Downhole Drilling Controller Using Wellbore Energy for Path Correction
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Solution Overview
Problem
Current downhole drilling technologies face inefficiencies due to deviations from planned wellbore paths, leading to overshoots and undulations, which increase drilling costs and complexity, as existing trajectory models lack a clear criterion for wellbore smoothness and quality.
Innovation Solution
A system that includes a controller module communicably coupled to a measurement and drilling system, which calculates a return path based on minimum wellbore energy criteria to correct deviations and minimize overshoots and undulations, using real-time data from sensors to adjust the drill bit's trajectory and maintain a smoother wellbore path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If PID control is used to correct wellbore trajectory deviations, then the drilling path can be adjusted back to the planned track, but overshoots and undulations occur in the wellbore trajectory
Solution Approach 1:
The system continuously monitors the actual wellbore trajectory using measurement systems and compares it with the planned path. When deviations are detected, the control system automatically adjusts drilling parameters through feedback loops, enabling real-time correction without manual intervention and preventing overshoots by progressively reducing correction magnitude as the trajectory approaches the planned path
Solution Approach 2:
The control system dynamically adjusts drilling parameters such as weight on bit, rotational speed, and directional drilling angles based on real-time trajectory deviations. The system adapts the correction strategy according to the magnitude and direction of deviations, modifying control actions to maintain smooth trajectory correction while returning to the planned wellbore path
2Extent of automation
If conventional trajectory models are used for drilling automation, then the drilling process can be automated, but the wellbore smoothness cannot be clearly defined or optimized
Solution Approach 1:
The system introduces new quantitative parameters for wellbore quality assessment, including curvature, torsion, and a composite smoothness index. These parameters transform the subjective concept of wellbore quality into measurable and optimizable quantities, enabling the automated system to evaluate and optimize trajectory smoothness alongside position accuracy
Solution Approach 2:
The system replaces manual trajectory evaluation and adjustment with an automated computational system that uses mathematical models and algorithms to assess wellbore quality parameters and determine optimal correction actions, eliminating subjectivity in quality assessment and enabling precise automated control
3Manufacturing precision
If frequent trajectory corrections are made to maintain planned path alignment, then the wellbore accuracy is improved, but drilling efficiency decreases due to increased operational complexity
Solution Approach 1:
The control system applies partial corrections only when trajectory deviations exceed predetermined thresholds, rather than continuously adjusting at every measurement point. This approach maintains wellbore accuracy within acceptable tolerances while minimizing the frequency and magnitude of corrections, thereby preserving drilling efficiency and reducing operational complexity
Data Source
AI summary
Disclosed are systems and method for automating downhole drilling based on the profile and energy of the wellbore being drilled. One method includes advancing a bottom hole assembly (BHA) within a subterranean formation and thereby forming a wellbore along an actual wellbore path, the BHA including a controller module, one or more sensors, and a steering assembly, taking survey measurements with the sensors at two or more survey stations along the actual wellbore path, comparing the survey measurements with data corresponding to a planned wellbore path, determining a return path based on minimum energy of the actual wellbore path when the actual wellbore path has deviated from the planned wellbore path, and conveying a corrective command signal to the steering assembly in order to reorient a trajectory of the actual wellbore path such that it returns to the planned wellbore path.