Free Exhibits - District Court of Colorado - Colorado

Case 1:03-cv-02579-RPM

Document 142

Filed 01/11/2007

Page 1 of 7

-1
United States Patent
Gray Jr
et

Patent Date

Number

4606415
Aug 19
1986

al

METHOD AND SYSTEM DETECTING AND IDENTIFYING ABNORMAL DRILLING
CONDITIONS

4253530 4295366 Primary

3/1981

Sharki

ci

al

175/25 ....

Gibson

etal

175/48X

75

Inventors Rundell

Gray Jr Herbert
Thomas Williams of

Attorney

Agent

or

FirmRobert
Gillespie

Kulason

James

OLoughlin

Ronald

Houston
Assignee Texaco White Plains

ABSThACr N.Y
method abnormal and
drilling

system

for

detecting
It

and
the

AppI
Filed

conditions
ratio

determines
the the the

Nov 19
E2IB 21/08
175/24 175/38 175/48 Search 175/65 References 166/53 47/06

pump

speed-pressure

over

range output

of
pressure the

mt Q4
u.s
Field

working from the

measures

pump
detects ratio

nd
which
the

measures from

speed

pump
speed-

Then

it

chiæge of

normal abnormal
condition

pump
depends normal
If

pressure

conditions upon
or the

175/24

38
55

Identification

abnormal

66 250

whether output
the

the

pump speed
decreased
drilling

increased

above

pressure

normal
returning three greater

former observed

U.S
3.058532

PATENT
Alder

DOCUMENTS
175/25
et al

order
the

to

identify

one

of

conditions
than

If

the

number of decreases
are

predetermined of
or

3324717 3470971 3517553 3595075
3.726136

6/967
10/1969 6/1970

extent Brooks

counted

over

predetermined malfunctioning

Dower
Williams
ci

time 175/25 175/25 73/155 175/48

which

may

indicate

pump valve

valves

Dower ..._.. McKean ci

17

Drawing

WS

0002031

Case 1:03-cv-02579-RPM

Document 142

Filed 01/11/2007

Page 2 of 7

US

Pau.1nt

Aug 19

1986

Sheet

of

4606415

40/

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ELECT6WICS

DIGITAL

__________-j
PRESSURE
TRANSMITTER

2/SPZA/

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TI/A

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PRES5

WS

Case 1:03-cv-02579-RPM

Document 142

Filed 01/11/2007

Page 3 of 7

67

rio

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Case 1:03-cv-02579-RPM

Document 142

Filed 01/11/2007

Page 4 of 7

4606415
pressure ratio

an

abnormal

condition

is

indi

METHOD

AND SYSTEM
DRILLING

cated Again
ploying lating said briefly the

IDENTIFYING CONDITIONS
This general
invention

invention

is

em
pump
to said for
It

mud and
method which
pressure

having abnormal only

adjacent
detecting

well

con-

concerns
specifically

well the

drilling invention

procedures concerns
identifying

in

cerns tions

drilling

measuring of
said

speed
said

method and/or
abnormal Heretofore
pressure

system has been

for

and

output
conditions

pump

whereby
is

conditions

may be
briefly fluid
is

identified

common
on
the

practice

to

provide

10

Again wherein
cating returned

the into valves to

bore hole

hole

instrumentation

pump
there are

by
is

system
patents

during
dealing

well

drilling

and

number wherein

of

pump having
with

The mud
the as the detecting

cuttings

circulating

is

monitored no and

ways
simple method

How-

drilled

The

invention

concerns comprises of and
to said said

method of
steps

ever

there for

has

been

known

malfunctions

which
the

of continuously
fluid to

system
conditions

identifying

measunng monitoring
its

pressure said

circulating

with process Pat
an
It

during Arps U.S
deals

Thus
issued

is

signal patent

proportional

pressure

It

comprises speed
signal of

2925251
earth

16 and
information

which
20
in

the

step

of

borehole means
for the

pump and developing
tional to said

the measuring second electrical

properthe

system
the

speed
ratio

comprises of
said

normal
the
drill

hole

during
electrical the

pressure-speed

lust

4etermining and from

and comprises detected
the

deviation actuating

ling
trical

concerning
characteristics for

normal
the 25 said
is

of

the

earth types pressure drilling

and of

an alarm

when

system provides
tion to the hole

transmitting

Once
created

more

by means and
transmitted

of

briefly

invention

concerns during removing
drilling cuttings as

pulses

down
It is

up

the

column
the pressure 30

for

abnormal
circulating

conditions
fluid for

concerned
as received patent

with
at is

of surface
issued to

employing
said said well fluid

and means from
for

pulses

the

pump
means
for

for the

Another Pat with
tions

one

Brooks

et

al

U.S
deals

measuring

output
the

3324717
system and
it

dated

June optimizing
fluid

pressure

patent

method
measures makes

speed

of

pump and pump It also
for electronic

measuring
electric

pressure

and thse

openpump
meabeing
35

generating said said electric

means

of and

said

output means

pressure for

and

circuit

receiving

speed

it

separate

records

detecting

said

abnonnal

surements

pltls

that procedure
It

are

conditions

made
recordings of
drilling ling

makes

parallel

some

eight attempts

measurements improve not recognize
in

during
the or dril deal

BRIEF DESCRIPTION
The foregoing and other invention will be more fully the best mode tion
of
carrying there out are the

OF
objects set

procedure thereby

and

benefits

of

procedures
the

forth

below by

connec
inventors

with

concepts
patent

involved
is

the

Another

to

Walther 1976

Jr

et

al
patent has

No
back valve back

invention

and

in

connection
the

with

3968844
pressure by-pass pressure

issued

That

which wherein

illustrations

provided

valve
the

down
wall

hole string

check above
It

the

FIG
ments of according
to
is

schematic system
the

valve making

near

the

drill

bit static

con
pressure

showing method and/or

the

carry out

system

cerned which
in

with

measurements

of

indicate

when
to

drilling

mud

has

thinned

FIG
so

diagram
in

elements
circuits
in

that

annulus
patent issued

Also 4295366
with se
It

Gibson et al
That
patent
is

Pat

No
per

may be involved
with
the

the carrying

accordance
to

Oct 20
the

1981 of

invention

system for and
is

out

method

according

return dbes

FIG
sure

an

illustration at

shaped
fluid

conduit
not

recording improper according

showing portions the output of mud valves
is

pres

pump

it

returning

make any
circulating the 55

developed system

seating to the

provision
fluid cants

measuring
it

pressure not teach

of or

the

does

suggest

appli

FIGS
drilled
in

well

11

is

being

invention

12
and
in 16 involves
at

drilling there the

proce

BRIEF
The
circulated

SUMMARY
is in

dure
drill

is

has

lower

invention

well

wherein formation

fluid

is

60

thereof

procedure
that
is

drilling

not
It is

from

shown
circulated drilling
lates
it

hole and
fluid
It

wherein

pump
method

is

employed
detecting the

to

circulate identifying

commonly termed mud pump 19 pump 19
from
pit

picks

concerns

and
steps

or container

20

up the circu
19

abnormal
ing the

conditions
ratio for

of

as

indicated

by

arrows from
to the

pump
swivel

normal
pressure the

condi
from of
said

65

out

through
that
at

or path of

tions

and
It

output
also

hose

pump pump

comprises change
in

speed normal

shown
fluid or

the

top

the

The
the
drill

drilling string 15

and

mud

circulates

down

WS

0002034

Case 1:03-cv-02579-RPM

Document 142

Filed 01/11/2007

Page 5 of 7

4606415
and
out

through
the well

drill

bit

up through
will return line

the or

watch mine which Another
the

level

of

mud

in

the

pit

and

so deter

annulus

and
to the

out

three

exists

conduit
that the

24 and

back

be understood

abnormal
pressure transmitter

which may be detected
readings operation of sometimes
get that
its

pick

up and
they
line

of annulus where
cussed often cause get

formation and they
to the
settle

and

carry the cuttings flow back up the
the as

convalve

cerning
or

the

pump
Formation of

19
cuttings

return

mud
will the

pit

20
dis-

valves
seat

stuck

out

However
some
19

be

valve

more
carried

detail to the

hereafter

of

cuttings

the pump and prevent Under those conditions the in

mud

mud pump
of
the to valves circulate

where
in

may
the 10

rushes

through
seat

time erode narrow
pressure pressure rapidly

improper
it

not
the

valve

Such drops
in

cause
the

large

mud pump
Connected
near the

acting the of path

mud
drill is

occurring
fluid pressure sured In
IS is

pump 27

discharge
to the

which

to

circulating

equal

mea
the

output 27 with

pump
develops
pressure

19

there

pressure acor but

transmitter

an of

electrical the

signal fluid

to detect logic

the

valve
circuits so that

conditions

cordance

circulating various yet

comparison
pressure or

and

36
the

working
pressure preset

mud

This

transmitter
it

27

forms
reliable

setting

when

drops
pres.
is

preferably

is

and

fluctuations

occur of

that

ruggedly
factured

built

pressure

transmitter

such

as Divi-

level 93033

count

go below some number of such many of such
tolerated provide predetermined
actuate

by Calif Gould

made By determining
20

fluctuations

or

sion
is

drops

in

pressure

should
interval

count an

during
indication

PG3000
employed

Gauge more
in

Transmitter

than

number
the

The
culating

other system
19
is

mud
to

cir-

place and
25 the

The
will be

alarm 41
separate

tachometer
to

that the

attached speed
is

the

alerted
lights

Also by having
identified the

mud pump
during chometer
electrical sure

measure
well

of

pump
ta-

one be

of
directed to that

42

driller

will

As
30 and
pressure signals

11

faulty

valve
pressure valve

transmitter

27
the pres-

illustrates

recording of

read
condition

with
signals are

by

the

transmitter

circuit signal pass

respectively connections conditioning
signals to

transmitted

over go

the to 30

developed
the abscissae

Thus

the
is

pressure as the

is

shown
on

as the

and 34
electronics

respectively

which

while time normal
pressure

35
are

The
applied
the there as
is

35
circuits

FIG

graph
steady

pressure

line

48

is

the

comparison
included

while

the

pump
49

was
to

operating appear be those
It

36

to

which

external

pressure pressure

drops

began

to

memory
and
display control
It

element

drops
as the

49 were

discovered
the

logic-and-control

36 Also4
indicator

an alarm 41
as digital

33

caused
that

vaiycor drops
increased

pump.

will

be
the

are

well

pressure recording
in

continued

43

all

of which

are

controlled

outputs of
indicated

pressure

frequency

which

circuits

36
discovered of
that the

has been

making output of of

use

of from
the 40

pressure

measurement speed
the

pressure the

mud pump and
during
drilling conditions that

measurement

pump

operations

certain
it

may be made
gas
influx standpipe try
in

Thus
of

has
circulation or the de45

pump valves were increasingly being valve open Then pump with was turned off and another pump turned on in place indication That made clear that the difficulty pump was the valve or valves being held open FIG illustrates in diagram form elements
that the vide their separate signals as are part

covered

of

the

system

illustrated pressure

in

FIG
27
pro-

washout
transmitter crease the in

the

pressure to

measured
of

by

transmitter circuit case
in

27
pressure
will

decrease

over

the the

connections
In

system up
in

down
to to

33 maintain
the

respectively speed connection output 61 and
the signal to

pump
30

speed

order

FIG
proSo

30 goes
frequency-to-voltage

original eter

operating pressure Consequently which
signal
is

tachomwill the

converter

vide
tronic circuits

that

this

pump change

speed

60

Its

signals to

go

to

both

an

analog-digital

con
is

dcc-

verter

digital

62
has

system 36
will

i.e compare
the

logic-and-control

which
the

random 67
has to
its

access there-

with

only

memory

associated

normal from and

speed
the

for

pressure Consequently
pressure-speed as the driller
in

change be
55

normal

ratio

will will

The
over
voltage nals to the

pressure circuit

transmitter

output
isolated has

signals current

go
to

an

alarm
that

be

actuated begin
to
is

the

an

When

has happened
the level

may
20

then
in

converter
to digital 61

70

Converter

monitoring determine occurring
in

mud

order

another

AID

convener Both
of

output sig 71 as well as
the

which

foregoing with
fluid level

problems

display

conthe

60

verters

and

have 65 and

their outputs there are

connected

accordance by

foregoing
in

net
pit

fluid indicates

as

microprocessor

peripheral

observed
that fluid there

the

adapters 14 caption
In are

by
to the

single

with 65

has been

gas

influx

On
that

net

connected

microprocessor
interface

loss indicates

of
It

while no change by measuring of the pump the detected
the driller the 65

indicates

washout

may be noted
pressure
is

with
are

the

peripheral

adapters are for

only

the speed

output

74

there

two
bad

indicator

and
pressure/speed

which

appearance alarm 41 is

of abnormal

indicating

valve

or

change
for setting the

Then when

this

he

There

digital

82

WS

Case 1:03-cv-02579-RPM

Document 142

Filed 01/11/2007

Page 6 of 7

4606415
working
nection

pressure and with an alarm converter over 87

there

is

an

amplifier

con
digital-tosignal to

processor

65

At
time

the

same

time

the

timer
reset the the

running counter from
this are

Also
supplies

and

at

preset

will

92
the

analog
setting

low

pressure

The
counter whenever
within 78 will
It

65 92
befote

will

read 92

counts
In

circuit

connection
receives so that pressure pressure setting the

goes
input

counter

is

reset

way
made
light

comparison from convener compared counter
circuit peripheral the

89
70 low

signals are
is

number
preset

counts

signals

the

time

interval to

the other valve according out

indicator

There

be

illuminated that

show
system carrying abnormal

92

that applies

comparison
to

will

be noted

to

this

inven Thus

and

number of counts
over
circuit

one

of

the 10

tion

provides

means

for for

multi-purpese or of the
three

There processor clock
the timer

is

clock 65 and

96
to timer time will

with
this

93 micro
after the

mud system monitor
an

use with

drilling

alarm
are

if

either In are the

speed

manner

drops
possible matter
15

detected

case

predetermined
the

period 92
action

as
reset

indicated continue

Then
drilling

simple noting one of be deter

counter

be

by an output from by
the caption

for

driller level conditions

to

97 98

on

the the

drilling three

From
described

that

observation

connection

above

may

METHOD
As
deals lating well drilling

mined
by an
to this invention pressure 20

case alarm accompanied exceed

fourth

condition
indicator level
if

an

according procedure
that

reductions

for

employs
the

circu

predetermined Such
the

number of
is

times

during

interval

mud
pit

that to

pump
the

for circulating

condition

an

indication

of leaky valves
the detail

from

well and output

employs
pressure

pump
embodiments
in

only measurements of

of
those

speed two

While been
25 described

of

have

pump From
may be By making the
the the

measurements

abnormal

accor
to

conditions

identified

dance
as
in

with any claim
in

the limiting the

statues

this

is

not

be taken

two
speed of
is

when an
detected
ratio the
is

invention

but

merely

increase

greater

descriptive

thereof

than

speed/pressure
as to the

We
in the

may be

mud

wherein
drilled
is

circulated

for

Then
fied
in

one
the

of

conditions

may be identi
the level gas influx

30

removing

from
to circulate

and

manner One
an
the increase
pit

pump
detecting ing

employed

method
conditions

for

mination shows
is

level

identifying

abnormal

compris

identified

as

abnormal shows
in the

level

mod

pit

detennining
35

the

speed-pressure it

ratio

nonnal

ril

level
the

loss

And of mud
speed
pit in

three no change washout

.lingpndipns measuring measuring
detecting

determination
the

output speed change

pressure

from

said

pump

but
is

noted above

exists

of
in

said said

pump

and

identified

normal
condition to

The
tem according measured by from These where by
the the the to

method may be
the

carried

out by

sys
40

ratio In

whereby
drilling

an abnormal according

FIG

illustration

The speed
pressure transmitter

claim

tachometer
is

output
pressure to the

method

also

comprises
said

pump

measured go

27

identifying In step 45

detected according
to

condition claim
said

measurements normal

pressure/speed

microprocessor ratio is accounted
the

drilling identifying

of

comprises
in said

programming
ratio the to the indicator

When
light

speed be

exceeds illumi
fluid as to

detecting

an

increase the

speed of
said conditions

normal

determining
fluid

continuing one of

nated
level

Then
in

monitor

the

abnonnal

order
the

make

the

determination

may be
In
50

identified drilling to claim wherein according determination reduction

which
Another valve ation
cate

three

abnormal
is

abnormal

that

in

to
is

the

continuing

volume

or valves case
pressure the

pump
drops
signals

while

system

in

oper
indi

ume whereby
In

loss drillling

of according
to

is

pressure as

transmitter has

claim
is

sudden

been

described
into

above
the

continuing

an

increase

These

pressure

drop 65

are

connected compared
fed

mi
55

ume whereby
In well

gas

influx

is

identified to claim

croprocessor

they
signals

are

with

according washout according comprises
in said

speed
pressure

The

pressure

are

also

directly

continuing

no claim

change

converter

70

into

comparison from

circuit

89
are

Here compared which working
digital sent
is

ume whereby
In step

signals

converter

70

drilling identifying decreases

to

said

with

the

predetermined by
that the
is

low
in

pressure 65

setting the via

of

calculated pressure

microprocessor by
the calculated

detecting

output and

pressure

exceeding predeter

operator
pressure

predetermined counting mined condition
65 ln

extent
of

switch
via

low

setting

number

decreases faulty

in

one
87

of
to

the the

peripheral

adapters

74

and

D/A
circuit

verter

comparison
the pressure

over
transmitter

con con
are into

time

pump mud

valve

nection lower than
the

When
the

employing

and adja dril

pressure

setting

outputs
are

will

go

having
cent

pump
said

for

mud from
method abnormal

counter of

92
the

Then
peripheral

counts

transmitted to the

another

74

micro-

ling

conditions

comprising

WS

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Case 1:03-cv-02579-RPM

Document 142

Filed 01/11/2007

Page 7 of 7

4606415
measuring only whereby output
pressure

of

said

said reduction

deviation

comprises
fluid

determining
pressure

pump
In well also

may be
to

of

circulating

below

identified drilling

predetermined claim counting determined

level and olsaid
reductions

during claim

pre 13
an

method

interval drilling

15
an
increase in

detecting

measured
said

according

to

wherein
said pit

determining one of 10
step three drilling

of

mud

in

whereby

said increase
in

comprises speed normal
pressure-

may be
according
the
is

identified

well

to

claim

wherein an
increase

speed

ratio drilling

of

delermining gas
influx

36 mud

borehole
the

according three

to said

claim

15

further said

whereby
11
step ln.well

identified to

comprising claim decrease
15

step

of monitoring one of

level

according
level identified

malfunctions

may

he

of determining
circulation well
di-illing

determined

loss

17
ing well

system

for detecting

abnormal
circulating drilled

conditions fluid

12
step

accurding

to

claim no change

said

employing
as said said fluid

dur re

of
is

washout

identified

moving cuttings pump for
means
for into

and from

comprising
pressure

13
the

the

borehole by
causes as reciprocating said the to

wherein

output of

fluid valves cuttings

pump
means
for

pump having
be drilled steps

measuring and

the

speed means

with

with method of of

pump
each
said

to

electric put

signal pressure

generating said

for

out

mud

of

speed and
for said said electric

malfunctions

comprising

electronic circulatsignals said to said

circuit

means

continuously
ing fluid
first

pressure to
its

and

for detecting

abnormal

entry

into

and

means comprises
means having randon.access and

oping pressure

microprocessor
read.only

continuously developing
to said

measuring second

speed

of
signal

pump
proportional

and
30

means means
said

for setting for

pressure said

value
pressure signal

comparing
pressure

output

with

low
for

value
the

means
ratio

number of
set

said

determining
first

of

said pressure signal value

output

low
of

and

second
deviation

pressure

electrical

predetermined
for

detecting actuating

normal detected
drilling

means claim

when
quantity
is

said-

number
valve

an

alarm according
to

predetermined

whereby

34
wherein

In

13

said

pump

detected

40

45

50

55

60

65

\VS

0002037