Method and system for predicting performance of a drilling system for a given formation

• US 7,357,196 B2
• Filed: 08/30/2005
• Issued: 04/15/2008
• Est. Priority Date: 03/25/1996
• Status: Expired due to Term

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Pruitt, Gerald L., Goldman, William A., Weaver, Gary E., King, William W., Matthews, Oliver III
• Primary Examiner(s): DANG, HOANG C
• Application Number:
  US11/215,673
• Publication Number:
  US 20050284661A1
• Time in Patent Office: 959 Days
• Field of Search: 703/10, 702/9, 175/39, 175/40, 175/24
• US Class Current: 175/24
• CPC Class Codes: E21B 12/02 Wear indicators
• CPC Class Codes: E21B 2200/22 Fuzzy logic, artificial intelligence, neural networks or the like
• CPC Class Codes: E21B 44/00 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
• CPC Class Codes: E21B 44/005 Below-ground automatic control systems
• CPC Class Codes: E21B 49/00 Testing the nature of borehole walls; Formation testing; Methods or apparatus for obtaining samples of soil or well fluids, specially adapted to earth drilling or wells
• CPC Class Codes: E21B 49/003 by analysing drilling variables or conditions E21B49/005 takes precedence; systems specially adapted for monitoring a plurality of drilling variables or conditions E21B44/00

Abstract

A method and apparatus for predicting the performance of a drilling system for the drilling of a well bore in a given formation includes generating a geology characteristic of the formation per unit depth according to a prescribed geology model, obtaining specifications of proposed drilling equipment for use in the drilling of the well bore, and predicting a drilling mechanics in response to the specifications as a function of the geology characteristic per unit depth according to a prescribed drilling mechanics model. Responsive to a predicted drilling mechanics, a controller controls a parameter in the drilling of the well bore. The geology characteristic includes at least rock strength. The specifications include at least a bit specification of a recommended drill bit. Lastly, the predicted drilling mechanics include at least one of bit wear, mechanical efficiency, power, and operating parameters. A display is provided for generating a display of the geology characteristic and predicted drilling mechanics per unit depth, including either a display monitor or a printer.

Claims

1. An apparatus for controlling a drilling system having an automatic drilling mode comprising:

a first input device for receiving data representative of a geology characteristic of a formation per unit depth, the geology characteristic including at least rock strength;

a second input device for receiving data representative of specifications of proposed drilling equipment of the drilling system for use in drilling of a well bore in the formation, the specifications including at least a specification of a drill bit;

a measurement device processor operatively connected to said first and second input devices;

the processor operable to determine predicted drilling mechanics in response to the specifications data of the proposed drilling equipment as a function of the geology characteristic data per unit depth according to a drilling mechanics model and outputting data representative of the predicted drilling mechanics, the predicted drilling mechanics including at least one selected from the group consisting of bit wear, mechanical efficiency, power, and operating parameters;

a computer controller operable to provide drilling operation control signals responsive to the predicted drilling mechanics data to control a parameter in drilling of the well bore with the drilling system, the parameter including at least one selected from the group consisting of weight-on-bit, rpm, pump flow rate, and hydraulics;

the measurement device processor operable for outputting control parameter data responsive to the predicted drilling mechanics data;

the control parameter data adaptable for use in recommended controlling of a control parameter in drilling of the well bore with the drilling system in the automatic drilling node; and

the control parameter including at least one selected from the group consisting of weight-on-bit, rpm, pump flow rate, and hydraulics.

2. The apparatus of claim 1, wherein the geology characteristic includes at least one characteristic selected from the group consisting of rock strength, log data, lithology, porosity, and shale plasticity.

3. The apparatus of claim 1, wherein the proposed drilling equipment specifications include at least one specification selected from the group consisting of a drill bit, drill string, down hole motor, top drive motor, rotary table assembly, mud system, and mud pump.

4. The apparatus of claim 1, wherein the operating parameters include at least one selected from the group consisting of weight-on-bit, rotary rpm (revolutions-per-minute), cost, rate of penetration, and torque.

5. The apparatus of claim 1, wherein the mechanical efficiency of the predicted drilling mechanics includes total torque, the total torque including cutting torque and frictional torque at the bit.

6. The apparatus of claim 1, further comprising:

a device responsive to at least one of the geology characteristic data and the predicted drilling mechanics data, the device configured to provide an indicator of a corresponding at least one of the geology characteristic and predicted drilling mechanics per unit depth.

7. The apparatus of claim 6, wherein

the indicator of the geology characteristic includes at least one graphical representation selected from the group consisting of a curve representation, a percentage graph representation, and a band representation, and

the indicator of the predicted drilling mechanics includes at least one graphical representation selected from the group consisting of a curve representation, a percentage graph representation, and a band representation.

8. The apparatus of claim 7, further wherein the at least one graphical representation of the geology characteristic and the at least one graphical representation of the predicted drilling mechanics are coded.

9. The apparatus of claim 7, wherein bit wear is determined as a function of cumulative work done according to a bit wear model and expressed in the form of at least one representation selected from the group consisting of a

curve representation and a percentage graph representation, wherein the curve representation of bit wear may include at least one representation selected from the group consisting of bit work expressed as specific energy level at the bit, cumulative work done by the bit, and optional work losses due to abrasivity, and

the percentage graph representation is indicative of a bit wear condition at a given depth, further wherein the percentage graph of bit wear is coded, including a first code representative of expired bit life, and a second code representative of remaining bit life.

10. The apparatus of claim 7, wherein bit mechanical efficiency is determined as a function of a torque/weight-on-bit signature for the given bit according to a mechanical efficiency model and expressed in the form of at least one representation selected from the group consisting of a curve representation and a percentage graph representation, wherein

the curve representation of bit mechanical efficiency includes total torque and cutting torque at the bit, and

the percentage graph representation of bit mechanical efficiency graphically illustrates total torque, total torque including cutting torque and frictional torque components, further wherein the graphically illustrated percentage graph representation of bit mechanical efficiency is coded, including a first code for illustrating cutting torque, a second code for illustrating frictional unconstrained torque, and a third code for illustrating frictional constrained torque.

11. The apparatus of claim 10, further comprising:

mechanical efficiency represented in the form of a percentage graph illustrating drilling system operating constraints which have an adverse impact upon mechanical efficiency, the drilling system operating constraints corresponding to constraints which result in an occurrence of frictional constrained torque;

the percentage graph indicating a corresponding percentage of impact that each constraint has upon the frictional constrained torque component of the mechanical efficiency at a given depth; and

the drilling system operating constraints including maximum torque-on-bit (TOB), maximum weight-on-bit (WOB), minimum revolution-per-minute (RPM), maximum revolution-per-minute (RPM), maximum penetration rate (ROP), in any combination, and an unconstrained condition.

12. The apparatus of claim 7, further comprising power expressed in the form of at least one representation selected from the group consisting of a curve representation and a percentage graph representation,

the curve representation for power includes power limit and operating power level, the power limit corresponding to a maximum power to be applied to the bit and the operating power level including at least one of the following selected from the group consisting of constrained operating power level, recommended operating power level, and predicted operating power level, and

the percentage graph representation of power illustrates drilling system operating constraints that have an adverse impact upon power, the drilling system operating constraints corresponding to those constraints which result in a power loss, the power constraint percentage graph further for indicating a corresponding percentage of impact that each constraint has upon the power at a given depth, further wherein the percentage graph representation of drilling system operating constraints on power is coded, including different codes for identifying different constraints.

13. The apparatus of claim 6, further comprising:

a device configured to provide an indicator of the proposed drilling equipment details, in addition to at least one of the geology characteristic and predicted drilling mechanics, the proposed drilling equipment details including at least one recommended bit used in predicting the performance of the drilling system.

14. The apparatus of claim 13, wherein

the proposed drilling equipment includes at least one selected from the group consisting of a drill bit, drill string, down hole motor, top drive motor, rotary table assembly, mud system, and mud pump.

15. The apparatus of claim 13, wherein

first and second bit selections are recommended for use in a predicted performance of the drilling of the well bore, further wherein the first and second identifiers indicate portions of the predicted performance to which the first and second bit selections apply, respectively.

16. The apparatus of claim 15, wherein said indicator device further provides an illustration of each recommended bit selection and corresponding bit specifications.

17. The apparatus of claim 6, further comprising:

a bit selection change indicator configured to indicate a recommended change in bit selection from a first bit selection to a second bit selection at a given depth in the well bore.

18. A method for controlling a drilling system comprising:

receiving data representative of a geology characteristic of a formation per unit depth, the geology characteristic including at least rock strength;

receiving data representative of specifications of proposed drilling equipment of the drilling system for use in drilling a well bore in the formation, the specifications including at least a specification of a drill bit;

determining a predicted drilling mechanics in response to the specifications data of the proposed drilling equipment as a function of the geology characteristic data per unit depth according to a drilling mechanics model and outputting data representative of the predicted drilling mechanics, the predicted drilling mechanics including at least one selected from the group consisting of bit wear, mechanical efficiency, power, and operating parameters;

controlling automatically a parameter in a drilling of the well bore with the drilling system in response to the predicted drilling mechanics data, the parameter including at least one selected from the group consisting of weight-on-bit, rpm, pump flow rate, and hydraulics;

selecting at least one characteristic from the group consisting of rock strength, log data, lithology, porosity, and shale plasticity;

selecting at least one proposed drilling equipment specification from the group consisting of a drill bit, drill string, down hole motor, top drive motor, rotary table assembly, mud system, and mud pump; and

selecting at least one operating parameter from the group consisting of weight-on-bit, rotary revolutions-per-minute, cost, rate of penetration, and torque.

19. The method of claim 18, wherein the mechanical efficiency of the predicted drilling mechanics includes total torque, the total torque including cutting torque and frictional torque at the bit.

20. The method of claim 18, further comprising:

outputting control parameter data responsive to the predicted drilling mechanics data, the control parameter data adaptable for use in a recommended controlling a control parameter in drilling of the well bore with the drilling system, the control parameter including at least one selected from the group consisting of weight-on-bit, rpm, pump flow rate, and hydraulics.

21. The method of claim 18, still further comprising:

changing a drill bit from a first bit selection to a second bit selection in response to a change indicator based upon the predicted drilling mechanics.

22. The method of claim 18, further comprising the step of:

providing an indicator of at least one of the geology characteristic and predicted drilling mechanics per unit depth in response to a corresponding at least one of the geology characteristic data and the predicted drilling mechanics data.

23. The method of claim 18, wherein

providing an indicator of the geology characteristic includes displaying at least one graphical plot selected from the group consisting of a curve representation, a percentage graph representation, and a band representation, and

providing an indicator of the predicted drilling mechanics includes displaying at least one graphical plot selected from the group consisting of a curve representation, a percentage graph representation, and a band representation.

24. The method of claim 18, further comprising:

selecting at least one of a drill bit, design parameter, operating parameter, and control parameter of the drilling equipment in response to the predicted drilling mechanics data.

25. A computer program stored on a computer-readable medium for execution by a computer for controlling a drilling system, said computer program comprising:

instructions for receiving data representative of a geology characteristic of a formation per unit depth, the geology characteristic including at least rock strength;

instructions for receiving data representative of specifications of proposed drilling equipment for use in drilling of a well bore in the formation, the specifications including at least a specification of a drill bit;

instructions for determining a predicted drilling mechanics in response to the specifications data of the proposed drilling equipment as a function of the geology characteristic per unit depth according to a drilling mechanics model and outputting data representative of the predicted drilling mechanics, the predicted drilling mechanics including at least one selected from the group consisting of bit wear, mechanical efficiency, power, and operating parameters; and

instructions for determining a control parameter data in response to the predicted drilling mechanics data, the control parameter data being adaptable for use in a recommended automatic control of a control parameter in drilling of the well bore with the drilling system, the control parameter including at least one selected from the group consisting of weight-on-bit, rpm, pump flow rate, and hydraulics.

26. The computer program of claim 25, wherein the geology characteristic includes at least one characteristic selected from the group consisting of rock strength, log data, lithology, porosity, and shale plasticity.

27. The computer program of claim 25, wherein the proposed drilling equipment specifications include at least one specification selected from the group consisting of a drill bit, drill string, down hole motor, top drive motor, rotary table assembly, mud system, and mud pump.

28. The computer program of claim 25, wherein the operating parameters include at least one selected from the group consisting of weight-on-bit, rotary rpm (revolutions-per-minute), cost, rate of penetration, and torque.

29. The computer program of claim 25, wherein the mechanical efficiency of the predicted drilling mechanics includes total torque, the total torque including cutting torque and frictional torque at the bit.

30. The computer program of claim 25, still further comprising instructions for providing an indicator for changing a drill bit from a first bit selection to a second bit selection in response to a change indicator based upon the predicted drilling mechanics.

31. The computer program of claim 25, further comprising:

instructions for controlling a parameter in drilling of the well bore with the drilling system in response to the predicted drilling mechanics data, the parameter including at least one selected from the group consisting of weight-on-bit, rpm, pump flow rate, and hydraulics.

32. The computer program of claim 25, further comprising:

instructions for providing an indicator of at least one of the geology characteristic and predicted drilling mechanics per unit depth in response to a corresponding at least one of the geology characteristic data and the predicted drilling mechanics data.

33. The computer program of claim 32, wherein

providing the indicator of the geology characteristic includes displaying at least one graphical plot selected from the group consisting of a curve representation, a percentage graph representation, and a band representation, and

providing the indicator of the predicted drilling mechanics includes displaying at least one graphical plot selected from the group consisting of a curve representation, a percentage graph representation, and a band representation.

34. The computer program of claim 33, wherein

the geology characteristic includes at least one characteristic selected from the group consisting of rock strength, log data, lithology, porosity, and shale plasticity, and

the operating parameters include at least one selected from the group consisting of weight-on-bit, rotary rpm (revolutions-per-minute), cost, rate of penetration, and torque, further wherein rate of penetration includes instantaneous rate of penetration (ROP) and average rate of penetration (ROP-AVG).

35. The computer program of claim 25, further comprising:

instructions for selecting at least one of a drill bit, a design parameter, an operating parameter, and a control parameter of the drilling equipment in response to the predicted drilling mechanics data.