Automated steering of a drilling system using a smart bottom hole assembly

Abstract

A method of drilling a wellbore is described using a BHA including an RSS that comprises an adjustment mechanism movable between first and second configurations to alter a drilling direction of the BHA, BHA sensor(s), and a controller. The method includes drilling, using the BHA, the wellbore with the adjustment mechanism in the first configuration; receiving, by the first controller, real-time data including inclination and azimuth angle data from the BHA sensor(s); determining, by the first controller and based on the real-time data, a relationship between an actual measurement and a target measurement that is associated with a target well path; automatically moving, by the first controller and in response to the determination of the relationship, the adjustment mechanism from the first to the second configuration; and drilling, using the BHA, the wellbore while the adjustment mechanism is in the second configuration.

What is claimed is: 
     
       1. A method of drilling a wellbore using a rotary steerable system that comprises a bottom hole assembly (“BHA”) that comprises an adjustment mechanism, BHA sensor(s), and a first controller, the method comprising:
 drilling, using the BHA, the wellbore when the adjustment mechanism is in a first configuration;
 wherein the adjustment mechanism is movable between at least the first configuration and a second configuration to alter a drilling direction of the BHA; 
 
 receiving, by the first controller, real-time feedback data from the BHA sensor(s);
 wherein the real-time feedback data includes inclination angle data and azimuth angle data; 
 
 determining, by the first controller and based on the real-time feedback data, a relationship between an actual measurement derived from the real-time feedback data and a target measurement that is associated with a target well path;
 wherein the actual measurement comprises an actual inclination angle and an actual azimuth angle; and 
 wherein the target measurement comprises a target inclination angle and a target azimuth angle; 
 
 monitoring, continuously using an algorithm, by the first controller, and based on the real-time feedback data, the relationship between the actual measurement derived from the real-time feedback data and the target measurement; 
 determining, by the first controller and based on the continuous monitoring of the relationship between the actual measurement derived from the real-time feedback data and the target measurement, an updated relationship between the actual measurement derived from the real-time feedback data and the target measurement; and 
 revising, by the first controller and based on the updated relationship between the actual measurement derived from the real-time feedback data and the target measurement, drilling instructions associated with a target well path to create revised drilling instructions associated with a revised target well path;  
 automatically moving, by the first controller and in response to the determination of the updated relationship between the actual measurement derived from the real-time feedback data and the target measurement and in response to the creation of the revised drilling instructions associated with the revised target well path, the adjustment mechanism from the first configuration to the second configuration; and 
 drilling, using the BHA, the wellbore while the adjustment mechanism is in the second configuration. 
 
     
     
       2. The method of  claim 1 , wherein the BHA sensor(s), the adjustment mechanism, and the first controller form a first closed-loop control system in which the input is the target inclination angle and a second closed-loop control system in which the input is the target azimuth angle measurement. 
     
     
       3. The method of  claim 1 ,
 wherein the target measurement is associated with the target well path;  
 wherein the actual measurement is an actual position and the target measurement is a target position; and 
 wherein the method further comprises:
 storing the target well path in the first controller; 
 storing the revised target well path in the first controller;  
 receiving, by the first controller, depth data relating to the depth of the BHA in the wellbore; and 
 determining the actual position based on the depth data and the real-time feedback data from the BHA sensor(s); 
 wherein the actual position further comprises an actual build rate and an actual turn rate; and 
 wherein the target position further comprises a target build rate and a target turn rate. 
 
 
     
     
       4. The method of claim  1   3 , wherein drilling the wellbore while the adjustment mechanism is in the second configuration comprises moving the BHA towards the revised target well path. 
     
     
       5. The method of  claim 1 ,
 wherein the target measurement is associated with the target well path;  
 wherein the real-time feedback data further comprises lithologic related data; 
 wherein the actual measurement further comprises an actual lithology measurement of a formation through which the wellbore extends; 
 wherein the target measurement further comprises a target lithology associated with a portion of the target well path; 
 and 
 wherein drilling the wellbore while the adjustment mechanism is in the second configuration further comprises moving the BHA towards a the revised target well path that is based on the actual lithology measurement and the target lithology. 
 
     
     
       6. The method of  claim 1 , further comprising:
 monitoring a drilling parameter using surface sensor(s) positioned at or near a surface of a well that is associated with the wellbore; 
 identifying a drilling event based on the monitored drilling parameter, using a second controller that is positioned at the surface and that is operably coupled to the surface sensor(s); and 
 automatically, using the second controller, mitigating the drilling event in response to the identification of the drilling event. 
 
     
     
       7. The method of  claim 3 ,
 wherein the BHA sensor(s) comprise:
 a first sensor configured to detect inclination angle data; and 
 a second sensor configured to detect data relating to a distance travelled by the BHA; 
 wherein receiving, by the first controller, real-time feedback data from the BHA sensor(s) comprises receiving the inclination angle data from the first sensor and receiving the data relating to the distance travelled by the BHA from the second sensor; 
 
 wherein the method further comprises:
 calculating, by the first controller, and based on the data relating to the distance travelled by the BHA, a distance travelled by the BHA; and 
 calculating, by the first controller, and based on the distance travelled by the BHA and the inclination angle data, an actual dogleg severity. 
 
 
     
     
       8. The method of  claim 1 ,
 wherein a second controller is positioned at or near a surface of a well that is associated with the wellbore; 
 wherein the method further comprises:
 determining, by the second controller, that the adjustment mechanism should move between the first and second configurations; and 
 automatically downlinking in response to the determination, from the second controller to the first controller, instructions to move the adjustment mechanism between the first configuration and the second configuration. 
 
 
     
     
       9. The method of  claim 1 , further comprising continuously determining using an algorithm, by the first controller and based on the real-time feedback data, the relationship between the actual measurement and the target measurement. 
     
     
       10. The method of  claim 3 ,
 wherein the BHA sensor(s) comprise a first sensor and a second sensor spaced along a longitudinal axis of the BHA; 
 wherein the method further comprises:
 comparing, by the first controller, the real-time feedback data from the first sensor and the real-time feedback data from the second sensor to determine a difference; and 
 determining, by the first controller and using the difference, the actual position. 
 
 
     
     
       11. An apparatus adapted to drill a wellbore comprising:
 a bottom hole assembly (“BHA”) that comprises:
 an adjustment mechanism that is movable between at least a first configuration and a second configuration to alter a drilling direction of the BHA; 
 BHA sensor(s) that monitor real-time feedback data that comprises inclination angle data and azimuth angle data, and 
 a first controller in communication with the BHA sensor(s); 
 
 wherein the first controller is configured to:
 receive the inclination angle data and the azimuth angle data real-time feedback data from the BHA sensor(s); 
 determine, based on the inclination angle data and the azimuth angle data real-time feedback data, a relationship between an actual measurement derived from the real-time feedback data and a target measurement that is associated with a target well path;
 wherein the actual measurement comprises an actual inclination angle and an actual azimuth angle; and 
 wherein the target measurement comprises a target inclination angle and a target azimuth angle; 
 
 monitor, continuously using an algorithm, by the first controller, and based on the real-time feedback data, the relationship between the actual measurement derived from the real-time feedback data and the target measurement; 
 determine, by the first controller and based on the continuous monitoring of the relationship between the actual measurement derived from the real-time feedback data and the target measurement, an updated relationship between the actual measurement derived from the real-time feedback data and the target measurement; and 
 revise, by the first controller and based on the updated relationship between the actual measurement derived from the real-time feedback data and the target measurement, drilling instructions associated with a target well path to create revised drilling instructions associated with a revised target well bath; 
 and  
 automatically move, in response to the determination of the updated relationship between the actual measurement derived from the real-time feedback data and the target measurement and in response to the creation of the revised drilling instructions associated with the revised target well path, the adjustment mechanism from the first configuration to the second configuration to alter a drilling direction of the BHA. 
 
 
     
     
       12. The apparatus of  claim 11 , wherein the BHA sensor(s), the adjustment mechanism, and the first controller form a first closed-loop control system in which the input is the target inclination angle and a second closed-loop control system in which the input is the target azimuth angle measurement. 
     
     
       13. The apparatus of  claim 11 ,
 wherein the target measurement is associated with the target well path;  
 wherein the actual measurement is an actual position and the target measurement is a target position; and 
 wherein the first controller is further configured to:
 store the target well path; 
 store the revised target well path;  
 receive depth data relating to the depth of the BHA in the wellbore; and 
 determine the actual position based on the depth data and the real-time feedback data from the BHA sensor(s); 
 wherein the actual position further comprises an actual build rate and an actual turn rate; and 
 wherein the target position further comprises a target build rate and a target turn rate. 
 
 
     
     
       14. The apparatus of claim  11   13 , wherein drilling the wellbore while the adjustment mechanism is in the second configuration comprises moving the BHA towards the target well path. 
     
     
       15. The apparatus of  claim 11 ,
 wherein the target measurement is associated with the target well path;  
 wherein the real-time feedback data further comprises lithologic related data; 
 wherein the actual measurement further comprises an actual lithology measurement of a formation through which the wellbore extends; 
 wherein the target measurement further comprises a target lithology associated with a portion of the target well path; 
 and 
 wherein the first controller is further configured to automatically move, in response to the determination of the updated relationship, the adjustment mechanism from the first configuration to the second configuration to alter a drilling direction of the BHA towards a the revised target well path that is based on the actual lithology measurement and the target lithology. 
 
     
     
       16. The apparatus of  claim 11 , further comprising:
 a surface sensor(s) positioned at or near a surface of a well that is associated with the wellbore,
 wherein the surface sensor(s) and/or the BHA sensors(s) is configured to monitor a drilling parameter; and 
 
 a second controller that is positioned at the surface and that is in communication with the surface sensor(s), wherein the second controller is configured to detect a drilling event based on the monitored drilling parameter. 
 
     
     
       17. The apparatus of  claim 11 ,
 wherein the BHA sensor(s) comprise:
 a first sensor configured to detect inclination angle data; and 
 a second sensor configured to detect data relating to a distance travelled by the BHA; 
 
 wherein the first controller is further configured to:
 receive the data relating to the distance travelled by the BHA from the second sensor; 
 calculate, based on the data relating to the distance travelled by the BHA, a distance travelled by the BHA; and 
 calculate, based on the distance travelled by the BHA and the inclination angle data, an actual dogleg severity. 
 
 
     
     
       18. The apparatus of  claim 11 , further comprising:
 a second controller that is positioned at or near a surface of a well that is associated with the wellbore, wherein the second controller is configured to:
 determine that the adjustment mechanism should move between the first and second configurations; and 
 automatically downlink in response to the determination, from the second controller to the first controller, instructions to move the adjustment mechanism between the first configuration and the second configuration. 
 
 
     
     
       19. The apparatus of  claim 11 , wherein the first controller is further configured to continuously determine, using an algorithm and based on the real-time feedback data, the relationship between the actual measurement and the target measurement. 
     
     
       20. The apparatus of  claim 13 ,
 wherein the BHA sensor(s) comprise a first sensor and a second sensor spaced along a longitudinal axis of the BHA; 
 wherein the first controller is further configured to:
 compare the real-time feedback data from the first sensor and the real-time feedback data from the second sensor to determine a difference; and 
 determine, using the difference, the actual position. 
 
 
     
     
       21. The method of  claim 1 , further comprising:
 monitoring a drilling parameter using the BHA sensor(s); 
 identifying a drilling event based on the monitored drilling parameter, using a second controller that is positioned at the surface and that is operably coupled to surface sensor(s) positioned at or near a surface of a well that is associated with the wellbore; and 
 automatically, using the second controller, mitigating the drilling event in response to the identification of the drilling event. 
 
     
     
       22. The method of  claim 8 , further comprising:
 receiving, by the second controller, the real-time feedback data from the BHA sensor(s) and depth data that is associated with the real-time feedback data; 
 wherein the target measurement is associated with the target well path;  
 wherein determining, by the second controller, that the adjustment mechanism should move between the first and second configurations comprises:
 determining, by the second controller and based on the depth data and the real-time feedback data, a projected well path; and 
 determining, by the second controller, a difference between the projected well path and the revised target well path; 
 wherein the determination that the adjustment mechanism should move between the first and second configurations is based on the difference between the projected well path and the revised target well path; 
 
 wherein the automatic downlinking, from the second controller to the first controller, occurs without approval from a drilling operator; and 
 wherein the rotary steerable system forms a closed-loop control system that continuously: 
 receives the real-time feedback data from the BHA sensor(s) and the depth data that is associated with the real-time feedback data; determines the difference; between the projected well path and the revised target well path; and automatically moves the adjustment mechanism in response to the difference. 
 
     
     
       23. The method of  claim 1 ,
 wherein the real-time feedback data includes inclination angle data and azimuth angle data;   wherein the actual measurement comprises an actual inclination angle and an actual azimuth angle; and   wherein the target measurement comprises a target inclination angle and a target azimuth angle.    
     
     
       24. The method of  claim 23 , wherein the BHA sensor(s), the adjustment mechanism, and the first controller form a first closed-loop control system in which the input is the target inclination angle and a second closed-loop control system in which the input is the target azimuth angle.  
     
     
       25. The method of  claim 1 , wherein the adjustment mechanism is movable between at least the first configuration and the second configuration to alter a drilling direction of the BHA and/or an angular deflection.  
     
     
       26. The method of  claim 1 , wherein the BHA sensor(s) comprise any one or more of:
 a downhole annular pressure sensor;   a shock/vibration sensor;   a mud motor delta pressure sensor;   a bit torque sensor;   a toolface sensor;   a weight on bit sensor;   a torque on bit sensor;   a bend on bit sensor;   an inclination sensor;   a depth sensor;   an azimuth sensor; and   a speed sensor.    
     
     
       27. The method of  claim 1 , further comprising sending, by the first controller and in response to the determination of the updated relationship, control signals to a second controller that is positioned at the surface.  
     
     
       28. The method of  claim 27 , wherein the second controller is operably coupled to any one or more of:
 a top drive;   a draw works; and   mud pump(s).    
     
     
       29. The apparatus of  claim 11 ,
 wherein the real-time feedback data includes inclination angle data and azimuth angle data;   wherein the actual measurement comprises an actual inclination angle and an actual azimuth angle; and   wherein the target measurement comprises a target inclination angle and a target azimuth angle.    
     
     
       30. The apparatus of  claim 29 , wherein the BHA sensor(s), the adjustment mechanism, and the first controller form a first closed-loop control system in which the input is the target inclination angle and a second closed-loop control system in which the input is the target azimuth angle.  
     
     
       31. The apparatus of  claim 11 , wherein the adjustment mechanism is movable between at least the first configuration and the second configuration to alter a drilling direction of the BHA and/or an angular deflection.  
     
     
       32. The apparatus of  claim 11 , wherein the BHA sensor(s) comprise any one or more of:
 a downhole annular pressure sensor;   a shock/vibration sensor;   a mud motor delta pressure sensor;   a bit torque sensor;   a toolface sensor;   a weight on bit sensor;   a torque on bit sensor;   a bend on bit sensor;   an inclination sensor;   a depth sensor;   an azimuth sensor; and   a speed sensor.    
     
     
       33. The apparatus of  claim 11 , wherein the first controller is further configured to, in response to the determination of the updated relationship, send control signals to a second controller that is positioned at the surface.  
     
     
       34. The apparatus of  claim 33 , wherein the second controller is operably coupled to any one or more of:
 a top drive;   a draw works; and   mud pump(s).