PERCUSSION DRILLING APPARATUS AND METHOD FOR MEASUREMENT WHILE DRILLING
20240133289 ยท 2024-04-25
Assignee
Inventors
- Kamil ROGOZINSKI (Welshpool Western Australia, AU)
- Paul KALISCH (Welshpool Western Australia, AU)
- Jonathan LOWE (Welshpool Western Australia, AU)
- Nick BUTERS (Welshpool Western Australia, AU)
- Ralf ZAEPER (Welshpool Western Australia, AU)
- Kai-Uwe OTT (Welshpool Western Australia, AU)
- Matt SCHUBERT (Welshpool Western Australia, AU)
- Timothy HOPPER (Welshpool Western Australia, AU)
Cpc classification
E21B21/12
FIXED CONSTRUCTIONS
E21B47/01
FIXED CONSTRUCTIONS
International classification
E21B21/12
FIXED CONSTRUCTIONS
Abstract
A measurement tool for use in pneumatic percussion drilling comprises a body comprising one or more measuring instruments positioned in a drill string above a pneumatically operated hammer of the drill string.
Claims
1.-18. (canceled)
19. A measurement tool for use during pneumatic percussion drilling, the measurement tool comprising: a body comprising one or more measuring instruments positioned in a drill string above a pneumatically operated hammer of the drill string, wherein the drill string comprises a reverse circulation hammer drill.
20. A measurement tool according to claim 19, wherein the body is positioned immediately above the pneumatically operated hammer.
21. A measurement tool according to claim 19, wherein the measuring instrument comprises one or more orientation and/or inertial movement sensors.
22. A measurement tool according to claim 21, wherein the measuring instrument comprises one or more gyroscopes.
23. A measurement tool according to claim 21, wherein the measuring instrument comprises one or more accelerometers.
24. A measurement tool according to claim 19, wherein the measuring instrument comprises a gamma ray detector.
25. A measurement tool according to claim 19, wherein the measuring instrument is connected to the body by one or more dampers for dampening shock/vibration from the pneumatic percussion drilling that is experienced by the measuring instrument.
26. A measurement tool according to claim 19, wherein the measuring instrument is within a compartment in an annular portion of the body.
27. A measuring tool according to claim 26, wherein the compartment is within an outer diameter of the body.
28. A measuring tool according to claim 26, wherein the compartment is within an annular portion of the body, radially outward of a fluid return channel.
29. A measurement tool according to claim 26, wherein the compartment is within an annular portion of the body between fluid supply channels.
30. A measurement tool according to claim 26, wherein the compartment is sized relative to the instrument so that movement of the instrument during percussion drilling is clear of the walls of the compartment.
31. A measurement tool according to claim 19, wherein the body has one or more fluid supply channels and a fluid return channel.
32. A drilling apparatus comprising a body comprising one or more measuring instruments positioned in a drill string above a pneumatically operated hammer of the drill string, wherein the drill string comprises a reverse circulation hammer drill.
33. A method of measuring a measurement tool during reverse circulation (RC) pneumatic percussion drilling operations comprising the steps: drilling a hole using a drill string having an RC drill bit, a pneumatic hammer for the RC drill bit and a measuring instrument above the hammer; and measuring the orientation of the tool as the hole is being drilled.
34. A method according to claim 33, wherein during each pause in drilling the measuring instrument takes a measurement.
35. A method according to claim 34, wherein the measurement comprises a calibration measurement.
36. A method according to claim 34, wherein the pause in drilling comprises an addition or removal of a drill rod.
37. A method according to claim 35, wherein the measurement comprises taking a first measurement at a first position then rotating 180 degrees and taking a second measurement at a second position.
38. A method according to claim 37, wherein the first measurement is recorded when at the second position and the second measurement is recorded at the first position.
39. A method according to claim 33, wherein the method further comprises damping vibrations/shock experienced by the measuring instrument.
40. A measurement tool according to claim 19, wherein the measurement tool is connected immediately above the hammer in place of a standard drill rod in the drill string.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0106] Preferred embodiments of the invention will now be described with reference to the following drawings, in which:
[0107]
[0108]
[0109]
[0110]
[0111]
[0112]
[0113]
[0114]
[0115]
[0116]
[0117]
[0118]
[0119]
[0120]
[0121]
[0122]
[0123]
[0124]
[0125]
[0126]
[0127]
[0128]
[0129]
[0130]
[0131]
[0132]
DESCRIPTION OF EMBODIMENTS
[0133] Referring to
[0134] The body 10 comprises longitudinally extending compartments 212 arranged around an outer diameter of the body 10. Each compartment 212 is in the form of a recess or slot as seen in
[0135] The body 10 further comprises a communications port 196 which provides a data connection to the one or more measuring instruments 180 and/or recharging of a battery (not shown) mounted within the compartment 212. The communications port 196 will be discussed below in detail below with reference to
[0136] As seen in
[0137] Referring to
[0138] In an embodiment, one of the sub-portions is a silicone or rubber and the other of the sub-portions is an elastomer. Preferably the silicone comprises a soft silicone gel, such as Alpha GEL made by Taica Corporation. Other suitable materials may include, but are not limited to, polymers, such as sorbothane, or one of a number of compositions of room temperature vulcanizing (RTV) silicone. Preferably the elastomer is a polymer, such as polyurethane. In an embodiment, the movement limiting portion constrains movement of one or both of the sub-portions such that a vibrational/shock force is applied to the respective sub-portions causing it/them to elastically deform.
[0139] In an embodiment, the movement limiting portion is a shroud 124. In an embodiment, the silicone or rubber sub-portion is a damper, preferably a silicone damper 130 (for example, a Taica M6 Stainless Steel Shock Mount MN-3 SUS or similar as described below in relation to
[0140] Percussion drilling is an umbrella term that includes but is not limited to, reverse circulation drilling and rotary air blast drilling. The present invention may be suitable for any form of drilling where the drill string experiences high impact and/or repetitive impact forces. The forces that the measuring instrument 180 experiences may be axial, radial and/or rotational shock/vibration experienced independently, or a combination of the aforementioned. Such forces may impede the measuring instrument 180 from collecting accurate data and/or functioning entirely.
[0141] In an embodiment, the compressible/resilient ring 160 is a polyurethane ring 160. The silicone damper 130 and polyurethane ring 160 are housed within the shroud 124. The silicone damper 130 comprises a smaller diameter plate 154 which has a post 138 projecting therefrom for inserting into the support post hole 150 of the support 186 positioned on each respective end of a backplate 184 to which the measuring instrument 180 is rigidly coupled, such as by screws. The shroud 124 assists the silicone dampers 130 and the polyurethane rings 160 to stay inline with the backplate 184 or other measuring instrument, such as gamma ray detector 182, while also preventing the dampers from deforming outside the bounds of the inner boundary of the shrouds 124. The shrouds 124 reduce or prevent lateral motion of the silicone damper 130 and the polyurethane rings 160. The silicone damper 13 is prevented from moving outside the inner diameter of the shroud 124. The person skilled in the art will readily appreciate that many arrangements and types of dampers may be used in place of the described dampers based on the expected conditions the body 10 will experience during operation.
[0142] For example, where axial forces are the only shock/vibration expected to be experienced the polyurethane rings 160 may be removed. Furthermore, the polyurethane ring 160 may be replaced with a damper that dampens axial vibration such as a second silicone damper 130. Alternatively, where rotational forces are the only shock/vibration expected for the measuring instrument 180 to experience, multiple dampers which dampen rotational forces may be employed. This may be in the form of multiple polyurethane rings 160 which have differing damping properties that independently or in combination to account for the expected shock/vibration conditions.
[0143] Referring to
[0144] Referring to
[0145] In an embodiment, plate 132 is of a larger diameter surface than the diameter of plate 134. The post 136 provides means to rigidly affix the silicone damper 130 to the shroud 124 by extending through a centre hole 140 of the shroud 124. The centre hole 140 may be threaded. The post 136 may be threaded to provide a means for the post 136 to be rigidly affixed to the shroud 124. The post 136 may be affixed by way of a nut, preferably a self tightening nut or vibration resistant nut such as a Nyloc? nut 156. Alternatively, a locking or sealing adhesive, such as Loctite? or a self-locking washer, such as Nordlock? may be used. The post 138 provides for insertion into the hole 150 in the support 186 to provide a connection which allows for flexibility and movement of the backplate 184 and measuring instrument 180 in response to shock/vibration from percussion drilling.
[0146] The backplate 184 and measuring instrument 180 may be interchangeable with any measuring tool or apparatus having supports 186 affixed at respective longitudinal ends with dimensions which fit within the compartments 212, such as gamma detector 182. To fit within the compartments the length of the measuring tool and damping apparatuses must line up with a respective hole in the sidewall 114 of the compartment 212.
[0147]
[0148] Referring to
[0149] Referring to
[0150] As the major axis 188 of the support 186 is less than or equal in length to the minor axis 128 of the shroud 124, the polyurethane ring 160 prevents the major axis 188 of the support 186 from moving to be parallel with the minor axis 128 of the shroud 124 due to it interposing between the support 186 and the side walls 144 and by that imposition causing the polyurethane ring 160 to be elastically radially compressed by a force urging the support 186 to rotate about the post 136, or otherwise move in stages as the gap 174 is closed and then further compressed once the gap 174 is closed.
[0151] The supports 186 on each end of the backplate 184 comprise a shoulder 192. The polyurethane ring 160 is coupled to the support 186 by the support 186 being inserted into the centre hole 164 and the surface 170 of each polyurethane ring 160 abutting against shoulder 192.
[0152] Referring to
[0153] Referring to
[0154] To increase the rotational damping response, posts (not shown) may extend radially from the first shell portion 510 and/or the second shell portion 512 into the silicone core 514. The addition of the radially extending posts provides additional surface area to receive a response from the silicone core 514 during movement. The custom moulded damper 500 may act as an alternative or a replacement to the silicone damper 130 and affixed similar between the backplate 186 and the shroud 124 in a similar or otherwise suitable manner. Alternative embodiments may use a combination of different dampers described herein.
[0155] Referring to
[0156] The number of each type of O-rings provided are for exemplary purposes. There may be 1, 2, 3, 4, 5, 6 or more O-rings positioned radially between the support 186 and the housing 614. Similarly, there may be 1, 2, 3, 4, 5, 6 or more O-rings positioned axially between the support 186 and the housing 614. The support 186 and housing 614 each may comprise one or more shoulders for seating each of the O-rings axially between the support 186 and the housing 614. The O-rings may comprise the same or varying compositions of materials such that the overall damping effect can customised for a specific application. The support 186 may also be elliptical in shape (as shown in
[0157] Referring to
[0158] The spatial positioning of the measuring instruments 180 within the compartments 212 can be seen in
[0159] During operation of the percussion drill, the rotational forces may cause the backplate 184 to rotate with respect to the body 10 which will cause the respective major axes 188 of the supports 186 to rotate towards the respective minor axes 128 of the shrouds 124. As the rotation of the plate occurs the polyurethane rings 160 will compress due to the material properties and cross-section 162. The compression resists against this rotation providing dampening until it reaches a maximum point. The maximum point being no further than where the major axis 188 of the support 186 and the minor axis 128 of the shroud 124 align. The ring is selected so that the resistance due to compression is elastic and the maximum expected forces applied do not reach plastic deformation and the rotation does not reach the maximum point.
[0160] In an embodiment, the polymer ring dampens by elastically resisting deformation urging legs of the U or V shape together until they meet and then dampens by elastically resisting deformation of the legs being compressed further together. In particular, the cross-section 162 and material properties allow the polyurethane ring 160 to elastically deform as the major axis 188 of the support 186 rotates towards the minor axis 128 of the shroud 124. The elastic deformation of the polyurethane ring 160 provides increasing resistance against the support 186 to the continued rotation of the support 160. Likewise, the elastic deformation of the silicone damper 130 provides increasing resistance to other directional forces. In this manner, the vibration/shock from the rotation of the measuring instrument 180 being coupled to the backplate 184 is reduced to a level which the measuring instrument 180 is capable of functioning.
[0161] For example, the average acceleration the drill rod positioned immediately above the bottom hole assembly experiences at any given time during operation is approximately a peak of 2500 g-force. The damping apparatus described herein allows the body 10 to perform the same function of a standard drill rod while also reducing the acceleration experienced by the measuring instrument closer to approximately a peak of 20 g-force. Where previously measure while drilling operations were not possible due to the shock/vibration experienced during percussion drilling operations, the damping apparatus reduces/eliminates enough shock/vibration such that measure while drilling operations can be conducted. Without the damping apparatus described herein a measuring instrument may be subjected to for example in excess of 3000 g force of acceleration due to shock/vibration and consequently would be inoperable/damaged/destroyed making measure while drilling operations impractical or impossible to be employed during percussion drilling operations.
[0162] Alternative embodiments of the present invention may require more or less damping apparatuses to be used to dampen the shock/vibration. The backplate 184 in the embodiment provided is of such a length and mass that having a damping apparatus at each end provides an optimal reduction of vibration/shock. However, where the measuring instrument 30 only requires a plate 38 that is shorter it may be sufficient to couple it to a single damping apparatus. Alternatively, if the measuring instrument 30 is longer requiring the plate to be longer, there may be a further damping apparatus providing at some point along the length of the plate 38. The damping apparatus provided along the length of the plate 38 may comprise a radial damper. Additional dampers may be employed depending on the expected conditions to be experienced.
[0163] Alternative damping apparatuses may incorporate a number of alternative dampers or components including, but not limited to, springs or fluid dampers. Springs may be used to resist and/or dampen the rotation of the backplate 184 with respect to the body 10. Alternatively, or in addition, fluid dampers may be used which work by moving a planar body through a viscous fluid. The viscous fluid resists and/or dampens the movement of the planar body which resists and/or dampens the movement of the backplate 184 and support 186.
[0164] Alternative rotational dampers include having one or more bodies radially extending within a rubber or elastomer body, such as silicone damper 130. The radially extending bodies can rotate against a cushion like body, such as the silicone, provided by the rubber or elastomer body but are biased towards their initial position within the rubber body. For example, as discussed briefly above, the post 138 of the plate 154 may extend through a portion or all of the silicone damper 130 without connecting to the other post 136 of the plate 152 of the silicone damper. The post 138 may have one or more radially extending bodies within the boundaries of the silicone of the silicone damper 130. In this embodiment the post 138 would be rigidly connected to the plate 184. As the plate 184 rotates the post 138 also rotates thereby moving the bodies radially extending through the silicone damper 130. The radially extending bodies dampen the rotational force while also providing a resistance and biasing force to return the post 138 and therefore, the backplate 184 to its neutral orientation.
[0165] The shape of the shroud 124 and support 186 may have a circular or other shaped cross section where alternative damping means for damping and/or resisting rotation of the backplate 184 or other measuring tool, such as a gamma ray detector 182, relative to the body 10.
[0166]
[0167] The cross-sectional area of the compartment 212 may be greater than the cross-sectional area of the fluid supply channels 318, thus allowing for a measuring instrument 180 of greater dimensions to be housed within the compartment 212 than would be able to be housed in a compartment having the same cross-sectional area as the fluid supply channels 318.
[0168] The cross-sectional profile of the compartment 212 may be different than the cross-sectional profile of the fluid supply channels 318, which are beneficially round, thus allowing for a measuring instrument 180 of different proportions to be housed within the compartment 212 than would be able to be housed in a compartment having the same cross-sectional profile as the fluid supply channels 318.
[0169] The different cross-sectional area and/or profile of the compartment is advantageous as the incorporation of a wider variety of measuring instruments 180 is enabled. The compartments 212 may be shaped to be generally U shaped in cross-section. The compartment may comprise a substantially flat base.
[0170] The compartment 212 may comprise sloped sidewalls that are wider apart at an opening of the compartment 212 than the sidewalls are apart at the base.
[0171] The compartment 212 may comprise an opening in the radial direction of the body 10 for access to the compartment 212.
[0172] The radial opening facilitates access to the compartment 212 when the casing 12 is removed.
[0173] Referring to
[0174] The fluid return channel 320 eventually receives return of the fluid provided through the fluid supply channels 318 as well as any cuttings or debris produced from the drilling operations. Due to the fluid return channel 320 comprising solid debris it is typically of a larger diameter relative to the fluid supply channels 318. The fluid return channel 320 is fluidly isolated from the fluid supply channels 318 and compartments 212, 212. The fluid return channel 320 is defined by the fluid return pipe 322 which connects to each successive drill rod from the bottom hole assembly up to a surface return unit, such as a cyclonic separator, container or sample bag.
[0175] The fluid supply channels 318 supply working fluid from a surface unit (not shown) through the body 10 providing compartments 212, 212 without impeding the volumetric flow rate of fluid required to operate the bottom hole assembly, such as to provide pressurised air to the hammer and drill bit in reverse circulation drilling.
[0176] There is provided a communications port 196 (seen in
[0177] Referring to
[0178] Referring to
[0179] Again, referring to
[0180] In alternative embodiments, the splines 414, 418 may be positioned on the casing 12 and the respective complementary spline mating portions 416, 420 may be located on the body 10. The splines 414, 418 may be affixed to the body 10 or integrally formed therein. Alternative embodiments may have the splines 414, 418 affixed to the casing 12 or integrally formed therein. Complementary spline mating portions 416, 420 may be affixed to the casing 12 or integrally formed therein. Alternative embodiments may have the complementary spline mating portions 416, 420 affixed to the body 10 or integrally formed therein.
[0181] The combination of spline 414 and complementary spline mating portion 416 form a torque transferring mechanism which is also able to be separated so as to provide access to the compartments 212/212 and the measuring instrument(s) therein. The interaction of spline 418 and complementary mating portion 420 provide a physical connection for sharing a torque load between the body 10 and casing 12. Each torque transferring mechanism transfers a torque applied to the body 10 throughout the body 10 and the casing 12. Conversely, the torque applied to the casing 12 is applied to the casing 12 and the body 10.
[0182] In use measuring the orientation of a measurement tool during percussion drilling operations comprises drilling a hole using a drill string having a percussion drill bit and a measuring instrument; and measuring the orientation of the tool as the hole is being drilled. As the drill string progresses into the drilled bore hole the action of the percussion drill bit is paused to add another drill rod, and when the drill string is extracted drill rods are removed. During each pause in drilling the measuring instrument takes a calibration measurement.
[0183] In an embodiment, the measurement comprises taking a first measurement, which may be a calibration measurement, at a first position then rotating 180 degrees and taking a second measurement at a second position.
[0184] The casing 12 comprises complementary spline mating portions 416, 420 which slideably receives the body 10, the body 10 comprising spline 414, 418. To slideably receive the body 10 within the casing 12, the outer diameter at spline 418 must be smaller than an inner diameter of the complementary spline mating portion 416. In an embodiment, the casing is separable from the internal body. In an alternative embodiment, the body 10 and casing 12 may each comprise one of the splines 214, 220 and one of the complementary spline mating portions 416, 420. Alternatively, the outer diameter of spline 416 may be smaller than an inner diameter of the complementary spline mating portion 420 requiring the body 10 to be slideably inserted into the casing 12 from the opposite end.
[0185] As discussed above, with reference to the manifold 324, the upper portion of the body comprises connection means for fluidly connecting to a multi annulus drill rod above the torque transferring mechanism located at the upper end of the body 10 as well as below the lower torque transferring mechanism located at the lower end of the body 10. The fluid return channel 320 connects directly to the fluid return channels of the drill rod immediately above and below the body 10 to fluidly isolate the fluid return channel 320. The annulus of the drill rod above the body in the drill string fluidly connects with the manifold 324 of the upper end of the body 10 at or adjacent to the upper torque transferring mechanism. The manifold 324 directs the supply fluid through the fluid supply channels 318 to the lower end of the body 10 to a chamber which fluidly connects with the annulus of the drill rod or bottom hole assembly below the body 10 at or adjacent to the lower torque transferring mechanism.
[0186] Measurements were conducted to test the effectiveness of the present invention. The accelerations in all three axes were measured with and without the damper apparatus described. The drill bit was actuated at a drill site to measure the un-damped forces, with a supply pressure to a RC drill of 450 psi a rate of penetration of 1 m/min, rotation speed of 50-55 RPM and an air flow rate of 6001/s. The measured half sine pulse equivalent force was 3700 g in the x Axis, 1200 g in the y axis and 5200 in the z axis.
[0187] Then a test drill against a rubber block was established in a test environment. One shock mounted sensor system with an aluminum test chassis that weighed 410 grams and one with a steel chassis weighing 512 grams were tested. Each test setup was subjected to approx. 1 minute of drilling into the rubber block and the vibration data of the test chassis was recorded.
[0188] The steel 512 g chassis experience RMS acceleration as follows: [0189] x-axis1.26 g y-axis1.42 g z-axis1.46 g
[0190] The steel 512 g chassis experience peak acceleration as follows: [0191] x-axis8.49 g y-axis18.27 g z-axis21.25 g
[0192] The aluminium 410 g chassis experience RMS acceleration as follows: [0193] x-axis1.64 g y-axis2.08 g z-axis1.47 g
[0194] The aluminium 410 g chassis experience peak acceleration as follows: [0195] x-axis7.72 g y-axis10.52 g z-axis21.25 g
[0196] In the context described herein, pneumatic percussion drilling is where there is a hammer actuated by pressurised air that strikes an anvil component of or connected to a drill bit so that the drill bit impacts on rock on the bottom of a drill hole so as to break the rock. The hammer is directly next to the drill bit. This type of percussion drilling is used in rotary air blasting (RAB) and reverse circulation drilling (RC drilling). Pneumatic percussion drilling is used in mineral exploration. It is to be distinguished from hydraulic (often water or mud) powered percussion drilling used in hydrocarbon well drilling. It is also to be distinguished from mechanical percussion drilling where the drill string is lifted and dropped, usually from the surface. In hydraulic and mechanical percussion drilling a casing within which the drill string can move is usually used. However, in pneumatic percussion drilling a casing is usually not used.
[0197] RC drilling will be understood to be where the pressurised air flow is also used to blow the rock broken by the drill bit impact into one or more holes in the drill bit and then up through the drill string. The drill rods have an inner tube through which the air and recovered rock return to the surface and an outer tube, which between this and the inner tube, the pressurised air travels down the drill string to the hammer and the drill bit. This is distinguished from RAB, which is where the broken rock air is blown up the drill hole outside of the drill string. The inner tube is not required in the drill rods for RAB.
[0198] Percussion drilling can be distinguished from air core drilling where the drill bit cuts, rather than breaks from impact, but there is pressurised air that returns the cuttings through the drill string. Percussion drilling can also be distinguished from diamond core drilling where ring is cut by diamond teeth and a core sample can be retrieved.
[0199] The sensors in the measuring instrument may be for example accelerometers, such as micro-mechanical systems (MEMS) accelerometers, and gyroscopes, such as MEMS gyroscopes or fibre optic gyroscopes. Suitable devices include TDK Tronics Gyror3300, Gladiator DIGS100, Fitzoptika VG091A-4LD, Analog Devices ADIS16465-2 or Silicon Sensing CRH03. Typically the sensors are arranged to provide 3 axes of acceleration measurement and 3 polar axes of rotational measurement so as to provide an Inertial Measuring System which can measure while moving and can auto-correct for drift while stationary, such as during rod addition/removal.
[0200] Modifications may be made to the present invention within the context of that described and shown in the drawings. Such modifications are intended to form part of the invention described in this specification.