Rotary Steerable Actuator Tool Face Control
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Solution Overview
Problem
Rotary steerable drilling systems face challenges in controlling the direction of drilling, particularly in maintaining the desired non-collinear condition between the drill bit and stabilizers, leading to difficulties in generating curved boreholes effectively.
Innovation Solution
A control technique that processes parameters related to the operation of a rotatable collar to control the positioning of an actuator tool face, using bi-stable valve actuators and sensors to ensure precise orientation and firing of the actuators, thereby controlling the drilling orientation and direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional actuator control methods are used in rotary steerable systems, then the system can operate with standard control mechanisms, but the precision and reliability of tool face control deteriorates, leading to difficulties in maintaining the desired non-collinear condition
Solution Approach 1:
The patent implements a feedback control system that continuously monitors collar position and velocity, then adjusts actuator firing sequences accordingly. The control system processes real-time parameters from position sensors and velocity measurements, dynamically modifying actuator activation timing to maintain precise tool face orientation despite varying collar speeds and positions.
Solution Approach 2:
The control system automatically adjusts actuator firing sequences based on measured collar parameters without requiring external intervention. The system self-regulates by processing its own operational data (position and velocity measurements) and autonomously modifying control signals to maintain optimal tool face orientation.
2Manufacturing precision
If actuator firing sequences are not adjusted for varying collar speeds, then the control system operates with fixed timing, but the accuracy of maintaining non-collinear condition deteriorates
Solution Approach 1:
The control system transitions from fixed timing to dynamic timing adjustment. Actuator firing sequences are continuously modified based on real-time collar velocity measurements, allowing the system to adapt its control strategy to varying operational conditions while maintaining precise tool face orientation and borehole curvature accuracy.
Solution Approach 2:
The system changes the timing parameters of actuator firing sequences based on measured collar velocity and position. By dynamically adjusting these control parameters in response to varying operational conditions, the system maintains accurate tool face control and borehole curvature generation across different drilling scenarios.
3Reliability
If simple position control is used without considering collar velocity, then the control mechanism remains simple, but the reliability of maintaining correct tool face orientation deteriorates
Solution Approach 1:
The control system incorporates dual feedback loops that monitor both collar position and velocity. These feedback signals are processed to dynamically adjust actuator firing timing, ensuring reliable tool face orientation maintenance under varying operational conditions while accounting for the interplay between position and velocity parameters.
Solution Approach 2:
The control system uses velocity measurements to predictively adjust actuator firing sequences in advance. By considering collar velocity trends, the system proactively modifies timing parameters to maintain correct tool face orientation before deviations occur, enhancing reliability through anticipatory control adjustments.
Data Source
AI summary
A technique facilitates controlling the direction of drilling when using a rotary steerable system to drill a borehole. The method comprises processing parameters related to operation of a rotatable collar of the rotary steerable system. The parameters are used in cooperation with characteristics of actuators to control the positioning of an actuator tool face which, in turn, controls the drilling orientation of the rotary steerable system.