WO2018012985A1 - Drilling tool with downhole electric power generator assembly - Google Patents

Drilling tool with downhole electric power generator assembly Download PDF

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Publication number
WO2018012985A1
WO2018012985A1 PCT/NO2017/050187 NO2017050187W WO2018012985A1 WO 2018012985 A1 WO2018012985 A1 WO 2018012985A1 NO 2017050187 W NO2017050187 W NO 2017050187W WO 2018012985 A1 WO2018012985 A1 WO 2018012985A1
Authority
WO
WIPO (PCT)
Prior art keywords
assembly
drilling tool
segment
electric power
drive shaft
Prior art date
Application number
PCT/NO2017/050187
Other languages
French (fr)
Inventor
Viktor Tokle
Arnstein LÖVÖ
Original Assignee
Devico As
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Devico As filed Critical Devico As
Priority to AU2017295458A priority Critical patent/AU2017295458B2/en
Priority to CA3027346A priority patent/CA3027346A1/en
Publication of WO2018012985A1 publication Critical patent/WO2018012985A1/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/18—Structural association of electric generators with mechanical driving motors, e.g. with turbines
    • H02K7/1807—Rotary generators
    • H02K7/1823—Rotary generators structurally associated with turbines or similar engines
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B41/00—Equipment or details not covered by groups E21B15/00 - E21B40/00
    • E21B41/0085—Adaptations of electric power generating means for use in boreholes
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/02—Core bits
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/26—Drill bits with leading portion, i.e. drill bits with a pilot cutter; Drill bits for enlarging the borehole, e.g. reamers
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B25/00—Apparatus for obtaining or removing undisturbed cores, e.g. core barrels or core extractors
    • E21B25/02—Apparatus for obtaining or removing undisturbed cores, e.g. core barrels or core extractors the core receiver being insertable into, or removable from, the borehole without withdrawing the drilling pipe
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B33/00—Sealing or packing boreholes or wells
    • E21B33/10—Sealing or packing boreholes or wells in the borehole
    • E21B33/12—Packers; Plugs
    • E21B33/128—Packers; Plugs with a member expanded radially by axial pressure
    • E21B33/1285—Packers; Plugs with a member expanded radially by axial pressure by fluid pressure
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK 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
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK 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
    • E21B7/067—Deflecting the direction of boreholes with means for locking sections of a pipe or of a guide for a shaft in angular relation, e.g. adjustable bent sub
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B7/00—Special methods or apparatus for drilling
    • E21B7/24—Drilling using vibrating or oscillating means, e.g. out-of-balance masses
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/12—Casings or enclosures characterised by the shape, form or construction thereof specially adapted for operating in liquid or gas
    • H02K5/132—Submersible electric motors

Definitions

  • the present invention is related to a drilling tool with downhole electric power generator assembly, particularly for wireline drilling, as described in claim 1.
  • the present invention is especially related to a drilling tool including a rotation preventing assembly and a downhole electric power generator assembly capable of producing electric power sufficient to drive a downhole ultrasonic actuator assembly.
  • Downhole generators are well known in various drilling industries, often utilized to produce power for logging and geological instruments.
  • the generator generally consists of one stationary section (stator) and one moving or rotating section (rotor), where one section may carry a copper winding or coil and the other section permanent magnets. With relative motion between the sections the kinetic energy may be converted to electric energy through electromagnetic induction.
  • the most common downhole generator design is turbine assemblies where drilling fluid is used to build up pressure and spin the rotor. This is particularly common in directional drilling with downhole motors, where the drill string is already held stationary and the drill bit is rotated along with the turbine.
  • Another well known design uses eccentric masses to create relative rotation between the stator and rotor.
  • the drill string will generally rotate, and the eccentric mass be part of the stator.
  • the mass is attracted to the low side due to the gravity force it will resist the rotation force from the drill string, and that way cause relative motion between the stator and rotor.
  • the turbine generator designs have limited efficiency, as the turbine may only reach a relatively low speed compared to the speed a diamond core drilling rig can rotate the drill string.
  • the output from a turbine will also highly depend on the load and mud flow rate, and the rotation speed and power generation may vary significantly with only minor changes in any of these.
  • the eccentric mass design will only work efficiently in a relatively flat/horizontal borehole where the gravity attraction to the eccentric mass is strongest. With a higher capacity generator the power generated would also be sufficient to drive a ultrasonic actuator. Ultrasonic vibrations is known to significantly increase the production rate of the drilling process.
  • Diamond core drilling is a highly valuable exploration method, as core samples may be collected from several geological formations of interest several hundred meters below ground. It is however also a slow drilling method, where the borehole often must go through and retrieve core from long sections of geological formations of lower interest. It may in some cases be desired to start the boreholes with a faster non-coring type of drilling, for instance hammer drilling or sonic/ultrasonic drilling, and then switch over to diamond core drilling as the formation of interest is reached.
  • these drilling techniques will normally require a different set of drill rig, drill string and drilling crew be brought to the drill site, which rarely will be economically or practically feasible.
  • Utilizing directional drilling is another option to reduce drilling time, by sidetracking existing boreholes and steering the branch hole towards a nearby target. The time and effort required to drill down to the depth of the sidetrack is then avoided.
  • directional drilling with directional core barrels, wedges or downhole motors may also be time consuming, especially in fractured or low quality rock formations.
  • drilling tool is therefore needed that will increase the production rate of the drilling process without requiring a different drill rig, drill string or drilling crew.
  • the drilling tool should include directional drilling capability.
  • Such drilling tool may be a downhole drilling tool equipped with a high capacity electric power generator assembly for driving an ultrasonic actuator assembly.
  • the main object of the present invention is to provide a drilling tool with a downhole electric power generator assembly partly or entirely solving the above drawbacks of prior art.
  • An object of the present invention is to provide a drilling tool arranged for continuous drilling without requiring retrieving of a core sample. It is further an object to provide a drilling tool that may with small adjustments be utilized both as a directional drilling tool and as a non-directional drilling tool.
  • a further object of the present invention is to provide a drilling tool being provided with energy efficient push increasing means, and especially push increasing means which can be arranged in the drilling tool accompanied with power sources for the push increasing means in the drilling tool, accordingly providing the drilling tool with downhole push increasing means being self-supplied with power.
  • a drilling tool with a downhole electric power generator assembly according to the present invention is disclosed in claim 1. Preferable features of the drilling tool are disclosed in the remaining claims.
  • the drilling tool according to the present invention includes a bottom hole assembly with a foremost full-face drill bit, wherein the drilling tool is provided with at least one rotation preventing assembly including at least one pressure pad or packer element arranged for engaging a borehole wall by activation by pressure from supply of drilling fluid and displaceable axially along the borehole wall during drilling.
  • the drilling tool according to the present invention is further provided with a downhole electric power generator assembly located either in front of or behind the rotation preventing assembly.
  • the drilling tool according to the present invention is further provided with an inner drive shaft accommodated in the rotation preventing assembly and downhole electric power generator assembly transferring the feed and rotation forces from a drill string of a drill rig onto the full-face drill bit.
  • the downhole electric power generator assembly according to the present invention is formed by an outer tube arranged for housing at least one stator generator segment and at least one rotor generator segment. According to the present invention the at least one stator generator segment is arrange to the outer tube, interior thereof.
  • the at least one rotor generator segment is according to the present invention accommodated in a part or segment of the inner drive shaft.
  • the at least one stator generator segment is according to the present invention arranged to accommodate the drive shaft with the accommodated at least one rotor generator segment.
  • the drive shaft with the accommodated at least one rotor generator segment can be provided with an axial gear assembly allowing rotation of higher speed than the drill string rotation.
  • the drilling tool according to the present invention is further preferably provided with a thrust bearing assembly with contact surfaces preferably formed by hard metals, cemented carbide or Polycrystalline Diamond (PCD), allowing relative rotation between the drill bit and rotation preventing assembly.
  • the drilling tool according to the present invention is according to a further embodiment provided with an adjustable nozzle or valve providing a throttle control for drilling fluid supplied through the bottom hole assembly, thus forming a pressure inside the drilling tool sufficient to activate the rotation preventing assembly.
  • the drilling tool is provided with ultrasonic push increasing means in the form of an ultrasonic actuator assembly, wherein the ultrasonic actuator assembly is arranged at a front part of the drilling tool, i.e. close to the drill bit and in physical contact with the drill bit, and wherein the ultrasonic actuator assembly is driven by the downhole electric power generator assembly.
  • the ultrasonic push increasing means according to the present invention is arranged to work both at horizontal and vertical boreholes, which is not the case with prior art solutions. Accordingly, it will provide downhole push increasing means being self-powered.
  • the drilling tool according to the present invention is according to a further embodiment provided with an instrumentation assembly comprising a survey instrument accommodating metering elements to measure direction and inclination, angle of rotation, natural gamma or other geospatial or geophysical parameters.
  • an instrumentation assembly comprising a survey instrument accommodating metering elements to measure direction and inclination, angle of rotation, natural gamma or other geospatial or geophysical parameters.
  • the drilling tool according to the present invention is further provided with a underlying the drill bit deflection assembly, arranged in lower part of the drilling tool, the deflection assembly being adjustable in a single plane to bend lower part of an inner drive shaft, so that a front part of the drilling tool and drill bit, are provided with a rotational axis deviating from a non-rotatable section of the drilling tool.
  • the drilling tool according to the present invention is according to a further embodiment provided with an orientation assembly, preferably a magnetic orientation assembly, provided with a permanent magnet for orientation reference of the instrumentation assembly.
  • an orientation assembly preferably a magnetic orientation assembly, provided with a permanent magnet for orientation reference of the instrumentation assembly.
  • a muleshoe orientation assembly wherein the muleshoe is arranged for orientating deflection direction in an orientation and connector assembly for the drilling tool, the orientation and connector assembly forming upper part of the bottom hole assembly.
  • the muleshoe is further arranged for orienting the instrumentation assembly in the drilling tool by means of the orientation and connector assembly.
  • the orientation and connector assembly further provides a locking system to lock rotatable and non-rotatable sections of the drilling tool.
  • the locking system is activated by the instrumentation assembly as it is sent down the drill string and lands in the orientation and connector assembly.
  • a drilling tool with a downhole electric power generator assembly where the at least one rotor generator segment rotates with a speed relative to the at least one stator generator segment which is equally high or higher than the drill string rotation speed.
  • a drilling tool which can be used for continuous drilling without stopping to retrieve a core sample.
  • Figure 1 shows a principle drawing of a drilling tool with directional drilling capacity according to the present invention
  • Figure 2 shows a principle drawing of a drilling tool without directional drilling capacity
  • FIG. 3 shows a principle drawing of an instrumentation assembly according to the present invention
  • Figure 4 shows an axial cross section through the front end of the drilling tool
  • Figure 5 shows axial cross section revealing details of the downhole electric power generator assembly and ultrasonic push increasing means according to the present invention.
  • FIG. 1 illustrating a drilling tool 11 with directional drilling capacity according to a first embodiment of the present invention, comprised by numerous parts in the longitudinal direction forming a bottom hole assembly 11.
  • the bottom hole assembly 11 comprises, in order from below and up, a foremost diamond drill bit 20 with a reamer 30, an ultrasonic actuator assembly 500 , drive shaft connection assembly 40, a thrust bearing assembly 50, a lower outer tube 60, a deflection assembly 70, an upper outer tube 80, stabilizer assembly 90, a downhole electric power generator assembly 510, rotation preventing assembly 100, a magnetic orientation assembly 200 and an orientation and connector assembly 300.
  • the thrust bearing assembly 50, downhole electric power generator assembly 510, lower outer tube 60, deflection assembly 70, stabilizer assembly 90, rotation preventing assembly 100 and magnetic orientation assembly 200 being arranged for accommodating an inner drive shaft 150 transferring feed and rotation forces from a drill string of a drill rig onto the full-face drill bit 20.
  • Figure 2 illustrating a drilling tool without directional drilling capacity according to a second embodiment of the present invention, comprised by numerous parts in the longitudinal direction forming a bottom hole assembly 11.
  • the bottom hole assembly 11 comprises, in order from below and up, a foremost diamond drill bit 20 with a reamer 30, ultrasonic actuator assembly 500, drive shaft connection assembly 40, a thrust bearing assembly 50, a downhole electric power generator assembly 510, stabilizer assembly 90, rotation preventing assembly 100, and an orientation and connector assembly 300.
  • the thrust bearing assembly 50, downhole electric power generator assembly 510, stabilizer assembly 90 and rotation preventing assembly 100 being arranged for accommodating an inner drive shaft 150 transferring feed and rotation forces from a drill string of a drill rig onto the full-face drill bit 20.
  • the drilling tool further includes an instrumentation assembly 400, shown in Figure 3, formed by a survey instrument 401, in which survey instrument 401 is arranged metering elements to measure direction and inclination, angle of rotation, natural gamma or other geospatial or geophysical parameters, e.g. by means of magnetometer and accelerometer, wherein a muleshoe 402 is arranged on the survey instrument 401, above the metering elements. Above the muleshoe 402 is arranged a pump-in assembly 403 for drilling fluid.
  • the instrumentation assembly 400 reads the orientation of the drilling tool and allows for re-orientation.
  • the drill bit 20 including external water recesses 21 (shown in Figures 1-2), is tubular and exhibits an inner stem 22 with a thread for insert into the reamer 30, which in a similar manner is thread-connected to the ultrasonic actuator assembly 500 being thread-connected to lower end of the drive shaft connection assembly 40, which in turn is thread-connected to a lower part of an interior rotating drive shaft 150.
  • the ultrasonic actuator assembly 500 and drive shaft connection assembly 40 are integrated as one unit.
  • the drive shaft connection assembly 40 is further provided with an adjustable nozzle or valve 41 adjustable via exterior adjustment means 42, such as an adjusting screw extending to the surface of the drive shaft connection assembly 40, providing a throttle control for drilling fluid supplied through the bottom hole assembly 11, thus forming a pressure inside the bottom hole assembly 11 sufficient to activate the rotation preventing assembly 100 (Fig. 1-2).
  • the pressure upstream of drive shaft connection assembly 40 may be 20-30 bars.
  • the rotation preventing assembly 100 is in a preferable embodiment formed by a packer pipe 101 including a packer housing having at least one pressure pad or packer element 102, lower 103 and upper 104 end pieces, respectively, and front 105 and rear 106 stuffing boxes, respectively. Accordingly, the rotation preventing assembly 100 is provided with seals and connections at both sides thereof enabling arrangement into the bottom hole assembly 11.
  • the at least one pressure pad or packer element 102 of the rotation preventing assembly 100 is arranged for, at activation, to extend out of the packer pipe 101 and into engagement with a borehole wall for locking rotation of the rotation preventing assembly 100, as well as parts of the bottom hole assembly 11 between the orientation and connector assembly 200 and the drill bit 20, in relation to the borehole wall.
  • the at least one pressure pad or packer element 102 is/are arranged to be pressed outward to the borehole wall by means of pressure from drilling fluid being supplied to the bottom hole assembly 11 via the pump-in assembly of the instrumentation assembly 400 and is/are arranged to be displaced axially along the borehole wall during drilling.
  • the pressure acting upon the rotation preventing assembly 100/pressures pad/element 102 is adjustable by using the exterior adjustment means 42 to control the adjustable nozzle or valve 41.
  • the drilling tool in accordance with the present invention in a simple manner to different rock types requiring varying water quantities and varying pressure of the rotation preventing assembly 100.
  • the drilling tool according to the present invention further comprises a radial thrust bearing assembly 50, arranged between the drive shaft connection assembly 40 and lower outer tube 60 for the first embodiment and between the drive shaft connection assembly 40 and the downhole electric power generator assembly 510 in the second embodiment, as shown in Figure 1-2 and 4.
  • the thrust bearing assembly 50 is formed by a stator assembly 51 which have a contact surface 52 provided with sliders or slider bits, and a rotor assembly 53 which have a contact surface 54 provided with sliders or slider bits and is arranged to lower part of the inner drive shaft 150. All sliding or contact surfaces of the thrust bearing assembly 50 are preferably formed by hard metals, preferably chosen among tungsten (wolfram carbide) or titanium carbide or ceramic, cemented carbide or Polycrystalline Diamond (PCD). Especially, the sliders or bits are formed by these mentioned materials.
  • the thrust bearing stator 51 and rotor 53 assemblies can further be provided with holes (not shown) for allowing a flow of cooling fluid for cooling of the thrust bearing assembly 50.
  • the thrust bearing assembly 50 is preferably placed in front of the rotation preventing assembly 100, but may with small modifications be fitted behind (not shown) the rotation preventing assembly 100.
  • the magnetic orientation assembly 200 is in the shown embodiment formed by an outer tube 201 wherein a permanent magnet 202 is arranged for orientation reference of the instrumentation assembly 400.
  • the orientation and connector assembly 300 may further be provided with a lock pin (not shown) for locking rotatable and non-rotatable sections of the drilling tool, which lock pin can be activated by the instrumentation assembly 400.
  • the deflection position can be determined in order to control the orientation of the drilling tool and optionally adjust the deflection position.
  • the inner part of the drilling tool can rotate independently from the stationary outer part of the drilling tool.
  • the drilling tool according to the present invention is accordingly so arranged that by supplying drilling fluid under pressure to the rotation preventing assembly 100, the drill bit 20, reamer 30 and drive shaft connection assembly 40 can rotate independent of the stationary part of the drilling tool.
  • the ultrasonic actuator assembly 500 is formed by an outer tube 501 for housing at least one ultrasonic actuator 502 in the form of e.g. piezo transducer, which ultrasonic actuator assembly 500 is arranged at front part of the drilling tool, e.g. arranged between the reamer 30 and the shaft connection assembly 40.
  • the ultrasonic actuator assembly 500 is further arranged to guide drilling fluid via center of the ultrasonic actuator assembly 500 or arranged to guide drilling fluid in the wall of the outer tube 501. It should further be mentioned that it is important that the ultrasonic actuator 502 should be in physical contact with the drill bit 20 to have high efficiency.
  • the downhole electric power generator assembly 510 is formed by an outer tube 511 housing at least one stator generator segment 512 and at least one rotor generator segment 513.
  • the outer tube 511 is used for arrangement of the at least one stator generator segment 512, including at least one permanent magnet.
  • the inner drive shaft 150 or drive shaft segment is according to the present invention arranged for accommodating the at least rotor generator segment 513, including at least one coil.
  • the at least one stator generator segment 512 is further arranged for accommodating the part or section of inner drive shaft 150 with the accommodated rotor generator segment 513.
  • the stator generator segment 512 comprises at least one coil and the rotor generator segment 513 comprises at least one permanent magnet.
  • the at least one rotor generator segment 512 is arranged to rotate at a speed at least equal to the rotation speed of the drill string.
  • an axial gear assembly (not shown) may a rotation of higher speed than the drill string rotation be achieved.
  • the at least one rotor generator segment 513 rotates in relation to the at least one stator generator segment 512 producing high voltage power. It should be mentioned that sets of stator generator segments 512 and rotor generator segments 513 can be distributed in the longitudinal direction of the outer tube 511 providing sufficient electrical power produced.
  • the outer tube 511 is arranged either in front of the rotation preventing assembly 100, as shown in the example, or behind the rotation preventing assembly, but always in the stationary part of the drilling tool.
  • the ultrasonic actuator assembly 500 and downhole electric power generator assembly 510 are connected by means of wires or conductive layers in the inner drive shaft 150 via appropriate connection means in the ultrasonic actuator assembly 500 and downhole electric power generator assembly 510. Accordingly, the ultrasonic push increasing means in the form of the ultrasonic actuator assembly 500 and the downhole electric power generator assembly 510 according to the present invention provides downhole push increasing means which is self-supplied with power.
  • the drilling tool according to the present invention may further include instrument and surface communication assemblies, enabling continuous logging while drilling.
  • the logging parameters may include azimuth, inclination, angle of rotation, natural gamma or other geospatial or geophysical data.
  • the surface communication system may for instance be a mud pulse system or a drill string telemetry system. Both the instrument and communication assemblies may be powered by the downhole electric power generator assembly.

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  • Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Physics & Mathematics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Mechanical Engineering (AREA)
  • Power Engineering (AREA)
  • Earth Drilling (AREA)
  • Processing Of Stones Or Stones Resemblance Materials (AREA)

Abstract

Drilling tool with downhole electric power generator assembly (500), wherein the drilling tool comprising a bottom hole assembly (11) with a foremost full-face drill bit (20) driven by an internal drive shaft (150) transferring feed and rotation forces from a drill string of a drill rig onto the full-face drill bit (20), and further comprising a rotation preventing assembly (100) including at least one pressure pad or packer element (102) for engagement with a borehole wall by activation by pressure from supply of drilling fluid, and a downhole power generator assembly (510), wherein the downhole electric power generator assembly (510) is formed by an outer tube (511) housing at least one stator generator segment (512) and at least one rotor generator segment (513), wherein the at least one stator generator segment (512) is arranged to the outer tube (511) and wherein a part or segment of the inner drive shaft (150) is arranged for accommodating the at least one rotor generator segment (513), wherein the stator generator segment (512) is arranged for accommodating the inner drive shaft (150) with the at least one accommodated rotor generator segment (513).

Description

Drilling tool with downhole electric power generator assembly
The present invention is related to a drilling tool with downhole electric power generator assembly, particularly for wireline drilling, as described in claim 1.
The present invention is especially related to a drilling tool including a rotation preventing assembly and a downhole electric power generator assembly capable of producing electric power sufficient to drive a downhole ultrasonic actuator assembly.
Background
Downhole generators are well known in various drilling industries, often utilized to produce power for logging and geological instruments. The generator generally consists of one stationary section (stator) and one moving or rotating section (rotor), where one section may carry a copper winding or coil and the other section permanent magnets. With relative motion between the sections the kinetic energy may be converted to electric energy through electromagnetic induction.
The most common downhole generator design is turbine assemblies where drilling fluid is used to build up pressure and spin the rotor. This is particularly common in directional drilling with downhole motors, where the drill string is already held stationary and the drill bit is rotated along with the turbine.
Another well known design uses eccentric masses to create relative rotation between the stator and rotor. With this design the drill string will generally rotate, and the eccentric mass be part of the stator. As the mass is attracted to the low side due to the gravity force it will resist the rotation force from the drill string, and that way cause relative motion between the stator and rotor.
The turbine generator designs have limited efficiency, as the turbine may only reach a relatively low speed compared to the speed a diamond core drilling rig can rotate the drill string. The output from a turbine will also highly depend on the load and mud flow rate, and the rotation speed and power generation may vary significantly with only minor changes in any of these.
The eccentric mass design will only work efficiently in a relatively flat/horizontal borehole where the gravity attraction to the eccentric mass is strongest. With a higher capacity generator the power generated would also be sufficient to drive a ultrasonic actuator. Ultrasonic vibrations is known to significantly increase the production rate of the drilling process.
Diamond core drilling is a highly valuable exploration method, as core samples may be collected from several geological formations of interest several hundred meters below ground. It is however also a slow drilling method, where the borehole often must go through and retrieve core from long sections of geological formations of lower interest. It may in some cases be desired to start the boreholes with a faster non-coring type of drilling, for instance hammer drilling or sonic/ultrasonic drilling, and then switch over to diamond core drilling as the formation of interest is reached. However, these drilling techniques will normally require a different set of drill rig, drill string and drilling crew be brought to the drill site, which rarely will be economically or practically feasible.
Utilizing directional drilling is another option to reduce drilling time, by sidetracking existing boreholes and steering the branch hole towards a nearby target. The time and effort required to drill down to the depth of the sidetrack is then avoided. However, directional drilling with directional core barrels, wedges or downhole motors may also be time consuming, especially in fractured or low quality rock formations.
A drilling tool is therefore needed that will increase the production rate of the drilling process without requiring a different drill rig, drill string or drilling crew. Preferably, the drilling tool should include directional drilling capability. Such drilling tool may be a downhole drilling tool equipped with a high capacity electric power generator assembly for driving an ultrasonic actuator assembly.
Object
The main object of the present invention is to provide a drilling tool with a downhole electric power generator assembly partly or entirely solving the above drawbacks of prior art.
It is further an object to provide a drilling tool with a downhole electric power generator assembly where the rotor of the downhole electric power generator assembly rotates at the same or a higher speed than the drill string.
It is further an object of the present invention to provide a drilling tool being provided with a downhole electric power generator assembly working both in horizontal and vertical boreholes. It is further an object to provide a drilling tool with full-face drill bit operated with a fixed outer tube which is moved forward during drilling.
An object of the present invention is to provide a drilling tool arranged for continuous drilling without requiring retrieving of a core sample. It is further an object to provide a drilling tool that may with small adjustments be utilized both as a directional drilling tool and as a non-directional drilling tool.
A further object of the present invention is to provide a drilling tool being provided with energy efficient push increasing means, and especially push increasing means which can be arranged in the drilling tool accompanied with power sources for the push increasing means in the drilling tool, accordingly providing the drilling tool with downhole push increasing means being self-supplied with power.
Further objects of the present invention will appear from the following description, claims and attached drawings.
The invention
A drilling tool with a downhole electric power generator assembly according to the present invention is disclosed in claim 1. Preferable features of the drilling tool are disclosed in the remaining claims.
The drilling tool according to the present invention includes a bottom hole assembly with a foremost full-face drill bit, wherein the drilling tool is provided with at least one rotation preventing assembly including at least one pressure pad or packer element arranged for engaging a borehole wall by activation by pressure from supply of drilling fluid and displaceable axially along the borehole wall during drilling.
The drilling tool according to the present invention is further provided with a downhole electric power generator assembly located either in front of or behind the rotation preventing assembly.
The drilling tool according to the present invention is further provided with an inner drive shaft accommodated in the rotation preventing assembly and downhole electric power generator assembly transferring the feed and rotation forces from a drill string of a drill rig onto the full-face drill bit. The downhole electric power generator assembly according to the present invention is formed by an outer tube arranged for housing at least one stator generator segment and at least one rotor generator segment. According to the present invention the at least one stator generator segment is arrange to the outer tube, interior thereof. The at least one rotor generator segment is according to the present invention accommodated in a part or segment of the inner drive shaft. The at least one stator generator segment is according to the present invention arranged to accommodate the drive shaft with the accommodated at least one rotor generator segment.
According to a further embodiment the drive shaft with the accommodated at least one rotor generator segment can be provided with an axial gear assembly allowing rotation of higher speed than the drill string rotation.
The drilling tool according to the present invention is further preferably provided with a thrust bearing assembly with contact surfaces preferably formed by hard metals, cemented carbide or Polycrystalline Diamond (PCD), allowing relative rotation between the drill bit and rotation preventing assembly. The drilling tool according to the present invention is according to a further embodiment provided with an adjustable nozzle or valve providing a throttle control for drilling fluid supplied through the bottom hole assembly, thus forming a pressure inside the drilling tool sufficient to activate the rotation preventing assembly.
According to a further embodiment of the drilling tool according to the present invention the drilling tool is provided with ultrasonic push increasing means in the form of an ultrasonic actuator assembly, wherein the ultrasonic actuator assembly is arranged at a front part of the drilling tool, i.e. close to the drill bit and in physical contact with the drill bit, and wherein the ultrasonic actuator assembly is driven by the downhole electric power generator assembly.
The ultrasonic push increasing means according to the present invention is arranged to work both at horizontal and vertical boreholes, which is not the case with prior art solutions. Accordingly, it will provide downhole push increasing means being self-powered.
The drilling tool according to the present invention is according to a further embodiment provided with an instrumentation assembly comprising a survey instrument accommodating metering elements to measure direction and inclination, angle of rotation, natural gamma or other geospatial or geophysical parameters. For use as a directional drill the drilling tool according to the present invention is further provided with a underlying the drill bit deflection assembly, arranged in lower part of the drilling tool, the deflection assembly being adjustable in a single plane to bend lower part of an inner drive shaft, so that a front part of the drilling tool and drill bit, are provided with a rotational axis deviating from a non-rotatable section of the drilling tool.
The drilling tool according to the present invention is according to a further embodiment provided with an orientation assembly, preferably a magnetic orientation assembly, provided with a permanent magnet for orientation reference of the instrumentation assembly. Optionally a muleshoe orientation assembly, wherein the muleshoe is arranged for orientating deflection direction in an orientation and connector assembly for the drilling tool, the orientation and connector assembly forming upper part of the bottom hole assembly. The muleshoe is further arranged for orienting the instrumentation assembly in the drilling tool by means of the orientation and connector assembly.
The orientation and connector assembly further provides a locking system to lock rotatable and non-rotatable sections of the drilling tool. According to the present invention the locking system is activated by the instrumentation assembly as it is sent down the drill string and lands in the orientation and connector assembly.
According to the present invention there is provided a drilling tool with a downhole electric power generator assembly where the at least one rotor generator segment rotates with a speed relative to the at least one stator generator segment which is equally high or higher than the drill string rotation speed.
By the present invention it is provided a drilling tool producing electric power independent of the borehole angle.
By the present invention it is provided a drilling tool which is not exposed to blocking in jointed and fractured rock, accordingly providing a solution which is well adapted for drilling in jointed and fractured rock.
By the present invention it is provided a drilling tool which can be used for continuous drilling without stopping to retrieve a core sample.
Further preferable features and advantageous details of the present invention will appear from the following example description, claims and attached drawings. Example
The present invention will below be described in further detail with references to the drawings, where:
Figure 1 shows a principle drawing of a drilling tool with directional drilling capacity according to the present invention,
Figure 2 shows a principle drawing of a drilling tool without directional drilling capacity,
Figure 3 shows a principle drawing of an instrumentation assembly according to the present invention,
Figure 4 shows an axial cross section through the front end of the drilling tool, and Figure 5 shows axial cross section revealing details of the downhole electric power generator assembly and ultrasonic push increasing means according to the present invention.
Reference is now made to Figure 1 illustrating a drilling tool 11 with directional drilling capacity according to a first embodiment of the present invention, comprised by numerous parts in the longitudinal direction forming a bottom hole assembly 11. The bottom hole assembly 11 comprises, in order from below and up, a foremost diamond drill bit 20 with a reamer 30, an ultrasonic actuator assembly 500 , drive shaft connection assembly 40, a thrust bearing assembly 50, a lower outer tube 60, a deflection assembly 70, an upper outer tube 80, stabilizer assembly 90, a downhole electric power generator assembly 510, rotation preventing assembly 100, a magnetic orientation assembly 200 and an orientation and connector assembly 300. The thrust bearing assembly 50, downhole electric power generator assembly 510, lower outer tube 60, deflection assembly 70, stabilizer assembly 90, rotation preventing assembly 100 and magnetic orientation assembly 200 being arranged for accommodating an inner drive shaft 150 transferring feed and rotation forces from a drill string of a drill rig onto the full-face drill bit 20.. Reference is now made to Figure 2 illustrating a drilling tool without directional drilling capacity according to a second embodiment of the present invention, comprised by numerous parts in the longitudinal direction forming a bottom hole assembly 11. The bottom hole assembly 11 comprises, in order from below and up, a foremost diamond drill bit 20 with a reamer 30, ultrasonic actuator assembly 500, drive shaft connection assembly 40, a thrust bearing assembly 50, a downhole electric power generator assembly 510, stabilizer assembly 90, rotation preventing assembly 100, and an orientation and connector assembly 300. The thrust bearing assembly 50, downhole electric power generator assembly 510, stabilizer assembly 90 and rotation preventing assembly 100 being arranged for accommodating an inner drive shaft 150 transferring feed and rotation forces from a drill string of a drill rig onto the full-face drill bit 20.
According to a further embodiment of the drilling tool according to the present invention it further includes an instrumentation assembly 400, shown in Figure 3, formed by a survey instrument 401, in which survey instrument 401 is arranged metering elements to measure direction and inclination, angle of rotation, natural gamma or other geospatial or geophysical parameters, e.g. by means of magnetometer and accelerometer, wherein a muleshoe 402 is arranged on the survey instrument 401, above the metering elements. Above the muleshoe 402 is arranged a pump-in assembly 403 for drilling fluid. The instrumentation assembly 400 reads the orientation of the drilling tool and allows for re-orientation.
Reference is no made to Figure4, illustrating the lower part of the drilling tool according to the present invention, in an axial cross-section. The drill bit 20 including external water recesses 21 (shown in Figures 1-2), is tubular and exhibits an inner stem 22 with a thread for insert into the reamer 30, which in a similar manner is thread-connected to the ultrasonic actuator assembly 500 being thread-connected to lower end of the drive shaft connection assembly 40, which in turn is thread-connected to a lower part of an interior rotating drive shaft 150. In an alternative embodiment the ultrasonic actuator assembly 500 and drive shaft connection assembly 40 are integrated as one unit.
The drive shaft connection assembly 40 is further provided with an adjustable nozzle or valve 41 adjustable via exterior adjustment means 42, such as an adjusting screw extending to the surface of the drive shaft connection assembly 40, providing a throttle control for drilling fluid supplied through the bottom hole assembly 11, thus forming a pressure inside the bottom hole assembly 11 sufficient to activate the rotation preventing assembly 100 (Fig. 1-2). The pressure upstream of drive shaft connection assembly 40 may be 20-30 bars.
The rotation preventing assembly 100, shown in Figures 1-2, is in a preferable embodiment formed by a packer pipe 101 including a packer housing having at least one pressure pad or packer element 102, lower 103 and upper 104 end pieces, respectively, and front 105 and rear 106 stuffing boxes, respectively. Accordingly, the rotation preventing assembly 100 is provided with seals and connections at both sides thereof enabling arrangement into the bottom hole assembly 11. The at least one pressure pad or packer element 102 of the rotation preventing assembly 100 is arranged for, at activation, to extend out of the packer pipe 101 and into engagement with a borehole wall for locking rotation of the rotation preventing assembly 100, as well as parts of the bottom hole assembly 11 between the orientation and connector assembly 200 and the drill bit 20, in relation to the borehole wall. The at least one pressure pad or packer element 102 is/are arranged to be pressed outward to the borehole wall by means of pressure from drilling fluid being supplied to the bottom hole assembly 11 via the pump-in assembly of the instrumentation assembly 400 and is/are arranged to be displaced axially along the borehole wall during drilling.
Accordingly, the pressure acting upon the rotation preventing assembly 100/pressures pad/element 102, is adjustable by using the exterior adjustment means 42 to control the adjustable nozzle or valve 41. In this way, it is possible to adapt the drilling tool in accordance with the present invention in a simple manner to different rock types requiring varying water quantities and varying pressure of the rotation preventing assembly 100.
The drilling tool according to the present invention further comprises a radial thrust bearing assembly 50, arranged between the drive shaft connection assembly 40 and lower outer tube 60 for the first embodiment and between the drive shaft connection assembly 40 and the downhole electric power generator assembly 510 in the second embodiment, as shown in Figure 1-2 and 4. The thrust bearing assembly 50 is formed by a stator assembly 51 which have a contact surface 52 provided with sliders or slider bits, and a rotor assembly 53 which have a contact surface 54 provided with sliders or slider bits and is arranged to lower part of the inner drive shaft 150. All sliding or contact surfaces of the thrust bearing assembly 50 are preferably formed by hard metals, preferably chosen among tungsten (wolfram carbide) or titanium carbide or ceramic, cemented carbide or Polycrystalline Diamond (PCD). Especially, the sliders or bits are formed by these mentioned materials. The thrust bearing stator 51 and rotor 53 assemblies can further be provided with holes (not shown) for allowing a flow of cooling fluid for cooling of the thrust bearing assembly 50.
The thrust bearing assembly 50 is preferably placed in front of the rotation preventing assembly 100, but may with small modifications be fitted behind (not shown) the rotation preventing assembly 100. The magnetic orientation assembly 200 is in the shown embodiment formed by an outer tube 201 wherein a permanent magnet 202 is arranged for orientation reference of the instrumentation assembly 400. The orientation and connector assembly 300 may further be provided with a lock pin (not shown) for locking rotatable and non-rotatable sections of the drilling tool, which lock pin can be activated by the instrumentation assembly 400. When activated, the deflection position can be determined in order to control the orientation of the drilling tool and optionally adjust the deflection position. By removing the instrumentation assembly 400, the inner part of the drilling tool can rotate independently from the stationary outer part of the drilling tool.
The drilling tool according to the present invention is accordingly so arranged that by supplying drilling fluid under pressure to the rotation preventing assembly 100, the drill bit 20, reamer 30 and drive shaft connection assembly 40 can rotate independent of the stationary part of the drilling tool.
Reference is now made to Figures 1, 2, 4 and 5 showing details of the downhole electric power generator assembly 510 and ultrasonic push increasing means in the form of an ultrasonic actuator assembly 500. The shown example in Figure 4 and 5 is for the second embodiment in Figure 2, but the implementation is applicable for the first embodiment in Figure 1 as well. The ultrasonic actuator assembly 500 is formed by an outer tube 501 for housing at least one ultrasonic actuator 502 in the form of e.g. piezo transducer, which ultrasonic actuator assembly 500 is arranged at front part of the drilling tool, e.g. arranged between the reamer 30 and the shaft connection assembly 40. The ultrasonic actuator assembly 500 is further arranged to guide drilling fluid via center of the ultrasonic actuator assembly 500 or arranged to guide drilling fluid in the wall of the outer tube 501. It should further be mentioned that it is important that the ultrasonic actuator 502 should be in physical contact with the drill bit 20 to have high efficiency.
The downhole electric power generator assembly 510 according to the present invention is formed by an outer tube 511 housing at least one stator generator segment 512 and at least one rotor generator segment 513. In the shown example the outer tube 511 is used for arrangement of the at least one stator generator segment 512, including at least one permanent magnet. The inner drive shaft 150 or drive shaft segment is according to the present invention arranged for accommodating the at least rotor generator segment 513, including at least one coil. The at least one stator generator segment 512 is further arranged for accommodating the part or section of inner drive shaft 150 with the accommodated rotor generator segment 513. In an alternative embodiment, the stator generator segment 512 comprises at least one coil and the rotor generator segment 513 comprises at least one permanent magnet. According to the present invention the at least one rotor generator segment 512 is arranged to rotate at a speed at least equal to the rotation speed of the drill string. By providing the drive shaft with the accommodated at least one rotor generator segment with an axial gear assembly (not shown) may a rotation of higher speed than the drill string rotation be achieved. Accordingly, as the inner drive shaft 150 rotates, the at least one rotor generator segment 513 rotates in relation to the at least one stator generator segment 512 producing high voltage power. It should be mentioned that sets of stator generator segments 512 and rotor generator segments 513 can be distributed in the longitudinal direction of the outer tube 511 providing sufficient electrical power produced.
The outer tube 511 is arranged either in front of the rotation preventing assembly 100, as shown in the example, or behind the rotation preventing assembly, but always in the stationary part of the drilling tool.
The ultrasonic actuator assembly 500 and downhole electric power generator assembly 510 are connected by means of wires or conductive layers in the inner drive shaft 150 via appropriate connection means in the ultrasonic actuator assembly 500 and downhole electric power generator assembly 510. Accordingly, the ultrasonic push increasing means in the form of the ultrasonic actuator assembly 500 and the downhole electric power generator assembly 510 according to the present invention provides downhole push increasing means which is self-supplied with power.
Modifications The drilling tool according to the present invention may further include instrument and surface communication assemblies, enabling continuous logging while drilling. The logging parameters may include azimuth, inclination, angle of rotation, natural gamma or other geospatial or geophysical data. The surface communication system may for instance be a mud pulse system or a drill string telemetry system. Both the instrument and communication assemblies may be powered by the downhole electric power generator assembly.

Claims

Claims
1. Drilling tool with downhole electric power generator assembly (500), wherein the drilling tool comprising a bottom hole assembly (11) with a foremost full-face drill bit (20) driven by an internal drive shaft (150) transferring feed and rotation forces from a drill string of a drill rig onto the full- face drill bit (20), and further comprising a rotation preventing assembly (100) including at least one pressure pad or packer element (102) for engagement with a borehole wall by activation by pressure from supply of drilling fluid, and a downhole power generator assembly (510), wherein the downhole electric power generator assembly (510) is formed by an outer tube (511) housing at least one stator generator segment (512) and at least one rotor generator segment (513), wherein the at least one stator generator segment (512) is arranged to the outer tube (511) and wherein a part or segment of the inner drive shaft (150) is arranged for accommodating the at least one rotor generator segment (513), wherein the stator generator segment (512) is arranged for accommodating the inner drive shaft (150) with the at least one accommodated rotor generator segment (513).
2. Drilling tool according to claim 1, characterized in that the at least one rotor generator segment (513) is arranged to rotate with the inner drive shaft (150) at a rotational speed at least equal to rotation speed of the drill string.
3. Drilling tool according to claims 1-2, characterized in that:
- the at least one stator generator segment (512) comprises at least one coil and that the at least one rotor generator segment (513) comprises at least one permanent magnet, or
- the at least one stator generator segment (512) comprises at least one permanent magnet and that the at least one rotor generator segment (513) comprises at least one coil.
4. Drilling tool according to claim 1, characterized in that it further is provided with an ultrasonic actuator assembly (500) formed by an outer tube (501) for housing at least one ultrasonic actuator (502) powered by the electric power generator assembly (510).
5. Drilling tool according to claim 4, characterized in that in the ultrasonic actuator assembly (500) is arranged at front part of the drilling tool, behind the drill bit (20), and in physical contact with the drill bit (20).
6. Drilling tool according to claim 4, characterized in that the ultrasonic actuator assembly (500) is arranged to guide drilling fluid via center of the ultrasonic actuator assembly (500) or arranged to guide drilling fluid in the wall of the outer tube (501).
7. Drilling tool according to claim 4, characterized in that the ultrasonic actuator assembly (500) and electric power generator assembly (510) are connected by means of wires or conductive layers in the inner drive shaft (150) via appropriate connection means in the ultrasonic actuator assembly (500) and electric power generator assembly (510).
8. Drilling tool according to claim 1, characterized in that it further comprises a thrust bearing assembly (50) allowing relative rotation between the inner drive shaft (150) and stationary section of the drilling tool.
9. Drilling tool according to claim 1, characterized in that it further includes an instrumentation assembly (400) comprising a survey instrument (401) accommodating metering elements to measure direction and inclination, angle of rotation, natural gamma or other geospatial or geophysical parameters, as well as a muleshoe (402), wherein the muleshoe (402) is arranged for orientating deflection direction in an orientation and connector assembly (300) for the drilling tool, the orientation and connector assembly (300) forming upper part of the drilling tool.
10. Directional drill according to claim 8, characterized in that the orientation and connector assembly (300) is arranged for accommodating the instrumentation assembly (400) and providing a locking system to lock stationary section of the drilling tool to rotatable section of the drilling tool.
11. Drilling tool according to claims 9-10, characterized in that it further includes a magnetic orientation assembly (200) provided with a permanent magnet (202) for orientation reference of the instrumentation assembly (400).
PCT/NO2017/050187 2016-07-13 2017-07-07 Drilling tool with downhole electric power generator assembly WO2018012985A1 (en)

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AU2017295458A AU2017295458B2 (en) 2016-07-13 2017-07-07 Drilling tool with downhole electric power generator assembly
CA3027346A CA3027346A1 (en) 2016-07-13 2017-07-07 Drilling tool with downhole electric power generator assembly

Applications Claiming Priority (2)

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NO20161162 2016-07-13
NO20161162A NO341987B1 (en) 2016-07-13 2016-07-13 Directional drill

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NO341987B1 (en) 2018-03-12
CA3027346A1 (en) 2018-01-18
AU2017295458A1 (en) 2018-12-13
NO20161162A1 (en) 2018-01-15

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