Equipment and methods for downhole surveying and data acquisition for a drilling operation

Abstract

An adaptor (64,66) has attachment means to releasably attach a core orientation instrument (60) or survey probe to a drill string component and/or drill string, preferably by one or more screw threads (70, 72, 76, 78), retaining screws, bolts, clips or pins or welding/soldering. Anti release means, such as a circlip, can be used to prevent release of the adaptor. A survey system for obtaining data from a drilling operation includes a core orientation instrument, a downhole survey probe and a common single remote controller/data logger configured to control or communicate with both the survey probe and the core orientation instrument. Further, a survey system includes multiple components arranged in a portable container for transport and deployment at a drilling site include a survey probe, a core orientation instrument and a single controller configured to control or communicate with the survey probe and core orientation instrument.

Claims

1. An adaptor for attachment to an end of a core orientation instrument or survey probe for use in a survey system, and attachment means to releasably attach the adaptor, and thereby the core orientation instrument or survey probe, to at least one drill string component, said adaptor releasably attachable to the instrument or probe by one or more screw threads and, when so attached, additionally retainable to the core orientation instrument or survey probe by at least one retainer.

2. The adaptor according to claim 1, the said adaptor provided at each of two ends of the core orientation instrument or of the survey probe.

3. The adaptor according to claim 1, said adaptor releasably retainable to the instrument or probe by one or more retaining screws, bolts, clips or pins.

4. The adaptor according to claim 1, including a screw thread at one end thereof for releasable engagement with a corresponding screw threaded end of the instrument or probe, and another screw thread at the opposite end of the adaptor for engagement with a corresponding screw thread of another adaptor or a drill string component.

5. The adaptor according to claim 1, said adaptor including at least one aperture through a side wall thereof, said at least one aperture allowing electromagnetic radiation from an electronic instrument to pass to or from the core orientation instrument or survey probe relative, or to allow lubrication fluid to flow through the adaptor, to or from an exterior.

6. The adaptor according to claim 5, wherein the electronic instrument is within the core orientation instrument or within the survey probe and the electromagnetic radiation data is transmitted out of the at least one aperture to an external receiver.

7. The adaptor according to claim 1, further including a subsequent weld connection between the adaptor and the core orientation instrument, the survey probe or the at least one drill string component to prevent subsequent release of the adaptor.

8. A downhole survey system for obtaining data from a drilling operation, the system including at least one adaptor as claimed in claim 1, the core orientation instrument for use in determining orientation of a core sample, the survey probe for use in determining characteristics relating to a borehole created during a drilling operation, and a common controller configured to control or communicate with both the survey probe and the core orientation instrument.

9. The downhole survey system according to claim 8, wherein the common controller includes means to capture or receive progress log of drilling data.

10. The downhole survey system according to claim 9, wherein the common controller is arranged to transmit said progress log of drilling data to the data capture means.

11. The downhole survey system according to claim 8, including one or more adaptors for attachment to an end or both respective ends of the core orientation instrument or survey probe, said adapter(s) arranged to vary the effective diameter of the core orientation instrument or survey probe for attachment to drill string extension components having a respective connecting thread diameter greater than the diameter of a connecting thread of the core orientation instrument or survey probe.

12. The downhole survey system according to claim 11, wherein a said respective adaptor is releasably attachable to the core orientation instrument or to the survey probe.

13. The downhole survey system according to claim 11, wherein a larger diameter adapter is arranged to connect to a smaller diameter said adaptor, or said larger diameter adapter is arranged to replace said smaller diameter adapter.

14. The adaptor according to claim 8, wherein the receiver is a common controller for use in controlling or communicating with the core orientation instrument and the survey probe.

15. The downhole survey system according to claim 1, further including at least one telescopic rod extension for direct or indirect connection to the survey probe or the core orientation instrument.

16. The downhole survey system according to claim 15, wherein the telescopic rod extension includes at least one side wall incorporating or predominantly formed of composite material.

17. A downhole survey system for obtaining data from within a borehole of a drilling operation, the system including at least one core orientation instrument for use in determining orientation of a core sample, the at least one core orientation instrument having an internal communicator, the system further including at least one downhole survey probe for use in determining downhole characteristics relating to a borehole created during a drilling operation, the at least one downhole survey probe having an internal communicator, and the system including a common controller retained at the surface and configured to control or communicate with the respective internal communicator of the at least one survey probe and the at least one core orientation instrument when the respective at least one core orientation instrument or the at least one survey probe is returned to the surface from the borehole.

18. The downhole survey system according to claim 17, further including a second controller retained at the surface to communicate with the respective internal communicator of each of the at least one core orientation instrument and with each of the at least one downhole survey probe.

19. The downhole survey system according to claim 18, wherein the second controller is configured to communicate with the common controller.

20. The downhole survey system according to claim 18, further including a controller power pack to supply electrical power to second controller, and a communication dock enabling data communication between a portable memory device and the second controller when the second controller is docked therewith.

21. The downhole survey system according to claim 18, wherein the second controller is arranged and configured to capture survey data or core orientation data, and to transmit said survey or core orientation data in electronic form to a data capture means for later use.

22. The downhole survey system according to claim 21, wherein the second controller is arranged and configured to transmit data to the common controller for assimilation or use with other data in the common controller or for transmission to an external data capture device.

23. The downhole survey system according to claim 8, wherein the common controller is arranged and configured to capture survey data or core orientation data, and to transmit said survey or core orientation data in electronic form to a data capture means for later use.

24. A downhole survey system including multiple components arranged to be housed in a portable container for transport and deployment at a drilling site, the multiple components including a survey probe for deployment downhole, a core orientation instrument for deployment downhole, and a common controller retained aboveground at the drilling site and configured to control or communicate with one or both of the survey probe and core orientation instrument when recovered aboveground from downhole.

25. The downhole survey system according to claim 24, further including a telescopic rod extension.

26. The downhole survey system according to claim 24, further including multiple sized adaptor collars for use in adapting the core orientation instrument to threadingly engage with a selected extension barrel.

27. The downhole survey system according to claim 24, including one or more adaptors for attachment to an end or both respective ends of the core orientation instrument or survey probe, said adapter(s) arranged to vary the effective diameter of the core orientation instrument or survey probe for attachment to drill string extension components having a respective connecting thread diameter greater than the diameter of a connecting thread of the core orientation instrument or survey probe.

28. The downhole survey system according to claim 27, wherein a said respective adaptor is releasably attachable to the core orientation instrument or to the survey probe.

29. The downhole survey system according to claim 28, wherein a larger diameter adapter is arranged to connect to a smaller diameter said adaptor, or said larger diameter adapter is arranged to replace said smaller diameter adapter.

30. A method of collecting downhole survey data from a drilling operation, the method including: providing a downhole survey system, the system including at least one survey probe, at least one core orientation instrument and a common controller, collecting data in the common controller retained aboveground from one or both of the survey probe and the core orientation instrument having gathered data downhole and subsequently retrieved to aboveground, and the common controller transmitting said collected data to a common data capture means which records the collected data from one or both of the survey probe and the core orientation instrument.

31. The method according to claim 30, wherein the common controller communicates remotely with at least one survey probe, core orientation instrument or drilling operation remote from the controller.

32. An adaptor for attachment to an end of a core orientation instrument or survey probe for use in a survey system, and attachment means to releasably attach the adaptor, and thereby the core orientation instrument or survey probe, to at least one drill string component, and wherein the adaptor includes at least one aperture through a side wall thereof, the at least one aperture permitting electromagnetic radiation from an electronic instrument transmitting data via the electromagnetic radiation to pass to or from the core orientation instrument or survey probe.

33. The adaptor according to claim 32, the said adaptor provided at each of two ends of the core orientation instrument or of the survey probe.

34. The adaptor according to claim 32, said adaptor releasably attachable to the instrument or probe by one or more screw threads, retaining screws, bolts, clips or pins.

35. The adaptor according to claim 34, said adaptor further releasably retainable to the instrument or probe by one or more retaining screws, bolts, clips or pins.

36. The adaptor according to claim 32, including a said screw thread at one end thereof for releasable engagement with a corresponding screw threaded end of the instrument or probe, and another screw thread at the opposite end of the adaptor for engagement with a corresponding screw thread of another adaptor or a drill string component.

37. The adaptor according to claim 32, further including a subsequent weld connection between the adaptor and the core orientation instrument, the survey probe or the at least one drill string component to prevent subsequent release of the adaptor.

38. The adaptor according to claim 32, wherein the electronic instrument is within the core orientation instrument or within the survey probe and the electromagnetic radiation data is transmitted out of the at least one aperture to an external receiver.

39. The adaptor according to claim 38, wherein the receiver includes a common controller for use in controlling or communicating with the core orientation instrument and the survey probe.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows currently used equipment in surveying at a drill site and capturing drilling data.

(2) FIG. 2 shows an embodiment of the present invention with reduced number of components compared with currently used systems and including improved data capture and component control through an electronic controller.

(3) FIG. 3 shows a core orientation instrument with adaptors according to an embodiment of the present invention.

(4) FIGS. 4a and 4b show in cross section an adaptor for a core orientation instrument according to an embodiment of the present invention.

(5) FIGS. 5a to 5c show alternative versions of an adaptor for a core orientation instrument according to an embodiment of the present invention.

(6) FIG. 6 shows a set of downhole survey system equipment in a storage means for protection and transport.

DESCRIPTION OF PREFERRED EMBODIMENT

(7) A known system 10 will first be described with reference to FIG. 1. FIG. 1 shows a comparison of currently required equipment to carry out surveying, core orientation using three sizes for varying drill hole diameters in deep hole drilling, and logging all events and activity at a drill-rig site.

(8) Extracting Core Samples During Drilling

(9) As with the description of known systems and components in the background section above, the common system 10 and method for core extraction and orientation requires a process of dismantling at least two assembly sections to complete the orientation. As every 3 m or 6 m requires core orientation, a significant amount of time is spent during this process. For deep hole drilling where at least three hole sizes are encountered, the equipment count (and weight) for core orientation equipment almost trebles (as seen in FIG. 1). This occurs because a relatively wide borehole can first be drilled. As friction increases with depth, a narrower hole is needed, and then again a third much narrower drill. Thus, three different diameters of core orientation instruments 18, 20, 22 are required to match the three different drill widths. This significantly increases the number of components required in a known system. Matching extension barrels (drill string extensions) are also required to connect the core orientation instrument 18, 20, 22 to the drill string. Because there are three hole sizes, there are three matching extension barrels 24. A core orientation instrument controller 28 is used to control and communicate with the core orientation instrument. This is in addition to a separate survey probe controller, typically because these instruments may come from different manufacturers or are supplied as stand alone sub systems.

(10) Surveying the Drill Hole at Different Depths

(11) The survey instrument/probes 12 used in today's mining industry are of an average length of 1 m or more. They all require operation in a brass pressure barrel 14 which needs to be disassembled from one end (at least) to start the probe's operation and again to stop operation and extract data after removal from a drill-hole. It is inherent for all magnetic survey instruments that an average of 5 m separation of its sensors from the drill bit and steel drill pipes is required before making a valid reading. This is achieved using multiple solid aluminium rod extensions 16. A survey instrument controller 26 is used to control the survey instrument and obtain data from the instrument.

(12) Keeping a Progressive Log of Drilling

(13) As described above and shown in FIG. 1, the industry norm is to use handwritten forms and faxes 30 through to typing pools for data entry 32 and eventual analysis/reporting of data and accounting 34. This long standing method is plagued with human error and lost opportunity through inefficient double and triple handling of data collection and recording drill-rig activity. Client billing cycles are delayed and only sparse analysis (if at all) is available from the collected data.

(14) An embodiment of the present invention is shown in FIG. 2. Such a system requires fewer components than needed in a known system. Replaceable adapters on the core orientation unit replace the various sizes of core orientation units in known systems. This is a significant saving in equipment costs and operational costs, as well as avoiding the need to transport the additional electronic equipment to and from sites.

(15) Extracting Core Samples During Drilling

(16) For extraction of core samples, the system 38 shown in FIG. 2 uses a single size (smallest diameter size) core orientation unit 18 with multiple size adaptors 46, 48 to match with different stages of deep-hole drilling. This beneficially avoids the need for multiple size core orientation instruments used in the known systems.

(17) Drill string extensions 50, 52, 54 are utilised. Only one section needs to be dismantled to remove the core sample as this core orientation unit has a unique facility to communicate internal data without the need to remove the unit from its back-end attachment.

(18) Surveying the Drill Hole at Different Depths

(19) A system of the present invention can utilise state-of-the-art SMT (Surface Mount Technology) or wire bonding miniaturisation to achieve a survey instrument probe 40 no longer than half a meter (500 mm), be fully encased in its own brass pressure housing, will not need dismantling for the start/stop/extract data process, and achieves magnetic sensor separation using an extendable/telescopic, preferably composite, material extension rod 42. The probe 40 is designed to operate in harsh environments, and with thicker wall pressure housing (due to internal electronic component miniaturisation), is easily adaptable for deep-hole drilling.

(20) Keeping a Progressive Log of Drilling

(21) As seen in FIG. 2, a system of the present invention integrates all functions of an electronic controller 56 with core orientation and survey instrumentation 40, 44, thereby only requiring a single controller rather than the multiple controllers of the known art. The controller can provide seamless and instant electronic data capture and communication for the drilling companies, newly designed hardware and software functions will empower the driller to operate from a central singular (hand-held) controller, with full access and monitoring/validation of all instrument data, consumables, drilling target progressive achievement and full analysis of work progress at the mine site.

(22) The single common controller for communicating with and controlling the core orientation instrument/unit and also the probe(s) avoids the need for multiple controllers. Furthermore, data capture by one controller allows different data sets to be compared or used to derive further data. For example magnetic field data from a probe can be combined with core orientation data to help determine subsurface geological features or potential sites for deposits.

(23) FIG. 3 shows a core orientation instrument 60 with a central body 62 for housing electronics, a first threaded end 76 and a second threaded end 78. The first threaded end is arranged to receive an adaptor 64. This adaptor has an external threaded portion 70 for connection to drill string component, such as a greater unit (not shown). This first adaptor 64 includes an internal thread 80 arranged to threadingly engage with the external first threaded end 76. After screwing the adaptor 64 onto the first end of the core orientation instrument, a circlip 68 is applied to retain the adaptor in place. The circlip engages into grooves 72 through the wall of the adaptor. To prevent the adaptor from unscrewing form the end of the core orientation instrument, the circlip will engage against a shoulder of the end of the core orientation instrument. The circlip must be removed before the adaptor can be unscrewed. At the other end of the core orientation instrument, another external thread 78 is arranged to engage with an adaptor 66. This adaptor has spaced apertures 74 to allow light to transmit data from the core orientation instrument to a light receiver or controller. This adaptor can connect the core orientation instrument to a core barrel. It will be appreciated that the adaptors can be used with other survey tools, such as survey probes.

(24) FIGS. 4a and 4b show an adaptor in cross section. FIG. 4a shows the adaptor before it is threaded onto the end of the core orientation instrument, and FIG. 4b shows the adaptor attached and the retaining circlip in place.

(25) FIGS. 5a to 5c show alternative arrangements for releasably attaching the adaptor to the core orientation instrument. FIG. 5a shows a circlip type retainer, FIG. 5b shows a multiple retaining screw (grub screw) alternative. The retaining screws screw into threaded holes through the wall of the adaptor and bite into the wall of the core orientation instrument or engage into holes in the casing of the body. In FIG. 5c, a screw threaded locking collar or sleeve 84 threads onto an external thread 82 of the adaptor. Tightening the collar or sleeve clamps the adaptor to the core orientation instrument.

(26) The external threads 70, 78 of the adaptors can be sized to suit the matching required size of the drill string components. Thus, instead of requiring various sizes of core orientation instrument or other survey instrument, only one smaller size of instrument is required and the end connections can be adapted by use of the adaptors to suit a required size of corresponding drill string components. This reduces the number of components required for a survey system, reduces overall capital cost, avoids the need for multiple electronics instruments, and makes the entire system portable in a transportable case.

(27) In use, the second controller may be used to capture data for one surveying task, such as core orientation data, whilst the common controller (considered a master or primary controller) is used for data on a second task, such as handling a log of drilling or survey probe data. All data may be combined by data transmission into one of the controllers, preferably the common controller. Data transmission may be infra red or wireless communication directly from one controller to the next, or from on controller via a docking station to a memory device and thence into the second controller. Alternatively, data from both controllers may be transmitted to a remote device, such as a computer, for further processing.

(28) The docking station may also act as a power charger for an on-board battery in one or both controllers. An AC and/or car battery supply adapter/transformer may be provided as part of the downhole survey system equipment to aid with power and charging of the controllers. Data transmission equipment may also be provided, such as a Wifi or satellite communication enabled device to transmit data to a remote location or device.

(29) FIG. 6 shows components of a downhole survey system 100 according to an embodiment of the present invention. The components are housed in a container for safe transport to and from a drill site and for secure storage. This prevents damage to the components and ensures all components in the system are accounted for by providing a particular storage position for each component. The components in the embodiment are shown housed in a protective foam inlay 102 that sits inside the container (not shown). The components include a downhole probe 104, and extension rod 106 (which may be of a preselected length or may be telescopic) to connect the probe to a drill string or other components. One or more downhole instruments, such as core orientation units 108,110, can be included. The system further includes the option to use adaptors 112,114,116,118 etc, to connect one or more of the instruments and/or probes to a drill string. The adaptors are provided according to one or more embodiments of the adaptor of the present invention. One or more of the adaptors includes at least one aperture for entry/exit of light for communicating data to or from an instrument or probe. The system further includes a hand held electronic common controller 120 to receive, transmit and store data relating to a drilling operation obtained by the probe or a core orientation unit. The controller is termed a common controller because it operates with both the probe and at least one of the instruments. Such a controller can communicate with the probe and one or more of the other instruments in the system to receive or send data or instructions to operate the probe or instrument(s) or report on drilling activities, such as a log of drilling. The controller includes a display screen. A second controller 121 is also provide stored underneath the common controller. This second controller can be a slave controller providing reduced functionality compared to the common controller. The second controller can be used to communicate with one of the probe or instrument while the common controller is used to communicate with another of the probe or instrument, or to report on drilling activities, such as a log of drilling. A charging device 122 is also provided. This acts as a power source to charge an on-board respective battery for the common controller and/or second controller. The charging device may provide communication through wifi and/or satellite to a remote device or location. A shock absorber device 124 is also provided to limit shocks through the probe and instrument(s) when in use downhole. Tools, such as spanners 126 are also provided, as well as a core orientation determining device 128.