Method and apparatus for monitoring the condition of a downhole drill bit, and communicating the condition to the surface

• US 7,357,197 B2
• Filed: 10/17/2001
• Issued: 04/15/2008
• Est. Priority Date: 11/07/2000
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Osborne, Andrew J. Jr., Jesus, Orlando De, Schultz, Roger L.
• Primary Examiner(s): WRIGHT, GIOVANNA COLLINS
• Application Number:
  US10/036,105
• Publication Number:
  US 20020144842A1
• Time in Patent Office: 2,372 Days
• Field of Search: 175/39, 175/40, 175/25, 175/48, 175/218, 175/231, 175/232, 731/51, 367/85
• 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
• CPC Class Codes: E21B 47/22 by negative mud pulses using a pressure relieve valve between drill pipe and annulus

Abstract

A method and apparatus for signalling the surface operator about downhole conditions. Sensors located downhole collect data while drilling and the data is processed to determine bit failure, for example. When the sensor data indicates a failure, the pressure of drilling mud is varied using a valve on the downhole unit, and this pressure variance is indicated by a pressure gauge visible to the operator. This pressure change tells the operator a failure has been indicated.

Claims

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

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

downhole circuitry for processing states of said sensors to thereby derive and communicate

a first warning state when the states of said sensors indicate that failure of the bit is beginning, and

a second warning state when the states of said sensors indicate that final failure of the bit is at hand.

2. The system of claim 1, wherein said first warning state is indicated to a surface operator by variation of drilling fluid pressure, said variation caused by movement of a valve located in said drill string.

3. The system of claim 1, wherein said first and said second warning states are indicated to a surface operator by varying the position of a valve located in said drill string.

4. The system of claim 1, wherein said first warning state and said second warning state are independently derived, and said second warning state can be detected by said sensors and said circuitry even under some failure conditions which would preclude detection of said first warning state.

5. The system of claim 1, wherein said sensors include both a first type of sensor and a second type of sensor.

6. A downhole assembly which indicates a failure condition, comprising:

a valve assembly whose action includes irreversible movement;

wherein said irreversible movement of said valve assembly changes mud flow impedance from a first state which is initially present during normal drilling into at least one intermediate state having reduced mud flow impedance which indicates a failure condition, and thereafter irreversibly into a final state, which returns mud flow impedance to substantially that seen during normal drilling.

7. The downhole assembly of claim 6, further comprising sensors located on said downhole assembly which monitor parameters indicative of drill bit condition.

8. The downhole assembly of claim 6, wherein said valve movement occurs at a time constant of at least about one second.

9. The downhole assembly of claim 6, wherein said mud flow impedance is varied by opening an aperture which allows mud to flow from the interior of the drill string to a bore hole.

10. A method of operating a drill rig, comprising the step of:

using downhole circuitry to signal a change in downhole equipment condition by causing a reduction in drilling fluid long-time average pressure;

wherein said reduction in drilling fluid long-time average pressure is caused by irreversible movement of a valve.

11. A method of operating a drill rig, comprising the step of:

using downhole circuitry to signal a change in downhole equipment condition by causing a reduction in drilling fluid long-time average pressure;

wherein said change in downhole equipment condition is determined by an adaptive filter that uses past signal measurements obtained from sensors located on the drill string to predict future signal measurements.