Method and system for drilling a borehole

Abstract

A method of drilling a borehole from a surface location with a drill string, and a system for implementing the method are provided. The method includes a rotary mode that involves rotating the drill string at a rotary mode rotation rate in order to drill the borehole for a rotary interval, an orientation mode that involves rotating the drill string at an orientation mode rotation rate and transitioning the rotation of the drill string from the orientation mode rotation rate to a surface stop orientation, and maintaining the drill string at a surface fixed orientation in order to drill the borehole in a directional mode for a directional interval. The surface stop orientation is selected based upon a predicted relationship between the surface stop orientation and a toolface stop orientation.

Claims

1. A method of drilling a borehole from a surface location with a drill string comprising a surface end having a surface orientation and a distal end having a toolface orientation, the method comprising: (a) a rotary mode comprising rotating the drill string at a rotary mode rotation rate in order to drill the borehole for a rotary interval; (b) an orientation mode comprising: (i) rotating the drill string at an orientation mode rotation rate; (ii) transitioning the rotation of the drill string from the orientation mode rotation rate to a non-rotating state in which the surface orientation is at a surface stop orientation, wherein the transitioning is performed in accordance with a plurality of ramp down transition parameters which specify the manner and rate at which the drill string decelerates from the orientation mode rotation rate to the non-rotating state; and (c) a directional mode comprising maintaining the surface orientation at a surface fixed orientation in order to drill the borehole for a directional interval.

2. The method as claimed in claim 1, further comprising repeating any one or a combination of the rotary mode, the orientation mode and the directional mode one or more times in order to drill the borehole with alternating rotary intervals and directional intervals.

3. The method as claimed in claim 1 wherein the rotary mode, the orientation mode and the directional mode are implemented within a length of a single joint of drill pipe added to the drill string.

4. The method as claimed in claim 1 wherein the rotary mode rotation rate is the same as the orientation mode rotation rate, such that rotating the drilling string at the orientation mode rotation rate is performed while rotating the drill string at the rotary mode rotation rate.

5. The method as claimed in claim 1 wherein the surface stop orientation is the same as the surface fixed orientation.

6. The method as claimed in claim 1, further comprising a counter-rotation mode comprising either counter-rotating or co-rotating, or both counter-rotating and co-rotating the drill string from the surface stop orientation to the surface fixed orientation.

7. The method as claimed in claim 6, wherein the counter-rotation mode is performed in order to release torque from the drill string.

8. The method as claimed in claim 7 wherein torque is released from the drill string to achieve a desired residual torque in the drill string at the surface location.

9. The method as claimed in claim 6, wherein the counter-rotation mode is performed in order to achieve a desired balance torque along the length of the drill string.

10. The method as claimed in claim 9 wherein the desired balance torque is approximately equal to an expected torque in the drill string during the directional mode.

11. The method as claimed in claim 6 wherein the toolface orientation is at a toolface fixed orientation when the surface orientation is at the surface fixed orientation, and wherein the surface stop orientation takes into account a predicted relationship between the surface fixed orientation and the toolface fixed orientation such that the surface fixed orientation following the counter-rotation mode is predicted to result in the toolface orientation being within a desired toolface fixed orientation range.

12. The method as claimed in claim 6 wherein the toolface orientation is at a toolface fixed orientation when the surface orientation is at the surface fixed orientation, further comprising repeating the counter-rotation mode if the toolface fixed orientation is not within a desired toolface fixed orientation range.

13. The method as claimed in claim 12 wherein the counter-rotation mode is performed in accordance with at least one selected counter-rotation parameter, further comprising modifying the at least one selected counter-rotation parameter if the toolface fixed orientation is not within the desired toolface fixed orientation range, before repeating the counter-rotation mode, wherein the at least one selected counter-rotation parameter is modified based upon a difference between the toolface fixed orientation and the desired toolface fixed orientation range.

14. The method as claimed in claim 1 wherein the toolface orientation is at a toolface stop orientation when the surface orientation is at the surface stop orientation and wherein the surface stop orientation is selected based on a predicted relationship between the surface stop orientation and the toolface stop orientation.

15. The method as claimed in claim 1, further comprising achieving a desired differential pressure of a fluid circulating through the drill string before transitioning the rotation of the drill string from the orientation mode rotation rate to the non-rotating state.

16. The method as claimed in claim 15 wherein the desired differential pressure is achieved by allowing drill-off of the drill string while rotating the drill string at the orientation mode rotation rate.

17. The method as claimed in claim 1 wherein the toolface orientation is at a toolface stop orientation when the surface orientation is at the surface stop orientation, further comprising repeating the orientation mode if the toolface stop orientation is not within a desired toolface stop orientation range.

18. The method as claimed in claim 17, further comprising applying a correction factor to the surface stop orientation, before repeating transitioning the rotation of the drill string to the orientation mode rotation rate to the non-rotating state, wherein the correction factor is selected based upon a difference between the toolface stop orientation and the desired toolface stop orientation range.

19. The method as claimed in claim 1 wherein the toolface orientation is at a toolface stop orientation when the surface orientation is at the surface stop orientation, further comprising repeating the orientation mode if the toolface stop orientation is not within a desired toolface stop orientation range, and modifying at least one of the ramp down transition parameters if the toolface stop orientation is not within the desired toolface stop orientation range, before repeating transitioning the rotation of the drill string from the orientation mode rotation rate to the non-rotating state, wherein the at least one ramp down transition parameter is modified based upon a difference between the toolface stop orientation and the desired toolface stop orientation range.

20. The method as claimed in claim 1 wherein, as the drill string is rotated at the orientation mode rotation rate in the orientation mode, the surface orientation has a surface reference orientation and the toolface orientation has a toolface reference orientation, further comprising determining a relationship between the toolface reference orientation and the surface reference orientation, wherein the surface stop orientation is selected based on the relationship.

21. The method as claimed in claim 20 wherein the surface reference orientation and the toolface reference orientation are determined at a plurality of coincident time intervals over a time period.

22. The method as claimed in claim 21 wherein the surface reference orientation and the toolface reference orientation are averaged over the time period.

23. The method as claimed in claim 1 wherein each of the plurality of ramp down transition parameters is selected from the group of parameters consisting of a number of degrees of rotation to the non-rotating state, a time of rotation to the non-rotating state, and a deceleration curve to the non-rotating state.

24. A system for drilling a borehole from a surface location with a drill string, for use with an encoder for transmitting surface orientation data indicative of a surface orientation of a surface end of the drill string, a downhole instrument for transmitting toolface orientation data indicative of a toolface orientation of a distal end of the drill string, and a rotary drive for rotating the drill string, the system comprising: (a) a processor operatively connected to the encoder to receive the surface orientation data, to the downhole instrument to receive the toolface orientation data, and to the rotary drive to control rotation of the drill string; (b) a non-transitory storage medium having instructions stored thereon, wherein the processor is configured to read the instructions, and wherein the instructions cause the processor to implement a method comprising: (i) a rotary mode comprising rotating the drill string at a rotary mode rotation rate in order to drill the borehole for a rotary interval; (ii) an orientation mode comprising: (A) rotating the drill string at an orientation mode rotation rate; (B) transitioning the rotation of the drill string from the orientation mode rotation rate to a non-rotating state in which the surface orientation is at a surface stop orientation, wherein the transitioning is performed in accordance with a plurality of ramp down transition parameters which specify the manner and rate at which the drill string decelerates from the orientation mode rotation rate to the non-rotating state; and (iii) a directional mode comprising maintaining the surface orientation at a surface fixed orientation in order to drill the borehole for a directional interval.

25. The system as claimed in claim 24, the method further comprising repeating any one or a combination of the rotary mode, the orientation mode and the directional mode one or more times in order to drill the borehole with alternating rotary intervals and directional intervals.

26. The system as claimed in claim 24 wherein the rotary mode, the orientation mode and the directional mode are implemented within a length of a single joint of drill pipe added to the drill string.

27. The system as claimed in claim 24 wherein the rotary mode rotation rate is the same as the orientation mode rotation rate, such that rotating the drilling string at the orientation mode rotation rate is performed while rotating the drill string at the rotary mode rotation rate.

28. The system as claimed in claim 24 wherein the surface stop orientation is the same as the surface fixed orientation.

29. The system as claimed in claim 24, the method further comprising a counter-rotation mode comprising either counter-rotating or co-rotating, or both counter-rotating and co-rotating the drill string from the surface stop orientation to the surface fixed orientation.

30. The system as claimed in claim 29 wherein the counter-rotation mode is performed in order to release torque from the drill string.

31. The system as claimed in claim 30 wherein the torque is released from the drill string to achieve a desired residual torque in the drill string at the surface location.

32. The system as claimed in claim 29, wherein the counter-rotation mode is performed in order to achieve a desired balance torque along the length of the drill string.

33. The system as claimed in claim 32 wherein the desired balance torque is approximately equal to an expected torque in the drill string during the directional mode.

34. The system as claimed in claim 29 wherein the toolface orientation is at a toolface fixed orientation when the surface orientation is at the surface fixed orientation, and wherein the surface stop orientation takes into account a predicted relationship between the surface fixed orientation and the toolface fixed orientation such that the surface fixed orientation following the counter-rotation mode is predicted to result in the toolface orientation being within a desired toolface fixed orientation range.

35. The system as claimed in claim 29 wherein the toolface orientation is at a toolface fixed orientation when the surface orientation is at the surface fixed orientation, further comprising repeating the counter-rotation mode if the toolface fixed orientation is not within a desired toolface fixed orientation range.

36. The system as claimed in claim 35 wherein the counter-rotation mode is performed in accordance with at least one selected counter-rotation parameter, further comprising modifying the at least one selected counter-rotation parameter if the toolface fixed orientation is not within the desired toolface fixed orientation range, before repeating the counter-rotation mode, wherein the at least one selected counter-rotation parameter is modified based upon a difference between the toolface fixed orientation and the desired toolface fixed orientation range.

37. The system as claimed in claim 36, further comprising applying a correction factor to the surface stop orientation, before repeating transitioning the rotation of the drill string to the orientation mode rotation rate to the non-rotating state, wherein the correction factor is selected based upon a difference between the toolface stop orientation and the desired toolface stop orientation range.

38. The system as claimed in claim 24 wherein the toolface orientation is at a toolface stop orientation when the surface orientation is at the surface stop orientation, further comprising repeating the orientation mode if the toolface stop orientation is not within a desired toolface stop orientation range.

39. The system as claimed in claim 24 wherein the toolface orientation is at a toolface stop orientation when the surface orientation is at the surface stop orientation, further comprising repeating the orientation mode if the toolface stop orientation is not within a desired toolface stop orientation range, and modifying at least one of the ramp down transition parameters if the toolface stop orientation is not within the desired toolface stop orientation range, before repeating transitioning the rotation of the drill string from the orientation mode rotation rate to the non-rotating state, wherein the at least one ramp down transition parameter is modified based upon a difference between the toolface stop orientation and the desired toolface stop orientation range.

40. The system as claimed in claim 24 wherein, as the drill string is rotated at the orientation mode rotation rate in the orientation mode, the surface orientation has a surface reference orientation and the toolface orientation has a toolface reference orientation, the method further comprising determining a relationship between the toolface reference orientation and the surface reference orientation, wherein the surface stop orientation is selected based on the relationship.

41. The system as claimed in claim 40 wherein the computer comprises at least one timing clock, and the surface reference orientation and the toolface reference orientation are determined at a plurality of coincident time intervals set by the at least one timing clock over a time period.

42. The system as claimed in claim 41 wherein the surface reference orientation and the toolface reference orientation are averaged over the time period.

43. The system as claimed in claim 24 wherein each of the plurality of ramp down transition parameters is selected from the group of parameters consisting of a number of degrees of rotation to the non-rotating state, a time of rotation to the non-rotating state, and a deceleration curve to the non-rotating state.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Embodiments of the invention will now be described with reference to the accompanying drawings, in which:

(2) FIG. 1 is a diagram of an exemplary borehole profile including a vertical section, a lateral section, and a curve section connecting the vertical section and the lateral section, which may be drilled by a non-limiting implementation of the invention.

(3) FIG. 2 is a graph of an exemplary drill string torque curve as a function of the length of a borehole, during simultaneous rotation of the drill string to the right to effect rotary drilling and operation of a downhole drilling motor to rotate the drill bit to the right, during performance of the rotary mode of a non-limiting implementation of the invention.

(4) FIG. 3 is a graph of an exemplary drill string torque curve as a function of the length of a borehole, immediately after rotation of the drill string to the right has stopped, but while operation of the drilling motor continues, during performance of the directional mode of a non-limiting implementation of the invention.

(5) FIG. 4 is a graph of an exemplary drill string torque curve as a function of the length of a borehole following counter-rotation of the drill string to the left to release torque from the drill string resulting from rotary mode drilling as operation of the drilling motor continues, wherein the residual torque in the drill string at the surface location is approximately zero, during performance of the counter-rotation mode of a non-limiting implementation of the invention.

(6) FIG. 5 is a graph of an exemplary drill string torque curve as a function of the length of a borehole following co-rotation of the drill string to the right to apply an amount of balance torque to the drill string from the surface location as operation of the drilling motor continues, wherein the balance torque in the drill string at the surface location is approximately equal to the torque generated by the drilling motor, during performance of the counter-rotation mode of a non-limiting implementation of the invention.

(7) FIG. 6 is a flow chart of an exemplary drilling sequence in accordance with a non-limiting implementation of the invention.

(8) FIG. 7 is a flow chart of an exemplary data flow in accordance with a non-limiting implementation of the invention.

(9) FIG. 8 is a table illustrating a hypothetical exemplary drilling sequence in accordance with a non-limiting implementation of the invention.

(10) FIG. 9 is a table providing exemplary ranges for ramp down (transition) parameters during performance of the orientation mode and counter-rotation parameters during performance of the counter-rotation mode in accordance with a non-limiting implementation of the invention.

(11) FIG. 10 is a table providing exemplary possible modifications to ramp down (transition) parameters during performance of the orientation mode and counter-rotation parameters during performance of the counter-rotation mode as consequences of possible events occurring during performance of the orientation mode and counter-rotation mode in accordance with a non-limiting implementation of the invention.

DETAILED DESCRIPTION

(12) FIGS. 1-10 depict aspects of non-limiting embodiments of a method and a system for drilling a borehole from a surface location using a combination of rotary intervals and directional intervals.

(13) Referring to FIG. 1, an exemplary borehole profile includes a vertical section extending from a drilling rig at a surface location, a lateral section and a curve section. The curve section extends between a kickoff point (KOP) at the start of the curve section and an end of the curve. All or portions of the vertical section, the lateral section and/or the curve section may be drilled using the method of the invention.

(14) Referring to FIG. 2, an exemplary drill string torque curve is depicted during simultaneous rotation of the drill string to the right and operation of a downhole drilling motor to rotate the drill bit to the right, during performance of the rotary mode of a non-limiting implementation of the invention. A relatively high torque is present within the vertical section of the borehole due to the torque applied to the drill string to effect rotary mode drilling, which diminishes gradually through the curve section of the borehole and gradually through the lateral section of the borehole to a torque at the distal end of the drill string which is approximately equal to the torque applied to the drill bit by the drilling motor.

(15) Referring to FIG. 3, an exemplary drill string torque curve is depicted immediately after rotation of the drill string to the right has stopped, but while operation of the drilling motor continues, during performance of directional mode drilling in a non-limiting implementation of the invention. A relatively lower torque than in FIG. 2 is present within the vertical section of the borehole. The torque in the vertical section of the borehole is due to residual torque within the drill string following rotary mode drilling. The torque diminishes gradually through the curve section of the borehole and gradually through the lateral section of the borehole to a torque at the distal end of the drill string which is approximately equal to the torque applied to the drill bit by the drilling motor.

(16) Referring to FIG. 4, an exemplary drill string torque curve is depicted after the drill string has been counter-rotated to the left from the surface location to release residual torque from the drill string, but while operation of the drilling motor continues, during performance of the counter-rotation mode of a non-limiting implementation of the invention. The torque in the vertical section of the borehole is approximately zero as a result of the counter-rotation of the drill string. The torque gradually increases through the curve section of the borehole to be approximately equal to the torque applied to the drill bit by the drilling motor. The torque in the lateral section of the borehole first continues to increase gradually and then diminishes gradually to a torque at the distal end of the drill string which is approximately equal to the torque applied to the drill bit by the drilling motor.

(17) Referring to FIG. 5, an exemplary drill string torque curve is depicted after an amount of right-hand balance torque has been applied to the drill string at the surface location, but while operation of the drilling motor continues, during performance of the counter-rotation mode of a non-limiting implementation of the invention. The balance torque in the vertical section of the borehole is approximately equal to the torque applied to the drill bit by the drilling motor. The torque gradually increases through the curve section of the borehole and the lateral section of the borehole and then diminishes gradually in the lateral section to a torque at the distal end of the drill string which is approximately equal to the torque applied to the drill bit by the drilling motor.

(18) Referring to FIG. 6, a flow chart of an exemplary drilling sequence in accordance with a non-limiting implementation of the invention is depicted.

(19) Referring to FIG. 7, a flow chart of an exemplary data flow in accordance with a non-limiting implementation of the invention is depicted.

(20) Referring to FIG. 8, a table illustrating a hypothetical exemplary drilling sequence in accordance with a non-limiting implementation of the invention is provided.

(21) Referring to FIG. 9, a table providing exemplary ranges for ramp down (transition) parameters during performance of the orientation mode and counter-rotation parameters during performance of the counter-rotation mode in accordance with a non-limiting implementation of the invention is provided.

(22) Referring to FIG. 10, a table providing exemplary possible modifications to ramp down (transition) parameters during performance of the orientation mode and counter-rotation parameters during performance of the counter-rotation mode as consequences of possible events occurring during performance of the orientation mode and counter-rotation mode in accordance with a non-limiting implementation of the invention is provided.

(23) FIGS. 1-10 are exemplary only. The features of the method and the system depicted in FIGS. 1-10 and described herein may be included in various combinations and sub-combinations in alternate methods and systems.

(24) More particularly, the method of the invention may be performed using any suitable apparatus or any suitable combination of apparatus, including but not limited to an exemplary system comprising some or all of the following apparatus.

(25) In the exemplary system embodiment, a surface apparatus at the surface location may comprise an encoder which transmits real-time surface orientation data to a surface computer with respect to the surface orientation of the drill string. The surface orientation of the drill string is the angular orientation of a reference position adjacent or at a proximal end of the drill string.

(26) The surface orientation of the drill string may be indicated by a rotating part of a rotary drive, by a top drive quill orientation, by a rotary table orientation, or by any other orientation which relates to the orientation of the drill string at the surface location.

(27) In the exemplary system embodiment, the surface apparatus may comprise a top drive equipped with an encoder which transmits real-time encoder data to a surface computer relating to a top drive quill orientation. In some applications, the top drive may have the ability to follow commands from the surface computer to rotate and stop the drill string at a particular angular orientation.

(28) In the exemplary system embodiment, the surface computer may have an onboard timing clock (synchronized with downhole instruments) to read top drive encoder orientations at preset time intervals. The surface computer may also have the ability to receive data (including toolface orientation data) from downhole instruments such as a measurement while drilling (MWD) tool.

(29) In the exemplary system embodiment, a downhole apparatus may comprise a downhole computer with a timing clock synchronized with the surface computer.

(30) In the exemplary system embodiment, the downhole computer may be capable of obtaining downhole toolface orientation data at precise time intervals coincident with the surface computer obtaining top drive encoder orientation data. In the exemplary system embodiment, the downhole computer may be capable of reading, storing and averaging toolface orientation data over a defined period of time and may be capable of commanding a conventional MWD tool to transmit the toolface orientation data to the surface location.

(31) The toolface orientation is the angular orientation of a reference position adjacent to the distal end of the drill string. The toolface orientation may be indicated by the orientation of a bend in a bent motor or bent sub or by any other suitable reference position adjacent to the distal end of the drill string.

(32) In general, the downhole computer and the surface computer are collectively a computer that comprises a processor that is capable of reading a set of instructions stored in a non-transitory storage media, to cause the processor and any operatively connected components (such as an encoder, a rotary drive such as a top drive, and a downhole instrument such as a MWD tool) to perform one or more steps embodying to implement a desired functionality. The computer may be located at the surface, or in the downhole environment, or a combination of the surface and the downhole environment. As such, it will be understood that references in this document to the downhole computer and to the surface computer do not limit the invention in respect to the location of the computer. Further, the computer or portions thereof may be located remotely from the borehole site.

(33) The exemplary embodiment of the method may include the following.

(34) In the exemplary method embodiment, the surface computer may command the top drive to rotate the drill string at a rotation mode rotation rate in the rotary mode (FIG. 6, step 600). The rotation mode rotation rate, the weight-on-bit (WOB), and flow rate of the drilling fluid may be selected to optimize for the rate-of-penetration (ROP).

(35) In the exemplary method embodiment, upon the drill bit reaching a directional mode depth (FIG. 6, step 602), the surface computer may command the top drive to rotate the drill string at an orientation mode rotation rate (such as exactly 20 revolutions per minute (rpm)) (FIG. 6, step 604) in an orientation mode while the top drive encoder sends top drive quill orientation data coincident with the timing clock at T+3 second intervals to the surface computer. Thus the top drive should confirm rotation of 20 rpm by transmitting exactly the same top drive quill orientation (in degrees) every 3 seconds (i.e., the time required for a single rotation of the drill string at 20 rpm), The top drive quill orientation during the orientation mode may represent a surface reference orientation of the drill string.

(36) In the exemplary method embodiment, the downhole computer may optionally be configured to recognize the orientation mode of rotation of the drill string from the surface location (such as 20 rpm) because of a downhole accelerometer package of a MWD tool, and in response may obtain instantaneous actual toolface orientation data at intervals (such as T+3 second intervals), coincident with the transmission of the top drive quill orientation data from the top drive to the surface computer. Further, the downhole computer may optionally command the MWD tool to transmit the toolface orientation data to the surface computer, which may represent a toolface reference orientation at or adjacent to the distal end of the drill string.

(37) In the exemplary method embodiment, the downhole computer may optionally calculate an average toolface orientation from instantaneous actual toolface orientation data obtained at intervals (such as T+3 second intervals) over a time period (such as 1 minute), coincident with the transmission of the top drive quill orientation data from the top drive to the surface computer, and may command the MWD tool to transmit the average toolface orientation to the surface computer, which may represent a toolface reference orientation at or adjacent to the distal end of the drill string.

(38) In the exemplary method embodiment, the downhole computer may optionally be configured to obtain instantaneous actual toolface orientation data in response to any rotation rate of the drill string or within a range of rotation rates of the drill string, coincident with the transmission of the top drive quill orientation data from the top drive to the surface computer, and may command the MWD tool to transmit a toolface orientation and/or an average toolface orientation to the surface location, which may represent a toolface reference orientation of the distal end of the drill string.

(39) In the exemplary method embodiment, the orientation mode may be continued for a length of time which is sufficient to enable the rotation of the drill string to achieve a relatively steady state in which the relationship between the surface reference orientation and the toolface reference orientation is relatively constant.

(40) In the exemplary method embodiment, a desired differential pressure of a fluid circulating through the drill string may be achieved (FIG. 6, step 606) before transitioning the rotation of the drill string from the orientation mode rotation rate to the surface stop orientation, as discussed below. In some applications, this may be achieved by the surface computer allowing drill-off of the drill string while rotating the drill string at the orientation mode rotation rate.

(41) The surface computer may optionally determine a relationship between the toolface reference orientation and the surface reference orientation (FIG. 6, step 608; and FIG. 8, Delta (Quill) to Desired Toolface)). In many applications of the method, it may not be necessary to obtain the reference orientations and/or determine the relationship between the reference orientations.

(42) The surface computer may optionally direct the top drive to stop the rotation of the drill string at a surface stop orientation of the top drive quill which may be predicted to provide a desired toolface stop orientation, based upon the determined relationship between the toolface reference orientation and the surface reference orientation (FIG. 6, step 610). When the surface orientation of the drill string is at the surface stop orientation, the toolface orientation is at a toolface stop orientation.

(43) In the exemplary method embodiment, the command from the surface computer to the top drive to stop rotation may be in accordance with ramp down (transition) parameters which specify the manner and rate at which the drill string decelerates from the orientation mode rotation rate (such as 20 rpm) and stops at the surface stop orientation (FIG. 9, Ramp Down (Transition) Parameters). The ramp down (transition) parameters for similar drilling conditions may in many applications of the method be consistent to increase the likelihood that each stop command may provide a consistent result with respect to the actual toolface orientation which is achieved. Ramp down (transition) parameters may comprise, without limitation, one or more parameters such as degrees of rotation to the surface stop orientation, time of rotation to the surface stop orientation, the deceleration curve of the drill string to the surface stop orientation, etc.

(44) The method may optionally include implementing the counter-rotation mode to move the surface orientation of the drill string from the surface stop position to a surface fixed orientation in order to release torque from the drill string and/or balance torque within the drill string, which torque may otherwise result in unwanted rotation of the drill string and the toolface orientation as the directional mode progresses during the following directional interval.

(45) After the drill string is stopped at the surface stop orientation, the counter-rotation mode may be implemented (FIG. 6, step 610). The counter-rotation mode may be performed by counter-rotating the drill string from the surface location to release torque and/or by co-rotating the drill string from the surface location to provide a balance torque in the drill string at the surface location. At the completion of the counter-rotation mode, the drill string will be stopped at a surface fixed orientation, which may be the same as or different from the surface stop orientation. At the completion of the counter-rotation mode, the toolface orientation will be at a toolface fixed orientation, which may be the same as or different from the toolface stop orientation.

(46) The counter-rotation mode may be performed in a manner so that the toolface orientation does not change as the surface orientation moves from the surface stop orientation to the surface fixed orientation. Alternatively, a predicted movement of the toolface orientation in the counter-rotation mode may be accounted for in performing the orientation mode so that an amount of movement of the toolface orientation during the counter-rotation mode does not result in an unacceptable error in the toolface orientation in comparison with a desired toolface fixed orientation range when the surface orientation is at the surface fixed orientation.

(47) In applications of the method in which the counter-rotation mode is not implemented, the surface fixed orientation may be the same as the surface stop orientation, and the toolface fixed orientation may be the same as the toolface stop orientation.

(48) After rotation of the drill string has stopped following the orientation mode, the MWD tool may transmit the toolface stop orientation to the surface computer and the toolface stop orientation may be compared with a desired toolface stop orientation (FIG. 6, step 612). The desired toolface stop orientation, the toolface stop orientation and the surface stop orientation may be compared to determine a relationship between the surface stop orientation and the toolface stop orientation, and/or a relationship amongst the surface stop orientation, the toolface stop orientation, and the desired toolface stop orientation.

(49) If an unacceptable amount of error exists between the desired toolface stop orientation and the toolface stop orientation (FIG. 6, step 614), then the surface computer may command the top drive to restart the orientation mode (FIG. 6, step 616) and to stop rotation of the drill string at a new surface stop orientation which applies a correction factor (FIG. 6, step 620; FIG. 8. Toolface Error) to the previous surface stop orientation, to account for the difference between the previous toolface stop orientation and the desired toolface stop orientation.

(50) Alternatively or additionally, if an unacceptable amount of error exists between the desired stop toolface orientation and the toolface stop orientation (FIG. 6, step 614), then the surface computer may command the top drive to restart the orientation mode (FIG. 6, step 616) and to stop rotation of the drill string at a new surface stop orientation in accordance with the ramp down (transition) parameters which are modified taking into account the difference between the previous toolface stop orientation and the desired toolface stop orientation (FIG. 6, step 622; and FIG. 10).

(51) In applications of the method in which the counter-rotation mode is implemented, the surface fixed orientation may be different from the surface stop orientation, and the toolface fixed orientation may be different from the toolface stop orientation.

(52) After rotation of the drill string has stopped following the counter-rotation mode, the MWD tool may transmit the toolface fixed orientation to the surface computer and the toolface fixed orientation may be compared with a desired toolface fixed orientation (FIG. 6, step 612). The desired toolface fixed orientation, the toolface fixed orientation and the surface fixed orientation may be compared to determine a relationship between the surface fixed orientation and the toolface fixed orientation, and/or a relationship amongst the surface fixed orientation, the toolface fixed orientation, and the desired toolface fixed orientation.

(53) If an unacceptable amount of error exists between the desired toolface fixed orientation and the toolface fixed orientation (FIG. 6, step 614), then the surface computer may command the top drive to restart the orientation mode (FIG. 6, step 616) and to stop rotation of the drill string at a new surface stop orientation which applies a correction factor (FIG. 6, step 620; FIG. 8, Toolface Error) to the previous surface stop orientation, to account for the difference between the previous toolface fixed orientation and the desired toolface fixed orientation.

(54) Alternatively or additionally, if an unacceptable amount of error exists between the desired fixed toolface orientation and the toolface fixed orientation (FIG. 6, step 614), then the surface computer may command the top drive to restart the orientation mode (FIG. 6, step 616) and to stop rotation of the drill string at a new surface stop orientation in accordance with the ramp down (transition) parameters which are modified taking into account the difference between the previous toolface fixed orientation and the desired toolface fixed orientation (FIG. 6, step 622; and FIG. 10).

(55) Alternatively or additionally, if an unacceptable amount of error exists between the desired toolface fixed orientation and the toolface fixed orientation (FIG. 6, step 614), then the surface computer may modify the counter-rotation parameters to take into account the difference between the previous toolface fixed orientation and the desired toolface fixed orientation (FIG. 6, step 622; and FIG. 10), before repeating the counter-rotating mode.

(56) The process of repeating the orientation mode and/or repeating the counter-rotation mode (FIG. 6, step 616) and stopping rotation of the drill string at a new surface stop orientation may be continued until the desired toolface stop orientation or the desired toolface fixed orientation, as the case may be, has been achieved within an acceptable range representing an acceptable error threshold.

(57) The orientation mode may therefore be performed following either the rotary mode or the directional mode. If the orientation mode follows the rotary mode, the purpose of performing the orientation mode may be to provide a transition between the rotary mode and the directional mode. If the orientation mode follows the directional mode, the purpose of performing the orientation mode may be to adjust the actual toolface orientation during a directional interval or to provide weight to the drill bit during a directional interval by overcoming static friction in the drill string.

(58) After completion of the directional mode to drill a directional interval of the borehole (FIG. 6, steps 624 and 626), the method may transition to the rotary mode to drill a rotary interval, in which the drill string is rotated at a rotary mode rotation rate. The transition from the directional mode to the rotary mode may be performed in accordance with ramp up (transition) parameters (FIG. 6, step 628). Ramp up (transition) parameters may comprise, without limitation, one or more parameters such as target rotary mode rotation rate, degrees of rotation to achieve the target rotary mode rotation rate, time of rotation to achieve the target rotary mode rotation rate, the acceleration curve of the drill string to achieve the rotary mode rotation rate, etc. In the exemplary method embodiment, the target rotary mode rotation rate, along with the weight-on-bit (WOB) and flow rate of drilling fluid, may be selected to provide an optimum rate of penetration (ROP) or to otherwise optimize drilling during the rotary interval.

(59) In the exemplary method embodiment, the rotary mode, the orientation mode, the directional mode and the counter-rotating mode may be repeated one or more times in order to drill all or a portion of a borehole.

(60) The invention may potentially provide a number of benefits.

(61) A first potential benefit of the invention is that since there is minimal delay in transitioning between rotary drilling and non-rotary drilling, lost rig time is minimized and it becomes more feasible to implement numerous rotary intervals and directional intervals for each 9 meter joint of drill pipe which is added to the drill string, potentially resulting in the production of a smoother borehole, which in turn could potentially allow a longer lateral section to be drilled following a curve section.

(62) A second potential benefit of the invention is that problems associated with providing weight to the drill bit may be reduced. If drill-off is detected and static friction cannot be overcome then a short rotary interval may be initiated to transfer weight to the drill bit and then a directional interval can be resumed, potentially resulting in higher average rates of penetration during drilling.

(63) As indicated above, in many applications of the method, it may not be necessary to obtain the reference orientations and/or to compare the reference orientations. As a result, in many applications, the method of the invention may be performed without use of timing clocks and/or comparison of reference orientations.

Example 1

(64) In a first example, the method of the invention may be performed as follows in order to drill a 9 meter length of borehole: 1. the driller decides to drill a 9 meter curve section of borehole using the method of the invention; 2. decisions are made with respect to the percentage of the curve section which will be drilled in rotary mode (the rotary period), the percentage of the curve section which will be drilled in directional mode (the directional period), the number and length of each rotary interval, and the number and length of each directional interval. These decisions may be based on many parameters including, but not limited to, knowledge of the underground formations present, the progress of the borehole path thus far, the amount of bend in the downhole motor, the type of borehole and its intended use, etc.; 3. the driller inputs into the surface computer the rotary period and the directional period (FIG. 7, Directional Driller); 4. the driller inputs into the surface computer the length of the rotary interval(s) and the directional interval(s) in one meter increments (FIG. 7, Directional Driller); 5. the driller enters into the surface computer the desired toolface stop orientation and allowable toolface error for each directional interval (FIG. 7, Directional Driller); 6. the driller enters into the surface computer ramp down (transition) parameters for a stop command (e.g., stop from 20 rpm at a constant deceleration rate deceleration or an exponential deceleration rate, within a specified number of degrees of top drive quill rotation and/or in a specified number of seconds) (FIG. 7, Directional Driller); 7. the driller enters into the surface computer ramp up (transition) parameters to start rotary mode drilling (e.g., ramp up to 45 rpm in 10 sec at a constant acceleration rate or exponential acceleration rate, within a specified number of degrees of top drive quill rotation and/or in a specified number of seconds) (FIG. 7, Directional Driller); 8. the surface computer commands the top drive to initiate the rotary mode of drilling in accordance with the specified ramp up (transition) parameters; 9. the driller manually adjusts weight on bit, fluid flow rate, and the rotary mode rotation rate to optimize drilling during the rotary mode; 10. the surface computer senses feedback on depth indicating the end of a rotary interval; 11. the surface computer initiates a command to the top drive to reduce the rotation rate of the drill string to the orientation mode orientation rate (e.g., 20 rpm) to begin the orientation mode; 12. the driller allows weight to drill-off in the orientation mode in order to achieve a desired differential pressure through the drill string (e.g., 200 psi); 13. the downhole computer senses the orientation mode and obtains, records and averages the toolface reference orientation and transmits the toolface orientation data to the surface computer; 14. the surface computer compares the actual toolface orientation to the desired toolface stop orientation and commands the rotation of the drill string to stop from the orientation mode rotation rate in accordance with the specified ramp down (transition) parameters with the goal of achieving the desired toolface stop orientation; 15. the counter-rotation mode is implemented by counter-rotating the drill string from the surface location and possibly co-rotating the drill string from the surface location, so that the surface orientation of the drill string moves from a surface stop orientation to a surface fixed orientation; 16. the toolface fixed orientation after the rotation of the drill string has stopped is obtained by the downhole computer and transmitted to the surface computer; 17. if the toolface fixed orientation is outside of a desired toolface fixed orientation range and is thus unacceptable, then the orientation mode is repeated using a correction factor representing the difference between the toolface fixed orientation and a desired toolface fixed orientation within a desired toolface fixed orientation range. In some circumstances, before the orientation mode is repeated, the ramp down (transition) parameters and/or the counter-rotation parameters may be modified in addition to or in substitution for the use of a correction factor; 18. if the toolface fixed orientation is within the desired toolface fixed orientation range and is thus acceptable, then the directional mode of drilling is performed for the directional interval; 19. when the directional interval is completed, the surface computer commands the top drive to transition to the rotary mode of drilling in accordance with the ramp up (transition) parameters; and 20. the above sequence is repeated until the 9 meter curve section is completed.

Example 2

(65) In a second example, the method of the invention may be performed as follows in order to drill a desired length of borehole: 1. the top drive quill orientation is reset to 0 degrees coincident with a mark (such as a chalk line scribe) marked on the drill string for visual reference; 2. the rotary mode of drilling is performed for a rotary interval while rotating the drill string at a rotary mode rotation rate; 3. at the completion of the rotary interval, rotation of the drill string is reduced to the orientation mode rotation rate (e.g., 20 rpm); 4. weight is drilled-off until a desired differential pressure through the drill string (e.g., 200 psi) is achieved; 5. the surface computer commands the top drive to stop rotation of the drill string from the orientation mode rotation rate at the surface stop orientation in accordance with selected ramp down (transition) parameters; 6. the drill string is counter-rotated from the surface stop orientation to the left by 450 degrees (1.25 revolutions) and to the right by 270 degrees (0.75 revolutions) to the surface fixed orientation, and the top drive brake is applied to maintain the surface orientation of the drill string at the surface fixed orientation; 7. the desired differential pressure through the drill string (e.g., 200 psi) is maintained; 8. the directional interval is drilled in directional mode of drilling, with the drill string held at the surface fixed orientation at the surface location; 9. when the directional interval is completed, the computer commands the top drive to transition to the rotary mode of drilling in accordance with selected ramp up (transition) parameters; and 10. the above sequence is repeated until the desired length of borehole is drilled using the method.

(66) In this document, the word comprising is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article a does not exclude the possibility that more than one of the elements is present, unless the context clearly requires that there be one and only one of the elements.