System and method for remotely controlled surface steerable drilling

• US 9,404,356 B2
• Filed: 10/13/2015
• Issued: 08/02/2016
• Est. Priority Date: 12/22/2011
• Status: Active Grant

• Current Assignee: Motive Drilling Technologies Inc. (Helmerich & Payne Incorporated)
• Original Assignee: Motive Drilling Technologies Inc. (Helmerich & Payne Incorporated)
• Inventors: Benson, Todd W., Chen, Teddy
• Primary Examiner(s): Stephenson, Daniel P
• Application Number:
  US14/882,079
• Publication Number:
  US 20160032705A1
• Time in Patent Office: 294 Days
• US Class Current: 1/1
• 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 44/02 Automatic control of the tool feed E21B44/005, E21B44/10 take precedence
• CPC Class Codes: E21B 47/024 of devices in the borehole determining slope or direction of the borehole E21B47/022
• CPC Class Codes: E21B 7/04 Directional drilling
• CPC Class Codes: E21B 7/10 Correction of deflected boreholes
• CPC Class Codes: G05B 15/02 electric

Abstract

A system and method for surface steerable drilling are provided. In one example, the system receives feedback information from a drilling rig and calculates an estimated position of a drill bit in a formation based on the feedback information. The system compares the estimated position to a desired position along a planned path of a borehole. The system calculates multiple solutions if the comparison indicates that the estimated position is outside a defined margin of error relative to the desired position. Each solution defines a path from the estimated position to the planned path. The system calculates a cost of each solution and selects one of the solutions based at least partly on the cost. The system produces control information representing the selected solution and outputs the control information for the drilling rig.

Claims

1. A method for identifying potential issues while drilling comprising:

monitoring, by a surface steerable system located remotely at a location separate from a drilling rig, a plurality of operating parameters for drilling rig equipment that is part of the drilling rig and bottom hole assembly (BHA) equipment for a BHA coupled to the drilling rig and positioned in a borehole that is being drilled, wherein the operating parameters control the drilling rig equipment and the BHA equipment;

receiving, by the surface steerable system located remotely at the location separate from the drilling rig, a plurality of current inputs corresponding to performance data of the drilling rig equipment and the BHA equipment during a drilling operation of the borehole;

determining, by the surface steerable system located remotely at the location separate from the drilling rig, that an amount of change between any of the plurality of current inputs and a corresponding plurality of previously received inputs exceeds a defined threshold;

determining, by the surface steerable system located remotely at the location separate from the drilling rig, whether a modification to the operating parameters has occurred that would result in the amount of change between the plurality of current inputs and the corresponding plurality of previously received inputs exceeding the defined threshold;

identifying, by the surface steerable system located remotely at the location separate from the drilling rig, that a failure has potentially occurred in at least one of the drilling rig equipment and the BHA equipment if no modification has occurred to the operating parameters; and

performing, by the surface steerable system located remotely at the location separate from the drilling rig, a defined action if the failure has potentially occurred, wherein the defined action includes activating additional monitoring that includes performing the monitoring more frequently and performing the monitoring at a higher level of detail.

2. The method of claim 1 wherein performing the defined action includes causing, by the surface steerable system, an alteration to the operating parameters, wherein the alteration to the operating parameters modifies the drilling operation to address a failure.

3. The method of claim 1 wherein the performance data includes a rate of penetration (ROP) and the amount of change is an amount of change in the ROP.

4. The method of claim 1 wherein the performance data includes a build rate and the amount of change is an amount of change in the build rate.

5. The method of claim 1 wherein the performance data includes a directional heading of the BHA and the amount of change is an amount of change in the directional heading.

6. The method of claim 1 further comprising processing, by the surface steerable system located remotely at the location separate from the drilling rig, the plurality of inputs to obtain the performance data.

7. The method of claim 6 wherein the processing includes:

extracting the performance data from the plurality of inputs; and

normalizing the performance data.

8. The method of claim 7 wherein determining that the amount of change exceeds the defined threshold includes comparing the normalized performance data to a set of ideal performance data.

9. The method of claim 8 wherein the ideal performance data includes additional performance data obtained from drilling rig equipment and BHA equipment while drilling a plurality of other boreholes.

10. The method of claim 9 further comprising retrieving, by the surface steerable system located remotely at the location separate from the drilling rig, the ideal performance data from a remote database.

11. The method of claim 10 further comprising searching, by the surface steerable system located remotely at the location separate from the drilling rig, located remotely at the location separate from the drilling rig the ideal performance data within the remote database to identify ideal performance data collected from other boreholes located in a region in which the borehole is located.

12. The method of claim 1 further comprising:

monitoring, by the surface steerable system located remotely at the location separate from the drilling rig, the plurality of current inputs and the corresponding plurality of previously received inputs to identify the occurrence of a pattern of specifically defined conditions, wherein the pattern indicates a potential future failure with one of the drilling rig equipment and the BHA equipment; and

determining, by the surface steerable system located remotely at the location separate from the drilling rig, how to address the potential future failure if the pattern is identified as occurring.

13. The method of claim 1 further comprising uploading, by the surface steerable system located remotely at the location separate from the drilling rig, information about the operating parameters, the plurality of current inputs, the corresponding plurality of previously received inputs, and the problem to a remote system.

14. The method of claim 1 wherein performing the defined action if the failure exists includes:

identifying one of a plurality of contacts as available at the time the failure is identified; and

sending an alert to notify the available contact of the problem.

15. A method for identifying potential issues while drilling comprising:

monitoring, by a surface steerable system located remotely at a location separate from a drilling rig, a plurality of operating parameters for drilling rig equipment that is part of the drilling rig and bottom hole assembly (BHA) equipment for a BHA coupled to the drilling rig and positioned in a borehole that is being drilled for a plurality of drilling locations, wherein the operating parameters control the drilling rig equipment and the BHA equipment at each of the plurality of drilling locations;

receiving, by the surface steerable system located remotely at the location separate from the drilling rig, a plurality of current inputs corresponding to performance data of the drilling rig equipment and the BHA equipment during a drilling operation of the borehole at each of the plurality of drilling locations;

determining, by the surface steerable system located remotely at the location separate from the drilling rig, that an amount of change between any of the plurality of current inputs and a corresponding plurality of previously received inputs exceeds a defined threshold;

determining, by the surface steerable system located remotely at the location separate from the drilling rig, whether a modification to the operating parameters has occurred that would result in the amount of change between the plurality of current inputs and the corresponding plurality of previously received inputs exceeding the defined threshold;

identifying, by the surface steerable system located remotely at the location separate from the drilling rig, that a failure has potentially occurred in at least one of the drilling rig equipment and the BHA equipment located at one of the plurality of drilling locations if no modification has occurred to the operating parameters; and

performing, by the surface steerable system located remotely at the location separate from the drilling rig, a defined action if the failure has potentially occurred, wherein the defined action includes activating additional monitoring that includes performing the monitoring more frequently and performing the monitoring at a higher level of detail for at least one of the plurality of drilling locations.

16. The method of claim 15 wherein performing the defined action includes causing, by the surface steerable system, an alteration to the operating parameters for at least one of the plurality of drilling locations, wherein the alteration to the operating parameters modifies the drilling operation to address the failure.

17. The method of claim 15 wherein the performance data includes a rate of penetration (ROP) and the amount of change is an amount of change in the ROP.

18. The method of claim 15 wherein the performance data includes a build rate and the amount of change is an amount of change in the build rate.

19. The method of claim 15 wherein the performance data includes a directional heading of the BHA and the amount of change is an amount of change in the directional heading for at least one of the plurality of drilling locations.

20. The method of claim 15 further comprising processing, by the surface steerable system located remotely at the location separate from the drilling rig, the plurality of inputs to obtain the performance data.

21. The method of claim 20 wherein the processing includes:

extracting the performance data from the plurality of inputs; and

normalizing the performance data.

22. The method of claim 21 wherein determining that the amount of change exceeds the defined threshold includes comparing the normalized performance data to a set of ideal performance data.

23. The method of claim 22 further comprising retrieving, by the surface steerable system located remotely at the location separate from the drilling rig, the ideal performance data from a remote database.

24. The method of claim 23 further comprising searching, by the surface steerable system located remotely at the location separate from the drilling rig, the ideal performance data within the remote database to identify ideal performance data collected from at least one of the plurality of drilling locations.

25. The method of claim 15 further comprising:

monitoring, by the surface steerable system located remotely at the location separate from the drilling rig, the plurality of current inputs and the corresponding plurality of previously received inputs to identify the occurrence of a pattern of specifically defined conditions in at least one of the plurality of drilling locations, wherein the pattern indicates a potential future failure with one of the drilling rig equipment and the BHA equipment; and

determining, by the surface steerable system located remotely at the location separate from the drilling rig, how to address the potential future failure if the pattern is identified as occurring in one of the plurality of drilling locations.

26. The method of claim 15 further comprising uploading, by the surface steerable system located remotely at the location separate from the drilling rig, information about the operating parameters, the plurality of current inputs, the corresponding plurality of previously received inputs, and the problem to a remote system.

27. The method of claim 15 wherein performing the defined action if the failure exists includes:

identifying one of a plurality of contacts as available at the time the failure is identified; and

sending an alert to notify the available contact of the problem.