Direct feedback from the drilling process will be key to enhance overall drilling performance further, improve steering and will help detect drilling dysfunctions early. This is especially true for demanding drilling applications, such as drilling in difficult geological formations. Faults, hard stringers or borehole instabilities can have a negative impact on rate of penetration (ROP) or even worse can damage equipment and cause non-productive time (NPT). This gets pronounced for extended reach drilling, where long drill strings delay the received feedback from the drilling process or effects along the drill string (e.g friction) skew the results. To overcome these obstacles a near bit sensor was developed to provide real time weight-on-bit (WOB), torque-on-bit (TOB), bending and bending orientation data. It is directly integrated into the steering unit of the rotary steerable system (RSS) with the goal to be simplistic, cost efficient and robust. To discuss potential uses and limitations of the load sensor, the basic design and operational principle are shown. Different usage scenarios of the system are presented in theoretical terms and backed by real-world data. One scenario is the possibility to diagnose reasons for low ROP, for instance weight transfer issues can be distinguished from bit damages if WOB and TOB real time data is available. For early detection of unwanted deflections in directional drilling, for instance due to faults or tilted beds, near bit bending and bending orientation measurements of the RSS system can be used. The near bit sensor design proves to be reliable and cost efficient. It shows high potential to increase ROP and reduce NPT and overall drilling cost.
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