Hybrid Rotary Steerable System for High Build-Up Rate Drilling
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Solution Overview
Problem
Existing directional drilling systems face challenges in achieving high build-up rate and wellbore quality, with push-the-bit systems producing unsmooth trajectories and rough well walls, while point-the-bit systems have lower build-up rates and smoother trajectories.
Innovation Solution
A hybrid rotary steerable system that combines point-the-bit and push-the-bit functions by using a swingable bit shaft with a flexible joint and active stabilizer, along with eccentric wheels and motors to control the drill bit's tilt and lateral displacement, allowing for simultaneous tilt and lateral movement to enhance build-up rate and trajectory smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If push-the-bit system is used, then build-up rate is improved, but drilling trajectory smoothness deteriorates
Solution Approach 1:
The patent merges point-the-bit and push-the-bit systems into a hybrid rotary steerable system that integrates both steering mechanisms. The system combines a bendable bit shaft (point-the-bit mechanism) with lateral force applying devices (push-the-bit mechanism), allowing simultaneous operation of both modes to achieve high build-up rate while maintaining trajectory smoothness
Solution Approach 2:
The system dynamically switches between point-the-bit and push-the-bit modes based on real-time drilling conditions and desired trajectory requirements. The control system adjusts the contribution of each mechanism continuously, making the system adaptable to varying operational demands and optimizing both productivity and trajectory quality
2Manufacturing precision
If point-the-bit system is used, then drilling trajectory smoothness is improved, but build-up rate deteriorates
Solution Approach 1:
The hybrid system combines point-the-bit and push-the-bit mechanisms, allowing the smooth trajectory capability of point-the-bit to be preserved while adding the high build-up rate capability of push-the-bit through coordinated operation of both steering modes
Solution Approach 2:
The rotary steerable system achieves multi-functionality by incorporating both point-the-bit steering (through bit shaft bending) and push-the-bit steering (through lateral force application), enabling the single system to perform both functions and optimize performance across different operational scenarios
3Productivity
If hybrid system with both point-the-bit and push-the-bit functions is used, then build-up rate and trajectory smoothness are improved, but system complexity increases
Solution Approach 1:
The hybrid system is segmented into distinct functional modules: point-the-bit steering mechanism (bendable bit shaft with universal joints), push-the-bit steering mechanism (lateral force applying devices), and control system. This modular segmentation allows independent optimization and maintenance of each subsystem while reducing overall system complexity
Data Source
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AI summary
A rotary steerable drilling system includes a collar, a drill bit, and a bit shaft connecting the drill bit to the collar. The bit shaft is coupled to the collar through a joint capable of transmitting a torque from the collar to the bit shaft and is swingable with respect to the collar around the joint. The system, further includes first eccentric wheel and second eccentric wheel coupled to the bit shaft and rotatable to swing the bit shaft with respect to the collar around the joint to change a drilling direction, a controller for controlling the first eccentric wheel and second eccentric wheel to harmoniously rotate such that the swing of the bit shaft substantially compensates rotation of the bit shaft, and an active stabilizer mounted on the bit shaft and capable of pushing the bit shaft to deviate to cause a lateral displacement and a tilt angle of the drill bit.