Roller cone rock bits and fixed cutter bits are commonly used in the oil and gas industry for drilling wells.
Significant expense is involved in the design and manufacture of drill bits. Therefore, having accurate models for simulating and analyzing the drilling characteristics of bits can greatly reduce the cost associated with manufacturing drill bits for testing and analysis purposes. For this reason, several models have been developed and employed for the analysis and design of fixed cutter bits. These fixed cutter simulation models have been particularly useful in that they have provided a means for analyzing the forces acting on the individual cutting elements on the bit, thereby leading to the design of, for example, force-balanced fixed cutter bits and designs having optimal spacing and placing of cutting elements on such bits. By analyzing forces on the individual cutting elements of a bit prior to making the bit, it is possible to avoid expensive trial and error designing of bit configurations that are effective and long lasting.
However, roller cone bits are more complex than fixed cutter bits in that cutting surfaces of the bit are disposed on the roller cones, wherein each roller cone independently rotates relative to the rotation of the bit body about axes oblique to the axis of the bit body. Additionally, the cutting elements of the roller cone bit deform the earth formation by a combination of compressive fracturing and shearing, whereas fixed cutter bits typically deform the earth formation substantially entirely by shearing. The bit's contact with the earth formation may result in small upward and downward displacements of the bit itself (and/or a bottom hole assembly). This vertical movement is characterized as “bit bounce.” A bit's axial stability is based on the amount of bit bounce that occurs during a drilling operation. Some bit bounce is to be expected during a drilling operation, however, substantial fluctuations in vertical movements result in axial instability. Thus, bit bounce is typically undesirable, because it results in vibrations in the drill string causing inefficiency in the drilling operation and, in some cases, potentially damaging the bit prematurely.
Accurate analysis of the drilling performance of roller cone bits requires more complex models than for fixed cutter bits. Until recently, no reliable roller cone bit models had been developed which could take into consideration the location, orientation, size, height, and shape of each cutting element on the roller cone, and the interaction of each individual cutting element on the cones with earth formations during drilling.
In recent years, some researchers have developed a method for modeling roller cone cutter interaction with earth formations. See D. Ma et al, The Computer Simulation of the Interaction Between Roller Bit and Rock, paper no. 29922, Society of Petroleum Engineers, Richardson, Tex. (1995).
There is a great need to optimize performance of roller cone bits drilling earth formations, particularly with respect to the axial stability of the bits. The axial stability of a bit relates to extent that the bit moves along the axis of the bit (or drill string) during drilling. The axial stability is a function of the weight-on-bit and the reaction forces exerted on the bit by the bottom of the borehole. Any axial instability during drilling will have a negative impact on the bit and the drill string. In addition, axial instability also reduces drilling efficiency. Therefore, it is desirable to have methods for analyzing axial stability of a roller cone bit and for optimizing a roller cone bit to have an improved axial stability.
In general, one aspect of the invention relates to a method for designing a bit for boring in earth formations. The method includes defining parameters for a calculation, wherein the parameters relate to a geometry of the bit, calculating to determine interference between the bit and the earth formations, obtaining vertical displacements with respect to a bit revolution based on the interference between the bit and the earth formations, and applying a criterion to the vertical displacements to evaluate bit performance.
In general, one aspect of the invention relates to a system for designing a bit for boring in an earth formation. The system includes means for defining parameters for a calculation, wherein the parameters relate to a geometry of the bit, calculating to determine interference between the bit and the earth formations, means for obtaining vertical displacements with respect to a bit revolution based on the interference between the bit and the earth formations, and means for applying a criterion to the vertical displacements to evaluate bit performance.
In general, one aspect of the invention relates to a method for designing a bottom hole assembly for boring earth formations. The method includes defining parameters for a calculation, wherein the parameters relate to a geometry of a bit of the bottom hole assembly, calculating to determine interference between the bit and the earth formations, obtaining vertical displacements with respect to a bit revolution based on the interference between the bit and the earth formations, and applying a criterion to the vertical displacements to evaluate bit performance with the bottom hole assembly.
In general, one aspect of the invention relates to a method for designing a bit for boring earth formation. The method includes graphically displaying vertical displacements of the bit interfering with the earth formation, and applying a criterion to the vertical displacements to evaluate bit performance.
In general, one aspect of the invention relates to a method for designing a bottom hole assembly for boring earth formation. The method includes graphically displaying vertical displacements of the bottom hole as a bit of the bottom hole assembly interferes with the earth formation, and applying a criterion to the vertical displacements to evaluate bit performance with the bottom hole assembly.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
The present invention involves analyzing axial stability through simulation to evaluate cutting structure performance, e.g., ROP, footage drilled, etc. In general, the present invention involves defining a set of parameters of a cutting structure during a drilling operation in a simulation and executing the simulation in view of the defined parameters. The present invention further involves obtaining vertical movements with respect to revolution of the cutting structure and applying a criterion to the vertical movements to evaluate the cutting structure performance.
In one or more embodiments, the present invention may generally be characterized as comprising three phases: simulation, analysis, and optimization. In the first phase, simulation includes defining a design of a bit for drilling into the earth formations and representing the bit during a drilling operation. One example of a method for simulating a bit drilling through earth formations can be found in U.S. Pat. No. 6,516,293, assigned to the assignee of the present invention, and now incorporated herein by reference in its entirety. Next, the analysis phase involves extracting data from the simulation phase and generating a representation of the data so that a criterion may be applied. Finally, based on whether the bit satisfies the criterion, the design of the bit design may be modified in an optimization phase.
A roller cone bit (rock bit) typically includes one or more roller cones. Each roller cone typically includes a plurality of cutting elements (teeth) arranged in one or more rows. Thus, the resultant reaction force of a rock bit may be a sum of reaction force of each individual roller cone. The reaction force of each roller cone in turn may reflect a sum of all reaction forces of the plurality of cutting elements. Accordingly, factors that may influence the resultant reaction force of a rock bit may include, for example, the number of roller cones, the configuration of the roller cones on the rock bit, the configuration and number of cutting elements on each roller cone, etc. In addition, the properties (formation properties) and the bottom hole shape may also influence the resultant reaction forces experienced by the rock bit.
In one or more embodiments, the resultant reaction force of a rock bit is based on the sum of reaction forces of the individual cutting elements (or teeth) as they contact the earth formations. These reaction forces are a function of both the depth of penetration (B) of individual cutting elements in view of the interference projection area (A) as shown in
However, when the WOB (602) is greater than the resultant vertical reaction force (604) as in
Conversely, when the WOB (702) is less than the resultant vertical reaction force (704) as in
One skilled in the art will appreciated that determining the vertical movements of a drill bit may include additional forces and the vertical movements of the drill bit may be calculated in a variety of ways.
Referring back to
The generalized bit bounce curve (900) has a generally positive slope indicating that the bit is drilling through the earth formations. The slope (902) of a bit bounce curve (900) approximates the rate of penetration, which is the rate a bit cuts through the earth formations. Accordingly, a higher slope indicates a greater rate of penetration.
Additionally, the bit bounce curve (900) may be measured over three revolutions of three hundred-sixty degrees (360°) of the bit through the earth formation. For example, the localized bit bounce curve (800) is measured over one revolution through the earth formation. Preferably, the displacement of the bit is obtained at every three degrees (3°); therefore, the localized bit bounce curve comprises one hundred-twenty data points (all of which are not shown in
In one or more embodiments, spikes or aberrations may be present in a bit bounce curve, which is typical of insert-rock interaction. Additionally, in on or more embodiments, a bit bounce curve may have a wavy and/or sinusoidal shape.
The analysis phase continues, after a representation of the vertical movement of the bit has been generated, when a criterion is applied to the generated representation (Step 308). In one or more embodiments, the criterion relates to a standard of axial stability. In one or more embodiments, various characteristics may be compiled to generate a criterion by which the axial stability of a bit may be determined.
For example, the criterion may limit a number of spikes in a bit bounce curve or require a slope of the bit bounce curve to be substantially straight, rather than wavy or the criterion may eliminate the sinusoidal shape of the bit bounce curve. One skilled in the art will understand that the sinusoidal shape of the bit bounce curve typically results in the planar surface of the bottom hole being saddle-shaped, which prevents the bit from performing optimally.
Alternatively, the criterion may also define minimum and/or maximum fluctuations in the vertical displacement of the bit. For example, referring to
In
In another aspect of the invention,
Typically, the first iteration (1202) may not be considered, when applying a criterion, because the bit is just beginning to drill into the earth formation. If the earth formation is a smooth planar surface, then the initial contact of the teeth of a roller cone drill bit with the earth formation may result in the first iteration of a bit bounce curve having a slope substantially equal to zero (a horizontal line). Because the first iteration is typically does not necessarily provide the steady-state of the bit, a window (1206) of the generalized bit bounce curves are considered when applying the criterion. The window (1206) includes an upper limit (1208), which is the point at which the steady-state of the bit operation is achieved and this point is measured in inches drilled through the formation. The window (1206) may also include a lower limit (1210) defined by the user to reduce the number of curves of consideration with respect to applying a criterion.
In another embodiment, the criterion may use a bottom hole profile as shown in
In
In Step 310, it is determined whether the current bit design satisfies the criterion. If the criterion is satisfied, then the analysis concludes. Otherwise, the optimization phase is initiated by modifying a bit parameter (Step 312) and the bit design is resimulated with the modified bit parameter (Step 314). A bit parameter may include location of cutting elements, geometry of cutting elements, orientation of bit, etc.
In
In one or more embodiments of the invention, a bottom hole assembly (BHA) may be analyzed in conjunction with a bit when determining the axial stability. Bottom hole assemblies are designed for specific application and typically include sensors, e.g., for measuring the resitivity, porosity, and density of the formation. Additionally, BHA may include pressures sensors, temperature sensors, etc. One skilled in the art will appreciate that a BHA may have a dampening or magnifying effect on the behavior of a bit bounce curve. Similarly, the BHA may have a dampening or magnifying effect on the shape of a bottom hole profile. Therefore, considering the effects of a BHA on the drilling system provides accurate analysis of a drilling operation.
In one or more embodiments, the present invention may be implemented on virtually any type computer system regardless of the platform being used. For example, as shown in
In one or more embodiments, using the keyboard (1508) and/or mouse (1510), a user may input initial or modified set of parameters known as simulation input (1514). The initial or modified parameters are input to the system and used by the processor (1502) (or simulator) to execute a simulation. The results of the simulation (or simulation output (1516)) in the form of graphics (computer-generated graphics of a bit, bottom hole profile, etc.), graphs (polar plots, box-whisker plots, chart plots, etc.), tables, etc. may be output from the computer system (1500) and displayed on a monitor (1512), for example. After reviewing the simulation on the monitor (1512, a user may change a bit parameter using the mouse (1510) and reinitiate a simulation of the design on the computer system (1500).
Advantages of embodiments of the present invention may include one or more of the following. In one or more embodiments, the present invention may be used to minimize behavioral characteristics of axial instability, for example, bit bounce that reduces vibrations in the drilling string thereby improving cutting efficiency. Embodiments of the present invention can potentially increase the life of the bit by preventing damage due to repetitive impact of the cutting structure against the bottom surface of the well bore during drilling.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
This is an utility application, which claims priority pursuant to 35 U.S.C. §119(c) to U.S. Provisional Application No. 60/487,495, filed on Jul. 15, 2003. That application is expressly incorporated by reference it its entirety.
Number | Date | Country | |
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60487495 | Jul 2003 | US |