Drill String Torsional Energy Control via Top Drive Setpoints
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Solution Overview
Problem
In oil/gas drilling operations, the accumulation of torsional energy in the drill string due to a stuck drill bit or BHA can lead to high rotational acceleration and mechanical stress when released, damaging equipment, as current systems do not allow for a smooth or controlled release of this energy.
Innovation Solution
An apparatus comprising a rotation sensor, torque sensor, and processing device that monitors rotational speed and torque measurements to detect when the drill string is stuck, then controls the release of torsional energy by decreasing the top drive's rotational and torque set-points and lifting the drill string, thereby preventing uncontrolled acceleration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drill string is lifted to free a stuck drill bit or BHA, then the stuck condition is resolved, but uncontrolled release of accumulated torsional energy causes high rotational acceleration and mechanical stress that can damage equipment
Solution Approach 1:
The system detects stuck conditions in advance by monitoring torque and rotational speed, and initiates controlled energy release procedures before the drill string is lifted. This preliminary detection and response prevents the accumulation of dangerous levels of torsional energy that would otherwise be released uncontrollably during subsequent lifting operations.
Solution Approach 2:
The system changes operational parameters (torque and rotational speed setpoints) based on detected stuck conditions. By adjusting these parameters dynamically, the system controls the release of torsional energy during the freeing process, transforming the harmful uncontrolled energy release into a controlled process that protects equipment from damage.
2Productivity
If the top drive continues to rotate the drill string after the drill bit becomes stuck, then rotational drilling continues, but torsional energy accumulates in the drill string leading to potential equipment damage
Solution Approach 1:
The system continuously monitors torque and rotational speed parameters and uses this feedback to detect when the drill bit becomes stuck. Based on this feedback, the system automatically adjusts the top drive's rotational speed and torque setpoints, preventing further accumulation of torsional energy while allowing the drilling operation to be paused or continued in a controlled manner.
Solution Approach 2:
The system dynamically adjusts the top drive's operational parameters (rotational speed and torque) in response to changing downhole conditions. When a stuck condition is detected, the system transitions from constant rotation to controlled variable-speed rotation, allowing the drill string to rotate back and release accumulated energy without causing damage.
3Reliability
If telemetry signals are used to detect stuck conditions, then the drill bit or BHA stuck status is identified, but the detection delay of several seconds to a minute or longer allows excessive torsional energy to accumulate
Solution Approach 1:
The system performs preliminary detection of stuck conditions using real-time monitoring of torque and rotational speed parameters at the surface, eliminating the need to wait for delayed telemetry signals from downhole. This preliminary surface-based detection allows the system to respond immediately to stuck conditions before excessive torsional energy accumulates in the drill string.
Data Source
AI summary
Apparatus and methods for controlling release of torsional energy from a drill string having a lower portion that is stuck against a subterranean formation and a top end rotated by a top drive. The method may include decreasing a rotational speed set-point of the top drive, decreasing a torque set-point of the top drive, and/or decreasing flow rate of drilling mud being pumped downhole via the drill string, thereby decreasing torque output by a mud motor rotating a drill bit. The method may further include lifting the drill string to free the drill string. Decreasing the torque set-point of the top drive may comprise decreasing the torque set-point of the top drive to a minimum torque level that the top drive can output. Decreasing the rotational speed set-point of the top drive may comprise decreasing the rotational speed set-point of the top drive to zero.