| CPC E21B 44/005 (2013.01) [E21B 4/02 (2013.01); E21B 47/12 (2013.01); F04C 2/107 (2013.01); G05B 19/048 (2013.01); F04C 2270/80 (2013.01)] | 19 Claims |
|
1. A system, comprising:
a drilling operation at a well site, wherein the drilling operation comprises a plurality of drilling parameters which define the processes of the drilling operation and a positive displacement motor, wherein the positive displacement motor comprises:
a power section comprising a stator and a rotor, wherein the rotor is configured to rotate within the stator in response to a passage of drilling mud,
a transmission section configured to transmit torque from the rotor to a driveshaft,
a bearing assembly section comprising the driveshaft and a plurality of bearings, wherein the driveshaft is configured to drive a drill bit connected to the positive displacement motor,
a plurality of embedded sensors, wherein each embedded sensor has an embedded sensor type and an embedded sensor location in the positive displacement motor, the plurality of embedded sensors comprising:
a first sensor with an ultrasonic sensor type disposed at a first location in the power section and configured to measure a thickness of the stator;
a second sensor with a rotations per minute (RPM) sensor type disposed at a second location in the transmission section; and
a third sensor with a temperature sensor type disposed at a third location in the bearing assembly section,
a process control unit, and
a communication line that axially traverses, at least a portion of, the positive displacement motor and connects the plurality of embedded sensors to the process control unit; and
a computer communicably connected to the plurality of embedded sensors and comprises:
one or more computer processors, and
a non-transitory computer readable medium storing instructions executable by a computer processor, the instructions comprising functionality for:
receiving, from the process control unit, a data stream from the plurality of embedded sensors;
monitoring the data stream according to the embedded sensor type and the embedded sensor location;
generating a first alert if an embedded sensor in the plurality of embedded sensors, as monitored by the data stream, resides outside a pre-defined range specific to the embedded sensor based on the embedded sensor type and the embedded sensor location;
processing the data stream to predict a failure mode and time to the failure mode; and
detecting a failure in the positive displacement motor based on the data stream and generating a second alert indicating the failure.
|