Drilling Control System Adjusts Bit Angle for Hard Rock Layers

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Solution Overview

Problem

Drilling operations are hindered by unexpected hard rock layers, known as stringers, which reduce the rate of penetration and cause wear on drilling equipment, leading to inefficient and potentially hazardous drilling conditions.

Innovation Solution

Implementing a system that uses a bottomhole assembly with a disintegrating device and sensors to monitor formation layer orientations, detect changes in drilling performance, and adjust the drilling trajectory by setting an optimal angle of attack relative to the detected formation layer orientation, thereby optimizing drilling through hard rock layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If drilling operations proceed through hard rock layers (stringers) without adjustment, then drilling continues along the planned trajectory, but the rate of penetration decreases and equipment wear increases

Engineering Contradiction:

Improverate of penetrationVSAvoidequipment wear and drilling complications

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary detection of formation layer orientations using sensors (dipmeters, image logs) before the disintegrating device encounters the hard rock layer. This advance information allows the drilling system to proactively adjust the angle of attack before contact occurs, preventing the harmful effects of unexpected stringer encounters rather than reacting after damage has occurred.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the drilling trajectory and angle of attack in real-time based on detected formation layer orientations. Rather than maintaining a fixed drilling path, the system continuously modifies the angle of approach to the formation layers, optimizing the disintegrating device's contact angle with hard rock layers to maintain productivity while reducing equipment wear.

Inventive Principle:

Principle #15Dynamics

2Productivity

If the drilling trajectory is adjusted to optimize angle of attack on formation layers, then drilling efficiency improves, but the drilling path deviates from the original trajectory

Engineering Contradiction:

Improvedrilling efficiencyVSAvoidtrajectory control

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system employs continuous feedback loops where sensors monitor formation layer orientations in real-time, the system processes this data to determine optimal angle of attack, and the drilling trajectory is adjusted accordingly. This closed-loop control ensures that trajectory deviations are minimized while maintaining optimal drilling efficiency, as the system constantly compares actual performance with target parameters and makes corrective adjustments.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system changes key drilling parameters (angle of attack, trajectory orientation) based on detected formation characteristics. By systematically varying these parameters in response to formation layer orientations, the system optimizes drilling efficiency through hard rock layers while maintaining controllable and predictable trajectory adjustments rather than random or excessive deviations.

Inventive Principle:

Principle #35Parameter changes

3Loss of time

If sensors are positioned remote from the disintegrating device to monitor formation layers, then formation orientation data is obtained in advance, but the angle of attack adjustment may be less precise

Engineering Contradiction:

Improveadvance detection capabilityVSAvoidformation orientation accuracy at bit location

Core Design Contradiction:

Loss of timeVSMeasurement precision

Solution Approach 1:

The system implements a nested sensor configuration where multiple sensing zones are arranged concentrically around the drill string, with sensors at different distances from the disintegrating device. This nested arrangement allows the system to combine advance detection capability (from remote sensors) with precise formation orientation measurement (from closer sensors), effectively resolving the contradiction between early warning and measurement accuracy.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The system uses formation layer orientation data from remote sensors as an intermediary to predict and prepare for upcoming stringers. The remote sensor data serves as a warning signal that triggers more precise measurements and trajectory adjustments, allowing the system to bridge the gap between early detection and precise angle of attack control at the bit location.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11414976B2Systems and methods to control drilling operations based on formation orientations

Publication Date: 2022.08.16 BAKER HUGHES CO

AI summary

Systems and methods for controlling subsurface drilling operations are described. The methods include performing the subsurface drilling operation using a bottomhole assembly having a disintegrating device, detecting, with a sensor, a formation layer orientation, approaching, with the disintegrating device, a rock layer, and generating a steering command to change an angle of attack of the disintegrating device relative to the rock layer based on the detected formation layer orientation.