Methods and apparatus for driving a means in a drill string while drilling

Abstract

A method and at least one mechanism for carrying out the method is disclosed. A method of (1) generating time modulated torque pulses by engaging and disengaging a mud turbine driven rotating torque generator in the bottom of a wellbore, and (2) monitoring the top of the drill string for the torque pulses therein may be practiced by a mud driven turbine inertial wheel for being momentarily and precisely braked or decelerated relative to a drill collar on the lower end of a drill string in a wellbore while drilling for generating the time modulated torque pulses in the drill string for being monitored at the surface. Mechanical, electrical, and fluid operated brakes and a mud turbine driven motor are disclosed for providing power to a motor at the bottom of the drill string or for being intermittently braked rapidly for generating the torque pulses.

Methods and apparatuses for driving a means, as a power generator in a drill string while drilling, in a well are disclosed. One method comprises (1) circulating drilling mud internally of the drill string, (2) rotating a turbine in the drill string with the circulating drilling mud, (3) driving the power generator in the drill string with the mud driven turbine, and (4) powering a modulated torque pulse generator control system with the power generator for generating modulated torque pulses in the drill string. A transmission system for driving a modulated pulse generator means while drilling comprises (1) mud driven turbine means including a cylindrically shaped turbine having inwardly extending vanes for receiving and having drilling mud circulating therethrough, and (2) the mud driven cylindrical turbine means being responsive to the circulating drilling mud for powering the modulated pulse generator means while drilling.

Description

This is a division of application Ser. No. 363,784, filed May 24, 1973, now U.S. Pat. No. from a conventional mud pump 39, FIG. 1, is sufficient to cause high speed rotation of motor-generator 21 for generating more than adequate electric current for driving practically any motor or system desired in the drill string.

DESCRIPTION OF THE METHOD METHODS

A method is set forth for transmitting data from the bottom of a drill string in a wellbore during drilling thereof to the top of the wellbore comprising the steps of,

1. generating data by measuring preselected subsurface parameters,

2. generating torque pulses relative to the data by intermittently braking a mud turbine driven rotating torque pulse generator in a drill collar preferably on the lower end of the drill string at the bottom of the wellbore, and

3. monitoring the top of the drill string for the torque pulses therein.

For greater details, the second step may comprise:

1. interrupting the turning of a mud turbine driven rotating inertial wheel on a drill string during drilling by momentarily braking the mud turbine driven rotating inertial wheel to generate torque pulses in the drill string relative to the data.

The second step may be modified further as by:

1. braking a mud turbine driven rotating inertial wheel on the lower end of a rotating drill string, and

2. controlling the braking of the mud turbine driven rotating inertial wheel relative to the drill string for generating the precise torque pulses in the drill string relative to the data.

More details of the third step of the basic method comprise:

1. monitoring the time modulation between the torque pulses in the drill string.

The torque pulses may be either positive or negative.

Further details of the third basic step comprise:

1. monitoring the time modulation of either the length of the time between the pulses, the length of the pulse, or the number of pulses in the drill string due to intermittent braking of the mud turbine driven rotating torque pulse generator relative to the drill collar.

Methods are set forth for driving a means in a drill string while drilling as a pulse generator system comprises the following steps:

(1) rotating a cylindrically shaped turbine with inwardly extending vanes on the internal surface of the cylinder,

(2) circulating drilling mud internally of the cylindrical turbine,

(3) contacting the inwardly extending vanes of the cylindrical turbine with the circulating drilling mud as the drilling mud circulates through the cylindrical turbine for rotating the turbine, and

(4) driving the pulse generator system by rotation of the cylindrical turbine while drilling.

Another method for driving a torque pulse generator means for generating modulated torque pulses in a drill string while drilling comprises the following steps:

(1) circulating drilling mud through the drill string,

(2) rotating turbine means in the drill string with the circulating drilling mud, and

(3) powering the torque pulse generator means with the rotating turbine means for generating modulated torque pulses in the drill string while drilling.

An apparatus for driving an electrical generator in the lower end of a drill string while drilling for powering a control system in the drill string for controlling a torque pulse generator for generating modulated torque pulses in the drill string comprises:

(1) pump means for circulating drilling mud from the upper end of the drill string downwardly to the drill string lower end while drilling,

(2) mud driven turbine wheel means in the drill string lower end connected to a power generator in said drill string lower end,

(3) said mud driven turbine wheel means being responsive to said downwardly circulating mud in the drill string while drilling for driving said power generator,

(4) a modulated torque pulse generator control system mounted in the drill string, and

(5) said power generator being responsive to said mud driven turbine wheel means for powering said modulated torque pulse generator control system while drilling.

DESCRIPTION OF APPARATUSES OR SYSTEMS OF DATA TRANSMISSION FROM A WELLBORE AND APPARATUS FOR DRIVING A MEANS IN A DRILL STRING WHILE DRILLING

The drawings disclose several embodiments of the invention for carrying out or practicing the above described method for transmitting intelligence from the bottom of a wellbore of conditions at the bottom to the surface, either while drilling is in progress or during a lull in drilling.

FIG. 1, in greater detail discloses schematically a system for carrying out the basic method of data transmission from a wellbore during drilling operations.

In a drilling rig 11, FIG. 1, a suitable motor 12 not shown, drives a rotary table 14 with a sensitive torque meter 13 connected there-between. A drill string 15 in wellbore 16 has a kelly 17 rotated at its upper end by the rotary table 14 and has interconnected thereto drill pipes 18, measurement and instrumentation module 25, drill collar 10, and a drill bit 19. A conventional drilling mud pump may be incorporated with motor 12 or preferably may be separate therefrom for circulating the mud through the drill string 15.

EMBODIMENT OF FIG. 2

A feature of the invention is the mud turbine driven rotatable torque pulse generators or inertial wheels, as wheel or cylinder 22 of FIG. 2, having conventional mechanical brakes, such as but not limited to brake shoe type brakes 23a, controlled by a conventional brake controller 24 for being intermittently actuated or braked while drilling for varying the torque generated in the drill collar 10a and the drill string by the braked or decelerated inertial wheel or cylinder 22 for generating torque pulses timed or proportional to the wellbore information desired to be transmitted from control system 24. Control system 24 is powered by the generator 21 and its mud driven turbine wheel or cylinder 20 having the propeller blades or vanes 22a-22d described above.

Controller 24 and measurement and instrumentation module 25 include temperature, pressure, weight on the bit, and of other logging parameters such as SP (self potential) or resistivity for operating the brake 23a off and on for generating intermittent torque pulses time modulated in proporation to the data transmitted, such as but not limited to a conventional logging pulse generator. The measurement and instrumentation module 25, FIG. 1, is connected with wire 26, FIG. 2, to the controller 24 for generating data by measuring preselected subsurface parameters. Likewise, the controller may incorporate therein any suitable downhole tape recorder system as disclosed in U.S. Pat. No. 3,566,597.

These torque variations or torque pulses generated in the lower end of the drill string by the intermittent braking or decelerating of the rotating inertial wheel 22 relative to the drill collar 10a in drill string 15 in precisely timed intervals representing well bottom data from the controller 24 are transmitted up through the drill string, through the rotary table 14 to the sensitive torque meter 13 where the data is received. This torque meter is any suitable torque meter, such as but not limited to the Texaco Torque Meter disclosed in U.S. Pat. No. 3,295,367 by Dr. H. A. Rundell.

While only one inertial wheel 22, FIG. 2, and its attendant operating parts as the conventional clutch or brake 23a, etc., all positioned in a torque pulse generating module portion of drill collar 10a, FIG. 1, are illustrated for simplicity and clarity of disclosure, several inertial wheels are preferred to be controlled by the single controller 24, FIG. 2.

Mud turbine driven rotatable torque pulse generator or rotating inertial wheel or cylinder 22, FIG. 2, is rotatably mounted in bearings 27a and 27b in drill collar 10a and protected from the drilling mud in the center of the drill collar, if so desired, by a protective sleeve (not shown). An exemplary protective sleeve is illustrated in our above-identified co-pending parent patent application. The clutch or brake mechanism 23a having conventional brake shoes similar to automobile mechanical wheel brakes is controlled by the controller 24 so that during drilling and particularly when the drilling mud is circulated down internally of the drill string, rotating the turbine wheels or cylinders, passing through the drill bit and returning in the annular space around the drill string to the surface, the clutch or brake mechanism 23a may intermittently decelerate or engage and disengage the spinning wheel 22 relative to the spinning drill collar 10a to produce a series of opposite or positive torque forces in the drill collar for detection at the surface by the torque meter. Accordingly, vanes 22a-22d are preferably angularly set to rotate the turbine driven inertial wheel 22 in a direction opposite to the direction of rotation of the drill string for maximum relative motion between the two for increased range of braking action.

Thus in the embodiment of FIG. 2, the mud turbine driven rotatable torque pulse generator or inertial wheel is usually freely turning relative to the spinning drill collar and accordingly may be decelerated at any moment to generate positive torque pulses in the drill string 15.

In the embodiment of FIG. 2 the conventional motor-generator device 21 is connected between the drill collar 10a and the inertial wheel 20 with a stator on one element, as on the drill collar 10a and a rotor on the other element, as the inertial wheel 20. In operation, with several inertial wheels and motor-generators, some are connected with conventional electrical connections to generate electricity for storage thereof at the controller 24 with relative movement between the inertial wheels and the drill collar.

In operation of the modification of FIG. 2, as the mud turbine driven rotatable torque pulse generating inertial wheel or cylinder 22 is freely spinning, at the proper preset time, the brake for each of the several inertial wheels, if more than one wheel is utillized, is engaged at the precise moment to transmit the coded, time modulated torque pulses to the surface torque meter for transmission of live information or information that has been stored in the controller and measurement and instrumentation module for transmission when called for.

Further, the embodiment of FIG. 2 may be operated by the controller 24 for precisely controlling the individual braking of at least two inertial wheels for generating two torque pulses with the time therebetween being relative to, or equal to a function of, the measured parameter, as temperature of the formation, for example.

MODIFICATION OF FIG. 3

FIG. 3 discloses another modification of the embodiment of FIG. 2 wherein a magnetic clutch or brake 23b is substituted for the brake 23a of FIG. 2. Inertial wheel 22, one of several inertial wheels, if so desired, is rotatably mounted in drill collar 10b similar to the embodiment of FIG. 2. Inertial wheel 22 has annular flanges 28 and 29 integral therewith and surrounded by a suitable magnetic particle fluid or powder 30 which is solidified by an electrical coil internally of brake 23b and connected by wire 31 to and controlled by a controller (not shown) similar to that of FIG. 2. Mud propeller blades or vanes 40a-40d rotate inertial wheel 22 relative to drill collar 10b.

In operation of the magnetic particle brake operated inertial wheel 22 of FIG. 3, with the magnetic particles declutched and lying loosely, the mud turbine driven inertial wheel is allowed to rotate at the desired high speed. Then at the preselected time, the clutch or brake 23b is engaged or solidified momentarily or intermittently to suddenly engage the inertial wheels in precise succession to generate the time modulated torque pulses up the drill string to the torque meter 13, FIG. 1, for transmission of data from the area of the bottom of the well to the top in an efficient manner. Likewise, this modification may be operated in various methods as suggested for the modification of FIG. 2.

MODIFICATION OF FIG. 4

FIG. 4 illustrates another modification of the rotating torque pulse generator of FIG. 2 in the form of hydraulic brakes 23c connected with hydraulic lines 32 to a suitable hydraulic source for braking the inertial wheels 22 for generating precisely timed torque pulses in the drill collar 10c, FIG. 4, of the drill string. The inertial wheel 22 illustrated has an annular flange 33 integral with the outer surface thereof for operating with the two hydraulic brakes 23c. Each brake comprises a piston 34 operable in a cylinder 35 connected to the high pressure hydraulic fluid line 32 similar to controller 24 of FIG. 2. Piston 34 has conventional sealing O-rings 36, a friction wear pad or surface 37 on the outer end of the piston for pressing against the top side of flange 33, and a tension spring 38 connected between the inner end of the piston and the cylinder for maintaining the brakes free and unlocked when the hydraulic lines are unpressurized. The hydraulic brakes 23c for working against the lower side of the flange 33 is similar to that above and may have a shield, if so desired, for protecting the inertial wheel 22 from the mud internally of the drill string as utilized and illustrated in our above-identified copending patent. Mud driven turbine blades or vanes 41a-41c rotate inertial wheel or cylinder 22 relative to drill collar 10c.

Thus in operation of the hydraulic brakes 23c of FIG. 4, with the hydraulic pressure line depressurized, the mud turbine driven inertial wheel or cylinder 22 is allowed to rotate at the desired speed. At the preselected time, the hydraulic brakes 23c are actuated or pressurized to momentarily or intermittently suddenly engage the friction pads 37 with both sides of flange 33 of each of the inertial wheels to generate torque pulses up the drill string to the torque meter at the surface for transmission of data from the bottom of the well to the top. Likewise, this modification may be operated in the various other methods set forth in regard to the operation of the modification of FIG. 2 and FIG. 3.

In the latter torque pulse generators of FIGS. 2, 3, and 4, while it is preferred that a motor-generator like 20 of the embodiment of FIG. 2 be utilized to power the controllers and instruments in each, storage batteries may be used if so desired.

Obviously other methods may be utilized for transmission of signals with the embodiments of either FIGS. 2, 3, or 4 than those listed above, depending on the particular information desired to be transmitted.

Accordingly, it will be seen that while drilling is in progress, the disclosed methods and several data transmission systems will transmit information from the bottom of a wellbore to the surface and will operate in a manner which meets each of the objects set forth hereinbefore.

While only a few methods of the invention and several mechanisms for carrying out the methods have been disclosed, it will be evident that various other methods and modifications are possible in the arrangement and construction of the disclosed methods and data transmission systems without departing from the scope of the invention and it is accordingly desired to comprehend within the purview of this invention such modifications as may be considered to fall within the scope of the appended claims.

Claims

1. A method for driving an electrical generator in the lower end of a drill string while drilling for powering a control system in the drill string for controlling a torque pulse generator for generating modulated torque pulses in the drill string comprising the steps of,

(a) circulating drilling mud internally of the drill string upper end to the drill string lower end,

(b) flowing the drilling mud internally of a vaned turbine wheel in the drill string,

b (c) rotating a the vaned turbine wheel in the drill string by action of the downwardly circulating drilling mud and internally of the vaned turbine wheel,

(d) controlling the modulated torque pulse generator with a control system,

(c) (e) driving a the electrical generator in the drill string with the internal mud driven rotating vaned turbine wheel, and

(d) (f) generating electricity with said electrical generator for powering the modulated torque pulse generator control system while drilling.

2. A transmission cycle for driving a power generator in the lower end of a drill string for powering a control system in the drill string while drilling for controlling a torque pulse generator for generating modulated torque pulses in the drill string comprising,

(a) pump means for circulating drilling mud from the upper end of the drill string downwardly to the drill string lower end while drilling,

(b) turbine wheel means in the drill string lower end having drilling mud circulating internally thereof,

(b) (c) said mud driven turbine wheel means in the drill string lower end being connected to a power generator in said drill string lower end,

(c) (d) said mud driven turbine wheel means being responsive to said downwardly circulating mud in the drill string therethrough while drilling for driving said power generator,

(d) (e) a modulated torque pulse generator control system mounted in the drill string, and

(e) (f) said power generator being responsive to said mud driven turbine wheel means with said drilling mud circulating therethrough for powering said modulated torque pulse generator control system while drilling.

3. A method for driving a power generator in a drill string while drilling for powering a control system in the drill string for controlling a torque pulse generator for generating modulated torque pulses in the drill string comprising the steps of,

(a) circulating drilling mud internally of the drill string,

(b) flowing the circulating drilling mud internally of a vaned turbine wheel in the drill string,

(c) rotating the vaned turbine wheel in the drill string with the circulating drilling mud therein,

(d) driving the power generator in the drill string with the internal mud driven vane turbine wheel, and

(e) powering a torque pulse generator control system while drilling with the power generator for generating modulated torque pulses in the drill string. 4. A method as recited in claim 3 wherein the method comprises the additional steps,

(a) rotating the turbine with inwardly extending vanes on the internal surface thereof, and

(b) circulating the drilling mud internally of the vaned turbine for driving the power generator for powering the torque pulse generator

control system. 5. A transmission system for driving a torque pulse generator means for generating modulated torque pulses in a drill string while drilling comprising,

(a) pump means for circulating drilling mud through a mud driven turbine means in a drill string while drilling, wherein,

(b) said mud driven turbine means comprises a cylinder rotatably mounted in the drill string,

(c) inwardly extending vanes on the internal surface of said cylinder,

(d) torque pulse generator means in said drill string,

(e) said pump means being means for circulating drilling mud through said cylinder while drilling for rotating said cylinder for powering said torque pulse generator means for generating modulated torque pulses in the drill string,

(f) said mud driven turbine means being responsive to said circulating drilling mud while drilling for driving said torque pulse generator means for generating the modulated torque pulses in said drill string. 6. A method for driving a torque pulse generator means for generating modulated torque pulses in a drill string while drilling comprising the steps of,

(a) circulating drilling mud through the drill string,

(b) flowing the drilling mud internally of a vaned turbine means in the drill string,

(c) rotating turbine means in the drill string with the circulating drilling mud, and

(d) powering the torque pulse generator means with the rotating vane turbine means for generating modulated torque pulses in the drill string

while drilling. 7. A method for driving a pulse generator system in a well while drilling comprising the steps of,

(a) rotating a cylindrically shaped turbine rotor with inwardly extending vanes on the internal surface of the cylinder,

(b) circulating drilling mud internally of the cylindrical turbine,

(c) contacting the inwardly extending vanes of the cylindrical turbine with the circulating drilling mud as the drilling mud circulates through the cylindrical turbine for rotating the turbine, and

(d) driving the pulse generator system by rotation of the cylindrical turbine while drilling. 8. A transmission system for driving a modulated pulse generator control system means in a drill string while drilling in a well comprising,

(a) mud driven turbine means including a cylindrical shaped turbine having inwardly extending vanes,

(b) said cylindrical shaped turbine means inwardly extending vanes having drilling mud circulating internally thereof, and

(c) said mud driven cylindrical turbine means with the inwardly extending vanes being responsive to said circulating drilling mud for powering said modulated pulse generator control system means while drilling.

9. A transmission system for driving a pulse generator means for generating modulated pulses in a drill string while drilling in a well comprising,

(a) pump means for circulating drilling mud through a drill string while drilling,

(b) mud driven turbine means for a power generator means in the drill string,

(c) said mud driven turbine rotor means comprising a cylindrically shaped turbine having inwardly extending vanes for receiving and having drilling mud circulating internally of said cylindrical turbine,

(d) said mud driven cylindrical turbine means with said inwardly extending vanes being responsive to said circulating drilling mud therethrough while drilling for driving said power generator means,

(e) pulse generator means in the drill string, and

(f) said power generator means being responsive to said mud driven cylindrical turbine means for powering said pulse generator means while drilling.