Rotary Steerable State Estimation Without Downhole Sensors
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Solution Overview
Problem
Rotary steerable drilling systems face challenges in accurately controlling drilling operations due to the lack of real-time data on states like flow rate, turbine speed, and toolface angle, as implementing sensing devices is not feasible due to cost, space, and reliability constraints.
Innovation Solution
A state estimator using a mathematical model of the rotary steerable system to estimate these states without the need for sensors, allowing for precise control and self-calibration based on actual outputs compared to estimated outputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensing devices are implemented to measure states like flow rate, turbine speed, and toolface angle, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a mathematical model that replicates the behavior of the physical drilling system, allowing estimation of states without physical sensors. The model serves as a virtual copy that produces estimated outputs matching actual sensor readings, enabling state estimation through computation rather than physical measurement devices
Solution Approach 2:
The patent replaces the mechanical sensing system with a computational approach. Instead of using physical sensors to detect states, the system uses a mathematical model with differential equations and state estimation algorithms to compute states from available measurements, substituting mechanical detection with mathematical computation
2Measurement precision
If sensing devices are implemented to measure states like flow rate, turbine speed, and toolface angle, then measurement precision is improved, but cost increases
Solution Approach 1:
The patent creates a mathematical model that replicates the behavior of the physical drilling system, allowing estimation of states without physical sensors. The model serves as a virtual copy that produces estimated outputs matching actual sensor readings, enabling state estimation through computation rather than physical measurement devices
Solution Approach 2:
The patent replaces the mechanical sensing system with a computational approach. Instead of using physical sensors to detect states, the system uses a mathematical model with differential equations and state estimation algorithms to compute states from available measurements, substituting mechanical detection with mathematical computation
3Measurement precision
If sensing devices are implemented to measure states like flow rate, turbine speed, and toolface angle, then measurement precision is improved, but reliability worsens due to space constraints and operational conditions
Solution Approach 1:
The patent creates a mathematical model that replicates the behavior of the physical drilling system, allowing estimation of states without physical sensors. The model serves as a virtual copy that produces estimated outputs matching actual sensor readings, enabling state estimation through computation rather than physical measurement devices
Solution Approach 2:
The patent replaces the mechanical sensing system with a computational approach. Instead of using physical sensors to detect states, the system uses a mathematical model with differential equations and state estimation algorithms to compute states from available measurements, substituting mechanical detection with mathematical computation
4Ease of operation
If more data is collected regarding outputs and states, then control precision is improved, but device complexity increases due to additional sensing devices
Solution Approach 1:
The patent creates a mathematical model that replicates the behavior of the physical drilling system, allowing estimation of states without physical sensors. The model serves as a virtual copy that produces estimated outputs matching actual sensor readings, enabling state estimation through computation rather than physical measurement devices
Solution Approach 2:
The mathematical model serves multiple functions simultaneously: it predicts system behavior, estimates unmeasured states, provides feedback for control, and adapts to changing conditions. This single computational framework replaces what would otherwise require multiple specialized sensors and processing systems
Data Source
AI summary
A method of estimating a state of a rotary steerable drilling system comprising applying a control input to a rotary steerable drilling system, sensing an actual output of the rotary steerable drilling system, inputting the control input into a mathematical model of the rotary steerable drilling system, receiving an estimated output of the rotary steerable drilling system from the mathematical model, generating an error compensation signal based on a difference between the actual output and the estimated output, and applying the error compensation signal to the mathematical model.