EP3194716A1 - System and method for determining productivity of a drilling project - Google Patents
System and method for determining productivity of a drilling projectInfo
- Publication number
- EP3194716A1 EP3194716A1 EP15772127.5A EP15772127A EP3194716A1 EP 3194716 A1 EP3194716 A1 EP 3194716A1 EP 15772127 A EP15772127 A EP 15772127A EP 3194716 A1 EP3194716 A1 EP 3194716A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- phase
- phases
- data
- machine
- time stamp
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
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- 238000005553 drilling Methods 0.000 title claims abstract description 92
- 230000008569 process Effects 0.000 claims abstract description 87
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B44/00—Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B19/00—Handling rods, casings, tubes or the like outside the borehole, e.g. in the derrick; Apparatus for feeding the rods or cables
- E21B19/16—Connecting or disconnecting pipe couplings or joints
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/02—Drilling rigs characterised by means for land transport with their own drive, e.g. skid mounting or wheel mounting
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F17/00—Digital computing or data processing equipment or methods, specially adapted for specific functions
- G06F17/40—Data acquisition and logging
Definitions
- Embodiments are directed to a method for use by a drilling machine comprising receiving drilling machine data during execution a plurality of processes by the drilling machine associated with each of a plurality of phases of a drilling project.
- the method comprises automatically detecting a start state and an end state of each of the phases, generating time stamp data in response to detecting at least the start state of each phase, receiving an operator input confirming the start state of a particular phase of the plurality of phases, and electronically identifying the particular phase based on the operator input.
- the method also comprises storing the identity, a time duration, and the machine data for each of the particular and preceding phases, and generating an output comprising the identity, a time duration, and the machine data for each of the phases.
- Some embodiments are directed to a method for use by a drilling machine comprising receiving drilling machine data during execution a plurality of processes by the drilling machine associated with each of a plurality of phases of a drilling project.
- the method comprises automatically detecting a start state and an end state of each of the phases, generating time stamp data in response to detecting at least the start state of each phase, receiving an operator input confirming the start state of a particular phase of the plurality of phases, and electronically identifying the particular phase and one or more phases preceding the particular phase based on the operator input.
- the method also comprises storing the identity, a time duration, and the machine data for each of the particular and preceding phases, and generating an output comprising the identity, a time duration, and the machine data for each of the phases.
- Other embodiments are directed to a method for use with a drilling machine comprising receiving data about the drilling machine during a plurality of processes associated with each of a plurality of non-excavation phases of a drilling project.
- the method comprises automatically detecting a start state and an end state of each of the phases, generating time stamp data in response to detecting at least the start state of each phase, receiving an operator input confirming the start state of a particular phase of the plurality of phases, and electronically identifying the particular phase based on the operator input.
- the method also comprises storing the identity, a time duration, and the machine data for the particular phase, and generating an output comprising the identity, time duration, and machine data for the particular phase.
- the processor is configured to receive drilling machine data during execution of each of a plurality of phases of a drilling project, cooperate with the state detector to automatically detect a start state and an end state of each of the phases, and cooperate with the timer device to determine a time duration of each phase.
- the processor is also configured to cooperate with the user interface to receive an operator input confirming the start state of a particular phase of the plurality of phases, and electronically identify the particular phase and one or more phases preceding the particular phase based on the operator input.
- the processor is further configured to store the identity, a time duration, and the machine data for each of the particular and preceding phases in the memory, and generate an output comprising the identity, a time duration, and the machine data for each of the phases.
- FIG. 1 illustrates a horizontal directional drilling (HDD) machine with which embodiments of the disclosure can be implemented;
- Figure 2 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments
- Figure 3 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments
- Figure 4 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments
- Figure 5 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments
- Figure 6 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments
- Figure 7 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments
- Figure 8 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments
- Figure 9 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments
- Figure 10 is a block diagram of an apparatus for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments;
- Figure 1 1 illustrates a project manifest implemented as a relational database in accordance with various embodiments
- Figure 12 illustrates various components of a system for automatically tallying drill rods of a drill string and for automatically identifying and acquiring data for boring phase processes performed by a drilling machine in accordance with various embodiments; and
- Figure 13 is a block diagram of various components of a system for accurately tallying drill rods added to and removed from a drill string in accordance with various embodiments of the disclosure.
- Systems, devices or methods according to the present invention may include one or more of the features, structures, methods, or combinations thereof described herein.
- a device or system may be implemented to include one or more of the advantageous features and/or processes described below. It is intended that such a device or system need not include all of the features described herein, but may be implemented to include selected features that provide for useful structures, systems, and/or functionality.
- Embodiments are directed to systems and methods for determining overall productivity of a drilling project that involves a multiplicity of discrete phases.
- Embodiments are directed to systems and methods for increasing the accuracy of drilling project productivity computations by infrequently querying a drilling machine operator to confirm the state of one or more phases of a drilling project.
- Embodiments are directed to systems and methods for infrequently querying a drilling machine operator or other authorized person to confirm the state of one or more phases of a drilling project via operator input, and correctly identifying and producing productivity computations for one or more drilling project phases that precede the phase as confirmed by the operator input.
- the operator may be located at or remote from the drilling machine when providing an input to confirm the state of one or more phases of a drilling project.
- the drilling machine operator may be considered a remotely located person, such as a locator operator or a site supervisor, who operates a user interface device that communicatively couples to the drilling machine.
- Embodiments of the disclosure are generally directed to drilling projects, such as those involving horizontal and/or vertical drilling.
- Various embodiments of the disclosure are directed to horizontal directional drilling, which is understood by those of ordinary skill in the drilling industry as involving directional drilling of relatively shallow and predominantly horizontal bores through the earth, such as for running utilities under a streets and rivers, for example.
- Various embodiments are directed to vertical drilling, which is understood by those of ordinary skill in the drilling industry to involve drilling of relatively deep and predominantly vertical bores in the earth.
- the present disclosure describes various methodologies in the context of horizontal directional drilling, it is understood that the disclosed methodologies may be applied in the context of vertical drilling machines, including those with a directional (i.e., steering) capability.
- FIG. 1 illustrates a horizontal directional drilling machine 100, in accordance with various embodiments.
- the drilling machine 100 shown in Figure 1, includes a propulsion apparatus 123 coupled to a drill rod manipulation apparatus 121.
- the propulsion apparatus 123 includes an engine 106 and one or more hydraulic pumps 117 supported by a chassis 102.
- a track drive 119 or other drive arrangement allows the drilling machine 100 to be maneuvered around the worksite.
- the drill rod manipulation apparatus 121 includes a rack 1 10, a carriage 116, and a vise arrangement 115.
- the carriage 1 16 is configured for longitudinal displacement along the rack 1 10 and can travel longitudinally between a rear position, nearest the chassis 102, and a front position, nearest the vise arrangement 1 15.
- the carriage 1 16 supports a gearbox 108, which includes a rotary drive 154 configured to rotatably couple and decouple to and from a drill rod 114.
- the gearbox 108 and rotary drive 154 travel longitudinally with the carriage 1 16 along the rack 110.
- the gearbox 108 supports or is coupled to a rotation motor 11 1 and a displacement motor 1 13.
- the rotation and displacement motors 11 1 and 1 13 are hydraulic motors.
- Other embodiments may utilize electric motors rather than, or in addition to, hydraulic motors. Other modes of propulsion are contemplated.
- Operation of the rotation and displacement motors 11 1 and 113 is monitored using one or more sensors, respectively, such as pressure transducers.
- the rotary drive of the gearbox 108 is monitored using one or more pressure transducers 122.
- the longitudinal displacement of the gearbox 108 is monitored by one or more positions sensors 120, 126 and/or a rotary encoder 124 provided on a pinion gear.
- a pressure transducer 122, torque transducer 128 or other sensor (or combination of sensors) provides an indication of torque produced by the rotary drive 154 of the gearbox 108. It is understood that one or more sensors can be used to measure torque directly or indirectly (e.g., a sensor that senses a parameter like fluid pressure that can be correlated to torque).
- one or more torque thresholds or limits can be established for purposes of determining occurrence of drill rod addition and removal events and for purposes of providing an accurate tally of drill rods added to and removed from a drill string 1 12, in accordance with various embodiments, as is coordinated by a controller 101 of the drilling machine 100.
- the controller 101 is configured to execute one or more algorithms for automatically identifying and acquiring data for phase-specific processes performed by the drilling machine 100 in accordance with various embodiments.
- the HDD machine may not be directly involved in activities. However, monitoring process attributes of the HDD machine during these processes enable insight into the overall productivity related to that specific HDD project. During the drilling machine operation phase, monitoring process attributes of the HDD machine enable insight into productivity during machine operation.
- Some crews attempt to document notes including observations of activities that occurred during specific projects, or during a specific day, that impact productivity.
- Embodiments of the disclosure are directed to a system that includes an HDD machine with a control and data logging system, combined with an operator interface that requires minimal operator input to confirm suspected operating states.
- the control system can process logged data to derive attributes of processes that have occurred previously, and that are associated with a specific HDD project.
- the resulting derived attributes and machine information can be generated and displayed to the operator and supervisors while the project is in-process, and can be compiled into a digital summary report, or manifest, for that specific project, for review during the phase and for review when the project is completed.
- Embodiments are directed to a component of an HDD machine that is capable of automatically identifying phase-specific process attributes for an HDD project including processes that occur while the HDD machine is being operated to perform a boring operation, and also processes that occur before the boring operation has started at the specific location, for that specific project, and after the boring operation is finished for that specific project. Attributes of a process typically include the duration of each process and machine parameters associated with that process.
- HDD project refers to a drilling project that involves a multiplicity of discrete project phases.
- phase-specific refers to operations that are related to a specific phase of an HDD project.
- automated or “automatically” refers to a process wherein at least some actions occur without operator interaction, thus the term is used herein to describe a process where minimal or no operator interaction is required.
- process attributes refers to information about a specific process of a given phase, and can be derived from data measured during the execution of the process and possibly other data.
- process refers to a step that is a routine part of completing a specific project.
- Embodiments of the disclosure are directed to a system that includes a machine state detection algorithm for an HDD machine, to enable the machine to recognize specific states of operation. That data can be combined with time stamp and data logging, in a temporary cache of memory for example. Other attributes, in addition to the time stamps, can be recorded in a temporary cache of memory, as a function of the machine state.
- a method involves operating 20 an HDD machine during a multiplicity of phases of an HDD project.
- the method involves detecting 22 a suspect phase of the multiplicity of phases.
- a suspect phase is generally one in which limited information is known about the phase or one in which other phases rely on knowing additional information about the suspect phase.
- a typical suspect phase is one in which information currently available to the HDD machine is insufficient for the HDD machine to correctly identify the phase within an acceptable degree of accuracy (e.g., a likelihood of correctly identifying the phase is > 92%).
- an operator prompt is generated 24 requesting confirmation of the suspect phase.
- an input from the operator is received 26 confirming the suspect phase.
- productivity data is produced 28 for the suspect phase.
- Various types of output can be generated 29 for the suspect phase.
- Figure 3 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments.
- the method shown in Figure 3 involves operating 30 an HDD machine during a multiplicity of phases of an HDD project, and detecting 32 a suspect phase of the multiplicity of phases. In response to detecting the suspect phase, an operator prompt requesting confirmation of the suspect phase is generated 34.
- the method also involves receiving 36 an input from the operator confirming the suspect phase, and producing 38 productivity data for the suspect phase.
- the method further involves identifying 40 one or more phases preceding the suspect phase based in part on the operator input, and producing 42 productivity data for each of the preceding phases.
- the method generally involves generating 44 various types of output data for the suspect phase and preceding phases.
- Figure 4 illustrates various processes for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments.
- the method shown in Figure 4 involves operating 402 an HDD machine during a multiplicity of phases of an HDD project, and generating 404 an operator prompt about a particular phase.
- the method also involves receiving 406 from the operator an input confirming a state of the particular phase, and electronically identifying 408 the particular phase based on the operator input.
- the method further involves storing 410 the identity and information about the particular phase, and generating 412 an output comprising the identity and information about the particular phase.
- the method shown in Figure 5 involves operating 502 an HDD machine during a multiplicity of phases of an HDD project, generating 504 an operator prompt about a particular phase, receiving 506 from the operator an input confirming a state of the particular phase, and electronically identifying 508 the particular phase based on the operator input.
- the method shown in Figure 5 also involves electronically identifying 510 one or more phases preceding the particular phase based on the operator input, and storing 512 the identity and information about the particular phase and the preceding phases.
- the method further involves generating 514 output comprising the identities and information about the particular phase and the preceding phases.
- the embodiment of the method illustrated in Figure 6 involves many of the processes shown in Figure 4 along with additional processes.
- the method shown in Figure 6 involves operating 602 an HDD machine during a multiplicity of phases of an HDD project, generating 604 an operator prompt about a particular phase, receiving 606 from the operator an input confirming a state of the particular phase, and electronically identifying 608 the particular phase based on the operator input.
- the method shown in Figure 6 also involves determining 610 a duration of time to complete a particular phase, and storing 612 the identity, duration of time, and information about the particular phase.
- the method also involves generating 614 output comprising the identity, time duration, and information about the particular phase.
- the method shown in Figure 7 involves many of the processes shown in Figure 5 along with additional processes.
- the method shown in Figure 7 involves operating 702 an HDD machine during a multiplicity of phases of an HDD project, generating 704 an operator prompt about a particular phase, receiving 706 from the operator an input confirming a state of the particular phase, and electronically identifying 708 the particular phase based on the operator input.
- the method shown in Figure 7 also involves electronically identifying 710 one or more phases preceding the particular phase based on the operator input, and determining 712 a duration of time to complete the particular phase and the preceding phases based in part on the operator input.
- the method further involves storing 714 the identity, time duration, and information about the particular phase of the preceding phases, and generating 716 output comprising the identities, time durations, and information about the particular phase in the preceding phases.
- Figure 8 illustrates an embodiment of a method for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments.
- the method shown in Figure 8 involves performing 902 a multiplicity of HDD machine processes for a multiplicity of phases of an HDD project, and producing or receiving 804 HDD machine data during execution of the processes.
- the method also involves automatically detecting 806 a start state and an end state of each of the phases, and generating 808 time stamp data in response to detecting at least the start state of each phase.
- the method also involves receiving 810 an operator input confirming the start state of a particular phase of the plurality of phases, electronically identifying 812 the particular phase based on the operator input, and storing 814 the identity, time duration, and machine data for the particular phase.
- the method further involves generating 816 output comprising the identity, time duration, and machine data for the particular phase.
- Figure 9 illustrates an embodiment which involves many the processes shown in Figure 8 in accordance with various embodiments.
- the method shown in Figure 9 involves performing 902 a multiplicity of HDD machine processes for a multiplicity of phases of an HDD project, producing or receiving 904 HDD machine data during execution of the processes, automatically detecting 906 a start state and an end state of each of the phases, and generating 908 time stamp data in response to detecting at least the start state of each phase.
- the method also involves receiving 910 an operator input confirming the start state of a particular phase of the plurality of phases and electronically identifying 912 the particular phase based on the operator input.
- the method further involves electronically identifying 914 one or more preceding phases based in part on the operator input, storing 916 the identities, time durations, and machine data for the particular phase and the preceding phases, and generating 918 output comprising the identities, time durations, and machine data for the respective phases.
- FIG 10 is a block diagram of an apparatus for automatically identifying and acquiring data for phase-specific processes performed by an HDD machine in accordance with various embodiments.
- the apparatus shown in Figure 10 includes an HDD machine 105 which comprises a number of components, including those described previously with reference to Figure 1 including various sensors 109.
- the HDD machine 105 includes a processor 101 which is coupled to a memory 162, a timestamp generator 166 (or other type of timer device), a state detector 164, and a user interface 160.
- the processor 101 receives various forms of HDD machine data from the HDD machine 105.
- the state detector 164 is configured to determine the state of HDD project phases, such as a start state and/or and end state of each phase.
- the memory 162 is configured to store a project manifest 168, which includes information associated with each phase of a multiplicity of phases of an HDD project executed by the HDD machine 105.
- the HDD machine 105 is configured to perform processes during a number of different phases of an HDD project.
- the different phases of an HDD project can include one or more of a transport phase 180, a set-up phase and 82, a boring phase 184, a pullback/reaming phase 186, and a breakdown phase 188. It is noted that each of these phases can include one or more sub-phases.
- the following table illustrates various processes associated with a number of different phases of an HDD project.
- Each of the phases is associated with various HDD machine inputs or actions, some of which may involve an operator.
- the representative list of steps or processes in Table 1 may be tracked for a specific phase, along with some considerations for inputs or actions of a drilling machine that may be useful to determine the machine is performing that step.
- Tooling set up - drill head is on and front vice closed
- Figure 10 further shows a sequence 190 of phases of an HDD project organized in chronological order of occurrence for illustrative purposes.
- the beginning and end of each discrete phase 192 of the sequence 190 of phases is denoted by a state change, Sn.
- Detecting a state change, Sn typically involves detecting one or both of a start state and an end state for each phase by the state detector 164.
- a duration of time, t n , for each phase 192 is computed for each phase 192.
- the duration of time, t n for each phase 192 can be computed as the total amount of time that has elapsed between start and end states of each phase 192.
- the duration of time, t n , for a particular phase 192 can be computed as the total amount of time that has elapsed between the end state of the immediately preceding phase and the end state of the particular phase 192.
- the time stamp generator 166 can be configured to generate timestamps at each of the state changes to allow for computation of the elapsed time for each phase.
- the time stamp generator 166 can also be configured to generate timestamps at each of state change of one or more sub-phases of a particular phase, to allow for computation of the elapsed time for each sub-phase.
- a timer device can be used as a time stamp generator 166 and configured to directly provide the elapsed time for each particular phase.
- detecting one or both of a start state and an end state of a particular phase or sub-phase by the state detector 164 involves analyzing signals or data received from one or more sensors of the HDD machine. In some embodiments, detecting one or both of a start state and an end state of a particular phase or sub-phase involves analyzing signals transmitted over a network or communication bus of the HDD machine 105. Analyzing network or communication bus traffic generally reduces the number of sensors required to determine (e.g., discriminate between) state changes of the various phases or sub-phases, such as by analyzing control signals in addition to sensor signals
- phase n-3 is the earliest phase 192 to occur in time of the sequence 190 of phases
- phase n+2 is the last phase 192 of the sequence 190 to occur.
- the state detector 164 is configured to detect a change in state, Sn-3, as the beginning of phase n-3 and a subsequent change in state, Sn-2, as the end of phase n-3.
- each phase can have its own start state and its own end state, with the beginning and ending of a particular phase defined by the start and end states of the particular phase.
- the processor 101 acquires HDD machine data from the HDD machine 105 and temporarily stores the machine data, the time duration data, and a phase ID code for identifying phase n-3 in a cache memory 163 (e.g., temporary memory).
- a cache memory 163 e.g., temporary memory.
- various attributes of the data acquired during phase n-3 can be calculated based on the various data acquired during phase n-3
- the derived attributes calculated for phase n-3 can represent information about specific processes performed during phase n-3 that can be derived from data measured during execution of these processes.
- the processor 101 coordinates the transfer of data for phase n-3 from the cache memory 163 to archive memory (e.g., permanent memory), such as memory 162.
- archive memory e.g., permanent memory
- the data acquired and, optionally, computed during phase n-3 is stored in a project manifest 168 in archive memory 162.
- the project manifest 168 can be configured as a relational database in the memory 162.
- the project manifest 168 can include all phase-related data for a given HDD project, with individual fields being populated by various forms of data associated with each phase.
- the phase- related data stored in the project manifest 168 can include an ID code, time data, machine data, and derived attributes for each phase stored in the project manifest 168.
- data acquired for each sub-phase of a given project phase can also be stored in the relational database of the project manifest 168.
- FIG 11 illustrates a project manifest 168 implemented as a relational database in accordance with various embodiments.
- the project manifest 168 includes a number of data fields including project name, phase, ID code, sub-phase, total time, machine data, and derived attributes. It is understood that other and/or additional information fields can be included within the project manifest 168.
- phase n-3 and n-2 may be two different transport phases 180, and phase n-1 may be a set-up phase 182.
- the fourth phase, phase n, of the sequence 190 represents a suspect phase for which additional information is required or desired.
- phase n of the sequence 190 may represent a boring phase 184.
- the boring phase 184 is typically a relatively complex phase which can include sub-phases. Due to the complexity of this phase, it may be difficult to determine with high accuracy the exact start of the boring phase 184.
- Knowing the exact start of the boring phase 184 allows data acquired and computed during the boring phase 184 to be accurately assigned to this phase. Moreover, knowing the exact start of the boring phase 184 allows with great certainty one or more preceding phases to be correctly identified. Having properly identified the boring phase 184, for example, the processor 101 is configured to electronically identify one or more of the preceding phases with high accuracy, and to correctly associate acquired data for each of these phases with the identified preceding phases.
- the state detector 164 detects a change of state Sn and, in response, the processor 101 coordinates with the user interface 160 to generate an operator prompt 172.
- the user interface 160 may include a display and an input device mounted on the HDD machine 105.
- the user interface 160 includes a remote device that communicates with the processor 101 (e.g., via a wireless connection) and includes a user interface facility, such as a locator (with a display and input device) or a tablet.
- the processor 101 is configured to determine with some degree of accuracy that the suspect phase, phase n, is likely the initiation of a boring phase 184. This initial determination by the processor 101 can be accomplished by analyzing communication bus traffic on the HDD machine network and/or by analyzing sensor data.
- the operator prompt 172 can involve presenting a question about the identity of the present phase (e.g., "Is this the start of a boring phase?") on a display of the user interface 160.
- the user interface 160 is configured to receive a tactile or audio input 173 from the operator in response to the prompt 172.
- the processor 101 enables initiation of the boring phase 184. It is noted that, according to some embodiments, initiation of the boring phase 184 (or other phase) is locked-out (prevented) until a confirming input 173 is received from the operator by the user interface 160.
- the processor 101 can correctly (with 100% accuracy based on operator input and contextual data) identify the current phase, phase n, and generates a phase identification, ID n , for the current phase. Having correctly identified the current phase, phase n, via operator input, the processor 101 is configured to correctly identify one or more preceding phases, such as phases n-1, n-2, and n-3. Generally, the processor 101 can make a reasonably accurate determination of the identity of the preceding phases, based on the various information acquired during each of the preceding phases. After the identity of phase n has been confirmed by the operator, the processor 101 can more accurately determine the identity of the preceding phases. For example, the processor 101 can be configured to recognize proper and improper sequences of HDD project phases and sub-phases.
- phase n Accurately knowing the identity of a particular phase, such as phase n, allows the processor 101 to eliminate from consideration those phases and sub-phases that logically cannot or should not occur prior to the particular phase.
- phase n in the sequence 190 is shown as requiring or desiring an operator input confirmation, more than one phase may be subject to an operator confirmation procedure in accordance with various embodiments.
- Figure 12 illustrates various components of a system for automatically tallying drill rods of a drill string and for automatically identifying and acquiring data for boring phase processes performed by a drilling machine 105 (which may be an HDD machine or other drilling machine) in accordance with various embodiments.
- the system includes a controller 101, which typically includes a processor or other logic device.
- the controller 101 which is coupled to memory 162, is configured to implement drill rod tally logic 103, in accordance with various embodiments.
- the controller 101 is also configured to execute one or more algorithms for automatically identifying and acquiring data for boring phase processes performed by the drilling machine 105.
- the controller 101 is communicatively coupled to a drilling machine 105, a drill rod manipulation apparatus 107, and a sensor system 109.
- the drill rod manipulation apparatus 107 is configured to facilitate adding and removal of drill rods respectively to and from a drill string comprising a multiplicity of drill rods coupled together.
- the sensor system 109 includes various sensors provided on the drill rod manipulation apparatus 107 and the drilling machine 105. The sensors of the sensor system 109 monitor various components of the system to determine the state of the components, from which the controller 101 can coordinate rod tallying methodologies of the present disclosure.
- the drilling machine 105 shown in Figure 12 is configured for horizontal directional drilling.
- a horizontal directional drilling machine for example, is understood by those of ordinary skill in the drilling industry as a machine that provides directional drilling of relatively shallow (e.g., depths of less than about 20-30 feet) and predominantly horizontal bores through the earth, such as for running utilities under a roadway, for example.
- the drilling machine 105 shown in Figure 12 is configured for vertical drilling, which may include vertical directional drilling.
- a vertical drilling machine is understood by those of ordinary skill in the drilling industry to be a machine that provides drilling of relatively deep (e.g., hundreds or thousands of feet) and predominantly vertical bores in the earth (e.g., oil and gas wells).
- the present disclosure describes various rod tallying methodologies in the context of horizontal directional drilling, it is understood that the disclosed methodologies may be applied in the context of vertical drilling machines, including those with a directional (i.e., steering) capability.
- Vertical drilling rigs have traditionally used a measure of the weight hanging on the rotation unit as an indication of when the drill string is suspended. This measure of weight appears to have historically been a primary input used to calculate drill rod length. Accordingly, vertical rigs have not relied on make-up/break-out processes to monitor the rod count. Further, unlike horizontal directional drilling rigs, vertical drilling machines or rigs generally include devices known as slips, which are passive devices that, once installed, limit movement of a given drill string. This difference between vertical and horizontal drilling rig configuration would directly impact any rod counting logic, in that a slip is an extra system element that does not interact with the make-up/break-out processes in the same way that vises do on horizontal directional drilling rigs.
- Figure 13 is a block diagram of various components of a system 150 for accurately tallying drill rods added to and removed from a drill string, in accordance with various embodiments of the disclosure.
- the system 150 is also configured for automatically identifying and acquiring data for boring phase processes performed by a drilling machine (see drilling machines 100 and 105 shown in Figures 1 and 12, respectively).
- the system 150 shown in Figure 13, includes a controller 101, which is communicatively coupled to a number of components.
- the system 150 includes a number of sensors 152 provided on a drilling machine that monitor various system parameters that are assessed during rod tallying methodologies of the present disclosure.
- the controller 101 is communicatively coupled to the rotary drive 154, such as that shown as part of the gearbox 108 of Figure 1.
- the controller 101 is also communicatively coupled to a displacement drive 156 and a vise arrangement 158.
- the vise arrangement 158 includes two independently controllable vises, such as an upper vise and a lower vise.
- rod tallying methodologies are conducted fully automatically without intervention of a human operator.
- rod tallying methodologies are conducted semi-automatically with some intervention by a human operator.
- a user interface 160 is communicatively coupled to the controller 101 and is used during rod tallying procedures, in accordance with various embodiments.
- the system shown in Figure 13 can be used to implement various rod tallying methodologies disclosed herein and in commonly owned US Application Serial No. 14/755,978, filed on June 30, 2015, and US Provisional Application Serial No. 62/019,873 filed on July 1, 2014, which are incorporated herein by reference.
- the following illustrative embodiments can be implemented by an HDD machine described previously hereinabove. This description assumes that it is logical to define the starting point of a typical HDD project phase as the end of the previous phase. Thus, consideration is given to various ways that a phase will end. According to some embodiments, an important aspect of this system, as described hereinbelow, is the automatic assignment of phase [states]. In the following illustrative embodiments, the project [phases] are for the most part highlighted in [brackets] to draw attention to the importance of these [phases]. The assumption will be that while boring, the system will be in a project phase of [boring]. To enter into the
- [boring] phase the system will require that an operator confirm that a boring project has started. While in the project phase of [boring], there will be a number of sub-phases to track various metrics of the processes of these sub-phases, that will be described in more detail below. This description will start by describing various ways that the project phase can be changed from [boring] to [breakdown start], as the HDD project is finished.
- Product being installed will be pulled-back (during a pullback/reamer phase) until it is located where the crew wants it before disconnecting the product from the puller, or the swivel from the reamer.
- the assumption of this description is that a manager may want to track activities that occur between the time the product is first pulled back to that location and the time the HDD machine is moved away from that phase, the process that will be referred to as the break-down process.
- a bore may end, including: ) The product may be pulled into an entry pit and disconnected from the reamer or a drill head in the entry pit.
- the machine may be set-back a significant distance from the entry-pit, and the drill string may enter the ground at an entry point, extend several rods to a desired depth and leveled out as it enters the entry pit, where it will extend through the entry pit before re-entering the ground.
- the pull-back it will be possible to detect when the pull-back has ended by a number of options:
- the rod count could still be as high as 3 or more rods, so the system may utilize logic to recognize when pull-back force is significantly lower,
- the system may then request operator confirmation that the pullback has ended, even if rod count may be >0 ( ote this type of logic could be a trigger for a cross-bore detection, or frac-out detection: if fluid pressure drops suddenly, the system automatically asks the operator if the pull-back is finished, and if the response is NO, then it could be an indication of a cross-bore).
- this type of logic could be a trigger for a cross-bore detection, or frac-out detection: if fluid pressure drops suddenly, the system automatically asks the operator if the pull-back is finished, and if the response is NO, then it could be an indication of a cross-bore).
- the system includes logic (e.g., fuzzy logic) at the start of the bore, to monitor torque and rotation to automatically log the point when the bore starts, even if the boring does not start until after rod 1, such as after the drill head passes through the entry pit.
- a relative rod count could be automatically be set to 0 when the drill head first starts the actual bore, where the system could maintain both a relative rod count and an absolute rod count.
- the actual bore could be defined as the bore between either the entry point (if there is not an entry pit), or the entry pit and the exit pit. With an entry pit the rod count could be 3 or more to bore to a depth, when the bore passes through the entry pit before starting the actual bore.
- the system can monitor thrust, rotation, drill string extension and fluid pressure to automatically detect an entry pit during the pilot bore, and then automatically request operator confirmation that the actual bore is being started, to verify accuracy of the relative rod count. If that has been implemented, then the system can automatically request operator confirmation that a bore is finished whenever the drill string is pulled back to that point, e.
- the system designer may need to consider whether additional requests for confirmation will be annoying for an operator, and consider if it is better to sense this automatically, considering the reliability of automatic sensing.
- the product may be pulled back to an entry point: the rod count may or may not be at 0, as the machine may be set-back some distance from the entry point.
- the rig may know, from what happened during the pilot shot, where the bore started, or it could automatically assess pullback force, torque, fluid flow and pressure to detect the end, at which time the system could automatically generate an operator confirmation request, to verify if the pull-back is completed, or to simply automatically detect the end of the pullback, if it can be accomplished reliably.
- Rack tilt up control used along with a time stamp. This would allow assessment of the time between finishing the pull-back, and raising the rack.
- Engine metrics could be logged, such as amount of time engine is running at low idle, at high idle.
- Rod n data can be logged, to log metrics for the amount of time required to pull- back rods after the product is released.
- the project phase will automatically be changed from [break-downo] to [breakdown ⁇ and a time stamp logged when the ground drive controls are first used.
- the ground drive controls may be utilized before many of the break-down tasks are completed, and tracking the use of the ground drive system may provide insight into how efficiently a crew is operating.
- the system When in the [break-down n ] state, the system will automatically monitor the ground drive controls, and ground drive hydraulic pressure and flow. If the ground drive is used for a predetermined amount of time, or in a specific way, such as counter rotation, or to move a predetermined distance, then the system will assume that the break-down process is finished, the project phase will automatically be updated to [transport 0 ], and the final project manifest can be generated for the previous project or phase.
- the operator will not be at the control station, and not able to see or reply to a confirmation request during the subsequent process.
- the system will automatically update the project phase to [breakdown 0 ] and log a timestamp, when the ground drive controls are first used. If the system utilized logic during the pilot bore, then this conclusion could be reached only when the system knows the drill head, backreamer or product are at approximately the same location as where the bore started.
- the operator will most likely, but not always, tilt the rack into its transport position, and then use the drill's ground drive system to continue pulling-in the product.
- the system can log parameters and accumulate usage metrics, such as:
- Engine metrics could be logged, such as amount of time engine is
- Rod n data can be logged, to log metrics for the amount of time required to pull-back rods while in this state, i.e. in the event the ground drive is used to pullback some distance, and then the carriage is used to pull back an additional distance.
- the system When in the [breakdown ⁇ ] phase, the system will be monitoring the ground drive controls again. When in this mode, if the ground drive controls are used again, within a short period of time, and for a short period of time, such as to move the drill a short distance, then the system will assume this is just an additional ground drive pull-back, and the system will automatically update the project phase to [breakdown i] with a time stamp.
- the system When in a [breakdown n ] phase, the system will monitor the way that the ground drive controls are used to identify when the breakdown phase is finished, such as if the ground drive is used for a predetermined amount of time, or in a specific way, such as counter rotation, or to move a predetermined distance, then the system will assume that the break-down process is finished, the project phase will automatically be updated to [transporto], and the final manifest can be generated for the previous project or phase.
- the project phase is set to [transporto], in either scenario, the previous phase will be assumed to be finished and the next phase started.
- transport mode the system may be set-up to monitor and record various parameters, including:
- Maximum ground drive pressure that may be an indication of how the machine is being operated during transport
- the system When in the [transport ⁇ phase, the system will monitor the rack tilt control to divide parameters into separate phases. While in transport, the rack will normally be tilted up while the machine is moving. However, when the machine is moved onto a trailer, the rack is normally lowered, thus the change in the rack position can be an indication of when the machine is on a trailer. Once the machine arrives at a jobsite, the rack will then be tilted up in order to move the machine to the location of set-up for the next phase. Once in the set-up position, the rack will be lowered and the bore started. Thus, the last instance of lowering the rack, before a new bore is confirmed to a have started, is the time that jobsite set-up started.
- the rig state will be automatically set to [transporto], with a time stamp corresponding to when the previous phase ended. This time will be defined as corresponding to when the next phase starts.
- state When the machine is loaded onto a trailer, and the rack tilted down, state will be updated to [transport ⁇ and a time stamp will automatically be logged.
- Various other metrics can be tracked during these various states, including engine running duration, engine average rpm, etc.
- the rack When the machine arrives at the jobsite, on the trailer, the rack will be tilted back to transport, and the system will then automatically change the state to [transports] with a time stamp. Once the machine is put into position to start the next project, the rack may be lowered, and the system will automatically update the state to [tracks] with a time stamp. It is possible that the rig is not in the exactly correct position, so the process of tilting the rack and moving the machine could be repeated any number of times. Each of these movements, repositionings, will result in additional project status events of [track n ] each with a unique time stamp, and with a unique record of other parameters.
- the system will generate an operator confirmation request, to verify that a bore has started. Once that confirmation is received, then the system will process the previously logged [transport ⁇ state to save that record as a summary of the set-up phase.
- Embodiments of the disclosure include an algorithm that assesses various machine parameters and automatically assigns a machine phase (e.g., phase ID) for a set of related HDD machine processes.
- the HDD machine phases can include, for example, Stationary Transport, Moving Transport (under remote control), Moving Transport(under on-rig control), Trailer Transport, Set-up stationary, Set-up moving (under remote control), Setup moving (under on-rig control), Pilot Bore rod n start, Pilot Bore rod n end, Pullback rod n start, and Pullback rod n end.
- the algorithm when the HDD machine phase transitions from one phase to another, stores data for the phase to a temporary cache of memory, along with a time stamp indicating the time that the new phase was detected.
- the algorithm requests confirmation from the operator that a pilot bore has started. Once that confirmation is received, the algorithm initiates actions for that specific phase including the following:
- the data log cache is updated, to clear-out data points that will not be needed for future calculations.
- the algorithm automatically queries the data log cache to calculate the just-finished rod time, and also stores the recorded machine attributes for that rod, to the digital summary report.
- the above-described process allows for situations where a trip-out may occur during a pilot bore by including logic wherein if the rod count decrements more than 1 rod, the system automatically queries the operator asking for confirmation that pullback has started. If the operator's response is no, then the data is logged as a trip-out. For example, one pilot rod may have a rod time of 30 sec during the initial bore, 10 sec during trip-out and then 10 sec during the subsequent trip-in. Once the pilot bore is finished, the rod count decrements more than one rod, and the operator confirms that a pull-back has started, then the algorithm will query the data-log to assign time metrics to a tooling change-over process, and the subsequent rod by rod data will be tracked as pull-back data.
- Pullback can have several variations including the simplest form where a drill string is formed during a pilot bore, and then that drill string is pulled-back during a pull- back during which the bore hole is expanded and product is pulled-in. More complicated bores include variations including:
- the reamer string is disconnected from the drill string, a reamer installed on the drill string, the reamer string attached to the other side of the reamer, and pulled into the bore hole along with the reamer.
- the drill string is then attached to the reamer string when the reamer is pulled back to the entry pit, and a second reamer is then attached to the reamer string and it is pulled back.
- Additional complications can occur during the transition from the pilot bore to a subsequent process, including the possibility that extra rod could be pushed-out through the exit pit to make it easier to change tooling, so it may be difficult to detect the actual length of the bored hole, by a knowledge of the number of rods in a drill string. Some of this complexity can be managed by periodically requesting input from the operator.
- the system can cache machine parameters such as hydraulic pressures that correlate to rotational torque applied to the drill string or to longitudinal force applied to the drill string, for instance. These other datasets can be evaluated to derive other information that can be related to a specific process.
- Systems, devices, or methods according to the present invention may include one or more of the features, structures, methods, or combinations thereof described herein.
- a device or system may be implemented to include one or more of the advantageous features and/or processes described below.
- a device or system according to the present invention may be implemented to include multiple features and/or aspects illustrated and/or discussed in separate examples and/or illustrations. It is intended that such a device or system need not include all of the features described herein, but may be implemented to include selected features that provide for useful structures, systems, and/or functionality.
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US201462051406P | 2014-09-17 | 2014-09-17 | |
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WO2016209230A1 (en) * | 2015-06-25 | 2016-12-29 | Tde Petroleum Data Solutions, Inc. | Method for standardized evaluation of drilling unit performance |
DE102018006464A1 (en) * | 2018-08-16 | 2020-02-20 | Tracto-Technik Gmbh & Co. Kg | Device for positioning an electronic unit on an earth drilling device |
CA3145945C (en) | 2019-08-13 | 2022-06-21 | Spencer P. Taubner | Systems and methods for detecting steps in tubular connection processes |
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US20080127195A1 (en) * | 2006-11-28 | 2008-05-29 | Siemens Ag | Project-process-transformer |
US20110106384A1 (en) * | 2008-06-16 | 2011-05-05 | Commonwealth Scientific And Industrial Research Organisation | Method and system for machinery control |
US8204691B2 (en) * | 2008-12-18 | 2012-06-19 | Robert Paul Deere | Method and apparatus for recording and using down hole sensor and diagnostic events in measurement while drilling |
CA2804075C (en) * | 2012-01-30 | 2020-08-18 | Harnischfeger Technologies, Inc. | System and method for remote monitoring of drilling equipment |
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