Prognostics And Health Management Methods And Apparatus To Predict Health Of Downhole Tools From Surface Check

• US 20140121973A1
• Filed: 10/22/2013
• Published: 05/01/2014
• Est. Priority Date: 10/25/2012
• Status: Abandoned Application

• Current Assignee: Schlumberger Technology Corporation (Schlumberger NV)
• Original Assignee: Schlumberger Technology Corporation (Schlumberger NV)
• Inventors: Buchanan, Steven Eugene, Haddad, Gilbert, Awad, Mahmoud Ismail
• Application Number:
  US14/060,462
• Publication Number:
  US 20140121973A1
• Time in Patent Office: Days
• US Class Current: 702/6
• CPC Class Codes: E21B 41/00 Equipment or details not covered by groups E21B15/00 - E21B40/00
• CPC Class Codes: G01M 5/0033 by determining damage, crack or wear
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods

Abstract

A method includes analyzing historical surface check data to train classifiers indicative of data separation between healthy and unhealthy downhole tools. The method also includes developing, based on the classifiers, prognostics health and management algorithms to predict failures in the downhole tools.

Claims

1. A method comprising:

analyzing historical surface check data to train classifiers indicative of data separation between healthy and unhealthy downhole tools; and

developing, based on the classifiers, prognostics health and management algorithms to predict failures in the downhole tools.

2. The method of claim 1, wherein analyzing historical surface check data comprises removing noise from the historical surface check data.

3. The method of claim 1, wherein analyzing historical surface check data comprises filtering the historical surface check data based on component settings for the downhole tools.

4. The method of claim 1, wherein analyzing historical surface check data comprises detecting anomalies in the historical surface check data that indicate the data separation between the healthy and unhealthy downhole tools.

5. The method of claim 1, wherein developing prognostics and health management algorithms comprises defining functions representing the classifiers to define boundaries of healthy and unhealthy data.

6. The method of claim 1, comprising analyzing historical downhole operational data to train the classifiers.

7. The method of claim 1, wherein analyzing historical surface check data comprises identifying features indicative of the data separation between healthy and unhealthy downhole tools and filtering the historical surface check data based on the identified features.

8. A method comprising:

performing a surface check on a downhole tool to generate surface check data; and

analyzing the surface check data using prognostic health management algorithms to determine health of the downhole tool.

9. The method of claim 8, wherein the prognostic health management algorithms are developed using a combination of historical surface check and historical downhole operational data.

10. The method of claim 8, comprising replacing the downhole tool in response to detecting that the downhole tool has failed or is likely to fail.

11. The method of claim 8, comprising operating the downhole tool in a wellbore to generate downhole operational data.

12. The method of claim 11, comprising analyzing the downhole operational data using the prognostic health management algorithms to determine the health of the downhole tool.

13. The method of claim 12, wherein analyzing the downhole operational data comprises analyzing the downhole operational data using a downhole controller of the downhole tool.

14. The method of claim 12, comprising automatically adjusting operational parameters of the downhole tool in response to detecting that the downhole tool is unhealthy.

15. The method of claim 8, wherein performing a surface check comprises simulating a surface check.

16. The method of claim 15, comprising adjusting job scheduling in response to determining that the downhole tool is unhealthy.

17. A downhole tool comprising:

a prognostics health management model comprising prognostics health management algorithms developed using historical surface check data; and

a controller configured to automatically adjust operation of the downhole tool based on results of the prognostics health management model.

18. The downhole tool of claim 17, wherein the prognostics health management algorithms are developed using historical downhole operational data.

19. The downhole tool of claim 17, wherein the controller is configured to adjust a motor speed, a current level, or an operating pressure based on the results of the prognostics health management model.

20. The downhole tool of claim 17, wherein the controller is configured to execute the prognostics health management model during a surface check to determine health of the downhole tool.