Patent Application
20220025714
The present disclosure generally relates to wellbore drilling and, more particularly, to sensing drill bit wear in drilling tools used in the oil and gas industry.
Drilling wellbores in some formations poses challenging conditions, such as a diminished rate of penetration (ROP), drill bit vibrations, drill bit damage, and high pressure and high temperature (HPHT) conditions. The drilling conditions are appraised at the surface by a drilling advisor to determine appropriate drilling parameters, such as revolutions per minute (RPM) of the drill, weight on bit (WOB), and gallons per minute (GPM) of drilling mud pumped during drilling, in light of the perceived drilling conditions.
This specification describes downhole drilling systems and methods that can be used to monitor and predict the condition of a drill bit in drilling tools during wellbore drilling. The drill bit is disposed at the end of the drilling system to drill the downhole formation. This drill bit includes a body, two or more blades, and a sensor module embedded in the drill bit. In some examples, the sensor module is embedded into the body of the drill bit. The sensor module includes sensors, instrumentation and signal processing circuits, batteries, insulated conductors, receivers, transmitters, and data storing and processing devices. During a drilling operation, the sensor module measures the electrical or field properties (e.g., acoustic and capacitive properties) that are used to monitor and evaluate the condition of the drill bit.
The drill bit with an onboard sensor module enables virtual drill bit grading (i.e., assessment of drill bit condition) and improved drilling automation. The data from the sensors can be transferred to the data processing system to improve and automate the drilling operation. The onboard sensor module can measure and predict condition of the drill bit. This allows the user to have more confidence when correlating damage reduction to specific drill bit features and enables continuous process improvement.
In some aspects, a method for drilling a wellbore includes: sensing electrical resistance of an insulated conductor extending from a surface of a drill bit to a sensor inside the drill bit; calculating drill bit dimensions based on the sensed electrical resistance; and transmitting sensed electrical resistance, calculated drill bit dimensions, or both uphole to a system for controlling drilling operations.
Embodiments of the method for drilling a wellbore can include one or more of the following features.
In some embodiments, the method includes correlating rate of penetration with drill bit dimensions. In some cases, the method includes calculating lost time associated with reductions in drill bit dimensions. In some cases, the method includes comparing the lost time associated with reductions in drill bit dimensions with non-productive time associated with replacing the drill bit. In some cases, the method includes calculating time until drill bit replacement is required based on a rate of reduction of drill bit dimensions.
In some embodiments, the method includes updating a drilling plan based on the calculated drill bit dimensions.
In some embodiments, the method includes providing calculated drill bit dimensions as input to a drilling automation algorithm.
In some aspects, a system for drilling wellbores includes: a drill bit including: an electrical resistance sensor disposed inside the drill bit; two insulated conductors extending from a surface of the drill bit to the sensor; and an onboard computer operable to calculate drill bit dimensions based on electrical resistance measured by the electrical resistance sensor.
Embodiments of the system for drilling wellbores can include one or more of the following features.
In some embodiments, the insulated conductors include copper with insulating materials disposed between the copper and a body of the drill bit. In some cases, the two insulated conductors have the same dimensions and extend in parallel from the surface of the drill bit to the sensor.
In some embodiments, the system includes a data processing system operable to control drilling operations, the data processing system in electronic communication with the onboard computer. In some cases, the data processing system is configured to receive sensed electrical resistance, calculated drill bit dimensions, or both from the onboard computer. In some cases, the data processing system includes algorithms to correlate drilling rate of penetration with drill bit dimensions. In some cases, the data processing system includes algorithms to calculate lost time associated with reductions in drill bit dimensions. In some cases, the data processing system includes algorithms to compare the lost time associated with reductions in drill bit dimensions with non-productive time associated with replacing the drill bit. In some cases, the data processing system includes algorithms to calculate time until drill bit replacement is required based on a rate of reduction of drill bit dimensions.
In some embodiments, the onboard computer is a printed circuit board.
In some embodiments, the system includes a battery electrically connected to the onboard computer and the sensor.
The prediction of the drill bit grade or condition is done during drilling while the drill bit is downhole. This approach can be used to adjust the drilling automation algorithms for improved drilling performance based on measured data in real-time and can improve the economics of drilling operations. Drill bit condition affects the invisible lost time (e.g., time lost associated with decreases in the rate of penetration due to increased wear on the drill bit). Wear of the drill bit eventually requires a replacement of the drill bit and causes non-productive time associated with tripping the drill string out of and back into the wellbore for the replacement of the drill bit. Understanding the exact drill bit conditions further reduces cost by reducing the invisible lost time and the non-productive time that constitute a significant portion of the overall drilling costs. For example, the ability to accurately predict the drill bit grade can guide decisions on when it is time to trip the drill bit and replace it instead of continuing to drill with a damaged tool. Knowing the exact bit conditions can improve the ROP, extend the drill bit life, guide drilling practices, improve trip plans, enhance drill bit design, and automate drilling operations.
The details of one or more embodiments of these systems and methods are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of these systems and methods will be apparent from the description and drawings, and from the claims.
This specification describes downhole drilling systems and methods that can be used to monitor and predict the condition of a drill bit in drilling tools during wellbore drilling. The drill bit is disposed at the end of the drilling system to drill the downhole formation. This drill bit includes a body, two or more blades, and a sensor module that is embedded into the drill bit blade. In some examples, the sensor module is embedded into the body of the drill bit. The sensor module includes sensors, instrumentation and signal processing circuits, batteries, insulated conductors, receivers, transmitters, and data storing and processing devices. During a drilling operation, the sensor module measures the electrical or field properties (e.g., acoustic and capacitive properties) that are used to monitor and evaluate the condition of the drill bit.
In the drill bit 108, the sensor module 112 is embedded in the drill bit 108. The sensor module 112 includes an electrical resistance sensor 210, two insulated conductors 204a, 204b, onboard computer 206 (for example, a printed circuit board) connected to the electrical resistance sensor 210, and a battery 208 to power the onboard computer 206 and the electrical resistance sensor 210. The electrical resistance sensor 210, the onboard computer 206, and the battery 208 are embedded within the body 214 of the drill bit 108. The insulated conductors extend from the electrical resistance sensor 210 through one of the blades 212 of the drill bit 108. For a steel drill bit bodies, the cavity receiving the electrical resistance sensor 210, the onboard computer 206, and the battery 208 can be formed during machining and these components subsequently installed. For matrix drill bit bodies, the electrical resistance sensor 210, the onboard computer 206, and the battery 208 can incorporated during 3D printing or additive manufacturing processes used to form the drill bit bodies.
The two insulated conductors 204a, 204b extend in parallel from the electrical resistance sensor 210 to a surface of the drill bit 108. The two insulated conductors 204a, 204b have equal dimensions. The body of the two insulated conductors 204a, 204b includes copper material or other conductive metal material. Insulating materials (e.g., fiberglass, cellulose, mineral wool, natural fibers, polystyrene, polyisocyanurate, polyurethane, perlite, and combinations thereof) encapsulate the body of the conductors. The insulating layer of the conductors 204a, 204b is placed between the conductive material of the insulated conductor and the blades 212 and body 214 of the drill bit 108.
The electrical resistance sensor 210 is a piezoresistive sensor. The electrical resistance sensor 210 measures the resistance of a circuit formed by (1) one of the insulated conductors 204a, 204b, (2) the portion of the blade 212 between the insulated conductors 204a, 204b, and (3) the other of the insulated conductors 204a, 204b. As the blades 212 of the drill bit 108 wear away during use, the insulated conductors 204a, 204b also wear away shortening their length. The shortening of the insulated conductors 204a, 204b reduces the electrical resistance measured by the electrical resistance sensor 210. Some drill bits use other types of sensors (e.g., an impedance sensor, a resistivity sensor, or a capacitance sensor) to measure the electrical resistance.
During a drilling operation (for example, while the drill bit 108 is drilling into a formation), the electrical resistance sensor 210 senses a change in electrical resistance across the conductors 204a, 204b, as the length of the conductors decreases. The electrical resistance sensor 210 then transmits the resistance data to the onboard computer 206. The onboard computer 206 includes a data processing system that calculates drill bit wear based the resistance data and transmits the sensed electrical resistance and the calculated drill bit dimensions uphole to a surface data processing system 202 controlling drilling operations. The connection between the onboard computer 206 and the surface data processing system 202 may be a wired connection, a wireless connection, or both. In some cases, the onboard computer 206 transmits the sensed electrical resistance or the calculated drill bit dimensions rather than both uphole to a surface data processing system controlling drilling operations.
The surface data processing system 202 uses the received sensor data and executes algorithms to determine and control the drilling operations. In some implementations, the surface data processing system is configured to receive sensor data from the onboard computer 206 and calculate drill bit dimensions. In some implementations, the surface data processing system is configured to correlate a drilling rate of penetration with the calculated drill bit dimensions. In these implementations, the surface data processing system can calculate lost time associated with reductions in drill bit dimensions and compare the lost time associated with reductions in drill bit dimensions with non-productive time associated with replacing the drill bit. This approach enables the surface data processing system 202 to predict the time until drill bit replacement is required based on a rate of reduction of the drill bit dimensions. Based on the received data and the calculated parameters, modifications to the drilling parameters can be implemented to increase the life of the drill bit or to improve the rate of penetration. Additionally, a determination can be made to trip out the drill bit and replace it with a new one can be based on the predicted end-of-life of the drill bit.
The computer 502 can serve in a role as a client, a network component, a server, a database, a persistency, or components of a computer system for performing the subject matter described in the present disclosure. The illustrated computer 502 is communicably coupled with a network 530. In some implementations, one or more components of the computer 502 can be configured to operate within different environments, including cloud-computing-based environments, local environments, global environments, and combinations of environments.
At a high level, the computer 502 is an electronic computing device operable to receive, transmit, process, store, and manage data and information associated with the described subject matter. According to some implementations, the computer 502 can also include, or be communicably coupled with, an application server, an email server, a web server, a caching server, a streaming data server, or a combination of servers.
The computer 502 can receive requests over network 530 from a client application (for example, executing on another computer 502). The computer 502 can respond to the received requests by processing the received requests using software applications. Requests can also be sent to the computer 502 from internal users (for example, from a command console), external (or third) parties, automated applications, entities, individuals, systems, and computers. Each of the components of the computer 502 can communicate using a system bus 503. In some implementations, any or all of the components of the computer 502, including hardware or software components, can interface with each other or the interface 504 (or a combination of both), over the system bus 503. Interfaces can use an application programming interface (API) 512, a service layer 513, or a combination of the API 512 and service layer 513. The API 512 can include specifications for routines, data structures, and object classes. The API 512 can be either computer-language independent or dependent. The API 512 can refer to a complete interface, a single function, or a set of APIs.
The service layer 513 can provide software services to the computer 502 and other components (whether illustrated or not) that are communicably coupled to the computer 502. The functionality of the computer 502 can be accessible for all service consumers using this service layer. Software services, such as those provided by the service layer 513, can provide reusable, defined functionalities through a defined interface. For example, the interface can be software written in JAVA, C++, or a language providing data in extensible markup language (XML) format. While illustrated as an integrated component of the computer 502, in alternative implementations, the API 512 or the service layer 513 can be stand-alone components in relation to other components of the computer 502 and other components communicably coupled to the computer 502. Moreover, any or all parts of the API 512 or the service layer 513 can be implemented as child or sub-modules of another software module, enterprise application, or hardware module without departing from the scope of the present disclosure.
The computer 502 includes an interface 504. Although illustrated as a single interface 504 in
The computer 502 includes a processor 505. Although illustrated as a single processor 505 in
The computer 502 also includes a database 506 that can hold data for the computer 502 and other components connected to the network 530 (whether illustrated or not). For example, database 506 can be an in-memory, conventional, or a database storing data consistent with the present disclosure. In some implementations, database 506 can be a combination of two or more different database types (for example, hybrid in-memory and conventional databases) according to particular needs, desires, or particular implementations of the computer 502 and the described functionality. Although illustrated as a single database 506 in
The computer 502 also includes a memory 507 that can hold data for the computer 502 or a combination of components connected to the network 530 (whether illustrated or not). Memory 507 can store any data consistent with the present disclosure. In some implementations, memory 507 can be a combination of two or more different types of memory (for example, a combination of semiconductor and magnetic storage) according to particular needs, desires, or particular implementations of the computer 502 and the described functionality. Although illustrated as a single memory 507 in
The application 508 can be an algorithmic software engine providing functionality according to particular needs, desires, or particular implementations of the computer 502 and the described functionality. For example, application 508 can serve as one or more components, modules, or applications. Further, although illustrated as a single application 508, the application 808 can be implemented as multiple applications 508 on the computer 502. In addition, although illustrated as internal to the computer 502, in alternative implementations, the application 508 can be external to the computer 502.
The computer 502 can also include a power supply 514. The power supply 514 can include a rechargeable or non-rechargeable battery that can be configured to be either user- or non-user-replaceable. In some implementations, the power supply 514 can include power-conversion and management circuits, including recharging, standby, and power management functionalities. In some implementations, the power-supply 514 can include a power plug to allow the computer 502 to be plugged into a wall socket or a power source to, for example, power the computer 502 or recharge a rechargeable battery.
There can be any number of computers 502 associated with, or external to, a computer system containing computer 502, with each computer 502 communicating over network 530. Further, the terms “client,” “user,” and other appropriate terminology can be used interchangeably, as appropriate, without departing from the scope of the present disclosure. Moreover, the present disclosure contemplates that many users can use one computer 502 and one user can use multiple computers 502.
Implementations of the subject matter and the functional operations described in this specification can be implemented in digital electronic circuitry, intangibly embodied computer software or firmware, in computer hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Software implementations of the described subject matter can be implemented as one or more computer programs. Each computer program can include one or more modules of computer program instructions encoded on a tangible, non-transitory, computer-readable computer-storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively, or additionally, the program instructions can be encoded in/on an artificially-generated propagated signal. The example, the signal can be a machine-generated electrical, optical, or electromagnetic signal that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. The computer-storage medium can be a machine-readable storage device, a machine-readable storage substrate, a random or serial access memory device, or a combination of computer-storage mediums.
The terms “data processing apparatus,” “computer,” and “electronic computer device” (or equivalent as understood by one of ordinary skill in the art) refer to data processing hardware. For example, a data processing apparatus can encompass all kinds of apparatus, devices, and machines for processing data, including by way of example, a programmable processor, a computer, or multiple processors or computers. The apparatus can also include special purpose logic circuitry including, for example, a central processing unit (CPU), a field programmable gate array (FPGA), or an application specific integrated circuit (ASIC). In some implementations, the data processing apparatus or special purpose logic circuitry (or a combination of the data processing apparatus or special purpose logic circuitry) can be hardware- or software-based (or a combination of both hardware- and software-based). The apparatus can optionally include code that creates an execution environment for computer programs, for example, code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of execution environments. The present disclosure contemplates the use of data processing apparatuses with or without conventional operating systems, for example LINUX, UNIX, WINDOWS, MAC OS, ANDROID, or IOS.
A computer program, which can also be referred to or described as a program, software, a software application, a module, a software module, a script, or code, can be written in any form of programming language. Programming languages can include, for example, compiled languages, interpreted languages, declarative languages, or procedural languages. Programs can be deployed in any form, including as stand-alone programs, modules, components, subroutines, or units for use in a computing environment. A computer program can, but need not, correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data, for example, one or more scripts stored in a markup language document, in a single file dedicated to the program in question, or in multiple coordinated files storing one or more modules, sub programs, or portions of code. A computer program can be deployed for execution on one computer or on multiple computers that are located, for example, at one site or distributed across multiple sites that are interconnected by a communication network. While portions of the programs illustrated in the various figures may be shown as individual modules that implement the various features and functionality through various objects, methods, or processes, the programs can instead include a number of sub-modules, third-party services, components, and libraries. Conversely, the features and functionality of various components can be combined into single components as appropriate. Thresholds used to make computational determinations can be statically, dynamically, or both statically and dynamically determined.
The methods, processes, or logic flows described in this specification can be performed by one or more programmable computers executing one or more computer programs to perform functions by operating on input data and generating output. The methods, processes, or logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, for example, a CPU, an FPGA, or an ASIC.
Computers suitable for the execution of a computer program can be based on one or more of general and special purpose microprocessors and other kinds of CPUs. The elements of a computer are a CPU for performing or executing instructions and one or more memory devices for storing instructions and data. Generally, a CPU can receive instructions and data from (and write data to) a memory. A computer can also include, or be operatively coupled to, one or more mass storage devices for storing data. In some implementations, a computer can receive data from, and transfer data to, the mass storage devices including, for example, magnetic, magneto optical disks, or optical disks. Moreover, a computer can be embedded in another device, for example, a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a global positioning system (GPS) receiver, or a portable storage device such as a universal serial bus (USB) flash drive.
Computer readable media (transitory or non-transitory, as appropriate) suitable for storing computer program instructions and data can include all forms of permanent/non-permanent and volatile/non-volatile memory, media, and memory devices. Computer readable media can include, for example, semiconductor memory devices such as random access memory (RAM), read only memory (ROM), phase change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), and flash memory devices. Computer readable media can also include, for example, magnetic devices such as tape, cartridges, cassettes, and internal/removable disks. Computer readable media can also include magneto optical disks and optical memory devices and technologies including, for example, digital video disc (DVD), CD ROM, DVD+/−R, DVD-RAM, DVD-ROM, HD-DVD, and BLURAY. The memory can store various objects or data, including caches, classes, frameworks, applications, modules, backup data, jobs, web pages, web page templates, data structures, database tables, repositories, and dynamic information. Types of objects and data stored in memory can include parameters, variables, algorithms, instructions, rules, constraints, and references. Additionally, the memory can include logs, policies, security or access data, and reporting files. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
Implementations of the subject matter described in the present disclosure can be implemented on a computer having a display device for providing interaction with a user, including displaying information to (and receiving input from) the user. Types of display devices can include, for example, a cathode ray tube (CRT), a liquid crystal display (LCD), a light-emitting diode (LED), and a plasma monitor. Display devices can include a keyboard and pointing devices including, for example, a mouse, a trackball, or a trackpad. User input can also be provided to the computer through the use of a touchscreen, such as a tablet computer surface with pressure sensitivity or a multi-touch screen using capacitive or electric sensing. Other kinds of devices can be used to provide for interaction with a user, including to receive user feedback, for example, sensory feedback including visual feedback, auditory feedback, or tactile feedback. Input from the user can be received in the form of acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending documents to, and receiving documents from, a device that is used by the user. For example, the computer can send web pages to a web browser on a user's client device in response to requests received from the web browser.
The term “graphical user interface,” or “GUI,” can be used in the singular or the plural to describe one or more graphical user interfaces and each of the displays of a particular graphical user interface. Therefore, a GUI can represent any graphical user interface, including, but not limited to, a web browser, a touch screen, or a command line interface (CLI) that processes information and efficiently presents the information results to the user. In general, a GUI can include a plurality of user interface (UI) elements, some or all associated with a web browser, such as interactive fields, pull-down lists, and buttons. These and other UI elements can be related to or represent the functions of the web browser.
Implementations of the subject matter described in this specification can be implemented in a computing system that includes a back end component, for example, as a data server, or that includes a middleware component, for example, an application server. Moreover, the computing system can include a front-end component, for example, a client computer having one or both of a graphical user interface or a Web browser through which a user can interact with the computer. The components of the system can be interconnected by any form or medium of wireline or wireless digital data communication (or a combination of data communication) in a communication network. Examples of communication networks include a local area network (LAN), a radio access network (RAN), a metropolitan area network (MAN), a wide area network (WAN), Worldwide Interoperability for Microwave Access (WIMAX), a wireless local area network (WLAN) (for example, using 802.11 a/b/g/n or 802.20 or a combination of protocols), all or a portion of the Internet, or any other communication system or systems at one or more locations (or a combination of communication networks). The network can communicate with, for example, Internet Protocol (IP) packets, frame relay frames, asynchronous transfer mode (ATM) cells, voice, video, data, or a combination of communication types between network addresses.
The computing system can include clients and servers. A client and server can generally be remote from each other and can typically interact through a communication network. The relationship of client and server can arise by virtue of computer programs running on the respective computers and having a client-server relationship.
Cluster file systems can be any file system type accessible from multiple servers for read and update. Locking or consistency tracking may not be necessary since the locking of exchange file system can be done at application layer. Furthermore, Unicode data files can be different from non-Unicode data files.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any suitable sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
Particular implementations of the subject matter have been described. Other implementations, alterations, and permutations of the described implementations are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results. In certain circumstances, multitasking or parallel processing (or a combination of multitasking and parallel processing) may be advantageous and performed as deemed appropriate.
Moreover, the separation or integration of various system modules and components in the previously described implementations should not be understood as requiring such separation or integration in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
Accordingly, the previously described example implementations do not define or constrain the present disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of the present disclosure.
Furthermore, any claimed implementation is considered to be applicable to at least a computer-implemented method; a non-transitory, computer-readable medium storing computer-readable instructions to perform the computer-implemented method; and a computer system comprising a computer memory interoperably coupled with a hardware processor configured to perform the computer-implemented method or the instructions stored on the non-transitory, computer-readable medium.
A number of embodiments of these systems and methods have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of this disclosure. Accordingly, other embodiments are within the scope of the following claims.
