Earth-boring tool monitoring system for showing reliability of an earth-boring tool and related methods

Abstract

An earth-boring tool monitoring system may generate a contour plot representing reliabilities of an earth-boring tool within a range of operating loads, the contour plot showing a range of reliabilities of the earth-boring tool from 100 percent reliable to 0 percent reliable and may overlay a plurality of markers over the contour plot, each marker representing an instance in time and representing operating loads of the earth-boring tool at that instance in time. Furthermore, the earth-boring tool monitoring system shifts the contour plot based on a cumulative amount of damage experienced by the earth-boring tool.

1 . An earth-boring tool monitoring system, comprising:
 at least one processor; and   at least one non-transitory computer-readable storage medium storing instructions thereon that, when executed by the at least one processor, cause the system to:
 generate a contour plot representing reliabilities of an earth-boring tool within a range of operating loads, the contour plot showing a range of reliabilities of the earth-boring tool from about 100 percent reliable to about 0 percent reliable; and 
 overlay a plurality of markers over the contour plot, each marker representing an instance in time and representing operating loads of the earth-boring tool at that instance in time. 
   
     
     
         2 . The earth-boring tool monitoring system of  claim 1 , wherein the range of reliabilities is represented with a color gradient or grayscale gradient. 
     
     
         3 . The earth-boring tool monitoring system of  claim 1 , wherein the contour plot is generated based on simulation data from simulations or laboratory testing of drilling operations. 
     
     
         4 . The earth-boring tool monitoring system of  claim 1 , wherein the contour plot is generated based on historical data from previously performed drilling operations. 
     
     
         5 . The earth-boring tool monitoring system of  claim 1 , further comprising instructions that, when executed by the at least one processor, cause the system to:
 after overlaying the plurality of markers over the contour plot, detect a user interaction to change an operating parameter of the earth-boring tool due to risk indicated by at least one marker of the plurality of markers; and   in response to detecting the user interaction, change the operating parameter of the earth-boring tool.   
     
     
         6 . The earth-boring tool monitoring system of  claim 1 ,
 wherein overlaying a plurality of markers over the contour plot comprises overlaying one or more markers of the plurality of markers in a first color when, based at least in part on the operating loads represented in the one or more markers, the earth-boring tool is at low risk of failure.   
     
     
         7 . The earth-boring tool monitoring system of  claim 6 , further comprising overlaying at least one additional marker of the plurality of markers in a second color when, based at least in part on the operating loads represented in the at least one additional marker, the earth-boring tool is at high risk of failure. 
     
     
         8 . The earth-boring tool monitoring system of  claim 1 , wherein the range of operating loads comprises a range of torque and a range of weight-on-bit, and wherein each marker of the plurality of markers represents an applied torque and applied weight-on-bit of the earth-boring tool at the instance in time represented by the marker. 
     
     
         9 . The earth-boring tool monitoring system of  claim 1 , wherein data for the operating loads for the plurality of markers is acquired from a surface control unit of a drilling assembly. 
     
     
         10 . The earth-boring tool monitoring system of  claim 1 , wherein data for the operating loads for the plurality of markers is acquired from sensors disposed downhole on the earth-boring tool. 
     
     
         11 . An earth-boring tool monitoring system, comprising:
 at least one processor; and   at least one non-transitory computer-readable storage medium storing instructions thereon that, when executed by the at least one processor, cause the system to:
 generate a contour plot representing a range of reliabilities of an earth-boring tool within a range of operating loads; 
 overlay a plurality of markers over the contour plot, each marker representing an instance in time and representing operating loads of the earth-boring tool at the instance in time; and 
 shift the contour plot based at least in part on a cumulative amount of damage experienced by the earth-boring tool. 
   
     
     
         12 . The earth-boring tool monitoring system of  claim 11 , further comprising instructions that, when executed by the at least one processor, cause the system to determine the cumulative damage experienced by the earth-boring tool based at least in part on simulation data from simulations of drilling operations. 
     
     
         13 . The earth-boring tool monitoring system of  claim 11 , further comprising instructions that, when executed by the at least one processor, cause the system to determine the cumulative damage experienced by the earth-boring tool based at least in part on historical data from previously performed drilling operations. 
     
     
         14 . The earth-boring tool monitoring system of  claim 9 , wherein overlaying a plurality of markers over the contour plot comprises overlaying one or more markers of the plurality of markers in a first color when, based on the operating loads represented in the one or more markers, the earth-boring tool is at low risk of failure. 
     
     
         15 . The earth-boring tool monitoring system of  claim 14 , further comprising overlaying at least one additional marker of the plurality of markers in a second color when, based on the operating loads represented in the at least one additional marker, the earth-boring tool is at high risk of failure. 
     
     
         16 . The earth-boring tool monitoring system of  claim 11 , wherein shifting the contour plot based at least in part on a cumulative amount of damage comprises shrinking an operational window of the contour plot. 
     
     
         17 . An earth-boring tool monitoring system, comprising:
 at least one processor; and   at least one non-transitory computer-readable storage medium storing instructions thereon that, when executed by the at least one processor, cause the system to:
 generate a contour plot representing a range of reliabilities of an earth-boring tool within a range of operating loads; 
 overlay a first marker over the contour plot representing a first instance in time, representing a first operating load of the earth-boring tool at that instance in time, and having a first color indicating no risk; 
 shift the contour plot based at least in part on a cumulative amount of damage experienced by the earth-boring tool; and 
 overlay a second marker over the contour plot representing a second instance in time, representing a second operating load of the earth-boring tool at the second instance in time that is less than the first operating load, and having a second color indicating risk. 
   
     
     
         18 . The earth-boring tool monitoring system of  claim 17 , wherein the shift of the contour plot is based at least partially on an age of the earth-boring tool. 
     
     
         19 . The earth-boring tool monitoring system of  claim 17 , wherein the range of reliabilities is represented with a color gradient or a grayscale gradient. 
     
     
         20 . The earth-boring tool monitoring system of  claim 17 , wherein the range of operating loads comprises a range of torque and a range of weight-on-bit.