System and method for optimizing drilling with a rotary steerable system

Abstract

A system and method for optimizing drilling with a rotary steerable system may monitor downhole signals associated with vibrational loads along a drill string during drilling. A downhole controller at a rotary steerable bottom-hole adapter may generate a control indication for modifying drilling parameters of a drill bit in response to detecting harmful vibrational loads for the drill string. A modification of the drilling speed and direction of the drill bit used for drilling may be performed based on the control indication.

What is claimed is: 
     
         1 . A system for improved drilling, the system comprising:
 a processor;   a memory coupled to the processor, wherein the processor contains instructions executable by the processor for:
 receiving information from a sensor in a bottom hole assembly (BHA) coupled to a drill string, wherein the BHA is coupled to a drill bit drilling a borehole; 
 detecting, responsive to the information from the sensor, a drilling condition indicative of a vibrational load; 
 determining whether the vibrational load falls outside a target range therefor, and 
 if the vibrational load falls outside the target range therefor, then generating, by the rotary steerable BHA, a control indication that a drilling parameter associated with the drilling of the borehole should be modified. 
   
     
     
         2 . The system of  claim 1  wherein the vibrational load is at least one of an axial vibrational load, a radial vibrational load, and a torsional vibrational load. 
     
     
         3 . The system of  claim 2 , wherein the instructions further comprise instructions for transmitting the control indication to a control system at a surface location, wherein the control system is enabled to control the drilling parameter. 
     
     
         4 . The system of  claim 3 , wherein the instructions further comprise instructions for, responsive to transmitting the control indication, receiving updated information from the sensor, determining therefrom an updated vibrational load, determining whether the updated vibrational load is closer to the threshold than the vibrational load and, if the updated vibrational load is closer to the threshold than the vibrational load, generating a second control indication to further adjust the drilling parameter. 
     
     
         5 . The system of  claim 1 , wherein the drill bit is enabled to rotate by the BHA independently of the rotation of the drill string by the drill rig, and wherein the instruction further comprise instructions for, based on the control indication, causing, by the rotary steerable BHA, angular velocity or angular position of the drill bit to be modified to thereby reduce the vibrational load. 
     
     
         6 . The system of  claim 5 , wherein the causing, by the rotary steerable BHA, the rotation of the drill bit to be modified further comprises instructions for adjusting a continuously variable transmission (CVT) in the rotary steerable BHA, the CVT being coupled to the drill bit and driving the rotation of the drill bit. 
     
     
         7 . The system of  claim 5 , wherein the causing, by the rotary steerable BHA, rotation of the drill bit to be modified further comprises instructions for causing a mud motor coupled to the drill bit and driving the rotation of the drill bit to be adjusted. 
     
     
         8 . The method of  claim 5 , wherein the causing, by the rotary steerable BHA, the rotation of the drill bit to be modified further comprises at least one of:
 instructions for adjusting a rotational speed of the drill bit; and   instructions for reversing a rotational direction of the drill bit.   
     
     
         9 . The system of  claim 1 , further comprising instructions for modifying, by the rotary steerable BHA, an angle of a drilling axis of the drill bit with respect to a rotational axis of the drill string that is rotating in proximity to the rotary steerable BHA. 
     
     
         10 . The system of  claim 9 , wherein the instructions for modifying, by the rotary steerable BHA, an angle of a drilling axis of the drill bit further comprise instructions for setting the angle to a fixed value with respect to the drill string, wherein the angle rotates with the drill string. 
     
     
         11 . The system of  claim 9 , wherein the instructions for modifying, by the rotary steerable BHA, an angle of a drilling axis of the drill bit further comprise instructions for continuously setting the angle to maintain the drill bit in a geostationary location when the drill string rotates and the drill bit rotates. 
     
     
         12 . The system of  claim 1 , wherein the drilling condition comprises at least one of a stick-slip condition and a lateral vibration. 
     
     
         13 . The system of  claim 1 , wherein the sensor comprises at least one of: a microelectronics system (MEMS) gyroscope; a MEMS accelerometer, and a magnetometer. 
     
     
         14 . A method for improved drilling, the method comprising:
 drilling a borehole using a bottom hole assembly (BHA) coupled to a drill string, wherein the drill string is enabled for rotation by a drilling rig, and wherein a drill bit is coupled to the BHA;   detecting, using a sensor included with the BHA, a drilling condition indicative of a vibrational load on the drill string, wherein the vibrational load exceeds a threshold for the drill string; and   based on the drilling condition, generating, by the BHA, a control indication that a drilling parameter associated with the drilling by the drill string should be modified to reduce the vibrational load.   
     
     
         15 . The method of  claim 14 , further comprising:
 transmitting the control indication to the surface to a steering control system enabled to control the drilling parameters for the drill string, wherein the steering control system is enabled to control the top drive and a mud circulation system.   
     
     
         16 . The method of  claim 15 , further comprising:
 responsive to transmitting the control indication, receiving updated drilling parameters from the steering control system to reduce the vibrational load.   
     
     
         17 . The method of  claim 14 , wherein the drill bit angular rotation is enabled to rotate by the rotary steerable BHA independently of the rotation of the drill string by the top drive, and further comprising:
 based on the control indication, causing, by the rotary steerable BHA, rotation of the drill bit to be modified to reduce the vibrational load.   
     
     
         18 . The method of  claim 17 , wherein the causing, by the rotary steerable BHA, the angular rotation of the drill bit to be modified further comprises:
 adjusting a continuously variable transmission (CVT) included in the rotary steerable BHA, the CVT being coupled to the drill bit and driving the angular rotation of the drill bit.   
     
     
         19 . The method of  claim 17 , wherein the causing, by the rotary steerable BHA, angular rotation of the drill bit to be modified further comprises:
 causing a mud motor coupled to the drill bit and driving the rotation of the drill bit to be adjusted.   
     
     
         20 . The method of  claim 17 , wherein the causing, by the rotary steerable BHA, the angular rotation of the drill bit to be modified further comprises at least one of:
 adjusting an angular rotational speed of the drill bit; and   reversing an angular rotational direction of the drill bit.   
     
     
         21 . The method of  claim 14 , further comprising:
 modifying, by the rotary steerable BHA, an angle of a drilling axis of the drill bit with respect to a rotational axis of the drill string that is rotating in proximity to the rotary steerable BHA.   
     
     
         22 . The method of  claim 21 , wherein the modifying, by the rotary steerable BHA, an angle of a drilling axis of the drill bit further comprises:
 setting the angle to a fixed value with respect to the drill string, wherein the angle rotates with the drill string.   
     
     
         23 . The method of  claim 21 , wherein the modifying, by the rotary steerable BHA, an angle of a drilling axis of the drill bit further comprises:
 continuously setting the angle to maintain the drill bit in a geostationary location when the drill string rotates and the drill bit rotates.   
     
     
         24 . The method of  claim 14 , wherein the drilling condition comprises at least one of:
 a stick-slip condition; and a lateral vibration.   
     
     
         25 . The method of  claim 14 , wherein the sensor comprises at least one of a microelectronics system (MEMS) gyroscope; a MEMS accelerometer; and a magnetometer. 
     
     
         26 . A method for improved drilling, the method comprising:
 drilling a borehole using a rotary steerable bottom hole assembly (BHA) coupled to a drill string, wherein the drill string is enabled for rotation by a drilling rig and wherein a drill bit is coupled to the BHA, wherein the angular position and angular velocity of the drill bit may be controlled independently of the rotation of the drill string by the rig;   detecting, using a sensor included in the BHA or a sensor located at the surface, a drilling condition;   determining whether a correction of the drilling condition is indicated, due to the drilling condition being less than a minimum threshold therefor, exceeding a maximum threshold therefor, or falling outside a target range therefor; and   responsive to a determination that a correction of the drilling condition is indicated, generating, by the BHA, a control indication that the angular position, the angular velocity, or both, of the drill bit should be modified.   
     
     
         27 . The method of  claim 26  further comprising modifying the angular position, the angular velocity, or both, of the drill bit responsive to the control indication. 
     
     
         28 . The method of  claim 26 , further comprising:
 transmitting the control indication to a steering control system enabled to control the drilling parameters for the drill string, wherein the steering control system is located at the surface and is enabled to control the top drive and a mud circulation system.   
     
     
         29 . The method of  claim 28 , further comprising:
 responsive to transmitting the control indication, receiving updated drilling parameters from the steering control system to reduce the vibrational load.   
     
     
         30 . The method of  claim 26 , wherein the drill bit is enabled to rotate by the rotary steerable BHA independently of the rotation of the drill string by the top drive, and further comprising:
 based on the control indication, causing, by the rotary steerable BHA, angular rotation of the drill bit to be modified by adjusting a continuously variable transmission (CVT) included in the rotary steerable BHA, the CVT being coupled to the drill bit and driving the rotation of the drill bit.   
     
     
         31 . The method of  claim 30 , wherein the causing, by the rotary steerable BHA, angular rotation of the drill bit to be modified further comprises:
 causing a mud motor coupled to the drill bit and driving the angular rotation of the drill bit to be adjusted.   
     
     
         32 . The method of  claim 30 , wherein the causing, by the rotary steerable BHA, the angular rotation of the drill bit to be modified further comprises at least one of:
 adjusting an angular rotational speed of the drill bit; and   reversing a rotational direction of the drill bit.   
     
     
         33 . The method of  claim 26 , further comprising:
 modifying, by the rotary steerable BHA, an angle of a drilling axis of the drill bit with respect to a rotational axis of the drill string that is rotating in proximity to the rotary steerable BHA.   
     
     
         34 . The method of  claim 33 , wherein the modifying, by the rotary steerable BHA, an angle of a drilling axis of the drill bit further comprises:
 setting the angle to a fixed value with respect to the drill string, wherein the angle rotates with the drill string.   
     
     
         35 . The method of  claim 33 , wherein the modifying, by the rotary steerable BHA, an angle of a drilling axis of the drill bit further comprises:
 continuously setting the angle to maintain the drill bit in a geostationary location when the drill string rotates and the drill bit rotates.   
     
     
         36 . The method of  claim 26 , wherein the drilling condition comprises at least one of:
 a stick-slip condition; and a lateral vibration.   
     
     
         37 . The method of  claim 26 , wherein the sensor comprises at least one of: a microelectronics system (MEMS) gyroscope; a MEMS accelerometer, and a magnetometer.