Adjustable Bent Sub

This invention pertains to adjustable drill string connections usable to change the orientation of a lower portion relative to an upper portion of the drill string. The most immediate use of the invention will be in a drilling motor body to deflect the lower motor centerline. The motor is considered part of the drill string into which it is installed.

Directional drilling is a well established art in the well drilling industry. Various elements are available for inclusion in the drill string to influence the course of the well bore as drilling progresses. Apparatus for use downhole to indicate at the surface various parameters measured downhole are now in common use and generally known as Measurement While Drilling or MWD arrangements. At the present time the drill string often has to be oriented rotationally relative to earth to measure and influence the course of the well bore as it is further drilled.

Frequent measurements and corrections now practical demand only small amounts of bend in drill strings to deflect the drill string centerline to make well bore corrections. It is practical to rotate the drill string with such slight bends to drill ahead along the existing centerline. There are two salient problems in making up the downhole assembly to drill with bent elements, commonly known as bent subs, whatever their length. The first problem pertains to rotational alignment of drill string components separated by threaded connections. The second problem pertains to adjustably bending the bent sub to deflect the centerline of the lower portion of the string relative to the upper portion. Apparatus of this invention addresses those two problems.

It is therefore an object of this invention to provide an adjustable sub to change the rotational orientation of axially spaced portions of a drill string.

It is another object of this invention to provide an adjustable sub to deflect the centerline of a drill string.

It is yet another object of this invention to provide adjustable subs that require no shims and may complete the adjustment by the application of torque in the manner used on tool joints, with the same tongs.

It is still a further object of this invention to provide adjustable subs for use in drilling motor housings to change the orientation of the lower end relative to the upper end of the bodies.

These and other features and advantages will be apparent to those skilled in the art from consideration of the included claims and appended drawings.

The alignment sub is provided in two forms, a rotational alignment sub and a deflection sub. Common features will be described first.

There are three essential tubular members, two members each have straight threaded bores, or boxes, on one end, each box facing the other. One box has coarser threads than the other. A third member is a double ended shoulderless pin extending threadedly into each box to form a generally elongated tubular assembly with opposite ends of the pin threadedly mating the threads in the related box. Opposite ends of the assembly, or sub, are arranged to attach to the extending portions of the drill string of which the sub is an element. If the sub is part of a drilling motor body, one end may be the lower portion that carries the output shaft. The output shaft, in that case, usually extends through the bore of the third member to a torque producing rotor above the sub.

The faces on the boxes are threadedly drawn together in the usual tool joint tightening process to make the assembly rigid and usable in the drill string. When assembled, the pin can be unscrewed from the coarser threaded box to leave a gap between the two faces. The finer threaded box can then be screwed further onto the pin to bring the two faces together again. More rotation is required of the finer threads with the result that radial lines in each of the boxes, if originally coincident, will be rotationally displaced. This changes the rotational relationship of one box relative to the other and, hence, changes the rotational relationship of axially spaced portions of the drill string containing the apparatus of this invention. To make changes in the opposite direction, the finer thread is first unscrewed to space the box faces.

The rotational alignment sub accomplishes the intended purpose by relative rotation of opposite ends of the sub as described above. The deflection sub differs in that the double ended pin, and the associated boxes are on a centerline that crosses the axis of the centerline of the drill string at a small angle. The preferred construction has the pin centerline crossing the centerline of the end attached to the upwardly continuing drill string at a point coinciding with the plane of the two box faces which is perpendicular to the pin centerline. Also preferred is construction which permits one configuration to place centerlines of opposite ends of the sub on one line, a straight configuration. Rotation of one end, relative to the other, one half turn then yields a total axis deflection of twice the amount of angle of the pin centerline relative to the straight configuration centerline.

To deflect the centerlines of opposite ends of the sub the same process described for changing the rotational relationship is used. Unscrewing the coarse end of the pin as before and retightening the finer threaded box results in a change in the rotational relationship between the box .containing members. The changed rotational relationship between ends containing the deflected box centerline results in changing the angle of the extended centerline of one box containing member relative to the extended centerline of the other. That action results in change in the deflection of axially spaced portions of the drill string containing the deflection adjusting sub.

When the apparatus is used in a drilling motor body the radial walls of all members may be thinner than those used up-string. The bores in the members may be larger to accomodate a motor driveshaft.

To assure that the pin turns on the preferred end relative to mating box threads set screws are optionally installed radially in the walls of each box containing member to be selectively tightened against the pin to rotationally secure the pin to a box. After tightening up the assembly for use, the screws can all be tightened.

The rotational alignment and deflection subs can be, and usually will be, used in series by merely screwing them together in making up the downhole assembly. They can, however, be combined in one assembly of five principal components. One end of the rotational alignment sub and one end of the deflection sub is combined to form a tubular center member having a coaxial threaded box on one end and threaded box on the other end that has an axis deflected from the axis of the coaxial box. A tool joint connection is saved by this process.

When adjusting the deflection sub one end is rotated relative to the other an amount proportional to the amount of deflection intended for the centerline. That rotation may require correction of the rotational alignment between selected radial lines axially spaced along the drill string assembly. The rotational alignment sub is usable to do this correcting by processes previously described herein.

At the juncture of the box faces for both forms of the sub at least one index line is needed and is usually inscribed in the outer surface. One box may have scribe lines distributed about the periphery to indicate the amount of rotation of one box relative to the index of the other. Such lines may wear away in time. A self adhesive, temporary, decal has been devised to stick on at least one box periphery to serve the same purpose. For the rotational alignment sub, the decal is marked in degrees. For the deflection sub, the decal is marked with the amount of deflection produced by rotation of one box relative to the other. The decals have an index line that is aligned with the deeply inscribed index line for the related box. The decals wear away rather quickly but are readily replaced when adjustments are to be made.

In the drawings wherein like captions refer to like features, FIG. 1 is a cutaway of a rotational orienting sub and the simplest form of the invention.

FIG. 2 is an elevation of the sub of FIG. 1, mostly cut away, showing only the central portion after some adjustment steps have been taken.

FIG. 3 is an elevation of the sub of FIG. 2 after adjustment is made.

FIG. 4 is an elevation of the center portion of the sub of FIGS. 1 and 3 showing an optional adjustment aiding accessory.

FIG. 5 is an elevation similar to FIG. 4 but more appropriate for use on the subs of FIGS. 6 and 8.

FIG. 6 is a sectional view of an axis deflection adjustment sub in the straight configuration.

FIG. 7 is an elevation, partly cut away, of the sub of FIG. 6 after adjustment for maximum deflection.

FIG. 8 is an elevation of a combination sub having features of the subs of both FIG. 1 and FIG. 6.

The sub of this invention is to be assembled into a drill string and to serve as a length thereof. A drill string is construed to include everything below the swivel, including the drill head, or bit. The sub has a bore through which drilling fluid will flow. Other bore conducted elements may also pass through the sub bore, such as wire lines, motor driveshafts and Measurement While Drilling (MWD) apparatus and the like. An optional use of the sub is to be part of a drilling motor body and to adjustably bend that body. In all cases, opposite ends of the drill string extend from opposite ends of the orienting sub.

In FIG. 1 a rotational orienting sub is assembled and ready for field use. The axis of members 1, 2, and 3 are on the same line. Member 1 has means on the left end, a tool joint pin 1a, to connect to the upwardly continuing drill string. Member 1 has bore 1b with straight threads 1c, and face 1e. The box differs from a tool joint box in that it has straight threads. Member 2 is identical to member 1 with the exception that threads 1c have twice the pitch as threads 2c, and pin 2a to attach to a downwardly continuing portion of the drill string. Double pitch threads 1c is a matter of choice because the threads must only differ in pitch to function, in principle, as described herein.

Member 3 is a double ended, threaded and shoulderless, tool joint pin. The threads 3c and 3d match the threads 1c and 2c respectively. Set screws 1d and 2d can be selectively tightened on surfaces 3a and 3b respectively to cause the pin to turn in the selected box when the two ends of the sub are separated as shown in FIG. 2 for adjustment. Anything that normally passes along the drill string bore can pass through bores 1g, 3e, and 2g. Seals marked s protect set screws if they are not independently sealed.

Preferred construction of the sub provides juxtaposed index lines on the box peripheries when the pin 3 is centered in the torqued up boxes. In FIG. 2, set screws 2d have been tightened on surface 3a, set screws 1d have been loosened to clear surface 3b, and pin 3 has been unscrewed from the box of member 1. Index lines 1f and 2f are peripherally separated an amount d1 and faces 1e and 2e are separated as shown by action of the double pitch threads.

FIG. 3 shows the sub after set screws 1d are tightened, set screws 2d are loosened, and member 2 is tightened up on the single pitch threads 2c and 3d. The finer threads require more rotation of member 2 to bring the faces 1e and 2e into contact and the index lines 1f and 2f are now separated by peripheral distance d2. The distance d2 expressed in angular degrees represents the amount the adjustment just described has changed the rotational relationship between opposite ends of the sub, and, hence, between opposite ends of the drill string into which the sub is assembled.

If the single and dual pitch combination is used the thread forms can be identical. The coarse thread is loosened half as much as the final desired rotational change. In the case of 4 pitch threads, a full circle reorientation is possible in only one-fourth inch change in axial position of the pin within the boxes. A marker is normally used on member 3 to show when it is axially displaced from the neutral position. Further adjustment processes may be altered to bring member 3 toward neutral axial position.

In FIG. 4 a stick-on decal is shown as normally applied while adjusting the rotation orienting sub. The zero line is shown aligned with index line 2f. When index line 1f is moved, the amount of movement is shown opposite line 1f. The decal quickly wears away, leaving a clean surface for the next decal when adjustment is to be made.

FIG. 5 will be more easily explained after the axis deflection sub is described.

FIG. 6 represents an axis deflecting sub that could be constructed exactly like the sub of FIG. 1 except for the angular relationship between the centerline L2 of the double ended pin and the line L1 which, in this instance, contains the centerlines of both members 7 and 9. The angles .phi.1 and .phi.2 are normally both one and one-half degrees. It is two degrees here for graphic clarity. Preferred construction features that aid in design, fabrication, and use but by no means comprise limitations includes the condition that plane 10, containing both faces in contact of boxes of members 7 and 8 be perpendicular to line L2 and be coincident with the intersection of lines L1 and L2. Angles .phi.1 and .phi.2 are identical. Members 7 and 8 are identical excepting that threads 7b are double threads and threads 8b are single pitch, preferably all of the same thread form. Small departures from these conditions cause almost undetectable operational differences and even large differences in the above stated geometric relationships may leave the operational principle intact. This is considered by and is within the scope of the claims.

With the adjustment state shown the axes of the members 7 and 8 lie on the same line, the pin 9 is axially centered and index scribe lines (not shown) on the outer periphery near plane 10 are coincident.

Consider set screws 7c loosened and 8c tightened. Rotation of member 8 will rotate pin 9 about L2. The right end of L1 will rotate about the right end of L2, describing the surface of a cone, while the left ends of L1 and L2 remain stationary. After this first deflection action, the faces of the boxes will be separated as shown in FIG. 2. Member 7 must now be rotated to compress the faces in preparation for torqueing up for use. Now both members have been rotated about the pin axis. At each end line L1 will have generated some imaginary surface of a cone about L2. Only the rotational relationship between opposite ends of the sub need be considered to determine the resulting angle of end-to-end deflection of L1. The line L1 becomes bent or deflected at plane 10 up to a maximum angle of twice .phi.1, at 180 degrees of rotation between sub ends. The rotation of the opposite ends and control of pin 9 can be carried out as previously described for FIGS. 1, 2, and 3. This drawing is the configuration intended for use in drilling motor bodies to bend the body between the power producing rotor and the support bearings for the output drive shaft. The support bearings represent the means to attach to the downwardly continuing portion of the drill string for this construction. The rotor and the drill head driving shaft are connected by shaft component 11 which passes through bore 9a. The seals marked s are needed to protect the set screws if they are not independently sealed. Bores 7a and 8a are on the same extended axis. Mating threads 9b and 7b differ in pitch from mating threads 8b and 9c. Surfaces 9d are for set screw grip as previously described.

FIG. 7 shows the sub after maximum deflection and retightening for service. Stick-on decals are shown in place. Index line 7f indicates four degrees deflection. Index line 8f is out of sight, one-half turn away, on the far side and will indicate 180 degrees on decal 16. Some operators prefer engraving the markings shown on the decals directly into the periphery of the sub. That poses no problem if wear rate is acceptable. Either of the index lines can be located in relation to some other feature of the downhole assembly whether on decals or engraved in the sub. The example cited above illustrates relationships and their changes that result from manipulation of sub members and no limitation is intended.

FIG. 8 is a special form of combination sub having both rotational alignment and axis deflection capabilities. The juncture between members 12 and 13 compares with that of FIG. 1. The juncture between members 13 and 14 compares with that of FIG. 6. Otherwise stated, the left end has a pin axis coincident with the box axes for rotational alignment and the right end has the pin axis crossing the axis of member 13 for axis deflection adjustment. Member 12 may be identical to member 1 of FIG. 1. Member 14 may be identical to member 8 of FIG. 6. The left end of member 13 has the box of FIG. 1, and the right end has the box of member 7 of FIG. 6. Fewer members are needed to replace two orienting subs.

In use, the FIG. 8 arrangement permits the rotational misalignment caused by adjusting for axial deflection to be directly noted on the scales, such as shown in FIG. 7, on member 13 for use directly in correcting the rotational alignment at the member 12-member 13 juncture as previously described herein.

FIG. 5 can now be described with reference to FIG. 7. FIG. 5 shows some surface of the sub of FIG. 6. In FIG. 5 the sub is straight and index lines 7f and 8f are coincident. Index lines 15a and 16a are applied to also be coincident. Steps taken to change the rotational relationship between opposite ends of the sub have been defined. Quantification markings about the periphery of decal 15 will be the degrees, relative to index 16a, that a plane containing both ends of the bent line L1 will be rotated relative to index 15a. Quantification markings on decal 16 will be in degrees up to a maximum of twice .phi.1, four degrees total in this case in reference to the index line 15a. Preferred markings on decal 15 is zero to 180 degrees in both peripheral directions. Preferred markings for decal 16 is zero to maximum deflection in both directions with clockwise and counterclockwise indicators.

A simplified system for the decals provides an index line that is placed on the outer periphery where a plane containing lines L1 and L2, for each end, intersects plane 10 at the most obtuse angle. In the oil field that point is called the "short side". The decals are marked 0 to 4 on one and 0' to 4' on the other. Only 180 degrees are marked, the other 180 degrees unmarked. To deflect the axis 3 degrees, for instance, the opposite ends are manipulated until the 3 and 3' are superimposed. This point is the tool face or lies on the plane that contains the axis of both ends of the sub.

Descriptive matter used herein has include arrangements of planes and lines. Some of these are preferences, not limitations. Salient points of novelty for the rotational alignment sub comprises threads of different pitches, as described, on adjustment members. For the deflection sub the axes of the adjustment threads are not parallel to the general centerline of the drill string in the least deflected state.

From the foregoing, it will be seen that this invention is one well adapted to attain all of the ends and objects hereinabove set forth, together with other advantages which are obvious and which are inherent to the methods and apparatus.

It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

As many possible embodiments may be made of the apparatus and method of this invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.