System and method for monitoring and controlling underground drilling

• US 9,696,198 B2
• Filed: 02/21/2014
• Issued: 07/04/2017
• Est. Priority Date: 02/01/2010
• Status: Active Grant

• Current Assignee: APS Technology Inc
• Original Assignee: APS Technology Inc
• Inventors: Turner, William Evans, Wassell, Mark Ellsworth
• Primary Examiner(s): WRIGHT, GIOVANNA COLLINS
• Application Number:
  US14/186,928
• Publication Number:
  US 20140251688A1
• Time in Patent Office: 1,229 Days
• 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 47/00 Survey of boreholes or wells monitoring pressure or flow of drilling fluid E21B21/08
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence
• CPC Class Codes: G01V 9/00 Prospecting or detecting by methods not provided for in groups G01V1/00 - G01V8/00
• CPC Class Codes: G05B 13/048 using a predictor
• CPC Class Codes: G05B 2219/24075 Predict control element state changes, event changes
• CPC Class Codes: G05B 2219/2616 Earth moving, work machine
• CPC Class Codes: G05B 23/0243 model based detection method, e.g. first-principles knowledge model
• CPC Class Codes: G06F 17/18 for evaluating statistical data , e.g. average values, frequency distributions, probability functions, regression analysis forecasting specially adapted for a specific administrative, business or logistic context G06Q10/04

Abstract

A system and method for monitoring underground drilling in which vibration is monitored by creating a model of the drill string using finite element techniques or finite difference techniques and (i) predicting vibration by inputting real time values of operating parameters into the model, and then adjusting the model to agree with measured vibration data, (ii) predicting the weight on bit and drill string and mud motor speeds at which resonance will occur, as well as when stick-slip will occur, so that the operator can avoid operating regimes that will result in high vibration, (iii) determining vibration and torque levels along the length of the drill string based on the measured vibration and torque at one or more locations, (iv) determining the remaining life of critical components of the drill string based on the history of the vibration to which the components have been subjected, and (v) determining the optimum drilling parameters that will avoid excessive vibration of the drill string.

Claims

1. A system configured to monitor operation of a drill string having a drill bit configured to drill a borehole into an earthen formation, the system comprising:

a plurality of sensors configured to obtain drilling data associated with operation of the drill string, at least one of the plurality of sensors configured to obtain the drilling data at a downhole location in the borehole, the drilling data being indicative of one or more operating parameters of the drill string during the drilling operation; and

a processor configured for communication with the plurality of sensors, the processor configured to, in response to receiving the drilling data;

a) determine a vibration of the drill string, a rotary speed of the drill string, a weight applied to the drill bit, and a rate of penetration of the drill bit through the earthen formation, wherein the rate of penetration is based on the vibration of the drill string, the rotary speed of the drill string, and the weight applied to the drill bit; and

b) predict a maximum rate of penetration of the drill bit through the earthen formation that will not result in the vibration exceeding a predetermined maximum amplitude of vibration.

2. The system of claim 1, wherein the processor further configured to predict the maximum rate of penetration of the drill bit through the earthen formation that will not result in resonant vibration of the drill string when operating at the rotary speed of the drill string.

3. The system of claim 1, wherein the vibration is a measured vibration, and wherein the processor is configured to, in response to an input of desired operating parameters for the drilling operation, predict a vibration of the drill string based on the desired operating parameters, wherein the desired operating parameters include at least a desired rate of penetration.

4. The system of claim 3, wherein the processor is configured to, in response to the prediction of the vibration, compare the predicted vibration to the measured vibration, and if the predicted vibration is different from the measured vibration, adjust a value of the predicted vibration based on the drilling data obtained by the plurality of sensors.

5. The system of claim 3, wherein the predicted of vibration is based on a finite element model of the drill string.

6. The system of claim 5, wherein the processor is configured to execute instructions to run the finite element model of the drill string by performing a force response analysis by applying an oscillating weight to the drill bit.

7. The system of claim 3, wherein the processor is configured to, in response to a determination if the measured vibration of the drill string exceeds a predetermined value for the vibration, cause one or more operating parameters to automatically change during a drilling operation.

8. The system of claim 7, wherein the one or more operating parameters that automatically change during a drilling operation include the rotation of the drill string.

9. The system of claim 7, wherein the one or more operating parameters that automatically change during a drilling operation include a flow rate of a drilling mud passing through the mud motor coupled to the drill bit so as to cause a change in an operating speed of the mud motor.

10. The system of claim 7, wherein the one or more operating parameters that automatically change during a drilling operation include the weight applied to the drill bit.

11. The system of claim 1, wherein the vibration is an axial vibration of the drill string.

12. The system of claim 1, wherein the vibration is a lateral vibration of the drill string.

13. The system of claim 1, wherein the vibration is a torsional vibration of the drill string.

14. The system of claim 1, wherein one or more of the plurality of sensors are configured to obtain the drilling data at a surface of the earthen formation.

15. The system of claim 1, wherein the drilling data includes a rotational speed of a mud motor operatively coupled to the drill bit.

16. The system of claim 1, wherein the drilling data includes an inclination of the drill string.

17. The system of claim 1, wherein the drilling data includes an azimuth of the drill string.

18. The system of claim 1, wherein the drilling data includes a diameter of the borehole.

19. The system of claim 1, wherein the drilling data includes a build rate.

20. The system of claim 1, wherein the drilling data includes a turn rate.

21. The system of claim 1, wherein the weight applied to the drill bit is determined based on drilling data obtained via one or more of the plurality of sensors located on a sub disposed on a surface of the formation.

22. The system of claim 1, wherein the weight applied to the drill bit is determined based on drilling data obtained via one or more of the plurality of sensors located on a sub disposed downhole.

23. The system of claim 1, wherein the processor is configured to determine if at least one of a plurality of predetermined symptoms of lost drilling performance is present in the drilling operation based at least on the vibration of the drill string.

24. The system of claim 23, wherein the processor is configured to, determine, for each respective predetermined symptom of lost drilling performance determined to be present in the drilling operation, the most likely cause of lost drilling performance present in said drilling operation.