Adaptive shell module with embedded functionality

An apparatus for use in a borehole formed in an earthen formation, comprising:

• a drill string configured to be conveyed along the borehole;
• a flex sub positioned along the drill string, the flex sub having a tubular with a reduced diameter flex section connecting a first end to a second end, the flex section having a surface that is continuously radially recessed from an outer surface of the first end and an outer surface of the second end, the flex sub having a bore extending from the first end to the second end;
• a segmented shell disposed around the radially recessed surface, the shell being configured to be more flexible than the flex section, the shell having an outer surface that is flush with the outer surfaces of the first end and the second end;
• at least one module embedded in the shell, the at least one module including at least one sensor configured to estimate a selected parameter of interest;
• and
• a positioning module connected to the flex sub, the positioning module having a plurality of independently extendable ribs configured to engage a borehole wall and selectively laterally displace the flex sub in the borehole,
• wherein the drill string and the flex sub convey a drilling fluid to an exit of the drill string;
• and
• wherein:
• the flex section is made of a metal and the segments are formed of a non-metal;
• and
• the module further includes at least one of:
• (i) memory module storing information related to the estimated selected parameter of interest, (ii) a transmitter transmitting the information related to the estimated selected parameter of interest, and (iii) a battery supplying power to the at least one sensor.

A method for performing a selected operation in a borehole formed in an earthen formation, comprising:

• forming a work string having:
• a flex sub having a reduced diameter flex section connecting a first end to a second end, the flex section having a surface radially recessed from an outer surface of the first end and a second end, the flex sub having a bore extending from the first end to the second end;
• and
• a shell disposed around the radially recessed surface, the shell being configured to be more flexible than the flex section, wherein:
• the shell is formed of segments;
• the flex section is made of a metal and the segments are formed of a non-metal;
• and
• at least one module is embedded in the shell;
• flowing a drilling fluid through the flex sub and the work string to an exit of the work string;
• and
• conveying the work string through the borehole.