System and method for estimating remaining useful life of a downhole tool

• US 8,825,414 B2
• Filed: 07/12/2011
• Issued: 09/02/2014
• Est. Priority Date: 07/14/2010
• Status: Expired due to Fees

• Current Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Garvey, Dustin R., Baumann, Joerg, Lehr, Joerg, Hummes, Olof, John, Martin
• Primary Examiner(s): Charioui, Mohamed
• Assistant Examiner(s): KUAN, JOHN CHUNYANG
• Application Number:
  US13/180,959
• Publication Number:
  US 20120089336A1
• Time in Patent Office: 1,148 Days
• Field of Search: 702/6, 702/9, 702/34, 702/176, 702/179
• US Class Current: 702/34
• CPC Class Codes: E21B 47/00 Survey of boreholes or wells monitoring pressure or flow of drilling fluid E21B21/08

Abstract

A system for determining the amount of life consumed for a tool includes at least one sensor associated with the tool for generating observation data, a memory in operable communication with the at least one sensor, the memory including a database for storing the observation data generated by the sensor, and a processor in operable communication with the memory. The processor includes a model generator that generates a current model for a current run of the tool. The current model includes parameters of a functional approximation of the observation data. The processor also includes a classifier that classifies the current model and a current run estimator that determine the amount of life consumed based on the classification of the current model and a time of use associated with the current run.

Claims

1. A system for determining an amount of life consumed for a tool, the system comprising:

at least one sensor associated with the tool for generating observation data;

a memory in operable communication with the at least one sensor, the memory including a database for storing the observation data generated by the at least one sensor; and

a processor in operable communication with the memory, the processor including;

a model generator that generates a current model having a failure time for a current run of the tool, the current model including parameters of a functional approximation of the observation data;

a classifier that classifies the current model;

a current run estimator that determines the amount of life consumed based on the classification of the current model and a time of use associated with the current run by dividing the time of use by the failure time of the current model; and

a total lifetime calculator that adds the amount of life consumed by the current run to a running total of life consumed by prior runs of the tool to produce a total life consumed.

2. The system of claim 1, wherein the observation data include an amount of time the tool was exposed to a particular condition.

3. The system of claim 2, wherein the particular condition is experienced in a borehole penetrating the earth.

4. The system of claim 1, wherein the functional approximation of the observation data is a function that defines a degradation curve of the current run and is based on the parameters.

5. The system of claim 4, wherein the current model includes an amount of time the tool was operated.

6. The system of claim 1, further comprising:

a usage store that stores the running total of life consumed.

7. The system of claim 1, wherein the tool is a drilling tool.

8. The system of claim 1, wherein the sensor is part of a bottom hole assembly.