A New Rotary-Steerable System Designed for Vertical and Nudge Applications in North America Pad Development Drilling

Jones, Steve; Sugiura, Junichi; Feddema, Chad; Charter, Marc

doi:10.2118/189705-ms

Cited by 5 publications

References 19 publications

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Optimizing Drilling by Simulation and Automation with Big Data

Hutchinson

Thornton

Theys

et al. 2018

SPE Annual Technical Conference and Exhibition

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For many years the aerospace and automotive industries have realized significant improvements in efficiency, performance and cost savings by simulating multiple prototype vehicle designs and control systems under various operating conditions. These same simulation techniques have now been introduced to the oilfield drilling industry and are delivering insights for more effective drilling tool designs, bottom hole assembly optimization, drilling severity minimization, dysfunction recognition and for drilling performance improvement with fewer downhole failures. Drilling is a non-linear, coupled and dynamic hydro-geomechanical process, the physics for all aspects of which must be captured to enable a robust automated drilling control process. Drill string, drilling tool and drill bit failures are frequently incorrectly blamed upon the invisible geology through which they drill. Field engineers frequently report more severe downhole vibrations at rotation speeds other than those predicted by linear frequency-based finite element critical speeds analyses. The same multi-body dynamics simulation techniques used by the automotive and aerospace industries, however, are now being applied to capture the non-linear aspects of the drilling process and provide more realistic predictions of drilling performance. Simulation validation is achieved by comparing virtual data to physical data with an implicit understanding of the uncertainties of each. Recommendations are presented for improving the usefulness and the quality of physical drilling data which simulation can then also help assure. The ultimate objective is to deliver better quality boreholes which are less costly with fewer drilling tool failures. These novel simulation techniques are enabling manufacturers to benefit from lower development costs and shorter times to market with more reliable proprietary drilling tool designs. Drilling contractors are using simulations to optimize top-drive controls and drill more effectively. Product developers are able to configure higher performing and more optimal bottom hole assemblies. Operators are able to reduce overall drilling costs with the potential benefits of higher performing drilling automation systems and greater production from better quality boreholes.

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Optimizing Drilling by Simulation and Automation with Big Data

Hutchinson

Thornton

Theys

et al. 2018

SPE Annual Technical Conference and Exhibition

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Downhole Attitude-Hold Controller Leads to Automatic Steering of Directional Wells with Improved Accuracy and Reduced Tortuosity

Zalluhoglu

Tilley

Zhang

et al. 2020

IADC/SPE International Drilling Conference and Exhibition

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This paper illustrates the performance of a precise attitude-hold control feature enabled for a new-generation rotary steerable system (RSS) via an intelligent downhole navigation and control system. State-of-the-art downhole navigation sensors and a high-bandwidth pad actuation system are combined with advanced signal processing and control algorithms to ensure tight directional control of RSS along vertical, tangent, and lateral sections, maximizing the pay-zone contact for hydrocarbon extraction. The intelligent downhole navigation and control system blends sensors measuring gravitational and magnetic fields surrounding the RSS to track the propagation of the borehole. The sensory measurements are conditioned by a set of advanced signal-processing techniques prior to being fed to the attitude-hold controller. The controller then generates a control signal to minimize both deviation from a reference trajectory and wellbore tortuosity. Case histories from wells drilled using the automated attitude-hold control feature are presented. The field data include results from vertical, tangent, and lateral sections of wells in various formations from several conventional and unconventional applications. One case suggests significant reduction in generated doglegs upon engaging the attitude-hold controller in a lateral section with a challenging formation. Another case study shows that inclination was maintained within a tight error bound of ±0.1° during a tangent section. An example from a vertical well is also provided, where the vertical-hold control feature was able to hold inclination within 0.1° on average. The ability to tightly lock-in to a desired borehole attitude and to quickly adapt after altering the reference trajectory has proven that the attitude-hold control feature improves wellbore placement accuracy substantially, while minimizing tortuosity.

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Rotary Steerable Drilling Dynamics and Associated BHA Changes to Improve Overall BHA Performance and Reliability

Jones¹,

Sugiura²,

Johnson

2023

SPE/IADC International Drilling Conference and Exhibition

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During the advanced development phase of a push-the-bit rotary steerable system (RSS), downhole drilling dynamics were captured utilizing high-frequency embedded drilling dynamics sensors distributed throughout the bottom-hole assembly (BHA). The RSS development testing was conducted in a challenging pocket of the Delaware Basin in the Permian Region of North America. This specific Delaware area has proven difficult to drill with conventional steerable motors due to rapid shoulder wear on the bit and sliding difficulties (Sugiura et al. 2022). The initial RSS BHAs were designed based on the directional objectives of the well. As the runs and wells progressed, the multiple embedded drilling dynamics sensor data, BHA/bit component wear and reliability, and drilling performance were all analyzed. From these learnings, systematic BHA changes were implemented and measured. This process continued until the drilling pace, reliability and repeatability were at an acceptable level for the project. This paper details the drilling dynamics, drilling parameters, BHA configurations, formations, and logic for BHA/drilling parameter changes in the 12 ¼-in. intermediate section.

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A New Rotary-Steerable System Designed for Vertical and Nudge Applications in North America Pad Development Drilling

Cited by 5 publications

References 19 publications

Optimizing Drilling by Simulation and Automation with Big Data

Optimizing Drilling by Simulation and Automation with Big Data

Downhole Attitude-Hold Controller Leads to Automatic Steering of Directional Wells with Improved Accuracy and Reduced Tortuosity

Rotary Steerable Drilling Dynamics and Associated BHA Changes to Improve Overall BHA Performance and Reliability

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