Automated Downlink Testing for Rotary Steerable Drilling Systems
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Solution Overview
Problem
Conventional drilling systems face challenges in accurately executing downlink sequences due to human error, system delays, and miscommunication, leading to incorrect tool settings, increased borehole tortuosity, equipment wear, and lost drilling time.
Innovation Solution
An electronic application that identifies and executes a downlink testing sequence for the surface control system of a drilling rig, varying target operating parameters over a predetermined time, measuring output values, and calculating differences to determine compliance, with notifications for system performance and successful downlink confirmation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control of downlink sequences is used, then the driller can adjust control parameters, but human error causes missed alerts or misread stopwatches leading to failed downlinks
Solution Approach 1:
The surface control system automatically executes downlink sequences without requiring continuous human intervention. The system self-regulates by automatically alternating control parameters between two values according to the programmed sequence, eliminating the need for the driller to manually time each parameter change and reducing human error.
Solution Approach 2:
The patent replaces the mechanical stopwatch-based timing system with an electronic automated control system. The electronic system uses programmed logic to automatically track and execute the downlink sequence timing, substituting electronic automation for manual mechanical timing methods to improve precision and reliability.
2Measurement precision
If automated programs are used to alert the driller, then timing precision improves, but system complexity increases due to additional control systems
Solution Approach 1:
The patent combines the alert function and the control parameter adjustment function into a single integrated automated system. Rather than having separate alerting devices and separate control mechanisms, the system merges these functions so that one automated program both times the sequence and automatically adjusts the control parameters, reducing overall system complexity.
Solution Approach 2:
The surface control system is designed to perform multiple functions: it acts as a timer, an alert system, and an automated control parameter adjuster all within a single system. This multi-functionality eliminates the need for separate dedicated devices for each function, thereby managing complexity while maintaining precision.
3Device complexity
If downlink sequences are executed manually, then system simplicity is maintained, but delays and miscommunication increase leading to lost drilling time
Solution Approach 1:
The downlink sequence is programmed and prepared in advance before execution. The control parameters, timing sequence, and alternation pattern are pre-configured in the automated system, allowing the sequence to be executed without real-time human decision-making during the actual downlink process, thereby eliminating delays and miscommunication.
Solution Approach 2:
The automated system ensures continuous execution of the downlink sequence without interruptions or pauses for manual intervention. The control parameters are adjusted continuously according to the programmed timeline, maintaining uninterrupted communication with the bottom hole assembly and preventing lost drilling time.
4Reliability
If surface control systems have delays or faulty programming, then downlink accuracy decreases, but detecting and measuring these issues is difficult
Solution Approach 1:
The system incorporates feedback mechanisms that monitor the actual execution of downlink sequences and compare them against the programmed sequence. This feedback allows the system to detect deviations, delays, or programming errors in real-time and identify whether the surface control system is operating correctly or requires adjustment.
Data Source
AI summary
A method that includes an electronic application identifying a downlink sequence for execution by a surface control system of a drilling rig, with the sequence including target output values of a mud pump system and/or a drive system. The method includes instructing the control system to operate in accordance with the sequence. The application receives measured output values of the mud pump system and/or the drive system and calculates differences between the target and measured output values. When the differences are within a level of tolerance, then the application identifies the control system as compliant; and when the differences are greater than the level of tolerance, then the application identifies the control system as non-compliant. The method also includes the application receiving data from a BHA of the drilling rig and determining, based on the data received, if a downlink to the BHA was successful.