System and method for surface steerable drilling

• US 9,494,030 B2
• Filed: 06/25/2014
• Issued: 11/15/2016
• 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 C.
• Primary Examiner(s): MICHENER, BLAKE E
• Application Number:
  US14/314,697
• Publication Number:
  US 20140305704A1
• Time in Patent Office: 874 Days
• Field of Search: 175/10, 175/24, 175/26, 175/40, 175/50, 175/61, 175/62, 702/9, 703/10
• US Class Current: 1/1
• CPC Class Codes: E21B 19/165 Control or monitoring arrangements therefor
• 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 45/00 Measuring the drilling time or rate of penetration
• CPC Class Codes: E21B 47/00 Survey of boreholes or wells monitoring pressure or flow of drilling fluid E21B21/08
• CPC Class Codes: E21B 47/02 Determining slope or direction
• CPC Class Codes: E21B 47/024 of devices in the borehole determining slope or direction of the borehole E21B47/022
• CPC Class Codes: E21B 47/047 Liquid level measuring depth or liquid level using radioactive markers E21B47/053
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: E21B 47/09 Locating or determining the position of objects in boreholes or wells , e.g. the position of an extending arm; Identifying the free or blocked portions of pipes
• CPC Class Codes: E21B 47/10 Locating fluid leaks, intrusions or movements
• CPC Class Codes: E21B 47/12 Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
• CPC Class Codes: E21B 7/04 Directional drilling

Abstract

A system and method for surface steerable drilling are provided. In one example, the method includes monitoring operating parameters for drilling rig equipment and bottom hole assembly (BHA) equipment for a BHA, where the operating parameters control the drilling rig equipment and BHA equipment. The method includes receiving current inputs corresponding to performance data of the drilling rig equipment and BHA equipment during a drilling operation and determining that an amount of change between the current inputs and corresponding previously received inputs exceeds a defined threshold. The method further includes determining whether a modification to the operating parameters has occurred that would result in the amount of change exceeding the defined threshold and identifying that a problem exists in at least one of the drilling rig equipment and BHA equipment if no modification has occurred to the operating parameters. The method includes performing a defined action if a problem exists.

Claims

1. A method for dynamically predicting a drilling build rate during drilling of a borehole, comprising:

monitoring, by a surface steerable system coupled to a drilling rig, a plurality of bottom hole assembly (BHA) parameters and surrounding geological environment parameters that change the drilling build rate;

receiving, by the surface steerable system, a plurality of current inputs for the bottom hole assembly (BHA) parameters and the surrounding geological environment parameters that change the drilling build rate;

determining, by the surface steerable system, a current drilling build rate responsive to the plurality of the BHA parameters and the surrounding geological environment parameters that change the drilling build rate;

determining, by the surface steerable system, an angle of attack of a BHA to a formation transition when passing through the formation transition from a first layer to a second layer responsive to the plurality of BHA parameters and a first material comprising the first layer and a second material comprising the second layer;

predicting a future drilling build rate responsive to the plurality of BHA parameters and the surrounding geological environment parameters that change the drilling build rate and the determined angle of attack when the BHA passes through the formation transition from the first layer to the second layer; and

controlling and predicting slides for the BHA using the surface steerable system responsive to the predicted future drilling build rate that is responsive to the determined angle of attack when the BHA passes through the formation transition from the first layer to the second layer.

2. The method of claim 1, wherein the step of predicting further includes determining the future build rate based on an orientation of the BHA within a formation layer.

3. The method of claim 1, wherein the step of determining the angle of attack further comprises determining the angle of attack based on an orientation of the BHA to account for the formation transition.

4. The method of claim 1, wherein the step of determining further comprises the step of determining the current drilling building rate responsive to a grain of the formation.

5. The method of claim 1, wherein the plurality of BHA parameters further comprises at least one of drill bit parameters, mud motor bend settings, stabilization and mud motor bit to bend distance.

6. The method of claim 1, wherein the plurality of surrounding geological environment parameters that change the drilling build rate further comprises at least one of formation compressive strength and formation thickness.

7. The method of claim 1 further comprising:

comparing, by the surface steerable system, the determined current drilling build rate to previously determined build rates; and

further wherein the step of predicting is further based on the results of the comparison of the determined current drilling build rate with the previously determined build rates.

8. The method of claim 7 further including the step of determining, by the surface steerable system, a rate of penetration (ROP) of the BHA responsive to the plurality of BHA parameters and the surrounding geological environment parameters.

9. A method for dynamically predicting a drilling build rate during drilling of a borehole, comprising:

monitoring, by a surface steerable system coupled to a drilling rig, a plurality of bottom hole assembly (BHA) parameters and surrounding geological environment parameters that change the drilling build rate;

receiving, by the surface steerable system, a plurality of current inputs for the plurality of bottom hole assembly (BHA) parameters and the surrounding geological environment parameters that change the drilling build rate;

determining, by the surface steerable system, a current drilling build rate responsive to the plurality of BHA parameters and the surrounding geological environment parameters that change the drilling build rate;

comparing, by the surface steerable system, the determined current drilling build rate to previously predicted build rates based on calculation based predictions;

updating the calculation based predictions based on the comparison;

determining, by the surface steerable system, an angle of attack of a BHA to a formation transition when passing through the formation transition from a first layer to a second layer responsive to the plurality of BHA parameters and a first material comprising the first layer and a second material comprising the second layer;

predicting a future drilling rate responsive to the plurality of BHA parameters, the surrounding geological environment parameters that change the drilling build rate and the updated calculation based predictions parameters and the determined angle of attack when the BHA passes through the formation transition from the first layer to the second layer; and

controlling and predicting slides for the BHA using the surface steerable system responsive to the predicted future drilling build rate that is responsive to the determined angle of attack when the BHA passes through the formation transition from the first layer to the second layer.

10. The method of claim 9, wherein the step of predicting further includes determining the future rate based on an orientation of the BHA within a formation layer.

11. The method of claim 9, wherein the step of determining the angle of attack further comprises determining the angle of attack based on an orientation of the BHA to account for the formation transition.

12. The method of claim 9, wherein the step of determining further comprises the step of determining the current drilling build rate responsive to a grain of the formation.

13. The method of claim 9, wherein the plurality of BHA parameters further comprises at least one of drill bit parameters, mud motor bend settings, and mud motor bit to bend distance.

14. The method of claim 9, wherein the plurality of surrounding geological environment parameters that change the drilling build rate further comprises at least one of formation compressive strength and formation thickness.

15. The method of claim 9 further including the step of determining, by the surface steerable system, a rate of penetration (ROP) of the BHA responsive to the plurality of BHA parameters and the surrounding geological environment parameters.

16. A surface steerable system for use with a drilling rig, comprising:

a network interface;

a processor coupled to the network interface;

a memory coupled to the processor, the memory storing a plurality of instructions for execution by the processor, the plurality of instructions including;

instructions for monitoring a plurality of bottom hole assembly (BHA) parameters and a surrounding geological environment parameters that change a drilling build rate;

instructions for receiving a plurality of current inputs relating to the plurality bottom hole assembly (BHA) parameters and the surrounding geological environment parameters that change the drilling build rate;

instructions for determining a current drilling build rate responsive to the plurality of BHA parameters and the surrounding geological environment parameters that change the drilling build rate;

instructions for determining an angle of attack of a BHA to a formation transition when passing through the formation transition responsive to the plurality of BHA parameters and a first material comprising the first layer and the second material comprising a second layer;

instructions for predicting a future drilling build rate responsive to the plurality of BHA parameters and the surrounding geological environment parameters that change the drilling build rate and the determined angle of attack when the BHA passes through the formation transition; and

controlling and predicting slides for the BHA using the surface steerable system responsive to the predicted future drilling build rate that is responsive to the determined angle of attack when the BHA passes through the formation transition from the first layer to the second layer.

17. The surface steerable system of claim 16, wherein the step of predicting further includes determining the future build rate based on an orientation of the BHA within a formation layer.

18. The surface steerable system of claim 16 further including instructions for determining the angle of attack based on an orientation of the BHA to account for the formation transition.

19. The surface steerable system of claim 16, including instructions for determining the current drilling build rate responsive to a grain of the formation.

20. The surface steerable system of claim 16, wherein the plurality of BHA parameters further comprises at least one of drill bit parameters, mud motor bend settings, and mud motor bit to bend distance.

21. The surface steerable system of claim 16, wherein the plurality of surrounding geological environment parameters that change the drilling build rate further comprises at least one of formation compressive strength and formation thickness.

22. The surface steerable system of claim 16 further comprising:

instructions for comparing, by the surface steerable system, the determined current drilling build rate to previously determined build rates; and

instructions for predicting the future drilling build rate based on the results of the comparison of the determined current drilling build rate with the previously determined build rates.

23. The surface steerable system of claim 22 further including instructions for determining a rate of penetration (ROP) of the BHA responsive to the plurality of BHA parameters and the surrounding geological environment.

24. A surface steerable system for use with a drilling rig, comprising:

a network interface;

a processor coupled to the network interface;

a memory coupled to the processor, the memory storing a plurality of instructions for execution by the processor, the plurality of instructions including;

instructions for monitoring a plurality of bottom hole assembly (BHA) parameters and surrounding geological environment parameters that change a drilling build rate;

instructions for receiving a plurality of current inputs relating to the plurality of bottom hole assembly (BHA) parameters and the surrounding geological environment parameters that change the drilling build rate;

instructions for determining a current drilling build rate responsive to the plurality of BHA parameters and the surrounding geological environment parameters that change the drilling build rate;

instructions for comparing the determined current drilling build rate to previously predicted build rates based on calculation based predictions;

instructions for updating the calculation based predictions based on the comparison;

instructions for determining an angle of attack of a BHA to a formation transition when passing through the formation transition responsive to the plurality of BHA parameters and a first material comprising the first layer and a second material comprising the second layer;

instructions for predicting a future drilling build rate responsive to the plurality of BHA parameters, the surrounding geological environment parameters that change the drilling build rate and the updated calculation based predictions and the determined angle of attack when the BHA passes through the formation transition from the first layer to the second layer; and

instructions for controlling and prediction slides for the BHA using the surface steerable system responsive to the predicted future drilling bit rate that is responsive to the determined angle of attack when the BHA passes through the formation transition from the first layer to the second layer.

25. The surface steerable system of claim 24, wherein the plurality of BHA parameters further comprise at least one of drill bit parameters, mud motor bend settings, stabilization and mud motor bit to bend distance.

26. The surface steerable system of claim 24, wherein the plurality of surrounding geological environment parameters that change the drilling build rate further comprises at least one of formation compressive strength formation thickness.

27. The surface steerable system of claim 24 further including the step of determining, by the surface steerable system, a rate of penetration (ROP) of the BHA responsive to the plurality of BHA parameters and the surrounding geological environment parameters.