Sensory processes for determining proximity to magnetic structures, fields, or
5 magnetic anomalies have improved significantly in recent years. During natural
resource exploration, sensory measurements may be utilized to intercept various
devices or components, determine capacity, make predictions, and implement
exploration actions. In some cases, making measurements may require bulky sensor
devices that may be difficult to operate, inaccurate, expensive, and complicated.
10 BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative embodiments of the present invention are described in detail below with
reference to the attached drawing figures, which are incorporated by reference herein
and wherein:
FIG. 1 is a schematic representation of a logging-while-drilling (LWD) environment
15 in accordance with the disclosed embodiments;
FIG. 2 is a schematic, pictorial representation of a logging environment in accordance
with the disclosed embodiments;
FIG. 3 is a schematic representation of a sensor system on a drill string with a rotary
steering system in accordance with the disclosed embodiments;
20 FIG. 4 is a schematic representation of a second sensor system on a drill string with a
rotary steering system in accordance with the disclosed embodiments;
FIG. 5 is a pictorial representation of a magnetic field cross section in the absence of a
magnetizable object near a drilling tool in accordance with the disclosed
embodiments;
WO 2015/195089 PCT7US2014/042619
FIG. 6A is a schematic, pictorial representation of a magnetic field cross section of a
drilling tool in the presence of a magnetizable object in accordance with the disclosed
embodiments;
FIG. 6B is a schematic, pictorial representation of a sensor system in accordance with
5 the disclosed embodiments;
FIG. 6C is a pictorial representation of a bucking field generated by magnets in
accordance with the disclosed embodiments;
FIG. 6D is a schematic, pictorial representation of a bucking field generated by a
sensor system in accordance with the disclosed embodiments;
10 FIG. 7A is a schematic, pictorial representation of a steerable drilling tool being
utilized to intersect an existing well in accordance with the disclosed embodiments;
FIG. 7B-C are schematic, cross sectional views of alignment of a well intersection in
accordance with the disclosed embodiments;
FIG. 8A-C are schematic, cross sectional views of a reluctance sensor system in
15 accordance with the disclosed embodiments;
FIG. 9 is a schematic, circuit representation of a sensor system in accordance with the
disclosed embodiments;
FIG. 10 is a schematic, representation of a downhole sensor system within a casing in
accordance with the disclosed embodiments;
20 FIGS. 11 and 12 are schematic, representations of a steerable drilling tool being
utilized with a branched well in accordance with the disclosed embodiments; and
FIG. 13 is a block diagram of a drilling system in accordance with the disclosed
embodiments.
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DETAILED DESCRIPTION OF THE DRAWINGS
The illustrative embodiments provide a sensor system, method, and drilling tool or
apparatus for measuring or detecting a magnetizable structure in a subterranean
environment. The illustrative embodiments may be utilized to intersect a well, such
5 as when a relief well is drilled to intersect with a blowout well in order to disable or
fix the blowout well. The illustrative embodiments may also be utilized to avoid
intersecting with wells that are in close proximity to one another, such as in an
offshore platform environment where wells may be closely spaced together. In one
embodiment, the embodiments may measure the change in magnetic reluctance with
10 respect to an azimuthal direction around the circumference of the embodied systems
or tools. The illustrative embodiments may also be utilized to perform ranging within
or outside of a wellbore. For example, the sensor system may determine the distance
between the tool and the sides of the casing, detect branch locations, and measure
casing wall thickness. As used herein, "or" does not require mutual exclusivity.
15 In one embodiment, the sensor of the illustrative systems may be a magnetometer.
However, the sensors may represent one or more magnetometers, gaussmeters, flux
gate, gradiometers, Hall effect sensors, coil loops, or other sensors configured to
detect or measure the strength or intensity of magnetic fields (or changes in the
strength or intensity of the magnetic fields). A magnetometer measures the magnetic
20 field strength while the magnetic gradiometer measures the rate of change of the
magnetic field strength (e.g., dB/dr) as a spatial derivative. For example, the
gradiometers may measure a difference in magnetic field strength in different radial
positions (e.g., dB=B2 - Bl, dr = r2 - rl), such as preselected radial distances. In one
embodiment, the values measured by the gradiometers may be the difference in the
25 magnetic field strength measured by two magnetometers divided by a separation
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distance. The magnetometers may be positioned to have their sense axis and
orientation in the same direction. In other embodiments, an array of sensors may be
utilized to provide more accurate results and for redundancy in the event of a failure.
In one embodiment, the magnetometer measures the magnetic field strength that is
5 incident in the selected radial direction.
As described herein, the illustrative embodiments may utilize one or more reluctance
sensors including magnetometers or gradiometers. Reluctance sensor systems may
include one or more permanent magnets. For example, the sensors as noted above
may include coils or windings to detect a change in the magnetic field generated by
10 the permanent magnet. The rotation of the sensor may be utilized to detect changes in
the magnetic flux to detect speed, direction, and position of target devices. The target
devices may represent ferrous metal or magnetic targets. Sensing is performed
without contacting the target (until desired).
The illustrative embodiments may have numerous benefits improvements over
15 existing systems. In one embodiment, the sensor system may not require current to
flow on the target well or components. This may be particularly important for areas
with large amounts of salt formations. Salt formations make active excitation very
difficult. As a result, in highly resistive formations, the sensor system may guide the
drilling tool to a desired intersection. Less parts may be required as the transmitter
20 and receiver for ranging coexist in the same location on the bottom hole assembly.
The various embodiments have a number of low-power applications. The use of
bucking magnets and magnetometers may provide for a radial azimuthal sensitivity
similar to more expensive and complex tools. In other embodiments, the sensor
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system may be utilized to measure casing wear, be a multilateral window finder,
provide casing collar location, and provide a milling profile.
The illustrative embodiments provide a highly accurate directional and distance
measurement of nearby magnetizable structures in order to avoid, follow in close
5 proximity, or intersect target wells, devices, components, earth formations, or so
forth. The illustrative embodiments may be utilized to steer a relief well to intersect
with the target well in the form of active excitation. In one embodiment, the sensor
system may be utilized with a standard or steerable drill bit. In other embodiments,
the sensor system may be utilized as part of a logging tool.
10 Distance measurements performed by the sensor system may be determined in any
number of ways. In one embodiment, a model reference may be utilized to determine
how much of a magnetization field intensity and the magnetization field orientation
may be created for a given structure based on the shape of the structure and the
magnetic permeance of the material the structure is made of. The measured results
15 may be compared against the expected results to determine proximity, orientation, or
configuration of the sensed structure. The system may also determine distance by
measuring the magnetic field gradient of the magnetized object that is superimposing
itself on the permanent magnetic field. The sensor system may also measure the
change in magnetic intensity as the downhole tool draws near or veers away from the
20 magnetizable object. The sensor system may also determine distance by measuring
the magnetic intensity over a neutral environment. In another embodiment, the sensor
system may impose a smaller AC excitation field on top of the reluctance field
(preferably in the same bucking format) using opposing windings on each magnet.
This form of active ranging may also be utilized in conjunction with a static magnetic
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field from a permanent magnet. The illustrative embodiments may also use any
number of structures or devices to magnify, channel, manage, or otherwise affect the
magnetic field.
FIG. 1 shows an illustrative logging-while-drilling environment (LWD) 100. LWD
5 may also be referred to as measurement-while-drilling (MWD). A drilling platform 5
is equipped with a derrick 10 that supports a hoist 15. The rig operator drills an oil or
gas well for production or exploration using a string of drill string 20. The hoist 15
suspends a top drive 25 that rotates the drill string 20 as it lowers the drill string 20
through the wellhead 30. Connected to the lower end of the drill string 20 is a drill bit
10 35. The drill bit 35 is rotated and drilling accomplished by rotating the drill string 20,
by use of a downhole motor near the drill bit 35 or the top drive 25, or Kelly pipe and
rotary table (not shown) or by both methods.
In one embodiment, recirculation equipment 40 pumps drilling mud or other fluids
through the flow line 80 to the derrick 10 and goes up the derrick 10 through a stand
15 pipe 81 then connects to a swivel 83 on the top drive via a flexible hose 82 to permit
fluid to be pumped through the top drive 25 and into the drill string 20 below, through
top drive 25, and down through the drill string 20 at high pressures and volumes to
emerge through nozzles or jets in the drill bit 35. The drilling fluid then travels back
up the hole via the annulus formed between the exterior of the drill string 20 and the
20 borehole wall 50, through a blowout preventer, through a return line 45 and into a
retention pit 55, reservoir, or enclosed receptacle on the surface. On the surface, the
drilling fluid may be cleaned and then recirculated by the recirculation equipment 40.
The drilling fluid may be utilized to carry cuttings from the base of the bore to the
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surface and balance the hydrostatic pressure in the rock formations in the LWD
environment 100.
The bottom hole assembly 60 (i.e., the lowermost part of drill string 20) may include
thick-walled tubulars called drill collars, which add weight, stability, and rigidity to
5 aid the drilling process. The thick walls of these drill collars make them useful for
housing instrumentation, tools, and LWD sensors. For example, the bottom hole
assembly 60 of FIG. 1 may include a sensor system 65 (also referred to as a
reluctance sensor) and a communications and control module 70.
The sensor system 65 may include a number of permanent magnets and coils
10 configured to sense changes in the magnetic field when the sensor system 65 is within
the proximity of ferromagnetic materials, paramagnetic materials, magnetic earth
formations (e.g., pyrite, paramagnetic shale, etc.), or other components affected by
magnetic fields. The sensor system 65 may be encompassed in a downhole tool or
sub. In one embodiment, the sensor system 65 does not include magnetic materials to
15 avoid affecting the readings taken by the sensor system 65. Typical materials for the
sensor system 65 may include many forms of austenitic stainless steels
In one embodiment, the sensor system 65 is a reluctance sensor that is positioned as
close to the drill bit 35 as possible or integrated with the drill bit 35 including such
positions as on the face of a polycrystalline diamond compact (PDC) drill bit or in the
20 cutter component. In other embodiments, the sensor system 65 may be part of the drill
string 20 that sits just above the drill bit 35. Various configurations of a drill string 20
and sensor system 65 are shown in FIGs. 4-7. The sensor system 65 may be useful
for taking measurements in highly resistive formations, such as salt formations where
existing active excitation tools are not as effective.
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In addition, the sensor system 65 or bottom hole assembly 60 may include, without
limitation, a natural gamma ray detector, a resistivity tool, a nuclear magnetic
resonance tool, a neutron porosity tool, or other exploration formation descriptor tools
and sensors. Other tools and sensors may also be included in the bottom hole
5 assembly 60 or sensor system 65, including, but not limited to, position sensors,
orientation sensors, accelerometers, compasses, pressure sensors, temperature sensors,
vibration sensors, and so forth.
From the various bottom hole assembly 60 sensors, the communications and control
module 70 (telemetry module) collects data regarding the formation properties or
10 various drilling parameters, tool configurations and readings, from the sensor system
65 and stores the data in internal memory. In addition, some or all of the data may be
transmitted to the surface by wireline communications, wireless communications,
magnetic communications, seismic communications, mud telemetry, or so forth.
For example, the communications and control module 70 may communicate
15 information to the surface. The communications signals may be received by a surface
receiver 84, converted to an appropriate format, and processed into data by one or
more computing or communications devices, such as computer 75. As used herein,
computing devices such as computers may comprise one or more central processing
units (CPU) or hardware or software control logic communicably coupled to a storage
20 device, such as a hard disk, random access memory, magnetic RAM (MRAM) or
other forms of non-volatile memory, that contains a set of processor executable
instructions or software.
In certain embodiments, the set of software may be stored on a portable information
storage media 80 —such as thumb drives, CDs, DVRs, etc.—and later stored within
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the computer 75 or executed from the portable information storage media. The
computer 75 may also receive user input via an input device 91, such as a keyboard,
mouse pointer and mouse buttons, microphone, or other device to process and decode
the received signals. The resulting sensory and telemetry data may be further
5 analyzed and processed by computer 75 to generate a display of useful information on
a computer monitor 90 or some other form of a display device or output, such as a
mobile device like a hand held smart phone or a tablet PC. For example, a driller may
employ the system of the LWD environment 100 to obtain and view ranging,
intersection, or magnetic field information for the borehole wall 50 or downhole
10 components, structures, or formations.
FIG. 2 is a schematic, representation of a logging environment 200 in accordance with
the disclosed embodiments. The logging environment 200 may include any number
of tools, devices, locations, systems, and equipment that may be utilized to provide
the sensor tools, systems, and methods herein described. The logging environment
15 200 may also include a reservoir 201.
As previously noted, the reservoir 201 is a designated area, location, or threedimensional
space that may include natural resources, such as crude oil, natural gas,
or other hydrocarbons. The reservoir 201 may include any number of formations,
surface conditions, environments, structures, or compositions. The illustrative
20 embodiments may utilize sensors to determine properties and measurements of the
reservoir 201 and a wellbore 203 penetrating the reservoir. For example, changes in
the magnetic flux may be utilized to measure parameters (e.g., distances, direction,
casing thicknesses, casing magnetic permeance, etc.), properties, structures or
formations, deposits, downhole tools or components, or other properties of the
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reservoir 201 and the wellbore 203. The permeance, reluctance, or other related
parameters may be similarly utilized. For example, a distance to the wellbore walls
may be determined utilizing the changes in the magnetic flux. Processing or
computations utilizing the magnetic flux density may be performed downhole, on-site,
5 off-site, at a movable location, at a headquarters, utilizing fixed computational
devices, utilizing wireless devices, or over a data network using remote computers in
real-time or for later after the fact processing.
The data and information determined from examination of the wellbore 203 may be
utilized to perform measurements, analysis, or actions for exploration or production of
10 the reservoir 201. The wellbore 203 may be drilled and configured with the reservoir
201 to extract wellbore fluids or gases from the formation. The size, shape, direction,
and depth of the wellbore 203 may vary based on the conditions and estimated natural
resources available. The wellbore 203 may include any number of support structures
or materials, divergent paths, surface equipment, or so forth.
15 In one embodiment, the processes herein described may be performed utilizing
specialized sensor tools, including reluctance sensors, induction proximity sensors,
resistivity sensors, magnetic field sensors, acoustic proximity sensors, location
sensors (e.g., that permit the measurement of a distance or direction to a manmade
subterranean structure), orientation sensors (e.g., gyroscopes, compasses,
20 accelerometers, etc.) logic, interconnects, power sources, and other similar electrical
components. The logic utilized by the tools may include processors, controllers,
memories, field programmable gate arrays (FPGAs), batteries, wires, leads, pins,
connectors, amplifiers, application specific integrated circuits, computer instructions,
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code, programs, or applications, or any combination of software, hardware, and
firmware.
In one embodiment, the logging environment 200 may include a network 202, a
wireless network 204, a facility 206, a computer 208, a management system 210,
5 servers 212 and 214, a database 216, a tablet 218, a wireless device 220, a portable
computer 222, and a mobile computing system 224. The mobile computing system
224 may be any computer system where one or more components of the system are
portable, i.e., not permanently fixed in one geographical location, and may include
one or more databases, tablets, wireless devices or computers. The mobile computing
10 system 224 may be in direct or indirect communications with the downhole
equipment 226 and/or tool 228 by use of a computing or communications network. In
one embodiment, the mobile computing system 224 communicatess with the
downhole equipment 226 and/or tool 228 by use of the network 202. The network 202
may be any type of computing or communications network including one or more of
15 the following networks: a wide area network, a local area network, one or more
private networks, the Internet or public networks, a telephone network (e.g., publicly
switched telephone network), a cable network, a satellite network, one or more
cellular networks, cloud networks, virtual networks, and other wireless and data
networks.
20 The wireless network 204 is one example of a wireless network for regional or local
communications (e.g., WiFi, GMS, 4G, LTE, PCS, Bluetooth, Zigbee, WiMAX,
GPRS, etc.). The network 202 and the wireless network 204 may include any number
of network nodes, devices, systems, equipment, and components (not depicted), such
as routers, servers, network access points/gateways, cards, lines, wires, switches, DNS
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servers, proxy servers, web servers, and other network nodes and devices for assisting
in routing and computation of data/communications as herein described.
In another embodiment, integrated or external tools or components communicating
with the mobile computing system 224 may be configured to penetrate an earth
5 formation through the wellbore 203 to stimulate, energize, and measure parameters of
a formation or a nearby man made structure. One or more sensors or logging tools
(e.g., probes, drill string measurement devices, nuclear magnetic resonance imagers,
etc.) may be integrated with or connected to the downhole equipment 226 and tool
228 communicating with the mobile computing system 224 to perform signal
10 generation, measurements, logging, data retrieval, data storage, processing, and
information display.
For example, the mobile computing system 224 may determine any number of static
and dynamic properties of the reservoir 201. The static and dynamic properties may
include measurements of or changes in pressure, wellbore distances and diameters,
15 ranges, depth, temperature, composition (e.g., hydrocarbon composition levels,
measurements, and statistics), fluid flow rate, fluid composition, density, porosity,
position and displacement, depth, and so forth. Changes or variations in how the
formations within the reservoir 20lor wellbore 203 affect the magnetic flux of the
tool 228 may be utilized to make any number of determinations regarding the natural
20 formations, structures, or man-made components within the reservoir 201.
For example, at various times during the drilling process, a drill string (see FIG. 1)
may be removed from the wellbore 203. Once the drill string has been removed,
logging operations may be conducted using the tool 228 which may be a wireline or
wireless tool. For example, the tool 228 may be a sensing instrument suspended by a
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cable having conductors for transporting power to the tool and telemetry from the tool
to the surface. The tool 228 may be preconfigured for testing or configured in realtime
for the conditions of the logging environment. The tool 228 may be configured
to operate with or without rotation.
5 The tool 228 may alternatively represent any number of LWD, MWD, seismic-whiledrilling
(SWD), or other downhole or reservoir tools. In one embodiment, the tool
228 may rotate one or more sensors to enhance measurements made by the tool 228.
The tool 228 may store or communicate the signals and data generated as measured
by changes in the magnetic flux to determine proximities to components or properties
10 in each section of the reservoir 201 or the wellbore 203. The tool 228 may be selfcontained
and powered or connected to one or more fixed or mobile stations, systems,
devices, equipment, or vehicles at the surface.
In one embodiment, the tool 228 or other portions of the mobile computing system
224 may communicate one or more magnetic fields from the tool 228. The magnetic
15 field utilized by the tool 228 to perform measurements may be generated by the tool
228 or by any number of devices in close proximity to the tool 228. One or more of
the computer 208, tablet 218, wireless device 220, portable computer 222, or mobile
computing system 224 may execute a software program to configure the tool 228 and
retrieve and utilize the measurements acquired in the process herein described. For
20 example, in one embodiment the wireless device 220 may be configured to increase or
decrease the amplitude, bucking effect, sensitivity, or other parameters utilized by the
tool 228. The tool 228 may also be configured with programs or algorithms for selfconfiguration
based on applicable environments, parameters, conditions, or so forth.
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The wireless device 220 may also be utilized to filter particular types of fields, turn
the tool (in any of three dimensions), or so forth.
In another embodiment, the computations and analysis of the data read by the tool 228
may be performed by an information handling system. The information handling
5 system may include random access memory (RAM), one or more processing
resources such as a central processing unit (CPU) or hardware or software control
logic, ROM, and/or other types of nonvolatile memory. Additional components of the
information handling system may include one or more disk drives, one or more
network ports for communication with external devices as well as various input and
10 output (I/O) devices, such as a keyboard, a mouse, and a video display. The
information handling system may also include one or more buses operable to transmit
communications between the various hardware components. For the purposes of this
disclosure, computer-readable media may include any instrumentality or aggregation
of instrumentalities that may retain data and/or instructions for a period of time.
15 Computer-readable media may include, for example, without limitation, storage
media such as a direct access storage device (e.g., a hard disk drive or floppy disk
drive), a sequential access storage device (e.g., a tape disk drive), compact disk, CDROM,
DVD, RAM, RDM, electrically erasable programmable read-only memory
(EEPROM), and/or flash memory; as well as communications media such wires,
20 optical fibers, microwaves, radio waves, and other electromagnetic and/or optical
carriers; and/or any combination of the foregoing.
In one presented in embodiment of FIG. 2, the computations and analysis of the data
read by the tool 228 may be performed by an information handling system which
includes a management system 210, servers 212 and 214, or other network devices.
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For example, the user may submit information and parameters utilizing the wireless
device 220, personal computer 208, tablet 218, portable computer 222, or mobile
computing system 224 to perform the calculations on the server 212 with the results
being stored in the database 216 for subsequent access. The database 216 may store
5 the depths and locations of components, sensor orientation information, casing
thicknesses, static properties, dynamic properties, parameters, configuration, settings,
and so forth. The database 216 may be accessed by any number of users and devices
in the logging environment 200 to retrieve and update the data.
In one embodiment, the servers 212 and 214 may execute an application that is
10 available to any of the devices of the logging environment 200 through the network
202 and the wireless network 204. For example, the application may display a user
interface for receiving parameters, properties, and other information for configuring
the tool 228 or reviewing the measurements of the tool 228. In one embodiment, the
server 214 is a Web server that hosts the application for downhole measurement
15 processing that is accessible through one or more browsers utilized by any of the
personal computer 208, tablet 218, wireless device 220, portable computer 222, and
mobile computing system 224.
Turning now to FIG. 3 showing a portion of a drill string 300 with a sensor system
302 in accordance with the disclosed embodiments. In one embodiment, the sensor
20 system 302 may be integrated as part of a near-bit sub. In another embodiment, the
drill string 300 may include a sensor system 303 positioned above an optional mud
motor 304 connected to a rotary steerable tool 310drive shaft 307, and a drill bit 308.
In one embodiment, a rotary steerable tool 310 may use a tilt or point bit steering
arrangement where the drill bit 308 is tilted in a desired direction for drilling while the
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housing 306 remains stationary within the formation through the use of gripping
devices 311 (non-blocking) to prevent the housing 306 from rotating with the drill
string 300. The drive shaft 307 may be elastically bent with a bow like profile with
respect to the longitudinal axis of the housing 306 between one or more fulcrum
5 points to permit the drill bit 308 to tilt while the mud motor 304 or the drill string 300
or both rotate the drive shaft 307.
In another embodiment, a sensor system 312 may be integrated with the rotary
steerable tool 310. For example, the sensor system 312 may be located in the
nonrotating housing 306 of the rotary steerable tool 310. Since the sensor system 312
10 is stationary in the non-rotating housing 306, the rotation of the drill bit 308 may
cause cyclical fluctuations in the magnetic field as the drill bit 308 rotates.
Regardless of the location of the sensor system 302 (alternatively sensor systems 303,
312), the sensor system 302 may monitor the rotation of the drill bit 308 and
compensate for the cyclical fluctuations of the magnetic field that result from the
15 motion of the drill bit 308. In one embodiment, the sensor system 302 may determine
the revolutions per minute of the drive shaft 307 connected to the drill bit 308 to
subtract the fluctuation effects of the rotation on the magnetic field. The
compensation for rotation may be performed downhole to tune the sensor system 302
by subtracting those effects from the measurements of the sensor system 302 or by
20 electronically filtering out the signals received by magnetometers associated with a
number of blades and rotation speed of fixed cutter drill bit 308 that cause variance in
reluctance and other affects to the magnetic field. Compensation may also be
performed or apply to any variance in the magnetic field sensed by the sensor due to a
difference in rotation speeds between the sensor and other elements in the drill string.
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This may also apply to embodiments that include roller cone drill bits where a
variance may occur as the roller cone drill bit is rotated.
In one embodiment, compensation may include digitizing the received signal, running
a fast Fourier transform (FFT) on the sampled data, identifying the energy at
5 frequencies related to the rotation speed of the shaft, subtracting that part of the signal
from the FFT spectrum, and then re-inverting the frequency domain FFT back into a
time domain of signal strength verse time or azimuthal position leaving the signal
associated with the magnetization detection of the nearby man made structure in the
processed signal. Many other digital filtering techniques are applicable and know to
10 those skilled in the art.
FIG. 4 shows a sensor system 402 on a motor based drilling system 403 in accordance
with the disclosed embodiments. In certain embodiments, the motor based drilling
system 403 may include a Moineau style positive displacement motor (PDM), turbine
motor (e.g. a turbo drill), vane motor, or electric motor that is connected to a drive
15 shaft 405 having a drill bit 406. The motor based drilling system 403 may also
incorporate a mud motor 408 for increasing the speed of rotation or torque applied to
the drill bit 406 and a bent sub 404 that is part of the mud motor 408 torsional power
section for the purpose of steering the drilling direction of the bore hole. The bearing
housing 407 connects to a bearing assembly which is also part of the mud motor 408,
20 which provides for supporting the drive shaft 405 during on and off bottom loading
and supports the drive shaft 405 radially with radial support bearings to keep the drive
shaft 405 centered in the bearing assembly. Hence, the bent sub 404 tilts the drill bit
406 in a desired direction or a toolface direction. When the drill string (not shown or
labeled) is slid the toolface direction is not rotating and thus the bit 406 is tilted in a
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generally fixed direction which aids the drilling of the borehole in the desired
direction of the tilted angle. When it is desired to drill in a different direction, the
toolface is oriented from surface to point in a new direction and weight or force is
applied to the drill bit 406 to cause drilling to steer in the new direction of the
5 toolface. When it is desired to drill straight ahead the drill string may be rotated,
which rotates the bearing housing 407 with the mud motor resulting in no specific
toolface direction being held stationary while the drill bit 406 rotates. As shown in
FIG. 4, the drill bit 406 averages out a direction of drilling a new bore hole that is
typically straight ahead. In one embodiment, the sensor system 402 may be coupled
10 to the driveshaft 405 that may serve as a source for a magnetic North reference. The
sensor system 402 may be located adjacent to or inside the drill bit 406 or may be
located further up in the motor based drilling system 403 or drill string so as to not
interfere with the ferromagnetic and magnetic material of the lower assemblies. In
one embodiment, the bottom hole components may be made of non-magnetic material
15 so that the sensor system 402 is as close to the bottom of the drill string as possible to
aid in steering. The use of non-magnetic materials may prevent a magnetic circuit
path on the drill string from having a shunting effect of the magnetic flux on the
magnetic source thus reducing the amount of magnetic flux that may be used for
sensing. In another embodiment, a north seeking gyroscope may be positioned in a
20 near bit sub to provide a northward or relational reference to a fixed direction either
during rotation or when the drill string is stopped. Magnetometers tuned to measure
the Earth's magnetic field may also be used to determine a magnetic north direction in
cooperation with accelerometers to resolve the horizontal plane portion of the earth's
magnetic field. Direction or orientation determined by a sensor system 410 or
25 interconnected devices, sensors, or tools, may be utilized to determine a relative
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direction to a target, such as a target well, based on reluctance sensor readings of the
sensor system 410. In another embodiment, the sensor system 410 may include
accelerometers for determining position, orientation, gravitational, and other
information associated with the drill string. For example, accelerometers may be
5 utilized to determine a high side and low side reference of the bore hole for the sensor
system 410 when operating at an inclined angle from the down direction. Orientation
data may be transmitted to surface over a telemetry system, such as a mud pulse
telemetry system, wired drill pipe, acoustic telemetry, or electromagnetic telemetry
system, to allow the operator to maintain the orientation in a desired direction.
10 Orientation data may also be transmitted to a down hole automated toolface controller
to aid the automated controller in maintaining the toolface at a target value or
direction. For example, two orthogonal, accelerometers (e.g., x axis and y axis
oriented) may be integrated with the sensor system 410 to determine orientation and
relative positioning including a high side in an inclined position.
15 In another embodiment, a sensor 412 may also be integrated into the bearing housing
407, bent sub 404, or body of the mud motor 408 rather than into a near bit sub or
drill bit. For example, the sensor 412 may be configured to not rotate during sliding
for steering purposes as is the sensor 412 may also be mechanically coupled either
directly or indirectly to the bearing housing 407 and may reside above or below the
20 bearing housing 407 without being mechanically coupled to the drive shaft 405 which
rotates based on hydraulic power from drilling fluid flow in the drill string while the
drill string remains stationary. In one embodiment, it is desirable for the sensor 412
to be as close to the drill bit 406 as possible for accurate determinations of proximity
to a target object relative to the drill bit 406.
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FIG. 5 is a pictorial representation of a magnetic field cross section in the absence of a
magnetizable object near a drilling tool 500 in accordance with the disclosed
embodiments. As shown in FIG. 5, the sensor system 502 is positioned adjacent a
drill bit 504. In one embodiment, the sensor system 502 may include one or more
5 permanent magnets to create a bucking effect forcing the shape of a magnetic field
506 coming away from the like poles, in this case the North poles to push magnetic
flux radially outward thus focusing part of the magnetic field in a more radial
direction away from the axis of the drilling tool 500 at this location. As shown in
FIG. 5, the magnetic field 506 does not interact with any magnetizable objects.
10 The magnetic field 506 as shown is represented by isotropic lines of the field strength
given off by multiple bucking magnets (e.g., two magnets). The magnetic field 506
may vary in appearance based on real circumstances, geometries, magnetic properties
of a target casing, materials utilized to make the drill bit, formations near the sensor
system 502 and components in the drilling tool 500 (including steering assemblies and
15 near bit sub).
Turning now to FIGs. 6A-C, FIG. 6A is a pictorial representation of a magnetic field
cross section of a drilling tool 600 in the presence of a magnetizable target object 606
in accordance with the disclosed embodiments. One of the improvements of the
illustrative embodiments over previous permanent magnet sensors is that a magnetic
20 field 602 around the longitudinal axis of the drilling tool 600 may be uniform in shape
as compared to transaxis magnets used in different rotating magnet ranging methods.
As a result, a sensor system 604 of the drilling tool 600 offers more sensitivity to near
field magnetizing effects that may perturb the magnetic flux density in the magnetic
circuit of the sensor system 604.
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Turning now to FIG. 6B, showing the sensor system 604 of FIG. 6A. In one
embodiment, to create a bucking effect two permanent magnets 608 and 610 (e.g.,
ring magnets) or two electromagnets that generate a magnetic field when electric
current is flowing through windings (not shown) are utilized. The magnets 608 and
5 610 are placed close to each but not necessary against each other, such that the dipole
moments of each magnet 608 and 610 are approximately aligned and opposing each
other on the longitudinal axis of the sensor system 604. For example, a first magnet
608 may have opposing North pole of one magnet against the North pole of the
second magnet 610, such that the poles face each other. Likewise both the South
10 poles of each magnet 608 and 610 may be aligned to face each other in this
arrangement. This is often referred to as a bucking magnet effect. In this manner, the
magnetic lines of flux coming from each side create an opposing repulsion force
against each other trying to push the magnets 608 and 610 apart rather than attract
themselves toward each other (which would be the case if the arrangement was a
15 North pole facing a South pole magnet).
In one embodiment, the sensor system 604 may include a position sensor 628
configured to determine the position of the magnets 608 and 610. The position sensor
628 may also indicate the distance between the magnets 608 and 610 for determining
the bucking effect and magnetic field parameters and characteristics.
20 The sensor system 604 may further include at least one actuator 612 and 614.
Although shown as multiple actuators 612 and 614, the actuators 612 and 614 may be
replaced by a single actuator. The first actuator 612 may move the first magnet 608
along the longitudinal axis of the sensor system 604 and the second actuator 614 may
similarly move the second magnet 610. In other embodiments, the actuators 612 and
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614 may also move the magnets 608 and 610 horizontally, rotationally, or in any three
dimensional direction. The motion of the magnets 608 and 610 toward or away from
each other adjusts the bucking effect utilized by the sensor system. In another
embodiment, the actuators 612 and 614 may determine or indicate the relative
5 positions of the magnets 608 and 610 for determining the parameters and effects of
the magnetic field.
In one embodiment, where the sensor system 604 and associated drill bit 624 are
being utilized to mill into a casing or attempting to closely follow an external
magnetizable object, the separation distance between the two bucking ring magnets
10 608 and 610 may be adjusted to maximize the flux density at the radius of the drill bit
624 at the same time maximizing the flux density passing through a magnetometer
616 (or gradiometers). In one embodiment, the sensor system 604 is calibrated before
downhole use utilizing a calibration process or the magnets 608 and 610 may be set to
pre-determined positions at the rig site based on requirements for the next bit run.
15 The separation distance of the magnets 608 and 610 may be managed downhole in
real time to adjust the focus of the radial field. For example, the position sensor 628
may be utilized to determine adjustments for adjusting the field. In one embodiment,
at least one ring magnet (e.g. magnet 608) is attached to an actuator 612 (e.g., a
sliding piston) that is actuated to move the ring magnet 608 closer or further away
20 from the other ring magnet 610. In one embodiment, ring magnets 608 and 610 may
be cylindrical with a hollow or filled core.
It may be preferable to move both magnets 608 and 610 equi-distant apart along the
longitudinal access of the tool while maintaining the magnetometers 616 and 617 at
the center point of the two ring magnets 608 and 610 with a selected radial offset.
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Adjustments to the position or location of the magnets 608 and 610 may be made to
adjust the peak radial flux point or flux density either further away for closer to the
longitudinal axis of the magnets 608 and 610.
In one embodiment, the magnetometer 617 may also be positioned or integrated with
5 one or more extendable pads 618. In one embodiment, the extendable pads 618 are
positioned at the same longitudinal position on the sensor system 604, but at different
circumferential positions on the sensor system 605, such that the extendable pads 618
are in alignment with the bucking field of the magnets 608 and 610. The extendable
pads 618 may extend or retract radially from the sensor system 604 to aid in
10 optimizing the position of the magnetometer 617. In one embodiment, a pad position
actuator 620 may move the extendable pads 618 away from the longitudinal axis of
the sensor system 604. For example, the extendable pads 618 may maximize the
magnetic flux that passes through or intersects the magnetometer 617 at a focal radius.
By being able to extend the magnetometer 617 closer to a magnetizable structure, the
15 sensitivity of the sensor system 604 to the magnetizable field created in the
magnetizable structure by the bucking magnetic field may be increased. The
magnetometer 617 is moved in a radial direction on the extendable pads 618 along the
sensing axis of the magnetometers.
In one embodiment, the location of the magnetometer 617 may be determined from
20 the pad position actuator 620. In another embodiment, the location of the
magnetometer 617 may be determined by a position sensor 626. For example, the
position sensor 626 may determine the position of the magnetometer 617 on the
extendable pads 618. The position of the magnetometer 617 may be determined
relative to the fixed magnetometer 616.
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In one embodiment, it may further be advantageous to position one stationary
magnetometer 616 on the body of the tool co-aligned with the magnetometer 617 thus
allowing an adjustable radial difference between the two magnetometers 616 and 617
which may be used to change the sensitivity to the magnetic gradient field in a radial
5 direction from the sensor system 604. A radial distance sensor, such as the position
sensor 626, may be used to monitor and calculate the radial difference between the
two magnetometers 616 and 617 to the gradient field with respect to distance between
the two magnetometers 616 and 617 and the distance to the magnetizable structure the
gradiometer senses in the magnetic circuit. Likewise, intensity measurements may be
10 made by us ing either magnetometer 616and617.
In one embodiment, magnetometer 617 may consist of two radially spaced
magnetometers in the extendable pads 618 which may also provide a movable
gradient field measurement using the two magnetometers. Other means of using one
magnetometer at different radial positions of the extendable pads 618 may also be
15 used to measure the gradient field.
In one embodiment, a magnetic field master controller 622 (or processor) may control
the position of the magnets 608 and 610 and any sensors, such as the magnetometer
617. The controller 622 may be communicably coupled to one or more position
sensors 628 and receive input signals from the position sensor on the position of the
20 magnets 608 and 610. In response to input signals from the one or more position
sensors 628, the magnetic field master controller 622 may output control signals to the
multiple actuators 612 and 614, based on one or more control algorithms executed by
the controller, to move the magnets along longitudinal axis of the sensor system,
horizontally, rotationally, or in any three dimensional direction to adjust the bucking
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effect utilized by the sensor system. The one or more control algorithms of the
magnetic field master controller control movement of the magnets 608 and 610 and
the magnetometers 617 (or gradiometer) based on predetermined positions, sensed
position, sensed conditions, automatically implemented algorithms, or in response to
5 commands received from the surface using down link telemetry, such as
electromagnetic communications, acoustic telemetry, drill string variable torsional
telemetry, drill string RPM telemetry, wired pipe, or mud pulse telemetry. As a
result, the position of the magnets 608 and 610, magnetometer 617, or other sensors
may be optimized based upon the conditions, performance of the sensor system 604,
10 or radial distance to a magnetizable structure. In one embodiment, one or more of the
control algorithms are located in the magnetic field master controller. In another
embodiments, one or more of the control algorithms are located in one or more
processors located at the surface, such as a computer, tablet, wireless device, portable
computer or mobile computing system in communication with the magnetic field
15 master controller.
During an intersection process, the radial position of the magnetometer 617 and the
axial position of the magnets 608 and 610 may be adjusted to maximize the reluctance
response as distances from the magnetizable structure change thus self-tuning the
sensor system 604 for a maximum sensitivity. Such adjustments may also be
20 managed by a feedback control system where the extendable pad 618 and magnets
608 and 610 distances and positions are adjusted dynamically to sense for a maximum
signal response to the magnetizable structure. In one embodiment, the sensor system
604 may be dynamically adjusted or variably tuned utilizing the positioning of the
magnets, sensors, and other components or the magnetic field intensity.
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FIG. 6C illustrates the bucking effect of the magnets 608 and 610 in accordance with
the disclosed embodiments. As is well known, opposite poles attract each other and
the flux lines of magnets aligned by opposite poles extend between the poles without
much variation (not shown). However, as shown in FIG. 6C, the positioning of two
5 identical poles of the two magnets 608 and 610 forces the magnetic fields to extend
radially away from the magnets creating the bucking effect herein described.
Turning again to FIG. 6A, the magnets 608 and 610 within the sensor system 604 may
impose a polarizing magnetizing force on a ferrous material or paramagnetic material
in a target object 606. As the drill bit 624 rotates, the skewing of the magnetic field
10 602 may remain transfixed in the direction of the ferrous material of the target object
606 that has been magnetized. As a result, one side of the sensor system 604 may
have a different net magnetic field 602 than under conditions where no ferrous or
paramagnetic material is present (e.g., FIG. 5).
If the polarizing magnetic field from the ring magnets 608 and 610 is strong enough,
15 the ferrous material of the target object 606 may respond with an additive magnetic
field to the polarization field being applied to the ferrous material. Because the
ferrous material of the target object 606 may already possess a remnant magnetic
polarization, the remnant magnetic field may oppose or add to the polarization field
from the ring magnets 608 and 610. As the polarization field strength increases in the
20 ferromagnetic material, the magnetic domains in the target object 606 begin to align
with the polarization field, adding to the overall magnetic field strength in the
magnetic circuit utilized by the sensor system 604. The effects of a magnetizing
response field may also be detected by imparting a time changing polarizing magnetic
field at a desired frequency, such as 10 Hz, to detect the ferrous material more clearly
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through a magnetic induction effect. This may be achieved by using electrical coil
windings as the bucking magnetic field source or as a supplement to the magnetic
field from permanent magnets thus creating both a static and dynamic magnetic
polarization field to be applied to the surroundings of the sensor system 604.
5 If the remnant magnetism in the ferrous material is in an opposing dipole alignment,
such as a North polarizing field facing a North remnant field, the net magnetic field
strength or the magnetic gradient sensed by the magnetometer 616 or gradiometer
may actually be less than what is detected on the non-ferrous side. As a result, the
variance in the static magnetic field strength may be used as a location guide as to
10 where the ferrous structure is regardless of whether the magnetization field of the
ferrous material is currently additive or subtractive of the net magnetic field or
magnetic field gradient sensed at the magnetometer. In one embodiment, the magnets
608 and 610 may provide enough polarizing magnetic field to urge the ferrous
material of the target object 606 into as much magnetic alignment to create an
15 additive magnetizing field to the polarizing field being applied. The magnets 608 and
610 may provide a sufficient polarizing field to drive the nearby ferrous material into
or near magnetic saturation, such that the vast majority of the magnetization field
strength is available for sensing by the reluctance sensor. The data determined by
sensing the differences in magnetic flux are utilized to determine a distance or
20 direction to the target object 606.
Turning now to FIG. 6D, in another embodiment, magnetically permeable guides 625
within a house 621 may alter the magnetic flux path generated by the magnets 608
and 610 by guiding the flow along a more desirable radial path. In one embodiment,
the magnetically permeable guides are formed from a highly permeable material that
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has low resistivity to magnetic flux, such as soft iron, ferrite, or permalloy. The
magnetically permeable guides 625 may guide the flux through a path as shown and
the sensors 623 may be positioned in the path. The magnetically permeable guides
625 may be attached to the ends of the magnets 608 and 610 or in close proximity to
5 the ends of magnets 608 and 610. The magnetically permeable guides 625 may
reduce the air gap and better shape the magnetic field utilized.
As previously described, the sensors 623 may represent magnetometers, gradiometers,
or other magnetic field sensors. The magnetically permeable guides 625 may alter the
magnetic flux path by guiding the flux along a more desirable radial path and
10 positioning the sensors 623 in that path. For example, a gradiometer may be
positioned at a center point of the outter radius of the magnetically permeable guide.
The sensors 623 may also be positioned on moveable of fixed pads as is described
herein. In other embodiments, magnets may be polarized or bent into the desired
shape to maximize radial field strength.
15 Turning now to FIGs. 7A-C showing a schematic, pictorial representation of a
steerable drilling tool 700 being utilized to intersect a well 702, which may be an
existing or target well, in accordance with the disclosed embodiments. On occasion it
becomes necessary to drill an intersecting well 704 utilizing the drilling tool 700 to
correct for a problem or obstruction 708 within the existing well. For example, the
20 intersecting well 704 may be a relief well drilled to deal with a blowout on an upper
end of the well 702. In some instances only fluid communication between the two
wells is required. However, the situation may arise where it is desired to re-enter the
lower portion of an existing well so completion or work over equipment may be
accessed or deployed into the lower existing well portion. Such equipment may
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include, but is not limited to, sand screens, bridge plugs, liners or casing, packers,
multi-lateral junctions or any other permanent or temporary equipment, such as data
pressure recorders, flow meters, hydraulic fracturing equipment, sand vacuum,
bailers, fishing equipment, stimulation equipment, cementing equipment, or work
5 over tools. The intersection may also permit the permanent plugging of the hole
section by permitting cementing equipment or cement into the intersected well.
In many cases, it may be difficult to intersect the well 702. For example, it may be
difficult to intersect a magnetizable metal tubular 710, such as the casing or liner of a
well dead center. An operator may utilize a specialized mill 712 to drill into the
10 tubular 710 of the well 702 as shown in Figures 7B and 7C. For example, a milling
bit or mill 712 may be utilized for performing intersections of the metal tubular 710.
The mill 712 may be designed to cut steel or other hardened materials. In one
embodiment, the azimuthal profiles of a cut aperture into the well 702 may be
monitored as the profile of the reluctance measurements change to indicate whether
15 the mill 712 is centered when drilling into the tubular 710 of the target well. For
example, the azimuthal profiles (also referred to as reluctance profiles) may represent
the magnitude of the magnetic field sensed along the circumference of the tool.
In one embodiment, polar responses 714 and 716 (e.g., graphical representations of
the reluctance profile for a given radial direction using cylindrical coordinates) of the
20 magnetizing field strength measured by the reluctance sensor from the tubular 710
may be utilized to determine a direction and simulate an interface of the mill 712 and
the tubular 710. For example, the azimuthal profile or reluctance profile may
represent the data/measurements taken by the sensors and the polar responses 714 and
716, shown in one example as a graph in a Cartesian chart, may represent a display
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presented to a user for analysis. As a result, the steering may be modified to keep the
tool face of the steering system in the middle of the tubular 710 to perform a proper
and effective intersection. Although such an operation is not typically done for
blowouts, it may be utilized to reenter the tubular 710 when there is an obstruction
5 708 or a sheared or collapsed section of the well 702 above the intersection point.
The steerable drilling tool 700 may also be utilized to detect a lateral opening in a
casing string or down hole component. As a result, a steering member, may be
deflected, turned, or oriented towards the opening to facilitate entry.
FIG. 7B shows the mill 712 correctly intersecting with the tubular 710 based on the
10 physical interaction and the polar response 714. FIG. 7C shows the mill 712 skewed
to one side indicating that the mill 712 and the tubular 710 are not properly aligned.
The polar plot, response, or profile of the polar response 716 indicates that the tool
face direction is not positioned directly toward the center of the tubular 710. By
monitoring the polar responses 714 and 716 of the magnetizing field sensed by the
15 reluctance sensor, the sensor system (or alternative a user) may more accurately align
the tool face, such as the mill 712, during the milling operation to achieve reentry or
at least intersection back into the tubular 710. For example, the mill 712 may be
utilized to reenter an opening or component at a previously generated or occurring
opening or location. The sensor system may then be able to avoid skipping the mill
20 712 off of the tubular 710 especially if the earth formations around the intersection
point are soft.
The reluctance measurements may be binned azimuthally into arc segments of the
azimuthal profiles of the polar responses 714 and 716 of the tool and may include a
depth position or time of measurement of the sensor and mill 712, bit, or other
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intersection device, such as a laser cutter or high velocity fluid cutting jet, which may
be utilized for steering for any number of milling or drilling operations and to monitor
the progress of the milling into the target well, such as in a reverse multilateral or well
intersection where the window is milled from the outside into the target well after the
5 tubular 710 has been installed. Data sent from the sensor(s) to the steering controller
or operator on the surface may monitor the sensor response verses direction by for
example plotting the magnitude and direction of the sensed magnetic field strength or
gradient that surrounds the sensor.
The steering controller is one or more downhole tools for steering the drill string. It
10 may include the a bottom hole assembly and a sensor system with the corresponding
drill bit. For example, the steering controller is a rotary steerable tool for downhole
directional drilling and exploration. The steering controller may be configured to
rotate, bend, actuate, or otherwise change directions, positions, and orientation. The
steering controller may function automatically or based on operator instructions
15 received from a surface computer or from other surface devices.
In one embodiment, data sent to surface may be limited to the magnitude and
direction of peak values and direction of sensed field strength around the
circumference of the tool sensor. Higher data densities may permit a magnitude
profile to be tracked vs. depth or time on the polar profile of the polar response 716.
20 Turning now to FIGs. 8A-C showing a cross sectional view of a sensor system in
accordance with the disclosed embodiments. In one embodiment, the sensor system
800 may include a housing 802, a ring magnet 804, a drive shaft 806, and a flow bore
808.
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In one embodiment, the ring magnet 804 represents one or more permanent magnets.
In another embodiment, the ring magnet 804 may represent one or more
electromagnets or a combination of electromagnets and permanent magnets.
Electromagnets may allow the magnetic field to be adjusted in real-time or apply a
5 time varying magnetic field and may be more effective for high temperatures. The
power used for the electromagnets may be adjusted to a desired level with a DC bias
current to urge the magnetization of the ferrous target material into a desired magnetic
polarization in line with the applied polarizing field of the electromagnets while still
optionally including a time varying current.
10 Many possible types and orientations of permanent and electromagnets may be used
to effect magnetization of the target material. For example, a focused field technique
that has a radial focus along the longitudinal axis of the tool rather than along the
cross axis of the tool as was shown earlier may be utilized. In this configuration the
polarizing field affecting the ferrous target has an alternating magnetization response
15 as the shaft is rotated. By placing the sensor in a radial position, in a radial sense
direction, ideally between an S-S or an N-N pole the reluctance changes of the
magnetic circuit may be sensed as the ferrous target material comes into as sensing
range of the sensor during rotation. For non-rotating sensors, such as when sliding
with a mud motor where the sensor is on the mud motor body (and not the output
20 shaft) or in a non-rotating housing of a rotary steerable tool, a number of sensors
around the circumference of the tool may be used to distinguish the direction of the
magnetizable object relative to the cross axis of the tool.
Other configurations are possible as well as other directional polarization of the
magnetic source. The illustrative embodiments are configured where the objective is
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to force as much magnetic flux as possible into a radial direction away from the
longitudinal axis of the tool. Using ring magnets to buck a magnetic field radially
from the longitudinal axis offers the advantage that the longitudinal length of the
magnetic may be increased easily by adding more height to the magnet structure and
5 therefore results in a stronger radial polarizing magnetic field. Whereas, other
geometries may run out of available space for larger magnets as the magnetic field
strength increase becomes a function of the hole diameter.
The data collected by the reluctance sensor may be transmitted through an electrical
conductor with or without slip rings or other rotational electrical couplings. In
10 another embodiment, the data may be transmitted via a short hop wireless
communication to a long haul telemetry system or a steering controller, such as a
rotary steerable tool or a toolface control system on surface or downhole so that
directional calculations, actuations, adjustments, or so forth may be implemented. A
downhole device such as an orienting tool may be used on top of the BHA or the
15 drilling motor that adjusts angular position of the toolface bend direction of the
drilling motor in the desired direction for steering relative to the magnetizable target
structure. The control of this steering by any of these surface, downhole steering, or
orienting systems may be performed based on an automated response by the steering
controller in response to the positional data received from the reluctance sensor such
20 as keeping the steering on a desired intersection or follow trajectory. Hence, the
sensor system 800 may be utilized in conjunction with an autonomous steering system
where a pre-defined steering objective (e.g., intersection with a well or structure) is
preprogrammed into the downhole or surface steering controller or reprogrammed
from the surface as needed through instructions transmitted on a down linked
25 telemetry system, on surface, or near the surface, such as a mud pulse telemetry
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system or other telemetry methods disclosed herein. The steering system may utilize
data from the sensor system 800 to follow a path relative to the target well or intersect
the target well at a desired depth. Formation data may also be referenced with offset
data stored in the downhole steering assembly to track wherein the bottom of the hole
5 is relative to a desired path and intersection point if applicable. Further, the steering
controller may automate the intersection action when a favorable formation is sensed,
such as a high compressive strength formation rather than a soft formation
surrounding the target material.
The data read by the sensor system 800 may be transmitted to the surface and
10 processed at the drilling site or offsite such as in a real-time operations center
remotely located from the drilling site via a communications data network,. Steering
commands may be communicated back to the downhole assembly over a downlink
communications telemetry system on surface or near the surface, such as through a
mud pulse, wired pipe, electromagnetic telemetry, acoustic telemetry, torsion
15 telemetry, seismic communications, or so forth. In another embodiment, the magnetic
field may be generated by the use of electromagnets instead of the ring magnet 804.
In FIG. 8B, the sensor system 800 may include magnetometers 810. In one
embodiment, the magnetometers 810 represent radially oriented sense axis
magnetometers ideally aligned in an exact center portion between the two bucking
20 magnets to sense the maximum bucking field radially extending from the sensor
system 800. While an array of magnetometers 810 is shown in this embodiment.
Only one magnetometer or gradiometer is needed if the near-bit sub housing the
sensor system 800 is rotating and a tool face direction sensor (not shown) may be
utilized to measure the profile of the magnetic field and thus the magnetic reluctance
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over the circumference of the sensor system 800 to determine magnitude and direction
of the magnetic intensity or the magnetic gradient in an azimuthal manner. In general
the toolface direction sensor may be measured using two orthogonally oriented
accelerometers, for example, one each on either the X or Y cross longitudinal axis
5 direction. These accelerometers may be used to sense the high side of an inclined
hole. In another embodiment the sensor system 800 may adjust steering based on the
sensed magnetizing field from the reluctance sensors.
Hence, the use of a number of magnetometers 810 may eliminate the need for a
directional reference since a sensed azimuthal profile of the magnetizing field from
10 the ferrous material may be sensed. In another embodiment, the sensor system 800
may reference a home position of the drill tool or steering assembly, such as a bend
direction of the steering assembly. As a result, the need for a high side or magnetic
reference may be eliminated and replaced with a position sensor that monitors the
orientation of the drive shaft 806 relative to a default, home, or starting point of the
15 rotational path of the shaft. For example, a Hall effect sensor may be wired to the
drive shaft 806 and then to the processor of the sensor system 800 to determine at
what point in rotation the sensor is at relative to the tool face of the steering tool. The
magnetometers 810 may use the sensed change in the background earth magnetic field
as rotation progresses to determine where in the rotation each magnetometer 810 is to
20 resolve the direction of the target object relative to the tool face of the steering tool.
A directional reference sensor may also be combined with the magnetometers 810
when the rotation is stopped by triangulating and resolving where the peak field
strength is sensed to be by the magnetometers 810. A directional reference sensor,
such as a gyroscope may also be used to aid on maintaining an orientation relative a
25 fixed direction. The sensor system 800 may utilize this information to determine a
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direction to the target relative to the high side of the drilling tool or other reference
point.
The magnetometers 810 may be designed to measure an azimuthal magnetic field
strength profile around the circumference of the tool to facilitate a non-rotation
5 condition, such as a Hall Effect sensor, coil loop, or a flux gate designed for high
magnetic field strengths. In another embodiment, the sensor system 800 may employ
an AC only sensor that responds only to the rate of change of the external magnetic
field. For example, the sensor may utilize an induction sense coil winding co-axial
with the direction of the polarizing magnetic field coming from the magnetic source
10 in the reluctance sensor. As the drill bit sweeps across high and low magnetically
permeable zones, an inductive response is created in the coil windings which may
then be routed to the sensor electronics. The higher the rate of change of magnetic
flux density across the cross axis of the sensing coil, the more electromotive force
(EMF) is induced in the coil resulting in more current and a greater voltage for the
15 sensor circuitry to sense. The sensor system 800 may also be configured to monitor
the revolutions per minute (RPM) of the drive shaft 806 to know how vast the
magnetometers 810 or other sensing coils are passing through the varying magnetic
flux due to the presence of a magnetizable target.
In FIG. 8C, the sensor system 800 may include gradiometers 812. The gradiometers
20 812 may represent pairs of radially spaced and radial sense co-alignment
magnetometers in a direction in the cross plane of the longitudinal axis of the tool.
The distance between the matched gradiometers 812 may be optimized for each part
to measure the radial gradient field where there is peak sensitivity to changes in the
radial field strength. For example, the inner magnetometers of the gradiometers may
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be placed in a position where a sizeable portion of the radial magnetic field exists. In
another embodiment, the utilization of the magnetometers 810 or gradiometers 812
may be utilized to perform dynamic ranging. The sensor system 800 may also be
utilized with an active ranging system that uses AC electric current excitation in the
5 target material which then emits a characteristic magnetic field in the circumference
direction of the electric current flow direction. The sensor system 800 may be utilized
to sense the magnetic field from the current flowing on the target from the external
excitation source. As a result, the sensor system 800 may be a combination device.
FIG. 9 is a schematic, magnetic circuit representation of a sensor system 900 in
10 accordance with the disclosed embodiments. An air gap is a resistance to the flow of
magnetic flux flowing in a highly magnetically permeable material, such as the
permanent magnets or magnetically permeable metal of a tubular which may
represent a target 902. The magnetic intensity (H) of the permanent magnets 904 may
be controlled. The two magnetic flux sources, represented by electromagnets 904
15 may buck in the middle forcing the flow of flux out in the a first gap (Gl) which may
represent a radial launch of the bucking field away from the drilling tool. The
electromagnets may also be replaced with permanent magnets in the same polar
orientation. The orientation of the poles may be inconsequential so long as both of
the north poles or both of the south poles of the permanent or electromagnets are
20 converging together in the magnetic circuit. In another embodiment, one magnetic
source may be a permanent magnet while the other magnetic source may be an
electromagnet. Alternatively, a magnetic source may be a combination of a
permanent magnet and an electromagnet.
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A portion of the magnetic circuit of the sensor system 800 may include the magnetic
source on the source side of the circuit. In this case, the magnetic flux may be
directed or redirected around the magnetic circuit using preferably highly
magnetically permeable material, such as soft iron to route the magnetic flux to a
5 desired exit and entry point in the magnetic circuit. In the examples shown thus far,
there has been no addition of permeable material in the magnetic circuit other than the
magnetic source itself. This is not to say, however, that the magnetic flux may not be
routed into a desired direction by flowing the flux through a magnetically permeable
material in the sensor. See for example in FIG. 6B which shows the extendable pad
10 618 containing the magnetometer 616, a portion of magnetically permeable material
may be placed in front of or behind the magnetometer 616 to reduce the flux gap
losses and concentrate more flux through the sensing axis of the magnetometer 616
and the magnetic permeable guides 620 of FIG. 6D as well.
Turning now to FIG. 8D, the housing 802 and drive shaft 806 may be formed of a
15 non-magnetic material, such as Austenitic stainless steel, Inconel, or other materials
utilized for load bearing bottom hole assemblies. The non-magnetic materials may be
utilized so that the target object is the only component to reduce the magnetic circuit
loop resistance of the magnetic field of the sensor system 800 as the target comes into
or leaves from the sensor range of the sensor system 800. As a result, the housing 802
20 and the drive shaft 806 do not significantly affect the magnetic field. As shown, the
ring magnets 804 may be radially positioned around the drive shaft 806. The
gradiometers 812 may be positioned between the ring magnets 804 to better sense
changes in the magnetic flux.
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Turning again to FIG. 9, the magnetic flux flows through the low magnetically
permeable gap of drilling fluid and the formation until it reaches the highly
magnetically permeable material of the target 902 where the resistance to the
magnetic flow of flux is very low in comparison (e.g., typically 1000-3500 times
5 better). Lower gaps 906 and 908 (G2 and G3) is wherein the flux leaves the target
902 and returns back through a lower and upper side of the sensor system 900 which
in this case is the South pole between the magnets 904 (e.g., an upper and lower
permanent magnet). It should be understood that a magnetometer may also be
positioned in the lower gaps G2 and G3 906 and 908, but as one can see the flux
10 density in G2 and G3 906 and 908 is less, thus, the Gl position offers the best
location for flux density and thus sensing a change in the magnetic circuit flux
intensity or gradient.
In one embodiment, by placing a magnetometer 901 in the Gl position just as the
bucking field extends radially, the sensor system 900 may then monitor changes in
15 reluctance, gap distance, or magnetic material bulk of the target 902 by determining
how much flux density or magnetic field strength changes at this position. For
example, as the air gap increases, the flux density may decrease. Variations in the
magnitude in flex density sensed through the sensor system 900 may be utilized to
determine relative and absolute distance to the target 902. To obtain absolute distance
20 may require knowledge of the shape and magnetic permeance of the target 902. The
distance to the target 902 as sensed and calculated by the sensor system 900 may be
utilized to take any number of steering or avoidance actions.
In one embodiment, the magnetometer 901 may be placed on a bucking side
essentially doubling the flux density from the magnets 904 passing through that side
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of the sensor system 900. The orientation of the poles of the magnetic fields may be
altered to create an azimuthal sensitivity for the magnets 904 that may affect a
magnetizable material in the target 902. In one embodiment, the bucking field
provides a method of targeting a specific direction or object with or without rotation
5 of the sensor system 900. In another embodiment, utilizing a single cross axis magnet
may be utilized to determine the distance and direction to the target 902.
The sensor system 900 may utilize an algorithm for subtracting the neutral field from
the measured field to give a user or system an indication of components of a sensed
signal that are from the magnetizing effects of the magnetizable materials in the target
10 as compared to the static shape of the magnetic field imposed by the reluctance
sensor. Hence, only the magnetizing field is used in the calculation and the polarizing
field is removed from the calculation since it is known. The polarizing field may be
best determined when the sensor system 900 is in an environment where there is no
magnetizable material nearby that would create a magnetizing field. This reading or
15 value may be utilized to establish a compensation, bias, or nulling value for the sensor
which can be subtracted from future measurements.
FIG. 10 is a schematic, representation of a downhole sensor system 1000 within a
tubular 1002. In one embodiment, the tubular 1002 may represent a casing or liner.
The sensor system 1000 may be placed anywhere within a drill string 1004. For
20 example, the sensor system 1000 may be placed above a steering assembly or further
up in the drill string 1004 to help monitor wear on the tubular 1002 especially in the
casing or liner of "while-drilling" applications where the casing or liner is
reciprocated. In one embodiment, the sensor system 1000 is azimuthal and may look
for signs of eccentric or concentric wear in the tubular 1002 from the drill string 1004
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as the hole depth in the wellbore increases and the tubular 1002 experiences increased
abrasion from friction on the bore wall.
In one embodiment, the sensor system 1000 may include a number of sensors or
systems at a desired intervals or positions along the drill string 1004. For example,
5 the distinct sensor systems may be utilized to monitor casing/liner wall thickness. In
conventional drilling with the drill string the casing or liner is stationary. As metal in
the tubular 1002 is worn off by the rotating drill string, the strength of the permeance
(inverse of reluctance) of the magnetizing field from the casing or liner is diminished.
As a result, determinations of thickness or changes in thickness may be performed by
10 the difference in magnetizing field resulting from the metal being rubbed or shaved
away from the tubular 1002. In one embodiment, the thickness of the casing is logged
and utilized to measure and anticipate future issues or failures. For example, the
measured casing thickness may be measured at specific depths within the casing and
these values may be compared to previous measurements or expected responses to
15 detect the absence of ferrous material which is indicative of casing wear (e.g., higher
reluctance, lower permeance detected by the magnetic circuit of the sensor system
1000).
For example, FIG. 10 illustrates a typical key seat profile where the drill string 1004
including various pipes and interconnected components is rubbing one side of the
20 tubular 1002 and wearing it down. The sensor system 1000 may have a model for the
expected permeance of the casing or may be measured in a new or competent section
of a casing first (as a default or golden standard) and then a reduction of the
permeance of the rest of the tubular 1002 may be measured to calculate deterioration
and wear. This wear information may be utilized to make changes to the drilling
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operation to stop drilling and put in place measurements, devices, systems, or
processes to protect the tubular 1002 from further damage if the amount of damage
begins to approach threshold levels that indicate potential danger or permanent
damage beyond acceptable limits. The sensors may be positioned throughout the drill
5 string 1004 to monitor changes in the permeance and repeatedly measure areas with a
new sensor system as drilling continues to compare results from the first pass with the
next pass to see if any notable changes have occurred. This information may be
utilized to determine how the drill string is riding within the tubular 1002.
In one embodiment, the sensor system 1000 may be referred to as a caliper. The
10 sensor system 1000 may be used to measure the relative standoff (or distance
between) of the reluctance sensor of the sensor system 1000 from the tubular 1002 to
account for being off center as is shown in FIG. 10 to get a better image of the wall
thickness of the tubular 1002 for a full 360 degree view and analysis of the tubular
1002.
15 A telemetry or communications module in communication with or integrated with the
sensor system 1000, such as wired drill pipe, may be individually address each sensor
in the drill string on a data network and communicate the measurements and readings
from each sensor to the surface or another location in the drill string, such as the
MWD/LWD system in the BHA. In another embodiment, a wireline tool may be
20 inserted within the wellbore to interrogate the sensor system 1000 through a wireless
connection (e.g., inductive coupling, Bluetooth, radio frequency, near field
communications, WiFi, etc.) for recorded data. For example, a dart carrying a
communication interface to sensor system 1000 and having data storage capabilities
may be pumped to the depth of each the sensor system 1000 to retrieve the data then
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later retrieved after all desired sensors have been interrogated and data retrieved from
them. The measurements taken by the sensor system 1000 may be communicated
through the drill string 1004, using wired drill pipe, wirelessly, seismically,
acoustically, magnetically, electromagnetically, torsionally or utilizing any number of
5 other communications methods applicable to downhole tools. In one embodiment,
each sensor system 1000 may include a telemetry or communications module for
periodically transmitting data, information, and measurements to the surface.
Turning now to FIGs. 11 and 12 are a schematic, representation of a steerable drilling
tool 1100 or hole finder tool being utilized with a branched well 1102 in accordance
10 with the disclosed embodiments. One embodiment, a sensor system 1104 may be
configured to find an orientation of an aperture in the casing of the branch 1102 often
called a multilateral window. For example, as shown in FIGs. 11 and 12 the branch
12 1102 may include a branch that separates from the main bore. The sensor system
1104 including one or more magnetometers 1106 or gradiometers may be
15 alternatively be placed differently, such as above a pivot arm 1108, as part of a
housing, motor, or other drill string component.
Detection of the branch may allow the tool 1100 to be oriented to enter the branch.
For example, the operator may be able to avoid having a bend in the mud motor of the
steerable drilling tool 1100, such as a down hole adjustable bent housing or a work
20 over tool may be pointed toward the branch. In other embodiments, other assemblies
besides steerable assemblies may be run with this sensor to aid completions
equipment, work over equipment, cementing equipment, fracturing equipment or any
other temporary or permanent install equipment to be selectively guided into or away
from a lateral junction. The sensor system 1104 may also be utilized to detect where
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a casing collar is in the target well which may be utilized for recording, depth
tracking, or information generation. For example, the information may be utilized to
create a three dimensional model or database of available information about the
branched well. Likewise the sensor system 1104 may be used to detect casing collars
5 when the sensor is in an adjacent bore to the target well and in this manner track the
depth of the sensor relative to the target well.
FIG. 13 is a block diagram of a drilling system 1300 in accordance with the disclosed
embodiments. In one embodiment, the drilling system 1300 may include a number of
components including at least a reluctance sensor system 1310, a bottom hole
10 assembly 1330, and a surface system 1350.
The various components of the reluctance sensor system 1310, bottom hole assembly
1330, and surface system 1350 may be connected by pins, wires, traces,
communications connectors, leads, fiber optics, or other communications or
conductive components. In another embodiment, all or a portion of the acoustic tool
15 may be integrated in a single circuit or ASIC.
The bottom hole assembly 1330 may include a long haul telemetry system 1332, a
logging while drilling tool 1334 (or MWD, SWD, logging only, etc.), a steering
controller 1336, orientation sensors 1338, and a short hop transceiver 1340.
The surface system 1350 may include a surface computer 1352, a visual display 1354,
20 a memory 1356, a data downlink 1358, and a data receiver 1359. The surface system
1350 may further communicate with a surface orientation controller 1360 and a digital
network 1362.
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The reluctance sensor system 1310 may include at least one
gradiometer/magnetometer or a gradiometer/magnetometer array 1312 (making up the
reluctance sensor sensing portion), a sampling digitizer 1314, and sensor system
processor 1316, a short hop transceiver 1318, orientation sensors 1320, and a memory
5 1322. As shown the gradiometer/magnetometer array 1312 may include a single
array of magnetometers or a paired set of gradiometers disposed proximate one
another about the periphery of the reluctance sensor system 1310.
The sensor system processor 1316 may represent one or more processing units or a
microcontroller. A microcontroller is a small computing component on a single
10 integrated circuit including, for example, a processor, core, memory, and
programmable input/outputs. In one embodiment, the microcontroller may be an
application-specific integrated circuit (ASIC) or field programmable gate array
(FPGA).
The sensor system processor 1316 is circuitry or logic enabled to control execution of
15 a set of instructions. The processor may be one or more microprocessors, digital
signal processors, application-specific integrated circuits (ASIC), central processing
units, or other devices suitable for controlling an electronic device including one or
more hardware and software elements, executing software, instructions, programs,
and applications, converting and processing signals and information, and performing
20 other related tasks. The sensor system processor 1316 may be a single chip or
integrated with other computing or communications elements. The sensor system
processor 1316 and other components of the sensor system 1302 may be hardened for
downhole conditions including shock, temperature, and pressure resistance, water
proof or resistant, and so forth.
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The sensor system processor 1316 or other component of the reluctance sensor system
1310 may control operation of a drill tool by sending commands for changing
direction, altering rotation speed, decoupling, stopping or starting one or more motors,
bits, cutting tools, or rotation devices, or sending other commands or instructions to
5 components of the drilling system 1300. The commands may be made based on
changes in parameters or measurements of the magnetic field intensity, reluctance,
permeance, magnetic flux density, or other parameters.
The memory 1322 is a hardware element, device, or recording media configured to
store data for subsequent retrieval or access at a later time. The memory 1322 may be
10 static or dynamic memory. The memory 1322 may include a hard disk, random
access memory, cache, removable media drive, mass storage, or configuration suitable
as storage for data, instructions, and information. In one embodiment, the memory
1322 and sensor system processor 1316 may be integrated. The memory may use any
type of volatile or non-volatile storage techniques and mediums.
15 The sampling digitizer 1314 may be configured to digitize data samples read by the
gradiometer/magnetometer array 1312. In one embodiment, the sampling digitizer
1314 may include analog-to-digital converters that convert the signals received from
the gradiometer/magnetometer array 1312 into digital signals that may be processed
by the sensor system processor 1316.
20 The orientation sensor 1320 may include any number of accelerometers, levels,
compasses, gyroscopes, rotation rate sensors, home position sensors and other sensors
for determining the orientation of the sensor system 1310 including additional
portions of a drill string.
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The short hop transceiver 1318 may be configured to communicate with the bottom
hole assembly through a wired or wireless connection. The short hop transceiver
1318 communicates data with the short hop transceiver 1340. The data may be raw
data or processed data based on the configuration of the sensor system 1310. In one
5 embodiment, the data is processed so that the steering controller 1336 may make
automatic adjustments the direction, speed, and orientation of the sensory system
(including a drill or milling bit) based on the data.
The LWD tool 1334 may include any number of components typically utilized
downhole. The long haul telemetry system 1332 may be configured to communicate
10 with the data receiver 1359 of the surface system 1350 and the data downlink 1358.
The communications may be performed through wireline systems, the drill string,
wirelessly, acoustically, magnetically, or utilizing any other communications system
suitable for communicating with the bottom hole assembly 1330 when positioned
downhole. In another embodiment, the data receiver 1359 and the data downlink
15 1358 may represent a single transceiver.
The orientation sensors 1338 may similarly determine the direction, orientation, and
position of the bottom hole assembly 1330. The steering controller 1336 is one or
more downhole tools for steering the drill string including the bottom hole assembly
1330 and the sensor system 1310 with the corresponding drill bit. For example, the
20 steering controller 1336 may be a rotary steerable tool for downhole directional
drilling and exploration. The steering controller 1336 may be configured to rotate,
bend, actuate, or otherwise change directions, positions, and orientation. The steering
controller 1336 may function automatically or based on operator instructions received
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from the surface computer 1352, surface orientation controller 1360 or devices in
communication with the surface computer 1352 through the digital network 1362.
The surface computer 1352 may represent one or more networked computing and
communications devices. The surface system 1350, bottom hole assembly 1330, and
5 sensor system 1310 may execute specific sets of instructions, programs, steering or
avoidance algorithms, or so forth. In other embodiments, ASICs, programmable
logic, or hardware may be utilized to implement the described processes.
The visual display 1354 may be a computer monitor, television, tablet computing
device, smart glass, heads up display, or other visual display device. Any number of
10 other peripherals may also be utilized with the drilling system 1300. The memory
1356 (as well as the other memories of the drilling system 1300) may be utilized for
temporary or long term storage. For example, the memory 1356 may include one or
more databases for storing data received from the sensor system 1310 for utilization
by the various devices and components of the drilling system 1300 as well as for
15 subsequent recording and simulation purposes.
The surface orientation controller 1360 may represent any number of controllers for
controlling all or portions of the surface system 1350, bottom hole assembly 1330,
and the sensor system 1310. For example, the surface orientation controller 1360 may
be utilized to control a mud motor. The digital network 1362 may include any
20 number of wired, wireless, private, public, or other networks. Any number of
connected systems, devices, or equipment may communicate with the drilling system
1300 utilizing the digital network 1362.
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In addition to the embodiments described above, many examples of specific
combinations are within the scope of the disclosure, some of which are detailed
below.
Example 1. A drilling apparatus that includes a drill bit; a steering controller that
5 steers the drill bit; a downhole steering system coupled to the drill bit and comprising
a steering controller; a reluctance sensor system comprising at least one sensor and
two or more magnets positioned to create a bucking effect; and a surface computer
communicably coupled to the at least one sensor and the steering controller, where
the surface computer contains a set of instructions that, when executed by the surface
10 computer, cause the surface computer to receive magnetic flux measurements from
the sensor, determine a distance or direction to a target object based in part on the
magnetic flux measurement; and transmit the determined distance or direction to the
steering controller.
Example 2. The drilling apparatus according to example 1, wherein the bit is a
15 milling bit.
Example 3. The drilling apparatus according to example 1 or 2, wherein the
reluctance sensor system is integrated with the drill bit.
Example 4. The drilling apparatus according to example 1, 2 or 3, wherein the surface
computer determines an azimuthal profile associated with the changes in magnetic
20 flux to determine a direction of the drill bit relative to the target object.
Example 5. The drilling apparatus according to example 1, 2, 3 or 4, wherein the two
or more magnets creating a bucking effect for extending the magnetic field radially
from a longitudinal axis of the drilling apparatus.
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Example 6. The drilling apparatus according to example 1, 2, 3, 4 or 5, wherein the
two or magnets are connected to actuators for positioning the two or magnets relative
to each other in response to commands from the surface computer.
Example 7. The drilling apparatus according to example 1, 2, 3, 4, 5 or 6, wherein the
5 reluctance sensor system including a housing of the reluctance sensor is formed of a
non-magnetic material.
Example 8. The drilling apparatus according to example 1, 2, 3, 4, 5, 6 or 7, wherein
the reluctance sensor system includes an array of gradiometers for sensing the
changes in the magnetic flux.
10 Example 9. The drilling apparatus according to example 1, 2, 3, 4, 5, 6, 7, or 8,
wherein the steering controller utilizes the change in magnetic flux to steer the drill bit
toward the target object for autonomous intersection.
Example 10. A sensor system that includes a plurality of magnets positioned to
generate a magnetic field with a bucking effect; a plurality of magnetometers; a
15 magnetic field master controller communicably coupled to the plurality of
magnetometers, where the magnetic field master controller contains a set of
instructions to receive measurements from the magnetometers corresponding to
changes in reluctance of a magnetic flux of the magnetic field generated by the
plurality of magnetics, and to determine a distance or direction to a target object based
20 on the magnetic flux measurements; and a transceiver for communicating the
distance.
Example 11. The sensor system according to example 10, further comprising one or
more orientation sensors for determining an orientation of the sensor system.
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Example 12. The sensor system according to example 10 or 11, wherein the sensor
system rotates with a connected drill bit.
Example 13. The sensor system according to example 10, 11 or 12, wherein the
sensor system communicates with a bottom hole assembly including a steering
5 controller for guiding a drill bit.
Example 14. The sensor system according to example 10, 11, 12 or 13, wherein the
magnetic field master controller determines an azimuthal profile associated with the
changes in reluctance of the magnetic field to determine a direction to the target
object.
10 Example 15. A method for steering a drill bit in a downhole tool, the method
comprising generating a magnetic field utilizing two or more permanent magnets of a
reluctance sensor system, wherein a same pole of the two or more permanent magnets
face each other to create a bucking effect; measuring changes in magnetic flux
utilizing the reluctance sensor system; determining a proximity to a target object in
15 response to changes in the magnetic flux; and steering the drill bit in response to the
proximity to the target object.
Example 16. The method according to example 15, further comprising determining a
direction and orientation of the drill bit.
Example 17. The method according to example 15 or 16, wherein the determining is
20 performed utilizing a polar plot associated with the changes in magnetic flux.
Example 18. The method according to example 15, 16 or 17, wherein the reluctance
sensor system is integrated with the drill bit.
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Example 19. The method according to example 15, 16, 17 or 18, further comprising
utilizing a bucking effect to extend the magnetic field radially from a longitudinal axis
of the sensor system
Example 20. The method according to example 15, 16, 17, 18 or 19, wherein steering
5 further comprises intersecting the target object utilizing the changes in magnetic flux.
Tn the previous embodiments, reference is made to the accompanying drawings that
form a part hereof. These embodiments are described in sufficient detail to enable
those skilled in the art to practice the invention, and it is understood that other
embodiments may be utilized and that logical, structural, mechanical, electrical, and
10 chemical changes may be made without departing from the scope of the invention.
To avoid detail not necessary to enable those skilled in the art to practice the
embodiments described herein, the description may omit certain information known
to those skilled in the art. The detailed description is, therefore, not to be taken in a
limiting sense, and the scope of the illustrative embodiments is defined only by the
15 appended claims.
In the drawings and description that are included, the drawing figures are not
necessarily to scale. Certain features of the invention may be exaggerated in scale or
in somewhat schematic form and some details of conventional elements may not be
shown in the interest of clarity and conciseness.
20 The previous detailed description is of a small number of embodiments for
implementing the invention and is not intended to be limiting in scope. The following
claims set forth a number of the embodiments of the invention disclosed with greater
particularity.

AMENDED CLAIMS
received by the International Bureau on
16 OCTOBER 2015
(16.10.2015)
1. A drilling apparatus, the drilling apparatus comprising:
a drill bit;
a downhole steering system coupled to the drill bit and comprising a steering
controller;
a reluctance sensor system comprising at least one sensor and two or more
magnets positioned to create a bucking effect; and
a surface computer communicably coupled to the at least one sensor and the
steering controller, where the surface computer contains a set of
instructions that, when executed by the surface computer, cause the
surface computer to receive magnetic flux measurements from the sensor,
determine a distance or direction to a target object based in part on the
magnetic flux measurement; and transmit the determined distance or
direction to the steering controller.
2. The drilling apparatus according to claim 1, wherein the bit is a milling bit.
3. The drilling apparatus according to claim 1, wherein the reluctance sensor system is
integrated with the drill bit.
4. The drilling apparatus according to claim 1, wherein the surface computer determines an
azimuthal profile associated with the changes in magnetic flux to determine a
direction of the drill bit relative to the target object.
5. The drilling apparatus according to claim 1, wherein the two or more magnets are
connected to actuators for positioning the two or more magnets relative to each other
in response to commands from the surface computer.
6. The drilling apparatus according to claim 1, wherein the reluctance sensor system
includes an array of magnetometers, and wherein the reluctance sensor system is
utilized during rotation of the drill bit.
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AMENDED SHEET (ARTICLE 19)
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7. The drilling apparatus according to claim 1, wherein the reluctance sensor system
including a housing of the reluctance sensor system is formed of a non-magnetic
material.
8. The drilling apparatus according to claim 1, wherein the reluctance sensor system
includes an array of gradiometers for sensing the changes in the magnetic flux.
9. The drilling apparatus according to claim 1, wherein the steering controller utilizes the
change in magnetic flux to steer the drill bit toward the target object for autonomous
intersection.
10. A sensor system comprising:
a plurality of magnets positioned to generate a magnetic field with a bucking
effect;
a plurality of magnetometers;
a magnetic field master controller communicably coupled to the plurality of
magnetometers, where the magnetic field master controller contains a set
of instructions to receive measurements from the magnetometers
corresponding to changes in reluctance of a magnetic flux of the magnetic
field generated by the plurality of magnets, and to determine a distance or
direction to a target object based on the magnetic flux measurements; and
a transceiver for communicating the distance.
11. The sensor system according to claim 10, further comprising:
one or more orientation sensors for determining an orientation of the sensor
system.
12. The sensor system according to claim 10, wherein the sensor system rotates with a
connected drill bit.
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AMENDED SHEET (ARTICLE 19)
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13. The sensor system according to claim 10, wherein the sensor system communicates with
a bottom hole assembly including a steering controller for guiding a drill bit,
14. The sensor system according to claim 10, wherein the magnetic field master
controller determines an azimutbal profile associated with the changes in reluctance
of the magnetic field to determine a direction to the target object-
15. A method for steering a drill bit in a downhole tool, comprising:
generating a magnetic field utilizing two or more permanent magnets of a
reluctance sensor system, wherein a same pole of the two or more
permanent magnets face each other to create a bucking effect; measuring
changes in magnetic flux utilizing the reluctance sensor system;
determining a proximity to a target object in response to changes in the magnetic
flux;and
steering the drill bit in response to the proximity to the target object.
16. The method according to claim 15, further comprising:
determining a direction and orientation of the drill bit
17. The method according to claim 15, wherein the determining is performed utilizing an
azimuthal profile associated with the changes in magnetic flux.
18. The method according to claim 15, wherein the reluctance sensor system is integrated
with the drill bit.
19: The method according to claim 15, further comprising utilizing the bucking effect to
extend the magnetic field radially from a longitudinal axis of the reluctance sensor
system.
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AMENDED SHEET (ARTICLE 19)
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20. The method according to claim 15, wherein steering further comprises: intersecting the
target object utilizing the changes in magnetic flux.