Adaptive Steering Pad Actuation for High Build Rate Drilling
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Solution Overview
Problem
Current drilling technologies face challenges in achieving high build rates and small build radii while drilling deviated wellbores, which limits the exposure of hydrocarbon reservoirs and efficiency in reaching horizontal orientations.
Innovation Solution
A bottomhole assembly (BHA) with a flex sub connecting two sections, a drilling motor, and a steering assembly comprising two axially spaced steering units with offset pads that generate opposing forces to enhance steering and allow axial misalignment, enabling a high build rate and efficient directional drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional drilling assemblies are used, then the structure is simple, but the build rate is low and build radius is large
Solution Approach 1:
The steering assembly is divided into multiple independent steering units (first steering unit and second steering unit) positioned at different axial locations. Each steering unit can independently generate steering forces in different directions, allowing the system to achieve high build rates through coordinated action of segmented components rather than requiring a single complex steering mechanism
Solution Approach 2:
The patent introduces axial spacing between steering units along the length of the bottomhole assembly, adding a dimensional aspect to steering control. The first steering unit and second steering unit operate at different axial positions, enabling three-dimensional force application that increases build rate while maintaining manageable complexity through modular design
2Strength
If rigid connection is used between BHA sections, then structural strength is high, but flexibility for directional change is reduced
Solution Approach 1:
A flex sub is introduced as a flexible connection element between the first BHA section and second BHA section. This flex sub maintains sufficient structural strength to transmit loads while providing the necessary flexibility to allow axial misalignment between rigid BHA sections, enabling the assembly to adapt to directional changes during drilling
3Productivity
If single steering unit is used, then device complexity is low, but steering precision and build rate are limited
Solution Approach 1:
Multiple steering units are combined within a single steering assembly, with the first steering unit and second steering unit working cooperatively to generate combined steering forces. This merging of multiple simpler units achieves higher build rate performance than a single complex unit would provide, while the modular nature keeps individual unit complexity manageable
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 solution allows for a high build rate of 25 degrees or greater per 30.48 meters, increasing the length of the bore in the pay zone and enhancing the exposure of hydrocarbon reservoirs, while maintaining flexibility and reducing the risk of damage during directional drilling.
Implementation Method 1
a flex sub connecting the first BHA section to the second BHA section, the flex sub flexing to allow an axial misalignment between the first BHA section and the second BHA section
Implementation Method 2
Each unit has at least one pad generating a force. The first steering unit generates a force in a first direction and the second steering unit generates a force in a second direction different from the first direction
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A bottomhole assembly (BHA) has a first section, a second section, and a drilling motor disposed along the second BHA section. The first BHA section is connected to the second BHA section with a flex sub. A steering assembly positioned along the BHA includes a first steering unit and an axially spaced apart second unit. Each steering unit has at least one pad. During operation, the first steering unit generates a force in a first direction and the second steering unit generates a force in a second direction different from the first direction. The first and the second steering units thereby cooperate to axially misalign the first BHA section and the second BHA section at the flex sub.