Real-Time Drilling Optimization via Torque Motor Control

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Solution Overview

Problem

Current drilling techniques are insufficient in detecting and preventing stuck pipe issues, particularly in extended reach horizontal drilling, due to the subjective nature of human interpretation and reliance on unreliable methods, leading to increased non-productive time and reduced efficiency.

Innovation Solution

A real-time system that calculates and optimizes the desired rate of penetration by utilizing the carrying capacity index and cutting concentration in the annulus, integrating hole cleaning and drilling rate through drilling specific energy to enhance mud rheology and prevent stuck pipe.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If drilling jars are used to un-stick the drill string, then stuck pipe can be addressed, but the effectiveness is limited in extended reach horizontal drilling due to reduced force transfer

Engineering Contradiction:

Improvestuck pipe resolutionVSAvoideffectiveness in extended reach horizontal drilling

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The system changes the parameter of force application by using rotational torque instead of axial hammering force. The torque motor located in the bottom hole assembly generates rotational force that can effectively act on the drill string even in extended reach horizontal sections where axial force transfer is compromised.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If high viscosity sweeps are pumped at regular intervals to clean the borehole, then stuck pipe incidents can be reduced, but drilling time is lost due to periodic interruptions

Engineering Contradiction:

Improvestuck pipe preventionVSAvoiddrilling speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system eliminates periodic interruptions by implementing continuous hole cleaning through rotational motion. The torque motor continuously rotates the drill string, creating continuous annular flow that constantly cleans cuttings from the borehole, replacing the discontinuous sweep method with uninterrupted cleaning action.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The drill string itself performs the cleaning function through rotation. Instead of relying on separate high-viscosity sweeps to clean the hole, the rotational motion of the drill string creates its own cleaning action by generating annular flow that continuously removes cuttings, making the system self-cleaning.

Inventive Principle:

Principle #25Self-service

3Difficulty of detecting and measuring

If operators rely on human interpretation of drilling parameters, then stuck pipe can be detected, but detection is delayed until after sticking occurs

Engineering Contradiction:

Improvestuck pipe detectionVSAvoiddetection delay

Core Design Contradiction:

Difficulty of detecting and measuringVSLoss of time

Solution Approach 1:

The system implements real-time feedback by continuously monitoring drilling parameters such as torque, rotational speed, and power consumption. The torque motor controller receives continuous feedback from sensors and automatically adjusts operating parameters, enabling real-time detection of stuck pipe conditions before they develop into problems.

Inventive Principle:

Principle #23Feedback

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 effectively optimizes drilling parameters, reducing stuck pipe incidents by improving hole cleaning efficiency, increasing the rate of penetration, and minimizing drilling specific energy, thereby enhancing overall drilling performance and reducing non-productive time.

Implementation Method 1

The mud leaves the drill string through the drill bit and returns to the surface through an annular space between the drilled wellbore wall and the exterior of the drill string

Methodology Applied

Scientific EffectFluid transport:

Implementation Method 2

The returning mud cools and lubricates the drill bit

Methodology Applied

Scientific EffectThermal convection: Convection

Implementation Method 3

The returning mud cools and lubricates the drill bit

Methodology Applied

Scientific EffectLubrication: Lubrication

Implementation Method 4

provides hydrostatic pressure to mechanically stabilize the wellbore and prevent fluid under pressure from entering the wellbore from certain permeable formations

Methodology Applied

Scientific EffectHydrostatic pressure: Pressure Gradient

Implementation Method 5

The mud may also include materials to create an impermeable barrier ('filter cake') on exposed formations having a lower fluid pressure than the hydrostatic pressure of the mud

Methodology Applied

Scientific EffectFilter cake formation: Deposition (physical)

Data Source

PatentUS10781682B2Systems and methods for optimizing rate of penetration in drilling operations

Publication Date: 2020.09.22 SAUDI ARABIAN OIL CO

AI summary

Systems and methods for predicting an efficient hole cleaning in vertical, deviated, and horizontal holes by developing a hole cleaning model that combines hole cleaning and drilling rate to optimize performance. Specifically by ensuring optimum mud rheology values that have an influence on drilling mud from the aspects of ECD, cuttings transport, shear thinning, and thixotropic, and developing an effective hole cleaning model by utilizing carrying capacity index (CCI) and cutting concentration in annulus (CCA).