Method and apparatus to improve design, manufacture, performance and/or use of well tools

• US 8,738,342 B2
• Filed: 02/11/2013
• Issued: 05/27/2014
• Est. Priority Date: 12/05/2007
• Status: Expired due to Fees

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Lind, William H., Glass, Kevin L.
• Primary Examiner(s): JONES, HUGH M
• Application Number:
  US13/764,582
• Publication Number:
  US 20130218528A1
• Time in Patent Office: 470 Days
• Field of Search: 703/10
• US Class Current: 703/10
• CPC Class Codes: E21B 41/00 Equipment or details not covered by groups E21B15/00 - E21B40/00
• CPC Class Codes: G06G 7/48 Analogue computers for specific processes, systems or devices, e.g. simulators
• CPC Class Codes: G06T 19/00 Manipulating 3D models or images for computer graphics

Abstract

Methods and systems are provided to improve design, manufacture and performance of oilfield equipment and well tools using three dimensional (3D) scanning technology and one or more feedback loops. Manufacturing processes and techniques associated with a well tool may be evaluated based on comparing “as built” 3D data with a design data file for the well tool. Based on differences between “as built” 3D data and the design data file, one or more changes in associated manufacturing procedures and/or techniques may be made. Computational fluid dynamic applications may be used to simulate fluid flow characteristics of a well tool using associated design data file, “as built” 3D data and/or after use 3D data. The associated design data file, manufacturing procedures and/or procedures for use of the well tool may be modified based on comparing simulated fluid flow data with desired fluid flow characteristics for the well tool.

Claims

1. A method to improve design, manufacture, performance and/or use of a well tool comprising:

scanning a well tool with a three dimensional (3D) scanning system to obtain a 3D image of the well tool as manufactured;

converting the 3D image of the well tool into an as built 3D data file;

comparing the as built 3D data file with an initial design 3D data file for the well tool;

evaluating a variation between the initial design 3D data file and the as built 3D data file; and

modifying a design parameter or a manufacturing procedure associated with the well tool based on the variation between the initial design 3D data file and the as built 3D data file.

2. The method of claim 1, further comprising:

conducting a computational flow data simulation of the well tool based on the as built 3D data file; and

modifying the design parameter or the manufacturing procedure associated with the well tool based on the computational flow data simulation.

3. The method of claim 1, further comprising:

conducting a first computational flow data simulation of the well tool based on the initial design 3D data file;

conducting a second computational flow data simulation based on the as built 3D data file;

evaluating a variation between the first computational flow data simulation and the second computational flow data simulation; and

modifying the design parameter or the manufacturing procedure associated with the well tool based on the variation between the first computational flow data simulation and the second computational flow data simulation.

4. The method of claim 1, further comprising:

scanning a used well tool with the 3D scanning system to obtain a 3D image of the used well tool after use at a well site;

converting the 3D image of the used well tool into an after use 3D data file;

comparing the after use 3D data file with the as built 3D data file;

evaluating a variation between the after use 3D data file and the as built 3D data file; and

modifying the design parameter or the manufacturing procedure associated with the well tool or an operating parameter associated with the used well tool based on the variation between the after use 3D data file and the as built 3D data file.

5. The method of claim 1, further comprising:

scanning a used well tool with the 3D scanning system to obtain a 3D image of the used well tool after use at a well site;

converting the 3D image of the used well tool into an after use 3D data file;

comparing the after use 3D data file with the as built 3D data file for the well tool;

evaluating a variation between the as built 3D data file and the after use 3D data file;

determining an amount of at least one of abrasion, erosion and wear of cutting structures associated with the used well tool based on the variation between the after use 3D data file and the as built 3D data file; and

converting the amount of at least one of abrasion, erosion and wear of the cutting structures into a corresponding IADC drill bit grade.

6. The method of claim 1, wherein modifying the manufacturing procedure comprises modifying a mold associated with manufacturing the well tool based on the variation between the initial design 3D data file and the as built 3D data file.

7. The method of claim 1, wherein modifying the manufacturing procedure comprises modifying at least one of tooling and fixtures associated with manufacturing the well tool based on the variation between the initial design 3D data file and the as built 3D data file.

8. The method of claim 1, further comprising:

scanning a used well tool with the 3D scanning system operable to obtain a 3D image of the well tool after use at a well site;

converting the 3D image of the used well tool into an after use 3D data file;

comparing the after use 3D data file with the initial design 3D data file for the well tool;

measuring and quantifying at least one of abrasion, erosion and wear of the used well tool; and

modifying at least one of the design parameter or the manufacturing procedure associated with the well tool and an operating parameter associated with the used well tool based on the at least one of abrasion, erosion and wear of the used well tool.

9. The method of claim 1, further comprising:

scanning a used well tool with the 3D scanning system to obtain a 3D image of the used well tool after use at a well site;

converting the 3D image of the used well tool into an after use 3D data file;

comparing the after use 3D data file with the initial design 3D data file for the well tool;

evaluating a variation between the after use 3D data file and the initial design 3D data file; and

modifying at least one of the design parameter or the manufacturing procedure associated with the well tool and an operating parameter associated with the used well tool based on the variation between the after use 3D data file and the initial design 3D data file.

10. A system operable to improve design, manufacture, performance and/or use of a well tool comprising:

a three dimensional (3D) scanning system operable to scan a well tool to obtain a three dimensional (3D) image of the well tool as manufactured; and

a computer communicatively coupled to the 3D scanning system, the computer including a processor communicatively coupled to a computer readable memory having processing instructions encoded thereon and, when executed by the processor, the processing instructions operable to perform operations comprising;

receiving the 3D image of the manufactured well tool from the 3D scanning system;

converting the 3D image of the manufactured well tool into an as built 3D data file;

comparing the as built 3D data file with an initial design 3D data file for the well tool;

evaluating a variation between the initial design 3D data file and the as built 3D data file; and

determining a modification to a design parameter or a manufacturing procedure associated with the well tool based on the variation between the initial design 3D data file and the as built 3D data file.

11. The system of claim 10, wherein the processing instructions are further operable to perform operations comprising:

conducting a computational flow data simulation of the well tool based on the as built 3D data file; and

determining the modification to the design parameter or the manufacturing procedure associated with the well tool based on the computational flow data simulation.

12. The system of claim 10, wherein the processing instructions are further operable to perform operations comprising:

conducting a first computational flow data simulation of the well tool based on the initial design 3D data file;

conducting a second computational flow data simulation based on the as built 3D data file;

evaluating a variation between the first computational flow data simulation and the second computational flow data simulation; and

determining the modification to the design parameter or the manufacturing procedure associated with the well tool based on the variation between the first computational flow data simulation and the second computational flow data simulation.

13. The system of claim 10, wherein:

the 3D scanning system is further operable to scan a used well tool to obtain a 3D image of the used well tool after use at a well site; and

the processing instructions further operable to perform operations comprising;

receiving the 3D image of the used well tool from the 3D scanning system;

converting the 3D image of the used well tool into an after use 3D data file;

comparing the after use 3D data file with the as built 3D data file for the well tool;

evaluating a variation between the after use 3D data file and the as built 3D data file; and

determining the modification to the design parameter or the manufacturing procedure associated with the well tool or an operating parameter associated with the used well tool based on the variation between the after use 3D data file and the as built 3D data file.

14. The system of claim 10, wherein:

the 3D scanning system is further operable to scan a used well tool to obtain a 3D image of the used well tool after use at a well site; and

the processing instructions further operable to perform operations comprising;

receiving the 3D image of the used well tool from the 3D scanning system;

converting the 3D image of the used well tool into an after use 3D data file;

comparing the after use 3D data file with the as built 3D data file for the well tool;

evaluating a variation between the as built 3D data file and the after use 3D data file;

determining an amount of at least one of abrasion, erosion and wear of cutting structures associated with the used well tool based on the variation between the after use 3D data file and the as built 3D data file; and

converting the amount of at least one of abrasion, erosion and wear of the cutting structures into a corresponding IADC drill bit grade.

15. The system of claim 10, wherein:

the 3D scanning system is further operable to scan a used well tool to obtain a 3D image of the used well tool after use at a well site; and

the processing instructions further operable to perform operations comprising;

receiving the 3D image of the used well tool from the 3D scanning system;

converting the 3D image of the used well tool into an after use 3D data file;

comparing the after use 3D data file with the initial design 3D data file for the well tool;

measuring and quantifying at least one of abrasion, erosion and wear of the used well tool; and

determining the modification to the design parameter or the manufacturing procedure associated with the well tool or an operating parameter associated with the used well tool based on the at least one of abrasion, erosion and wear of the well tool.

16. The system of claim 10, wherein:

the 3D scanning system is further operable to scan a used well tool to obtain a 3D image of the used well tool after use at a well site; and

the processing instructions further operable to perform operations comprising;

receiving the 3D image of the used well tool from the 3D scanning system;

converting the 3D image of the used well tool into an after use 3D data file;

comparing the after use 3D data file with the initial design 3D data file for the well tool;

evaluating a variation between the after use 3D data file and the initial design 3D data file;

determining the modification to the design parameter or the manufacturing procedure associated with the well tool or an operating parameter associated with the used well tool based on the variation between the after use 3D data file and the initial design 3D data file.

17. The system of claim 10, wherein the 3D scanning system comprises a 3D white light scanning system.