Method and apparatus for collecting drill bit performance data

• US 20060272859A1
• Filed: 06/07/2005
• Published: 12/07/2006
• Est. Priority Date: 06/07/2005
• Status: Active Grant

• Current Assignee: Baker Hughes Holdings LLC (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Trinh, Tu Tien, Sullivan, Eric C., Pastusek, Paul E., Lutes, Paul J., Pritchard, Daryl L., Glasgow, Keith
• Granted Patent: US 7,604,072 B2
• Time in Patent Office: Days
• US Class Current: 175/40
• CPC Class Codes: E21B 21/08 Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure valve arrangements therefor E21B21/10
• CPC Class Codes: E21B 47/00 Survey of boreholes or wells monitoring pressure or flow of drilling fluid E21B21/08
• CPC Class Codes: E21B 47/013 Devices specially adapted for supporting measuring instruments on drill bits
• CPC Class Codes: E21B 47/017 Protecting measuring instruments

Abstract

Drill bits and methods for sampling sensor data associated with the state of a drill bit are disclosed. A drill bit for drilling a subterranean formation comprises a bit body and a shank. The shank further includes a central bore formed through an inside diameter of the shank and configured for receiving a data analysis module. The data analysis module comprises a plurality of sensors, a memory, and a processor. The processor is configured for executing computer instructions to collect the sensor data by sampling the plurality of sensors, analyze the sensor data to develop a severity index, compare the sensor data to at least one adaptive threshold, and modify a data sampling mode responsive to the comparison. A method comprises collecting sensor data by sampling a plurality of physical parameters associated with a drill bit state while in various sampling modes and transitioning between those sampling modes.

Claims

1. A drill bit for drilling a subterranean formation, comprising:

a bit body bearing at least one cutting element and adapted for coupling to a drillstring;

a chamber formed within the bit body, the chamber configured for maintaining a pressure substantially near a surface atmospheric pressure while drilling the subterranean formation; and

one or more sensors disposed in the chamber and configured for sensing at least one physical parameter.

2. The drill bit of claim 1, wherein the at least one physical parameter is selected from the group consisting of vibration, acceleration, centripetal acceleration, temperature at a location in the drill bit, strain at a location in the drill bit, fluid pressure internal to the drill bit, fluid pressure external to the drill bit, fluid flow in the drill bit, fluid impedance, fluid turbidity, electromagnetic level, and magnetic flux.

3. The drill bit of claim 1, wherein at least one of the one or more sensors is secured to the chamber in a manner suitable for providing transmissibility of acceleration effects experienced by the drill bit to the at least one of the one or more sensors.

4. The drill bit of claim 1, further comprising at least one redundant sensor configured as a replacement sensor for at least one of the one or more sensors.

5. The drill bit of claim 1, further comprising a data analysis module disposed in the chamber.

6. The drill bit of claim 5, wherein the data analysis module comprises circuitry mounted on a flex-circuit board.

7. The drill bit of claim 5, further comprising:

an initiation sensor configured for detecting at least one initiation parameter and generating a power enable signal responsive to the at least one initiation parameter; and

a power gating module coupled to the initiation sensor, a power supply, and the data analysis module, wherein the power gating module is configured for operably coupling the power supply to the data analysis module when the power enable signal is asserted.

8. The drill bit of claim 7, wherein the at least one initiation parameter is selected from the group consisting of vibration, acceleration, centripetal acceleration, temperature at a location in the drill bit, strain at a location in the drill bit, fluid pressure internal to the drill bit, fluid pressure external to the drill bit, fluid flow in the drill bit, fluid impedance, fluid turbidity, electromagnetic level, and magnetic flux.

9. The drill bit of claim 1, further comprising a communication port configured for communication to a remote device selected from the group consisting of a remote processing system and a measurement-while-drilling communication system.

10. The drill bit of claim 9, wherein the communication port is further configured for communication using a connection selected from the group consisting of a wired connection and a wireless connection.

11. The drill bit of claim 9, wherein the communication occurs using a communication medium selected from the group consisting of electromagnetic energy, vibrational energy, and pressure differences.

12. A drill bit for drilling a subterranean formation, comprising:

a bit body bearing at least one cutting element;

a shank including a central bore formed therethrough, the shank secured to the bit body and adapted for coupling to a drillstring; and

an end-cap configured for disposition in the central bore, the end-cap comprising;

an end-cap body;

a first flange extending from the end-cap body; and

a second flange extending from the end-cap body such that the first flange, the second flange, the end-cap body, and at least one wall of the central bore form an annular chamber within the shank.

13. The drill bit of claim 12, wherein the end-cap is secured to the shank with a connection selected from the group consisting of a secure press-fit, a threaded connection, an epoxy connection, a shape-memory retainer, welded, and brazed.

14. The drill bit of claim 12, wherein the annular chamber is substantially sealed between the end-cap and the at least one wall of the central bore with at least one sealing ring comprising a high-pressure, high temperature static seal package.

15. The drill bit of claim 12, further comprising one or more sensors disposed in the annular chamber and configured for sensing at least one physical parameter.

16. The drill bit of claim 15, wherein the at least one physical parameter is selected from the group consisting of vibration, acceleration, centripetal acceleration, temperature at a location in the drill bit, strain at a location in the drill bit, fluid pressure internal to the drill bit, fluid pressure external to the drill bit, fluid flow in the drill bit, fluid impedance, fluid turbidity, electromagnetic level, and magnetic flux.

17. The drill bit of claim 15, further comprising at least one redundant sensor configured as a replacement sensor for at least one of the one or more sensors.

18. The drill bit of claim 12, further comprising a data analysis module disposed in the annular chamber.

19. The drill bit of claim 18, wherein the data analysis module comprises circuitry mounted on a flex-circuit board comprising an annular ring.

20. The drill bit of claim 19, wherein:

the flex-circuit board includes a reinforced backbone secured to the end-cap in a manner suitable for providing transmissibility of acceleration effects experienced by the drill bit to at least one sensor mounted on the reinforced backbone; and

portions of the flex-circuit board other than the reinforced backbone are adhered to the end-cap with a visco-elastic adhesive suitable for at least partially attenuating the acceleration effects experienced by the drill bit to non-sensor electronic components mounted on the flex-circuit board.

21. The drill bit of claim 18, further comprising:

an initiation sensor configured for detecting at least one initiation parameter and generating a power enable signal responsive to the at least one initiation parameter; and

a power gating module coupled to the initiation sensor, a power supply, and the data analysis module, wherein the power gating module is configured for operably coupling the power supply to the data analysis module when the power enable signal is asserted.

22. The drill bit of claim 21, wherein the at least one initiation parameter is selected from the group consisting of vibration, acceleration, centripetal acceleration, temperature at a location in the drill bit, strain at a location in the drill bit, fluid pressure internal to the drill bit, fluid pressure external to the drill bit, fluid flow in the drill bit, fluid impedance, fluid turbidity, electromagnetic level, and magnetic flux.

23. The drill bit of claim 12, further comprising a communication port configured for communication to a remote device selected from the group consisting of a remote processing system and a measurement-while-drilling communication system.

24. The drill bit of claim 23, wherein the communication port is further configured for communication using a connection selected from the group consisting of a wired connection and a wireless connection.

25. The drill bit of claim 23, wherein the communication occurs using a communication medium selected from the group consisting of electromagnetic energy, vibrational energy, and pressure differences.

26. A drill bit for drilling a subterranean formation, comprising:

a bit body bearing at least one cutting element;

a shank including a central bore formed therethrough, the shank secured to the bit body and adapted for coupling to a drillstring,

an electronics module configured as an annular ring disposed in the central bore; and

an end-cap disposed in the central bore, extending through an inside diameter of the annular ring and substantially sealing the electronics module between the end-cap and at least one wall of the central bore.

27. The drill bit of claim 26, wherein the end-cap is secured to the shank with a connection selected from the group consisting of a secure press-fit, a threaded connection, an epoxy connection, a shape-memory retainer, welded, and brazed.

28. The drill bit of claim 26, wherein the electronics module is substantially sealed between the end-cap and the at least one wall of the central bore with at least one sealing ring comprising a high-pressure, high temperature static seal package.

29. The drill bit of claim 26, wherein the electronics module comprises circuitry mounted on a flex-circuit board comprising the annular ring.

30. The drill bit of claim 29, wherein:

the flex-circuit board includes a reinforced backbone secured to the end-cap in a manner suitable for providing transmissibility of acceleration effects experienced by the drill bit to at least one sensor mounted on the reinforced backbone; and

portions of the flex-circuit board other than the reinforced backbone are adhered to the end-cap with a visco-elastic adhesive suitable for at least partially attenuating acceleration effects experienced by the drill bit to non-sensor electronic components mounted on the flex-circuit board.

31. The drill bit of claim 26, further comprising one or more sensors disposed in the annular chamber and configured for sensing at least one physical parameter.

32. The drill bit of claim 31, wherein the at least one physical parameter is selected from the group consisting of vibration, acceleration, centripetal acceleration, temperature at a location in the drill bit, strain at a location in the drill bit, fluid pressure internal to the drill bit, fluid pressure external to the drill bit, fluid flow in the drill bit, fluid impedance, fluid turbidity, electromagnetic level, and magnetic flux.

33. The drill bit of claim 31, further comprising at least one redundant sensor configured as a replacement sensor for at least one of the one or more sensors.

34. The drill bit of claim 26, further comprising:

an initiation sensor configured for detecting at least one initiation parameter and generating a power enable signal responsive to the at least one initiation parameter; and

a power gating module coupled to the initiation sensor, a power supply, and the electronics module, wherein the power gating module is configured for operably coupling the power supply to the electronics module when the power enable signal is asserted.

35. The drill bit of claim 34, wherein the at least one initiation parameter is selected from the group consisting of vibration, acceleration, centripetal acceleration, temperature at a location in the drill bit, strain at a location in the drill bit, fluid pressure internal to the drill bit, fluid pressure external to the drill bit, fluid flow in the drill bit, fluid impedance, fluid turbidity, electromagnetic level, and magnetic flux.

36. The drill bit of claim 26, further comprising a communication port configured for communication to a remote device selected from the group consisting of a remote processing system and a measurement-while-drilling communication system.

37. The drill bit of claim 36, wherein the communication port is further configured for communication using a connection selected from the group consisting of a wired connection and a wireless connection.

38. The drill bit of claim 36, wherein the communication occurs using a communication medium selected from the group consisting of electromagnetic energy, vibrational energy, and pressure differences.

39. An apparatus for drilling a subterranean formation, comprising:

a drill bit bearing at least one cutting element and adapted for coupling to a drillstring; and

a data analysis module disposed in the drill bit and comprising;

at least one sensor configured for sensing at least one physical parameter;

a memory configured for storing information comprising computer instructions and sensor data; and

a processor configured for executing the computer instructions, wherein the computer instructions are configured for;

collecting the sensor data by sampling the at least one sensor;

analyzing the sensor data to develop a severity index;

comparing the severity index to at least one adaptive threshold, and

modifying a data sampling mode responsive to the comparison.

40. The apparatus of claim 39, wherein the at least one sensor includes at least one accelerometer configured for sensing acceleration effects on the drill bit.

41. The apparatus of claim 39, wherein the at least one sensor includes at least one magnetometer configured for sensing magnetic fields acting on the drill bit.

42. The apparatus of claim 39, wherein the at least one physical parameter is selected from the group consisting of vibration, acceleration, centripetal acceleration, temperature at a location in the drill bit, strain at a location in the drill bit, fluid pressure internal to the drill bit, fluid pressure external to the drill bit, fluid flow in the drill bit, fluid impedance, fluid turbidity, electromagnetic level, and magnetic flux.

43. The apparatus of claim 39, wherein the data analysis module further comprises at least one redundant sensor and the computer instructions are further configured for sampling the at least one redundant sensor as a replacement for the at least one sensor.

44. The apparatus of claim 39, wherein the data analysis module further comprises a communication port configured for communication to a remote device selected from the group consisting of a remote processing system and a MWD communication system.

45. The drill bit of claim 44, wherein the communication port is further configured for communication using a connection selected from the group consisting of a wired connection and a wireless connection.

46. The drill bit of claim 44, wherein the communication occurs using a communication medium selected from the group consisting of electromagnetic energy, vibrational energy, and pressure differences.

47. The apparatus of claim 39, wherein the data analysis module further comprises a sensor receiver configured for communication with a remote sensor.

48. The apparatus of claim 39, wherein the data analysis module further comprises at least one power controller operably coupled to the processor and the at least one sensor, the at least one power controller configured for enabling power and disabling power to the at the least one sensor responsive to a power control signal from the processor.

49. The apparatus of claim 39, further comprising:

an initiation sensor configured for detecting at least one initiation parameter and generating a power enable signal responsive to the at least one initiation parameter; and

a power gating module coupled to the initiation sensor, a power supply, and the data analysis module, wherein the power gating module is configured for operably coupling the power supply to the data analysis module when the power enable signal is asserted.

50. The apparatus of claim 49, wherein the at least one initiation parameter is selected from the group consisting of vibration, acceleration, centripetal acceleration, temperature at a location in the drill bit, strain at a location in the drill bit, fluid pressure internal to the drill bit, fluid pressure external to the drill bit, fluid flow in the drill bit, fluid impedance, and fluid turbidity, electromagnetic level, and magnetic flux.

51. A method, comprising:

collecting sensor data at a sampling frequency by sampling at least one sensor disposed in a drill bit, wherein the at least one sensor is responsive to at least one physical parameter associated with a drill bit state;

analyzing the sensor data to develop a severity index, wherein the analysis is performed by a processor disposed in the drill bit;

comparing the severity index to at least one adaptive threshold; and

modifying a data sampling mode responsive to the comparison.

52. A method, comprising;

collecting background data by sampling at least one physical parameter associated with a drill bit state at a background sampling frequency while in a background mode; and

transitioning from the background mode to a logging mode after a predetermined number of background samples.

53. The method of claim 52, further comprising storing the background data in memory.

54. The method of claim 52, further comprising:

collecting logging data by sampling the at least one physical parameter at a logging sampling frequency while in the logging mode; and

transitioning from the logging mode to the background mode after a predetermined number of logging samples.

55. The method of claim 54, further comprising storing the logging data in memory.

56. The method of claim 52, further comprising:

collecting logging data by sampling the at least one physical parameter at a logging sampling frequency while in the logging mode; and

transitioning from the logging mode to a burst mode after a predetermined number of logging samples.

57. The method of claim 56, further comprising storing the logging data in a memory.

58. The method of claim 56, further comprising:

collecting burst data by sampling the at least one physical parameter at a burst sampling frequency while in the burst mode; and

transitioning from the burst mode to the background mode after a predetermined number of burst samples.

59. The method of claim 58, further comprising storing the burst data in a memory.

60. The method of claim 56, further comprising:

collecting burst data by sampling the at least one physical parameter at a burst sampling frequency while in the burst mode; and

transitioning from the burst mode to the logging mode, after a predetermined number of burst samples.

61. The method of claim 60, further comprising storing the burst data in memory.

62. A method, comprising;

collecting background data by sampling at least one physical parameter associated with a drill bit state at a background sampling frequency while in a background mode; and

transitioning from the background mode to a burst mode after a predetermined number of background samples.

63. The method of claim 62, further comprising storing the background data in memory.

64. The method of claim 62, further comprising:

collecting burst data by sampling the at least one physical parameter at a burst sampling frequency while in the burst mode; and

transitioning from the burst mode to the background mode after a predetermined number of burst samples.

65. The method of claim 64, further comprising storing the burst data in memory.

66. The method of claim 62, further comprising:

collecting burst data by sampling the at least one physical parameter at a burst sampling frequency while in the burst mode; and

transitioning from the burst mode to a logging mode after a predetermined number of burst samples.

67. The method of claim 66, further comprising storing the burst data in memory.

68. The method of claim 66, further comprising:

collecting logging data by sampling the at least one physical parameter at a logging sampling frequency while in the logging mode; and

transitioning from the logging mode to the background mode after a predetermined number of logging samples.

69. The method of claim 68, further comprising storing the logging data in memory.

70. The method of claim 66, further comprising:

collecting logging data by sampling the at least one physical parameter at a logging sampling frequency while in the logging mode; and

transitioning from the logging mode to the burst mode after a predetermined number of logging samples.

71. The method of claim 70, further comprising storing the logging data in memory.

72. A method, comprising;

collecting background data by sampling at least one physical parameter associated with a drill bit state while in a background mode;

analyzing the background data to develop a background severity index; and

transitioning from the background mode to a logging mode if the background severity index is greater than a first background threshold.

73. The method of claim 72, further comprising repeating the acts of collecting the background data and analyzing the background data at a background sampling frequency.

74. The method of claim 72, further comprising storing the background data in memory.

75. The method of claim 72, further comprising:

collecting logging data by sampling the at least one physical parameter while in the logging mode;

analyzing the logging data to develop a logging severity index;

transitioning from the logging mode to the background mode if the logging severity index is less than a first logging threshold; and

transitioning from the logging mode to a burst mode if the logging severity index is greater than a second logging threshold.

76. The method of claim 75, further comprising repeating the acts of collecting the logging data and analyzing the logging data at a logging sampling frequency.

77. The method of claim 75, further comprising storing the logging data in memory.

78. The method of claim 75, further comprising:

collecting burst data by sampling the at least one physical parameter while in the burst mode;

analyzing the burst data to develop a burst severity index;

transitioning from the burst mode to the background mode if the burst severity index is less than a first burst threshold; and

transitioning from the burst mode to the logging mode if the burst severity index is less than a second burst threshold.

79. The method of claim 78, further comprising repeating the acts of collecting the burst data and analyzing the burst data at a burst sampling frequency.

80. The method of claim 78, further comprising storing the burst data in memory.

81. A method, comprising;

collecting background data by sampling at least one physical parameter associated with a drill bit state while in a background mode;

analyzing the background data to develop a background severity index; and

transitioning from the background mode to a burst mode if the background severity index is greater than a second background threshold.

82. The method of claim 81, further comprising repeating the acts of collecting the background data and analyzing the background data at a background sampling frequency.

83. The method of claim 81, further comprising storing the background data in memory.

84. The method of claim 81, further comprising:

collecting burst data by sampling the at least one physical parameter while in the burst mode;

analyzing the burst data to develop a burst severity index;

transitioning from the burst mode to the background mode if the burst severity index is less than a first burst threshold; and

transitioning from the burst mode to a logging mode if the burst severity index is less than a second burst threshold.

85. The method of claim 84, further comprising repeating the acts of collecting the burst data and analyzing the burst data at a burst sampling frequency.

86. The method of claim 84, further comprising storing the burst data in memory.

87. The method of claim 84, further comprising:

collecting logging data by sampling the at least one physical parameter while in the logging mode;

analyzing the logging data to develop a logging severity index;

transitioning from the logging mode to the background mode if the logging severity index is less than a first logging threshold; and

transitioning from the logging mode to the burst mode if the logging severity index is greater than a second logging threshold.

88. The method of claim 87, further comprising repeating the acts of collecting the logging data and analyzing the logging data at a logging sampling frequency.

89. The method of claim 87, further comprising storing the logging data in memory.