Optimized directional drilling using MWD data

1. A system comprising:

a bottom hole assembly (BHA) controller associated with one or more downhole sensors and configured to:

receive data from the one or more downhole sensors,

determine a relationship from the data from the one or more downhole sensors, wherein the relationship is between at least one of a:

(i) measured differential pressure (DP) and measured toolface orientation;

(ii) measured weight-on-bit (WOB) and measured shock and vibration of a drill bit:

(iii) measured rotations per minute (RPM) of a drill bit and measured shock and vibration, wherein the relationship is determined for an interval of time; or

(iv) measured WOB and measured rate of penetration, and communicate the relationship to a surface controller; and

the surface controller configured to:

receive the relationship communicated from the BHA controller,

receive data from one or more surface sensors, and

provide control signals to a drilling system responsive to the relationship and the data received from the one or more surface sensors.

2. The system of claim 1 , wherein the surface controller is further configured to:

estimate at least one of a current toolface orientation, a current shock and a vibration of the drill bit, or rate of penetration using at least the data from the one or more surface sensors and the relationship.

3. The system of claim 1 , wherein the control signals adjust at least one of a WOB, a current RPM, a rate of penetration, a quill position, or a toolface position, or any combination thereof.

4. The system of claim 1 , wherein the surface controller is further configured to receive data from the one or more downhole sensors and wherein the control signals are provided responsive to the relationship and the data received from the one or more surface sensors and the one or more downhole sensors.

5. The system of claim 1 , wherein the data from the one or more surface sensors is directed to at least one of a current DP, WOB, or RPM.

6. The system of claim 1 , further comprising a BHA comprising the BHA controller and at least one of the one or more downhole sensors.

7. The system of claim 1 , further comprising:

a top drive system configured to:

receive the control signals from the surface controller, and

based on the control signals, adjust at least one of a WOB, a current RPM, a rate of penetration, a quill position, or a toolface position, or any combination thereof.

8. The system of claim 7 , further comprising a drawworks in operable association with the top drive system, wherein the drawworks and the top drive system are configured to:

receive the control signals from the surface controller, and

based on the control signals, adjust a current toolface orientation to a desired toolface orientation.

9. The system of claim 1 , wherein the surface controller is further configured to provide or update an algorithm that controls operation of at least one of a BHA or a top drive system responsive to receiving the relationship and the data from the one or more surface sensors.

10. The system of claim 1 , wherein determining the relationship comprises at least one of:

(i) fitting measured DP data to measured toolface orientation data on a curve,

(ii) fitting measured WOB data to shock and vibration data on a curve, or

(iii) fitting measured RPM data to measured shock and vibration data on a curve.

11. The system of claim 1 , wherein the relationship is expressed as a mathematical function or equation.

12. The system of claim 11 , wherein the relationship is determined by inputting a current DP, WOB, or RPM, or any combination thereof, into the mathematical function or equation to output a current toolface orientation, a current shock and vibration of the drill bit, or a rate of penetration, or any combination thereof.

13. A method of directional drilling comprising:

receiving, by a bottom hole assembly (BHA) controller, data from one or more downhole sensors;

determining, by the BHA controller, a relationship from the data from the one or more downhole sensors, wherein the relationship is between at least one of a:

(i) measured differential pressure (DP) and measured toolface orientation;

(ii) measured weight-on-bit (WOB) and measured shock and vibration of a drill bit;

(iii) measured rotations per minute (RPM) of a drill bit and measured shock and vibration, wherein the relationship is determined for an interval of time; or

(iv) measured WOB and measured rate of penetration;

communicating, by the BHA controller, the relationship to a surface controller;

receiving, by the surface controller, the relationship communicated from the BHA controller;

receiving, by the surface controller, data from one or more surface sensors; and

providing, by the surface controller, control signals to a drilling system responsive to the relationship and the data received from the one or more surface sensors.

14. The method of claim 13 , further comprising:

estimating, by the surface controller, at least one of a current toolface orientation, a current shock and vibration of the drill bit, or a rate of penetration using at least the data from the one or more surface sensors and the relationship.

15. The method of claim 13 , wherein the control signals adjust at least one of a WOB, a current RPM, a rate of penetration, a quill position, or a toolface position, or any combination thereof.

16. The method of claim 13 , wherein the data from the one or more surface sensors is directed to at least one of a current DP, WOB, or RPM.

17. The method of claim 13 , wherein determining the relationship comprises at least one of:

(i) fitting measured DP data to measured toolface orientation data on a curve,

(ii) fitting measured WOB data to shock and vibration data on a curve, or

(iii) fitting measured RPM data to measured shock and vibration data on a curve.

18. The method of claim 13 , wherein the relationship is expressed as a mathematical function or equation, and wherein the relationship is determined by inputting a current DP, WOB, or RPM, or any combination thereof, into the mathematical function or equation to output a current toolface orientation, a current shock and vibration of a drill bit, or rate of penetration, or any combination thereof.

19. A non-transitory machine-readable medium having stored thereon machine-readable instructions executable to cause a downhole controller to perform operations comprising:

receiving data from one or more downhole sensors;

determining a relationship from the data from the one or more downhole sensors, wherein the relationship is between at least one of a:

(i) measured differential pressure (DP) and measured toolface orientation;

(ii) measured weight-on-bit (WOB) and measured shock and vibration of a drill bit;

(iii) measured rotations per minute (RPM) of a drill bit and measured shock and vibration, wherein the relationship is determined for an interval of time; or

(iv) measured WOB and measured rate of penetration; and

communicating the relationship to a surface controller such that the surface controller can determine control signals to a drilling system responsive to the relationship and the data received from one or more surface sensors.

20. The non-transitory machine-readable medium of claim 19 , wherein determining the relationship comprises at least one of:

(i) fitting measured DP data to measured toolface orientation data on a curve,

(ii) fitting measured WOB data to shock and vibration data on a curve, or

(iii) fitting measured RPM data to measured shock and vibration data on a curve.

21. The non-transitory machine-readable medium of claim 19 , wherein the relationship is determined by inputting a current DP, WOB, or RPM, or any combination thereof, into a mathematical function or equation to output a current toolface orientation, a current shock and vibration of a drill bit, or a rate of penetration, or any combination thereof.