Flow Control Module for Rotary Steerable Drilling
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Solution Overview
Problem
Traditional mechanisms for steering rotary steerable drilling assemblies are complex and expensive, and can be problematic when passing through critical components like blowout preventers, making precise directional control in well drilling operations challenging.
Innovation Solution
A flow control module is integrated into the drilling system, which includes a housing, a fluid-controlled drive mechanism, and an offset mandrel that can be independently rotated, allowing for precise control of the drill bit's orientation by varying the flow of drilling fluid, enabling precise directional control without altering the volumetric flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional steering mechanisms are used, then directional control capability is achieved, but device complexity and cost increase
Solution Approach 1:
The patent replaces traditional mechanical steering mechanisms with a fluid-driven system. A fluid-controlled drive mechanism uses drilling fluid flow to rotate an offset mandrel, which in turn rotates the drill bit. This substitution eliminates complex mechanical linkages, engagement mechanisms, and steering components while achieving the same directional control function through fluid dynamics.
Solution Approach 2:
The invention employs hydraulic principles by using drilling fluid as the actuating medium. The flow control module regulates fluid flow to the drive mechanism, converting fluid pressure and flow into rotational motion of the offset mandrel and drill bit. This hydraulic approach simplifies the system by using the existing drilling fluid circulation system rather than requiring separate mechanical steering actuation systems.
2Ease of operation
If extendable engagement mechanisms are used for steering, then directional control is achieved, but reliability decreases due to problems passing through blowout preventers
Solution Approach 1:
The patent extracts the steering function from complex mechanical engagement mechanisms and implements it through a simplified fluid-driven rotation system. By removing the need for extendable engagement mechanisms that must pass through blowout preventers, the system eliminates the reliability issues associated with these complex components while maintaining the essential steering capability through offset mandrel rotation.
3Speed
If flow rate is altered to control drive mechanism speed, then speed control is achieved, but drilling fluid delivery requirements change
Solution Approach 1:
The flow control module utilizes parameter changes in fluid flow characteristics to control drive mechanism speed. By adjusting flow parameters such as velocity distribution, pressure differential, or flow direction within the drive mechanism, the system achieves speed control without changing the overall volumetric flow rate of drilling fluid delivered to the drill bit. This allows independent control of drive mechanism speed while maintaining consistent drilling fluid delivery for effective drilling operations.
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 enables accurate and efficient directional control of the drilling assembly, maintaining the drill bit's angular orientation relative to the formation, thereby improving the precision and safety of well drilling operations while avoiding the complexities and costs of traditional steering mechanisms.
Implementation Method 1
a fluid-controlled drive mechanism in fluid communication with the flow control module. The fluid-controlled drive mechanism may counter-rotate the offset mandrel with respect to the housing
Data Source
AI summary
Directional control of a rotary steerable drilling assembly can be facilitated by a flow control module for maintaining a geostationary position or orientation of components of the assembly. The drilling assembly can include a bit shaft and an offset mandrel for adjusting a longitudinal axis of the bit shaft. A drive mechanism can rotate the offset mandrel independently of the bit shaft to maintain the offset mandrel in a geostationary position or orientation relative to a formation of the earth and/or a wellbore. A flow control module controllably directs a fluid flow to the drive mechanism. The flow control module can include an inner body and an outer body, defining an annulus there between and one or more blades within the annulus, each of the blades being rotatable to provide a range of angles with respect to a longitudinal axis of the flow control module.