Pipe in pipe bha electric drive motor.

(54) Title: PIPE BHA ELECTRIC DRIVE MOTOR INSIDE PIPE.

(54) Title: PIPE IN PIPE BHA ELECTRIC DRIVE MOTOR.

(57) Summary

A pipe in a pipeline electric motor assembly comprising: a drill rod comprising an inner pipe and an outer pipe and an electric motor; wherein the electric motor is supplied with energy supplied by the inner pipe, and the outer pipe acting at least as conductors and associated methods.

(57) Abstract

A pipe in pipe electric motor assembly comprising: a drilling string comprising an inner pipe and an outer pipe and an electric motor; Where the electric motor is provided with power supplied by the inner pipe and the outer pipe acting at least as conductors and associated methods.

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PATENT TITLE No. 354392

Owner (s): HALLIBURTON ENERGY SERVICES, INC.

Home:

10200 Bellaire Boulevard, Houston, Texas, 77072, USA

<td>Denomination:</td><td>ELECTRIC DRIVING MOTOR BHA PIPE INSIDE PIPE.</td>

CIP:

Classification!

CPC:

Inventor (s)

Issue Date ^ df

The patent of refe

E2

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ZMAN

O coT ^ j ^ rfXsgn the áMEi leffY BIS 2 of the Industrial Property Law; 3rd of AciRdqffoTU ^ qW'the guidelines for the use of the Payment Portal and

RICHARQJ ^ okíAS THERE IS; KEIT ntefna &lt;Honal!

MX / a / 2014/00849 ^

Validity: Twenty years

Vepelmiehtq date:

In accordance with effe from the date of pr &lt;

Who subscribes the I presented ^ ftulQll% bace (Official Gazette of the Fede ^^ l (QQ 01/25/2006, 06/05 / 2009,06 / Regulation of the Mexican Institute articles 1^or, 3°, 4^or, 5^or section V and 12/27/1999, amended on 10/10/20 Deputy Generals, Coordinator, Departmental and other subordinates on 08/04/2004 and 09/13/2007).

Ororrogables counted to tallow ge tafcewlfe the Industrial Property

1997, 17 / l5 / al &amp; r 01/26/2004, 06/16/2005, Áa), 4th and 12th sections I and III of / 2004, 07/28/2004 and 09/07/2007); Industrial Property (DOF is empowered by the Divisional Directors, Coordinators 9, amended on 02/04/2000, 07/29/2004,

This letter is signed with an electronic signature, advance its Regulations, and 1 section III, 2 section V, 26 BIS and 26 TER of the Electronic Services (PASE) of the Mexican Institute of Industrial Property, in the procedures indicated.

THE DIVISIONAL DIRECTOR OF PATENTS

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NAHANNY CANAL REYES

Original string:

NAHANNY MARISOL CANAL REYES | 00001000000403252793 | Administration Service

Tax | 1695 || MX / 2018/18562 | MX / a / 2014/008492 | PCT patent title | 1223 | GAGV | Page (s)

JC3Zm6y2 / 0UCgYyMclmsG6DpSVg =

Digital stamp:

rE6Tuh83VghJ3N2snvNGJkdnvBNY9bjn + 50R9hlpEsvV8oNv8b8rxs78WvG57XKfqmeU45AYxfEw9XEM / mZfsB7bRI tx9f5 nuwoWpVrajzh9 + + + SBYotlkR7j4WuJhgfYVPROuMaF3WuS4HE4iqDBIxsAEHwxreXH7pEn4W5VUqsx6VOWF1z8 cl6S5A Yv1DSdiy10HDrBHPywUcPuWblflVKsU / IIZNs7jb0JUDDMamxmZI¡iN5FpxrnjlBZwZQ6pqww2WGde5 + kbt h68Mj6rP7rqWjKxeWcwN9c4INXLArY / lshUmbrshQOqYPWQ0dX8WAUN4sDlgbqMtc + / == l¡Wew

Arenal No. 550. Floor 1, Pueblo Santa Mana Tepepan, Xochimilco, 16020. Mexico City.

(55) 53340700 www.gob.mx/impi

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MX / 2018/18562

35W

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PIPELINE

BACKGROUND OF THE INVENTION

To produce hydrocarbons (eg oil, gas, etc.) from an underground formation, boreholes can be drilled so as to penetrate hydrocarbon-containing portions of the underground formation. In traditional drilling systems, the destruction of the rock is carried out through rotary power. This rotary power can be provided to the drill string through rotation of the drill string on the surface using a rotary table. This energy can also be provided by a higher drive or it can be provided from the mud flow using a mud motor. Through these modes of power supply, traditional bits such as tricone, compact polycrystalline diamond (PDC), and diamond bits are operated at various speeds and torques.

When a mud motor is used to generate the torque to perform drilling operations, hydraulic leaks along the drill string can limit the desired mud flow rate. This in turn can reduce applying to especially critical engine like Reelwell ™ where levels are conventional.

7Γ 7X ►í&gt; 't / o S- ·' ·): .Ó '-.' V - '* ·' ·

Λ to Jí.

the hydraulic power / í?

¹ mud to generate torsion. This is for drilling systems such as approximate

Falling flow velocities are reduced to 30% of the dramatic velocities at the f lu jof luj velocity or coupled with greater drilling depths that are focused for this technology can result in superior fluid friction during circulation and , therefore, the need for higher circulation pressures.

Such a system may impose certain limitations on the hydraulic power available for the downhole assembly in an ultra extended reach drill. Therefore, it is desirable to have means for generating downhole torque in the bit other than that which only comes from hydraulic means by circulation along the drill string.

In addition, special modifications to positive displacement motors (PDM) are often required to allow these systems to operate at lower flow rates. These modifications may involve lowering the volume of fluid required to drive the power section by rotation of the mud motor rotor by reducing the volume of fluid per stage section of the mud motor. At these flow rates

LOWER INSTITUTE^lɿV / o

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turbines would need to have hólír-p τηή. &lt;ρ ocj-rnrtu ^ e tightened with higher blade angles and higher flow velocities through the smaller propellers to operate effectively. This can result in higher flow resistance and increased risk of mud flow erosion for a given operating output torque. Therefore, it is desirable to develop a drilling system that creates rotary power generated from a device other than a PDM, propeller, or turbine engine where hydraulic pressure would be required to generate rotary force to drill the hole.

BRIEF DESCRIPTION OF THE FIGURES

Some specific exemplary embodiments of the disclosure may be understood by reference, in part, to the following description and accompanying drawings.

Figure 1 shows an illustrative display of a pipe-in-pipe electric BHA motor.

Figure 2 shows an illustrative cross section of the rotor and stator of the electric motor.

Figure 3 shows an illustrative cross section portion of a stator and rotor.

Figure 4 shows a block diagram of the electronic circuits of the engine.

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i '... &gt;

INDUSTRIAL / -y

Figure 5 shows a block diagram of the winding pairs.

Figure 6 shows an illustration of a schematic of the electronic circuits.

Figure 7 shows an illustrative display of a flow diverter within a pipeline within pipeline system.

Figure 8 shows an illustrative display of a pipe-in-pipe electric BHA motor.

Figure 9 shows an illustrative display of an electronic circuit insert.

Figure 10 shows an illustrative display of a pipe-in-pipe electric BHA motor.

Figure 11 shows an illustrative display of a bearing package.

Figures 12A-12F show various rotatable addressable BHA stacks according to some embodiments of the present disclosure.

While the modalities of this disclosure have been shown and described and are defined by reference to exemplary modalities of the disclosure, such references do not imply a limitation on the disclosure, and such limitation is not to be inferred. The subject matter disclosed

λ .. - «i '. · - -. · - ·. and it has the capacity to modify it¹^^ '' &lt;N 'ustriÁl considerable equivalents in form and function, as will occur to those skilled in the art and those who enjoy the benefit of this disclosure. The shown and described modalities of this disclosure are examples only and are not exhaustive of the scope of the disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Illustrative embodiments of the present invention are described in detail herein. In the interest of clarity, not all the features of a real implementation can be described in this specification. Of course, it will be appreciated that in developing such an actual modality, numerous implementation-specific decisions can be made to achieve specific implementation objectives, which may vary from implementation to implementation. Furthermore, it will be appreciated that such a development effort could be complex and time consuming, however it would be a routine undertaken by those skilled in the art who would benefit from the present disclosure.

In one embodiment, the present disclosure provides a pipe-in-pipe electric motor assembly comprising a drill rod comprising an inner pipe and an outer pipe and an electric motor, wherein the electric motor is

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supplied by the inner pipe and the outer pipe acting at least as conductors.

In another embodiment, the present disclosure provides a method of supplying power to an electric motor comprising providing a pipe-in-pipe electric motor assembly comprising a drill rod which includes an inner pipe and an outer pipe and an electric motor. , wherein the electric motor is supplied with energy supplied by the inner pipe and the outer pipe, acting at least as conductors and supplying energy to the electric motor.

In another embodiment, the present disclosure provides a method of drilling a borehole in an underground formation which comprises providing an in-pipe pipeline electric motor assembly comprising a drill rod which includes an inner pipe and an outer pipe. ; an electric motor; and a drill bit, where the electric motor is supplied with energy supplied by the inner pipe and the outer pipe, acting at least as conductors; provide power to the electric motor to generate rotary power; and apply the rotary energy to the bit.

To facilitate a better understanding of the present f ''^v '·' '' ~ Invention, the following are provided. some &lt;

• Pf jA HX .... .... . «.-: pi ·&gt; i modalities. In no way should the following examples be read to limit, or define, the scope of the invention. The modalities of the present disclosure may apply to horizontal, vertical, deviated or otherwise non-linear boreholes or construction boreholes such as in river crossing applications in any type of underground formation. The modalities can be applied to injection wells as well as production wells, including hydrocarbon wells.

The terms couple or couple as used herein are intended to mean either a direct or indirect connection. Therefore, if a first device is coupled to a second device, that connection can be through a direct connection, or through an indirect electrical connection through other devices and connections. The term well up as used herein means along the drill string or hole from the distal end to the surface, and down hole as used herein means along the drill string or hole from the surface towards the distal end ·.

It will be understood that the term oil well drilling equipment or oil well drilling system is not intended to limit the use of the equipment and '· pff'oges &amp; s / -described.

iNr&gt; and $ T¿ÍAi with those terms to drill an oil well. The terms also cover the drilling of natural gas wells or hydrocarbon wells in general. Furthermore, these wells can be used for production, monitoring or injection in relation to the recovery of hydrocarbons or other materials from the subsoil.

The present invention generally relates to well drilling and completion operations, and more particularly to systems and methods of using electric motors to drive a bit.

Figure 1 shows a general layout of the pipe-in-pipe electrical BHA motor assembly (100) in accordance with one embodiment of the present disclosure. As shown in Figure 1, the in-pipe electric pipe BHA motor assembly 100 may comprise inner pipe 110, outer pipe 120, work linkage 130, electric motor 135, stator windings (140), housing conveyor (150), motor housing (160), motor shaft (170), motor shaft magnets (180) electric motor controller (190), electric motor controller casing (200 ), flow diverter (210), drill bit (220) and high pressure flow restrictor (230). In some embodiments, energy, preferably current energy

............... .-. :

AR / 'INSTITUTE.' ,. .

direct, it can be transmitted between the tubcn¿! a'ul.lht'e¿^tr-gÍ'feY (110) and the outer pipe (120) from the —sopeE-fri-oío -a..lo. »», length of the working linkage (130). In some embodiments, the inner pipe (110) can be considered the hot energy conductor and the outer pipe (120) can be considered the ground. This may be important from a safety point of view to keep the outer pipe 120 as the ground, as it may be conductively connected to the drilling rig and may be difficult to keep isolated in a drilling environment.

The inner pipe (110) and the outer pipe (120) can be eccentric or concentric. In some embodiments, the outer surface of the inner pipe (110) can be covered with an insulating material to avoid short circuiting the inner pipe (110) through the mud or other points of contact with the outer pipe (120). . In other embodiments, the inner surface of the outer pipe (120) can be coated with an insulating material. Examples of insulating materials include dielectric materials. Suitable examples of dielectric materials include polyimide, a GORE ™ high strength reinforced fluoropolymer, nylon, TEFLON ™, and ceramic coatings. In some modalities, only in areas sealed and protected against peff ^^ ijon fluid is the; Bare metal from the inner pipe (110) exposed to make the electrical connections along the length of the working linkage (130) to the next inner pipe joint. Such areas can be filled with air or a non-electrically conductive fluid such as oil or a conductive fluid such as water-based drilling fluids as long as there is no path for electrical current to flow from the inner pipe to the outer pipe in a short circuit way.

In some embodiments, the stator windings (140) can be mounted in a pie slice shape within the casing conveyor 150. In some embodiments, the casing conveyor (150) can be attached within the motor casing (160). ) to prevent the conveyor from rotating relative to the work linkage (130).

In some embodiments, the drive shaft magnets (180) may comprise fixed permanent magnets mounted on the drive shaft (170) in a manner to promote reactive torque from variable magnetic poles created by the stator windings (140). In some embodiments, the electric motor may comprise a 6 pole motor. Various variations in the number of poles and the decision as to whether to attach the magnets to the motor shaft are in the housing as well as other forms of electric motors such^rá ^ -aomÓAmótQres / iiié / '??^Γ :). υΤ?.! ΑΙ direct drive with a mechanical switch drive winding arrangement and squirrel cage induction motors that do not use permanent magnets. Single-phase motors are possible with the help of capacitors to create a second pseudo-phase.

In some embodiments, the electric motor controller (190) can be positioned above the stator windings (140) to control various aspects of the electric motor (135). The electric motor controller (190) can communicate in both directions with the surface through the two-conductor path formed by the inner pipe (110) and the outer pipe (120) and through a feed through a cable or cables that are fed through the electric motor assembly to modules placed under the motor such as LWD and / or MWD and steering systems.

In some embodiments, the electric motor controller 190 may be housed within a controlled pressure cavity to protect electronic circuits. The electronic circuits of the electric motor controller can be coated with a ceramic coating to allow the cavity to be filled with oil and balanced in pressure with the ring allowing a thinner wall filling advantages to accommodate the cavity ϊ '1' ei electronic circuits .: The \ ΰΐ la with oil and having a pressure balance with the ring are that the thickness of the cavity wall of electronic circuits can be kept at a much smaller thickness because it does not have to sustain all the pressure of the fluid column leaving more space available for the electronic circuits and providing a better conduction of the heat generated by the electronic circuits to keep them within the operating limits.

In some embodiments, the stator windings (140) may be encapsulated in ceramic, rubber, or pot-type epoxy. This allows the encapsulated region to have additional short circuit protection that would normally be relegated to the typically polyether ether ketone (PEEK) coating found on the magnetic wire which may then be exposed to the mud, where some of the mud circulates through this region. to provide cooling for the windings and energize the electronic circuits as well as lubricate the mud bearings and radial bearings along the drive shaft (170).

During operation of the in-pipe electrical pipe BHA motor assembly (100), sludge can flow into the annular spaces formed by the inner pipe (110) and the outer pipe (120). The mud and the bó ^ .te'S. can • 'set ·, INÍWJTR¡ / -. i. '' mv returned to the surface inside the inner pipe (110). However, near the top of the electric motor (135), this flow rate may change slightly. The flow diverters (210), which are electrically insulated from the outer drill pipe and are preferably made of ceramic or metal with a dielectric insulating coating on the outer surface, allow mud and ring cuts formed by the Inner tubing (110) and outer tubing (120) enter the inner tubing as they pass downward by sludge flowing through the kidney-shaped grooves in flow diverter 210. Below this point, the sludge flowing downward can be diverted into a central bore where it passes through the electrical connection of the inner pipe (110) to the electric motor (135) within the motor casing (160). At this point, the sludge flowing down can take two separate paths. The first path is down to the central hole of the motor shaft (170) and down to the bit (220) at the bottom of the working linkage (130) where it exits the bit (220) and begins its way back to the hole to the inlet ports of the flow diverter. The other path is through a high pressure flow restrictor after

X .¿.L i. .i. (230) at the top of the 'irnwsfxiAi through the gap between the outer portion of the rotor the inner portion of the motor housing and out through the lower radial bearing assembly just above the shaft drill connection at the bottom of the motor housing. The high pressure flow restrictor (230) can be designed to leak a certain amount of drilling fluid to flow into the motor housing (160) to cool the stator windings (140) and lubricate the bearings axial and radial electric motor (135). The high pressure flow restrictor (230) can also be double as a radial bearing

In other embodiments, there may be a separate radial bearing (240). The radial bearings (240) may comprise marine rubber bearings, bearings

PDC or various hardened coatings such as fused tungsten carbide.

The high pressure flow restrictor (230) can be placed anywhere along the flow path as long as the flow is restricted somewhere along the path of the top of the drive shaft and the bottom of the motor housing. In some embodiments, the high pressure flow restrictor (230) can be placed directly underneath the upper radial bearings of said device and this device also acts as a fi lt.rg keeping larger solids entering the mud away

<td>of the</td><td>windings</td><td>stator (140) and</td><td>the</td><td>bearings</td><td colspan="2">radial</td>

<td> (240) .</td><td></td><td></td><td></td><td></td><td></td><td></td>

<td>The</td><td>figure 2</td><td colspan="3">shows a cross section of the</td><td>rotor</td><td>and</td>

<td>stator</td><td>without the</td><td>conveyor sleeve</td><td>of</td><td>winding</td><td> (250)</td><td>or</td>

motor housing (160). In this example, a 6-pole stator winding assembly (280) is shown. Stator windings 140 can be wrapped along one or more stator heads (290). In some embodiments, one or more stator heads 290 may comprise long rectangular cake slice wedges. One or more stator heads (290) can be made of soft iron with high permeability. Ideally, one or more stator heads (290) may contact each other or may be welded together.

In other embodiments, a stator head assembly can be made from a round bar using machining methods such as electrochemical machining, wire EDM, or machining with an electrostatic electrode spreading machine or even by extrusion of the shape of so the outside diameter of the stator head assembly is a solid diameter instead of 6 pieces jwyrjT'.n; . · '. &gt;

individual. Because it may be more costly to make the stator heads from a bar, .— idaalmarate₇..... ei ~ - stator winding assembly (280) is made of 6 pieces to reduce manufacturing costs. In the case where the stator heads are made from a bar, the stator windings would have to be threaded through the various passages. Although this can be difficult, the encapsulated coating could be injection molded into the inner area and ends. It would still be desirable to coat the stator to reduce corrosion and increase its life, but in this case, the pot material may be sufficient for this function. In some embodiments, the pot material can be made of various compounds such as epoxy, ceramic based compounds, nylon, polyether ether ketone (PEEK) such as polytetrafluoroethylene such as Arlon 100 from Greentweed.

In the cake slice type wedge concept illustrated in Figure 2, the stator heads can corrode when exposed to many types of mud systems in case the cake slice wedge contact area near the diameter The exterior is not covered with a protective material. However, for a minor tradeoff in energy efficiency, a very thin corrosion resistant coating can be applied to the

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stator heads at the contact points fé&gt; '· j i-ápiéí ^^ exterior to limit losses from the magnetic f Ί n jp while applying a heavier coating to the parts of the stator head exposed to the mud flow.

The stator windings (140) can be varnish, polyether ether ketone (PEEK) or other dielectric type coated magnetic wire ideally made of silver, copper, aluminum or any conductive element, including high temperature super conductive materials. The stator windings (140) can form various envelopes around the stator heads (290). Optionally, on top and incorporated into the stator windings (140) there may be a pot material, preferably a more flexible high temperature ceramic or epoxy. This material can be used to protect the stator windings (140) against mud corrosion and protection against erosion, especially caused by fine sands that can easily enter this area.

One or more stator heads (290) may have notches on the outside diameter and can be engaged with the casing conveyor (150) to support one or more stator heads (290) still from the generated torque. This torsion can then be brought to the

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motor housing (160) through the additional notches, si5¿dét chályétay18 in the key housing in the motor housing (160). Other ways to do this are easy to understand by those skilled in the art.

Optionally, the outer diameter of the conveyor casing (260) and the inner diameter of the motor casing (160) can be slightly tapered, reducing to the top, to allow for a precise fit and to prevent fine sludge particles from accumulating between the motor housing (160) and the conveyor housing (260). In this way, the sleeve of the winding conveyor (250) can be pulled or pressed out. The upper part of the winding conveyor sleeve (250) may have additional anti-rotation wrenches that engage the electronic circuit insert and / or additional key notches that engage the keys located in the motor housing (160).

In some embodiments, one or more stator heads (290) may be made of thin slices of the cross section shown in Figure 3. As shown in Figure 3, the shape of one or more stator heads ( 290) can be stamped from thin sheets of iron, coated with a thin sheet,

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/ '/. 'i isolated and stacked on top of each other. the ttañsp and then threaded with the winding. This is because long solid bars of one or more stator heads (290) along the length of the electric motor (135) would create large momentary currents that would greatly hinder the efficiency of the motor and create heat. The wires extend along the length of the stator head slices uninterruptedly winding around the group of stator head slices.

By using thin stamped sheets, the aforementioned problems with manufacturing costs and assembly problems can be solved while still providing a power stator design. The thickness of each stator portion would require some modeling to optimize but a thickness of l / 16-l / 4 is a typical range. Alternately, each individual stator head can be stamped thus requiring 6 stamped parts to make a layer and arranged as shown in Figure 2.

Referring now again to Figure 1, the drive shaft (170) may run out of the bottom of the electric motor (135) to be threaded into either a drill bit (220) or other BHA components. Although the tip end connection (300) on the drive shaft is shown in Figure 1, a box connection could replace the tip end connection (300). On the drive shaft (170), you can fifdgt'ar unóójpAíftás⁷drive shaft magnets (180). Figure 1 mges f-th which, ro, jmanps. ,, of motor shaft (180) mounted on the motor shaft (170). While there are other ways to craft a rotor for an electric motor, such as a squirrel cage induction motor, this permanent magnet method offers a great deal of torque delivery and mechanical stability. The motor shaft magnets (180) can be accommodated to be optimized for a 3 phase motor. Those skilled in the art of 3-phase motors will easily recognize the way this motor operates by pushing and pulling the shaft magnets with the electromotive force of the stator by modifying the phase of the current passing through the 6 windings. At higher operating temperatures, the windings would have to be used instead of magnets on the drive shaft to facilitate torque transfer, much like a squirrel cage motor. The primary limit of magnets is the Curie temperature where magnetization of the magnet is lost or at least a significant reduction in the magnet pole force occurs.

An advantage of this type of motor is that it can be controlled with solid state switches instead of using a switch. While a commutator would work, this is not ideal as you should use brushes on a

MF Τ

-Μ.

electrically isolated environment, which means that a cavity full of

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rotary for a mud barrier which would be problematic for reasons of reliability and maintenance in case the rotary seal has to operate at high RPMs for long hours as is the case here.

Referring again to Figure 1, the pipe-in-pipe electrical BHA motor assembly (100) may further comprise an electronic circuit assembly (310). The electronic circuit assembly (310) ideally has a memory processor to monitor and control the electric motor (135). The processor provides various functions, including but not limited to motor starting control, capacitors to aid in starting and operating, monitoring power consumption, motor speed control (which is mostly driven by frequency applied to the windings and the current allowed to flow into those windings), motor torque output control (constant or variable torque delivery), power control, motor temperature control (stator windings can be incorporated with temperature sensors), motor transmission and BHA sensor data to the surface through the pipe in the pipe conductors, receiving command of motor parameters such as speed

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power output limits, etc., data, data cüliyilltas ^ and other forms of pipeline surface requests on pipe conductors, leak detection and recovery, slip adhesion detection a closed loop response to manage bond glide to keep engine drilling conditions in a more favorable range.

The system automatically detects and stays away from bad drilling parameters and learns what they are as drilling progresses. The self-learning feature specifically focuses on sensing loss conditions and limits power delivery to the windings by essentially shutting down the motor in case the force applied to the motor and the subsequent drop in shaft RPM results in a threshold for motor loss or motor operation at a very low speed that could potentially damage the motor windings by having too much current flowing through them. The processor would obtain weight and torque data from the surface or a downhole sensor either in the engine or incorporated elsewhere in the drill string such as in the downhole assembly MWD system or a sensor located above in the linkage of

<img file="MX354392B_D0017.tif" />

drilling. This would essentially allow the. processor shutdown engine before or at the moment, rip up! 7ar-s ^ loss rotation speeds causing damage and after

<td>restart the</td><td>engine</td><td>with durations</td><td>of</td><td>proof</td><td>short for</td>

<td>determine if</td><td>the</td><td>applied load</td><td>he has</td><td>been</td><td>released and / or</td>

<td>information of</td><td colspan="2">additional sensor</td><td>the</td><td colspan="2">weight sensors and</td>

torsion indicating whether it is safe to operate. In addition to that, electronic circuits may contain current limiting circuits to limit the amount of current that can be applied to the motor winding coils to prevent harmful currents from circulating in the windings. The processor can record and monitor RPM versus applied power along with bit weight and torque to detect if there is a degradation in motor or bit performance that occurs over time and notify the surface computer and operators of this condition. For example, if the energy applied to the motor remains constant, but the torque applied to the formation is detected as being less than what was observed at a previous point in time, this may indicate a degradation in the performance of the bit or motor. This may also be a function of the properties of the formation that is being drilled. Because these data are surface based on the telemetry system, they can be

INSTITUTE '? ..TXTT.; ·?) -.Ζΰ study in real time and you can act in 'idasg ^ L dé *' ^ e5r necessary. Such data could be used, —ρστ — sjeflÍplu, · ** · to calculate the bit's mechanical efficiency to monitor it for signs of wear. Mechanical efficiency and / or torque and weight data can be compared against the deviated well ground model in the area to determine the optimum weight applied to the bit and the required torque of the electric motor to obtain preferred drilling performance for the formation to be drilled.

There are many ways to create 3-phase power from a direct current (DC) power source. A DC power source from the surface or other downstream power generation source is ideal in case the power has to be transmitted over long distances because the conductive mud between the inner and outer pipe creates losses in the transmission scenario. AC power. Frequently, power transmission lines through water, especially salt water, use direct current to minimize losses of electromagnetic radiation in the water surrounding the power transmission cable. Similarly, in an underground formation there are occasional intervals that have a high conductivity capacity

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MEXICAN INSTITUTE OF l&gt; PROPERTY which would improve energy losses along the way^{TO THE} pipe in the power transmission circuit cTe Ta pipe for changes in current flow along the pipe in the pipe system. In this way, it is beneficial to minimize current fluctuations as much as possible by using a direct current rather than an alternating current to energize the electric motor. That is, any form of electrical energy could be used to drive the motor. In some embodiments, DC power may be desirable as it may allow easier power control of some downstream circuits. Ideally, 3 phase energy transmitted from the surface to the downstream motor would be desired but this would mean that more conductors would be required in the piping system within the piping and this would reduce reliability and increase the complexity of the piping system within the pipeline to include at least 1 more driver and realistically a 4th since a ground return would be desirable but not essential.

A generalized block diagram is shown in Figure 4, which details the communications, sensors, and engine control elements of the system. Although not shown in Figure 4, there could be communications through the engine bottom or in the up and down directions on the linkage. These means would®&gt; Tia "through use '

1 / t A * of slip rings or inductive couplings and are known to those of skill in the art. The slip ring or inductive coupling allows communication and / or power to jump in any direction between the motor housing and the rotating motor shaft. Endpoint connectors with electrical conductors provide a signal path to the top or bottom of the motor where communications can continue on the next module. Ideally, the connection at the top of the motor is through a communications interface that is coupled into the two-pipe conductor's power delivery.

In some embodiments, the communications channel may be in direct communication with the pipeline within pipeline communications network or it may be communicating with a local network such as one for a MWD / LWD system or a drill bit nearby or at a bit communication or a plurality of networks and communication nodes. The processor can execute commands that are stored in a memory storage area that could be incorporated into the processor itself or in separate memory elements such as RAM or Flash RAM type chips or a solid state hard drive or other forms of devices

<img file="MX354392B_D0019.tif" />

memory retention / storage. The 'méKiqr.ia too' I know

I bd&gt; u 3T ai ¡. l * · 'can be used to record performance information regarding the motor such as winding temperature, tool temperature, mud temperature, shaft RPM, power output, torque output, system current, voltage and power, current winding, voltage and power input, and pressure on either side of the high pressure flow restrictor to watch for signs of wear and make sure the mud is flowing through the windings to keep them cool and insulated from the heat generated by resistance in the windings and the friction of the bearings mainly . The power supply supplies power from the pipe into the pipe conductors. Because the pipe in the pipe conductors can be used to energize everything, no connected lines are shown in Figure 4.

Pressure sensors can also be used for motor in the absence of detection inhibiting flow operation to protect the motor from overheating.

Additionally, batteries, rechargeable batteries, or a capacitor can be used to provide minimal power for communications, sensors, processor and memory modules, and any other desired electronic devices in the tool in case the power is turned off to drive the jy ^T - T motor. In this way, low-energy communications with the motor can continue even if there is not enough energy to energize the motor's electrical windings enough to drill the hole. This would allow the system to stay tuned to communications and other electronic functions, such as data logging from sensors, while a connection is being established, for example where power is maintained for the downhole motor this is made easy in a safe way when new tubing is added to the linkage.

The use of batteries can also allow communications and the sensors to be kept watchful so that data and command exchange can be performed while establishing a surface connection or other platform operation is occurring as long as it is established and maintained a surface connection for communications. In addition, communication between various network nodes can continue to be maintained on the work linkage so that sensors can be monitored even if surface communications are down, thus recording important data. This is especially useful when disconnecting from the hole and wanting to record certain areas in the exit path.

DC power can be converted to a 3 phase current by the motor controller.

To the'/.; · · ···

The contro'í'ádor · 'dé; motb'í ^^ éíj preferably uses solid-state electronic circuits to turn on the current for the windings and flip the polarity of those windings in a way to replicate the 3-phase energy from the surface . The current at 6 windings is administered in 3 pairs where the current in any pair is almost the same at any point in time except for minor drag effects. The pairs of windings can be opposed to each other in the motor as shown in Figure 2 with the phase relationship shown in Figure 5 where each pair is 120 ° out of phase with any adjacent pair of windings.

The phase relationships between the 3 phases can be controlled by a master controller that ensures that the 3 phases remain synchronized in frequency but with a phase separation of 120 °. To maximize power transfer to the rotor, a sine wave or other waveform can be generated for the 3 phase controller to energize the 3 pairs of windings. Each winding may preferably be connected in parallel, rather than connected in series to reduce the series resistance of the winding pairs. The windings and current flow can be timed so that each stator pole has the same orientation as its other

<img file="MX354392B_D0020.tif" />

JL '1 Λ par. This means that the interioms-itev ^ -each tip; 'pr' # .a

INDUSTRIAL

INDUSTRY:

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Stator poles can have the same polarity of the magnetic field such as north, south or neutral. In modalities where each coil. It is identically wrapped for each winding, each phase pair can be wired in parallel as shown in figure 5.

Critical functions of the motor controller may include: (1) switching polarity directions in sync with the desired direction of rotation; (2) maintain the phase separation of each pair of windings; (3) maintain the applied frequency and scale the frequency up and down at speeds acceptable to the motor based on changes in the desired motor speed; and (4) maintain energy levels for the windings to optimize torque delivery for the desired speed. Each of these functions can be achieved by modifying the supplied current or voltage, or both, to the winding pairs and / or by modifying the duty cycle of each wave. Alternatively, or additionally, start capacitors can be used to help the motor increase its speed. These capacitors are usually switched by the motor controller as the motor reaches approximately 75% of its rated speed.

It should be noted that, in some modes, the controller can simply alter the two channels (A and B, B and C or C and A) to

Jí M f asernde «any

OF THE .

change the direction of rotation of the rotor while still being able to emit the same amount of torque and energy to the bit.

This can be a traditional upgrade where these significant over PDM motors can only rotate in one direction. The ability to rotate many benefits such as helping a rotary connection to back out can have to jam, undo a piece stuck in the cutters by extending mechanical, hole and

<td>Release the</td><td>BHA,</td><td>activate someone else</td><td>mechanism</td>

<td>drill into</td><td>the</td><td>opposite direction</td><td>using</td>

<td>of bit that</td><td colspan="2">point in the direction</td><td>opposite, or</td>

<td>a cycle of</td><td>lifetime</td><td>cone bit</td><td>roller</td>

opposite direction.

the creating tension in

The controller each sinusoidal pair a motor shape can vary the energy for winding in a other tooth waveform method of some modalities, preferred as it is the square wave or cyclic waveform such as saw or triangle.

a sine wave can be more energy efficient. Furthermore, one skilled in the art would appreciate the use of various cycles

At the working one of each general average waveform supplied. In order to adjust the power of some modalities, the electronic circuits can be designed with solid state switches such as or relays to modify the direction of the

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INSTITUÍ ·. MEXICAN V

OF THE é'ROí'IEP-AO&gt;

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<img file="MX354392B_D0022.tif" />

through the windings of the DC source.

In one embodiment, a time varying signal can be emulated to couple the windings with square wave electrical pulses in opposite polarities. By adjusting the phase and duty cycle of each square wave, the average energy consumed by the motor per rotation can be modified respectively, this method can be achieved using semiconductor based switches such as silicon controlled rectifiers (SCR), thyristors or others forms of switching devices. Other methods may include transformers to modify the power applied to the motor windings. Such transformers could include variable couplers, up-scaling or down-scaling or multi-lead transformers. Figure 6 shows an arrangement where the switches are turned on and off by the controller to modify both the polarity and the duty cycle of the energy applied to each pair of windings. A timer on the microprocessor in the motor controller can maintain the pulse width and phase of the three channels and raise or lower the overall frequency as desired. The arrangement shown in Figure 6 can also be replicated for the other two winding pairs. The moLor controller '·

Or. '.^Λ:· - ^;

IMjlJ Η can receive commands from the surface or ideally from the local processor with the memory that is managing all the other engine functions. The instructions and / or control parameters in memory can also be programmed over a downlink communication channel while the engine remains downhole if desired.

The motor driver can be a small power amp switch used to supply enough power to turn the semiconductor switch on and off and can also turn on or off based on logic outputs from the processor. In some modes where the processor has to turn switches on and off, digital outputs or analog process outputs can be linked directly to the switch's control lines. Essentially, the process switches between either of the pair of switches to reverse the current through the pair of windings, or turns off both pairs of switches when the phase and duty cycle time so deems it necessary.

Referring again to Figure 1, the drive shaft magnets 180 can ideally be of a very high magnetic field resistance. Convenient types of motor shaft magnets (180) may include sanXrí ^ cÓfeáli.o · magnets;

'Wi.A i' .O * '? ·. ·' · In some modalities, the motor shaft magnets (180) can, ι be manufactured in a wedge-shaped mold to match the pockets on the motor shaft ( 170). In some embodiments, the drive shaft magnets being emptied after applying long align to in a mold is a loose fine particle powder that is pressed and sintered into the mold. You can weak magnetic field during this process to pole the magnet through the thickness of the bar the application.

semi-wedge, triangles, optimal orientation variation of the magnetic field

Although shapes in the preferred is to create for the shape of the magnet may be an alternate could be geometry.

cut the magnets and essentially sinter the magnet to

Once shapes such as a rectangle are attached, used

In order to retain the dust on the shaft during at or just any ideal on the shaft for the shaft for method of retaining engaging the creation of the magnet.

Magnets of the motor shaft (180), motor shaft (170) can be fastened in the sintered in place, in case through various means such as retaining bands / sleeves, grooves these are not such fasteners.

The polarity of the screw shaft magnets or motor (180) can be alternated with the north pole (N) facing outwards, then the magnet polarized or facing outwards, then north again the example of a four pole rotor .

One of skill in the art would note that the number of windings and magnets can be multiplied such as 12 stator poles and 8 rotor magnets or three stator poles and two rotor magnets.

Variations will depend on many factors but this arrangement is good for the task at hand in balancing reliability for smoother torque delivery while ensuring that the required peak torque is maintained for the engine design.

Referring now to Figures 7a and 7b, Figures 7a and 7b show an enlarged view of the top portion of Figure 1. In some embodiments, the flow diverter 210 may preferably be made of a electrically insulating material, such as ceramic. Ceramics offer high erosion resistance for flowing sand, cuts, debris, and other solids flowing from the ring to the inner bore of the inner pipe in the flow return path to ceramics made by companies such as

Carboceramics have various useful materials and molding techniques that would make this type of derailleur work well on ceramic material. In some

.......,. &gt; 3 modes, the flow diverter (210) can be_;uh aiii-llo, Λ derailleur. In some embodiments, the derailleur ring does not have to be ceramic as long as the inner pipe is insulated against any conductive material used for the derailleur. Alternately, the derailleur ring could be made of other non-conductive materials as well. The seals (320) can be located on the top and bottom of the flow diverter (210) to prevent annular flow between the inner pipe (110) and the outer pipe (120) so that there are no leaks to the

<td>center</td><td colspan="3">of the inner pipe</td><td> (110)</td><td>. Such</td><td>how</td><td colspan="2">was mentioned</td>

<td>before,</td><td>the flow</td><td>cancel</td><td>can</td><td>go down</td><td>since</td><td>the</td><td>surface</td><td>and</td>

<td>happen</td><td>through</td><td>of the</td><td colspan="2">grooves in</td><td>shape</td><td>of</td><td>kidney in</td><td>the</td>

flow diverter (210) and pass down into the engine area and eventually the end of the drill string. In some embodiments, the flow diverter 210 may be embedded in the inner pipe 110 and outer pipe 120 so that it can maintain orientation with the holes in the inner pipe 110 and the outer pipe 120 ) and prevents accidental rotation.

Figure 8 shows how the flow between the inner pipe (110) and the outer pipe is diverted into the inner pipe (110) for the section of pipe (115) that does not communicate with the other

Τ X &lt;'&lt;f; Λ section of the inner pipe (110). Est ^ .allows, that the; Flow was diverted down the center of the pipe section (115) to the BHA and out of the bit. In some embodiments, the inner pipe (110) may have an electrically insulated coating at all locations except one area (116). In this area (116) there is a short section that has an exposed metal section of the inner pipe (110) and is coupled with an electronic circuit insert (340) to facilitate the transfer of electrical energy to the electric motor controller (190 ). The electronic circuit insert (340) may be electrically insulated with a coating except for the exposed section. The coiled wire spring (350) can be used to promote connection in the sealed wet connection area (330). The electronic circuit insert (340) may have two ground lines (360) that return the electrical path to the outer pipe (120) once the current has passed through the various electronic and motor components. Although not shown, the flange end of the electronic circuit insert (340) may have orientation dowels and extra dowels to protect it against any torsional forces it might experience or other mechanical retention means to prevent rotation. There are a number of other ways to route power from the .inj £ c, ripr pipe.^:, (.110) to the \ electric motor controller (190), however this method is considered exemplary here in how this could be accomplished. The grounding connections of the grounding lines (360) can be sealed against the mud to ensure that the connectors are not damaged by the corrosive conditions of the mud. Mud can flow into the center of the electronic inserts (340) and up into the exterior of the motor housing now.

Figure 9 shows the electronic circuit insert (340). As mentioned before, the electronic circuit insert (340) can house the processor and the power control electronic circuits (370) to control the electric motor. The wires (375) through the sealed bulk interfaces (380) lead to the stator windings and sensors (385) below.

Figure 10 shows a number of elements but this is essentially the primary motor winding and the motor shaft area. At the top preferably a high pressure flow restrictor (230) can be located, which can be double as a radial bearing and has a small space flow path therein to allow the mud to flow through this. This is generally made of a high erosion resistant material such as

X Γ? Λ V tungsten carbide or a base alloy such as Stellite. Other variations of this combination are possible but the primary purpose here is to allow a certain amount of sludge to leak into the outer side of the drive shaft (170) for pressure balance of the winding area (17 5) and flow of sludge through windings to keep them cool. As shown in Figure 10, there may be two sections of stator windings (140) but a single winding section or a plurality of winding sections can be used to optimize the desired torque.

In some embodiments, Hall effect switches (190) can be incorporated into the winding conveyor to monitor the shaft position and RPM by observing small magnets (191) or the rotor magnet relative to the position on the shaft. The signal emitted from the Hall effect switch or other type of RPM sensor is routed back to the motor control electronics where the processor can automatically measure and adjust the motor speed based on sensor feedback. Other types of position sensors may also be included in the winding conveyor such as proximity sensors. By monitoring the position of the shaft as it rotates, you can better optimize torque delivery to the motor and observe pole slip which is the case for drill reaction torque.

T 71 7 7 '·' - ··· '·, occur' em^;'' í

1..Ύ i ?. Y Y- 'Y. - the perforation faith exceeds the motor loss point or vibration which could mean that one winding is applying more torque than another winding in an uneven way and, therefore, the applied applied torque of the windings can be adjusted to obtain as uniform a torque output as possible. In some embodiments, temperature sensors can also be incorporated into the conveyor or adjacent to the windings. Preferably, at least one temperature sensor can be used for each winding to monitor motor temperature. In addition, in some modes, a pressure sensor can be installed in the conveyor above (192A) and below (192B) the high pressure flow restrictor (230) to monitor the performance of the flow restrictor and ensure it is not occuring wear or plugging and confirm that the mud pumps are in fact to ensure engine cooling.

An optional radial bearing bracket (380) is located between the two winding and winding sections of the drive shaft, which may be lubricated with mud. An elastomeric marine bearing, roller, ball, bushing, or other bearing style can also be used. The stator winding conveyor has key notches (194) for

J W ' ⁿ I mate with the keys in the 17 ~ - ^ iptpx.a housing in order to ill. : Λ 'í-V'UUi trv.

Maintain the winding conveyor without it rotating.

Referring now to Figure 11, Figure 11 illustrates an axial load bearing package configuration that enables on and off of the lower rotation of the drive shaft (170) and has a radial bearing support (380) at the bottom . The drive shaft 170 may have a tip end connection 300 or a box connection. Other variations of this downhole electric motor are possible. For example, the drive shaft 170 can be divided into two sections where a torsion bar or universal coupling connects the two shafts through a fixed or adjustable bent housing. The bearing package can reside above or below the flex, or even above the motor section. An adjustable bent housing can be adjustable on the surface or down hole which means you can adjust the angle of inclination of the lower end of the motor shaft away from the tool axis to at least one angular position and usually a plurality of different positions angular. Preferably, thrust bearings (390) may reside above any bent subassembly.

In some embodiments, the electric motor may have an interface module that facilitates surface coupling, communication, and continuity with the drill pipe. The electric motor can be controlled from and respond to surface communications. The electric motor can have a variable torque and speed capacity. A reduction gear or planetary gears in conjunction with a variable speed electric motor can be used to facilitate the desired torque and speed output.

The electric motor can be a modular component of a downhole assembly or can be used autonomously. The motor can be used to enlarge or ream the drill hole with or without rotation of the drill string as typically provided from surface equipment. The electric motor can have multiple configurations to facilitate adaptability to the desired rock cutting / destruction mechanisms. These configurations can include laser drilling or laser drill as described in Sinha et al. In SPE / IADC 102017, compact polycrystalline diamond (PDC) cutting structures in fixed drill bits, roller cone bits, electric drive rock drilling apparatus such as that described in US 2010/000790 by Tetra, or other rock destruction devices. In fact, the presence of energy to energize the! Ú '5Í /' ^^r

Uk LA PROPIEPAi '• NPUSTR1AL for drilling electric motor naturally leads to pode

<img file="MX354392B_D0023.tif" />

Power required to drive a laser or drill bit assist.

Rotation for the cutter assembly can be provided by rotating the drill rod from the surface kit or any of the following: a modular motor assembly fitted to a separate rotary cutter assembly or where the rotation for the assembly an assembly Cutting integral can be provided by a motor assembly or fitted motor assemblies within the single assembly. The cutting structure in the cutting assembly can have the depth of cut (ultimate diameter) powered by an independent electric motor that controls ramps or pistons. When cutting rotation is not desired, the cutting structures of the cutter assembly can be relegated and the modular motor assembly can be commanded to shut down and, if necessary, the ability to rotate can be locked. Reaming could be optimized by allowing individual cylindrical reaming cutting assemblies to have power to rotate on their own shafts.

Referring now to Figures 12A-12F, Figures 12A-12F show various addressable BHA stacks according to some embodiments of the

<img file="MX354392B_D0024.tif" />

IMPI

MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY present disclosure.

In one embodiment, the addressable BHA stack can be configured in accordance with Figure 12A. In this scenario, a conventional BHA is rotated by the electric motor which eventually drives the axis of a rotary steerable tool. In other modalities, the electric motor can be tuned with a full motor telemetry system that bypasses communications from the non-rotating stator to the motor shaft through the use of a slip ring or an inductive coupler such as 2 coils or 2 toroids. Such techniques are described in United States Patent Application Publication Number 2010/0224356 and United States Patent Number 6,392,561. Other short jump telemetry techniques exist and are known to those of skill in the art.

In one embodiment, a rotary addressable BHA stack can be configured in accordance with Figure 12B. In this mode, the MWD / LWD can be moved up above the electric motor. Sensors can be mounted at the start instead of inserts, meaning they are attached from the side of the tool instead of being inserted at the end of the tool and slide into position and covered by hatches or protective sleeves as needed. The central bore of the linkage maintains the central pipe to manage the flow of 'ϊ-'r' -. 7 -

<img file="MX354392B_D0025.tif" />

return. In this way, the MWD supports both flow paths (up and down) within its confines, MWD / LWD sensors are arranged to allow flow through various means such as keeping the two inner flow paths as two concentric piping and mounting the MWD / LWD components in radial positions external to these flow paths as shown in Figure 12F. Alternately, the derailleur subassembly can be placed above the MWD then allowing the electric motor for the conventional MWD to be used, however a means of connecting electrical power to the lower motor is required and would require a cable or other conductor isolated was run from the upper derailleur assembly, through the MWD / LWD section to the power input section above the electric motor.

In one embodiment, a rotary addressable BHA stack can be configured in accordance with Figure 12C. In this embodiment, the electric motor may have a bent housing assembly attached to it using an internal coupling or torsion bar to facilitate transfer or torque from the upper shaft to the lower shaft. Because large amounts of torque are available from the engine, this type of configuration offers many advantages over PDM designs. As analyzed Jp £ V ^ i ^ fnente,_;

F ·! · '_' ./'.'Γί/. · · Y., F 'axial bearing can be placed above or poi *' á'tíhjo '^ dé'r ”bent sub-assembly. It is preferable to mount 'βΤ ^ Έο' ^ 'Τηθ € e axiáT' '' above the folded sub-assembly, however in order to shorten the bend to the distance of the bit. The bent subassembly can be fixed, adjustable, or downhole adjustable.

In one embodiment, an addressable BHA stack can be configured in accordance with Figure 12D. In this embodiment, the electric motor can provide power to a bottom reamer or hole opener and drive a rotor addressable assembly. In this case, both cutting structures are rotated by the electric motor.

In one embodiment, a rotary addressable BHA stack can be configured in accordance with Figure 12E. This configuration allows a conventional MWD / LWD to be used and an optional hydraulic motor to optionally be inserted under the MWD / LWD to obtain additional power to drive the bit. Such dual use of electrical and hydraulic energy from the surface to create torque could be used in a configuration to maximize bit torque for a given available power.

In one embodiment, a rotatable addressable BHA stack can be configured according to Figure 12e and can be modified by placing

<img file="MX354392B_D0026.tif" />

the MWD / LWD above the derailleur as yet another example.

Other configurations are apparent by virtue of this disclosure by simply moving these modules around and interconnecting them as required for hydraulic, electrical power, and communications needs.

Therefore, the present invention is well suited to carry out the objectives and achieve the mentioned purposes, as well as those inherent therein. Although the invention has been shown, described and is defined by references to examples of the invention, said reference does not imply a limitation on the invention, and said limitation will not be inferred. The invention has the capacity for considerable modification, alteration and equivalents in form and function, as will occur to those skilled in the art who will benefit from this disclosure. The examples shown and described are not exhaustive of the invention. Accordingly, the invention is intended to be limited only by the spirit and scope of the appended claims, providing full recognition of equivalents in all respects.