Downhole Tool Control System for Real-Time Torque Optimization

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Solution Overview

Problem

Current drilling systems face challenges in optimizing weight and torque distribution between disintegrating devices in varying formation properties, leading to inefficiencies and potential tool failures due to the inability to adjust drilling characteristics in real-time.

Innovation Solution

Implementing a control system that continuously monitors and adjusts the aggressiveness of disintegrating devices through real-time closed-loop communications, allowing for optimal weight and torque distribution between disintegrating devices, regardless of formation characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If real-time adjustment of drilling characteristics is implemented, then drilling efficiency and tool reliability are improved, but device complexity increases

Engineering Contradiction:

Improvetool reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system implements closed-loop feedback by continuously monitoring drilling characteristics (weight, torque, ROP) from multiple disintegrating devices and automatically adjusting their operation based on real-time performance data, enabling dynamic optimization of drilling parameters to prevent tool failures and improve reliability

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The drilling system performs self-optimization through automated control that monitors and adjusts its own components without external intervention, with the system evaluating its own performance and making real-time modifications to drilling parameters to maintain optimal operation and prevent failures

Inventive Principle:

Principle #25Self-service

2Productivity

If real-time monitoring and adjustment of multiple disintegrating devices is implemented, then drilling efficiency is improved, but device complexity increases

Engineering Contradiction:

Improvedrilling efficiencyVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides the drilling operation into separate controllable units by monitoring and controlling each disintegrating device individually, allowing independent optimization of weight, torque, and ROP parameters for each device while maintaining overall system efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The drilling system transitions from static, fixed-parameter operation to dynamic, real-time adjustment of drilling characteristics, with the ability to continuously modify weight, torque, and ROP parameters based on formation conditions and device performance to maximize drilling efficiency

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If automated control of drilling characteristics is implemented, then adaptability to varying formation properties is improved, but ease of operation decreases

Engineering Contradiction:

Improveadaptability to formation propertiesVSAvoidease of operation

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The system automatically adapts to varying formation properties through continuous monitoring of drilling characteristics and real-time adjustment of parameters, eliminating the need for manual operator intervention and maintaining optimal drilling conditions across diverse formation types

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Manual operator control is replaced with automated electronic control systems that monitor and adjust drilling parameters through sensors and control mechanisms, substituting human decision-making with automated algorithms that process real-time data and optimize drilling operations

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10954772B2Automated optimization of downhole tools during underreaming while drilling operations

Publication Date: 2021.03.23 BAKER HUGHES CO

AI summary

Systems and methods for adjusting a drilling operation, the methods and systems include obtaining, at a control system, a first drilling characteristic associated with a first drilling operation device that is part of a drilling system on a drill string; obtaining, at the control system, a second drilling characteristic associated with a second drilling operation device located apart from the first drilling operation device along the drill string; and controlling, with the control system, at least one adjustable element of the first drilling operation device in response to at least one of the obtained first drilling characteristic and the second drilling characteristic, wherein adjustment of the at least one adjustable element causes a change in at least one of the first drilling characteristic and the second drilling characteristic.