Fatigue Calculator Generation for Drill Collar Monitoring
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Solution Overview
Problem
Current methods for tracking fatigue in drill collar components during oil well drilling are labor-intensive and inefficient, relying on expert knowledge for finite element analysis and requiring multiple simulations to generate fatigue calculators, which can be time-consuming and prone to errors, especially when BHA configurations change.
Innovation Solution
A system and method for automatically generating fatigue calculators using master curve fitting coefficients, which determine curvature, bending moment, and fatigue damage in real-time, allowing for real-time tracking and management of fatigue damage in drill collar components, enabling proactive maintenance and reducing the risk of twist-offs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional finite element analysis methods are used to track fatigue in drill collar components, then accuracy in fatigue assessment is improved, but labor intensity and time consumption increase significantly
Solution Approach 1:
The system performs preliminary actions by pre-calculating and storing master curve fitting coefficients for different connection types (threaded connections, port holes, etc.) before actual drilling operations. These pre-computed coefficients capture the fatigue behavior characteristics, eliminating the need for time-consuming finite element simulations during field operations. The fatigue calculator uses these pre-prepared coefficients to rapidly assess fatigue damage.
Solution Approach 2:
The invention creates simplified copies of the complex finite element analysis results in the form of master curve fitting coefficients. Instead of performing full FEM simulations, the system uses these coefficient copies that represent the essential fatigue characteristics of different connection types. This copying approach maintains assessment accuracy while dramatically reducing computational time and resource requirements.
2Adaptability or versatility
If multiple simulations are performed to generate fatigue calculators for different BHA configurations, then comprehensive fatigue coverage is improved, but device complexity and operational difficulty increase
Solution Approach 1:
The system achieves universality by developing a single fatigue calculator framework that can handle multiple bottom hole assembly (BHA) configurations through the use of master curve fitting coefficients for different connection types (threaded connections, port holes, etc.). Instead of creating separate simulation models for each configuration, the universal calculator adapts to various configurations by selecting appropriate pre-computed coefficients, thereby maintaining comprehensive coverage while simplifying the operational process.
Solution Approach 2:
The invention utilizes parameter changes by varying the master curve fitting coefficients based on the specific connection type and BHA configuration being analyzed. Rather than changing the fundamental calculation methodology for each configuration, the system maintains a consistent computational framework and simply adjusts the input parameters (coefficients) to match the specific scenario, thereby reducing complexity while maintaining versatility.
3Measurement precision
If expert knowledge is required for finite element analysis, then analysis accuracy is improved, but ease of operation deteriorates
Solution Approach 1:
The system implements self-service by automating the fatigue analysis process. The fatigue calculator automatically selects the appropriate master curve fitting coefficients based on the connection type and performs the fatigue damage calculation without requiring expert intervention. This self-service capability maintains accurate fatigue assessment while eliminating the need for specialized expert knowledge, thereby dramatically improving ease of operation.
Solution Approach 2:
The master curve fitting coefficients serve as an intermediary between the complex finite element analysis and the simple fatigue calculation. Instead of requiring users to perform complex FEM analysis, the coefficients act as a mediator that translates the complex analysis results into a simplified form that can be easily applied. This intermediary approach preserves accuracy while removing the need for expert knowledge in operation.
Data Source
AI summary
Aspects of the disclosure can relate to a system for tracking fatigue damage experienced by a tool in real-time. The system can include a processor operably coupled to a memory and operable to execute one or more modules to generate master curve fitting coefficients for a connection type associated with a tool component (e.g., a component of a bottom hole assembly). The master curve fitting coefficients can be for a threaded connection master curve, a port hole master curve, and so forth. The processor can also be operable to execute the one or more modules to generate a fatigue calculator for the tool component. The system may receive a real-time trajectory for the tool, determine a curvature from the trajectory of the tool, determine a bending moment based upon the curvature, and determine fatigue damage for the tool component based upon the bending moment using the fatigue calculator.