DK2230375T3 - Resonance Enhanced drilling: a method and apparatus - Google Patents

Description

DESCRIPTION

[0001] The present invention concerns a drilling device, and in particular a drilling device for drilling into material such as a rock formation.

[0002] The field of drilling into rock and other materials has driven a number developments in drilling technology. In this regard, the extremely harsh conditions involved in this type of drilling as well as its cost and the related environmental issues, all put severe demands on the effectiveness, reliability and safety of drilling methods.

[0003] As a consequence, industries which employ downhole drilling, such as the oil industry, are keen to develop drilling devices and methodologies that meet these demands and increase drilling rates and decrease tool wear.

[0004] In this connection, the oil industry is increasingly having to drill deviated or horizontal long-reach wells in pursuit of new oil reserves. However, such drilling further compounds several issues that challenge present drilling technology such as demands of low weight-on-bit, reduced power availability, variability of rock conditions over the length of the well, danger of bore collapses/fractures, increased costs of tripping, and increased tool wear and failure.

[0005] It is known that drilling rates in certain circumstances can be improved by applying reciprocal axial movements to a drill-bit as it passes through the material to be drilled, so-called percussive drilling. This is because the impact of these axial movements promotes fractures in the drilled material, thereby making subsequent drilling and material removal easier.

[0006] In conventional percussive drilling, the penetration mechanism is based on fracturing material at the borehole by large low-frequency uncontrolled impacts applied by the drill-bit. In this way, drilling rates for medium to hard rocks can be increased compared to standard rotary drilling. However, the downside to this is that these impacts compromise borehole stability, reduce borehole quality and cause accelerated, and often catastrophic, tool wear and/or failure.

[0007] Another important development to drilling techniques has been the application of ultrasonic axial vibrations to a rotating drill-bit. In this way, ultrasonic vibration, rather than isolated high load impacts, is used to promote fracture propagation. This can offer significant advantages over conventional percussive drilling in that lower loads can be applied, allowing for low weight-on-bit drilling. However, the improvements exhibited by ultrasonic drilling are not always consistent and are not as such directly applicable to downhole drilling.

[0008] It is therefore an object of the present invention to provide a drilling apparatus and method which seek to alleviate such problems.

[0009] From GB328629, it is known to provide a percussive drill for deep-boring applications, the drill including an adjustable recoil means controlled by varying fluid pressure applied thereto.

[0010] US3990522 discloses a drill housing for a rotary percussive drill, which is pivotally attached to the end of a boom member that swings upwardly from a frame of a mobile member. Percussive control is maintained through a servovalve supported on the housing but controlled remotely.

[0011] From GB2345931 there is known an oscillating drill bit for drilling subterranean formations, the oscillation being in both an axial and torsional direction, to thereby produce chips of varying thicknesses which facilitate fracture of the chips along their thinner portions.

[0012] WO 97/31175 shows moling apparatus having a sensing means located on a projectile being driven through the ground, the sensing means sensing the dynamic resistance of the ground through which the projectile is passing, to thereby identify a ground characteristic.

[0013] GB2343465 discloses a method of drilling wherein a portion of the drill string is provided with oscillation force to reduce friction between the drill string and the bore wall and to facilitate advancement of the string through the bore.

[0014] According to a first aspect of the present invention there is provided drilling module according to claim 1.

[0015] In this way, the drilling apparatus can function autonomously and adjust the rotational and/or oscillatory loading of the drill-bit in response to the current drilling conditions so as to optimize the drilling mechanism and obtain improved drilling rates.

[0016] Preferably, the controller is configured to sweep a frequency range to evaluate conditions of the material through which the rotary drill-bit is passing to establish and maintain oscillation system resonance.

[0017] Conveniently, the oscillator is configured to apply high frequency axial oscillatory loading based on a basic resonance curve for the rotary drill-bit and modify the high frequency axial oscillatory loading to take into account interactions with the material being drilled.

[0018] Preferably, the controller is configured to determining appropriate loading parameters for the rotary drill-bit according to the following steps in order to achieve and maintain oscillation system resonance: 1. A) determine a limit of amplitude of the rotary drill-bit when resonating and interacting with the material being drilled; 2. B) estimate a suitable frequency sweeping range for loading the drill-bit; 3. C) estimate the shape of a resonance curve; 4. D) choose an optimum resonant frequency on the resonance curve at a point less than the maximum on the resonance curve; and 5. E) drive the rotary drill-bit based on this optimum resonant frequency.

[0019] Conveniently, the controller is configured to autonomously adjust rotational and high frequency axial oscillatory loading of the rotary drill-bit in response to current drilling conditions.

[0020] Preferably, the controller is configured to control the rotary drill-bit to impact on the material through which the rotary drill bit is passing to produce a first set of macro-cracks, the controller being further configured to control the rotary drill-bit to rotate and impact on the material a further occasion to produce a further set of macro-cracks, the controller being configured to synchronize rotational and oscillatory movements of the rotary drill-bit for promoting interconnection of the macro-cracks thus produced, to create a localized dynamic crack propagation zone ahead of the rotary drill-bit.

[0021] According to a further aspect of the present invention there is provided a method for controlling a resonance enhanced rotary drill comprising a rotary drill-bit and an oscillator for applying high frequency axial oscillatory loading to the rotary drill-bit of up to 1 kHz, the method comprising: applying high frequency axial oscillatory loading to the rotary drill-bit; taking downhole measurements; controlling the applied high frequency axial oscillatory loading downhole under closed loop real-time control by utilizing the downhole measurements to vary the high frequency axial oscillatory loading responsive to conditions of material through which the rotary drill-bit is passing to establish and maintain oscillation system resonance between the oscillator, the rotary drill-bit and the material through which the rotary drill-bit is passing whereby the high frequency axial oscillatory loading is sufficient to initiate cracks in the material through which the rotary drill-bit is passing.

[0022] Preferably, the method further comprises: sweeping a frequency range to evaluate conditions of the material through which the rotary drill-bit is passing to establish and maintain oscillation system resonance.

[0023] Conveniently, the high frequency axial oscillatory loading is applied based on a basic resonance curve for the rotary drill-bit and the high frequency axial oscillatory loading is modified to take into account interactions with the material being drilled.

[0024] Preferably, the method further comprises determining appropriate loading parameters for the rotary drill-bit according to the following steps in order to achieve and maintain oscillation system resonance: A) determine a limit of amplitude of the rotary drill-bit when resonating and interacting with the material being drilled; B) estimate a suitable frequency sweeping range for loading the drill-bit; C) estimate the shape of a resonance curve; D) choose an optimum resonant frequency on the resonance curve at a point less than the maximum on the resonance curve; and E) drive the rotary drill-bit based on this optimum resonant frequency.

[0025] Conveniently, the rotational and high frequency axial oscillatory loading of the rotary drill-bit are adjust autonomously in response to current drilling conditions.

[0026] Preferably, the rotary drill-bit is controlled to impact on the material through which the rotary drill bit is passing to produce a first set of macro-cracks, and to rotate and impact on the material a further occasion to produce a further set of macro-cracks, the rotational and oscillatory movements of the rotary drill-bit being synchronized to promote interconnection of the macro-cracks thus produced, to create a localized dynamic crack propagation zone ahead of the rotary drill-bit.

[0027] The control apparatus is preferably configured to perform the method as defined above when mounted in a drilling module as defined above.

[0028] Preferably, the method is used in the context of drilling rock formations, and the macro-cracks formed have a length of up to ten mm, preferably around 5 mm. Such a maximum length allows the extent of the crack propagation zone to be highly controlled.

[0029] An example of the present invention will now be described with reference to the accompanying drawings in which:-Figure 1 shows a drilling module according to an embodiment of the present invention; and

Figure 2 illustrates graphically how parameters for establishing resonant conditions in accordance with the present invention are found.

[0030] In the development of the present invention, it was realized that particularly high drilling rates could be achieved when drilling through materials such as rock formations if the loading of the drill-bit is set to promote resonance is the system formed by the drill-bit and the drilled formation.

[0031] However, whilst obtaining this resonance is possible on a test rig using standardized samples, it was a different matter when drilling through natural rock formations. This is because drilling conditions vary from layer to layer within a formation. Accordingly, the resonant conditions vary throughout the formation and therefore resonant conditions cannot be maintained throughout the drilling process.

[0032] The present invention overcomes this problem by recognizing the non-linear resonance phenomenon when drilling through a material and seeks to maintain resonance in the system combination of the drill-bit and drilled material.

[0033] In order to achieve this the applicants have, by accurately identifying the parameters and mechanisms affecting drilling, developed an accurate and robust mathematical model of the dynamic interactions in the borehole. This mathematical model allows the present invention to calculate and use feedback mechanisms to automatically adjust the drilling parameters so as to maintain resonance at the borehole site. By maintaining the resonance in this way, the action of the propagating crack zone ahead of the drill-bit is enhanced and the drilling rate is greatly improved, and therefore can be described as Resonance Enhanced Drilling (hereinafter RED).

[0034] Figure 1 shows an illustrative example of a RED drilling module according to an embodiment of the present invention. The drilling module is equipped with a polycrystalline diamond (PCD) drill-bit 1. A vibro-transmission section 2 connects the drill-bit 1 with a piezoelectric transducer 3 to transmit vibrations from the transducer to the drill-bit 1. Acoupling 4 connects the module to a drill-string 5 and acts as a vibration isolation unit to isolate vibrations of the drilling module from the shaft.

[0035] During a drilling operation, a DC motor rotates the drill shaft, which transmits the motion through sections 4, 3 and to the drill-bit 1. A relatively low static force applied to the drill-bit 1 together with the dynamic loading generate the propagating fracture zone, so that the drill-bit progresses through the material.

[0036] At the same time as the rotation of the drilling module 1, the piezoelectric transducer 3 is activated to vibrate at a frequency appropriate for the material at the borehole site. This frequency is determined by calculating the non-linear resonant conditions between the drill-bit and the drilled material, schematically shown in Figure 2, according to the following algorithm: A) calculating the nonlinear resonant response of the drill-bit without the influence of the drilled material; B) estimating the strength of impacts to produce a propagating fracture zone in the drilled material; (^calculating the nonlinear stiffness characteristics of the fractured drilled material; D) estimating a resonant frequency of the drill-bit interacting with the drilled material; and E) recalculating the value of the resonant frequency for a steady state by incorporating the nonlinear stiffness characteristics of the fractured drilled material.

[0037] The vibrations from the piezoelectric transducer 3 are transmitted through the drill-bit 1 to the borehole site and create a propagating crack zone in the material ahead of the drill-bit. As the drill-bit continues to rotate and move forward, it shears against the material in the formation, cutting into it. However, the creation of a propagating crack zone in the formation material ahead of the drill-bit significantly weakens it, meaning that the rotating shearing action dislodges more material, which can subsequently be removed.

[0038] The properties of the crack propagation dynamics can be tuned to optimize for ROP, hole quality and tool life, or ideally a combination of all three.

[0039] Cracks are started as a result of inserts in the drill-bit impacting on the formation. Other drilling techniques operate through shaving or shearing the rock or through the generation of much larger cracks. The following are the main features of the RED system in terms of means of operation and focus on the creation and propagation of 'macro' cracks in the immediate vicinity ahead of the drill-bit.

[0040] RED operates through a high frequency axial oscillation of a drilling head which impacts the material and the angular geometry of the drill-bit inserts initiate cracks in the material. Continued operation of the drilling bit, i.e continued oscillation and rotation, establishes a dynamic crack propagation zone ahead of the drill-bit.

[0041] This phenomenon may be best described as synchronized kinematics. Establishment of resonance in the system (system comprising the drilled material, (the oscillator) and the drill-bit) optimizes the efficiency and performance. The dynamic crack propagation zone is local to the drill-bit and a linear dimension typically measures no more than 1/10th of the diameter of the drill-bit.

[0042] Hence local crack propagation is controllable in terms of its directionality and the RED technique avoids crack propagation outside the zone immediately in front of the drill-bit.

[0043] RED hence can result in high quality true gauge hole.

[0044] As a result of the 'sensitivity' of the RED technique, its ability to drill holes using highly controlled local fracture and minimizing global stress in the formation, the RED technique will lend itself very well to drilling sensitive formations in challenging areas such as shallow gas; weak zones; and fractured high pressure zones.

[0045] According to the above, the present invention can maintain resonance throughout the drilling operation, allowing material to be dislodged from the formation at the borehole site more quickly, and consequently higher drilling rates are achieved. Furthermore, the utilization of resonance motion to promote fracture propagation allows lower weight to be applied to the drill-bit leading to decreased tool wear. As such, the present invention not only offers an increased rate of penetration (ROP) but also allows for increased tool life-span, and hence reduces the downtime required for tool maintenance or replacement.

[0046] Once drilled material mechanical properties are known, the drilling parameters can be modified to optimize performance of the drilling (according to ROP, hole Quality and tool life and reliability).

[0047] In terms of the RED technique, frequency and amplitude of oscillations can be modified to establish the most efficient and effective performance. The establishment of oscillation system resonance (between the (oscillator), the drill-bit and the drilled formation) provides the optimum combination of energy efficiency and drilling performance.

[0048] Figure 2 graphically illustrates how the parameters for establishing and maintaining resonant conditions are found.

[0049] Firstly, one needs to determine a limit of amplitude of the drill-bit when resonating and interacting with the material being drilled. In this connection, the limit of amplitude of the drill-bit is chosen at a value where resonance in the drill-bit will not become destructive. Beyond this limit there is a possibility that resonance will start to have a damaging effect.

[0050] Then, a suitable frequency sweeping range for loading the drill-bit is estimated. This is estimated so that a suitably narrow range can be evaluated which can then used to speed up the remainder of the method.

[0051] The shape of the resonance curve is then estimated. As can be seen, this is a typical resonance curve whose top has been pushed over to the right as a consequence of the effect of the drill-bit interacting with a material being drilled. It will be noted that as a consequence the graph has upper and lower branches, the consequence of moving on the curve beyond the maximum amplitude being a dramatic drop in amplitude from the upper branch to the lower branch.

[0052] As such, in order to avoid such dramatic changes, which are undesirable, the next step is to choose an optimum frequency on the resonance curve at a point less than the maximum on the resonance curve. The extent to which the optimum resonant frequency is chosen below the maximum essentially sets a safety factor and for changeable/variable drilling materials, this may be chosen further from the maximum amplitude point. The control means may in this regard alter the safety factor, i.e. move away from or towards the maximum point on the resonance curve, depending on the sensed characteristics of the material being drilled or progress of the drill. For example, if the ROP is changing irregularly due to low uniformity of material being drilled, then the safety factor may be increased.

[0053] Finally, the apparatus is driven at the chosen optimum resonant frequency, and the process is updated periodically within the closed loop operating system of the control means.

[0054] With the present invention, the weight of drill-string per meter can be up to 70% smaller than that of a conventional drill string operating with the same borehole diameter for use in the same drilling conditions. Preferably it is in the range 40-70% smaller, or more preferably it is substantially 70% smaller.

[0055] For example, under typical drilling conditions and a drilling depth of 12,500 ft (3787 m), for a 12 1/4" (0.31m) hole size, the drill-string weight per meter is reduced from 38.4 kg/m (Standard Rotary Drilling) to 11.7 kg/m (using RED technique) - a reduction of 69.6%.

[0056] Under typical drilling conditions and a drilling depth of 12,500 ft (3787 m), for a 17 1/2" (0.44m) hole size, the drill-string weight per meter is reduced from 49.0 kg/m (Standard Rotary Drilling) to 14.7 kg/m (using RED technique) - a reduction of 70%.

[0057] Under typical drilling conditions and a drilling depth of 12, 500 ft (3787 m), for a 26" (0.66m) hole size the drill-string weight per meter is reduced from 77.0 kg/m (Standard Rotary Drilling) to 23.1 kg/m (using RED technique) - a reduction of 70%.

[0058] As a result of the low WOB and the dynamic fracture it produces, the RED technique can save up to 35% of energy cost on the rig and 75% of drill collar weight savings.

[0059] It will be understood that the illustrated embodiment described herein shows an application of the invention only for the purposes of illustration. In practice the invention may be applied to many different configurations; the detailed embodiments being straightforward to those skilled in the art to implement.

[0060] For example, the drill-bit section of the module may be modified as appropriate to the particular drilling application. For instance, different drill-bit geometries and materials may be used.

[0061] In another example, other vibration means may be used as alternative to the piezoelectric transducer for vibrating the drilling module. For example, a magnetostrictive material may be used.

[0062] Furthermore, it is also envisaged that the vibration means may be deactivated when drilling through soft formations to avoid adverse effects. For example, the drilling module of the present invention may be deactivated so as to function as a rotary (only) drilling module when first drilling through an upper soft soil formation. The drilling module can then be activated to apply resonant frequencies once deeper hard rock formations are reached. This offers considerable time savings by eliminating the downtime which would otherwise be necessary to swap drilling modules between these different formations.

[0063] The present invention provides the following benefits, namely drilling having lower energy inputs, improved rate of penetration (ROP), improved hole stability and quality and improved tool life and reliability.

REFERENCES CITED IN THE DESCRIPTION

This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description • GB328629A [00091 . US3990522A [00101 • GB2345931A [0011] • GB2343465A Γ00131

Claims (13)

A drilling module comprising: a rotary drill bit (1); an oscillator configured to impose a high frequency axial oscillating load of up to 1 kHz to the rotary drill bit; a vibro transmission part (2) connecting the rotary drill head to the oscillator, wherein the vibro transmission part is configured to transmit the high frequency axial oscillating charge from the oscillator to the rotary drill head; a vibrational isolation unit (4) for connecting the drill module to a drill string (5), wherein the vibrational isolation unit is configured to isolate the high frequency axial oscillating charge from the drill string; sensors to take measurements down the hole; and a closed-loop real-time controller located downhole and configured to operate downhole during closed-loop, real-time control and using the measurements taken downhole by the sensors to control the oscillator by varying the high frequency axial oscillating charge responding on the state of the material through which the rotary drill bit passes, thus establishing and maintaining oscillation system resonance between the oscillator, the rotary drill bit and the material through which the rotary drill bit passes, whereby the high frequency axial oscillating charge is sufficient to initiate cracks in the material. the rotary drill head passes through The drilling module of claim 1, wherein the controller is configured to sweep a frequency range to evaluate the state of the material through which the rotary drill bit passes and thus establish and maintain oscillation system resonance. A drilling module, according to any one of the preceding claims, wherein the oscillator is configured to impose a high frequency axial oscillating charge, based on an elementary resonance curve, on the rotary drill bit and modify the high frequency axial oscillating charge to interact with the drilled material in consideration. A drilling module, according to any of the preceding claims, wherein the controller is configured to determine appropriate charge parameters for the rotary drill head in accordance with the following steps, to achieve and maintain oscillatory system resonance: , when it reacts to and interacts with the drilled material; B) assess an appropriate frequency sweep range for charging the drill head; C) assess the shape of a resonance curve; D) selecting an optimal resonant frequency on the resonance curve at one point less than maximum on the resonant curve; and E) drive the rotary drill head based on this optimum resonant frequency. A drilling module, according to any one of the preceding claims, wherein the controller is configured to autonomously adjust a rotating and high frequency axial oscillating charge of the drill head in response to current drilling conditions. The drilling module according to claim 5, wherein the controller is configured to control the rotary drill head so that the rotary drill head acts on the material it passes through to produce a first set of macroring cracks and wherein the controller is further configured to controlling the rotary drill bit to rotate and act upon the material one more time, thus producing a further set of macroring capabilities, and wherein the controller is configured to synchronize rotary and oscillating movements of the rotary drill bit to promote interconnection between the thus produced macro cracks, to create a localized dynamic crack propagation zone prior to the rotary drill bit. A method of controlling a resonant amplified rotary drill, comprising a rotary drill bit (1) and an oscillator for applying high frequency axial oscillating load up to 1 kHz to the rotary drill bit, and the method comprising: applying a high frequency axial oscillating charge to the rotary drill bit; to take measurements down the hole; controlling the applied high frequency axial oscillating charge downhole during closed-loop real-time control by using the downhole measurements to vary the high frequency axial oscillating charge responding to the state of the material through which the rotary drill bit is passing; thus establishing and maintaining oscillation system resonance between the oscillator, the rotary drill bit and the material through which the rotary drill bit passes, whereby the high frequency axial oscillatory charge is sufficient to initiate cracks in the material through which the rotary drill bit passes. The method of claim 7 further comprising: sweeping a frequency range to evaluate the state of the material through which the rotary drill bit passes through to establish and maintain oscillatory system resonance. The method of claim 7 or 8, wherein the high frequency axial oscillating charge is applied based on an elementary resonant curve of the rotary drill bit and the high frequency axial oscillating charge is modified to take into account interactions with the drilled material. A method according to any one of claims 7 to 9, further comprising determining appropriate charge parameters for the rotary drill head, in accordance with the following steps, to obtain and maintain oscillatory system resonance: A) determining a limit of oscillatory impact of the rotating drill head when it reacts to and interacts with the material being drilled; B) assess an appropriate frequency sweep range for charging the drill head; C) assess the shape of a resonance curve; D) selecting an optimal resonant frequency on the resonance curve at one point less than maximum on the resonant curve; and E) operating the rotary drill head, based on this optimal resonant frequency. A method according to any one of claims 7 to 10, wherein the rotating and high frequency axial oscillating charge of the rotary drill head is adjusted autonomously in response to current drilling conditions. The method of claim 11, wherein the rotary drill head is controlled to act upon the material through which the rotary drill head passes, to produce a first set of macroring cracks, and to rotate and act upon the material a further time to produce a further sets of macroring cracks, the rotating and oscillating movements of the rotary drilling head being synchronized to promote interconnection between the thus produced macroring cracks, to create a localized dynamic crack propagation zone prior to the rotary drilling head. Controller configured to perform the method of any of claims 7 to 12 when mounted in a drill module, according to any of claims 1 to 6.