Self-Contained Compact Rotary Steerable System for High Build-Up Rates
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Solution Overview
Problem
Existing rotary steerable systems are over 150 inches long and achieve build-up rates of less than 10 degrees per 100 feet of drilling, necessitating the removal or omission of functional components to reduce length, compromising their self-sufficiency.
Innovation Solution
A reduced-length rotary steerable system with a steering section and control section, featuring a two-piston configuration, distribution and main flow passages, and a valve assembly that activates pistons radially outward through fluid flow, maintaining self-sufficiency and achieving higher build-up rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotary steerable system length is reduced to achieve higher build-up rates, then the build-up rate improves, but the system loses self-sufficiency
Solution Approach 1:
The valve assembly is nested within the control section, with the valve body positioned inside the control section housing. The pistons are nested within the steering section, allowing compact arrangement that reduces overall length while maintaining all necessary functional components for self-sufficiency.
Solution Approach 2:
The control section and steering section are merged into a single integrated assembly with combined length less than 150 inches. The valve assembly integrates flow control and piston activation functions, eliminating the need for separate external control systems and maintaining self-sufficiency in a compact form.
2Productivity
If the rotary steerable system length is reduced, then the build-up rate improves, but the system length decreases
Solution Approach 1:
The system arranges components in a three-dimensional compact layout rather than linear extension. The valve assembly uses radial distribution flow passages to activate pistons positioned at different angular positions, achieving functional separation without increasing axial length.
Solution Approach 2:
The system is segmented into distinct functional modules: control section with valve assembly, steering section with pistons, and drill bit. This modular segmentation allows optimized spatial arrangement of each module to minimize overall length while maintaining build-up rate performance.
3Reliability
If traditional rotary steerable systems are used, then self-sufficiency is maintained, but the build-up rate remains low
Solution Approach 1:
The valve assembly uses hydraulic principles to control fluid flow through distribution flow passages, activating pistons radially outward to steer the drill bit. This hydraulic control mechanism enables precise directional control with higher build-up rates while maintaining system self-sufficiency.
Solution Approach 2:
The pistons are positioned radially outward from the central axis and can extend dynamically to contact the wellbore wall for steering. The valve assembly dynamically controls fluid distribution to activate specific pistons based on desired steering direction, enabling higher build-up rates through active dynamic control.
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 achieves build-up rates of at least 25 degrees per 100 feet of drilling while maintaining a combined length of less than 150 inches, enhancing directional control and efficiency in oil and gas well drilling.
Implementation Method 1
A valve assembly is provided that activates the pistons to extend radially outward
Implementation Method 2
A reduced-length, self-sufficient rotary steerable system and bottom hole assembly that achieves higher build-up rates
Data Source
AI summary
A self-sufficient rotary steerable system configured to provide a bottom hole assembly with a build-up rate of at least 25 degrees per 100 feet of drilling distance. The rotary steerable system has a reduced length without the removal or omission of functional components, including a power module, a control module, a communication module, a filter module, a valve module, and/or a pressure regulation module. The build-up rate is defined as a function of a length between a first contact point on a drill bit of the bottom hole assembly and a second contact point at a piston assembly of the rotary steerable system; length between the second contact point and a third contact point at a stabilizer of the rotary steerable system; the drill bit outer diameter; the piston assembly outer diameter; and the stabilizer outer diameter.