Hydrostatically-Actuatable Systems and Related Methods

This application is a continuation of U.S. patent application Ser. No. 17/757,449, filed Jun. 15, 2022, which is a national phase application under 35 U.S.C. § 371 of International Patent Application PCT Application No. PCT/IB2020/062072, filed Dec. 16, 2020,which claims the benefit of priority of U.S. Provisional Patent Application No. 62/948,688, filed Dec. 16, 2019, which are hereby incorporated by reference in their entirety.

The present invention relates generally to drilling systems and, more particularly to downhole drilling tools.

1. Field of Invention

The present invention relates generally to drilling systems and, more particularly to downhole drilling tools.

2. Description of Related Art

Wells are generally drilled into the ground or ocean bed to recover natural deposits of oil and gas, as well as other desirable materials that are trapped in geological formations in the Earth's crust. A well may be drilled using a drill bit attached to the lower end of a drill string. Drilling mud may be pumped down through the drill string to the drill bit. The drilling mud lubricates and cools the drill bit, and it carries drill cuttings back to the surface in an annulus between the drill string and the borehole wall.

For successful oil and gas exploration, it is beneficial to control the direction of drilling and to collect information about the subsurface formations that are penetrated by a borehole. For example, to control the direction of drilling, rotary steerable systems (RSS) are frequently used in drilling applications to allow accurate wellbore placement along a predetermined path. Information collected about the subsurface formation can include measurements of the formation pressure and formation permeability. These measurements may be used for predicting the production capacity and production lifetime of a subsurface formation.

Techniques for measuring formation properties using tools and devices that are positioned near the drill bit in a drilling system have been developed. Thus, formation measurements are made during the drilling process, and the terminology generally used in the art is “MWD” (measurement-while-drilling) and “LWD” (logging-while-drilling). MWD refers to measuring the drill bit trajectory, as well as borehole temperature and pressure, while LWD refers to measuring formation parameters or properties, such as resistivity, porosity, permeability, and sonic velocity, among others. Real-time data, such as the formation pressure, allows the drilling entity to make decisions about drilling mud weight and composition, as well as decisions about drilling rate and weight-on-bit, during the drilling process.

Tools and devices related to RSS, MWD, and LWD can include mechanical and/or electronic components to conduct measurements, provide power, and control the wellbore creation process. The internal components are typically contained in cylindrical pipes that can be pressure sealed to protect them from high hydrostatic pressures present within the wellbore. Further, the internal components need to be constrained within the collars to minimize the risk of damage due to shock and vibration during the wellbore creating process.

Traditionally, the internal components are mounted to a collar by means of through-bolts in the drill pipe and/or collar. This technique, however, introduces a weak-spot in the drill pipe and/or collar by creating a stress concentration from which fatigue cracks can originate under bending or torsional loading.

Another traditional solution to this problem has been the use of a locking nut that applies axial pressure on the internal components to lock them inside the collar against a fixed shoulder. The downside of this configuration is that it can restrict the any difference in thermal expansion between the collar and the internal components, caused, for example, by differences in material properties. In addition, this configuration makes changes in length of the internal assembly, for example to add additional components, more challenging as the collar locking features are matched to specific length of the overall internal assembly.

Yet another traditional solution is to slide the internal components into the collar and support the components by a number of spacer mounts attached to the internal components, where the spacer mounts centralize the components inside the collar and minimize the lateral movement of assembly. An example of such a system is disclosed in WO 2013/082376, entitled “Pressure Actuated Centralizer.” In this configuration, the internal components include an axial thread that secures the components at one end to a corresponding thread in the collar. In order to allow assembly and disassembly of the components and to account for tolerance stack up, a small degree of radial clearance or radial compliance between the mounts and the collar is required. The downside of this solution is that the radial clearance or can cause shock amplification if lateral shock from the drilling process is transmitted from the collar to the internal assembly, whose mass is less than the collar. Shock amplification can lead to accelerated failure of the internal components.

Thus, there exists a need to address such shock amplification and to prolong the life of the internal components.

Some embodiments of the present systems comprise a central body; at least one hydrostatically-actuatable assembly configured to extend radially outward from the central body, the hydrostatically-actuatable assembly having at least one piston body exposed to hydrostatic pressure; a plurality of passive structures, each of which is: configured to extend radially outward from the central body; and circumferentially spaced from the at least one hydrostatically-actuatable assembly and another one of the plurality of passive structures.

In some embodiments of the present systems, the at least one hydrostatically-actuatable assembly comprises a housing having a recess configured to receive the at least one piston body and wherein the at least one piston body is configured to be disposed within the recess of the housing such that the at least one piston body and the housing cooperate to define a sealed chamber therebetween.

Some embodiments of the present systems comprise an outer body within which the central body, the at least one hydrostatically-actuatable assembly, and the plurality of passive structures are disposed, and wherein, when the at least one piston body is exposed to a threshold hydrostatic pressure, the at least one hydrostatically-actuatable assembly is configured to move to contact an inner surface of the outer body to secure the central body relative to the outer body.

In some embodiments of the present systems, the at least one piston body has a first piston surface in communication with fluid in the chamber and a second piston surface in communication with fluid outside the central body.

In some embodiments of the present systems, the second piston surface is in communication with fluid in an annulus defined between the outer body and the central body.

In some embodiments of the present systems, the second piston surface has a surface area greater than a surface area of the first piston surface.

In some embodiments of the present systems, each of the passive structures are equidistantly spaced along the circumference of the central body from one another and from the at least one hydrostatically-actuatable assembly.

In some embodiments of the present systems, the central body comprises a longitudinal axis and each passive structure and hydrostatically-actuatable assembly is disposed at substantially the same position along the longitudinal axis of the central body.

Some embodiments of the present systems comprise an equal number of the hydrostatically-actuatable assemblies and passive structures.

Some embodiments of the present systems comprise an interface pad configured to be coupled to the at least one piston body, wherein the interface pad is movable relative to the housing between a retracted position and an extended position in response to the at least one piston body moving within the recess.

In some embodiments of the present systems, the chamber comprises fluid at atmospheric pressure. In some embodiments of the present systems, the chamber comprises ambient air.

In some embodiments of the present systems, at least one of the passive structures comprises a body having elastomeric material.

Some embodiments of the present hydrostatically-actuatable anchor mounts comprise a housing configured to extend from a central body having a central passageway, the housing having a recess configured to receive a piston body; a piston body configured to be disposed within the recess of the housing such that the piston body and the housing cooperate to define a sealed chamber therebetween, the piston body having: a first piston surface in communication with fluid in the chamber; a second piston surface sealed off from the chamber and the central passageway of the central body.

In some embodiments of the present the hydrostatically-actuatable anchor mounts, the second piston surface has a surface area greater than a surface area of the first piston surface.

Some embodiments of the present systems comprise an interface pad configured to be coupled to the piston body, wherein the interface is movable relative to the housing between a retracted position and an extended position in response to the piston body moving within the recess.

In some embodiments of the present the hydrostatically-actuatable anchor mounts, the chamber comprises fluid at atmospheric pressure. In some embodiments of the present the hydrostatically-actuatable anchor mounts, the chamber comprises ambient air.

In some embodiments of the present the hydrostatically-actuatable anchor mounts, the housing comprises a second recess configured to receive a second piston body, and further comprising a second piston body configured to be disposed within the second recess of the housing such that the second piston body and the housing cooperate to define a second sealed chamber therebetween, the second piston body having: a first piston surface in communication with fluid in the second chamber; a second piston surface sealed off from the second chamber and the central passageway of the central body.

Some embodiments of the present methods comprise coupling at least one hydrostatically-actuatable assembly to a central body, the hydrostatically-actuatable assembly having a piston body configured to be exposed to hydrostatic pressure; coupling a plurality of passive structures to the central body, wherein each of the plurality of passive structures are circumferentially spaced from one another and from the at least one hydrostatically-actuatable assembly; positioning the at least one hydrostatically-actuatable assembly, the plurality of passive structures, and the central body within an outer body; exposing the piston body to hydrostatic pressure such that the piston body causes the at least one hydrostatically-actuatable assembly to contact an inner surface of the outer body to secure the central body relative to the outer body.

Some embodiments of the present methods comprise mounting the hydrostatically-actuatable anchor mount to a central body. Some embodiments of the present methods comprise positioning the system into a borehole of a formation.

The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The term “substantially” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed embodiment, the terms “substantially,” “approximately,” and “about” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent.

The phrase “and/or” means and or or. To illustrate, A, B, and/or C includes: A alone, B alone, C alone, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C. In other words, “and/or” operates as an inclusive or.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, an apparatus that “comprises,” “has,” “includes,” or “contains” one or more elements possesses those one or more elements, but is not limited to possessing only those elements. Likewise, a method that “comprises,” “has,” “includes,” or “contains” one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps.

Any embodiment of any of the apparatuses, systems, and methods can consist of or consist essentially of—rather than comprise/include/contain/have—any of the described steps, elements, and/or features. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb.

The feature or features of one embodiment may be applied to other embodiments, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments.

Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described.

Some details associated with the embodiments described above and others are described below.

The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale (unless otherwise noted), meaning the sizes of the depicted elements are accurate relative to each other for at least the embodiment depicted in the figures.

Referring now to the figures, and more particularly, to, shown therein and designated by reference numeralis an embodiment of the present systems, such as, for example, a bottom hole assembly. As shown, systemcomprises an outer bodyand a central bodydisposed within the outer body.

In this embodiment, outer bodycomprises a collar that can be coupled at opposing ends to one or more segments of pipe, such as for example a drill pipe and/or a sub, and tripped downhole during drilling operations. As shown in, outer bodycomprises a conduitdefined by a sidewallof the outer body. Central bodyis disposed within conduitand is secured to outer bodyat a first endof the central body. In this embodiment, central bodyincludes a flow diverterat first end, which is coupled to a central body housingand outer body. Central bodycan be coupled to outer body(e.g., at first end) in any suitable fashion, such as by a threaded coupling or by one or more fasteners. As shown, central bodyincludes a second, free endthat is not secured to outer body.

Central body housingcan be configured to accommodate therein (e.g., in a chamber) one or more measurement devices, such as, for example, measurement-while-drilling (“MWD”) devices, logging-while-drilling (“LWD”) devices, and/or the like, to record and/or transmit formation measurements during the drilling process.

In some embodiments, a system (e.g.,) can comprise a rotatable steering system (RSS) coupled to pipe (e.g.,) to control the direction of drilling and allow accurate wellbore placement along a predetermined path. In some such embodiments, a central body (e.g.,) within the RSS can comprise a chamber (e.g.,) that includes therein one or more electrical and/or mechanical components to be protected from lateral shock and vibration as disclosed herein.

Systemincludes one or more hydrostatically-actuatable assembliesand a plurality of passive structuresconfigured to be disposed within conduitof outer body, and more particularly, within an annulusbetween central bodyand the outer body. As described herein, one or more hydrostatically-actuatable assembliesand passive structurescooperate to secure central bodyto outer bodyin order to protect the measurement devices within central body housingfrom lateral shock and vibration imparted on the central body during the wellbore creating process (e.g., impacts between outer bodyand/or pipeand the wellbore, impacts between a drill bit and the wellbore, and/or the like). Such lateral shock and vibration may otherwise compromise the effectiveness and/or integrity of the measurement devices within central body housing.

In order to reduce such lateral shock and vibration, each hydrostatically-actuatable assemblyand passive structureis configured to contact an inner surfaceof sidewallof outer bodyin order to restrict lateral movement of second endof central bodyrelative to the outer body as described herein. Each assemblyand passive structurecan be coupled to central bodyat any suitable position along a length of the central body in order to achieve the desired reduction of lateral shock and vibration, such as, for example, at or proximate to second endof the central body.

Each hydrostatically-actuatable assemblyis configured to extend radially outward from central body. As shown in, one or more hydrostatically-actuatable assembliescan comprise an assembly housingconfigured to be coupled to central body housing(e.g., by one or more fasteners). When coupled to central body housing, assembly housingis configured to extend radially outward from central body.

Each assemblyincludes one or more piston bodies, each of which are configured to be received in respective a recessof assembly housing. To illustrate, piston bodyis configured to be disposed within recessof assembly housingsuch that the piston body and the assembly housing cooperate to define a chamberof compressible fluid therebetween. Assembly chamberis configured to be sealed off from fluid within annulusby a plurality of seals(e.g., one or more elastomeric o-rings). For example, piston bodyincludes a first piston surfacein communication with compressible fluid in chamberand a second piston surfacesealed off from the chamber. Assembly chambercan comprise any suitable compressible fluid at atmospheric pressure. For example, assemblycan be assembled at surface such that piston bodyand assembly housingare coupled to capture ambient air within assembly chamber. As shown, for example, in, a surface area of first piston surface(i.e., the surface area of piston bodythat, when exposed to fluid, causes the piston body to exert a force in a first direction) is greater than a surface area of second piston surface(i.e., the surface area of the piston body that, when exposed to fluid, causes the piston body to exert a force in a second directionthat is opposite the first direction).

Although each assemblyis coupled to central body, each assembly (e.g., in its entirety) can be sealed off from fluid central body chamber. Thus, each assemblyis exposed only to fluid within annulus.

Each hydrostatically-actuatable assemblyis configured to respond to fluid forces within annulusto secure central body(e.g., at or near second end) to outer body. For example, as drilling mud is circulated during the drilling process, the drilling mud may enter pipeat a first endthereof and travel toward central bodyand outer body(i.e., towards the surface of the formation). The drilling mud may enter a first endof outer bodyand flow into one or more passagesof central bodyto direct the mud around the central body. The drilling mud can subsequently flow out of a second endof outer bodytowards the surface. By virtue of assemblybeing within annulusduring the drilling process, a column of drilling fluid within the annulus exerts hydrostatic forces on the assembly. In this instance, hydrostatic pressure is pressure that is exerted by fluid in a wellbore due to the force of gravity. Hydrostatic pressure increases in proportion to wellbore depth measured from surface because of the increasing weight of fluid exerting a downward force from above.