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Dr. Willard H. (Bill) Wattenburg: Directional Drilling
Dr. Willard H. (Bill) Wattenburg: Directional Drilling
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Dr.WillardH.(Bill)Wattenburg
DirectionalDrilling
DownHoleDirectionalDrillingToolswhoseangularpositioncanbecontrolledandmeasuredfromthewellhead.
Dr.BillWattenburg
Many people have asked me to explain the downhole directional drilling tools patented in 1995 and 1997, patent numbers
5,445,230and5,673,765(licensedtoSperrySun,partofDresserIndustries,laterpurchasedbyHalliburton).
www.google.com/patents?id=1z8aAAAAEBAJwww.google.com/patents?id=QfkiAAAAEBAJ
The1997 patent is an improvement on the 1995 design to make the tool more useful for small bore drilling, down to 2 inch
diameterflexiblecoileddrillpipe.The1997designhasthesamemainfeatures,butsomewhatsimplifiedfromthestandpointof
manufacturing(inotherwordswhatIlearnedafternineprototypesandfieldtestinginHouston).
Seethelastsectionbelowforthehistoryofthisadventure.
OverviewofDesign.SeeFigure1and2below.
ReferringtoFigures1and2below,themainhousingofthetoolconsistsofanuppercylinder1inwhichalowercylinder2
slidesandrotates.Theupperdrillpipe3isrigidlyattachedtotheuppercylinder1atasmallfixedbendangle4(Xdegrees).
Pressurizedmudfluid20whichdrivesthedrillingmotor30(mudmotor)flowsdowninsidethedrillpipe3throughthedirectional
drillingtooltothedrillpipe5connectedtothemudmotor30andthenoutontotheannulus21ofthewellbore.
Themainoperationalmodeofthistoolthatallowsdrillersatthewellheadtochangethebendangleinthedownholedrillpipe
isthefollowing:Theeffectivebendangleinthedrillpipeischangedeachtimeuppercylinder1israisedashortdistanceupfrom
lowercylinder2whichisconnectedtotheheavymudmotoranddrillbit.Thisreleasesaninternalrotationallockingmechanism
that locks cylinder 1 and cylinder 2 when they are closed together. When the drill string is lowered again at the well head,
cylinder2ispushedbackupinsidecylinder1.Ascylinder2comesbackupintocylinder1,aninternalratchetingmechanism
causescylinder2torotateafixedamount(say,45degrees).Thischangesthe effective bend angle in the drill string by one
increment(45degrees)asitpassesthroughthenestedcylinders1and2ofthistool.Oncethedrillstringisloweredinplaceat
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thewellhead,mudpressureisbroughtuptodrillinglevelsanddrillingcommenceswiththenewbendangleforthedrillingbit.
The ratchet movement to change angular position is accomplished when cylinder 1 is raised only about 6 inches and then
loweredbackoncylinder2.Thisupanddownactiontochangethebendangledownholeisveryeasyfordrillerstoexecute
atthewellhead.Theysimplyshutoffallmudfluidpressureintheannulusofthedrillstringtostopdrillingandeliminatefluid
pressureinthetool.Thentheyraisethedrillstringashortdistancetochangethebendanglebyoneincrement(45degrees).
Thisnewbendangleislockedinbyloweringthedrillstringwhichclosesupcylinders1and2(cylinder2fullyinsidecylinder1).
Whencylinders1and2areclosedtogetherinthedrillingmode,thecylindersarelockedinafixedrotationalpositionwithrespect
toeachothersothatthebendangledoesnotchangeduringdrillingoperations.
Figure2showstheupper3andlower5fixedbendsectionsorientedinthesamedirection(zerodegreesnetbendanglefor
thedrillpipe).Inthisorientationthecylindricaltoolisnothingmorethanasmalloffset7orkinkinthedrillpipe.Thecenterline
8oftheupperdrillsection3andthecenterline9ofthelowerdrillpipesection5areparallelwithanoffsetofdistance7.The
drillbitisnowpointedstraightdownwithnoeffectiveangulardeviation.
However,whentheupperandlowerfixedbendsections3and5areorientedinoppositedirections,asinFigure1,theeffective
bendangle6inthedrillpipepassingthroughthetoolismaximumat2timesthefixedbendangleofXdegrees.Continued
rotationofthecylindersanother180degreeswithrespecttoeachotherbringstheeffectivedrillstringbendanglebacktozero
degreesasshowninFigure2.
MajorProblems:
Solutions:
ThethirdcylinderideawastheEurekamomentforme(thirdprototype,oneyeartoolate)thatmanyothershadmissedfor
decades.Thisiswhatmadeaworkingcylindricaltoolpossible.
Myfirst working prototype with the third internal cylinder 10 was shipped to their main testing lab in Houston. I did not tell the
Dresserengineersaboutthethirdinternalcylinder10.TheythoughtmydevicewasstillanordinarydualcylindertoolandthatI
hadbuiltanordinary(thelatest)illfatedcylinderlockingmechanisminsidetokeepthecylindersfromexplodingapartunderhigh
internalpressure.Toteasethem,Istartedthetestwiththecylinders1and2extendedfullyapart.Wheninternalmudpressure
reachedamere10psi,thetool(cylinders1and2)actuallyclosedonitself.Thecylinders1and2stayedclosedwhenthe
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internalmudfluid20pressurereached500psi.Theengineersinattendancewereinabsolutedisbelief.Irememberoneofthe
seniorengineersstormingoutofthetestinglabshoutingthisisagoddamnfraud.Buttheboss,Exec.VPJimBryan,was
there.(HewastheonewhogotmeintothisprojectwhenhebetmethatIcouldnotbuildadownholedirectiondrillingtoolthat
couldbecontrolledfromthewellhead.WewereinLondonin1991helpingtheKuwaitOilCompanyputouttheir500oilwell
fires.SeeHistorysectionbelow.)
Jim Bryan looked around and ordered the test technicians to raise the mud fluid pressure to max, about 6000 psi. Other
companyengineerswereleavingthetestingfloor.Theywerecertainthatmy10inchdiametertoolwasgoingtoblowapartwith
piecesflyingoutthewalls.Theybelievedthatthetwonestedcylinderstheycouldseeontheoutsidewereexperiencing150,000
lbsofforcetoblowthemapart.Iwentoverandleanedonthetoolasthepressurecameup.JimBryanlookedathisassistant
andannounced:Idontknowwhatthiscleverbastardhasdone,butgivehimthemoneytobuildoneofthesethatwecanput
downholeanddosomerealdrilling.Ifitworkslikethis,givehimsomemoremoney.
2)The second essential component in the tool is an internal pressure relief valve25 that solves problem 2. This valve is
uniqueinthatitopenswidelyshortlyaftertheopeningthresholdpressureisreached.Thisuniquepressurereliefvalveinline
with the mud fluid pathway made it possible to measure the bend angle in the tool down hole. This pressure relief valve is
designedtoopenatpresetlowpressurescorrespondingtotherelativeangles(ratchetpositions)ofthedrillstringdownholethat
aresetbytheupanddownmotionofthedrillstringasdescribedabove.
Whenthereliefvalve25opens,itallowsinitialmudfluid20toflowatthewellheadtopside.Thepressurewhenmudfluidflow
first begins at topside is easily measured. There are eight preset pressure relief valve thresholds. These eight pressure
thresholdscorrespondtotheeightangularpositionsofthedrillstringthatcanbesetbythetooldownhole.These pressure
thresholdswhenmudflowfirstbeginstoflowareclearsignalsatthewellhead(topside)thatmeasuretheeffectivedrillangleof
the tool down hole. Operators only need to note the pressure at which mud flow first begins as they bring up the mud fluid
pressure(eventuallytothousandsofpsi)tobegindrillingafterpickingupthedrillstringandsettingitbackdowntosetanewdrill
bitangle.
Itookprototype#6toHoustontodemonstratethistopsidedrillanglemeasuringschemewiththevariablepressurereliefvalve.
AsIwasbraggingaboutthesuccessfultest,thecompanyengineersinformedmethatpressurereliefvalvesofanysortare
forbiddeninadownholedrillpipe.Theyjustknewtheyhadmewithanothergotcha.Anyexperiencedvalvedesignerwould
have known why. A normal spring loaded pressure relief valve only opens a small amount such that the high velocity flow
throughthevalvecreatesapressuredropthatkeepsthevalveopen.Thiscreatesalargeflowrestrictionthatisintolerableina
drillstring.Worseyet,thenarrowfluidpassagewayatthevalveseatisrapidlyerodedbyhighvelocitymudfluidsuchthatthe
valveiseatenaway.(IwasonedepressedpersonontheflightbackfromHouston.HowcouldIhavebeensostupidasnotto
haverealizedthatflawinmydesign?)
AchievingtheopenwidelyvalvefeaturewasmysecondEurekamoment.ThiswassimplyanecessitythatIhadtoinventor
giveup.
Again,theinternalthirdcylinder10schemesavedme.Itletmedesignanotherhydrauliccylinderassemblybetweenthethird
cylinder10andtheupperoutercylinder1thatsupportsthereliefvalveplunger.Thiscylindermechanismpushesthevalve
headbackandwidelyopensthevalveafterthevalvefirstopensandgivesaclearsignalofthedrillbitangletothetopside.(The
detailsofthisvalvedesignarefullyexplainedingreatdetailinthepatentspecifications.)
Idemonstratedprototype#7withtheopenswidelyreliefvalveinthetestlabatHouston.Whentheflowrateatfullmudfluid
pressurewasnotdecreasedwithmyvalveinthedrillpipeannulus,Igotthesamereaction.Thecompanyengineerwhoproudly
toldmeearlierthatreliefvalvesarenotpossibleindrillpipesdemandedthatmyprototypebetakenapartbeforehiseyes.He
wassurethatsomehowIhadlockedtheinternalreliefvalvewidelyopenbeforethetest.Imadehimasmallwagerthathewould
findthevalvenormallyclosedundernopressure.Ofcourse,hecouldnotseehoworwhyitworkedunderrealpressure
whenthetoolhousingwasclosed.Hepaidforthesteakdinnerthatnightwhilebuggingmeforhowitworked.ItoldhimI
wouldsendhimacopyofthepatentdisclosureandapplicationsohecouldseeitfirsthand.
ExecVPJimBryancametoseemydesigntestedonemoretimewithbothoftheshowstopperproblemsovercome.He
agreedtobuyalicenseforthepatentsandpayforallmyexpensesoverthelastfouryears.ButneveragainwillIshootmy
mouthoffabouthoweasysomethingwillbe.ThatiswhatIhaddonein1991.IhadconfidentlytoldJimBryan,whenwe
gettheseoilwellfiresinKuwaitoutIwilldesignadownholedirectionaldrillingtoolforyouthatyoucancontrol from the well
head.
History:
IgotinvolvedinthisprojecttodesignandbuildadownholedirectionaldrillingtoolbecauseIshotmymouthofftoafamousdriller
whileworkingontheKuwaitoilwellfiresinApril1991(seeKuwaitoilwellfiressectionatwww.wattenburg.us).JimBryan
wastheexecutivevicepresidentofDresserIndustries,amajorinternationaloilwellsupplyandservicecompany.Hecameto
helpwiththeKuwaitoilwellfires.Hisvastexperienceinthedrillingbusinessandhisknowledgeoftheoilwellequipmentthat
weweretryingtorescueinKuwaitwasinvaluable.Andhewasagreatguyasafriendandmentor.
Onenightoverdinner,Iaskedhimwhatsortoftechnologyhedreamedabouthavingforhisdrillingoperations.Hetoldme
aboutthegreatcostanddifficultyofchangingthedirectionthatadrillbitgoesdowninawellhole.Heexplainedhowthedriller
hadtopulluptheentiredrillpipe(tripthestring)toinsertabendangleinthedrillpipe(abentsub)justbeforethedrillbitso
thatthedrillbitwouldbegindrillingatanangleinsteadofstraightdown.Thenwhenthedrillbithaddrilledfarenoughinanew
direction,thedrillerhadtotripthestringagaintoreplacethebentsubwithanother one of a different angle ( or a straight ).
Pullingouttheentiredrillpipe(trippingthestring)forawellthatcouldbe5000ftdeepwasverycostlyandtimeconsuming.
Hetoldmethateverydrillerdreamedofhavingatoolinthedrillpipefardownholethatcouldchangethedrillinganglewithout
havingtotripthestringeachtime.Andthetoolhadtobeadjustablefromthewellheadandthetoolhadtotellthedrillerattop
sidewhatthedownholeangleofthetoolwasatanytime.
I thought about the drilling problem for a few minutes. I told him about some of the exotic things we had designed for
undergroundnuclear testing over the years at the Lawrence Livermore National Laboratory. I told him that I thought what he
wantedwouldnotbedifficultwhenIhadtime.
Jim Bryan calmly took out a piece of paper from his coat pocket and spent a few minutes writing out something for me. He
handedittome.Itwasahandwrittencheckfor$50,000drawnonaHoustonbank.Theconditionswere:Thischeckcanbe
cashedbyDr.BillWattenburgwhenhedeliverstoDresserIndustriesanoperationaldownholedirectionaldrillingtoolthatcanbe
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programmedatthewellheadwithinonehourtochangethedrillbitdirectiondownholewithouttrippingthestringandthetool
successfullyoperatesformorethan100hoursatadepthof1000feetormore.Ismiled.IwasconfidentthatIwouldneedonly
afewweekswhenIgotbacktotheLivermoreLabtocollectthis$50,000.
Thusbegananadventureinfrustrationthateventuallyrequiredninedifferentprototypes,sixdifferenttestsinHouston,andover
halfofmytimeforthenextthreeyearsbeforeIwonthebet.BythattimeIhad expended many times the $50,000 out of
pocket.Fortunatelyforme,thefinaltoolthatIdeliveredworkedfarbetterthanJimBryanoranyofhiscompanyengineershad
expected.Andtheywereveryinterestedinsomefeaturesofmytoolthatcouldbeusedinotherdownholetools,suchasthe
waythecylindersofthehousingcloseunderpressureandtheopenswidelypressurereliefvalve..
JimBryanofferedtolicensethepatentsonthedesign.Iwasdelightedtoturnaloserintoadecentprofitandleaveitwiththem.I
tookalumpsumpaymentforanonexclusivelicenseofthepatentsandmovedontootherproblemsforwhichIcouldoffersome
expertise.
Beforethisadventurewasover,Ilearnedthatwhenevertheoldtimersinanyfieldhavenotsolvedaveryseriousandexpensive
problemintheirbusiness,itisnotnecessarilybecausetheyareincompetent.Youwillhavetoworkprettyhardtobeatthemat
theirowngame.
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