Drilling system and method of operating a drilling system

• US 10,443,329 B2
• Filed: 04/14/2015
• Issued: 10/15/2019
• Est. Priority Date: 04/15/2014
• Status: Active Grant

• Current Assignee: Grant Prideco Incorporated (NOV, Inc.)
• Original Assignee: Managed Pressure Operations Pte. Ltd. (Akastor ASA)
• Inventors: Savage, Patrick David, Leuchtenberg, Christian
• Primary Examiner(s): Stephenson, Daniel P
• Application Number:
  US15/304,068
• Publication Number:
  US 20170037691A1
• Time in Patent Office: 1,645 Days
• CPC Class Codes: E21B 41/00 Equipment or details not covered by groups E21B15/00 - E21B40/00
• CPC Class Codes: E21B 44/06 in response to the flow or pressure of the motive fluid of the drive
• CPC Class Codes: E21B 45/00 Measuring the drilling time or rate of penetration
• CPC Class Codes: E21B 47/001 for underwater installation
• CPC Class Codes: E21B 47/008 Monitoring of down-hole pump systems, e.g. for the detection of "pumped-off" conditions
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: E21B 47/07 Temperature
• CPC Class Codes: E21B 47/10 Locating fluid leaks, intrusions or movements
• CPC Class Codes: E21B 47/12 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
• CPC Class Codes: E21B 7/12 Underwater drilling using heave compensators E21B19/09

Abstract

A drilling system for drilling a subterranean well bore includes a controller and a first and a second set of field devices. Each of the first and second set of field devices measure a physical characteristic of the drilling system and to transmit to the controller signals representing a measured value of the physical characteristic. The controller is programmed to use a first set of algorithms to process the signals received from the first set of field devices to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore, and a second set of algorithms to process the signals received from the second set of field devices to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore.

Claims

1. A drilling system for drilling a subterranean well bore, the system comprising:

a controller; and

at least two sets of field devices comprising a first set of field devices and a second set of field devices, each of the at least two sets of field devices being configured to measure a physical characteristic of the drilling system and to transmit to the controller signals representing a measured value of the physical characteristic,

wherein,

the controller is programmed to use a first set of algorithms to process the signals received from the first set of field devices to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore,

the controller is programmed to use a second set of algorithms to process the signals received from the second set of field devices to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore,

each of the at least two sets of field devices comprises at least one field device, and

wherein the controller is further programmed,

to assign a numerical importance level to each of the at least one field device,

to use the numerical importance level of each of the at least one field device in each of the first set of field devices or in the second set of field devices to assign a safety score for each of the first set of field devices or the second set of field devices, and

to subtract from the safety score the numerical importance level of any of the at least one field device determined to be faulty.

2. The drilling system as recited in claim 1, wherein,

the at least two sets of field devices further comprises a third set of field devices configured to measure a physical characteristic of the drilling system and to transmit to the controller signals representing a measured value of the physical characteristic, and

the controller is further programmed to use a third set of algorithms to process the signals received from the third set of field devices to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore.

3. The drilling system as recited in claim 2, wherein

the third set of field devices comprises at least one field device, and

each one of the at least one field device is included in only one of the at least three sets of field devices.

4. The drilling system as recited in claim 3, wherein the controller is further programmed,

to assign a numerical importance level to each of the at least one field device,

to use the numerical importance level of each of the at least one field device in each of the first set of field devices, the second set of field devices, or the third set of field devices to assign a safety score for each of the first set of field devices, the second set of field devices, or the third set of field devices, and

to subtract from the safety score the numerical importance level of any of the at least one field device determined to be faulty.

5. The drilling system as recited in claim 2, wherein the controller is further programmed so that, if one of the first set of algorithms, the second set of algorithms, and the third set of algorithms reaches a conclusion that there might have been an influx of formation fluid into the subterranean well bore, the controller automatically analyses the signals received from another of the at least two sets of field devices to corroborate the conclusion.

6. The drilling system as recited in claim 2, wherein,

the controller comprises at least one microprocessor, and

each of the at least one microprocessor is configured to use a common clock signal, to receive the signals from the at least two sets of field devices, and to record a time of receipt of each of the signals using the common signal clock.

7. The drilling system as recited in claim 2, wherein each of the at least two sets of field devices is different.

8. A controller for controlling a drilling system for drilling a subterranean well bore, the controller being programmed to,

process signals received from at least two sets of field devices comprising a first set of field devices and a second set of field devices, each of at least one two sets of field devices being operable to measure a physical characteristic of the drilling system and to transmit to the controller signals representing a measured value of the physical characteristic, each of the at least two sets of field devices comprising at least one field device,

to use a first set of algorithms to process the signals received from the first set of field devices to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore,

to use a second set of algorithms to process the signals received from the second set of field devices to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore,

to assign a numerical importance level to each of the at least one field device,

to use the numerical importance level of each of the at least one field device in each of the first set of field devices or in the second set of field devices to assign a safety score for each of the first set of field devices or the second set of field devices, and

to subtract from the safety score the numerical importance level of any of the at least one field device determined to be faulty.

9. The controller as recited in claim 8, wherein,

at least two sets of field devices further includes a third set of field devices which is operable to measure a physical characteristic of the drilling system and to transmit to the controller signals representing a measured value of the physical characteristic, and

the controller is further programmed to use a third set of algorithms to process the signals received from the third set of field devices to determine if the measured value represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore.

10. The controller as recited in claim 9, wherein,

the third set of field devices comprises at least one field device, and

the controller is further programmed,

to assign a numerical importance level to each of the at least one field device,

to use the numerical importance level of each of the at least one field device in each of the first set of field devices, the second set of field devices, or the third set of field devices to assign a safety score to each of the first set of field devices, the second set of field devices, or the third set of field devices, and

to subtract from the safety score the numerical importance level of any of the at least one field device determined to be faulty.

11. The controller as recited in claim 9, wherein the controller is further programmed so that if one of the first set of algorithms, the second set of algorithms, and the third set of algorithms sets of algorithms reaches a conclusion that there might have been an influx of formation fluid into the subterranean well bore, the controller automatically analyses the signals received from another of the at least two sets of field devices to corroborate the conclusion.

12. The controller as recited in claim 9, wherein,

the controller comprises at least one microprocessor, and

each of the at least one microprocessor is configured to use a common clock signal, to receive the signals from the at least two sets of field devices, and to record a time of receipt of each of the signals using the common signal clock.

13. A system for drilling a subterranean well bore, the system comprising:

a controller;

at least one drilling control device; and

at least one field device;

wherein,

the controller is connected to the at least one drilling control device so that the controller controls a drilling by effecting an operation of the at least one drilling control device,

the controller is connected to the at least one field device,

the at least one field device is configured to measure a physical characteristic of the system and to transmit to the controller signals representing a measured value of the physical characteristic,

the controller is programmed to process the signals received from the at least one field device and to determine if the measured value represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore,

the at least one field device is provided in each of at least three sets of field devices comprising a first set of field devices, a second set of field devices, and a third set of field devices, and

the controller is further programmed,

to use a first set of algorithms to process the signals received from the first set of field devices to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore,

to use a second set of algorithms to process the signals received from the second set of field devices device to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore, and

to use a third set of algorithms to process the signals received from the third set of field devices to determine if the measured values represented by the signals indicate that there might have been an influx of formation fluid into the subterranean well bore.

14. The system as recited in claim 13, wherein the controller comprises at least one microprocessor, each of the at least one microprocessor being configured to use a common clock signal, to receive the signals from the at least one field device, and to record a time of receipt of each of the signals using the common signal clock.

15. The system as recited in claim 13, wherein each of the at least two sets of field devices are different.

16. The system as recited in claim 13, wherein each field device of the at least two sets of field devices measures a physical characteristic of the drilling system which is the same as the field device of one or both of the other of the at least two sets of field devices.

17. The system as recited in claim 13, wherein each field device is included in only one of the at least two sets of field devices.

18. The system as recited in claim 13, wherein the controller is further programmed so that if one of the first set of algorithms, the second set of algorithms and the third set of algorithms determines that there might have been an influx of formation fluid into the subterranean well bore, the controller automatically analyses the signals received from another of the at least two sets of field devices to corroborate the conclusion.

19. The system as recited in claim 13, wherein the controller is further programmed so that, when one of the at least one field device is determined to be a faulty field device, the controller,

determines whether or not another field device is active which measures a same physical characteristic of the system,

assigns a higher importance level to the faulty field device if no such another field device exists,

assigns a lower importance level to the faulty field device if another field device is active which measures the same physical characteristic of the system, before then

recalculating the safety score of the set of field devices.

20. The system as recited in claim 13, wherein the controller is further programmed,

to assign a numerical importance level to each of the at least one field device,

to use the numerical importance level of each of the at least one field device in each of the first set of field devices, the second set of field devices, or the third set of field devices to assign a safety score to each of the first set of field devices, the second set of field devices, or the third set of field devices, and

to subtract from the safety score the numerical importance level of any of the at least one field device determined to be faulty.

21. The system as recited in claim 20, wherein the controller is further programmed so that the numerical importance level assigned to each of the at least one field device depends on a type of drilling operation in progress at the time.