System and method for monitoring and controlling underground drilling

• US 8,453,764 B2
• Filed: 02/01/2010
• Issued: 06/04/2013
• Est. Priority Date: 02/01/2010
• Status: Active Grant

• Current Assignee: APS Technology Inc
• Original Assignee: APS Technology Inc
• Inventors: Turner, William Evans, Wassell, Mark Ellsworth
• Primary Examiner(s): WRIGHT, GIOVANNA COLLINS
• Application Number:
  US12/698,125
• Publication Number:
  US 20110186353A1
• Time in Patent Office: 1,219 Days
• Field of Search: 175/40, 702/9, 703 9- 10
• US Class Current: 175/70
• 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 47/00 Survey of boreholes or wells monitoring pressure or flow of drilling fluid E21B21/08
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence
• CPC Class Codes: G01V 9/00 Prospecting or detecting by methods not provided for in groups G01V1/00 - G01V8/00
• CPC Class Codes: G05B 13/048 using a predictor
• CPC Class Codes: G05B 2219/24075 Predict control element state changes, event changes
• CPC Class Codes: G05B 2219/2616 Earth moving, work machine
• CPC Class Codes: G05B 23/0243 model based detection method, e.g. first-principles knowledge model
• CPC Class Codes: G06F 17/18 for evaluating statistical data , e.g. average values, frequency distributions, probability functions, regression analysis forecasting specially adapted for a specific administrative, business or logistic context G06Q10/04

Abstract

A system and method for monitoring underground drilling in which vibration is monitored by creating a model of the drill string using finite element techniques or finite difference techniques and (i) predicting vibration by inputting real time values of operating parameters into the model, and then adjusting the model to agree with measured vibration data, (ii) predicting the weight on bit and drill string and mud motor speeds at which resonance will occur, as well as when stick-slip will occur, so that the operator can avoid operating regimes that will result in high vibration, (iii) determining vibration and torque levels along the length of the drill string based on the measured vibration and torque at one or more locations, (iv) determining the remaining life of critical components of the drill string based on the history of the vibration to which the components have been subjected, and (v) determining the optimum drilling parameters that will avoid excessive vibration of the drill string.

Claims

1. A method of monitoring the operation of a drill string drilling into an earthen formation so as to form a bore hole using a drill bit, comprising the steps of:

(a) drilling a bore hole having a first diameter in said earthen formation by rotating said drill bit at a first rotary speed and applying a first weight on said bit;

(b) making a determination of the value of said first rotary speed at which said drill bit rotates;

(c) making a determination of the value of said first weight on said bit;

(d) making a determination of the value of said first diameter of said bore hole;

(d) measuring vibration in said drill string at at least one predetermined location along said drill string while rotating said drill bit at said first speed and applying said first weight on said bit;

(e) using a finite element model of said drill string to predict the vibration in said drill string at said at least one predetermined location based on said determined values of said first rotary speed of said drill bit, said first weight on bit and said first bore hole diameter;

(f) comparing said measured vibration to said predicted vibration and determining the difference therebetween;

(g) revising said finite element model so as to reduce said difference between said measured vibration and said vibration predicted by said model;

(h) drilling a bore hole having a second diameter in said earthen formation by rotating said drill bit at a second rotary speed and applying a second weight on said bit;

(i) making a determination of the value of said second rotary speed at which said drill bit rotates;

(j) making a determination of the value of said second weight on said bit;

(k) making a determination of the value of said second diameter of said bore hole;

(l) using said revised finite element model of said drill string to predict the vibration in said drill string based on said determined values of said second rotary speed of said drill bit, said second weight on bit and said second bore hole diameter.

2. The method according to claim 1, wherein said finite element model of said drill string predicts vibration based on a set of operating parameters, said set of operating parameters comprising rotary speed of said drill bit, weight on said bit, and diameter of said drill bit, and wherein the step of revising said finite element model so as to reduce said difference between said measured and predicted vibration comprises adjusting the value of a plurality of operating parameter in said set of operating parameters so as to identify an adjustment that reduces said difference between said predicted and measured vibration below a predetermined threshold.

3. The method according to claim 2, wherein said plurality of operating parameters are adjusted one at a time so as to identify an adjustment that reduces said difference between said predicted and measured vibration below said predetermined threshold.

4. The method according to claim 2, wherein said plurality of operating parameters are adjusted by adjusting two or more parameters at a time so as to identify an adjustment that reduces said difference between said predicted and measured vibration below said predetermined threshold.

5. The method according to claim 1, wherein said first and second bore hole diameters are approximately equal.

6. The method according to claim 1, wherein the step of drilling said bore hole in step (h) comprises continuing drilling said bore hole drilled in step (a).

7. The method according to claim 1, wherein the step of using said finite element model of said drill string to predict vibration in step (e) comprises performing a forced response analysis by applying an oscillating weight on said drill bit.

8. The method according to claim 1, wherein said finite element model of said drill string used to predict vibration in step (e) is based upon a forced response analysis performed by applying an oscillating weight on said drill bit.

9. A method of monitoring the operation of a drill string drilling into an earthen formation so as to form a bore hole using a drill bit, comprising the steps of:

a) operating said drill string at a first set of operating parameters, said first set of operating parameters comprising the speed at which said drill bit rotates, said drill string experiencing vibration at first and second locations along said drill string when operating at said first set of operating parameters, said vibration at said first and second locations being characterized by amplitudes, the amplitudes of said vibration at said first and second locations being related by a relationship;

b) determining the values of said parameters in said first set of operating parameters;

c) inputting said determined values of said parameters in said first set of operating parameters into a finite element model of said drill string;

d) using said finite element model of said drill string with said inputted values of said parameters to determine at least a portion of the vibratory mode shape of said drill string when operating at said first set of operating parameters;

e) using said portion of said vibratory mode shape to determine said relationship between the amplitude of vibration at said first location to the amplitude of vibration at said second location when operating at said first set of operating parameters;

f) measuring the amplitude of vibration of said drill string at said second location when operating at said first set of operating parameters;

g) determining the amplitude of vibration of said drill string at said first location by applying to said measured vibration at said second location said relationship between the amplitude of vibration at said first location to said amplitude of vibration at said second location determined from said portion of said vibratory mode shape.

10. The method according to claim 9, wherein using said portion of said vibratory mode shape to determine said relationship between the amplitude of vibration at said first location to the amplitude of vibration at said second location comprises determining a ratio of said amplitude of vibration at said first location to said amplitude of vibration at said second location.

11. The method according to claim 10, wherein the step of applying to said measured vibration at said second location said relationship comprises multiplying said amplitude of vibration measured at said second location by said ratio.

12. The method according to claim 9, wherein the step of using said finite element model of said drill string to determine at least a portion of said vibratory mode shape in step (d) comprises performing a forced response analysis by applying an oscillating weight on said drill bit.

13. The method according to claim 9, wherein said finite element model of said drill string used to determine at least a portion of said vibratory mode shape in step (d) is based upon a forced response analysis performed by applying an oscillating weight on said drill bit.

14. A non-transitory computer-readable storage medium having stored thereon computer-executable instructions for a method of monitoring the operation of a drill string drilling into an earthen formation so as to form a bore hole using a drill bit, the method comprising the steps of:

a) determining the values of the parameters in a first set of operating parameters at which said drill string is operating, said drill string experiencing vibration at first and second locations along said drill string when operating at said first set of operating parameters, said vibration at said first and second locations being characterized by amplitudes, the amplitudes of said vibration at said first and second locations being related by a relationship;

b) inputting said determined values of said parameters in said first set of operating parameters into a finite element model of said drill string;

c) using said finite element model of said drill string with said inputted values of said parameters to determine at least a portion of the vibratory mode shape of said drill string when operating at said first set of operating parameters;

d) using said portion of said vibratory mode shape to determine said relationship between the amplitude of vibration at said first location to the amplitude of vibration at said second location when operating at said first set of operating parameters;

e) measuring the amplitude of vibration of said drill string at said second location when operating at said first set of operating parameters;

f) determining the amplitude of vibration of said drill string at said first location by applying to said measured vibration at said second location said relationship between the amplitude of vibration at said first location to said amplitude of vibration at said second location determined from said portion of said vibratory mode shape.

15. The non-transitory computer-readable storage medium according to claim 14, wherein the step in the method of using said finite element model of said drill string to determine at least a portion of said vibratory mode shape in step (c) comprises performing a forced response analysis by applying an oscillating weight on said drill bit.

16. The non-transitory computer-readable storage medium according to claim 14, wherein said finite element model of said drill string used to determine at least a portion of said vibratory mode shape in step (c) is based upon a forced response analysis performed by applying an oscillating weight on said drill bit.

17. A method of monitoring the operation of a drill string drilling into an earthen formation so as to form a bore hole using a drill bit, comprising the steps of:

a) applying a torque to said drill string at a location proximate the surface of the earth so as to rotate said drill string, said application of torque at said location proximate the surface resulting in torque being experienced at first and second locations along said drill string between said drill bit and said location at which said torque is applied proximate the surface, said torque at said first and second locations being related by a relationship, said drill string undergoing angular deflections at said first and second locations;

b) determining the values of parameters in a first set of operating parameters associated with said rotation of said drill string;

c) inputting said determined values of said parameters in said first set of operating parameters into a finite element model of said drill string;

d) using said finite element model of said drill string with said inputted values of said parameters to determine said angular deflections in said drill string at at least said first and second locations along the length of said drill string when operating at said first set of operating parameters;

e) using said angular deflections at said first and second locations along said drill string to determine said relationship between said torque on said drill string at said first and second locations;

f) measuring said torque on said drill string at said second location when operating at said first set of operating parameters;

g) determining said torque on said drill string at said first location by applying to said measured torque at said second location said relationship between said torque on said drill string at said first location to said torque on said drill string at said second location.

18. The method according to claim 17, wherein the step of using said finite element model of said drill string to determine said angular deflections in said drill string in step (d) comprises performing a forced response analysis by applying an oscillating weight on said drill bit.

19. The method according to claim 17, wherein said finite element model of said drill string used to determine said angular deflections in said drill string in step (d) is based upon a forced response analysis performed by applying an oscillating weight on said drill bit.

20. A method of monitoring the operation of a drill string having a drill bit drilling into an earthen formation, comprising the steps of:

a) determining a set of operating parameters for said drill string that will result in the maximum rate of penetration of said drill bit into said earthen formation;

b) inputting said set of operating parameters into a finite element model of said drill string; and

c) using said finite element model with said inputted set of operating parameters to predict the vibration in said drill string that will result from operation of said drill string according to said set of operating parameters;

wherein the step of using said finite element model to predict vibration in said drill string comprises performing a forced response analysis by applying an oscillating weight on said drill bit.

21. The method according to claim 20, wherein the step of determining said set of operating parameters that will result in the maximum rate of penetration comprises the step of operating said drill string at a plurality of sets of operating parameters and measuring the rate of penetration associated with each said set of operating parameters.

22. The method according to claim 20, wherein said set of operating parameters comprises the rotary speed of said drill string and the weight applied to said drill bit.

23. A method of monitoring the operation of a drill string having a drill bit drilling into an earthen formation, comprising the steps of:

a) obtaining a data base relating sets of operating parameters for said drill string to rates of penetration of said drill bit into said earthen formation when operating at said sets of operating parameters;

b) using a finite element model of said drill string to predict vibration in said drill string when operating at said sets of operating parameters; and

c) using said data base relating sets of operating parameters to rates of penetration and using said predictions of vibration to predict the maximum rate of penetration of said drill string into said earthen formation that will not result in the vibration in said drill string violating a predetermined criteria;

wherein the step of using said finite element model to predict vibration in said drill string comprises performing a forced response analysis by applying an oscillating weight on said drill bit.

24. The method according to claim 23, wherein said predetermined criteria comprises a maximum amplitude of vibration for at least a portion of said drill string.

25. The method according to claim 23, wherein said predetermined criteria comprises said drill string not operating at a rotary speed that results in resonant vibration of said drill string.