Predictive Pressure Control for Drilling Sensor Failures
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Solution Overview
Problem
Existing well drilling technologies face challenges in precisely controlling bottom hole pressure during drilling operations, particularly when sensors or communication systems fail, leading to potential fluid loss, formation fracturing, or influx of fluids.
Innovation Solution
A pressure and flow control system that utilizes a rotating control device, redundant chokes, and a hydraulics model to regulate annulus pressure, combined with predictive devices and data validation to maintain desired downhole pressures even when sensor data is unavailable, ensuring continuous control through automated systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors and communication systems are used to regulate pressure during drilling, then pressure control precision is improved, but system reliability deteriorates due to potential sensor failure or communication loss
Solution Approach 1:
The system performs preliminary actions by predicting future pressure values and preparing compensatory pressure adjustments before sensor failures occur. The predictive device forecasts bottom hole pressure trends and the control system pre-adjusts choke positions or backpressure pump settings to maintain pressure control continuity, ensuring that control actions are already in place when sensor data becomes unavailable.
Solution Approach 2:
The system implements beforehand cushioning by creating a buffer of predictive capability that compensates for potential sensor failures. The predictive device acts as a cushion against the harmful effect of sensor failure by providing forecasted pressure values that smooth out the transition when actual sensor data is lost, preventing sudden pressure control disruptions and maintaining stable drilling operations.
2Measurement precision
If a closed annulus with rotating control device is used for managed pressure drilling, then bottom hole pressure control is improved, but device complexity increases
Solution Approach 1:
The predictive device serves multiple functions: it predicts bottom hole pressure under normal sensor operation, provides compensation during sensor failures, validates sensor data quality, and supports both automated and manual control modes. This multi-functionality reduces the need for separate systems for each control scenario, thereby managing complexity while maintaining improved pressure control.
3Measurement precision
If backpressure pump is used to apply pressure to annulus during connections, then pressure control is improved, but loss of time occurs due to connection operations
Solution Approach 1:
The system maintains continuity of useful action by ensuring that pressure control operations continue uninterrupted during drill string connections. The predictive device forecasts pressure requirements during connection activities, and the control system adjusts the backpressure pump and choke settings in advance to maintain bottom hole pressure control throughout the connection process, eliminating idle time and keeping drilling operations continuous.
Data Source
AI summary
A method of maintaining a desired downhole pressure during a drilling operation can include measuring a parameter with a sensor, communicating actual parameter values from the sensor to a predictive device, training the predictive device to output predicted parameter values in response to input of the actual parameter values, and outputting the predicted parameter values from the predictive device when the predictive device ceases receiving the actual parameter values. A well drilling system can include a predictive device which outputs predicted parameter values in response to input of actual parameter values to the predictive device. The predictive device continues to output the predicted parameter values, even when the predictive device fails to receive valid actual parameter values. Another well drilling system includes a data validator which communicates valid actual parameter values to the predictive device, but does not communicate invalid actual parameter values to the predictive device.