Directional Drilling Actuators with Variable Radial Extension
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Solution Overview
Problem
Current directional drilling technologies face challenges in efficiently steering drill bits to create geometric boreholes without the need for frequent rig relocations or additional equipment setups, especially in offshore drilling where costs are high and precision is critical.
Innovation Solution
The development of an actuator assembly with multiple chambers and actuators that extend radially to apply forces to the formation, allowing for precise control of the drill bit's direction through a combination of fluid channels and movable working surfaces, enabling both push-the-bit and point-the-bit steering mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If directional drilling is used to explore formations without moving the rig, then operational costs are reduced, but steering precision and control are more challenging to achieve
Solution Approach 1:
The steering system is divided into multiple independent actuators (first actuator, second actuator, third actuator) positioned at different locations around the drill string. Each actuator can be controlled independently to apply forces in different directions, enabling precise directional control through coordinated action of segmented components.
Solution Approach 2:
The system changes the physical state by extending and retracting actuators to different lengths. The first actuator has a first length, the second actuator has a second length greater than the first, and the third actuator has a third length greater than the second. By varying the extension length of each actuator, the system can precisely control the magnitude and direction of applied forces to achieve accurate steering.
2Measurement precision
If multiple actuators with different extension lengths are used, then steering precision is improved, but device complexity increases
Solution Approach 1:
Multiple actuators with different functionality (different extension lengths, different positions) are merged into a single integrated actuator assembly. The first, second, and third actuators are positioned within the same assembly and can be controlled together to achieve complex steering maneuvers, reducing the need for separate control systems for each actuator.
Solution Approach 2:
The actuator assembly serves multiple functions: it provides directional steering control, applies lateral forces to the formation, and can operate in different drilling conditions. Each actuator within the assembly can function independently or in combination with others, allowing the same assembly to handle various steering requirements without needing additional specialized equipment.
3Force
If actuators extend radially further from the longitudinal axis, then the ability to apply force to the formation is improved, but the risk of underreaming increases
Solution Approach 1:
Different actuators are designed with different extension lengths suited to their specific positions and functions. The first actuator has a first length, the second actuator has a second length greater than the first, and the third actuator has a third length greater than the second. This localized differentiation allows each actuator to apply appropriate force at its specific location without excessive extension that would cause underreaming.
Solution Approach 2:
The system prevents underreaming by carefully controlling the maximum extension length of each actuator before it contacts the formation. The actuators are designed with predetermined lengths that allow sufficient force application while maintaining a safety margin to prevent excessive penetration into the formation walls.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the ability to steer drill bits along planned paths with improved precision and reduced underreaming, allowing for more efficient directional drilling without the need for frequent rig relocations, thus lowering operational costs and increasing drilling efficiency.
Implementation Method 1
a first actuator positioned at least partially in the first chamber... The first actuator has a first working surface and is movable between an extended position and a retracted position... extending a first actuator a first radial distance and applying a first force to a formation
Implementation Method 2
a second actuator positioned at least partially in the second chamber... The second actuator has a second working surface and is movable between an extended position and a retracted position... extending a second actuator a second radial distance greater than the first radial distance and applying a second force to the formation
Data Source
AI summary
A rotary steerable drilling system having a series of actuators disposed with a drilling tool, the series of actuators arranged in close proximity and independently operable to distribute a total steering force applied to a wellbore wall across the series of actuators. The series of actuators are extendable to different distances, such that the radial extension length of the actuators increases between actuators.