CN112004989B - Earth-boring tool monitoring system for displaying reliability of earth-boring tools and related methods - Google Patents
Earth-boring tool monitoring system for displaying reliability of earth-boring tools and related methods Download PDFInfo
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 111
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B44/00—Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
- E21B44/02—Automatic control of the tool feed
- E21B44/04—Automatic control of the tool feed in response to the torque of the drive ; Measuring drilling torque
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B41/00—Equipment or details not covered by groups E21B15/00 - E21B40/00
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/12—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
- E21B47/13—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling by electromagnetic energy, e.g. radio frequency
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B2200/00—Special features related to earth drilling for obtaining oil, gas or water
- E21B2200/22—Fuzzy logic, artificial intelligence, neural networks or the like
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Abstract
An earth-boring tool monitoring system may generate a contour map representing reliability of an earth-boring tool over a range of operational loads, the contour map showing the range of reliability of the earth-boring tool from 100% reliable to 0% reliable, and may superimpose a plurality of markers on the contour map, each marker representing a point in time and representing an operational load of the earth-boring tool at the point in time. Further, the earth-boring tool monitoring system shifts the contour map based on an amount of accumulated damage experienced by the earth-boring tool.
Description
Priority statement
The present application claims "Earth-Boring Tool Monitoring System for Showing Reliability of an Earth-Boring Tool and Related Methods"( filed on 3/7 of 2018 for an earth-boring tool monitoring system and related method for displaying reliability of an earth-boring tool).
Technical Field
The present disclosure relates generally to earth-boring tool monitoring systems and methods of using such systems.
Background
Oil wells (wellbores) are typically drilled with a drill string. The drill string includes a tubular member having a drilling assembly including a single drill bit at a bottom end thereof. The drilling assembly may also include devices and sensors that provide information related to various parameters related to the drilling operation ("drilling parameters"), various parameters related to the behavior of the drilling assembly ("drilling assembly parameters"), and parameters related to the formation penetrated by the wellbore ("formation parameters"). The wellbore is drilled by rotating a drill bit and/or reamer attached to the bottom end of the drilling assembly to remove formation material from the drill string and/or by a drilling motor (also referred to as a "mud motor") in a bottom hole assembly ("BHA").
Disclosure of Invention
Some embodiments of the invention include an earth-boring tool monitoring system. The earth-boring tool monitoring system may include at least one processor and at least one non-transitory computer-readable storage medium having instructions stored thereon. When the instructions are executed by the at least one processor, the system may generate a contour plot representing the reliability of the earth-boring tool over a range of operational loads, the contour plot showing a range of reliability of the earth-boring tool from 100% reliable to 0% reliable, and superimpose a plurality of markers on the contour plot, each marker representing a point in time and representing the operational load of the earth-boring tool at that point in time.
In further embodiments, the present disclosure includes an earth-boring tool monitoring system. The earth-boring tool monitoring system may include at least one processor and at least one non-transitory computer-readable storage medium having instructions stored thereon. When the instructions are executed by the at least one processor, the system may generate a contour map representing a range of reliability of the earth-boring tool over a range of operational loads, superimpose a plurality of markers on the contour map, each marker representing a point in time and representing an operational load of the earth-boring tool at the point in time, and shift the contour map based on an accumulated amount of damage experienced by the earth-boring tool.
Some embodiments of the invention include an earth-boring tool monitoring system. The earth-boring tool monitoring system may include at least one processor and at least one non-transitory computer-readable storage medium having instructions stored thereon. When the instructions are executed by the at least one processor, the system may generate a contour plot representing a range of reliability of the earth-boring tool over a range of operational loads, superimpose a first marker on the contour plot representing a first point in time representing a first operational load of the earth-boring tool at that point in time and having a first color indicative of no risk, shift the contour plot based on an amount of cumulative damage experienced by the earth-boring tool, and superimpose a second marker on the contour plot representing a second point in time representing a second operational load of the earth-boring tool at that second point in time that is less than the first operational load and having a second color indicative of risk.
Drawings
For a detailed understanding of the present disclosure, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings, in which like elements are indicated generally by like numerals, and in which:
FIG. 1 is a schematic view of a wellbore system including a drill string including an earth-boring tool according to one or more embodiments of the present disclosure;
FIG. 2 is a graphical user interface showing a contour map of drill bit health displayed by an earth-boring tool monitoring system in accordance with one or more embodiments of the present disclosure;
FIG. 3 is a graphical user interface showing a contour map of bit health having indicia superimposed thereon and indicating real-time operational loads of an earth-boring tool in accordance with one or more embodiments of the present disclosure;
FIG. 4A is a graphical user interface showing a contour map before being updated due to accumulated damage to earth-boring tools in accordance with one or more embodiments of the present disclosure;
FIG. 4B is a graphical user interface showing a contour map after being updated due to accumulated damage to earth-boring tools in accordance with one or more embodiments of the present disclosure; and
Fig. 5 is a schematic diagram of a surface control unit of an embodiment of an earth-boring tool monitoring system of the present disclosure.
Detailed Description
The illustrations presented herein are not actual views of any drilling system, earth-boring tool monitoring system, or any component thereof, but are merely idealized representations which are employed to describe embodiments of the present invention.
As used herein, the terms "drill bit" and "earth-boring tool" mean and include, respectively, earth-boring tools for forming, expanding, or forming and expanding a borehole. Non-limiting examples of drill bits include fixed cutter ("drag") drill bits, fixed cutter coring drill bits, fixed cutter eccentric drill bits, fixed cutter bi-center drill bits, fixed cutter reamers, expandable reamers having blades carrying fixed cutters, and hybrid drill bits that include both fixed cutters and rotatable cutting structures (cones).
As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
As used herein, the term "may" with respect to a material, structure, feature, or method act indicates that this is contemplated for implementing embodiments of the disclosure, and that this term is used preferentially over the more restrictive term "yes" in order to avoid any implication that other compatible materials, structures, features, and methods may be used in combination therewith should or must be excluded.
As used herein, any relational terms, such as "first," "second," and the like, are used for clarity and ease of understanding of the present disclosure and the figures, and do not imply or depend on any particular preference or order unless the context clearly indicates otherwise. For example, these terms may refer to the orientation of elements of an earth-boring tool when disposed within a borehole in a conventional manner. Further, these terms may refer to the orientation of the elements of the earth-boring tool when disposed as shown.
As used herein, the term "substantially" with reference to a given parameter, characteristic or condition means and includes, to some extent: those skilled in the art will appreciate that a given parameter, characteristic, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. As an example, depending on the particular parameter, characteristic, or condition that is substantially met, the parameter, characteristic, or condition may be at least 90.0% met, at least 95.0% met, at least 99.0% met, or even at least 99.9% met.
As used herein, the term "about" as used with respect to a given parameter encompasses the stated values and has a meaning that is determined by the context (e.g., it includes the degree of error associated with the measurement of the given parameter, as well as variations caused by manufacturing tolerances, etc.).
Some embodiments of the present disclosure may include an earth-boring tool monitoring system 129. The earth-boring tool monitoring system 129 generates and displays a contour plot 202 that represents a range of potential operating loads (e.g., torque, weight on bit, 1000 revolutions ("Krev"), differential pressure, etc.) of the earth-boring tool and the associated reliability of the earth-boring tool at these operating loads. In some implementations, reliability is indicated by different colors. In addition, the earth-boring tool monitoring system 129 generates and superimposes a marker 302 on the contour plot 202, wherein the marker 302 represents the real-time operational load of the earth-boring tool at a point in time. Depending on where the marks 302 are superimposed on the contour plot 202 (e.g., within a high reliability region of the contour plot 202 or within a low reliability region of the contour plot 202), the marks 302 may be distinguished from one another via, for example, color. Further, the set of markers 302 may represent a mapping of the time period of earth-boring tool operation and the actual operational load applied to the earth-boring tool within a contour map. As will be discussed in more detail below, the earth-boring tool monitoring system 129 may enable an operator to quickly and efficiently visualize risk in order to manage and balance both risk and performance in real-time.
FIG. 1 is a schematic diagram of an example of a drilling system 100 that may be utilized to drill a borehole using the apparatus and methods disclosed herein. Fig. 1 shows a borehole 102, which may include an upper section 104 in which a casing 106 is installed, and a lower section 108 drilled with a drill string 110. The drill string 110 may include a tubular member 112 carrying a drilling assembly 114 at a bottom end thereof. The tubular member 112 may be constructed by joining sections of drill pipe or it may be a string of coiled tubing (coiled tubing). A drill bit 116 may be attached to the bottom end of the drilling assembly 114 for drilling a borehole 102 of a selected diameter in an earth formation 118.
The drill string 110 may extend to a drilling rig 120 at the surface 122. For ease of explanation, the rig 120 is shown as an onshore rig 120. However, the disclosed apparatus and methods may also be used with an offshore drilling rig 120 for drilling a borehole underwater. A rotary table 124 or top drive may be coupled to the drill string 110 and may be used to rotate the drill string 110 and rotate the drilling assembly 114, thereby rotating the drill bit 116 to drill the borehole 102. A drilling motor 126 may be provided in the drilling assembly 114 to rotate the drill bit 116. The drilling motor 126 may be used alone to rotate the drill bit 116 or to superimpose rotation of the drill bit 116 through the drill string 110. The drill 120 may also include conventional equipment, such as a mechanism to add additional sections to the tubular member 112 while drilling the borehole 102. A surface control unit 128, which may be a computer-based unit, may be placed at the surface 122 for receiving and processing downhole data transmitted by the sensors 140 in the drill bit 116 and the sensors 140 in the drilling assembly 114 and for controlling selected operations of the various devices and sensors 140 in the drilling assembly 114. The sensors 140 may include one or more of the sensors 140 that determine acceleration, weight on bit, torque, pressure, cutting element position, rate of penetration, inclination, azimuth, formation lithology, etc.
In some embodiments, the surface control unit 128 may include an earth-boring tool monitoring system 129. The earth boring tool monitoring system 129 may include a processor 130 and a data storage device 132 (or computer readable medium) for storing data, algorithms, and computer programs 134. The data storage device 132 may be any suitable device including, but not limited to, read Only Memory (ROM), random Access Memory (RAM), flash memory, magnetic tape, hard disk, and optical disk. In addition, the surface control unit 128 may also include one or more devices for presenting output to an operator of the drilling assembly 114, including, but not limited to, a graphics engine, a display (e.g., a display screen), one or more output drivers (e.g., a display driver), one or more audio speakers, and one or more audio drivers. In certain embodiments, the floor control unit 128 is configured to provide graphical data to a display for presentation to an operator. The graphical data may represent one or more graphical user interfaces and/or any other graphical content that may serve a particular implementation. As described in more detail with respect to fig. 2-4B, the earth-boring tool monitoring system 129 may generate and display a contour map 202 representative of the reliability of the earth-boring tool based on the potential operational loads. Further, although the earth-boring tool monitoring system 129 is described herein as being part of the surface control unit 128, the present disclosure is not so limited; instead, the earth-boring tool monitoring system 129 may be separate from the surface control unit 128 and may be located anywhere within the drilling assembly 114, or may be remote from the drilling assembly 114, as will be appreciated by those of ordinary skill in the art. The surface control unit 128 and the earth-boring tool monitoring system 129 are described in more detail below with reference to fig. 5.
During drilling, drilling fluid from its source 136 is pumped under pressure through the tubular member 112, which is discharged at the bottom of the drill bit 116 and returned to the surface 122 via the annular space (also referred to as the "annulus") between the drill string 110 and the inner sidewall 138 of the borehole 102.
The drilling assembly 114 may also include one or more downhole sensors 140 (collectively indicated by the numeral 140). The sensors 140 may include any number and type of sensors 140, including, but not limited to, sensors commonly referred to as Measurement While Drilling (MWD) sensors or Logging While Drilling (LWD) sensors, as well as sensors 140 that provide information related to the behavior of the drilling assembly 114, such as bit rotation (revolutions per minute or "RPM"), toolface, pressure, vibration, whirl, bending, and stick-slip. The drilling assembly 114 may also include a controller unit 142 that controls the operation of one or more devices and sensors 140 in the drilling assembly 114. For example, the controller unit 142 may be disposed within the drill bit 116 (e.g., within a shank and/or crown of a bit body of the drill bit 116). In some embodiments, the controller unit 142 may include, among other things, circuitry for processing signals from the sensor 140, a processor 144 (such as a microprocessor) for processing digitized signals, a data storage device 146 (such as solid state memory), and a computer program 148. Processor 144 may process the digitized signals and control downhole equipment and sensors 140 and communicate data information with surface control unit 128 via two-way telemetry unit 150.
FIG. 2 illustrates a graphical user interface 200 that may be generated and displayed by the earth-boring tool monitoring system 129 (FIG. 1). The graphical user interface 200 depicts the drill bit health of a drilling assembly (e.g., drilling assembly 114) (hereinafter referred to as an "earth-boring tool"). As used herein, the term "bit health" may refer to an indication of the reliability of an earth-boring tool over a range of operating loads based on previous loads and wear. Referring to fig. 1 and 2, as described above, the earth-boring tool monitoring system 129 may include at least one processor and at least one non-transitory computer readable storage medium. The storage medium may have stored thereon instructions that, when executed by the at least one processor, cause the earth-boring tool monitoring system 129 to perform actions, such as any of the actions described herein.
In some embodiments, the earth-boring tool monitoring system 129 generates a contour plot 202 that illustrates the reliability of the earth-boring tool over a range of operating loads. For example, the earth boring tool monitoring system 129 displays a contour map 202 on a display for viewing by an operator. As used herein, the term "reliability" may refer to the degree to which an earth-boring tool may be relied upon to perform a desired function given a particular operational load imposed on the earth-boring tool. For example, these terms may refer to a percentage of confidence that an earth-boring tool will perform as expected under a given operating load. Furthermore, the "reliability" of the earth-boring tool may be based at least in part on the single or multiple failure modes that the earth-boring tool may experience.
In some embodiments, the axes (e.g., X-axis and Y-axis) of the contour plot 202 may represent an operational load with respect to which the contour plot 202 depicts the reliability of the earth-boring tool. The operating load, and thus the axis of the contour plot 202, may include weight on bit ("WOB"), torque, pressure differential, krev, or any other parameter measured and/or utilized in drilling operations.
In some embodiments, the earth-boring tool monitoring system 129 may depict the reliability of the earth-boring tool as a color spectrum transitioning between a plurality of different colors. For example, the color spectrum may transition from a first color (e.g., dark blue) to a second color (e.g., dark red). In some embodiments, the first color of the contour plot 202 may represent 100% reliability (e.g., about 100% statistical confidence that the earth-boring tool will continue to operate as intended within the operational load included in the first color). In some embodiments, the second color of the contour plot 202 may represent about 0% reliability of the earth-boring tool within the operating load represented in dark red. In other words, the second color may represent an operational load that would cause the earth-boring tool to fail. Further, the color between the first color and the second color may represent a reliability range of 100% to 0%. Although specific colors mentioned herein represent different reliabilities, one of ordinary skill in the art will readily recognize that any reliability may be represented with any color, and the present disclosure is not limited to colors. Conversely, in some embodiments, a gray gradient may be utilized within the contour plot 202 to represent the reliability range. In further embodiments, the contour plot 202 may include defined regions (e.g., regions defined by lines) that respectively represent reliability or reliability ranges. In further embodiments, the contour plot 202 may include a mix of any of the foregoing ways of representing reliability.
Still referring to fig. 2, in some embodiments, the first color of the contour plot 202 may define an operating window 204. For example, the operating window 204 may represent a range of operating loads in which the earth-boring tool may operate with approximately 100% reliability. Those of ordinary skill in the art will appreciate that during operation, an operator or earth-boring tool will wish to maintain the operating load of the earth-boring tool within the operating window 204 to avoid failure.
In some embodiments, the earth-boring tool monitoring system 129 may generate a contour map 202 from the simulation data. The earth-boring tool monitoring system 129 may utilize, for example, software from simulation (e.g.,Etc.) to determine statistical confidence values and operating parameters for the reliability of a particular earth-boring tool, and generate a contour map 202 based on these reliabilities. In other embodiments, the earth-boring tool monitoring system 129 may generate a contour map 202 from the historical data. For example, for a given earth-boring tool, the earth-boring tool monitoring system 129 may utilize data obtained from previous drilling operations performed with similar and/or same types of earth-boring tools to determine statistical confidence values and operating parameters for the reliability of the given particular earth-boring tool and generate the contour map 202 based on these reliabilities. In some embodiments, the historical data may be obtained from previous drilling operations via one or more sensors (e.g., sensor 140 (fig. 1)) throughout the drilling assembly 114 (fig. 1). For example, in some embodiments, the historical data may be obtained via any of the sensors and/or means described in U.S. patent 8,100,196 to Pastusek et al, filed 2 months 6 a 2009, U.S. patent 7,859,934 to Pastusek et al, filed 2 months 16 a 2007, and U.S. patent 7,604,072 to Pastusek et al, filed 6 months 7 a 2005, the disclosures of which are incorporated herein by reference in their entirety. In further embodiments, the earth-boring tool monitoring system 129 may generate the contour map 202 from a mix of simulation data and historical data.
In some embodiments, the earth-boring tool monitoring system 129 may generate a contour map 202 specific to a particular type of earth-boring tool (e.g., reamer, expandable reamer, tricone bit, hybrid bit, etc.). In further embodiments, the earth-boring tool monitoring system 129 may generate a contour map 202 specific to a particular (i.e., individual) earth-boring tool. In further embodiments, the earth-boring tool monitoring system 129 may generate a contour map that shows the overall system health (i.e., combined drill bit, motor, and column health).
Fig. 3 illustrates a contour map 202 that may be generated and displayed by the earth-boring tool monitoring system 129, in accordance with an embodiment of the present disclosure. As shown in fig. 3, the earth-boring tool monitoring system 129 may superimpose a plurality of markers 302 on the contour map 202. Each marker 302 of the plurality of markers 302 may represent an actual (e.g., real-time) operational load (i.e., point of load) of the earth-boring tool at a point in time.
Further, since each of the markers 302 of the plurality of markers 302 represents a point in time, a set of the plurality of markers 302 may represent a time period during which the earth-boring tool is subjected to a plurality of different operational loads represented by the plurality of markers 302, and wherein each of the markers 302 represents a point in time within the time period. In some embodiments, the earth-boring tool monitoring system 129 may generate and display a line between successive ones 302 of the plurality of markers 302 (e.g., between markers 302 representing successive points in time). Thus, the plurality of markers 302 may form (e.g., define) a map of the actual operating load applied to the earth-boring tool within the contour map. Thus, trends and trends in earth-boring tools and operational loads can be easily visualized. Thus, the earth-boring tool monitoring system 129 may assist an operator in determining correlations between actual operating loads of the earth-boring tool and other parameters of the drilling operation. In further embodiments, the earth-boring tool monitoring system 129 may display a moving average of the plurality of markers and a trend line of the plurality of markers on a contour plot.
In one or more embodiments, the earth-boring tool monitoring system 129 may only maintain a certain number of markings 302 on the contour map 202 to maintain the visibility and clarity of the contour map. For example, as described above, a set of multiple markers 302 may represent a particular time period, and thus, markers 302 outside of that time period (e.g., the oldest markers 302) may disappear after the time period has elapsed since the markers 302 were displayed on the contour plot 202. For example, the earth-boring tool monitoring system 129 may deactivate the markers 302 outside of the time period. As a non-limiting example, when the earth-boring tool monitoring system 129 causes the latest mark 302 to be displayed, the earth-boring tool monitoring system 129 may cause the oldest mark 302 to disappear. In some embodiments, the period of time may be hours, days, weeks, or any other period of time. Further, the time interval between each marker 302 (e.g., the time period between points of time indicated by the markers 302) may be seconds, minutes, hours, days, or weeks.
In some embodiments, the markers 302 within the plurality of markers 302 may be distinguished from one another based on whether the markers 302 (as described above with respect to fig. 2) fall within the operating window 204 of the contour map 202 (e.g., 100% reliability) or fall within any other portion of the contour map 202. For example, in one or more embodiments, if the marker 302 falls within the operating window 204, the marker 302 may be displayed in a first color, and if the marker 302 falls outside of the operating window, the marker may be displayed in a second, different color (e.g., indicating that there is a risk to the earth-boring tool). In further embodiments, the earth-boring tool monitoring system 129 may utilize three or more colors to distinguish the markers 302 of the plurality of markers 302. For example, a first color may indicate no risk, a second color may indicate minimal risk (e.g., 70% to 99% reliable), and a third color may indicate severe risk (e.g., 0% to 69% reliable). In further embodiments, the marker 302 may have a first shape if the marker 302 falls within the operating window 204, and a second, different shape if the marker 302 falls outside of the operating window 204 (e.g., indicating that there is a risk to the earth-boring tool). Although specific ways of distinguishing the markers 302 are described herein, one of ordinary skill in the art will readily recognize that the earth-boring tool monitoring system 129 may distinguish the markers 302 based on the reliability represented by the markers 302 in any manner.
Still referring to fig. 3, in some embodiments, the earth-boring tool monitoring system 129 may obtain data for the plurality of markers 302 (e.g., actual real-time operating loads of the earth-boring tool represented by the plurality of markers 302) from the surface control unit 128 of the drilling system 100. In further embodiments, the earth-boring tool monitoring system 129 may obtain data for the plurality of markers 302 from one or more portions of the drilling system 100 (e.g., top drive, motor, drill string, drill bit, in-bit sensor, etc.). For example, the earth-boring tool monitoring system 129 may obtain data for the plurality of markers 302 from downhole sensors and/or controllers. For example, the earth boring tool monitoring system 129 may obtain data for the plurality of markers 302 from any of the sensors described in U.S. patent 8,100,196 issued 2/6/2009, 1/24/2012, issued Pastusek et al, U.S. patent 7,849,934 issued 2/16/2007, issued Pastusek et al, and U.S. patent 7,604,072 issued 6/7/2005, 10/20/2009, issued Pastusek et al.
Fig. 4A shows a contour plot 202 generated by the earth-boring tool monitoring system 129 and representing the bit health of the earth-boring tool prior to displacement of the contour plot 202, and fig. 4B shows the contour plot after displacement of the contour plot 202. Referring to fig. 4A and 4B, in some embodiments, the earth-boring tool monitoring system 129 may shift or regenerate the contour map 202 over a range of operating loads based on accumulated damage to the earth-boring tool. In other words, the earth-boring tool monitoring system 129 may update the contour map 202 based on the accumulated damage to the earth-boring tool. For example, during drilling operations, the earth-boring tool monitoring system 129 may shift the contour map 202 based on a lifetime of the earth-boring tool, a previously experienced operational load of the earth-boring tool, detected damage to the earth-boring tool, and the like.
In some embodiments, shifting the contour plot 202 may cause the operating window 204 (e.g., the area of the contour plot 202 representing 100% reliability) to shrink and the area of the contour plot 202 representing less than 100% reliability to increase. For example, in an example of an operating load that includes torque and WOB, during shifting, the maximum torque within the operating window 204 may be reduced and the maximum WOB within the operating window 204 may be reduced. Thus, the operating window 204 may be reduced and the range of operating loads in which the earth-boring tool may operate with 100% reliability may be reduced.
In one or more embodiments, the cumulative damage to the earth-boring tool may be calculated based on laboratory test data, simulation data, historical data (e.g., actual field failure, offset, bit logging, repair data, and assessment of surface defects), and/or data from one or more sensors of the earth-boring tool. Regardless, in some embodiments, the earth-boring tool monitoring system 129 may continuously displace (i.e., displace in continuous motion) the operating window 204. For example, the earth-boring tool monitoring system 129 may continuously displace the operating window 204 as the earth-boring tool ages, as the earth-boring tool experiences operational loads, and as damage to the earth-boring tool is detected and/or calculated throughout the drilling operation. In alternative embodiments, the earth-boring tool monitoring system 129 may shift the operating window 204 at intervals. For example, the earth-boring tool monitoring system 129 may shift the operating window 204 every 30 seconds, every 60 seconds, every 5 minutes, every 30 minutes, every 1 hour, every 6 hours, every day, etc. As a non-limiting example, the earth-boring tool monitoring system 129 may shift the operating window at any time interval.
Referring to fig. 4B, if the newly superimposed marker 302 is outside the operating window 204 (i.e., indicates risk based on the operating load) due to a shift in the contour plot 202, the newly superimposed marker 302 (i.e., the marker 302 superimposed after the most recent shift) may be distinguished from the previously superimposed marker 302. For example, as described above, the newly superimposed mark 302 may be displayed in a different color than the mark 302 within the operation window 204. Furthermore, the previously superimposed markers 302 that were not previously indicative of risk (e.g., positioned within the operating window 204) but are now indicative of risk due to shifting may remain unchanged.
In view of the above, the earth-boring tool monitoring system 129 of the present disclosure may provide advantages over conventional methods of monitoring earth-boring tools. For example, the earth-boring tool monitoring system 129 may enable an operator to quickly and efficiently visualize risk in order to manage and balance both risk and performance in real-time.
Fig. 5 is a block diagram of a surface control unit 128 according to one or more embodiments of the present disclosure. As shown in fig. 5, in some embodiments, the surface control unit 128 may include an earth-boring tool monitoring system 500. It should be appreciated that one or more earth-boring tool monitoring systems may implement the earth-boring tool monitoring system 500. The earth-boring tool monitoring system 500 may include a processor 502, a memory 504, a storage device 506, an I/O interface 508, and a communication interface 510, which may be communicatively coupled by a communication infrastructure 512. While an exemplary computing device is shown in fig. 5, the components shown in fig. 5 are not intended to be limiting. In other embodiments, additional or alternative components may be used. Further, in certain embodiments, the earth-boring tool monitoring system 500 may include fewer components than those shown in fig. 5. The components of the earth-boring tool monitoring system 500 shown in fig. 5 will now be described in more detail.
In one or more embodiments, the processor 502 includes hardware for executing instructions such as those comprising a computer program. By way of example, and not limitation, to execute instructions, processor 502 may retrieve (or fetch) instructions from an internal register, an internal cache, memory 504, or storage 506, and decode and execute the instructions. In one or more embodiments, the processor 502 may include one or more internal caches for data, instructions, or addresses. By way of example, and not limitation, the processor 502 may include one or more instruction caches, one or more data caches, and one or more Translation Lookaside Buffers (TLBs). The instructions in the instruction cache may be copies of instructions in memory 504 or storage 506.
Memory 504 may be used to store data, metadata, and programs for execution by the processor. Memory 504 may include one or more of volatile and nonvolatile memory such as random access memory ("RAM"), read only memory ("ROM"), solid state disk ("SSD"), flash memory, phase change memory ("PCM"), or other types of data storage. The memory 504 may be an internal memory or a distributed memory.
Storage 506 includes storage for storing data or instructions. By way of example, and not limitation, the storage device 506 may include the non-transitory storage media described above. The storage device 506 may include a Hard Disk Drive (HDD), a floppy disk drive, flash memory, an optical disk, a magneto-optical disk, a magnetic tape, or a Universal Serial Bus (USB) drive, or a combination of two or more of these. Storage 506 may include removable or non-removable (or fixed) media, where appropriate. The storage device 506 may be internal or external to the earth-boring tool monitoring system 500. In one or more implementations, the storage device 506 is a non-volatile solid-state memory. In other embodiments, storage 506 includes Read Only Memory (ROM). The ROM may be mask-programmed ROM, programmable ROM (PROM), erasable PROM (EPROM), electrically Erasable PROM (EEPROM), electrically Alterable ROM (EAROM), or flash memory, or a combination of two or more of these, where appropriate.
The I/O interface 508 allows a user to provide input to, receive output from, and otherwise transmit data to and receive data from the earth-boring tool monitoring system 500. The I/O interface 508 may include a mouse, keypad or keyboard, touch screen, camera, optical scanner, network interface, modem, other known I/O devices, or a combination of such I/O interfaces. The I/O interface 508 may include one or more devices for presenting output to a user, including but not limited to a graphics engine, a display (e.g., a display screen), one or more output drivers (e.g., a display driver), one or more audio speakers, and one or more audio drivers. In some embodiments, the I/O interface 508 is configured to provide graphical data to a display for presentation to a user. The graphical data may represent one or more graphical user interfaces and/or any other graphical content that may serve a particular implementation.
Communication interface 510 may include hardware, software, or both. In any event, the communication interface 510 may provide one or more interfaces for communication (e.g., packet-based communication) between the earth-boring tool monitoring system 500 and one or more other earth-boring tool monitoring systems or networks. By way of example and not limitation, communication interface 510 may include a Network Interface Controller (NIC) or network adapter for communicating with an ethernet or other wire-based network, or a Wireless NIC (WNIC) or wireless adapter for communicating with a wireless network, such as WI-FI.
Additionally or alternatively, the communication interface 510 may facilitate communication with one or more portions of an ad hoc (ad hoc) network, a Personal Area Network (PAN), a Local Area Network (LAN), a Wide Area Network (WAN), a Metropolitan Area Network (MAN), or the internet, or a combination of two or more of these. One or more portions of one or more of these networks may be wired or wireless. By way of example, communication interface 510 may facilitate communication with a Wireless PAN (WPAN) (e.g.,WPAN), WI-FI network, WI-MAX network, cellular telephone network (e.g., global system for mobile communications (GSM) network), or other suitable wireless network, or a combination thereof.
In addition, communication interface 510 may facilitate communication with various communication protocols. Examples of communication protocols that may be used include, but are not limited to, data transmission media, communication devices, transmission control protocol ("TCP"), internet protocol ("IP"), file transfer protocol ("FTP"), telnet, hypertext transfer protocol ("HTTP"), hypertext transfer security protocol ("HTTPs"), session initiation protocol ("SIP"), simple object access protocol ("SOAP"), extensible markup language ("XML") and variants thereof, simple mail transfer protocol ("SMTP"), real-time transport protocol ("RTP"), user datagram protocol ("UDP"), global system for mobile communications ("GSM") technology, code division multiple access ("CDMA") technology, time division multiple access ("TDMA") technology, short message service ("SMS"), multimedia message service ("MMS"), radio frequency ("RF") signaling technology, long term evolution ("LTE") technology, wireless communication technology, in-band and out-of-band signaling technology, and other suitable communication networks and technologies.
The communication infrastructure 512 may include hardware, software, or both that couple components of the earth-boring tool monitoring system 500 to one another. By way of example, and not limitation, communication infrastructure 512 may include an Accelerated Graphics Port (AGP) or other graphics bus, an Enhanced Industry Standard Architecture (EISA) bus, a Front Side Bus (FSB), a HyperTransport TM (HT) interconnect, an Industry Standard Architecture (ISA) bus, a,An interconnect, a Low Pin Count (LPC) bus, a memory bus, a Micro Channel Architecture (MCA) bus, a Peripheral Component Interconnect (PCI) bus, a PCI-Express (PCIe) bus, a Serial Advanced Technology Attachment (SATA) bus, a video electronics standards Association local area (VLB) bus, or another suitable bus, or a combination thereof.
The present disclosure also includes the following embodiments.
Embodiment 1: an earth-boring tool monitoring system, comprising: at least one processor; and at least one non-transitory computer-readable storage medium storing instructions thereon that, when executed by the at least one processor, cause the system to: generating a contour map representing the reliability of an earth-boring tool over a range of operating loads, the contour map showing a range of reliability of the earth-boring tool from about 100% reliable to about 0% reliable; and superimposing a plurality of markers on the contour map, each marker representing a point in time and representing an operational load of the earth-boring tool at the point in time.
Embodiment 2: the earth-boring tool monitoring system of embodiment 1, wherein the reliability range is represented by a color gradient or a gray gradient.
Embodiment 3: the earth-boring tool monitoring system of embodiments 1 and 2, wherein the contour map is generated based on simulated data from a simulated drilling operation or laboratory test.
Embodiment 4: the earth-boring tool monitoring system of embodiments 1-3, wherein the contour map is generated based on historical data from previously performed drilling operations.
Embodiment 5: the earth-boring tool monitoring system of embodiments 1-4, further comprising instructions that, when executed by the at least one processor, cause the system to: detecting a user interaction that alters an operating parameter of the earth-boring tool due to a risk indicated by at least one of the plurality of markers after superimposing the plurality of markers on the contour map; and in response to detecting the user interaction, changing the operating parameter of the earth-boring tool.
Embodiment 6: the earth-boring tool monitoring system of embodiments 1-5, wherein superimposing a plurality of markers on the contour plot comprises superimposing one or more of the plurality of markers in a first color when the earth-boring tool is at a low risk of failure based at least in part on the operational load represented in the one or more markers.
Embodiment 7: the earth-boring tool monitoring system of embodiment 6, further comprising superimposing at least one additional marker of the plurality of markers in a second color when the earth-boring tool is at high risk of failure based at least in part on the operational load represented in the at least one additional marker.
Embodiment 8: the earth-boring tool monitoring system of embodiments 1-7, wherein the operational load range comprises a torque range and a weight-on-bit range, and wherein each of the plurality of markers represents an applied torque and an applied weight-on-bit of the earth-boring tool at the point in time represented by the marker.
Embodiment 9: the earth-boring tool monitoring system of embodiments 1-8, wherein the data for the operational loads for the plurality of markers is obtained from a surface control unit of a drilling assembly.
Embodiment 10: the earth-boring tool monitoring system of embodiments 1-9, wherein the data for the operational loads of the plurality of markers is obtained from a sensor disposed downhole on the earth-boring tool.
Embodiment 11: an earth-boring tool monitoring system, comprising: at least one processor; and at least one non-transitory computer-readable storage medium storing instructions thereon that, when executed by the at least one processor, cause the system to: generating a contour map representing a range of reliability of the earth-boring tool over a range of operating loads; superimposing a plurality of markers on the contour map, each marker representing a point in time and representing an operational load of the earth-boring tool at the point in time; and shifting the contour map based at least in part on an amount of accumulated damage experienced by the earth-boring tool.
Embodiment 12: the earth-boring tool monitoring system of embodiment 11, further comprising instructions that, when executed by the at least one processor, cause the system to determine the cumulative damage experienced by the earth-boring tool based at least in part on simulated data from a simulated drilling operation.
Embodiment 13: the earth-boring tool monitoring system of embodiments 11 and 12, further comprising instructions that, when executed by the at least one processor, cause the system to determine the cumulative damage experienced by the earth-boring tool based at least in part on historical data from previously performed drilling operations.
Embodiment 14: the earth-boring tool monitoring system of embodiments 11-13, wherein superimposing a plurality of markers on the contour plot comprises superimposing one or more of the plurality of markers in a first color when the earth-boring tool is at a low risk of failure based on the operational load represented in the one or more markers.
Embodiment 15: the earth-boring tool monitoring system of embodiment 14, further comprising superimposing at least one additional marker of the plurality of markers in a second color when the earth-boring tool is at high risk of failure based on the operational load represented in the at least one additional marker.
Embodiment 16: the earth-boring tool monitoring system of embodiments 11-15, wherein shifting the contour map based at least in part on the accumulated amount of damage comprises narrowing an operating window of the contour map.
Embodiment 17: an earth-boring tool monitoring system, comprising: at least one processor; and at least one non-transitory computer-readable storage medium storing instructions thereon that, when executed by the at least one processor, cause the system to: generating a contour map representing a range of reliability of the earth-boring tool over a range of operating loads; superimposing a first marker on the contour plot representing a first point in time, representing a first operational load of the earth-boring tool at the point in time, and having a first color indicative of no risk; shifting the contour map based at least in part on an amount of accumulated damage experienced by the earth-boring tool; and superimposing a second marker on the contour plot representing a second point in time, representing a second operational load of the earth-boring tool at the second point in time that is less than the first operational load, and having a second color indicative of risk.
Embodiment 18: the earth-boring tool monitoring system of embodiment 17, wherein the displacement of the contour map is based at least in part on a lifetime of the earth-boring tool.
Embodiment 19: the earth-boring tool monitoring system of embodiments 17 and 18, wherein the reliability range is represented by a color gradient or a gray gradient.
Embodiment 20: the earth-boring tool monitoring system of embodiments 17-19, wherein the operating load range comprises a torque range and a weight-on-bit range.
The embodiments of the present disclosure described above and illustrated in the drawings do not limit the scope of the disclosure, which is encompassed by the scope of the appended claims and their legal equivalents. Any equivalent embodiments are within the scope of this disclosure. Indeed, various modifications of the disclosure in addition to those shown and described herein (such as alternative useful combinations of the described elements) will be apparent to those skilled in the art from this description. Such modifications and embodiments also fall within the scope of the appended claims and equivalents thereof.
Claims (13)
1. An earth-boring tool monitoring system, comprising:
at least one processor; and
At least one non-transitory computer-readable storage medium storing instructions thereon that, when executed by the at least one processor, cause the system to:
Generating and displaying in a graphical user interface a contour map representing the reliability of an earth-boring tool over a range of operational loads, the contour map showing a range of reliability of the earth-boring tool from 100% reliable to 0% reliable, the contour map defining an operational window comprising subranges of the range of operational loads over which the earth-boring tool is expected to operate at 100% reliability;
receiving operational data from one or more sensors of the earth-boring tool, the operational data comprising data associated with a sensed operational load of the earth-boring tool;
In response to determining that the operational data represents an operational load within the operational window, superimposing at least one first marker of a first color on a contour map in the graphical user interface;
In response to determining that the operational data represents an operational load outside of the operational window, superimposing at least one second marker of a different second color on a contour plot in the graphical user interface, wherein each of the at least one first marker and the at least one second marker represents a point in time and represents an actual real-time operational load of the earth-boring tool at the point in time, and wherein over time new markers are displayed in real-time and old markers disappear; and
Calculating cumulative damage to the earth-boring tool based on the laboratory test data, the simulation data, the historical data, and/or the data from the one or more sensors of the earth-boring tool;
Based at least in part on the calculated cumulative damage to the earth-boring tool, the operating window is continuously shifted by modifying the sub-range of the operating load range defining the operating window as the earth-boring tool ages.
2. The earth-boring tool monitoring system of claim 1, wherein the reliability range is represented by a color gradient or a gray gradient.
3. The earth-boring tool monitoring system of claim 1, wherein the contour map is generated based on simulated data from a simulated drilling operation or laboratory test.
4. The earth-boring tool monitoring system of claim 1, wherein the contour map is generated based on historical data from previously performed drilling operations.
5. The earth-boring tool monitoring system of claim 1, further comprising instructions that, when executed by the at least one processor, cause the system to:
Detecting a user interaction that alters an operating parameter of the earth-boring tool due to a risk indicated by at least one of the plurality of markers after superimposing the plurality of markers on the contour map; and
In response to detecting the user interaction, the operating parameter of the earth-boring tool is changed.
6. The earth-boring tool monitoring system of claim 1, wherein superimposing at least one first mark of a first color on the contour map comprises: when the earth-boring tool is at a low risk of failure based at least in part on the operational load represented in one or more indicia, the one or more indicia are superimposed in a first color.
7. The earth-boring tool monitoring system of claim 6, wherein superimposing at least one second mark of a second color on the contour map comprises: when the earth-boring tool is at high risk of failure based at least in part on the operational load represented in at least one additional marking, the at least one additional marking is superimposed in a second color.
8. The earth-boring tool monitoring system of claim 1, wherein the operational load range comprises a torque range and a weight-on-bit range, and wherein each marker of the plurality of markers represents an applied torque and an applied weight-on-bit of the earth-boring tool at the point in time represented by the marker.
9. The earth-boring tool monitoring system of claim 1, wherein data for the operational loads of the plurality of markers is obtained from a surface control unit of a drilling assembly.
10. The earth-boring tool monitoring system of claim 1, wherein the data for the operational loads of the plurality of markers is obtained from a sensor disposed downhole on the earth-boring tool.
11. The earth-boring tool monitoring system of claim 1, further comprising instructions that, when executed by the at least one processor, cause the system to determine the cumulative damage experienced by the earth-boring tool based at least in part on simulation data from a simulated drilling operation.
12. The earth-boring tool monitoring system of claim 1, further comprising instructions that, when executed by the at least one processor, cause the system to determine the cumulative damage experienced by the earth-boring tool based at least in part on historical data from previously performed drilling operations.
13. The earth-boring tool monitoring system of claim 1, wherein shifting the operating window based at least in part on an amount of accumulated damage comprises narrowing the sub-range defining the operating window.
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| US15/914,752 | 2018-03-07 | ||
| PCT/US2019/021033 WO2019173529A1 (en) | 2018-03-07 | 2019-03-06 | Earth-boring tool monitoring system for showing reliability of an earth-boring tool and related methods |
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| WO2019173529A1 (en) | 2019-09-12 |
| US20190277131A1 (en) | 2019-09-12 |
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