Active Stabilizer for Rotary Steerable Drilling Systems

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Solution Overview

Problem

Existing push-the-bit rotary steerable systems face challenges in achieving high steering precision and smooth drilling trajectories due to uneven well walls and vibrations, leading to difficulties in casing and trip-in/trip-out operations.

Innovation Solution

A rotary steerable system incorporating an active stabilizer with a body and actuators that apply a lateral force to deviate the drill string from the borehole center, combined with a sliding mechanism to constrain and guide radial movement, allowing precise directional control and stabilization against radial shaking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If push-the-bit rotary steerable system is used to achieve high build-up rate, then drilling efficiency is improved, but drilling trajectory smoothness and well wall quality deteriorate

Engineering Contradiction:

Improvebuild-up rateVSAvoiddrilling trajectory smoothness

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The stabilizer is divided into multiple independent contact points (first stabilizing contact point, second stabilizing contact point, third stabilizing contact point) arranged at different locations. This segmentation allows each contact point to independently interact with the well wall, providing distributed support and enabling smoother trajectory control while maintaining high build-up rate.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stabilizer employs movable contact points that can dynamically adjust their positions and engagement forces. The first, second, and third stabilizing contact points are not fixed but can move to adapt to well wall irregularities, providing dynamic stabilization that maintains trajectory smoothness during high-rate directional changes.

Inventive Principle:

Principle #15Dynamics

2Productivity

If push-the-bit rotary steerable system is used to achieve high build-up rate, then drilling efficiency is improved, but well wall roughness increases

Engineering Contradiction:

Improvebuild-up rateVSAvoidwell wall smoothness

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The stabilizer contact surface is segmented into multiple discrete contact points rather than a single large contact area. This segmentation distributes the stabilizing force across multiple locations, reducing localized well wall damage and producing smoother well walls even during high-rate directional drilling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different contact points (first, second, third stabilizing contact points) are positioned at specific locations to provide localized stabilization where needed. This allows the system to maintain well wall quality in critical areas while achieving high overall build-up rate.

Inventive Principle:

Principle #3Local quality

3Device complexity

If conventional stabilizer design is used, then device simplicity is maintained, but steering precision deteriorates

Engineering Contradiction:

Improvestabilizer structure simplicityVSAvoidsteering precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The stabilizer is segmented into multiple contact points with potentially different functions and positions. This segmentation enables precise control of drill string orientation by independently managing contact at each point, achieving high steering precision without excessive overall complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stabilizer incorporates movable contact points that can dynamically adjust to maintain optimal positioning. This dynamic capability enhances steering precision by ensuring continuous contact at the most effective locations, while the overall structure remains relatively simple.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system enables precise directional drilling with improved drilling quality, reduced vibrations, and smoother well walls, enhancing the build-up rate and smoothness of the drilling trajectory.

Implementation Method 1

The drill string includes at least one sliding portion, each capable of sliding within one of the at least one groove defined in the body of the active stabilizer, to constrain relative movement between the drill string and the active stabilizer along an axial direction of the drill string and guide relative movement between the drill string and the active stabilizer along a radial direction

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11591860B2Rotary steerable drilling system with active stabilizer

Publication Date: 2023.02.28 BAKER HUGHES OILFIELD OPERATIONS LLC

AI summary

A drilling system includes a drill string for connecting with a drill bit for drilling a borehole, a fixed stabilizer fixed on the drill string, and an active stabilizer including a body and actuators connecting the body and the drill string. The actuators are capable of driving the drill string away from a center of the borehole with a displacement. The body has an outer surface for contacting a wall of the borehole, an inner surface facing the drill string, and at least one guiding portion projecting from the inner surface and each defining at least one groove. The drill string includes at least one sliding portion slidable within the at least one groove respectively to constrain movement between the drill string and the active stabilizer along an axial direction of the drill string and guide movement between the drill string and the active stabilizer perpendicular to the axial direction.