CN112004989A - Earth-boring tool monitoring systems for displaying reliability of earth-boring tools and related methods - Google Patents
Earth-boring tool monitoring systems for displaying reliability of earth-boring tools and related methods Download PDFInfo
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP 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 DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP 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 DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP 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 DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP 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
Abstract
An earth-boring tool monitoring system may generate a contour map that represents the reliability of an earth-boring tool over a range of operating loads, the contour map illustrating the range of reliability of the earth-boring tool from 100% reliable to 0% reliable, and may superimpose a plurality of indicia on the contour map, each indicia representing a point in time and representing an operating 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 accumulated amount of damage experienced by the earth-boring tool.
Description
Priority declaration
The present application claims benefit of the filing date of U.S. patent application Ser. No. 15/914,752 of "Earth-Boring Tool Monitoring System for displaying Reliability of an Earth-Boring Tool and Related Methods", filed on 7.3.2018.
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 relating 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"). A wellbore is drilled by rotating a drill string from a drilling rig and/or by a drilling motor (also referred to as a "mud motor") in a bottom hole assembly ("BHA") to rotate a drill bit and/or reamer attached to a bottom end of the drilling assembly to remove formation material.
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 map representing the reliability of the earth-boring tool over a range of operating loads, the contour map illustrating the range of reliability of the earth-boring tool from 100% reliable to 0% reliable, and superimpose a plurality of markers on the contour map, each marker representing a point in time and representing an operating load of the earth-boring tool at the point in time.
In additional 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 operating loads, superimpose a plurality of markers on the contour map, each marker representing a point in time and representing an operating 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 map representing a range of reliability of the earth-boring tool over a range of operating loads, superimpose a first marker on the contour map representing a first point in time representing a first operating load of the earth-boring tool at the point in time and having a first color indicating no risk, shift the contour map based on an accumulated amount of damage experienced by the earth-boring tool, and superimpose a second marker on the contour map representing a second point in time representing a second operating load of the earth-boring tool at the second point in time that is less than the first operating load and having a second color indicating 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 generally indicated by like numerals, and in which:
FIG. 1 is a schematic illustration 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 illustrating a contour map of drill bit health displayed by an earth-boring tool monitoring system according to one or more embodiments of the present disclosure;
FIG. 3 is a graphical user interface showing a contour map of bit health with markers superimposed thereon and indicating real-time operating loads of an earth-boring tool in accordance with one or more embodiments of the present disclosure;
FIG. 4A is a graphical user interface illustrating a contour map prior to being updated due to accumulated damage to an earth-boring tool in accordance with one or more embodiments of the present disclosure;
FIG. 4B is a graphical user interface illustrating a contour map after being updated due to accumulated damage to an earth-boring tool, according to one or more embodiments of the present disclosure; and is
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, enlarging, or forming and enlarging a borehole. Non-limiting examples of drill bits include fixed-cutter ("drag") bits, fixed-cutter coring bits, fixed-cutter eccentric bits, fixed-cutter bi-center bits, fixed-cutter reamers, expandable reamers having blades carrying fixed cutters, and hybrid 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 materials, structures, features, or method acts indicates that this is contemplated for implementing embodiments of the present disclosure, and the use of this term in preference to the more limiting term "is" 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 the present disclosure and the drawings, and do not imply or depend on any particular preference or order unless otherwise clear from the context. 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 positioned 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 satisfied to a small degree of variance, such as within acceptable manufacturing tolerances. As an example, depending on the particular parameter, characteristic, or condition being 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 in relation to a given parameter encompasses the stated value and has a meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the given parameter, as well as variations due to 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 map 202 that represents a range of potential operating loads (e.g., torque, weight on bit, 1000 revolutions per minute ("Krev"), differential pressure, etc.) of the earth-boring tool and the associated reliability of the earth-boring tool at those operating loads. In some embodiments, the reliability is indicated by different colors. Further, the earth-boring tool monitoring system 129 generates and superimposes a marker 302 on the contour map 202, where the marker 302 represents the real-time operating load of the earth-boring tool at a point in time. Depending on the position at which the markers 302 are superimposed on the contour map 202 (e.g., within a high reliability region of the contour map 202 or within a low reliability region of the contour map 202), the markers 302 may be distinguished from each other via, for example, color. Further, the set of markers 302 may represent a time period of operation of the earth-boring tool and a mapping of actual operational loads applied to the earth-boring tool within the contour map. As will be discussed in more detail below, earth-boring tool monitoring system 129 may enable an operator to quickly and efficiently visualize risks 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 utilize the apparatus and methods disclosed herein to drill a borehole. Fig. 1 shows a borehole 102 that may include an upper section 104 with a casing 106 installed therein and a lower section 108 drilled with a drill string 110. 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. 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 the formation 118.
The drill string 110 may extend to a drilling rig 120 at the surface 122. For ease of explanation, the illustrated drilling rig 120 is a land drilling rig 120. However, the disclosed apparatus and method may also be used with an offshore drilling rig 120 for drilling boreholes 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, and thus the drill bit 116, to drill the borehole 102. A drilling motor 126 may be disposed 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 rig 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, and the like.
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. 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. Additionally, 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 surface 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 representing the reliability of the earth-boring tool based on the potential operating loads. Furthermore, although the earth-boring tool monitoring system 129 is described herein as part of the surface control unit 128, the disclosure is not so limited; rather, as one of ordinary skill in the art will appreciate, the earth-boring tool monitoring system 129 may be separate from the surface control unit 128 and may be disposed anywhere within the drilling assembly 114, or may be remote from the drilling assembly 114. 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 an annular space (also referred to as an "annulus") between the drill string 110 and an inner sidewall 138 of the borehole 102.
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 bit health of a drilling assembly (e.g., the drilling assembly 114) (hereinafter referred to as an "earth-boring tool"). As used herein, the term "bit health" may refer to a representation of the reliability of an earth-boring tool over a range of operating loads in terms of 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 store thereon instructions that, when executed by the at least one processor, cause 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 map 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 the contour map 202 on a display for viewing by an operator. As used herein, the term "reliability" (reliability and reliabilites) may refer to the extent 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 the earth-boring tool will perform as expected at a given operational load. Further, the "reliability" of an earth-boring tool may be based, at least in part, on a single or multiple failure modes that the earth-boring tool may experience.
In some embodiments, the axes (e.g., the X-axis and the Y-axis) of the contour plot 202 may represent an operating load against which the contour plot 202 plots the reliability of the earth-boring tool. The operational load, and thus the axis of the contour map 202, may include weight on bit ("WOB"), torque, differential pressure, Krev, or any other parameter measured and/or utilized in a drilling operation.
In some implementations, 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 map 202 may represent 100% reliability (e.g., a statistical confidence of about 100%, i.e., the earth-boring tool will continue to operate as expected within the operational loads 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 operational 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, a 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 color may be utilized to represent any reliability, and the present disclosure is not limited to colors. Conversely, in some embodiments, a grayscale gradient may be utilized within the contour map 202 to represent a reliability range. In further embodiments, the contour map 202 may include defined regions (e.g., regions defined by lines) that represent reliability or reliability ranges, respectively. 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 map 202 may define an operating window 204. For example, the operating window 204 may represent an operating load range at which the earth-boring tool may operate with approximately 100% reliability. One of ordinary skill in the art will appreciate that during operation, an operator or earth-boring tool will wish to maintain the operational loads of the earth-boring tool within the operational window 204 to avoid failure.
In some embodiments, the earth-boring tool monitoring system 129 may generate the contour map 202 from the simulation data. For example, the earth-boring tool monitoring system 129 may utilize simulation software (e.g.,
etc.) to determine statistical confidence values and operating parameters of the reliability of the 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 the contour map 202 from historical data. For example, for a given earth-boring tool, the earth-boring tool monitoring system 129 may determine statistical confidence values and operating parameters for the reliability of the given particular earth-boring tool using data obtained from drilling operations previously performed using similar and/or the same type of 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 drilling assembly 114 (fig. 1). For example, in some embodiments, historical data may be obtained via any of the sensors and/or approaches described in U.S. patent 8,100,196 to passtusek et al, filed on 6/2/2009, U.S. patent 7,859,934 to passtusek et al, filed on 16/2/2007, and U.S. patent 7,604,072 to passtusek et al, filed on 7/6/2005, the disclosures of which are incorporated herein by reference in their entireties. In further embodiments, the earth-boring tool monitoring system 129 may generate the contour map 202 from a mixture of simulated 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, tri-cone drill bit, hybrid drill bit, etc.). In further embodiments, the earth-boring tool monitoring system 129 may generate a contour map 202 that is 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 showing the overall system health (i.e., combined drill bit, motor, and string health).
FIG. 3 illustrates a contour map 202 that may be generated and displayed by the earth-boring tool monitoring system 129, according to an embodiment of the present disclosure. As shown in FIG. 3, the earth-boring tool monitoring system 129 may overlay a plurality of markers 302 on the contour map 202. Each marker 302 in the plurality of markers 302 may represent an actual (e.g., real-time) operational load (i.e., a load point) of the earth-boring tool at a certain point in time.
Further, because each of the markers 302 of the plurality of markers 302 represents a point in time, the 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 lines between successive marks 302 in the plurality of marks 302 (e.g., between marks 302 representing successive points in time). Accordingly, the plurality of markings 302 may form (e.g., define) a map of actual operating loads applied to the earth-boring tool within the contour map. Thus, trends and trends in earth-boring tools and operational loads may be readily visualized. Accordingly, the earth-boring tool monitoring system 129 may assist an operator in determining a correlation between actual operational 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 the moving average of the plurality of markers and the trend line of the plurality of markers on a contour map.
In one or more embodiments, the earth-boring tool monitoring system 129 may maintain only a certain number of markers 302 on the contour map 202 to maintain visibility and clarity of the contour map. For example, as described above, the set of multiple markers 302 may represent a particular time period, and thus, markers 302 outside of the time period (e.g., the oldest marker 302) may disappear after the time period has elapsed since the marker 302 was displayed on the contour map 202. For example, the earth-boring tool monitoring system 129 may cause the markings 302 to disappear outside of the time period. By way of non-limiting example, when the earth-boring tool monitoring system 129 causes the newest indicia 302 to be displayed, the earth-boring tool monitoring system 129 may cause the oldest indicia 302 to disappear. In some embodiments, the time period may be hours, days, weeks, or any other time period. Further, the time interval between each marker 302 (e.g., the time period between the time points 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 can be distinguished from each other 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 marks 302 of the plurality of marks 302. For example, a first color may indicate no risk, a second color may indicate minimal risk (e.g., 70% reliability to 99% reliability), and a third color may indicate severe risk (e.g., 0% reliability to 69% reliability). 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 markings 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 markings 302 based on the reliability represented by the markings 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 from the surface control unit 128 of the drilling system 100 (e.g., the actual real-time operating loads of the earth-boring tool represented by the plurality of markers 302). In further embodiments, the earth-boring tool monitoring system 129 may acquire data for the plurality of markers 302 from one or more portions of the drilling system 100 (e.g., a top drive, a motor, a drill string, a drill bit, an in-bit sensor, etc.). For example, the earth-boring tool monitoring system 129 may acquire data for a plurality of markers 302 from downhole sensors and/or controllers. For example, earth-boring tool monitoring system 129 may acquire data for plurality of markers 302 from any of the sensors described in U.S. patent 8,100,196 to passtusek et al, filed on 6/2009, 24/2012, U.S. patent 7,849,934 to passtusek et al, filed on 16/2/2007, and U.S. patent 7,604,072 to passtusek et al, filed on 7/2005, 10/2009, 20/2009.
Fig. 4A shows a contour map 202 generated by the earth-boring tool monitoring system 129, and the contour map represents the bit health of the earth-boring tool prior to shifting of the contour map 202, and fig. 4B shows the contour after shifting of the contour map 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 an operating load range 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 accumulated damage to the earth-boring tool. For example, during a drilling operation, the earth-boring tool monitoring system 129 may shift the contour map 202 based on the age of the earth-boring tool, previously experienced operational loads of the earth-boring tool, detected damage to the earth-boring tool, and the like.
In some embodiments, shifting the contour map 202 may cause the operating window 204 (e.g., the region of the contour map 202 representing 100% reliability) to shrink and the region of the contour map 202 representing less than 100% reliability to increase. For example, in an example of an operating load that includes torque and WOB, during the shift, the maximum torque within the operating window 204 may be decreased, and the maximum WOB within the operating window 204 may be decreased. Accordingly, the operating window 204 may be reduced, and the operating load range in which the earth-boring tool may operate with 100% reliability may be reduced.
In one or more embodiments, the cumulative damage of the earth-boring tool may be calculated based on laboratory test data, simulation data, historical data (e.g., actual field failures, deviations, drill bit logs, repair data, and evaluations 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 shift the operating window 204 (i.e., shift in a continuous motion). For example, the earth-boring tool monitoring system 129 may continuously shift the operating window 204 as the earth-boring tool ages, as the earth-boring tool experiences operating 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 time 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, and so forth. 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 of the operating window 204 (i.e., indicates risk based on operating load) due to a shift in the contour map 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 marker 302 may be displayed in a different color than the marker 302 within the operating window 204. Further, the previously superimposed marker 302 that previously did not indicate risk (e.g., was positioned within the operating window 204), but now indicates risk due to displacement, 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, earth-boring tool monitoring system 129 may enable an operator to quickly and efficiently visualize risks 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 understood that one or more earth-boring tool monitoring systems may implement earth-boring tool monitoring system 500. 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 via a communication infrastructure 512. While an exemplary computing device is illustrated in fig. 5, the components illustrated in fig. 5 are not intended to be limiting. In other embodiments, additional or alternative components may be used. Furthermore, in certain embodiments, 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, processor 502 includes hardware for executing instructions, such as those making up a computer program. By way of example, and not limitation, to execute instructions, processor 502 may retrieve (or fetch) instructions from internal registers, internal caches, memory 504, or storage 506, and decode and execute the instructions. In one or more embodiments, processor 502 may include one or more internal caches for data, instructions, or addresses. By way of example, and not limitation, 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 the instructions in memory 504 or storage 506.
The memory 504 may be used to store data, metadata, and programs for execution by the processor. The memory 504 may include one or more of volatile and non-volatile 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.
The storage device 506 includes storage for storing data or instructions. By way of example, and not limitation, storage device 506 may comprise 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, 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 embodiments, storage 506 is non-volatile solid-state memory. In other embodiments, storage device 506 includes Read Only Memory (ROM). Where appropriate, 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.
I/O interface 508 allows a user to provide input to, receive output from, and otherwise transmit data to and receive data from 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. 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 certain 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.
The communication interface 510 may include hardware, software, or both. In any event, communication interface 510 may provide one or more interfaces for communication (e.g., packet-based communication) between 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, 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), a WI-FI network, a WI-MAX network, a cellular telephone network (e.g., a global system for mobile communications (GSM) network), or other suitable wireless network or combination thereof.
Additionally, the 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 transfer 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, and the like, Wireless communication technologies, in-band and out-of-band signaling technologies, and other suitable communication networks and technologies.
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 reliability of an earth-boring tool over an operating load range, the contour map illustrating 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 operating 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 grayscale gradient.
Embodiment 3: the earth-boring tool monitoring system of embodiments 1 and 2, wherein the contour map is generated based on simulation data from a simulated drilling operation or a 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: after superimposing the plurality of markers on the contour map, detecting a user interaction that changes an operating parameter of the earth-boring tool due to a risk indicated by at least one of the plurality of markers; 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 markings on the contour map comprises superimposing one or more markings of the plurality of markings 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 markings.
Embodiment 7: the earth-boring tool monitoring system of embodiment 6, further comprising overlaying at least one additional indicia of the plurality of indicia 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 indicia.
Embodiment 8: the earth-boring tool monitoring system of embodiments 1-7, wherein the operating 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.
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 for 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 operating 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 simulated drilling operations.
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 markings on the contour map comprises superimposing one or more markings of the plurality of markings 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 markings.
Embodiment 15: the earth-boring tool monitoring system of embodiment 14, further comprising overlaying at least one additional indicia of the plurality of indicia 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 indicia.
Embodiment 16: the earth-boring tool monitoring system of embodiments 11-15, wherein shifting the contour map based at least in part on an amount of accumulated 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 map 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 indicating 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 map 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 indicating risk.
Embodiment 18: the earth-boring tool monitoring system of embodiment 17, wherein the shifting 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 grayscale 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 covered by the scope of the appended claims and their legal equivalents. Any equivalent embodiments are within the scope of the present disclosure. Indeed, various modifications of the disclosure (such as alternative useful combinations of the elements described) in addition to those shown and described herein will be apparent to those skilled in the art from the description. Such modifications and embodiments are also within the scope of the appended claims and their equivalents.
Claims (15)
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 reliability of an earth-boring tool over an operating load range, the contour map illustrating 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 operating load of the earth-boring tool at the point in time.
2. The earth-boring tool monitoring system of claim 1, wherein the reliability range is represented by a color gradient or a grayscale gradient.
3. The earth-boring tool monitoring system of claim 1, wherein the contour map is generated based on simulation data from a simulated drilling operation or a 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:
after superimposing the plurality of markers on the contour map, detecting a user interaction that changes an operating parameter of the earth-boring tool due to a risk indicated by at least one of the plurality of markers; and
in response to detecting the user interaction, changing the operating parameter of the earth-boring tool.
6. The earth-boring tool monitoring system of claim 1, wherein superimposing a plurality of markings on the contour map comprises superimposing one or more markings of the plurality of markings 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 markings.
7. The earth-boring tool monitoring system of claim 6, further comprising overlaying at least one additional indicia of the plurality of indicia 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 indicia.
8. The earth-boring tool monitoring system of claim 1, wherein the operating 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 the data for the operational loads for 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 for 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 shift the contour map based at least in part on an amount of accumulated damage experienced by the earth-boring tool.
12. The earth-boring tool monitoring system of claim 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 simulated drilling operations.
13. The earth-boring tool monitoring system of claim 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 historical data from previously performed drilling operations.
14. The earth-boring tool monitoring system of claim 11, wherein shifting the contour map comprises shifting the contour map based at least in part on a lifetime of the earth-boring tool.
15. The earth-boring tool monitoring system of claim 11, wherein shifting the contour map based at least in part on an amount of accumulated damage comprises narrowing an operating window of the contour map.
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| US15/914,752 US20190277131A1 (en) | 2018-03-07 | 2018-03-07 | Earth-boring tool monitoring system for showing reliability of an earth-boring tool and related methods |
| 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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| CN112004989A true CN112004989A (en) | 2020-11-27 |
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| US (1) | US20190277131A1 (en) |
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| US20190277131A1 (en) | 2019-09-12 |
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