Differential sensor measurement method and apparatus to detect a drill bit failure and signal surface operator

• US 6,648,082 B2
• Filed: 10/26/2001
• Issued: 11/18/2003
• Est. Priority Date: 11/07/2000
• Status: Expired due to Term

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Schultz, Roger L., Osborne, Andrew J. Jr., De Jesus, Orlando
• Primary Examiner(s): SCHOEPPEL, ROGER J
• Application Number:
  US10/040,304
• Publication Number:
  US 20020148644A1
• Time in Patent Office: 753 Days
• Field of Search: 175/39, 175/40, 175/50, 340/853.1, 340/853.3
• US Class Current: 175/39
• CPC Class Codes: E21B 12/02 Wear indicators
• CPC Class Codes: E21B 2200/22 Fuzzy logic, artificial intelligence, neural networks or the like
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• 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 47/18 through the well fluid , e.g. mud pressure pulse telemetry

Abstract

An apparatus and accompanying method for monitoring and reporting downhole bit failure. Individual sensors are placed on a sub which is separate from the drill bit itself, and are powered by a vibration driven power system. The sensor readings are used to compute values which represent the ratios of sensor readings on one sensor in relation to the readings of one or more other sensors. This creates a self-calibrating sensor system that accounts for changes in downhole conditions which might cause sensor readings to fluctuate, but which do not indicate failure.

Claims

1. A system for detecting drill bit failure, comprising:

a plurality of sensors located on a downhole section of the drill string; and

circuitry for differentially processing the states of said sensors to thereby derive information about the functioning of the bit.

2. The system of claim 1, wherein said sensors are located on a sub assembly in the drill string above the bit.

3. The system of claim 2, wherein the sensors are matched sensors.

4. The system of claim 1, wherein said circuitry comprises an adaptive filter.

5. The system of claim 1, wherein the sensors are matched sensors.

6. A system for monitoring drill bit performance, comprising:

a plurality of matched sensors located on a downhole section of a drill string;

wherein a measurement from at least one of said sensors is compared to at least one measurement from another of said sensors to derive information about remaining lifetime of the bit.

7. The system of claim 6, wherein said sensors are located on a sub assembly which has no electrical communication with the drill bit.

8. The system of Claim 6, wherein said sensors measure axial strain.

9. The system of claim 6, wherein said sensors measure vibrational frequency.

10. A system for detecting the probable failure of a drill bit, comprising:

a drill string extending through at least part of a well bore;

a sub assembly connected to the drill string, the sub assembly including

one or more sensors that monitor one or more parameters of operation of a drill bit,

a detection platform receiving data from said one or more sensors and including circuitry for differentially processing states of the sensors, and

a telemetry device which transmits signals from said detection platform to the surface; and

a drill bit removably attached to the sub assembly.

11. The system of claim 10, wherein said detection platform uses adaptive neural network analysis to predict bit failure.

12. The system of claim 10, wherein said detection platform uses an adaptive model to predict bit failure.

13. The system of claim 10, wherein said detection platform uses adaptive filtering to predict bit failure.

14. A system of claim 10, wherein said sensors are located on said sub assembly.

15. The system of claim 10, wherein the sensors are matched sensors.

16. A method of monitoring drill bit performance, comprising the steps of:

positioning a plurality of sensors on a section of a drill string uphole from a drill bit;

comparing measurements from said sensors to detect the process of bit failure.

17. The system of claim 16, wherein said sensors measure axial stain.

18. The system of claim 16, wherein said sensors measure vibrational frequency.

19. The system of claim 16, wherein sensor data is analyzed by an adaptive filter.

20. The method of claim 16, wherein at least some of said sensors are matched sensors.