at a location below said power assembly of said downhole drilling motor such that said at least one sensor does not rotate at said bit rotation speed; and detecting a downhole parameter with said at least one sensor.
2. The method of claim 1, further comprising:
relaying a signal representative of said detected downhole parameter from a position below said power assembly of said downhole drilling motor to a position above said power assembly of said downhole drilling motor.
relaying a signal representative of said detected downhole parameter from a position below said power assembly of said downhole drilling motor to a position above said power assembly of said downhole drilling motor.
3. The method of claim 1, wherein said step of supporting said at least one sensor further comprises:
supporting said at least one sensor such that said at least one sensor moves axially substantially in concert with said drill bit.
supporting said at least one sensor such that said at least one sensor moves axially substantially in concert with said drill bit.
4. The method of claim 1, further comprising:
relaying a signal representative of said detected downhole parameter from a lower downhole position above said power assembly of said downhole drilling motor to a surface location.
relaying a signal representative of said detected downhole parameter from a lower downhole position above said power assembly of said downhole drilling motor to a surface location.
5. The method of claim 1, further comprising:
supporting a first downhole transmitter at a location below said power assembly of said downhole drilling motor.
supporting a first downhole transmitter at a location below said power assembly of said downhole drilling motor.
6. The method of claim 5, wherein said step of supporting said first downhole transmitter further comprises:
supporting said first downhole transmitter such that said first downhole transmitter does not rotate at said bit rotation speed.
supporting said first downhole transmitter such that said first downhole transmitter does not rotate at said bit rotation speed.
7. The method of claim 5, further comprising:
transmitting said signal representative of said detected downhole parameter from said first transmitter to a second transmitter at a position above said power assembly of said downhole drilling motor.
transmitting said signal representative of said detected downhole parameter from said first transmitter to a second transmitter at a position above said power assembly of said downhole drilling motor.
8. The method of claim 1, wherein said step of supporting further comprises:
affixing said at least one sensor to a housing of said downhole drilling motor.
affixing said at least one sensor to a housing of said downhole drilling motor.
9. Apparatus for signalling within a borehole having therein a drill string with a drill bit at a lower end thereof, said drill bit being powered by a downhole drilling motor within said drill string, said downhole motor including a power assembly for rotating said drill bit, said apparatus comprising:
one or more sensors mounted below said power assembly of said downhole motor such that said one or more sensors are rotationally uncoupled with respect to said drill bit so as to be rotationally independent of said drill bit;
a first downhole signal transmitter positioned below said power assembly of said downhole motor for relaying signals representative of one or more parameters detected by said one or more sensors;
a second downhole signal transmitter positioned above said power assembly of said downhole motor for relaying said signals representative of said one or more parameters detected by said one or more sensors to a surface location; and at least one receiver positioned at said surface location for receiving said signals representative of said one or more parameters detected by said one or more sensors.
one or more sensors mounted below said power assembly of said downhole motor such that said one or more sensors are rotationally uncoupled with respect to said drill bit so as to be rotationally independent of said drill bit;
a first downhole signal transmitter positioned below said power assembly of said downhole motor for relaying signals representative of one or more parameters detected by said one or more sensors;
a second downhole signal transmitter positioned above said power assembly of said downhole motor for relaying said signals representative of said one or more parameters detected by said one or more sensors to a surface location; and at least one receiver positioned at said surface location for receiving said signals representative of said one or more parameters detected by said one or more sensors.
10. The apparatus of claim 9, further comprising:
a shaft rotatably secured to said bit for rotating said bit;
said one or more sensors being mounted so as to be axially moveable substantially in concert with said shaft and said bit.
a shaft rotatably secured to said bit for rotating said bit;
said one or more sensors being mounted so as to be axially moveable substantially in concert with said shaft and said bit.
11. The apparatus of claim 9, further comprising:
a housing annularly disposed with respect to said shaft, said one or more sensors being affixed to said housing.
a housing annularly disposed with respect to said shaft, said one or more sensors being affixed to said housing.
12. The apparatus of claim 11, wherein:
said first downhole signal transmitter is affixed to said housing.
said first downhole signal transmitter is affixed to said housing.
13. A method of signalling within a borehole having therein a drill string with a drill bit at a lower end thereof, said drill bit being powered by a downhole drilling motor within said drill string, said downhole drilling motor including a power assembly, said method comprising:
rotating said drill bit with said downhole drilling motor at a bit rotation speed in revolutions per minute with respect to said borehole;
supporting at least one signal transmitter at a location below said power assembly of said downhole drilling motor such that said at least one signal transmitter does not rotate at said bit rotation speed;
detecting a downhole parameter with at least one sensor;
and transmitting a signal representative of said detected downhole parameter with said at least one signal transmitter.
rotating said drill bit with said downhole drilling motor at a bit rotation speed in revolutions per minute with respect to said borehole;
supporting at least one signal transmitter at a location below said power assembly of said downhole drilling motor such that said at least one signal transmitter does not rotate at said bit rotation speed;
detecting a downhole parameter with at least one sensor;
and transmitting a signal representative of said detected downhole parameter with said at least one signal transmitter.
14. The method of claim 13, wherein said step of supporting said at least one signal transmitter further comprises:
supporting said at least one signal transmitter such that said at least one signal transmitter moves axially substantially in concert with said drill bit.
supporting said at least one signal transmitter such that said at least one signal transmitter moves axially substantially in concert with said drill bit.
15. The method of claim 13, further comprising:
relaying said signal representative of said detected downhole parameter from a lower downhole position above said power assembly of said downhole drilling motor to a surface location.
relaying said signal representative of said detected downhole parameter from a lower downhole position above said power assembly of said downhole drilling motor to a surface location.
16. The method of claim 13, wherein said step of transmitting further comprises:
transmitting from a position below said power assembly of said downhole drilling motor to a position above said power assembly of said downhole drilling motor.
transmitting from a position below said power assembly of said downhole drilling motor to a position above said power assembly of said downhole drilling motor.
17. The method of claim 13, wherein said step of supporting further comprises:
supporting said at least one sensor such that it does not rotate at said bit rotation speed.
supporting said at least one sensor such that it does not rotate at said bit rotation speed.
18. The method of claim 13, further comprising:
transmitting said signal representative of said detected downhole parameter from said at least one signal transmitter to a second signal transmitter at a position above said power assembly of said downhole drilling motor.
transmitting said signal representative of said detected downhole parameter from said at least one signal transmitter to a second signal transmitter at a position above said power assembly of said downhole drilling motor.
19. The method of claim 13, wherein said step of supporting further comprises:
affixing said at least one signal transmitter to a housing of said downhole drilling motor.
affixing said at least one signal transmitter to a housing of said downhole drilling motor.
20. Apparatus for signalling within a borehole having therein a drill string with a drill bit at a lower end thereof, said drill bit being powered by a downhole drilling motor within said drill string, said downhole motor including a power assembly for rotating said drill bit, said apparatus comprising:
one or more sensors positioned below said power assembly of said downhole motor for detecting one or more parameters;
a first downhole transmitter mounted below said power assembly of said downhole motor such that said first downhole transmitter is rotationally uncoupled with respect to said drill bit so as to be rotationally independent of said drill bit, said first downhole transmitter relaying a signal representative of said one or more parameters detected by said one or more sensors; and at least one receiver positioned at a surface location for receiving said signal representative of said one or more parameters detected by said one or more sensors.
one or more sensors positioned below said power assembly of said downhole motor for detecting one or more parameters;
a first downhole transmitter mounted below said power assembly of said downhole motor such that said first downhole transmitter is rotationally uncoupled with respect to said drill bit so as to be rotationally independent of said drill bit, said first downhole transmitter relaying a signal representative of said one or more parameters detected by said one or more sensors; and at least one receiver positioned at a surface location for receiving said signal representative of said one or more parameters detected by said one or more sensors.
21. The apparatus of claim 20, further comprising:
a shaft portion of said drill string rotatably secured to said bit for rotating said bit; and said first downhole transmitter being axially coupled with respect to said shaft portion so as to be substantially axially moveable with said shaft portion and said bit.
a shaft portion of said drill string rotatably secured to said bit for rotating said bit; and said first downhole transmitter being axially coupled with respect to said shaft portion so as to be substantially axially moveable with said shaft portion and said bit.
22. The apparatus of claim 21, further comprising:
an annular housing in surrounding relationship to said shaft portion, said first downhole transmitter being affixed to said annular housing.
an annular housing in surrounding relationship to said shaft portion, said first downhole transmitter being affixed to said annular housing.
23. The apparatus of claim 22, wherein:
said one or more sensors are affixed to said annular housing.
said one or more sensors are affixed to said annular housing.
24. Apparatus for signalling within a borehole having therein a drill string, said drill bit being powered by a downhole drilling motor within said drill string, at least a portion of said drill string forming a drive shaft rotatable by said downhole drilling motor, said drive shaft being secured to a drill bit at one end thereof and being rotatable by said downhole drilling motor adjacent a second end thereof to thereby rotate said drill bit in response to rotation of said drive shaft, said apparatus comprising:
a sensor support member mounted at a location below said second end of said drive shaft and being rotatably recoupled with respect to said drive shaft such that said sensor support member is rotatably independent of said drive shaft;
one or more sensors carried by said sensor support member for detecting one or more downhole parameters; and a signal transmission system for relaying signals representative of said one or more downhole parameters to a location in said drill string uphole with respect to said drive shaft.
a sensor support member mounted at a location below said second end of said drive shaft and being rotatably recoupled with respect to said drive shaft such that said sensor support member is rotatably independent of said drive shaft;
one or more sensors carried by said sensor support member for detecting one or more downhole parameters; and a signal transmission system for relaying signals representative of said one or more downhole parameters to a location in said drill string uphole with respect to said drive shaft.
25. The apparatus of claim 24, wherein:
said sensor support member is mounted radially outwardly with respect to said drive shaft.
said sensor support member is mounted radially outwardly with respect to said drive shaft.
26. The apparatus of claim 24, further comprising:
a motor housing in surrounding relationship to said drive shaft, said sensor support member being rotatably secured with respect to said motor housing.
a motor housing in surrounding relationship to said drive shaft, said sensor support member being rotatably secured with respect to said motor housing.
27. The apparatus of claim 24, further comprising:
a signal transmitter mounted at a position below said second end of said drive shaft for transmission of a signal representative of said one or more downhole parameters.
a signal transmitter mounted at a position below said second end of said drive shaft for transmission of a signal representative of said one or more downhole parameters.
28. The apparatus of claim 24, further comprising:
a motor housing in surrounding relationship to said drive shaft, said signal transmitter being rotatably secured with respect to said motor housing.
a motor housing in surrounding relationship to said drive shaft, said signal transmitter being rotatably secured with respect to said motor housing.
29. A method of signalling within a borehole having a drill string therein, at least a portion of said drill string forming a drive shaft with said drive shaft being rotatable by a drive unit, said drive shaft being attached to a drill bit at a first end of said drive shaft and being driven by said drive unit adjacent a second end thereof, said drill bit rotating in response to rotation of said drive shaft, said method comprising said following steps:
rotating said drive shaft with said drive unit to thereby rotate said drill bit at a drill bit rotation speed in revolutions per minute with respect to said borehole;
supporting at least one sensor at a location below said second end of said drive shaft such that said at least one sensor does not rotate at said drill bit rotation speed;
supporting a downhole signal transmitter at a location below said second end of said drive shaft; and sensing at least one parameter with said at least one sensor.
rotating said drive shaft with said drive unit to thereby rotate said drill bit at a drill bit rotation speed in revolutions per minute with respect to said borehole;
supporting at least one sensor at a location below said second end of said drive shaft such that said at least one sensor does not rotate at said drill bit rotation speed;
supporting a downhole signal transmitter at a location below said second end of said drive shaft; and sensing at least one parameter with said at least one sensor.
30. The method of claim 29, further comprising:
transmitting a signal representative of said at least one parameter with said downhole signal transmitter.
transmitting a signal representative of said at least one parameter with said downhole signal transmitter.
31. The method of claim 29, further comprising:
relaying a signal representative of said at least one parameter from a position below said top end of said drive shaft to a surface position.
relaying a signal representative of said at least one parameter from a position below said top end of said drive shaft to a surface position.
32. The method of claim 29, wherein said step of rotating further comprises:
pumping fluid through said drill string to activate said drive unit for rotation of said drive shaft.
pumping fluid through said drill string to activate said drive unit for rotation of said drive shaft.
33. A method of signalling within a borehole while drilling using a drill string having a drill bit at a lower end thereof, the drill bit being selectively powered by a downhole drilling motor within the drill string, the downhole drilling motor including a power assembly for rotating the drill bit, and a downhole drilling motor housing stationary with respect to the drill string above the power assembly of the drilling motor, the method comprising:
detecting a downhole parameter with a sensor located in the drill string below the power assembly of the drilling motor and stationary with respect to the downhole drilling motor housing;
transmitting a signal representative of the detected downhole parameter along the drill string from a lower downhole location in the drill string below the power assembly of the drilling motor to an upper downhole location in the drill string axially opposite the sensor with respect to the drilling motor;
receiving said signal at said upper downhole location in the drill string; and transmitting data indicative of said signal from said upper downhole location in said drill string to the surface.
detecting a downhole parameter with a sensor located in the drill string below the power assembly of the drilling motor and stationary with respect to the downhole drilling motor housing;
transmitting a signal representative of the detected downhole parameter along the drill string from a lower downhole location in the drill string below the power assembly of the drilling motor to an upper downhole location in the drill string axially opposite the sensor with respect to the drilling motor;
receiving said signal at said upper downhole location in the drill string; and transmitting data indicative of said signal from said upper downhole location in said drill string to the surface.
34. The method according to claim 33, further comprising:
positioning the sensor in a cavity within an outer housing below the power assembly of the downhole motor.
positioning the sensor in a cavity within an outer housing below the power assembly of the downhole motor.
35. The method according to claim 33, wherein the step of transmitting the signal comprises:
generating and transmitting an acoustic signal representative of the detected downhole parameter.
generating and transmitting an acoustic signal representative of the detected downhole parameter.
36. The method as defined in claim 35, further comprising:
position a rod within a cavity within an outer housing adjacent to its drill bit;
positioning a coil about the rod;
inputting a signal to the coil functionally related to the detected downhole parameter to deform the rod to produce the acoustic output signal.
position a rod within a cavity within an outer housing adjacent to its drill bit;
positioning a coil about the rod;
inputting a signal to the coil functionally related to the detected downhole parameter to deform the rod to produce the acoustic output signal.
37. The method according to claim 33, wherein the step of transmitting data comprises;
generating and transmitting mud pulse signals from said upper downhole location to the surface.
generating and transmitting mud pulse signals from said upper downhole location to the surface.
38. The method according to claim 33, wherein the step of transmitting the signal comprises:
encoding the signal representative of the detected downhole parameter; and initiating the transmission of the signal along the drill string in response to a control signal.
encoding the signal representative of the detected downhole parameter; and initiating the transmission of the signal along the drill string in response to a control signal.
39. The method of claim 33, wherein the step of transmitting a signal representative of the detected downhole parameter along the drill string further comprises:
transmitting the signal representative of the detected downhole parameter utilizing the metal housing of the drilling motor as a signal flow path for the transmitted signal.
transmitting the signal representative of the detected downhole parameter utilizing the metal housing of the drilling motor as a signal flow path for the transmitted signal.
40. Apparatus for signalling within a borehole while drilling using a drill string having a drill bit at a lower end thereof, the drill bit being selectively powered by a downhole drilling motor within the drill string, the downhole drilling motor including a power assembly for rotating the drill bit, and a downhole drilling motor housing stationary with respect to the drill string above the power assembly of the drilling motor, the apparatus comprising:
a sensor within the drill string at a stationary position with respect to the downhole drilling motor housing below the power assembly of the drilling motor to detect a downhole parameter and generate an output indicative of the detected downhole parameter;
a first downhole transmitter positioned within the drill string at a stationary position with respect to the downhole drilling motor housing below the power assembly of the drilling motor to receive the output from the sensor and transmit a signal along the drill string representative of the sensor output;
a downhole receiver positioned within the drill string axially opposite the sensor with respect to the drilling motor for receiving the signal transmitted by the first transmitter;
and a second downhole transmitter positioned within the drill string axially opposite the sensor with respect to the drilling motor for receiving the signal from the downhole receiver and for transmitting data indicative of the signal to the surface.
a sensor within the drill string at a stationary position with respect to the downhole drilling motor housing below the power assembly of the drilling motor to detect a downhole parameter and generate an output indicative of the detected downhole parameter;
a first downhole transmitter positioned within the drill string at a stationary position with respect to the downhole drilling motor housing below the power assembly of the drilling motor to receive the output from the sensor and transmit a signal along the drill string representative of the sensor output;
a downhole receiver positioned within the drill string axially opposite the sensor with respect to the drilling motor for receiving the signal transmitted by the first transmitter;
and a second downhole transmitter positioned within the drill string axially opposite the sensor with respect to the drilling motor for receiving the signal from the downhole receiver and for transmitting data indicative of the signal to the surface.
41. Apparatus according to claim 40, wherein the first downhole transmitter is an acoustic transmitter, and the second downhole transmitter is a mud pulse transmitter.
42. Apparatus according to claim 40, further comprising:
another sensor within the drill string positioned below the power assembly of the drilling motor for detecting another downhole parameter and generating the output indicative of the detected another downhole parameter; and the second downhole transmitter transmits data to the surface indicative of the output from the another sensor.
another sensor within the drill string positioned below the power assembly of the drilling motor for detecting another downhole parameter and generating the output indicative of the detected another downhole parameter; and the second downhole transmitter transmits data to the surface indicative of the output from the another sensor.
43. Apparatus according to claim 42, wherein the first downhole transmitter comprises:
a magnetostrictive member;
magnetic field means for applying a magnetic field to said magnetostrictive member as a function of the sensor output to produce an acoustic signal representative of the sensor output.
a magnetostrictive member;
magnetic field means for applying a magnetic field to said magnetostrictive member as a function of the sensor output to produce an acoustic signal representative of the sensor output.
44. Apparatus according to claim 43, further comprising:
the magnetostrictive member includes first and second pole pieces separated by an air gap; and a compression member for axially comprising the first and second pole pieces.
the magnetostrictive member includes first and second pole pieces separated by an air gap; and a compression member for axially comprising the first and second pole pieces.
45. Apparatus according to claim 40, further comprising:
a bend within the drill string below the power assembly of the drilling motor; and the sensor is fixedly positioned within the drill string below the bend.
a bend within the drill string below the power assembly of the drilling motor; and the sensor is fixedly positioned within the drill string below the bend.
46. Apparatus according to claim 45, wherein:
the drilling motor includes a lower bearing assembly; and the sensor is fixedly positioned within the drill string below the bearing assembly of the drilling motor.
the drilling motor includes a lower bearing assembly; and the sensor is fixedly positioned within the drill string below the bearing assembly of the drilling motor.
47. A data sensing and transmission assembly for positioning within a lower end of a drill string during drilling and axially below a power section of a downhole motor selectively rotating a drill bit, the downhole drilling motor having a housing stationary with respect to a rotatable shaft for interconnecting the power section and the drill bit, the assembly comprising:
the drill motor housing having a sealed cavity therein;
a sensor within the sealed cavity for detecting a downhole parameter and generating an output indicative of the detected downhole parameter; and a transmitter within the sealed cavity for receiving the output from the sensor indicative of the detected downhole parameter and for transmitting a signal along the drill string representative of the sensor output to a position axially above the power section of the downhole motor.
the drill motor housing having a sealed cavity therein;
a sensor within the sealed cavity for detecting a downhole parameter and generating an output indicative of the detected downhole parameter; and a transmitter within the sealed cavity for receiving the output from the sensor indicative of the detected downhole parameter and for transmitting a signal along the drill string representative of the sensor output to a position axially above the power section of the downhole motor.
48. The assembly according to claim 47, wherein the transmitter comprises:
a magnetostrictive member; and magnetic field means for applying a magnetic field to said magnetostrictive member in response to the sensor output to produce an acoustic signal representative of the sensor output.
a magnetostrictive member; and magnetic field means for applying a magnetic field to said magnetostrictive member in response to the sensor output to produce an acoustic signal representative of the sensor output.
49. The assembly according to claim 47, wherein the housing is a drilling motor bearing housing, and the sensor is rotationally fixed within the drilling motor bearing housing.
50. The assembly according to claim 47, further comprising:
providing a power supply within the sealed cavity for powering the transmitter.
providing a power supply within the sealed cavity for powering the transmitter.
51. The assembly according to claim 47, wherein the transmitter transmits acoustic signals having a frequency in the range of from 500 to 2,000 Hz.
52. The assembly according to claim 47, wherein the transmitter comprises:
a voltage to frequency converter within the sealed cavity for receiving voltage signals from the sensor and generating frequency signals in response thereto.
a voltage to frequency converter within the sealed cavity for receiving voltage signals from the sensor and generating frequency signals in response thereto.
53. The assembly according to claim 47, further comprising:
a downhole computer within the sealed cavity for storing the transmitted signals.
a downhole computer within the sealed cavity for storing the transmitted signals.
54. The assembly according to claim 47, further comprising:
another sensor within the sealed cavity for detecting another downhole parameter; and the transmitter transmits another signal indicative of the output from the another sensor.
another sensor within the sealed cavity for detecting another downhole parameter; and the transmitter transmits another signal indicative of the output from the another sensor.
55. The assembly according to claim 47, further comprising:
a bend in the drill string below the power section of the downhole motor; and the sensor and the transmitter are each positioned within the sealed cavity of the housing below the bend in the drill string.
a bend in the drill string below the power section of the downhole motor; and the sensor and the transmitter are each positioned within the sealed cavity of the housing below the bend in the drill string.
56. The assembly according to claim 54, wherein:
the drilling motor includes a lower bearing assembly; and the sensor is fixedly positioned within the drill string below the bearing assembly of the drilling motor.
the drilling motor includes a lower bearing assembly; and the sensor is fixedly positioned within the drill string below the bearing assembly of the drilling motor.
57. A method of signalling within a borehole while drilling using a drill string having a drill bit at a lower end thereof, the drill bit being selectively powered by a downhole drilling motor within the drill string, the downhole drilling motor including a power assembly for rotating the drill bit, and a drilling motor housing stationary with respect to a drive shaft passing through the drilling motor housing and interconnecting the power assembly and the drill bit, the method comprising:
providing a plurality of sensors within a sealed cavity in a sensor housing below the power assembly of the downhole motor, the sensor housing being stationary with respect to the drilling motor housing;
detecting one or more downhole parameters with the plurality of sensors;
transmitting one or more signals representative of the detected one or more downhole parameters along the drill string from a lower downhole location in the drill string below the power assembly of the drilling motor to an upper downhole location in the drill string axially opposite the plurality of sensors with respect to the drilling motor;
receiving said one or more signals at said upper downhole location in the drill string; and transmitting data indicative of said one or more signals from sand upper downhole location in said drill string to the surface.
providing a plurality of sensors within a sealed cavity in a sensor housing below the power assembly of the downhole motor, the sensor housing being stationary with respect to the drilling motor housing;
detecting one or more downhole parameters with the plurality of sensors;
transmitting one or more signals representative of the detected one or more downhole parameters along the drill string from a lower downhole location in the drill string below the power assembly of the drilling motor to an upper downhole location in the drill string axially opposite the plurality of sensors with respect to the drilling motor;
receiving said one or more signals at said upper downhole location in the drill string; and transmitting data indicative of said one or more signals from sand upper downhole location in said drill string to the surface.
58. The method according to claim 57, further comprising:
storing said one or more signals downhole.
storing said one or more signals downhole.
59. The method according to claim 57, wherein the step of transmitting data comprises:
generating and transmitting mud pulse signals from said upper downhole location to the surface.
generating and transmitting mud pulse signals from said upper downhole location to the surface.
60. The method according to claim 57, further comprising:
providing a bend in the drill string below the power assembly of the downhole drilling motor; and positioning the plurality of sensors in the sealed cavity below the bend.
providing a bend in the drill string below the power assembly of the downhole drilling motor; and positioning the plurality of sensors in the sealed cavity below the bend.
67. A method of signalling within a borehole while drilling using a drill string having a drill bit at a lower end thereof, the drill bit being selectively powered by a downhole drilling motor within the drill string, the downhole drilling motor including a power assembly for rotating a drill bit, and a downhole drilling motor housing stationary with respect to the rotating drill bit, the method comprising;
detecting a downhole parameter with a sensor located in the drill string below the power section of the drilling motor and stationary with respect to the drilling motor housing;
transmitting a signal representative of the detected downhole parameters along the drill string from a lower downhole location in the drill string below the power assembly of the drilling motor to an upper downhole location in the drill string axially opposite the sensor with respect to the drilling motor;
receiving said signal at said upper downhole location in the drill string;
transmitting data indicative of said signal in real time from said upper downhole location in said drill string to the surface; and altering drilling trajectory in response to the transmitted data.
detecting a downhole parameter with a sensor located in the drill string below the power section of the drilling motor and stationary with respect to the drilling motor housing;
transmitting a signal representative of the detected downhole parameters along the drill string from a lower downhole location in the drill string below the power assembly of the drilling motor to an upper downhole location in the drill string axially opposite the sensor with respect to the drilling motor;
receiving said signal at said upper downhole location in the drill string;
transmitting data indicative of said signal in real time from said upper downhole location in said drill string to the surface; and altering drilling trajectory in response to the transmitted data.
62. The method as defined in claim 61, further comprising:
storing said signal downhole at a location above the power assembly of the drilling motor.
storing said signal downhole at a location above the power assembly of the drilling motor.
63. The method according to claim 61, wherein the step of transmitting data comprises:
generating and transmitting mud pulse signals from said upper downhole location to the surface.
generating and transmitting mud pulse signals from said upper downhole location to the surface.
64. The method according to claim 61, further comprising:
providing a bend in the drill string below the power assembly of the downhole drilling motor; and positioning the sensor in the drill string below the power assembly of the drilling motor.
providing a bend in the drill string below the power assembly of the downhole drilling motor; and positioning the sensor in the drill string below the power assembly of the drilling motor.
65. The method according to claim 64, further comprising:
providing a lower bearing assembly within the downhole drilling motor; and positioning the sensor below the lower bearing assembly.
providing a lower bearing assembly within the downhole drilling motor; and positioning the sensor below the lower bearing assembly.
66. Apparatus for signalling within a borehole while drilling using a drill string having a drill bit at a lower end thereof, the drill string including a bent housing for effecting directional drilling, the drill bit being selectively powered by a downhole drilling motor within the drill string, the downhole drilling motor including a power assembly for rotating the drill bit, and a downhole drilling motor housing stationary with respect to the bent housing in the drill string, the apparatus comprising:
a sensor within the drill string at a stationary position with respect to the downhole drilling motor housing below the power assembly of the drilling motor to detect a downhole parameter and generate an output indicative of the detected downhole parameter;
a first downhole transmitter positioned within the drill string below the power assembly of the drilling motor to receive the output from the sensor and a transmit a signal along the drill string representative of the sensor output;
a downhole receiver positioned within the drill string axially opposite the sensor with respect to the drilling motor for receiving the signal transmitted by the first transmitter;
a second downhole transmitter positioned within the drill string axially opposite the sensor with respect to the drilling motor for receiving the signal from the downhole receiver and for transmitting data indicative of the signal to the surface; and a downhole memory unit within the drill string for storing data indicative of the detected downhole parameter.
a sensor within the drill string at a stationary position with respect to the downhole drilling motor housing below the power assembly of the drilling motor to detect a downhole parameter and generate an output indicative of the detected downhole parameter;
a first downhole transmitter positioned within the drill string below the power assembly of the drilling motor to receive the output from the sensor and a transmit a signal along the drill string representative of the sensor output;
a downhole receiver positioned within the drill string axially opposite the sensor with respect to the drilling motor for receiving the signal transmitted by the first transmitter;
a second downhole transmitter positioned within the drill string axially opposite the sensor with respect to the drilling motor for receiving the signal from the downhole receiver and for transmitting data indicative of the signal to the surface; and a downhole memory unit within the drill string for storing data indicative of the detected downhole parameter.
67. Apparatus according to claim 66, further comprising:
another sensor within the drill string positioned below the power assembly of the drilling motor for detecting another downhole parameter and generating an output indicative of the detected another downhole parameter; and the second downhole transmitter transmits data to the surface indicative of the output from the another sensor.
another sensor within the drill string positioned below the power assembly of the drilling motor for detecting another downhole parameter and generating an output indicative of the detected another downhole parameter; and the second downhole transmitter transmits data to the surface indicative of the output from the another sensor.
68. Apparatus as defined to claim 67, further comprising:
one or more sealed cavities within an annular sensor housing below the power assembly of the downhole motor for receiving the sensor and the another sensor, said drill bit being rotatable with respect to said annular sensor housing.
one or more sealed cavities within an annular sensor housing below the power assembly of the downhole motor for receiving the sensor and the another sensor, said drill bit being rotatable with respect to said annular sensor housing.
69. Apparatus according to claim 66, further comprising:
a downhole power supply for powering said sensor.
a downhole power supply for powering said sensor.
70. Apparatus as defined in claim 69, wherein said power supply is driven in response to rotation of a drive shaft rotating the drill bit.
71. The apparatus according to claim 66, further comprising:
the bent housing in the drill string is below the power assembly of the downhole motor; and the sensor and the first downhole transmitter are each positioned within the drill string below the bent housing.
the bent housing in the drill string is below the power assembly of the downhole motor; and the sensor and the first downhole transmitter are each positioned within the drill string below the bent housing.
72. A data sensing and transmission assembly for positioning within a lower end of a drill string during drilling and axially below a power section of a downhole motor selectively rotating a drill bit, the downhole motor including an outer motor housing stationary with respect to the rotating it, the assembly comprising:
a sensor housing below said power assembly of said downhole motor and stationary with respect to the drilling motor housing, the sensor housing having one or more sealed cavities therein;
a plurality of sensors within the one or more sealed sensor cavities for detecting one or more downhole parameters and generating an output indicative of the detected downhole parameters; and a transmitter within one or more sealed cavities for receiving the output from the plurality of sensors indicative of the detected downhole parameters and for transmitting a signal along the drill string representative of the output to a position axially above the power section of the downhole motor.
a sensor housing below said power assembly of said downhole motor and stationary with respect to the drilling motor housing, the sensor housing having one or more sealed cavities therein;
a plurality of sensors within the one or more sealed sensor cavities for detecting one or more downhole parameters and generating an output indicative of the detected downhole parameters; and a transmitter within one or more sealed cavities for receiving the output from the plurality of sensors indicative of the detected downhole parameters and for transmitting a signal along the drill string representative of the output to a position axially above the power section of the downhole motor.
73. The assembly as defined in claim 72, wherein said transmitter transmits mud signals to the surface.
74. The assembly as defined in claim 72, further comprising:
a bend in the drill string below the power section of the downhole motor; and the sensor housing is positioned within the downhole motor below the bend.
a bend in the drill string below the power section of the downhole motor; and the sensor housing is positioned within the downhole motor below the bend.
75. Apparatus for signalling within a borehole along a drill string having a drib bit at a lower end thereof and bet housing in the drill string for effecting directional drilling, the drill bit being selectively powered by a downhole drilling motor within the drill string, the downhole motor including a power assembly for rotating the drill bit, and a downhole motor housing stationary with respect to the bent housing in the drill string, the apparatus comprising:
one or more sensor positioned within the drill string below the power assembly of the drilling motor at a stationary position with respect to the downhole motor housing to detect one or more downhole parameters and generate one or more outputs indicative of the one or more detected downhole parameters;
a downhole transmitter positioned within the downhole motor housing below the power assembly of the drilling motor for transmitting signals representative of the one or more sensor outputs;
a signal connection between the downhole transmitter and each of the one or more sensors to allow the downhole transmitter to receive the one or more sensor outputs; and a receiver positioned uphold with respect to the power assembly of the downhole drilling motor for receiving the signals from the downhole transmitter.
one or more sensor positioned within the drill string below the power assembly of the drilling motor at a stationary position with respect to the downhole motor housing to detect one or more downhole parameters and generate one or more outputs indicative of the one or more detected downhole parameters;
a downhole transmitter positioned within the downhole motor housing below the power assembly of the drilling motor for transmitting signals representative of the one or more sensor outputs;
a signal connection between the downhole transmitter and each of the one or more sensors to allow the downhole transmitter to receive the one or more sensor outputs; and a receiver positioned uphold with respect to the power assembly of the downhole drilling motor for receiving the signals from the downhole transmitter.
76. The apparatus of claim 75, wherein each of the one or more sensors is fixably mounted within the downhole motor housing.
77. The apparatus of claim 75, wherein the downhole transmitter is positioned within a bearing housing portion of the downhole motor housing.
78. Apparatus for signalling within a borehole along a drill string having a drill bit at a lower end thereof, the drib bit being selectively powered by a downhole drilling motor within the drill string, the downhole drilling motor including a power assembly for rotating the drill bit, a rotary shaft interconnecting the power assembly and the drill bit, and a drilling motor housing stationary with respect to the rotary shaft, the apparatus comprising:
a bent housing stationary with respect to the drilling motor housing and stationary with respect to the rotating drill bit;
a bearing housing fixably positioned with respect to the bent housing a stationary with respect to the rotating drill bit;
a mandrel powered by the power assembly and rotatable within the bearing housing;
a sensor housing disposed downhole below the power assembly of the drilling motor, the sensor housing being stationary with respect to drilling motor housing;
a sensor fixably secured within the sensor housing to detect a downhole parameter and generate an output indicative of the detected downhole parameter; and a downhole transmitter secured within the sensor housing for receiving the output of the sensor and transmitting a signal representative of the detected downhole parameter.
a bent housing stationary with respect to the drilling motor housing and stationary with respect to the rotating drill bit;
a bearing housing fixably positioned with respect to the bent housing a stationary with respect to the rotating drill bit;
a mandrel powered by the power assembly and rotatable within the bearing housing;
a sensor housing disposed downhole below the power assembly of the drilling motor, the sensor housing being stationary with respect to drilling motor housing;
a sensor fixably secured within the sensor housing to detect a downhole parameter and generate an output indicative of the detected downhole parameter; and a downhole transmitter secured within the sensor housing for receiving the output of the sensor and transmitting a signal representative of the detected downhole parameter.
79. The apparatus of claim 78, wherein the sensor housing and the bearing housing are an integral housing.
80, The apparatus of claim 78, wherein the sensor housing and the bent housing are an integral housing.
Priority Applications (9)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002024061A CA2024061C (en) | 1990-08-27 | 1990-08-27 | System for drilling deviated boreholes |
| GB9420816A GB2280463B (en) | 1990-08-27 | 1991-05-15 | Borehole drilling and telemetry |
| GB9110516A GB2247477B (en) | 1990-08-27 | 1991-05-15 | Borehole drilling and telemetry |
| FR9110550A FR2666113A1 (en) | 1990-08-27 | 1991-08-23 | METHOD AND APPARATUS FOR DRILLING BORING HOLES AND BIT ASSEMBLY FOR CARRYING OUT SAID METHOD. |
| NO913346A NO304196B1 (en) | 1990-08-27 | 1991-08-26 | Method and equipment for signaling within a well during drilling |
| NL9101441A NL194556C (en) | 1990-08-27 | 1991-08-26 | Device for the deviant drilling of a borehole in an earth formation. |
| US07/750,650 US5163521A (en) | 1990-08-27 | 1991-08-27 | System for drilling deviated boreholes |
| DE4128287A DE4128287A1 (en) | 1990-08-27 | 1991-08-27 | Sinking borehole with drill string contg. motor for rotary bit - includes equipment for data measurement and transmitting data to surface |
| US08/582,832 USRE35790E (en) | 1990-08-27 | 1996-01-02 | System for drilling deviated boreholes |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002024061A CA2024061C (en) | 1990-08-27 | 1990-08-27 | System for drilling deviated boreholes |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2024061A1 CA2024061A1 (en) | 1992-02-28 |
| CA2024061C true CA2024061C (en) | 2001-10-02 |
Family
ID=4145822
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002024061A Expired - Lifetime CA2024061C (en) | 1990-08-27 | 1990-08-27 | System for drilling deviated boreholes |
Country Status (3)
| Country | Link |
|---|---|
| US (2) | US5163521A (en) |
| CA (1) | CA2024061C (en) |
| GB (1) | GB2247477B (en) |
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| US11888375B2 (en) | 2019-11-27 | 2024-01-30 | Ms Directional, Llc | Electric motor for operating in conductive fluids and related method |
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Also Published As
| Publication number | Publication date |
|---|---|
| GB2247477A (en) | 1992-03-04 |
| US5163521A (en) | 1992-11-17 |
| GB9110516D0 (en) | 1991-07-03 |
| CA2024061A1 (en) | 1992-02-28 |
| GB2247477B (en) | 1995-03-01 |
| USRE35790E (en) | 1998-05-12 |
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