System and methods for real-time wellbore stability service

• US 8,818,779 B2
• Filed: 12/21/2010
• Issued: 08/26/2014
• Est. Priority Date: 12/21/2009
• Status: Active Grant

• Current Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Sadlier, Andreas G., Dwyer, James Peter, Brudy, Martin O., Wolfe, Christopher A., Reese, Michael M.
• Primary Examiner(s): Jacob, Mary C
• Application Number:
  US12/974,759
• Publication Number:
  US 20110153296A1
• Time in Patent Office: 1,344 Days
• Field of Search: 703/7, 703/10
• US Class Current: 703/10
• 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

Abstract

Apparatus and method of conducting a drilling operation are provided. One embodiment of the method includes drilling a borehole, predicting a value of a first parameter relating to the drilling of the borehole using a geomechanical model, estimating a value of a second parameter from measurements taken by a sensor, updating the geomechanical model based at least in part on the estimated value of the second parameter, predicting a second value of the first parameter using the updated geomechanical model, and altering a drilling parameter for drilling the borehole based on the predicted second value of the first parameter.

Claims

1. A method of conducting a drilling operation, comprising:

drilling a borehole;

predicting a value of a first parameter relating to the drilling of the borehole using a Geomechanical Model;

estimating a value of a second parameter from measurements taken by a sensor; and

using a processor to control the drilling operation by;

updating the Geomechanical Model based at least in part on the estimated value of the second parameter,

predicting in real time a second value of the first parameter using the updated Geomechanical Model, and

altering a drilling parameter for drilling the borehole based on the predicted second value of the first parameter to reduce a tendency of a drill bit to drift in a direction of a minimum horizontal principal stress.

2. The method of claim 1 wherein the first parameter is a mud window.

3. The method of claim 1 wherein the second parameter is selected from a group consisting of a:

(i) formation permeability, (ii) formation pore pressure, (iii) formation top, (iv) caliper image of the borehole, (v) resistivity image of the borehole, (vi) formation resistivity, (vii) formation acoustic response, and (viii) formation acoustic image.

4. The method of claim 1 wherein the geomechanical model is a pre-drill geomechanical model based at least in part on one of:

(i) surface seismic data, and (ii) well data from a previously drilled borehole.

5. The method of claim 1 wherein measurements are taken at one of:

(i) in the borehole, and (ii) a surface location.

6. The method of claim 1 wherein altering the drilling parameter comprises altering a parameter selected from a group consisting of a:

(i) drilling methodology;

(ii) drilling fluid program;

(iii) casing selection point; and

(iv) direction of drilling.

7. The method of claim 1 wherein the measurement taken by the sensor relate to at least one of:

(i) downhole mud pressure;

(ii) equivalent circulating density of a mud in the borehole;

(iii) detection of gas in the borehole;

(iv) morphology and volume of cuttings and savings at a surface location;

(v) torque;

(vi) drag;

(vii) pick-up weight;

(viii) slack-off weight;

(ix) mud motor stator temperature;

(x) differential pressure across a mud motor;

(xi) fluid flow rate through a mud motor;

(xii) acceleration;

(xiii) vibration;

(xiv) whirl;

(xv) radial displacement;

(xvi) stick-slip;

(xvii) strain;

(xviii) stress;

(xix) bending moment;

(xx) bit bounce;

(xxi) axial thrust, friction;

(xxii) backward rotation;

(xxiii) buckling;

(xxiv) radial thrust; and

(xxv) drilling event.

8. An apparatus configured to conduct a drilling operation, the apparatus comprising:

a drill string for drilling a borehole;

a bottomhole assembly configured to be conveyed into a borehole on the drill string;

a sensor configured to make a measurement at one of;

(i) a downhole location, and (ii) a surface location; and

a processor configured to control the drilling operation by;

predicting a value of a first parameter relating to drilling of the borehole using a Geomechanical Model,

estimating a value of a second parameter from the measurement taken by the sensor,

updating the Geomechanical Model based at least in part on the estimated value of the second parameter,

predicting in real time a second value of the first parameter using the updated Geomechanical Model, and

altering a drilling parameter for drilling the borehole based on the predicted second value of the first parameter to reduce a tendency of a drill bit to drift in a direction of a minimum horizontal principal stress.

9. The apparatus of claim 8 wherein the first parameter is a mud window.

10. The apparatus of claim 8 wherein the Geomechanical Model further comprises a pre-drill Geomechanical Model based on at least one of:

(i) surface seismic data; and

(ii) well data from a previously drilled borehole.

11. The apparatus of claim 8 wherein the Geomechanical Model further comprises an updated Geomechanical Model derived from a pre-drill Geomechanical Model and the measurement made at one of:

(i) a downhole location; and

(ii) a surface location.

12. The apparatus of claim 8 wherein the at least one measurement further comprises a measurement made at a downhole location relating to at least one of:

(i) formation permeability;

(ii) formation pore pressure;

(iii) formation top;

(iv) caliper image of the borehole;

(v) resistivity image of the borehole;

(vi) formation resistivity;

(vii) formation acoustic response; and

(viii) formation acoustic image.

13. The apparatus of claim 8 wherein the drilling parameter is selected from a group consisting of a:

(i) drilling methodology;

(ii) drilling fluid program;

(iii) casing selection point; and

(iv) direction of drilling.

14. The apparatus of claim 8 wherein the processor is further configured to provide a signal when the measurement made by the sensor is outside a selected norm.

15. The apparatus of claim 14 wherein the signal relates to one of:

(i) a downhole mud pressure;

(ii) an Equivalent Circulating Density of a mud in the borehole;

(iii) a detection of gas in the borehole;

(iv) morphology and volume of cuttings and cavings;

(v) a torque measurement;

(vi) a drag measurement;

(vii) a pick-up weight;

(viii) a slack-off weight;

(ix) a mud motor stator temperature;

(x) a differential pressure across a mud motor;

(xi) fluid flow rate through a mud motor;

(xii) a measurement of acceleration;

(xiii) a measurement of a vibration;

(xiv) a measurement of whirl;

(xv) a measurement of radial displacement;

(xvi) a measurement of stick-slip;

(xvii) a measurement of strain;

(xviii) a measurement of stress;

(xix) a measurement of bending moment;

(xx) a measurement of bit bounce;

(xxi) a measurement of axial thrust, friction;

(xxii) a measurement of backward rotation;

(xxiii) a measurement of BHA buckling;

(xxiv) a measurement of radial thrust; and

(xxv) a catalog of drilling events.

16. A non-transitory computer-readable medium having stored thereon instructions that when executed by a processor enable the processor to perform a method for drilling a borehole, the method comprising:

predicting a value of a first parameter relating to the drilling of the borehole using a Geomechanical Model;

estimating a value of a second parameter from measurements taken by a sensor; and

controlling the drilling operation by;

updating the Geomechanical Model based at least in part on the estimated value of the second parameter,

predicting a second value of the first parameter using the updated Geomechanical Model, and

altering a drilling parameter for drilling the borehole based on the predicted second value of the first parameter to reduce a tendency of a drill bit to drift in a direction of a minimum horizontal principal stress.

17. The non-transitory computer readable medium of claim 16 wherein the first parameter is a mud window.

18. The non-transitory computer-readable medium of claim 16 wherein the Geomechanical Model comprises a pre-drill Geomechanical Model based on at least one of:

(i) surface seismic data, and (ii) well data from a previously drilled borehole.

19. The non-transitory computer-readable medium of claim 16 wherein the measurement made by the sensor comprises a measurement made at a downhole location selected from:

(i) a formation permeability, (ii) a formation pore pressure, (iii) a formation top, (iv) a caliper image of the borehole, (v) a resistivity image of the borehole, (vi) a formation resistivity, (vii) a formation acoustic response, and (viii) a formation acoustic image.

20. The non-transitory computer-readable medium of claim 16 wherein the drilling parameter is selected from a group consisting of a:

(i) drilling methodology, (ii) drilling fluid program, (iii) casing selection point, and (iv) direction of drilling.

21. A method of conducting a drilling operation, comprising:

conveying a drilling assembly for conducting the drilling operation into a borehole, the drilling assembly including a sensor configured to make a measurement relating to a selected parameter;

making the measurement by the sensor and estimating a value of the selected parameter using the sensor measurement; and

using a processor to control the drilling operation by;

predicting a value of the selected parameter using a Geomechanical Model,

comparing the estimated value of the selected parameter and the predicted value of the selected parameter, and

altering a parameter relating to the drilling operation based at least in part on comparing the estimated value and the predicted value of the selected parameter to reduce a tendency of a drill bit to drift in a direction of a minimum horizontal principal stress.