System and method for monitoring drilling systems

Abstract

The present disclosure provides methods and systems for monitoring a drilling system, including methods and systems for estimating the life consumption of downhole drilling tools. The system employs a plurality of sensors that provide sensor signals related to the status of components in the drilling system. The sensor signals are analyzed using Functional Principal Component Analysis (FPCA) to give estimations for one or more performance metrics, including the life consumption of downhole drilling tools.

1 . A method for monitoring a drilling system, comprising:
 collecting a first set of sensor signals;   constructing a model using Functional Principal Component Analysis (FPGA) based on the first set of sensor signals, wherein the model is used to estimate one or more performance metrics of a component in the downhole drilling tool;   collecting a second set of sensor signals;   revising the model based on the second set of sensor signals; and   estimating the one or more performance metrics of the component in the downhole drilling tool using the revised model,   wherein the sensor signals reflect one or more conditions of the component in the downhole drilling tool.   
     
     
         2 . The method of  claim 1 , wherein the component in the drilling system is chosen from a drill bit, a drill string, a downhole motor, a MWD/LWD instrument, a drilling pipe, a drilling collar, a battery, a sensor, or an alternator, a bearing, and a pump. 
     
     
         3 . The method of  claim 2 , wherein the condition of the component in the drilling system is chosen from a temperature, a pressure, a vibration, a weight on bit, a noise level, or an RPM. 
     
     
         4 . The method of  claim 1 , wherein the component in the drilling system is a printed circuit board assembly (PCBA). 
     
     
         5 . The method of  claim 1 , wherein the performance metric is chosen from a failure probability, a life consumption, or a remaining useful life. 
     
     
         6 . The method of  claim 1 , wherein the model comprises a plurality of model parameters, including a grand mean function, a plurality of eigenfunctions, and a plurality of FPCA function scores. 
     
     
         7 . The method of  claim 1 , wherein the first set of sensor signals is used as a training dataset to construct the model. 
     
     
         8 . The method of  claim 1 , wherein the second set of sensor signals comprises a test dataset. 
     
     
         9 . The method of  claim 7 , wherein the first set of sensor signals comprises signal readings from the component in the downhole drilling tool from inception of an operation to failure of the component. 
     
     
         10 . The method of  claim 8 , the first set of sensor signals comprises signal readings from the same component from more than one operations. 
     
     
         11 . A system for monitoring a downhole drilling tool, comprising:
 a drilling assembly;   a plurality of sensors disposed about the drilling assembly, wherein the sensors provide sensor signals associated with the drilling assembly;   a processor;   a non-transitory machine readable medium communicably coupled to the processor;   a set of processor-executable instructions embodied in the non-transitory machine readable medium, the instructions being configured to implement a method, the method comprising:   collecting a first set of sensor signals;   constructing a model using Functional Principal Component Analysis (FPGA) based on the first set of sensor signals, wherein the model estimates a performance metric of a component in the downhole drilling assembly;   collecting a second set of sensor signals;   revising the model based on the second set of sensor signals; and   estimating the performance metric of the component in the downhole drilling assembly using the revised model,   wherein the sensor signals reflect at least one condition of the component in the downhole drilling assembly.   
     
     
         12 . The system of  claim 11 , wherein the drilling assembly comprises a drill bit, a drilling collar, and a MWD/LWD instrument. 
     
     
         13 . A drilling system, comprising:
 a downhole drilling tool;   a plurality of sensors disposed about the downhole drilling tool, wherein the plurality of sensors traverse a underground formation with the downhole drilling tool and generate sensor signals that reflect a condition of one or more components of the downhole drilling tool;   a computer configured to implement a method, the method comprising:   collecting a first set of sensor signals;   constructing a model using Functional Principal Component Analysis (FPGA) based on the first set of sensor signals, wherein the model estimates a performance metrics of a component in the downhole drilling tool;   collecting a second set of sensor signals;   revising the model based on the second set of sensor signals; and   estimating the performance metrics of the component in the downhole drilling tool using the revised model.   
     
     
         14 . The drilling system of  claim 13 , wherein the component in the downhole drilling tool is chosen from a drill bit, a drill string, a downhole motor, a MWD/LWD instrument, a drilling pipe, a drilling collar, a battery, a sensor, or an alternator. 
     
     
         15 . The drilling system of  claim 14 , wherein the condition of the component in the downhole drilling tool is chosen from a temperature, a pressure, a vibration, an a weight on bit (WOB), or an RPM. 
     
     
         16 . The drilling system of  claim 13 , wherein the component in the downhole drilling tool is a printed circuit board assembly (PCBA). 
     
     
         17 . The method of  claim 13 , wherein the performance metric is chosen from a failure probability, a life consumption, or a remaining useful life.