Abstract:
A method of drilling under barriers (rivers, highways and the like) is set out. The horizontal drilling system mounts a guidance tool on the end of the drill string just behind the drill bit. The guidance tool includes a pair of right angle accelero meters and a 3-axis mounted gyro. The gyro furnishes data in a plane at right angles to the z-axis. This defines four data streams to the CPU enabling determination of drill bit location and pathway.

Description:
BACKGROUND OF THE DISCLOSURE  
         [0001]    This disclosure is directed to a method to form crossing under rivers and other natural barriers. The procedure accomplishes a river crossing which is the term that will be applied to crossing under a river with a pipeline. This term is sufficiently broad to also include rivers, highways, landing strips at airports and any other number of surface barriers. It may also be necessary to pass under large buildings where it is not possible to do tunneling or digging under the buildings. It is not uncommon to require river crossings of only a few hundred feet. For instance, crossing under rivers and swamps may require that a pipeline be buried perhaps 40 to 60 feet deep, perhaps 2,000 or 3,000 feet in length, and thereafter be restored to the normal grade position.  
           [0002]    It is common to locate a pipeline about 4 to 8 feet below the surface. With undulating surfaces, the pipeline is still laid in a ditch or trench which is formed with that depth. The ditch will rise and fall as the terrain varies. There are times, however, when that is not so easily done. Trenching machines that are used to form pipelines must operate with a certain amount of right away. Moreover, they operate on the surface, digging an open trench. It is not possible to run a trenching machine across a paved multiple lane highway. It is not possible to run a trenching machine over several railroad tracks, and it is exceedingly difficult to operate a trenching machine in a swamp. Even if the swamp water is only 2 or 3 feet deep, it normally is accompanied by a mud layer which makes heavy equipment manipulation difficult in the area.  
           [0003]    Many situations can be encountered in long distance pipelines where river crossings must be done. A river crossing heretofore has involved the insertion of a string of drill pipe, not joints of a pipeline, into a well borehole by a drilling rig laid on its side, so to speak, and the string of drill pipe rotates a drill bit to form a hole which is more or less horizontal, not vertical. Ordinary drilling of wells involves vertical drilling from the surface. This departs immediately from that requirement, and involves drilling at a highly inclined angle, even approaching the horizontal at the surface where the drill string enters the earth. In drilling a typical well, the first several hundred feet are normally drilled vertically. A good deal of speed can be accomplished at the start. That, however, is not the case with a river crossing. Rather, the drill bit and drill string are inclined by inclining the derrick so that the initial launch of the drill pipe into the earth is nearly horizontal. To be sure, the hole formed by this approach angles downwardly to dive under the river crossing. It will, however, deflect later so that it turns back towards the surface on the far side of the river or other barrier. There is an entrance point on the near or first bank and an exit point on the far or second bank. Once the entrance and exit points have been established, the pipeline is installed with welded pipe in the well borehole which defines the river crossing. Because this involves two different kinds of pipe which have two different types of construction, it is necessary to position in the well borehole a string of pipe which is sized and constructed consistent with pipeline construction techniques. More will be noted concerning that below. The term “drill pipe” will be used to refer to pipe which is normally used in drilling a well borehole. Drill pipe terminates with a pin and box connection for easy threaded engagement. These pin and box connections typically include API standard threaded connections, or any of the several premium connections now available. There are premium threads which provide an enhanced mode of connection. Suffice it to say, pipe used in a pipeline is not joined by threaded connections. Rather, pipe line joints are formed by welding. The welded pipe is joined by welding in the field typically with welding machines which form a bead fully around the pipe so that there is no chance of leakage. In addition, the welded pipe is coated with some kind of corrosion protection material. For many years, the corrosion protection comprised a layer of tar and felt paper. There are other more modern coatings which are placed on the steel pipe. The pipe joints making up the pipeline must be protected from chemical reaction with the earth. Without this protection, the pipe will corrode more rapidly and the value and benefit of the pipe will be lost much sooner due to this corrosion.  
           [0004]    The present disclosure sets forth an alternate use of the apparatus which is set forth in U.S. Pat. No. 5,821,414. It is been discovered that this apparatus can be installed in the form of a sonde which is placed in the drill pipe above the drill bit. This sonde includes a sealed chamber which encloses the measuring instruments. Preferably, it uses a pair of accelerometers which are mounted in a common horizontal plane transverse to the central axis of the sonde. They are positioned at right angles so that one will be described as the X-axis accelerometer or simply the X-accelerometer, and the other becomes the Y-accelerometer. It is theoretically possible to install a third accelerometer which is the Z-accelerometer, and to position along the axis of the sonde. That represent a data which would be otherwise redundant. While it can be included for added data to provide reduction of error, it can be omitted as the case may be. In another aspect, the equipment uses a gyroscope which is known as dual axis rate gyroscope. As before, the spin axis is aligned with the axis of the sonde. The dual axis rate gyro will be discussed in some detail below.  
           [0005]    The apparatus of the present disclosure is summarized as a sonde which is adapted to be lowered or otherwise installed adjacent to the drill bit on a string of drill pipe used in a river crossing. It is located at that position so that it can provide information regarding the pathway achieved during drilling. It is used to monitor the pathway by providing that data in the form of azimuth and inclination. This enables steering of a smooth pathway. It provides data at the well head which enables control of the drilling process. Through the use of a bent sub and a jet flow of drilling mud through the bit, the pathway can be changed. Alternately, it can be used above a mud motor which cooperates with a steering tool to redirect the pathway.  
         SUMMARY OF THE INVENTION  
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]    So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.  
         [0007]    [0007]FIG. 1 is a side view of a river crossing which shows a river between two banks, and a borehole pathway at a shallow angle extending from the left bank under the river and to the right bank;  
         [0008]    [0008]FIG. 2 is a plane view of a different river crossing showing a change of direction in the river crossing to make connection between the left and right banks;  
         [0009]    [0009]FIG. 3 is a view of a pump for delivering mud flow, a string of drill pipe, and alternate forms of connections made at the end of the drill string for advancing the drill bit;  
         [0010]    [0010]FIG. 4 is a block diagram schematic of data from sensors in the equipment which data is processed so that it forms a continuous presentation of drill bit azimuth and inclination; and FIG. 5 is a sectional view through one form of sonde supported on a wire line which enables the sonde to be positioned in the string of drill pipe. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0011]    The detailed description of the preferred embodiment is set forth below. As a beginning aspect, it is helpful to define the problem which is dealt with, and which places such extreme demands on drilling equipment and especially which requires precision steering of the drill string.  
         [0012]    Exemplary River Crossing  
         [0013]    Going now to FIG. 1 of the drawings, a representative river crossing is shown. In FIG. 1, the numeral  10  identifies a desired pathway. This pathway is calculated to pass under the river  12  which is shown above the pathway. The river  12  is confined between a left bank  14  and a right bank  16 . It has a mud bottom  18 . The water typically percolates into the soil for some depth so that it is very important to position the desired pathway at a greater depth than that. This desired pathway is determined in advance of drilling.  
         [0014]    On the left bank, a pipeline or other mechanism for connection to the river crossing is established. The most commonplace situation involves a cross-country pipeline which approaches the left bank, continues under the river  12  with the river crossing, and then continues on beyond the right bank. It will be observed that the path  10  emerges from the ground area several feet back from the edge of the water. Primarily, this involves a set back so that there will be sufficient area to install the drilling equipment, form the pathway  10  under the river  12 , and obtain the breakout of the drill bit at the far end. At the two exposed locations on the left and right banks, it is commonplace to then make arrangements to install the right kind of pipe along the path  10 , the right kind being defined by the requirements for the pipeline. Also, it is commonplace to tie the pipe under the river into the cross-country pipeline, conforming with pipeline construction obligations which are imposed on the river on the pipe actually at the river crossing  10 .  
         [0015]    A match up of sizes should be noted. The common sizes of drill pipe are typically around four or five inches. Typically, the drill bit appended to the end of the drill pipe cuts a hole in the range of about 7 to about 10 inches. This type hole is usually formed by the tri-cone drill bit which finds common application in drilling vertical wells. These dimensions may or may not match up with those required for the pipeline. The pipeline itself may have a 30′ to 60′ right of way (ROW) and may involve a larger pipeline have nominal diameter of about 8 to 16 inches. Assume for purposes of discussion that the pipeline is a 12 inch line. For that size, it is then necessary to use a somewhat larger drill bit attached to the string of drill pipe as will be discussed thereby forming a larger diameter river crossing  10 .  
         [0016]    To thereby provide a reasonable and not unusual example, assume that the river crossing  10  will be drilled with 5 inch drill pipe supporting a drill bit which forms a cylindrical borehole at least 12 inches in diameter. Assume also that the pipe to be placed in the river crossing  10  matches up with the pipe of the pipeline which is  12  inch pipe. Practical aspects of these connections will be assumed to be executed, and the river crossing  10  will thus be used as the pathway for installation of the  12  inch pipe after drilling. In another aspect, FIG. 1 also includes a symbol  20  marking the angle of deflection. In this particular example, the angle of inclination will be spoken of several times. This establishes a reference namely that the vertical direction (defined by gravity) is an inclination of 180°. This definition will be spoken of several times. As will be seen, FIG. 1 is illustrative of the circumstances, namely that the river crossing  10  begins at an extreme angle.  
         [0017]    Going now to FIG. 2 of the drawings, it shows the same or a different river crossing in plan view. FIG. 2 shows an ROW  22  at the left and a pipeline segment  24  which is installed in the conventional fashion. It is placed in the ROW typically by trenching with a trenching machine, and the pipe is then lowered into the trench and buried somewhere between 4 and 10 feet deep. Assume also that FIG. 2 shows a second ROW strip  26  with a continuation of the trench and pipeline location at  28 . At this particular instance, the river crossing that needs to be accomplished is generally indicated at  10 . This one is of note because it requires a straight line segment as well as an angular segment. More specifically, it is formed with a change in direction. The numeral  30  identifies a compass rose which is marked for the direction north to define the azimuth of the river crossing  10 . In this instance, part is wholly straight, but it connects as illustrated to a curving segment.  
         [0018]    Going back to FIG. 3 of the drawings, the numeral  32  identifies a mud pump which is represented schematically and which delivers a flow of drilling mud through a string of drill pipe  34 . The drill pipe is typical for oil field usage and is commonly provided in 30 foot lengths. They join together with a pin and box threaded connection. It will be assumed to include API standard threaded connections. At the remote end, the drill pipe is provided with a rotary drill bit  36 . It is advanced in drilling by rotation in the direction illustrated. The drill pipe may include or omit the conventional drill collars which are simply heavy weighted, thick wall, relatively stiff pipe sections. These are common in vertical holes because they help provide a true or vertical pathway. This keeps the drill bit from wandering as it drills, keeping in mind that the formation of a vertical well is done with similar equipment but encounters a significantly different set of obstacles and problems. In this instance, FIG. 3 shows a conventional string of drill pipe which is terminated in a typical tricone drill bit in which operates by rotation imparted from a rotary table at the derrick at the surface. The rotary table transmits rotation through the kelly threaded at the top of the drill string  34 .  
         [0019]    In FIG. 3 of the drawings, an alternate drill string is obtained by attaching a drill bit  40  at the end of a drill string. The drill bit  40  is rotated by a different type assembly. It again terminates with the drill bit  40  which is rotated by a mud motor  42  pointed in a direction which is determined by a steering mechanism  44 . In another alternate form, a bent sub  46  can be affixed at the end of the drill string. It connects at the outlet end with a jet bit  48 . Since the river crossing does not encounter rock in the ordinary circumstance, it is often possible to provide a sufficiently high pressure flow of drilling fluid that the fluid cuts away the earth by hydraulic action, not by rotary drilling. Guidance is achieved with the bent sub. The bent sub prompts lateral movement during drilling so that drilling is not straight, but curved and the bent sub can be used to control the curvature.  
         [0020]    In general terms, all the foregoing is believed to be well known and is available for execution in making the river crossing. The problem with the foregoing techniques is that they must be guided carefully. Quite often, it is necessary to cross under a river with a crossing of perhaps 1,000 to about 2,000 feet, a distance which is relatively easy to handle in vertical hole, but which is somewhat tricky to accomplish in the river crossing context. One aspect of the difficulty derives from guidance of the drill bit as it advances the hole.  
         [0021]    As noted with regard to the above mentioned U.S. Pat. No. 5,821,414 a system is set forth which involves a sonde which is lowered into the well borehole and more particularly into the drill pipe. This involves equipment which is located at the surface and also utilizes the downhole measuring instrument. The downhole sonde will be identified by the numeral  120 . It will be explained in the context of the surface located equipment as well as the equipment located down hole. The sonde  120  is lowered in the well borehole (in the pipe) on the wireline cable  114  which brings data out of the hole.  
         [0022]    The surface equipment will first be discussed. The depth measuring equipment (DME)  118  cooperates with a central processing unit (CPU)  100  and a recorder  124 . FIG. 5 also shows a surface interface  102  and a surface power supply  104  which provides power to the elements of the surface equipment. A drum  112  stores wireline cable  114 , and deploys and retrieves the cable within the borehole. The cable  114  passes over a measure or sheave well  116  and extends into the wellbore through a set of slips  106  around a pipe  108 . The wellbore is shown cased with casing  110 .  
         [0023]    The instrument probe  120 , connected to one end of the wireline  114  by means of a cable head  115 , is guided within the casing  110  by a set of centralizing bow springs  130 . The probe  120  encloses an electronic assembly and power supply  132  which powers and controls other elements within the probe. A motor  134  rotates a gyro  136  by means of a shaft  131 . The motor  134  also rotates the accelerometer assembly, shown separately as an X axis component  138  and a Y axis component  140 , by means of the shaft  131 . The shaft  131  is terminated at the lower end by a bearing assembly  151  and a lock assembly  153  which fixes the shaft  131  when the drive motor  134  is turned off. Probe instrumentation is relatively compact so the length and diameter of the survey probe  120  are relatively small. Furthermore, the instrumentation within the probe  120  is relatively simple thereby yielding a very reliable well survey system.  
         [0024]    The apparatus mentioned above is operated in a continuous mode. As will be detailed in several examples below, a first measurement is made which obtains the values of azimuth and inclination. These are represented by the symbols A and I. They are measured with the sonde stationary at the surface. With initial values of A and I, values are then obtained continuously during continuous use of the equipment to provide updated incremental progression. From the beginning point, the values of A and I are calculated and are output to define a continuous smooth data corresponding to the location of the sonde in the well borehole. These calculations are executed by the system which is exemplified in FIG. 4 of the drawings.  
         [0025]    The accelerometer outputs A x  and A y , represented by boxes  208  and  212 , are used to form the ratio A x /A y  at the step represented by step  222 . The outputs Gx and G y , represented by the boxes  200  and  204 , respectively, are combined with this ratio at step  222  to correct the ratio for any non gravity acceleration effects. The computation at step  222  yields the rate of roll over the HSR direction with respect to a reference rate of roll. This quantity is integrated over time, measured from a previously mentioned reference time to, which represents the initiation of the continuous mode operation, and combined with G x  and G y  at step  224  to yield a relative borehole inclination. This relative borehole inclination, when combined with the reference borehole inclination  214  stored in a memory device  220 , yields the desired borehole inclination I c  with the system operating in the continuous mode. The I c  output is represented at  230 .  
         [0026]    Still referring to FIG. 4, the relative borehole inclination, Gx and G y , and A x /A y , are combined and integrated over time, measured from to at step  226 . This yields a continuous relative azimuth value measured with respect to A, the reference azimuth  216  stored within the memory  220 . The relative azimuth is combined with the reference azimuth A at step  226  to yield the desired azimuth reading A c , represented at  240 , which in with the azimuth of the borehole computed with the survey system operating in the continuous mode of operation. As discussed previously, I c  and A c  are combined to yield a map of the borehole in three-dimensional space. All computations are preferably performed at the surface using a central processing unit defined in the following discussion of the system apparatus. To summarize, A c  and I c  are determined mathematically by integrating, over time, measured rates of change of inclination and azimuth with respect to measured, reference azimuth and inclination values. This approach greatly simplifies the downhole equipment required to obtain and accurate and precise map of the wellbore trajectory. The result is a smaller, more rugged survey instrument that those available in the prior art.  
         [0027]    Typical River Crossing Sequence  
         [0028]    Going now to FIG. 1 of the drawings, the numeral  50  identifies the beginning point of the river crossing  10 . That is the point at which the initial values of inclination and azimuth are determined. Conveniently, these values can literally be obtained from a simple compass and plumb bob. Alternately, more expensive instrumentation can be used, but they are nevertheless the initial data. At that juncture, through the use of conventional and well known drilling equipment, drilling is initiated. Below, drilling is referred to as the progression of the river crossing  10  either by rotary drilling techniques which are well know, or alternately by the jetting techniques which again are well known. Several alternate procedures can be implemented, but the key is that they are executed using a string of drill pipe with a bit at the end (either a rotary bit or a jet bit) and the progression is extended throughout the river crossing. Indeed, if important, one can change to another type of drilling technique.  
         [0029]    The sonde is lowered into the drill string  34  on the wireline which outputs data. It is somewhat inconvenient to have to slide each jointed pipe over the cable. However, this can be done without great loss of time and energy because the number of joints necessary to cross the river are limited. This approach enables all the data to be transmitted back to the surface. If appropriate, the wireline cable can be interrupted with a plug and socket for easy and convenient opening of the cable to thereby install added joints of pipe. In any event, the location  50  is the position or location of the first data point. The point  52  represents the location of another data point. The location  54  represents another data point, and the location  56  represents a data point that is approximately at the bottom of the trajectory-of the river crossing  10 .  
         [0030]    The points  50 ,  52 ,  54 , and  56  are typical data point locations where the measurements are made and data transmitted out. In the most common procedure, these points can normally coincide with the point in the sequence of operation where it is necessary to stop the drilling process, install another joint of pipe, and then continue. At that stage, it is necessary to interrupt the process, thereby prompting the sonde to stop its movement downwardly. In other words, the hole is no longer progressing. When the drilling stops, the sonde is supported at a fixed location and another data point can then be obtained. While the sonde is operated in a continuous fashion, the data points  52 ,  54 , and  56  typically coincide with stopping points in the drilling process. Because they are stopping points, such stopping points enable the process to collect data which updates the description of the river crossing  10 . In other words, the data is collected as the river crossing is formed. Because that data is available from the sonde and is provided quickly, the pathway of the sonde is known even better and steering control is then established to assure that the pathway is achieved. By obtaining data continuously, but especially by using data when the drilling process is interrupted, which interruption occur every 30 feet (equal to the length of one joint of drill pipe), the driller can then provide continual correction of the path of the river crossing  10  so that it can be controlled, changed and enhanced. Doing this enables the path to be extended indefinitely and under control. Control apparatus has not been shown in this disclosure because it is believed to be well known, i.e. control via steering tools and the like is a well developed technique. By this approach, the entire river crossing can be handled in terms of changes in depth. Depth changes involve changes in inclination. As shown in FIG. 1, the inclination initially is downwardly, but it ends up moving upwardly prior to emerging beyond the right bank  16 . In like fashion, FIG. 2 shows changes in azimuth. Whether drilling from the left bank to the right or in the reverse direction, it is necessary to change the azimuth on more than one occasion to assure that the river crossing  10  makes appropriate connection with the ROW on the far bank.  
         [0031]    For a better understanding of the progressive or continuous operation sequence, the above mentioned U.S. Pat. No. 5,821,414 develops substantial teaching on the three dimensional problem that is encountered and which is measured through the use of the sensors in the sonde  120 . In particular, this disclosure incorporates by reference the discussion of that problem in space which begins with column  6 , line  54  of that disclosure. Once the drill bit comes out of the earth at the distal end, the procdure is ended. The bit is removed and the string of drill pipe is pulled out of the crossing  10 . At this stage, the pipe sections of the pipeline are attached and pulled into the crossing  10 , advancing joint by joint as the drill string is pulled back. This enables the pipeline to be put in place for the crossing  10 ; the last steps involve welding the pipeline sections to the partially assembled pipeline.  
         [0032]    While the foregoing is directed to the preferred embodiment, the scope can be determined from the claims which follow.