Abstract: A rotary tool for operation within an underground borehole or within tubing in a borehole has a tool body and at least one sensor-containing unit attached to the tool body and positioned to contact the conduit wall. The sensor-containing unit includes an exterior portion to contact the borehole or tubing wall and one or more sensors is located in a cavity between the exterior portion and the tool body. The sensor-containing unit may be formed from the exterior portion, an attachment portion for attachment to the tool body, and one or more connecting portions extending between the attachment and exterior portions, with the sensor-containing cavity between the attachment and exterior portions. Possible rotary tools include drill bits, reamers, mills, stabilizers, and rotary steerable systems.

Abstract: A rotary tool for operation within an underground wellbore or within tubing in a wellbore has at least one force-sensitive element attached to the tool body and positioned to contact the conduit wall, wherein the force-sensitive element comprises an outer portion to contact the wellbore or tubing wall, at least one connecting portion which is more compliant than the outer portion and through which the outer portion is connected to the tool body, and at least one sensor responsive to force on the outer portion transmitted through the force-sensitive element to the tool body. The sensors may resolve forces into measurable forces on three axes. Possible rotary tools include drill bit, reamer, mill, stabilizer and rotary steerable system for a drill bit.

Abstract: A rotary tool for operation within an underground borehole or within tubing in a borehole has a tool body and at least one sensor-containing unit attached to the tool body and positioned to contact the conduit wall. The sensor-containing unit includes an exterior portion to contact the borehole or tubing wall and one or more sensors is located in a cavity between the exterior portion and the tool body. The sensor-containing unit may be formed from the exterior portion, an attachment portion for attachment to the tool body, and one or more connecting portions extending between the attachment and exterior portions, with the sensor-containing cavity between the attachment and exterior portions. Possible rotary tools include drill bits, reamers, mills, stabilizers, and rotary steerable systems.

Abstract: A rotary tool for operation within an underground borehole or within tubing in a borehole has a tool body and at least one sensor-containing unit attached to the tool body and positioned to contact the conduit wall. The sensor-containing unit includes an exterior portion to contact the borehole or tubing wall and one or more sensors is located in a cavity between the exterior portion and the tool body. The sensor-containing unit may be formed from the exterior portion, an attachment portion for attachment to the tool body, and one or more connecting portions extending between the attachment and exterior portions, with the sensor-containing cavity between the attachment and exterior portions. Possible rotary tools include drill bits, reamers, mills, stabilizers, and rotary steerable systems.

Abstract: A method for detecting an influx and/or loss of circulation in a wellbore, comprising measuring a condition in the wellbore using a downhole sensor; determining that a positive displacement pump is shut off or turned on; predicting pit volume and/or gas concentration at a plurality of time points after the positive displacement pump is shut off or turned on using the measured condition in the wellbore prior to the positive displacement pump is shut off or turned on, wherein the measured condition correlates with the pit volume and/or gas concentration; measuring pit volume and/or gas concentration at the plurality of time points; comparing the predicted and the measured pit volumes and/or gas concentrations at the plurality of time points; and producing a warning signal if the difference between the predicted and the measured pit volumes and/or gas concentrations is greater than a pre determined value.

Abstract: A rotary tool for operation within an underground borehole or within tubing in a borehole has a tool body and at least one sensor-containing unit attached to the tool body and positioned to contact the conduit wall. The sensor-containing unit includes an exterior portion to contact the borehole or tubing wall and one or more sensors is located in a cavity between the exterior portion and the tool body. The sensor-containing unit may be formed from the exterior portion, an attachment portion for attachment to the tool body, and one or more connecting portions extending between the attachment and exterior portions, with the sensor-containing cavity between the attachment and exterior portions. Possible rotary tools include drill bits, reamers, mills, stabilizers, and rotary steerable systems.

Abstract: A rotary tool for operation within an underground wellbore or within tubing in a wellbore has at least one force-sensitive element attached to the tool body and positioned to contact the conduit wall, wherein the force-sensitive element comprises an outer portion to contact the wellbore or tubing wall, at least one connecting portion which is more compliant than the outer portion and through which the outer portion is connected to the tool body, and at least one sensor responsive to force on the outer portion transmitted through the force-sensitive element to the tool body. The sensors may resolve forces into measurable forces on three axes. Possible rotary tools include drill bit, reamer, mill, stabilizer and rotary steerable system for a drill bit.

Abstract: A method is provided for controlling a managed pressure drilling system. The method comprises providing a fast system interpretation model for the operation of the managed pressure drilling system, obtaining real-time measurements from one or more sensors regarding the operation of the managed pressure drilling system, using the measurements to calibrate the fast system interpretation model for the managed pressure drilling system in real-time and using a predictive controller to run the calibrated fast system interpretation model to a time horizon in the future.

Abstract: A method for detecting an influx and/or loss of circulation in a wellbore, comprising measuring a condition in the wellbore using a downhole sensor; determining that a positive displacement pump is shut off or turned on; predicting pit volume and/or gas concentration at a plurality of time points after the positive displacement pump is shut off or turned on using the measured condition in the wellbore prior to the positive displacement pump is shut off or turned on, wherein the measured condition correlates with the pit volume and/or gas concentration; measuring pit volume and/or gas concentration at the plurality of time points; comparing the predicted and the measured pit volumes and/or gas concentrations at the plurality of time points; and producing a warning signal if the difference between the predicted and the measured pit volumes and/or gas concentrations is greater than a pre determined value.

Abstract: Optimizing the operation of a hydraulically powered rotor and stator driven drill as it drills a wellbore into the earth is described. Drilling optimization is provided measuring a first set of rotor and stator operating parameters including the speed of rotation of the rotor and rotor torque for a first period of time, generating a first set of relationships from the first set of operating parameters to enable the rotor speed and rotor torque to be predicted over a range of operating parameter values, determining from the relationships a first more optimal mode of operation, and changing at least one operating parameter to move the operation of the rotor and stator towards the more optimal mode of operation.

Abstract: A method for determining a drilling state of a bottom hole assembly in a wellbore includes acquiring one or more downhole sensor measurements and processing the sensor measurements using a downhole processor to determine a drilling state of the bottom hole assembly. An operating state of the bottom hole assembly may be automatically changed in response to the determined drilling state. A method for computing a dynamic drilling energy of a bottom hole assembly includes acquiring at least one sensor measurement and processing the sensor measurements to obtain at least one of (i) an energy of axial motion of the bottom hole assembly, (ii) an energy of rotational motion of the bottom hole assembly, and (iii) an energy of lateral motion of the bottom hole assembly.

Abstract: The invention provides a method of optimizing the rate of penetration of a hydraulically or pneumatically powered rotor and stator driven drill as it drills a wellbore into the earth, the method comprising: (a) measuring a first set of rotor and stator operating parameters including the weight applied to the drill bit, the speed of rotation of the rotor and rotor torque for a first period of time, (b) generating a first set of relationships from the first set of operating parameters to enable the rotor speed and rotor torque to be predicted over a range of operating parameter values, (c) determining the rate of penetration for the first period of time from measurements of weight applied to the bit and rotation speed of the bit, (d) determining whether any other combination of weight applied to bit and rotation speed of bit, provided by the relationships determined in step (b) are capable of providing a greater rate of penetration, and (e) adjusting at least one operating parameter to move the weight applied t

Abstract: The invention relates to downhole motors for rotating drill bits. The downhole motors may comprise stators, turbines or the like. The drilling motor may comprise a drilling apparatus comprising a drill bit connected to a rotor rotatably housed within a stator (or a turbine rotor in a housing), the rotor comprising at least one magnetic field source or magnetic field detector, and the stator comprising at least one magnetic field source if the rotor comprises a magnetic field detector or comprising at least one magnetic field detector if the rotor comprises a magnetic field source, thereby allowing the rotation speed of the rotor relative to the stator to be measured.

Abstract: Method for controlling bottomhole pressure in a borehole during managed pressure drilling. In the drilling procedure fluid is circulated down a drillstring and to surface through an annulus between the drillstring and an inner-wall of the borehole. A compressor/pump is used to inject gas into the returning drilling fluid at a gas injection point. The method comprises receiving a target bottomhole pressure; determining actual bottomhole pressure during the procedure; and adjusting a variable as directed by a feedback controller, which operates to reduce the difference between the target pressure and the measured pressure. The manipulated variable may be one or any combination of: (1) pressure of drilling fluid at the entry of the fluid into the drillstring, (2) the flow rate of drilling fluid out of the drillstring into the annulus, (3) pressure of the gas exiting from the compressor, and (4) the injection rate of the gas.

Abstract: A method is provided for controlling a managed pressure drilling system. The method comprises providing a fast system interpretation model for the operation of the managed pressure drilling system, obtaining real-time measurements from one or more sensors regarding the operation of the managed pressure drilling system, using the measurements to calibrate the fast system interpretation model for the managed pressure drilling system in real-time and using a predictive controller to run the calibrated fast system interpretation model to a time horizon in the future.

Abstract: A method for automating a downhole milling process includes receiving an input stream from at least one sensor within a downhole milling system, and segmenting the input stream. A safe operating envelope is identified based on segments of the input stream and models for the segments. At least one parameter of the milling system is then automatically changed along a path of optimal rate of penetration while remaining within the safe operating envelope. In some embodiments, an input stream may include surface pressure and the safe operating envelope may include swarf transport conditions.

Abstract: This disclosure relates in general to a method and system for controlling a drilling system for drilling a borehole in an earth formation. More specifically, but not by way of limitation, embodiments of the present invention provide systems and methods for controlling dynamic interactions between the drilling system for drilling the borehole and an inner surface of the borehole being drilled to steer the drilling system to directionally drill the borehole. In another embodiment of the present invention, data regarding the functioning of the drilling system as it drills the borehole may be sensed and interactions between the drilling system for drilling the borehole and an inner surface of the borehole may be controlled in response to the sensed data to control the drilling system as the borehole is being drilled.

Abstract: This disclosure relates in general to a method and system for controlling a drilling system for drilling a borehole in an earth formation. More specifically, but not by way of limitation, embodiments of the present invention provide systems and methods for controlling dynamic interactions between the drilling system for drilling the borehole and an inner surface of the borehole being drilled to steer the drilling system to directionally drill the borehole. In another embodiment of the present invention, data regarding the functioning of the drilling system as it drills the borehole may be sensed and interactions between the drilling system for drilling the borehole and an inner surface of the borehole may be controlled in response to the sensed data to control the drilling system as the borehole is being drilled.

Abstract: This disclosure relates in general to a method and system for controlling a drilling system for drilling a borehole in an earth formation. More specifically, but not by way of limitation, embodiments of the present invention provide systems and methods for controlling dynamic interactions between the drilling system for drilling the borehole and an inner surface of the borehole being drilled to steer the drilling system to directionally drill the borehole. In another embodiment of the present invention, data regarding the functioning of the drilling system as it drills the borehole may be sensed and interactions between the drilling system for drilling the borehole and an inner surface of the borehole may be controlled in response to the sensed data to control the drilling system as the borehole is being drilled.

Abstract: A method for determining a drilling state of a bottom hole assembly in a wellbore includes acquiring one or more downhole sensor measurements and processing the sensor measurements using a downhole processor to determine a drilling state of the bottom hole assembly. An operating state of the bottom hole assembly may be automatically changed in response to the determined drilling state. A method for computing a dynamic drilling energy of a bottom hole assembly includes acquiring at least one sensor measurement and processing the sensor measurements to obtain at least one of (i) an energy of axial motion of the bottom hole assembly, (ii) an energy of rotational motion of the bottom hole assembly, and (iii) an energy of lateral motion of the bottom hole assembly.