Intelligent Circulating Sub for Rotary-Sliding Drilling
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Solution Overview
Problem
Existing Circulating Subs are unsuitable for frequent changes between rotary drilling and sliding drilling due to slow actuation, reliance on ball drop activation, and inefficiencies in fluid flow management, leading to significant rig time losses and mechanical errors.
Innovation Solution
An intelligent Circulating Sub with an electronic control unit that distinguishes between rotary and sliding drilling using sensors and actuators, automatically adjusting the Circulating Sub's position to optimize fluid flow and prevent inappropriate actuation, such as during cement drilling or pressure testing, thereby improving drilling speed and borehole quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional Circulating Subs are actuated by ball drop or fluid flow rate changes, then the device can be activated, but the actuation time is significantly delayed and rig time is lost
Solution Approach 1:
The patent replaces mechanical actuation systems (ball drop mechanisms, hydraulic actuators requiring flow rate changes) with an electronic control system that uses sensors to detect drilling mode and electronically actuates the Circulating Sub. This substitution eliminates the time delays associated with mechanical systems while maintaining reliable activation.
Solution Approach 2:
The Circulating Sub incorporates an electronic control unit with sensors that automatically detect the drilling mode (rotary or sliding) and autonomously actuate the device without requiring external intervention such as ball drop or manual operation. The system serves itself by making real-time decisions based on sensor input, eliminating rig time losses.
2Productivity
If Circulating Subs remain closed during sliding drilling to maintain flow to mud motor, then fluid flow to motor is maintained, but the sub cannot quickly respond to switching to rotary drilling
Solution Approach 1:
The patent implements a dynamic control system that continuously monitors drilling mode through sensors and automatically adjusts the Circulating Sub state in real-time. The system transitions from a static closed position during sliding drilling to an open position during rotary drilling without delay, optimizing both productivity and actuation speed.
Solution Approach 2:
The electronic control unit receives feedback from sensors that detect rotation speed and drilling mode, and uses this feedback to automatically actuate the Circulating Sub. This closed-loop control system ensures the sub responds immediately to mode changes, achieving both high productivity and fast actuation speed.
3Adaptability or versatility
If Circulating Sub opens during sliding drilling due to fluid flow, then fluid can bypass to annulus, but inappropriate actuation occurs during cement drilling and pressure testing
Solution Approach 1:
The patent changes the actuation parameter from fluid flow rate to drilling mode detection using sensors that measure rotation speed and other operational parameters. This allows the system to distinguish between legitimate sliding drilling operations and situations like cement drilling or pressure testing where bypassing should not occur, improving both adaptability and actuation accuracy.
Solution Approach 2:
The patent replaces mechanical actuation based on fluid flow rate with an electronic control system that uses sensor data to intelligently determine when actuation is appropriate. This substitution eliminates inappropriate actuation during cement drilling and pressure testing while maintaining proper fluid flow management during actual sliding drilling.
4Adaptability or versatility
If frequent switching between rotary and sliding drilling is performed, then directional control is achieved, but prior art Circulating Subs cause significant rig time losses and mechanical errors
Solution Approach 1:
The electronic control system with sensors autonomously detects drilling mode changes and automatically actuates the Circulating Sub without requiring manual intervention or complex mechanical operations. This self-service capability allows frequent switching between rotary and sliding drilling modes while eliminating the rig time losses and mechanical errors associated with manual operation.
Solution Approach 2:
The patent replaces mechanical actuation systems with an electronic control system that rapidly detects mode changes and actuates the Circulating Sub. This substitution eliminates the mechanical delays and errors inherent in traditional systems, enabling frequent drilling mode switching while maintaining high rig time efficiency.
Data Source
AI summary
A downhole intelligent Circulating Sub controller detects the difference between rotary drilling and sliding drilling, responds appropriately and quickly to multiple changes between rotary drilling and sliding drilling that may occur several times each stand of pipe. Additional controls prevent actuation of the Circulating Sub at inappropriate times. In one embodiment, a separate modular control sub is disclosed that may be utilized with and/or removably secured to a Circulating Sub and/or other types of downhole tools.