Drilling process and apparatus

• US 5,318,136 A
• Filed: 09/04/1992
• Issued: 06/07/1994
• Est. Priority Date: 03/06/1990
• Status: Expired due to Fees

• Current Assignee: University of Nottingham
• Original Assignee: University of Nottingham
• Inventors: Rowsell, Philip J., Waller, Martin D.
• Primary Examiner(s): BUIZ, MIKADO RYAN
• Application Number:
  US07/924,057
• Time in Patent Office: 641 Days
• Field of Search: 175/24-27, 175/39, 175/40, 364/474.01, 364/474.02
• US Class Current: 175/24
• CPC Class Codes: E21B 44/00 Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
• CPC Class Codes: G05B 19/4163 Adaptive control of feed or cutting velocity without NC B23Q15/12
• CPC Class Codes: G05B 2219/34321 Database for control of a single machine
• CPC Class Codes: G05B 2219/42152 Learn, self, auto tuning, calibrating, environment adaptation, repetition
• CPC Class Codes: G05B 2219/45129 Boring, drilling
• CPC Class Codes: G05B 2219/49068 Minimum cost adaptive

Abstract

In a drilling process speed, bit thrust and penetration are monitored. Data stored in a data base relating rotational speed and thrust as adjustable variables is correlated with data on the penetration rate as controlled parameter to produce a matrix to enable prediction of penetration rate to be expected at known thrust and rotational rates. Likewise a similar matrix may be constructed for relating wear rate to adjustable variables for example speed and thrust. The parameters predicted from these variables at various values for the speed and thrust are used to construct a further matrix relating bit penetration and bit wear rates with cost per unit distance drilled and this third matrix searched for minimum cost. From the first two matrices rotation rate of the drill bit and thrust applied to the drill bit are adjusted to give a predicted penetration rate for minimum cost and the drill bit is operated at these conditions. All conditions are monitored and the information used to recalculate the various matrices to define the process.

Claims

1. A drilling process comprising urging a rotating drill bit towards a mass to be drilled, and controlling the thrust applied and the speed of rotation, the process comprising monitoring at least one parameter selected from controlled parameters including rate of penetrating of the drill bit and wear rate of the drill bit, and adjusting at least one related variable selected from adjustable variables including rate of rotation of the drill bit and thrust applied to the drill bit so as to bring the controlled parameters to operating values at which the cost of drilling per unit depth is substantially minimized.

2. A process according to claim 1 wherein a relationship between bit penetration rate and bit wear rate is determined and penetration rate substantially optimized whereby to substantially optimize the cost of drilling per unit depth.

3. Apparatus suitable for use in carrying out a process according to claim 1 comprising means for rotatably mounting a drill bit, drive means for rotating a drill bit mounted in the mounting means, means for controlling the speed of rotation of the drill bit, means for controlling the thrust applied to the drill bit, means for determining the rate of penetration of a drill bit in a drilling operation, and computer means adapted to store data, and to calculate values of adjustable variables predicted to be necessary to achieve drilling at a substantially minimum cost per unit depth.

4. A drilling process comprising establishing a first matrix storing known data relating variables selected from adjustable variables including rotation rate of a drill bit and thrust applied to a drill bit, to a first parameter selected from controlled parameters including bit penetration rate and bit wear rate, and using the known data points to interpolate predicted values for the first controlled parameter for other values of the adjustable variables, establishing a second matrix storing known data relating the first parameter and a second control parameter to a third parameter, and using the known data points to interpolate predicted values for the third parameter for other values of the first and second controlled parameters, searching the second matrix for an optimum value of the third parameter and thereby determining optimum values for the first and second parameters and adjusting the adjustable variables to the value indicated by the first matrix to be necessary to achieve the determined optimum value for the first control parameter.

5. A process according to claim 4 comprising monitoring the actual value for the first control parameter achieved with the adjustable variables at said indicated values and entering this data and recalculating the first matrix accordingly to provide a current first matrix, and re-adjusting the adjustable variables to the value indicated by the current first matrix to be necessary to achieve the determined value of the first parameter.

6. A process according to claim 4 comprising monitoring actual values for the first and second parameters entering this data, recalculating the second matrix accordingly, and utilising data from the recalculated second matrix to calculate revised predicted values for the first and second parameters to optimise said third parameter, and readjusting the adjustable variables to the value indicated by the current first matrix to be necessary to achieve the predicted value of the first parameter.

7. A process according to claim 4 wherein the adjustable variables are rotation rate and thrust applied.

8. A process according to claim 4 wherein the third parameter is cost per unit depth of hole.

9. A process according to claim 4 wherein the first controlled parameter is bit penetration rate.

10. A process according to claim 4 wherein the second controlled parameter is bit wear rate.

11. A process according to claim 4 wherein the equation by which values of the third parameter are calculated from the first and second parameters are calculated is ##EQU16## where C=cost per unit distance drilled

B=cost of the bit

R=rig cost per unit time

Tm=tripping time per unit distance drilled

D=depth of hole

W=wear rate

K=kerf height

P=penetration rate.

12. A process according to claim 4 comprising monitoring at least one further controlled parameter and establishing a further matrix or matrices by which values for the second controlled parameter can be predicted.

13. A process according to claim 12 wherein the further control parameter is specific energy, namely the energy required to excavate or break a value of rock.

14. A process according to claim 13 wherein the specific energy is calculated from the following relation ##EQU17## where e=specific energy

F=thrust

A=area of bit

N=revolutions of bit per minute

T=torque

P=penetration rate.