Downhole Torque Measurement via Rotational Velocity Integration
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Solution Overview
Problem
Drilling wells in subterranean rock formations is inefficient due to drill bit wear, changing rock conditions, and the difficulty in accurately measuring torque and angle of twist in harsh downhole environments, which affects drilling efficiency and increases costs.
Innovation Solution
A method and system for calculating torque and angle of twist in downhole components using rotational velocity measurements from multiple sensing instruments, integrated and synchronized to determine torque and power transmission through the drill string, reducing the need for strain gauges and other torque-measuring components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strain gauges are used to measure torque, then torque measurement capability is provided, but the device size and expense increase
Solution Approach 1:
The patent extracts the torque measurement capability from traditional strain gauge technology and implements it through a different mechanism - using a torque sensor that measures torque directly through a shaft mounted on bearings, eliminating the need for complex strain gauge arrangements and reducing device size and cost
Solution Approach 2:
The patent replaces the mechanical strain gauge measurement system with a bearing-mounted shaft torque sensor system, substituting the traditional method of measuring strain on the shaft surface with a direct torque measurement approach through the bearing-mounted shaft
2Reliability
If environmental protection is added to protect strain gauges, then sensor reliability improves, but size and expense increase
Solution Approach 1:
The patent removes the need for environmental protection housings by extracting the strain gauge technology entirely and replacing it with a torque sensor that can operate directly in the downhole environment through a bearing-mounted shaft configuration
Solution Approach 2:
The patent employs a simpler, more robust torque sensor design that does not require expensive environmental protection, accepting that the sensor may need replacement but reducing the overall system cost and complexity
3Productivity
If the drill bit continues to be used, then drilling operation continues, but drill bit wear increases reducing effectiveness
Solution Approach 1:
The patent implements a feedback mechanism by continuously monitoring torque and angle of twist downhole, providing real-time data about drilling conditions and drill bit performance, enabling operators to detect wear and optimize drilling parameters to extend drill bit life while maintaining effectiveness
Solution Approach 2:
The patent enables preliminary detection of drill bit wear conditions through downhole sensing, allowing operators to take preventive actions before complete failure occurs, such as adjusting drilling parameters or preparing for timely bit replacement
4Productivity
If power is increased to maintain penetration rate, then rate of penetration is maintained, but drill bit wear increases
Solution Approach 1:
The patent uses feedback from downhole torque and angle of twist measurements to provide real-time information about drilling efficiency and drill bit condition, enabling dynamic adjustment of surface power and drilling parameters to maintain penetration rate while minimizing drill bit wear
Data Source
AI summary
A drilling system may include one or more downhole components to which a torque is applied. To determine the torque, the rotational velocity may be determined at two locations on a downhole component. An angle of twist may be determined by taking the integral of the rotational velocity at the two points, and the torque may be proportional to the angle of twist. The angle of twist, physical properties based on the geometry and material of the downhole component may be used, and the distance between the two locations may be used to calculate the torque.