Anti-Whirl Control System for Drilling Operations

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Solution Overview

Problem

Current methods for reducing whirl in drilling operations are costly and ineffective, as they often require physical modifications to drilling bits and BHA designs, which are not always feasible, and do not provide real-time solutions for mitigating forward and backward whirl conditions.

Innovation Solution

A system and method that uses downhole drilling parameters to model and predict whirl regions, allowing for real-time adjustment of top drive RPM and Weight on Bit (WOB) to avoid or minimize whirl by scheduling optimal RPM and WOB values based on sensed conditions, using supervisory algorithms and sensors to maintain safe drilling operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If physical solutions such as adding stabilizers to BHA or modifying bit design are used to reduce whirl, then whirl reduction effectiveness is improved, but device complexity and cost increase

Engineering Contradiction:

Improvewhirl reduction effectivenessVSAvoidBHA modification complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes operational parameters (RPM, WOB, axial load) to control and prevent whirl instead of modifying physical BHA structure. The control system dynamically adjusts these parameters based on detected whirl conditions, eliminating the need for physical stabilizers or bit modifications while achieving effective whirl reduction.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces mechanical/physical solutions (stabilizers, BHA modifications) with a control system that uses sensor detection and automated parameter adjustment. This substitution of mechanical systems with automated control achieves whirl reduction without increasing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If physical modifications to BHA or bit are made to reduce whirl, then whirl control capability is improved, but ease of manufacture and deployment worsen

Engineering Contradiction:

Improvewhirl control capabilityVSAvoidBHA modification ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of manufacturing physical modifications to BHA or bit, the system changes operational parameters (RPM, WOB) through software control. This approach maintains whirl control capability while dramatically improving ease of manufacture since no physical modifications are needed.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The control system automatically detects whirl conditions and self-adjusts operational parameters without requiring manual intervention or physical modifications. This self-service capability eliminates the need for complex manufacturing and deployment processes associated with physical BHA modifications.

Inventive Principle:

Principle #25Self-service

3Reliability

If traditional whirl reduction methods are used, then whirl mitigation is achieved, but productivity decreases due to frequent bit trips and modifications

Engineering Contradiction:

Improvewhirl mitigation effectivenessVSAvoiddrilling continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The control system enables continuous drilling operations by dynamically adjusting parameters to prevent whirl without requiring bit trips or BHA modifications. This maintains uninterrupted drilling action, improving productivity while achieving effective whirl mitigation.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Replacing physical modification approaches with automated control eliminates the need to stop drilling for bit trips or BHA changes. The control system continuously manages whirl conditions, maintaining drilling continuity and maximizing productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If RPM set point is increased to improve drilling speed, then productivity is improved, but whirl risk increases when close to lateral resonant frequency

Engineering Contradiction:

Improvedrilling speedVSAvoidwhirl occurrence risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system dynamically adjusts RPM based on real-time detection of whirl conditions and proximity to resonant frequencies. Rather than using a fixed high RPM for maximum speed, the control system continuously adapts RPM to maintain productivity while avoiding whirl-inducing conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control system uses feedback from sensors detecting lateral vibrations and whirl conditions to automatically adjust RPM. This closed-loop control prevents whirl by reducing RPM when resonant conditions are detected, while maintaining high drilling speed when conditions are safe.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS10215010B1Anti-whirl systems and methods

Publication Date: 2019.02.26 NABORS DRILLING TECHNOLOGIES USA INC

AI summary

Systems and methods for reducing or eliminating whirl are described. The system includes a controller and a drive system. The controller is configured to collect downhole information, determine a natural frequency of a drill string in the lateral motion, determine correlative relationships, model a forward whirl region, generate a control algorithm, determine a top drive supervisory setpoint, and provide operational control signals. The drive system is configured to receive the one or more operational control signals and limit the top drive RPM.