Methods and systems for drilling boreholes

• US 9,316,053 B2
• Filed: 06/15/2012
• Issued: 04/19/2016
• Est. Priority Date: 11/11/2009
• Status: Active Grant

• Current Assignee: Flanders Electric Motor Service, Inc.
• Original Assignee: Flanders Electric Motor Service, Inc.
• Inventors: Stacy, Edward Curtis II, Garcia, Antonio
• Primary Examiner(s): Patel, Ramesh
• Application Number:
  US13/524,623
• Publication Number:
  US 20120253518A1
• Time in Patent Office: 1,404 Days
• US Class Current: 1/1
• 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: E21B 44/04 in response to the torque of the drive ; Measuring drilling torque E21B44/06 takes precedence; measuring stresses in a well bore pipe E21B47/007
• CPC Class Codes: E21B 7/00 Special methods or apparatus for drilling

Abstract

A computer-readable medium including program instructions for drilling a borehole. When the program instructions are executed by one or more processors of a computer system operatively associated with a drill rig, the program instructions cause the processor to carry out the steps of initiating a drilling phase and monitoring a drill parameter during the drilling phase. The drill parameter includes at least one of drill rotational speed, drill torque or number of drill retractions. The program instructions further cause the processor to carry out the step of determining whether the monitored drill parameter is within a predetermined specification for the monitored drill parameter in order to choose a drilling phase defect mitigation routine. After implementing the drilling phase defect mitigation routine, the processors carry out the step of resuming the drilling phase.

Claims

1. A computer-readable medium, the computer-readable medium being non-transitory and including program instructions for drilling a borehole that, when executed by one or more processors of a computer system operatively associated with a drill rig, cause the one or more processors to carry out the steps of:

initiating a drilling phase;

monitoring a drill parameter during the drilling phase, the monitored drill parameter comprising at least number of drill retractions;

determining whether the monitored drill parameter is within a predetermined specification for the monitored drill parameter;

choosing a drilling phase defect mitigation routine based on the monitored drill parameter when the monitored drill parameter is outside the predetermined specification;

implementing the drilling phase defect mitigation routine; and

resuming the drilling phase.

2. The computer-readable medium of claim 1, wherein the monitored drill parameter comprises drill depth, drill rotational speed and drill torque, and wherein the drilling phase defect mitigation routine comprising at least one of end-of-hole spin-out or end-of-hole water control.

3. The computer-readable medium of claim 2, wherein the monitored drill parameter comprises air pressure, wherein the drilling phase mitigation routine comprises air protection and wherein choosing the drilling phase defect mitigation routine comprises choosing said air pressure protection drill mitigation routine when said monitored air pressure is outside a predetermined specification for air pressure, said air pressure protection routine comprising:

retracting a drill bit;

applying air pressure to the drill bit;

monitoring the air pressure;

activating a drill water injection system to unclog the drill bit when the monitored air pressure is outside the predetermined specification; and

wherein resuming the drilling phase comprises resuming the drilling phase when the monitored air pressure is within the predetermined specification.

4. The computer-readable medium of claim 2, wherein said drilling phase mitigation routine comprises rotary stall protection and wherein choosing said drill phase defect mitigation routine comprises choosing said rotary stall protection routine when one or both of said monitored drill rotational speed is outside a predetermined specification for rotational speed and said drill torque is outside a predetermined specification for drill torque.

5. The computer-readable medium of claim 4, wherein said rotary stall protection routine comprises:

retracting a drill bit;

rotating the drill bit; and

resuming the drilling phase with one or both of a reduced down-force and an increased rotational drill bit speed.

6. The computer-readable medium of claim 2, wherein choosing said drill phase defect mitigation routine comprises choosing said end-of-hole spin-out routine when said monitored drill depth meets a predetermined specification for drill depth.

7. The computer-readable medium of claim 6, wherein said end-of-hole spin-out routine comprises:

retracting a drill bit to a position above a bottom of the borehole;

rotating the drill bit for a spin-out period if the drill bit was retracted two or fewer times during the drilling phase;

rotating the drill bit for a product of the spin-out period and the number of drill retractions if the drill bit was retracted 3 or more times during the drilling phase; and

retracting the drill bit from the borehole.

8. The computer-readable medium of claim 1, further comprising performing a collaring routine after said initiating the drilling phase.

9. The computer-readable medium of claim 8, wherein performing a collaring routine comprises:

performing a first phase collaring operation from a surface start until one or both of a penetration rate drops below a predetermined penetration rate and a drill bit reaches a maximum collaring depth, the maximum collaring depth; and

performing a second phase collaring operation after the penetration rate drops below the predetermined penetration rate.

10. The computer-readable medium of claim 9, wherein performing a second phase collaring operation comprises retracting the drill bit from the borehole.

11. The computer-readable medium of method of claim 10, wherein performing a second phase collaring operation comprises re-lowering the drill bit to a bottom of the borehole at reduced hoist and drill rotation speeds.

12. The computer-readable medium of claim 10, wherein performing a second phase collaring operation comprises activating a drill water injection system while retracting the drill bit from the borehole.

13. The computer-readable medium of claim 1, further comprising:

initiating a retraction phase;

monitoring at least one drill parameter during the retraction phase;

determining whether the monitored drill parameter is within a predetermined specification for the monitored drill parameter;

choosing a retraction phase defect mitigation routine based on the monitored drill parameter when the monitored drill parameter outside the predetermined specification; and

implementing the retraction phase defect mitigation routine.

14. The computer-readable medium of claim 13, wherein monitoring a drill parameter comprises monitoring at least one of hoist speed or number of drill retractions.

15. The computer-readable medium of claim 14, wherein choosing a retraction phase defect mitigation routine comprises choosing at least one of drill bit hang-up protection or hole clean-out.

16. The computer-readable medium of claim 15, further comprising choosing said drill bit hang-up protection routine when one or both of said monitored drill rotational speed is outside a predetermined specification for drill rotational speed and said monitored hoist speed is outside a predetermined specification for hoist speed.

17. The computer-readable medium of claim 16, wherein said drill bit hang-up protection routine comprises:

increasing the rotational speed of a drill bit;

lowering the drill bit;

determining whether the drill bit is freed; and

raising the drill bit at a reduced hoist speed.

18. The computer-readable medium of claim 17, further comprising:

alternately applying to the drill bit a down hoist force and an up hoist force; and

activating a water injection system if the drill bit is not freed after said alternately applying down and up hoist forces.

19. The computer-readable medium of claim 15, further comprising choosing said torque monitoring routine when said monitored drill torque is outside a predetermined specification for drill torque.

20. The computer-readable medium of claim 19, wherein said torque monitoring routine comprises:

performing said hole clean-out routine to re-drill the borehole by at least;

retracting a drill bit from the borehole and;

resuming the drilling phase; and

performing an end-of-hole spin-out routine.

21. The computer-readable medium of claim 15, further comprising choosing said hole clean-out routine when one or more of said monitored drill retractions is outside a predetermined specification for drill retractions, said monitored hoist speed is outside a predetermined specification for hoist speed, and said monitored drill torque is outside a predetermined specification for drill torque.

22. The computer-readable medium of claim 21, wherein said hole clean-out routine comprises:

lowering a drill bit to a position above a bottom of the borehole;

rotating the drill bit for a spin-out period if the drill bit was retracted two or fewer times during the drilling phase;

rotating the drill bit for a product of the spin-out period and the number of drill retractions if the drill bit was retracted at least 3 times during the drilling phase; and

retracting the drill bit from the borehole.

23. A computer-readable medium, the computer-readable medium being non-transitory and including program instructions for drilling a borehole that, when executed by one or more processors of a computer system operatively associated with a drill rig, cause the one or more processors to carry out the steps of:

monitoring a drill parameter during a drilling phase and a retraction phase;

using the monitored drill parameter to draw a conclusion about a borehole characteristic;

choosing a defect mitigation routine based on the borehole characteristic; and

implementing the defect mitigation routine.

24. The computer-readable medium of claim 23, wherein monitoring a drill parameter comprises monitoring at least one of air pressure, hoist speed and number of drill retractions.

25. The computer-readable medium of claim 24, wherein choosing a defect mitigation routine further comprises choosing at least one of air pressure protection, rotary stall protection, end-of-hole spin-out, and end-of-hole water control.

26. The computer-readable medium of claim 24, wherein choosing a defect mitigation routine comprises choosing at least one of drill bit hang-up protection, torque monitoring, and hole clean-out.

27. The computer-readable medium of claim 26, further comprising choosing an end-of-hole measurement routine when said monitored drill depth meets a predetermined borehole depth, said end-of-hole measurement routine comprising:

partially retracting a drill string from the borehole;

re-lowering the drill string in the borehole;

monitoring the drill parameter during said re-lowering;

comparing the monitored drill parameter with a corresponding set point; and

determining an “

on ground position”

when the monitored drill parameter falls outside the corresponding set point.

28. The computer-readable medium of claim 27, wherein said determining comprises determining an “

on ground position”

when the monitored drill parameter falls outside the corresponding set point for a predetermined period of time.

29. The computer-readable medium of claim 27, wherein monitoring the drill parameter during said re-lowering comprises monitoring at least one of drill hoist speed, pull-down force, and drill torque.

30. The computer-readable medium of claim 27, further comprising comparing the “

on ground position”

with the predetermined borehole depth.

31. The computer-readable medium of claim 27, further comprising resuming the drilling phase when the “

on ground position”

exceeds an allowable depth variation.

32. The computer-readable medium of claim 27, wherein said partially retracting comprises retracting the drill string by a retraction distance.

33. The computer-readable medium of claim 32, wherein the retraction distance is a percentage of the predetermined borehole depth.

34. A non-transitory computer readable medium storing program instructions for drilling a borehole that, when executed by a computer associated with a drill rig, cause the computer to carry out the steps of:

after initiating a drilling phase, performing a collaring routine to form a collar in the borehole, said collaring routine comprising a first phase collaring routine and a second phase collaring routine, said second phase collaring routine beginning after contacting competent ground in the borehole;

monitoring drill parameters associated with the drill rig comprising drill rotational speed, drill torque, drill depth, hoist speed and number of drill retractions;

determining whether at least one drill parameter is within a predetermined specification for at least one monitored drill parameter during the drilling phase and the retraction phase, the retraction phase following completion of the drilling phase; and

implementing a drilling phase defect mitigation routine when the at least one drill parameter is outside the predetermined specification for the drilling phase; and

implementing a retraction phase defect mitigation routine when the at least one drill parameter is outside the predetermined specification for the retraction phase.