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BillWattenburg

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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.
Themainhousingandoperationalactionofthisdirectionaldrillingtoolis shown in the Figures 1 and 2 below. Any device
installed in a drill pipe (string), such as this directional drilling device, is called a tool or a sub. The numbers in the text
henceforthrefertospecificcomponentsofthetoolaslabeledinFigures1and2.
ReferringtoFigures1and2below,themainhousingofthetoolconsistsofanuppercylinder1inwhichalowercylinder2
slidesandrotates.Theupperdrillpipe3isrigidlyattachedtotheuppercylinder1atasmallfixedbendangle4(Xdegrees).
The lower drill string 5 is rigidly
attachedtothelowercylinder2at
thesameangle4(Xdegrees)as
theupperdrillpipe3.InFigure
1 below, the effective bend
angle6betweenthecenterline
ofthedrillpipe3andthecenter
lineofthedrillpipe5canthusbe
changed from zero degrees to 2
times X degrees by rotating the
lowercylinder2insideofandwith
respecttotheuppercylinder1.
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:
1) The twocylinder housing
wantstoblowapart.
The two cylinder housing
described so far is totally
impractical in a down hole tool
that carries highly pressurized
fluid such as the mud fluid in a
drill string at thousands of psi.
It is obvious that the cylinders 1
and 2 will experience enormous
hydraulic force to push them
apart. Internal locking
mechanisms strong enough to
hold
them
together
are
cumbersome.Anyfailureofsuch
a locking mechanism means that
the lower drill string and the
drilling motor and bit are lost
when cylinder 2 is blown out of
cylinder 1 down hole. That is
whytheindustryhadabandoned
downhole drilling tools that used
concentric cylinders as for the
mainhousingofthetools.
2) How to confirm the down
holebendangleattopside?
There must be some way for
drillers at top side to measure
andconfirmthebendangleinthe
drill string down hole, no matter
howeasyitistochangethebend
angle.

Solutions:
Within the cylindrical housings 1
and 2 of this directional drilling
tool, there are two main
subassemblies that solve the
two show stopper problems 1)
and2)above.
Problem 1) was solved with a
third cylinder 10 inside the two
outsidehousingcylinders1and2.
Third cylinder 10 carries the
pressurizedmudfluid20throughthecenterofthetool.Theinternalcavitiesoftheoutertwocylinders1and2aresealedbyseal
positions12and13withtheinnerthirdcylinder10.Thisconfigurationmakesahydrauliccylinder11thatclosesthetwoouter
cylinders1and2onthemselvesratherthanexpandsthemapartwhenmudpressure20isappliedinsidetheassembly.
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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