U.S. patent application number 15/507337 was filed with the patent office on 2017-08-31 for system and method for determining productivity of a drilling project.
The applicant listed for this patent is Vermeer Corporation. Invention is credited to Douglas R. Hundt, Harley P. Janssen.
Application Number | 20170248000 15/507337 |
Document ID | / |
Family ID | 54238584 |
Filed Date | 2017-08-31 |
United States Patent
Application |
20170248000 |
Kind Code |
A1 |
Hundt; Douglas R. ; et
al. |
August 31, 2017 |
SYSTEM AND METHOD FOR DETERMINING PRODUCTIVITY OF A DRILLING
PROJECT
Abstract
Drilling machine data is received during execution a plurality
of processes by a drilling machine associated with each of a
plurality of phases of a drilling project. Processing includes
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. Processing also includes 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.
Inventors: |
Hundt; Douglas R.; (Pella,
IA) ; Janssen; Harley P.; (Otley, IA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Vermeer Corporation |
Pella |
IA |
US |
|
|
Family ID: |
54238584 |
Appl. No.: |
15/507337 |
Filed: |
September 16, 2015 |
PCT Filed: |
September 16, 2015 |
PCT NO: |
PCT/US2015/050344 |
371 Date: |
February 28, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62051406 |
Sep 17, 2014 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06F 17/40 20130101;
E21B 19/16 20130101; E21B 7/02 20130101; E21B 44/00 20130101 |
International
Class: |
E21B 44/00 20060101
E21B044/00; E21B 19/16 20060101 E21B019/16; E21B 7/02 20060101
E21B007/02 |
Claims
1. 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; 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; electronically
identifying the particular phase and one or more phases preceding
the particular phase based on the operator input; 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.
2. The method of claim 1, wherein receiving the operator input
comprises displaying a prompt for the operator input on a display
coupled to the drilling machine.
3. The method of claim 1, further comprising: deriving attributes
for each of the phases using one or both of the time stamp data and
the machine data for each phase; and storing the derived attributes
for each of the phases; wherein the generated output further
comprises the derived attributes for each of the phases.
4. The method of claim 1, wherein the time stamp data for each
phase comprises: a start time stamp and an end time stamp; or a
start time stamp and an end time stamp defined by a start time
stamp of a successive phase; or an end time stamp and a start time
stamp defined by an end time stamp of the preceding phase.
5. The method of claim 1, wherein: the machine data and the time
stamp data for each phase are stored in a temporary memory cache
after detecting the start state of each phase; and the method
further comprises transferring the machine data and the time stamp
data from the temporary memory cache to archive memory in response
to detecting the end state of each phase.
6. The method of claim 5, wherein the archive memory is configured
to define a project manifest organized by phase with each phase
associated with its respective machine data and time stamp
data.
7. The method of claim 1, wherein the machine data comprises at
least some of maximum ground drive pressure, average ground drive
pressure, maximum rotation pump pressure, average rotation pump
pressure, maximum thrust pump pressure, and average thrust pump
pressure.
8. The method of claim 1, wherein the particular phase comprises a
stationary transport phase, a moving transport phase, a trailer
transport phase, a set-up stationary phase, or a set-up moving
phase.
9. The method of claim 1, wherein the particular phase comprises a
set-up phase and the phase preceding the set-up phase comprises a
transport phase.
10. The method of claim 1, wherein: the particular phase comprises
a boring phase and the phase preceding the boring phase comprises a
set-up phase; or the particular phase comprises a boring phase and
the phase preceding the boring phase comprises a transport phase;
or the particular phase comprises a pullback or reaming phase and
the phase preceding the pullback or reaming phase comprises a
boring phase; or the particular phase comprises a breakdown phase
and the phase preceding the breakdown phase comprises a boring
phase; or the particular phase comprises a breakdown phase and the
phase preceding the breakdown phase comprises a pullback or reaming
phase.
11. The method of claim 1, wherein: the particular phase and the
one or more preceding phases define sub-phases of the same drilling
project phase; and electronically identifying the particular phase
comprises electronically identifying all sub-phases of the
particular phase and the one or more preceding phases.
12. The method of claim 1, wherein: the particular phase and the
one or more preceding phases define sub-phases of a boring phase, a
pullback phase or a reaming phase; and one or more of the
sub-phases involves the addition or removal of a drill rod
respectively to or from a drill string coupled to the drilling
machine.
13. 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; 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; electronically identifying the particular
phase based on the operator input; 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.
14. The method of claim 13, wherein electronically identifying the
particular phase comprising electronically identifying the
particular phase and one or more phases preceding the particular
phase based on the operator input.
15. An apparatus for use with a drilling machine, the apparatus
comprising: a processor; a memory; a timer device; a state
detector; and a user interface; wherein 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; cooperate with the timer device to determine a
time duration of each phase; cooperate with the user interface to
receive an operator input confirming the start state of a
particular phase of the plurality of phases; electronically
identify the particular phase and one or more phases preceding the
particular phase based on the operator input; 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.
16. The apparatus of claim 15, wherein: the user interface comprise
a display and an input device; and the processor is configured to
cooperate with the user interface to display a prompt for the
operator input on the display.
17. The apparatus of claim 15, wherein the processor is further
configured to: derive attributes for each of the phases using one
or both of the time stamp data and the machine data for each phase;
and store the derived attributes for each of the phases in the
memory; wherein the generated output further comprises the derived
attributes for each of the phases.
18. The apparatus of claim 15, wherein the memory is configured to
define a project manifest organized by phase with each phase
associated with its respective machine data and time stamp
data.
19. The apparatus of claim 15, wherein: the particular phase and
the one or more preceding phases define sub-phases of a boring
phase, a pullback phase or a reaming phase; and one or more of the
sub-phases involves the addition or removal of a drill rod
respectively to or from a drill string coupled to the drilling
machine.
20. The apparatus of claim 15, wherein at least some of the phases
define non-excavation phases of a drilling project.
Description
SUMMARY
[0001] 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.
[0002] 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.
[0003] 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.
[0004] 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.
[0005] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates a horizontal directional drilling (HDD)
machine with which embodiments of the disclosure can be
implemented;
[0007] FIG. 2 illustrates various processes for automatically
identifying and acquiring data for phase-specific processes
performed by an HDD machine in accordance with various
embodiments;
[0008] FIG. 3 illustrates various processes for automatically
identifying and acquiring data for phase-specific processes
performed by an HDD machine in accordance with various
embodiments;
[0009] FIG. 4 illustrates various processes for automatically
identifying and acquiring data for phase-specific processes
performed by an HDD machine in accordance with various
embodiments;
[0010] FIG. 5 illustrates various processes for automatically
identifying and acquiring data for phase-specific processes
performed by an HDD machine in accordance with various
embodiments;
[0011] FIG. 6 illustrates various processes for automatically
identifying and acquiring data for phase-specific processes
performed by an HDD machine in accordance with various
embodiments;
[0012] FIG. 7 illustrates various processes for automatically
identifying and acquiring data for phase-specific processes
performed by an HDD machine in accordance with various
embodiments;
[0013] FIG. 8 illustrates various processes for automatically
identifying and acquiring data for phase-specific processes
performed by an HDD machine in accordance with various
embodiments;
[0014] FIG. 9 illustrates various processes for automatically
identifying and acquiring data for phase-specific processes
performed by an HDD machine in accordance with various
embodiments;
[0015] 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;
[0016] FIG. 11 illustrates a project manifest implemented as a
relational database in accordance with various embodiments;
[0017] FIG. 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
[0018] FIG. 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.
[0019] 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.
DETAILED DESCRIPTION
[0020] 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.
[0021] 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.
[0022] 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.
[0023] 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.
[0024] FIG. 1 illustrates a horizontal directional drilling machine
100, in accordance with various embodiments. The drilling machine
100, shown in FIG. 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 110, a carriage 116, and a vise arrangement 115. The carriage
116 is configured for longitudinal displacement along the rack 110
and can travel longitudinally between a rear position, nearest the
chassis 102, and a front position, nearest the vise arrangement
115. The carriage 116 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 116 along the rack 110. The
gearbox 108 supports or is coupled to a rotation motor 111 and a
displacement motor 113. In some embodiments, the rotation and
displacement motors 111 and 113 are hydraulic motors. Other
embodiments may utilize electric motors rather than, or in addition
to, hydraulic motors. Other modes of propulsion are
contemplated.
[0025] 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.
[0026] 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.
[0027] 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.
[0028] 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.
[0029] 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.
[0030] 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.
[0031] 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.
[0032] 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.
[0033] Turning now to FIG. 2, there is illustrated various
processes for automatically identifying and acquiring data for
phase-specific processes performed by an HDD machine in accordance
with various embodiments. According to the embodiment shown in FIG.
2, 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%). In
response to detecting a suspect phase, an operator prompt is
generated 24 requesting confirmation of the suspect phase. In
response to the operator prompt, an input from the operator is
received 26 confirming the suspect phase. After receiving operator
confirmation of the suspect phase, productivity data is produced 28
for the suspect phase. Various types of output can be generated 29
for the suspect phase.
[0034] FIG. 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 FIG. 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.
[0035] FIG. 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 FIG. 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.
[0036] The method illustrated in FIG. 5 involves many of the
processes shown in FIG. 4 along with additional processes according
to various embodiments. The method shown in FIG. 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
FIG. 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.
[0037] The embodiment of the method illustrated in FIG. 6 involves
many of the processes shown in FIG. 4 along with additional
processes. The method shown in FIG. 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 FIG. 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.
[0038] The method shown in FIG. 7 involves many of the processes
shown in FIG. 5 along with additional processes. The method shown
in FIG. 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 FIG. 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.
[0039] FIG. 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 FIG. 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.
[0040] FIG. 9 illustrates an embodiment which involves many the
processes shown in FIG. 8 in accordance with various embodiments.
The method shown in FIG. 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.
[0041] 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 FIG. 10 includes an HDD machine 105 which
comprises a number of components, including those described
previously with reference to FIG. 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. According to some embodiments, 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.
[0042] In the representative embodiment shown in FIG. 10, the HDD
machine 105 is configured to perform processes during a number of
different phases of an HDD project. According to various
embodiments, 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.
TABLE-US-00001 TABLE 1 Phase Inputs/Actions Transport Using
telematics GPS bread crumbs Machine in certain position Machine in
a constant RPM Machine Tracking Tracks moving - speed, pressure
spikes Stake downs up Outrigger up Operator out of the seat Use of
rack tilt to help with break over point Using a remote (tracking
speed) Location vs. how long it was tracked Machine Warm Up Machine
idle - no hydraulic Machine Set up Rack Tilt goes down Stake downs
moving - not always used Outrigger moving - not always used Water
Pressure - mud inlet sensor - many run dry Locator and sonde synced
up Recording locator/sonde calibration event Tooling set up - drill
head is on and front vice closed Machine Pilot Boring Rod Count
begins Generate Operator Carriage and vice sequence occurring
Prompt After 2 rod counts query operator Receive Operator Input
"Are you drilling?" Implement Phase Set a time stamp.
Identification Procedure Rack tilt Operator in seat Swab Sequence
Time per Rod Abnormalities Rod Counting not happening Carriage not
moving Vices not moving Operator out of seat - How long? Rack tilt
angle change Low inlet mud pressure Machine Fault Codes Thrust
circuit failure, etc. Pressure Changes over the length of the
borepath Hydraulic spike signatures Pullback/Reaming Rod Count
Generate Operator Vices and carriage movement Prompt Query Operator
"Are you pulling back?" Receive Operator Input Count get to "0"
Implement Phase Query Operator "Bore complete?" Identification
Procedure Machine Tracking with GPS location product Stake downs up
Outriggers up Rack moved slightly
[0043] FIG. 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.sub.n, for each phase 192 is
computed for each phase 192. The duration of time, t.sub.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. In some
embodiments, the duration of time, t.sub.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. In some embodiments, a timer
device can be used as a time stamp generator 166 and configured to
directly provide the elapsed time for each particular phase.
[0044] 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.
[0045] With continued reference to FIG. 10, six discrete phases 192
of an HDD project are shown, with each phase having its associated
processes that are performed by the HDD machine 105. In FIG. 10,
phase n-3 is the earliest phase 192 to occur in time of the
sequence 190 of phases, and 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. In some
embodiments, 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.
[0046] During the time duration, t.sub.n-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.
[0047] 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. 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.
[0048] In the illustrative example shown in FIG. 10, the HDD
machine 105 executes three phases for which data is collected and
transferred to memory in the manner discussed hereinabove. By way
of example, phases 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. For example,
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.
[0049] As a shown in FIG. 10, 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. In
some embodiments, the user interface 160 may include a display and
an input device mounted on the HDD machine 105. In other
embodiments, 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.
[0050] 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.
[0051] 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, ID.sub.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. 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.
[0052] FIG. 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. In the embodiment shown in FIG. 12, 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.
[0053] In some embodiments, the drilling machine 105 shown in FIG.
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. In other embodiments, the drilling machine 105 shown
in FIG. 12 is configured for vertical drilling, which may include
vertical directional drilling. In contrast to a horizontal
directional drilling machine, 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). Although 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.
[0054] 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.
[0055] FIG. 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
FIGS. 1 and 12, respectively). The system 150, shown in FIG. 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 FIG. 1. The controller 101 is also communicatively
coupled to a displacement drive 156 and a vise arrangement 158. In
some embodiments, the vise arrangement 158 includes two
independently controllable vises, such as an upper vise and a lower
vise.
[0056] 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 FIG. 13
can be used to implement various rod tallying methodologies
disclosed herein and in commonly owned U.S. application Ser. No.
14/755,978, filed on Jun. 30, 2015, and U.S. Provisional
Application Ser. No. 62/019,873 filed on Jul. 1, 2014, which are
incorporated herein by reference.
[0057] With particular reference to FIGS. 12 and 13, 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.
[0058] 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: [0059] 1) The
product may be pulled into an entry pit and disconnected from the
reamer or a drill head in the entry pit. In this scenario, 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. In this scenario, it will be possible to
detect when the pull-back has ended by a number of options: [0060]
a. 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, [0061] b. or when the product is pulled-back
without rotation of the drill string, or pumping of fluid, which
can only occur after the backreamer or drill head have emerged from
the bore hole. [0062] c. The system may then request operator
confirmation that the pullback has ended, even if rod count may be
>0 (Note 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). [0063] d. 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.
[0064] e. However, 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. [0065] 2) 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 same considerations apply as for the above
scenario, where 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.
[0066] 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-down.sub.0] 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.
[0067] While in the [break-down.sub.0] state, it is possible to log
operating parameters and accumulate usage metrics, such as: [0068]
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. This information may be useful to monitor if it is more
efficient to raise the rack when doing some of the processes
required during break-down. [0069] Engine metrics could be logged,
such as amount of time engine is running at low idle, at high idle.
[0070] Rod.sub.n data can be logged, to log metrics for the amount
of time required to pull-back rods after the product is
released.
[0071] The project phase will automatically be changed from
[break-down.sub.0] to [break-down.sub.1] 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.
[0072] 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-down.sub.n] 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.
[0073] When in the [break-down.sub.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.sub.0], and the final
project manifest can be generated for the previous project or
phase. [0074] 3) There is one scenario that is a bit different: The
product may be pulled back to the entry point, but the pullback,
rotation and fluid all stopped before the reamer or drill head is
completely out of the bore, with the intention of completing the
pullback with the ground drive. [0075] In this scenario, the
operator will not be at the control station, and not able to see or
reply to a confirmation request during the subsequent process. To
address this scenario, the system will automatically update the
project phase to [breakdown.sub.0] and log a timestamp, when the
ground drive controls are first used. [0076] 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.
[0077] During this phase, 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.
During this state, the system can log parameters and accumulate
usage metrics, such as: [0078] a. Pullback max pressure, pullback
duration or distance [0079] b. Rack control usage along with a time
stamp. This would allow assessment of when the rack is raised or
lowered during this phase. This information may be useful to
monitor if it is more efficient to raise the rack at a specific
time. [0080] c. Engine metrics could be logged, such as amount of
time engine is running at low idle, at high idle. [0081] d.
Rod.sub.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. [0082] When
in the [breakdown.sub.0] 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.sub.1] with a time stamp. [0083] When in a
[breakdown.sub.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 [transport.sub.0], and the final
manifest can be generated for the previous project or phase.
[0084] Once the project phase is set to [transport.sub.0], 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:
[0085] Maximum ground drive pressure, that may be an indication of
how the machine is being operated during transport; [0086]
Accumulated time during that state that the engine is running;
[0087] Etc.
[0088] When in the [transport.sub.n] 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.
[0089] In a common scenario, the rig state will be automatically
set to [transport.sub.0], 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 [transport.sub.1] 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.
[0090] 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 [transport.sub.3] 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 [track.sub.4] 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.sub.n] 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 [transport.sub.n] state to save that record as a
summary of the set-up phase.
[0091] 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 rod.sub.n start, Pilot Bore
rod.sub.n end, Pullback rod.sub.n start, and Pullback rod.sub.n
end.
[0092] 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 rod.sub.1 end) to (pilot
bore rod.sub.2 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: [0093] 1) generates an
automatically assigned phase ID code and queries the operator for a
custom phase code; [0094] 2) creates a digital summary report or
manifest for that specific phase; [0095] 3) queries the data log
cache to calculate attributes of productivity for that specific
phase that have already occurred including: [0096] a. calculating
(transport time), and saving a machine transport report to this
record including recording machine attributes that occurred while
the machine was in transport state including maximum ground drive
pressure, average ground drive pressure; [0097] b. calculating
(set-up time); [0098] c. calculating (rod 1 time) and saving a rod
1 report to this record including recording machine attributes that
occurred while the machine was in rod 1 state including maximum
rotation pressure, average rotation pressure, maximum thrust
pressure, average thrust pressure; [0099] d. calculating (add rod 2
time); and [0100] e. after the calculations are completed, and data
is written to the digital summary report, the data log cache is
updated, to clear-out data points that will not be needed for
future calculations. As the bore progresses and each time the
status changes from a (rod.sub.n end) to the subsequent
(rod.sub.n+1 start), 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.
[0101] 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.
[0102] 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: [0103] Forming a
reamer string, where-in a section of the drill string can be
pushed-out beyond the exit extending the same distance as the
length of the bore. Once pushed out beyond the exit pit, 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. [0104] Push
reaming. [0105] Trailing rod--related to the reamer string noted
above.
[0106] 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.
[0107] 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.
[0108] 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.
[0109] 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.
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