Abstract:
A system and method for monitoring drilling operations by dividing a flow of fluid into at least one discrete fluid unit, circulating the fluid unit through a wellbore, and comparing a measured change to a property of the fluid unit to a predicted change in the property of the fluid unit. In addition to measuring the change to the property of the fluid unit, the fluid unit may be tracked by iteratively calculating the location of the fluid unit as it passes through the wellbore. Data collected for the fluid unit by a control system may be analyzed and used by the control system or an operator to diagnose problems or improve overall efficiency of drilling operations.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to monitoring operations during drilling of subsurface formations, in particular subsurface formations containing hydrocarbon deposits. 
       BACKGROUND 
       [0002]    During drilling of an oil or gas well, drilling fluids are circulated through the wellbore. The drilling fluids perform a variety of functions including cooling the drill bit, sweeping away cuttings from the bottom of the wellbore, and maintaining hydrostatic pressure to prevent blowouts or collapse of the wellbore. 
         [0003]    As a drilling fluid passes through the wellbore, properties of the drilling fluid may change as a result of downhole conditions. For example, the drilling fluid&#39;s density may change due to entrainment of gas or “cuttings,” pieces of rock from the subsurface formation. By monitoring and analyzing the changes undergone by the drilling fluid as it passes through the wellbore, a drilling operator can gain insight into the effectiveness of the drilling operations and optimize the drilling operations accordingly. Further, analysis of drilling fluids can significantly improve the overall safety of drilling operations by allowing drilling operators to identify problematic conditions before they endanger equipment, personnel, or the environment. 
         [0004]    Recent developments in metering technology have significantly improved the ability of drilling operators to collect drilling fluid data during drilling operations. For example, the introduction of Coriolis meters suitable for drilling fluids and sized for the flow requirements of drilling operations have enabled drilling operators to measure flow rate and density of drilling fluids in real time. Given this increased availability of drilling fluid data, new methods and tools for effectively monitoring and analyzing the drilling fluid data are required so that drilling operators can maximize the operational benefits associated with improved metering. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    Embodiments and advantages of the present invention may be best understood by one of ordinary skill in the art by referring to the following description and accompanying drawings. In the drawings: 
           [0006]      FIG. 1  illustrates a system for drilling operations, according to one embodiment of the invention. 
           [0007]      FIG. 2  is a flow chart depicting the process of monitoring fluid units. 
           [0008]      FIG. 3  is a graph depicting one embodiment in which changes in mass over time may be used to determine the effectiveness of cuttings removal. 
           [0009]      FIG. 4  is a second graph depicting another embodiment in which changes in density of a series of fluid units may be used to detect ballooning. 
       
    
    
     DETAILED DESCRIPTION 
       [0010]    For the purposes of this disclosure, a “fluid” may be, but is not limited to, a gas, a liquid, an emulsion, a slurry, and/or a stream of solid particles that has flow characteristics similar to liquid flow. 
         [0011]    “Formation” and “subsurface formation” refer to a body or section of geologic strata, structure, formation or other subsurface solid or collected material that is sufficiently distinctive and continuous with respect to other geologic strata or characteristics that it can be mapped, for example, by seismic techniques. A formation can be a body of geologic strata of predominantly one type or a combination of types, or a fraction of strata having substantially common set of characteristics. A formation can contain one or more hydrocarbon-bearing zones. Note that the terms formation, hydrocarbon bearing subterranean formation, reservoir, and interval may be used interchangeably, but may generally be used to denote progressively smaller subsurface regions, zones, or volumes. More specifically, a geologic formation may generally be the largest subsurface region, a subterranean formation may generally be a region within the geologic formation and may generally be a hydrocarbon-bearing zone (a formation, reservoir, or interval having oil, gas, heavy oil, and any combination thereof), and an interval may generally refer to a sub-region or portion of a reservoir. A hydrocarbon-bearing zone can be separated from other hydrocarbon-bearing zones by zones of lower permeability such as mudstones, shales, or shale-like (highly compacted) sands. In one or more embodiments, a hydrocarbon-bearing zone may include heavy oil in addition to sand, clay, or other porous solids. 
         [0012]    “Formation fluids” refer to fluids present in a formation and may include pyrolyzation fluid, synthesis gas, mobilized hydrocarbons, and water (steam). Formation fluids may include hydrocarbon fluids as well as non-hydrocarbon fluids. 
         [0013]    The term “wellbore” refers to a hole in a formation made by drilling or insertion of a conduit into the formation. A wellbore may have a substantially circular cross section, or another cross-sectional shape. As used herein, the terms “well” and “opening,” when referring to an opening in the formation may be used interchangeably with the term “wellbore.” 
         [0014]    Illustrative embodiments of the present invention are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will be appreciated that in the development of any such embodiment, numerous implementation-specific decisions may be made to achieve the specific implementation goals, which may vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure. 
         [0015]    In no way should examples of embodiments in this disclosure be read to limit, or define, the scope of the invention. Embodiments of the present disclosure may be applicable to horizontal, vertical, deviated, or otherwise nonlinear wellbores in any type of subterranean formation. Embodiments may be applicable to injection wells as well as production wells, including hydrocarbon wells. Embodiments may be implemented using a tool that is made suitable for testing, retrieval and sampling along sections of the formation. Embodiments may be implemented with tools that, for example, may be conveyed through a flow passage in a tubular string or using a wireline, slickline, coiled tubing, downhole robot or the like. “Measurement-while-drilling” (“MWD”) is the term generally used for measuring conditions downhole concerning the movement and location of the drilling assembly while the drilling continues. “Logging-while-drilling” (“LWD”) is the term generally used for similar techniques that concentrate more on formation parameter measurement. Devices and methods in accordance with certain embodiments may be used in one or more of wireline, MWD and LWD operations. 
         [0016]    The present application is directed to methods and systems for monitoring drilling operations, and specifically for monitoring drilling operations by analysis of drilling fluids. 
         [0017]      FIG. 1  is a schematic drawing of a drilling system including a system for monitoring drilling fluids according to one embodiment. A drilling system  100  includes a drilling rig  102  located at a surface  104  of a wellbore  112 . A hollow drill string  108  is supported by the drill rig  102  and penetrates the surface  104  into a subsurface formation  114  through a rotary table  110 . The rotary table  110  rotates the drill string  108 . The drill string  108  includes a Kelly  116 , a drill pipe  118  and a bottom hole assembly  120  located at the lower portion of the drill pipe  118 . The bottom hole assembly  120  may include a drill collar  123 , a downhole tool  124  and a drill bit  126 . The downhole tool  124  may be any of a number of different types of tools including MWD tools or LWD tools. Any or all of the drilling operations may be performed by a drilling operator or automatically by a control system  138 . 
         [0018]    In addition to the downhole tool  124 , the drill string  108  may include sensors  151  for monitoring and measuring different downhole parameters. These parameters may include temperature and pressure of the wellbore; the resistivity, density, or porosity of the surrounding formation; and the size, shape, and alignment of the borehole  112 ; or any other property of interest. 
         [0019]    During drilling, the drill string  108  is rotated by the rotary table  110 . The rotation of the drill string causes the drill bit  126  to remove material from the subsurface formation  114 , the removed material forming “cuttings”  128  within the wellbore  112 . 
         [0020]    As part of drilling operations, a drilling fluid may be circulated through the wellbore  112 . In one embodiment, the drilling fluid is pumped by a drilling fluid pump  132  into the drill string  108  from a drilling fluid reservoir  134 . The drilling fluid travels through the hollow interior of the drill string  108 , through the drill bit  126 , and into the wellbore  112 . The drilling fluid returns to the surface via an annulus  140  formed by the drill string  108  and the wellbore  112 . At the surface, the wellbore  112  may be capped by a blowout preventer  142  having a bell nipple  144 . After passing through the bell nipple  144 , the drilling fluid may travel through an outlet pipe  146  to a storage or containment pond or to the reservoir  134  for use in later drilling operations. Cuttings and other impurities may be removed from the drilling fluid by filtration or by allowing the cutting or impurities to settle out of the fluid. 
         [0021]    Drilling fluid may be circulated through the wellbore to perform various functions, including supporting the drill string  108 ; cooling and lubricating the drill bit  126 ; maintaining hydrostatic pressure on the subsurface formation  114  and formation fluids to prevent well blowouts; improving the stability of the wellbore  112 ; and removing cuttings  128  from the wellbore. The drilling fluid may be formulated to perform one or more functions particularly effectively. For example, “sweep” is a high-density drilling fluid formulated for improved removal of cuttings. 
         [0022]    The control system  138  may monitor one or more properties of the drilling fluid as the drilling fluid enters and exits the wellbore  112 . The property may be any measurable property of the fluid, including properties that are known to change as the drilling fluid passes through the wellbore. For example, mass, volume, and density are each properties of the drilling fluid that may change as the fluid passes through the wellbore due to, among other things, cuttings becoming entrained in the fluid. 
         [0023]    To monitor the fluid properties, the system  100  may include an inlet meter  160  located between the drilling fluid pump  132  and the drill string  108  and an outlet meter  162  located between the wellbore  112  and the reservoir  134 . In one embodiment, at least one of the inlet meter  160  and the outlet meter  162  are a type of meter capable of simultaneously measuring two or more of mass flow rate, volumetric flow rate, and density. For example, a Coriolis meter, which may be configured to simultaneously measure mass flow rate and density may be used as the inlet meter  160  and the outlet meter  162 . In some embodiments, measurements taken by the inlet meter  160  may be replaced by a calculated value based on speed and size of the drilling fluid pump  132  and tabulated or historical data of drilling fluid properties. 
         [0024]    The inlet meter  160  and the outlet meter  162  are installed as close to the wellbore as is practical. Doing so generally lessens any influence on the fluid properties not directly related to passage through the wellbore  112 . Equipment present in the system  100  may limit or make certain placements of the inlet meter  160  and the outlet meter  162  more convenient. For example, when a blowout preventer  142  is present, the outlet meter  162  may be easier to install and maintain if installed at the bell nipple  144  instead of in piping downstream of the blowout preventer  142 . 
         [0025]    The control system  138  may be centralized or distributed and may include one or more computer systems  170 . Each computer system may have at least a processor for executing instructions and a memory for storing instructions and other data related to the computer system and the drilling operations. A computer system may be one of a variety of devices having a processor and memory, including: a personal computer (laptop or desktop), a server, a workstation, a microcontroller, a microcomputer, a programmable logic controller (PLC), an integrated circuit, a mobile device such as a smartphone or personal data assistant (PDA), or any similar system. Although many of these devices combine a processor and a memory in a single assembly, the processor and memory may be distributed among several devices capable of communicating with each other. 
         [0026]    The memory for storing instructions may be in any format or combination of memory formats known in the art and accessible, directly or indirectly, by the processor. The memory may be in the form of installation memory, such as an installation CD/DVD-ROM or USB “thumb” drive, system memory (i.e., RAM), or other forms of computer storage including mechanical hard drives, solid state hard drives, optical discs, tape drives, flash memory, or SD cards. Depending on the type of memory used, the memory may be configured in a RAID or similar arrangement that provides redundancy or improved performance. 
         [0027]    Instructions executed by the processor may be stored in the memory as software, firmware, or any other format suitable for execution by the processor. The programs stored in memory may be created using any programming techniques and in any programming language. 
         [0028]    In one embodiment, the control system may perform one or more of a variety of functions including controlling drilling equipment; collecting data from sensors; retrieving data from logs or look-up tables; performing calculations on the collected or retrieved data for analysis; monitoring the drilling operations; communicating data to other computers or control systems via a local network or the internet; and storing data in a database or other similar form of collected data. 
         [0029]    A drilling operator may access the control system through a graphical user interface (GUI) as presented to the drilling operator on a display. In one embodiment, the GUI may dynamically display data in real-time. The GUI may also display historical data, enabling an operator to review data collected earlier in the drilling operation or during other drilling operations. The GUI may display graphs, charts, or other forms of data that may be manipulated or customized by the user or a system administrator to emphasize particular data of interest. For example, the user may add trend lines, change colors, or limit the data to a specific period of the drilling operations. 
         [0030]    The control system may be configured to issue alarms to personnel and equipment if the control system detects an abnormal condition. For example, the control system may issue an alarm if a sensor reading or a calculation result falls outside of a predetermined range of safe values. In response to the alarm, drilling operators may manually modify drilling operations to avoid potential harm to equipment, personnel, and the environment. Alternatively, the control system or drilling equipment may automatically respond to the alarm by entering into an alternate mode of operation directed to resolving the abnormal condition. If the abnormal condition is not removed after a certain period of time, worsens, or is sufficiently outside of normal operating conditions, the control system may send an emergency shutdown signal, stopping certain pieces of drilling equipment or halting drilling operations altogether. 
         [0031]      FIG. 2  is a flow chart illustrating a method for monitoring changes in a drilling fluid implemented in the control system according to one embodiment. A stream of drilling fluid is divided into at least one discrete fluid unit  202  by the control system. The amount of the drilling fluid in each fluid unit may be based on volume of the fluid unit, mass of the fluid unit, or any other suitable division. If an inlet meter is present, measurements from the inlet meter may be used by the control system to divide the fluid stream. As an alternative to using the inlet meter, the division of the drilling fluid may be based on characteristics and measurements from a drilling fluid pump used to circulate the drilling fluid through the wellbore. For example, the division of the fluid may be based on a predetermined number of pump cycles. 
         [0032]    Before a fluid unit enters the wellbore, a first value for a property of the fluid unit is determined  204 . The property may be directly measured using an inlet meter or may be calculated based on known parameters such as pump speed, pump volume, and fluid density. After the first value of the property is determined, an estimated change in the property is determined to predict the change in the property of the fluid unit as it passes through the wellbore. The estimated change in the fluid property may be determined by experimental results, analysis of data from previous drilling operations, predictive modelling, or other suitable methods. 
         [0033]    After the fluid unit has circulated through the wellbore, a second value of the property is measured  212  by an outlet meter and an actual change of the property is calculated by subtracting the first value of the property from the second value of the property  214 . The actual change in the property is then compared to the estimated change in the property  216 . 
         [0034]    Matching of the first values and second values for a particular fluid unit is performed by calculating a travel time  208  for the fluid unit to pass from a first location where the first value is determined, to a second location, where the second value is measured. Specifically, a first value for a fluid unit is measured at the first location, then, after the travel time has elapsed, a second value for the fluid unit is measured at the second location. 
         [0035]    In some embodiments, the travel time is the sum of an inflow time and an outflow time. The inflow time is the time required for a fluid unit to travel between the first location where the first value is measured and the bottom of the wellbore. The outflow time is the time required for the fluid unit to travel from the bottom of the wellbore to the second location where the second value is measured. 
         [0036]    Generally, travel time is calculated by determining a total volume between the first and second locations and dividing the volume by the flow rate of the drilling fluid. In embodiments where the travel time is divided into an inflow time and an outflow time, the inflow time is determined based on an inflow volume. The inflow volume is the volume of a flow path from the first location to the bottom of the drill string. The inflow volume is defined by inflow equipment including pipes and hoses between the first location point and the drill string inlet, the drill string, the drill bit, and any volumes of fittings or other equipment between the first location and the drill bit. 
         [0037]    After the first value is measured at the first location and the inflow time elapses, the fluid unit is assumed to be exiting the drill string and beginning to travel back to the surface. Similar to the inflow time, the outflow time may be calculated based on an outflow volume. The outflow volume is defined by the annulus between the drill string and the well-bore and any equipment through which the fluid unit may flow as it returns to the surface and to the second point of measurement. 
         [0038]    After the outflow time elapses  210 , the fluid unit is assumed to have reached the second location and the second value is measured  212 . As a result, the first and second values generally correspond to the same fluid unit. 
         [0039]    The steps depicted in  FIG. 2  may be applied to any number of fluid units. 
         [0040]    To facilitate calculating the inflow volume and the outflow volume, a volume or a geometry for one or more pieces of inflow and outflow equipment may be stored in a database or lookup table for retrieval by the control system. In the case of a stored geometry, the control system may calculate a volume corresponding to the geometry using general mathematical principles. Once the control system determines the volume of each piece of inflow or outflow equipment, the volumes of each piece of inflow or outflow equipment may be summed to calculate the inflow or outflow volume, respectively. In addition to stored volume and geometry data, in some embodiments, values used in calculating the inflow or outflow volume may be collected during drilling operations. For example, some values may be determined dynamically by using MWD tools. 
         [0041]    Once the inflow or outflow volume is calculated, the inflow or outflow time may be determined by dividing the inflow or outflow volume by the flow rate of the drilling fluid. In the above embodiment, flow rate is assumed to be constant. However, flow rate of the drilling fluid may vary due to changes in the drilling fluid and inconsistencies in pump performance. To accommodate for potential variations in flow rate, one embodiment of the system may periodically sample the flow rate of the drilling fluid and update the travel time accordingly. Further, flow rate throughout sections of the system may be inconsistent due to the presence of certain pieces of drilling equipment. For example, deep sea drilling may require one or more booster pumps to bring drilling fluids to the surface due to the depths involved in deep sea drilling. Accordingly, proper calculation of travel time may need to account for variations in flow rates in different subsections of the inflow and outflow volumes. 
         [0042]    In another embodiment, the fluid unit may be tracked as it passes through the wellbore. Tracking involves determining the location of the fluid unit at intermediate points between the first and second location. 
         [0043]    In general, if an initial location of a fluid unit and a flow rate of the fluid unit are known, a final location of the fluid unit may be determined as it moves along a flow path having a known cross-sectional area according to the formula: 
         [0000]    
       
      
       x 
       final 
       =x 
       initial 
       +Δt×Vdot×A  
      
       
         where x final  is a final location of the fluid unit along the flow path, x initial  is an initial location of the fluid unit along the flow path, Δt is the time for the fluid unit to travel between x final  and x initial , Vdot is the flow rate of the fluid per unit time, and A is the cross-sectional area of the flow path through which the fluid is flowing. 
       
     
         [0045]    The above equation may be implemented in an iterative, step-wise manner to determine the location of a fluid unit as it moves along the flow path. To do so, the final location determined by the equation over a first time period is used as the initial location of the fluid unit for a subsequent time period. Repeating this process for a total time while updating the cross-sectional area of the flow path and the flow rate as required produces a set of locations of the fluid unit that tracks the location of the fluid unit over the total time. 
         [0046]    This principle may be applied in the current system to track a fluid unit as it passes through the wellbore. Because the system knows or can determine an initial position of the fluid unit (the first location where the first value is measured), the geometry of the flow path, and the flow rate of, the system may determine the fluid unit&#39;s final position after a period of time has elapsed. The final position of the fluid unit may then be used as a new initial position for a subsequent determination of the fluid unit location. Iterating this process over the entire travel time enables the system to determine a location of the fluid unit corresponding to each time period. 
         [0047]    The locations may be calculated in real time by periodically sampling the flow rate and recalculating the inflow and outflow volumes. Based on the needs of the drilling operator, the frequency of the sampling and recalculation may be adjusted to minimize use of computational resources and avoid collecting unnecessary data. As an alternative to real-time tracking, location data may be generated by assuming a constant flow rate and estimating the inflow and outflow geometries. 
         [0048]    Tracking the fluid units provides additional detail regarding the drilling operations by allowing correlation of the location of a fluid unit with a change in its properties. For example, tracking may be used to determine the time at which a fluid unit passed through the drill bit. If the fluid unit passed through the drill bit during a time when drilling was not occurring and no cuttings were located at the bottom of the wellbore, an increase in density of the fluid unit might indicate washout or collapse of the wellbore. 
         [0049]    The data collected for each fluid unit may be displayed by the control system in real time or logged by the control system in a file or database. Analysis of the fluid unit data by an operator or by the control system may be performed on a single fluid unit or a set of fluid units. A set of fluid units may consist of the entire set of fluid units that have been measured by the system or may be a subset of all fluid units. When analyzing a set of fluid units, data may be numerically integrated for analysis of totalized values. For example, the masses of a set of fluid units may be integrated to determine their the total mass or total change in mass. 
         [0050]    Monitoring of the fluid units can enable an operator or control system to analyze the effectiveness of various drilling operations and detect abnormalities during the drilling process. The following example illustrates how the system and method may be used to monitor and analyze drilling operations. Specifically, the following examples illustrate applications of the system to monitor the effectiveness of cuttings removal and to detect the phenomenon of ballooning. These examples are intended only to illustrate, not limit, embodiments of the disclosed system and method. For example, monitoring changes in fluid units in accordance with the disclosed system and method may be used for monitoring fluid losses to the formation, detecting “kicks” caused by sudden influxes of formation fluids into the wellbore, and monitoring “bottoms up” for settling or barite sag when restarting drilling operations after an interruption. 
         [0051]      FIG. 3  depicts a graph as may be presented by the GUI in accordance with one embodiment. The graph depicts total mass of a fluid exiting a wellbore as measured by the system over time. The graph includes three lines: theoretical total mass  302 , measured total mass  304 , and the difference between the theoretical mass and the measured mass  306 . The theoretical total mass is the estimated mass based on the initial mass of the fluid plus any predicted change in the fluid as a result of cuttings becoming entrained in the fluid. The measured mass on the other hand, represents the actual mass of the fluid as it exits the wellbore. As a result, the difference between the theoretical and measured masses indicates that not all cuttings have been swept from the wellbore. Further, the inconsistent slope of the measured mass line indicates that cuttings are not swept from the wellbore in at a consistent rate. 
         [0052]    By examining individual fluid units or sets of fluid units, an operator could determine specific causes of the difference in mass or the changing sweep rate. For example, a first series of fluid units with less than expected masses followed by a second series of fluid units having expected masses could indicate a decreased diameter of the wellbore when the first series of fluid units passed through the drill bit. As another example, a first series of fluid units with expected masses followed by a second series of fluid units with higher than expected masses could indicate an increased diameter of the wellbore or partial collapse of the wellbore, either of which would introduce additional cuttings into the wellbore. 
         [0053]      FIG. 4  depicts a second graph as may be presented by the GUI.  FIG. 4  depicts an expected change in density  402  and a measured change in density  404  of a series of fluid units. Notably, the density measurements are depicted as being associated with specific fluid units and are independent of time. By associating measurements with fluid units instead of time, an operator can account for interruptions or delays in drilling operations that may impact measurements. 
         [0054]      FIG. 4  also illustrates how the system may detect ballooning. Similar to a balloon that is inflated and then releases air when inflation stops, ballooning occurs when pumped fluids are taken in by the formation and then returned to the wellbore once pumping stops. As depicted in  FIG. 4 , when fluids are returned to the wellbore, fluid units may become diluted as indicated by a decrease in density.