Self-Contained Rotary Steerable System With Nested Hydraulic Steering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary steerable systems are over 150 inches long and achieve build-up rates of less than 10 degrees per 100 feet of drilling, necessitating the removal or omission of functional components to reduce length, compromising their self-sufficiency.
Innovation Solution
A reduced-length rotary steerable system with a steering section and control section, featuring a two-piston configuration, distribution and main flow passages, and a valve assembly that activates pistons radially outward with a duration of about 180 degrees per rotation, maintaining self-sufficiency and achieving higher build-up rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the length of the rotary steerable system is reduced to achieve higher build-up rates, then the build-up rate improves, but the system loses self-sufficiency due to removal of functional components
Solution Approach 1:
The valve assembly is positioned within the steering section, and the control section is positioned within the valve assembly, creating a nested configuration where components are housed within each other. This nesting arrangement significantly reduces the overall length of the rotary steerable system while maintaining all necessary functional components for self-sufficiency, thereby achieving high build-up rates without compromising reliability
Solution Approach 2:
The system transitions from a linear arrangement of components to a three-dimensional nested configuration. By utilizing radial and axial dimensions efficiently, the valve assembly and control section are positioned within the steering section, reducing the system length from over 150 inches to under 100 inches while preserving all functional capabilities
2Length of moving object
If the length of the rotary steerable system is reduced by removing components, then the length decreases, but the system complexity is compromised
Solution Approach 1:
The control section and valve assembly are merged within the steering section, with the control section positioned inside the valve assembly. This integration combines multiple functional components into a unified compact structure, reducing the overall system length to under 100 inches while maintaining the complexity and functionality of all individual components
3Productivity
If the activation duration of pistons is extended to about 180 degrees per rotation, then the directional control efficiency improves, but the system length increases
Solution Approach 1:
The extended activation duration mechanism is achieved through the nested positioning of the control section within the valve assembly, which is itself positioned within the steering section. This compact nested arrangement provides the mechanical space necessary for 180-degree piston activation without increasing the overall system length, maintaining a compact configuration under 100 inches
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 achieves build-up rates of at least 25 degrees per 100 feet of drilling while maintaining a combined length of less than 150 inches, ensuring self-sufficiency and efficient directional control during oil and gas well drilling.
Implementation Method 1
A valve assembly is configured to direct a portion of a drilling fluid flowing through the rotary steerable system into a distribution flow passage, thereby activating one of the pistons and causing the piston to extend in a radially outward direction
Data Source
AI summary
A self-sufficient rotary steerable system configured to provide a bottom hole assembly with a build-up rate of at least 25 degrees per 100 feet of drilling distance. The rotary steerable system has a reduced length without the removal or omission of functional components, including a power module, a control module, a communication module, a filter module, a valve module, and/or a pressure regulation module. The build-up rate is defined as a function of a length between a first contact point on a drill bit of the bottom hole assembly and a second contact point at a piston assembly of the rotary steerable system; length between the second contact point and a third contact point at a stabilizer of the rotary steerable system; the drill bit outer diameter; the piston assembly outer diameter; and the stabilizer outer diameter.