Patent Application
20170248000
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.
Further embodiments are directed to an apparatus for use with a drilling machine comprising a processor, a memory, a timer device, a state detector, and a user interface. 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.
The above summary is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The figures and the detailed description below more particularly exemplify illustrative embodiments.
The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.
In the following description of the illustrated embodiments, references are made to the accompanying drawings forming a part hereof, and in which are shown by way of illustration, various embodiments by which the invention may be practiced. It is to be understood that other embodiments may be utilized, and structural and functional changes may be made without departing from the scope of the present invention.
Systems, devices or methods according to the present invention may include one or more of the features, structures, methods, or combinations thereof described herein. For example, 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. For example, 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. Although 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.
Operation of the rotation and displacement motors 111 and 113 is monitored using one or more sensors, respectively, such as pressure transducers. In some embodiments, 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). In some embodiments, 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 112, 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.
There are consistent aspects of workflow associated with HDD projects, including processes that occur during discrete phases of an HDD project such as a set-up and transport phase before machine operation starts, during a machine operation phase, and during a teardown phase, after machine operation is finished. The overall productivity of a crew is typically evaluated on the basis of productivity during all of these phases.
During setup, transport, and teardown phases, for example, 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. However, these notes are often made at the end of the day, after some time has passed. Thus, the accuracy of these notes is sometimes not as reliable as desired, and the amount of data is limited.
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. From the operator input, 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.
Various embodiments are described using the following terms, which are defined below and are applicable in certain, but not necessarily all, contexts. The term “HDD project” refers to a drilling project that involves a multiplicity of discrete project phases. The term “phase-specific” refers to operations that are related to a specific phase of an HDD project. The term “automatic” 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. The term “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. The term “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.
Turning now to
The method illustrated in
The embodiment of the method illustrated in
The method shown in
In the representative embodiment shown in
In general, 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 communicated over the network or communication bus of the HDD machine 105.
With continued reference to
During the time duration, tn−3, of phase n−3, 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). In some embodiments, various attributes of the data acquired during phase n−3 can be calculated based on the various data acquired during phase n−3 (and possibly other data). For example, 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.
In response to detecting the end state for phase n−3 (e.g., completion of phase n−3), such as by the state detector 164 detecting the state change Sn−2, 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. According to some embodiments, the data acquired and, optionally, computed during phase n−3 is stored in a project manifest 168 in archive memory 162. For example, 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. For example, 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. Moreover, such data acquired for each sub-phase of a given project phase can also be stored in the relational database of the project manifest 168. In this way, data can be analyzed for a multiplicity of sub-phases and phases to glean information about overall HDD project productivity and efficiency.
In the illustrative example shown in
As a shown in
In some embodiments, 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. In response to confirming that the present phase is the boring phase 184 using the operator input 173, 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.
In response to the confirmation input 173 received from the operator, 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, IDn, 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. 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. Although only one of the phases, 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.
In some embodiments, the drilling machine 105 shown in
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.
According to various embodiments, rod tallying methodologies are conducted fully automatically without intervention of a human operator. In some embodiments, rod tallying methodologies are conducted semi-automatically with some intervention by a human operator. In embodiments involving 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
With particular reference to
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. There are a number of different ways that a bore may end, including:
For these two scenarios, 1 and 2 defined above, that may include an automatically generated operator prompt of [Pullback ended?] and after the operator provides a positive response to that prompt, or if it is possible to reliably sense this automatically, then the status can be updated at that time to a project phase of [break-down0] and a timestamp will be logged. During this time, the crew will be doing a variety of tasks such as removing the product puller, pulling back the rest of the drill string, removing the reamer, cleaning the jobsite and the drill, cleaning the tooling, etc. At some point the rack of the drill will be tilted into its transport position.
While in the [break-down0] state, it is possible to log operating parameters and accumulate usage metrics, such as:
The project phase will automatically be changed from [break-down0] to [break-down1] 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 ground drive controls could be used any number of times during break-down, and each time that they are used, the project phase will be changed to [break-downn] where n=the number of times the ground drive controls are used while in the break-down phase. During each break-down phase it is possible to log operating parameters and accumulate usage metrics as noted above.
When in the [break-downn] 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 [transport0], and the final project manifest can be generated for the previous project or phase.
Once the project phase is set to [transport0], in either scenario, the previous phase will be assumed to be finished and the next phase started. While in transport mode, the system may be set-up to monitor and record various parameters, including:
When in the [transportn] 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.
In a common scenario, the rig state will be automatically set to [transport0], with a time stamp corresponding to when the previous phase ended. This time will be defined as corresponding to when the next phase starts. When the machine is loaded onto a trailer, and the rack tilted down, state will be updated to [transport1] 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.
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 [transport3] 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 [track4] 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 [trackn] each with a unique time stamp, and with a unique record of other parameters. Once an actual bore is started, and the drill rod tally changes from 1 to 2, then 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 [transportn] 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), Set-up moving (under on-rig control), Pilot Bore rodn start, Pilot Bore rodn end, Pullback rodn start, and Pullback rodn end.
According to some embodiments, when the HDD machine phase transitions from one phase to another, the algorithm 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. When the HDD machine phase changes from (pilot bore rod1 end) to (pilot bore rod2 start), for example, 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 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:
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.
In addition to caching timestamp data, 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.
The discussion and illustrations provided herein are presented in an exemplary format, wherein selected embodiments are described and illustrated to present the various aspects of the present invention. Systems, devices, or methods according to the present invention may include one or more of the features, structures, methods, or combinations thereof described herein. For example, 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.
Although only examples of certain functions may be described as being performed by circuitry for the sake of brevity, any of the functions, methods, and techniques can be performed using circuitry and methods described herein, as would be understood by one of ordinary skill in the art.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2015/050344 | 9/16/2015 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62051406 | Sep 2014 | US |
