Rotary Steerable Drilling System Imbalanced Force Control
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Solution Overview
Problem
Existing rotary steerable drilling systems face challenges in achieving high precision and efficiency while drilling directional wells, particularly due to uneven well formations and vibrations, which result in rough well walls and unsmooth trajectories, affecting steering precision and casing operations.
Innovation Solution
A rotary steerable drilling system that measures both direction and imbalance parameters to control the drilling trajectory, utilizing an active stabilizer and fixed stabilizers with a sliding mechanism and actuators to maintain radial stability and adjust the drill string's position, combined with a control system that harmoniously controls the drilling trajectory based on real-time measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If push-the-bit system is used to increase build-up rate, then drilling speed is improved, but well wall quality deteriorates becoming rough and unsmooth
Solution Approach 1:
The system dynamically adjusts the lateral force applied by the active stabilizer based on real-time formation conditions and drilling parameters. The stabilizer can transition between contacting and non-contacting states with the well wall, optimizing both build-up rate and well wall quality by adapting to changing conditions rather than maintaining a fixed pushing force
Solution Approach 2:
The system changes the operational parameters of the stabilizer, specifically controlling the magnitude and direction of lateral force, to achieve optimal drilling performance. By adjusting these parameters based on measured imbalance forces, the system maintains high build-up rate while preventing excessive well wall roughness
2Adaptability or versatility
If lateral force is applied to push the bit for directional control, then steering capability is improved, but steering precision deteriorates due to vibrations and uneven formations
Solution Approach 1:
The system uses sensors to measure imbalance forces and vibrations in real-time, then feeds this information back to the control system. The controller adjusts the lateral force applied by the active stabilizer based on this feedback, compensating for vibrations and formation variations to maintain precise steering control
Solution Approach 2:
The system measures the harmful imbalance forces and vibrations caused by uneven formations and converts this information into useful control signals. By applying counteracting forces through the active stabilizer, the system transforms the detrimental effects of formation variability into opportunities for enhanced steering precision
3Manufacturing precision
If repeated trajectory adjustments are made to follow designed trajectory, then trajectory accuracy is improved, but drilling efficiency deteriorates
Solution Approach 1:
The system performs preliminary trajectory correction by proactively adjusting the drill string position in advance based on predicted trajectory deviations. This prevents large deviations from occurring in the first place, reducing the need for repeated corrective adjustments and maintaining continuous drilling progress
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
The system significantly improves the accuracy and smoothness of the drilling trajectory, reducing undesired shaking and vibrations, and enhances the build-up rate, leading to higher drilling quality and efficiency.
Implementation Method 1
The sensor includes a strain gauge and is adapted to measure the imbalance parameters at the position of the drill bit
Implementation Method 2
The sensor includes an accelerometer and is adapted to measure vibration parameters including acceleration, frequency and direction of rotation of the drill bit
Data Source
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AI summary
A drilling system includes a rotatable string for connecting with a bit for drilling a borehole, and an active stabilizer which includes a body having an outer surface for contacting a wall of the borehole, and a plurality of actuators connecting the body and the string and capable of driving the string to deviate away from a center of the borehole with a displacement to change a drilling direction. The drilling system further includes a module for measuring direction parameters including at least one of a declination angle and an azimuth angle of the borehole, a module for measuring imbalance parameters including at least one of a lateral force, a bending moment and a torque near the drill dit, and a controller including a calculator for calculating an adjustment needed for the displacement, based on the measured parameters and expected values of these parameters.