Drill Bit Rate of Penetration Control via Multi-Loop PID Evaluation

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Solution Overview

Problem

Existing drilling technologies lack effective methods to control the rate of penetration of a drill bit during oil and gas drilling, risking catastrophic failure when increasing drilling parameters such as weight-on-bit or drill string torque.

Innovation Solution

A method and system that evaluate multiple control loops for drilling parameters like weight-on-bit, differential pressure, and torque, using proportional-integral-derivative (PID) control techniques to determine output signals that adjust the rate of penetration, selecting the signal of lowest magnitude or percentage error to control the drill bit's penetration rate, and sending it to a variable frequency drive or hydraulics system to manage the drilling process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If drilling parameters such as weight-on-bit or drill string torque are increased to increase the rate of penetration, then productivity is improved, but reliability deteriorates due to risk of catastrophic failure

Engineering Contradiction:

Improverate of penetrationVSAvoiddrilling process stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system dynamically adjusts drilling parameters in real-time by evaluating multiple control loops (weight-on-bit, torque, differential pressure, traveling block velocity) and selecting the most appropriate control signal based on current conditions. This dynamic adaptation allows the system to optimize rate of penetration while maintaining safety margins, preventing catastrophic failures by responding to changing downhole conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements closed-loop feedback control by continuously monitoring drilling parameters, comparing actual values against setpoints, and adjusting control outputs accordingly. The feedback mechanism evaluates error measurements from multiple parameters and uses proportional-integral control to maintain drilling parameters within safe operating ranges, thereby preventing catastrophic failures while optimizing penetration rate.

Inventive Principle:

Principle #23Feedback

2Reliability

If multiple control loops are evaluated and selected based on lowest magnitude or percentage error, then reliability is improved by preventing catastrophic failure, but device complexity increases

Engineering Contradiction:

Improvedrilling process stabilityVSAvoidcontrol system structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The control system is designed with multi-functionality by integrating multiple control loops (weight-on-bit, torque, differential pressure, traveling block velocity) into a single unified control platform. Each control loop serves multiple purposes: monitoring its specific parameter, comparing against setpoints, calculating error measurements, and contributing to the overall rate of penetration control. This universal approach manages complexity by having one system perform multiple control functions rather than separate independent systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system manages complexity by dynamically changing control parameters based on operating conditions. Instead of using fixed control parameters, the system adjusts which control loop is active and what setpoints are used based on real-time evaluation of error measurements and percentage errors. This parameter adaptation allows the system to maintain reliability while managing complexity through conditional logic rather than permanent structural complexity.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If automatic driller is used to control rate of penetration by taking into account drilling parameters, then reliability is improved, but ease of operation deteriorates due to automation complexity

Engineering Contradiction:

Improverate of penetration controlVSAvoiddrilling process control

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The automatic driller implements self-service by autonomously evaluating multiple control loops, comparing actual drilling parameters against setpoints, calculating error measurements, and selecting appropriate control actions without requiring continuous manual intervention. The system automatically adjusts drilling parameters to maintain rate of penetration within desired ranges, freeing operators from complex manual control tasks while improving reliability through consistent automated monitoring and adjustment.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10591625B2Method, system, and medium for controlling rate of penetration of a drill bit

Publication Date: 2020.03.17 PASON SYST

AI summary

Methods, systems, and techniques for controlling the rate of penetration of a drill bit use drilling parameter measurements read from drilling parameter sensors to evaluate control loops, with the output of one of the control loops at any given time being used by an automatic driller to control the rate of penetration. For each of the drilling parameters, the automatic driller reads a drilling parameter measurement, determines an error measurement that represents a difference between a drilling parameter setpoint and the drilling parameter measurement, and from the error measurement determines an output signal proportional to the rate of penetration of the drill bit. The output signal of one of the control loops is subsequently selected and used to control the rate of penetration.