Downhole Motor Bend Adjustment Automation
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Solution Overview
Problem
Manual adjustment of bend adjustment assemblies in downhole mud motors for directional drilling is error-prone and time-consuming, as it requires simultaneous monitoring and alteration of multiple drilling parameters, increasing the risk of manual errors and equipment safety hazards.
Innovation Solution
A drilling controller system that automatically shifts the bend adjustment assembly between configurations by concurrently operating the supply pump, rotary system, and hoisting system based on pre-defined actuation commands, reducing the need for manual intervention and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of bend adjustment assembly is performed, then the drilling parameters can be adjusted to change deflection angle, but the process is time-consuming and error-prone due to simultaneous monitoring of multiple parameters
Solution Approach 1:
The system pre-defines actuation commands with specific drilling parameter values (flowrate, rotational speed) required for each bend adjustment configuration transition. Before manual intervention is needed, the controller already has the exact parameters stored, enabling rapid automated execution when a configuration change is requested, thus reducing the time loss associated with manual parameter determination and adjustment.
Solution Approach 2:
The drilling controller automatically monitors drilling parameters and executes the sequence of operations for bend adjustment without requiring continuous manual intervention. The system serves itself by autonomously managing the complex coordination of multiple drilling parameters, reducing both time loss and human error while maintaining adaptability in deflection angle adjustment.
2Adaptability or versatility
If manual adjustment of bend adjustment assembly is performed, then drilling parameters can be changed, but the risk of manual errors and equipment safety hazards increases
Solution Approach 1:
The drilling controller continuously monitors drilling parameters (flowrate, rotational speed, pump status, rotary system status) and uses this feedback to automatically execute the correct sequence of operations for bend adjustment. This closed-loop feedback mechanism eliminates manual errors by ensuring parameters are precisely controlled and verified, thereby improving reliability and safety while maintaining the ability to adjust deflection angles.
Solution Approach 2:
The system autonomously manages the complex coordination of multiple drilling parameters during bend adjustment, eliminating human error sources. The controller self-monitors and self-corrects parameter deviations, ensuring safe operation without requiring continuous manual oversight, thus improving reliability while preserving adaptability.
3Loss of time
If automated control system is implemented, then time is reduced and safety is enhanced, but the device complexity increases
Solution Approach 1:
The drilling controller is designed as a multi-functional device that not only manages bend adjustment sequences but also monitors general drilling parameters, controls pump operations, and manages rotary system operations. By consolidating multiple functions into a single controller, the patent reduces overall system complexity despite the automated capabilities, while significantly reducing time loss for bend adjustments.
4Reliability
If automated control system is implemented, then manual errors are prevented and safety is improved, but the device complexity increases
Solution Approach 1:
The drilling controller integrates multiple safety and control functions into a single universal device, including parameter monitoring, sequence execution, and equipment control. This consolidation improves reliability through automated error prevention while minimizing the increase in overall system complexity by avoiding redundant dedicated components for each function.
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 reduces the time required for shifting the bend adjustment assembly, enhances safety by automating parameter adjustments, and prevents manual errors, ensuring precise control of the drilling trajectory while protecting equipment and operator safety.
Implementation Method 1
an actuator piston positioned in the actuator housing and coupled to the actuator housing, and the actuator assembly is configured to transfer torque between the bearing mandrel and the actuator housing in response to the provision of at least one of the actuation drilling fluid flowrate and the actuation drillstring rotational speed
Data Source
AI summary
A method for drilling a wellbore includes providing a mud motor connected to a downhole end of a drillstring, wherein a bend adjustment assembly of the mud motor is provided in a first configuration, pumping a drilling fluid at a drilling flowrate from a supply pump into the drillstring whereby a drill bit coupled to the drillstring is rotated to drill into the earthen formation, receiving by a drilling controller an actuation command instructing the drilling controller to shift the bend adjustment assembly from the first configuration to a second configuration, and operating by the drilling controller at least one of the supply pump to provide an actuation drilling fluid flowrate stored in a storage device of the drilling controller, and a rotary system to provide an actuation drillstring rotational speed stored in the storage device