Advanced inground operations, system and associated apparatus

• US 9,664,027 B2
• Filed: 07/19/2013
• Issued: 05/30/2017
• Est. Priority Date: 07/20/2012
• Status: Active Grant

• Current Assignee: Merlin Technologies Incorporated
• Original Assignee: Merlin Technologies Incorporated
• Inventors: Chau, Albert W., Medeiros, Benjamin John, Caswell, Craig
• Primary Examiner(s): Fuller, Robert E
• Assistant Examiner(s): MACDONALD, STEVEN A
• Application Number:
  US13/946,284
• Publication Number:
  US 20140020953A1
• Time in Patent Office: 1,411 Days
• CPC Class Codes: E21B 21/08 Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure valve arrangements therefor E21B21/10
• 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 44/02 Automatic control of the tool feed E21B44/005, E21B44/10 take precedence
• CPC Class Codes: E21B 47/02 Determining slope or direction
• CPC Class Codes: E21B 47/024 of devices in the borehole determining slope or direction of the borehole E21B47/022
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: E21B 47/10 Locating fluid leaks, intrusions or movements
• CPC Class Codes: E21B 47/12 Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
• CPC Class Codes: E21B 47/13 by electromagnetic energy, e.g. radio frequency
• CPC Class Codes: E21B 7/046 horizontal drilling drilling with mechanical conveying means E21B7/003
• CPC Class Codes: E21B 7/068 drilled by a down-hole drilling motor down-hole drives per se E21B4/00, E21B7/067 takes precedence
• CPC Class Codes: E21B 7/10 Correction of deflected boreholes
• CPC Class Codes: E21B 7/28 Enlarging drilled holes, e.g. by counterboring
• CPC Class Codes: G01V 3/18 specially adapted for well-logging

Abstract

Systems, apparatus and methods are described for purposes of initiating a response to detection of an adverse operational condition involving a system including a drill rig and an inground tool. The response can be based on an uphole sensed parameter in combination with a downhole sensed parameter. The adverse operational condition can involve cross-bore detection, frac-out detection, excessive downhole pressure, a plugged jet indication and drill string key-holing detection. A communication system includes an inground communication link that allows bidirectional communication between a walkover detector and the drill rig via the inground tool. Monitoring of inground tool depth and/or lateral movement can be performed using techniques that approach integrated values. Bit force based auto-carving is described in the context of an automated procedure.

Claims

1. A method for use in conjunction with a horizontal directional drilling system that includes a drill string that extends from a drill rig to an inground tool such that extension and retraction of the drill string generally produces corresponding movements of the inground tool during an inground operation, said drill string defining a through passage for carrying a pressurized flow of drilling mud from the drill rig to the inground tool for emission from the inground tool, said method comprising:

during the inground operation, monitoring an annular mud pressure in the ground surrounding the inground tool;

detecting a decrease in the annular mud pressure;

continuing to monitor the annular mud pressure subsequent to detecting said decrease for a recovery in the annular mud pressure such that a negative going pulse is defined in the annular mud pressure; and

initiating a response as being indicative of a potential cross-bore.

2. The method of claim 1 wherein said response includes issuing a warning to indicate the potential cross-bore.

3. The method of claim 2 wherein issuing requires detecting said decrease in conjunction with detecting an uphole mud pressure based on an uphole mud pressure threshold, a mud flow based on a flow rate threshold and detecting a movement of the drill string.

4. The method of claim 1 further comprising:

collecting supplemental data responsive to detecting said decrease for a time interval from before and/or subsequent to detecting the decrease.

5. The method of claim 4 wherein the supplemental data includes uphole mud pressure, downhole mud pressure and mud flow.

6. The method of claim 5, further comprising:

collecting additional data including at least one of a length of the drill string and a rate of drill string push/pull for a selectable time interval that is based on a first point in time at which said decrease was detected and a second point in time at which said recovery was detected.

7. The method of claim 6 further comprising:

defining the selectable time interval based on offsets such that the first point in time is prior to the decrease in annular mud pressure and the second point in time is after the recovery in the downhole mud pressure.

8. The method of claim 1 further comprising:

in an absence of detecting the recovery, issuing said warning as being indicative of a potential frac-out.

9. The method of claim 1 further comprising:

automatically suspending operation of the drill rig as said response.

10. The method of claim 1, further comprising:

establishing a minimum threshold for the annular mud pressure based on a hydrostatic pressure during normal operation of the drill rig and basing the initiation of said response on the minimum threshold.

11. The method of claim 1 wherein initiating said response further requires detecting said decrease in conjunction at least with detecting a movement of the drill string.

12. The method of claim 1, further comprising:

during the inground operation, monitoring a gas sensor that senses for one or more gases in an annular region surrounding said inground tool, said gases including natural gas, propane, hydrocarbon gases and sewer gas.

13. The method of claim 1, further comprising:

during the inground operation, monitoring a gas sensor that senses for one or more gases proximate to said drill rig, said gases including natural gas, propane, hydrocarbon gases and sewer gas.

14. A method for use in conjunction with a horizontal directional drilling system that includes a drill string that extends from a drill rig to an inground tool such that extension and retraction of the drill string generally produces corresponding movements of the inground tool during an inground operation, said drill string defining a through passage for carrying a pressurized flow of drilling mud from the drill rig to the inground tool for emission from the inground tool, said method comprising:

during the inground operation, monitoring an annular mud pressure in the ground surrounding the inground tool;

detecting a decrease in the annular mud pressure;

initiating a response based at least in part on detecting said change as being indicative of one of a potential cross-bore and a potential frac-out;

measuring a rate of change of the decrease in the annular mud pressure; and

distinguishing between the potential cross-bore and the potential frac-out based on the rate of change for use in initiating said response.

15. The method of claim 14 including selecting a threshold value for the rate of change of the decrease in the annular mud pressure in a range from −

20 psi/sec to −

100 psi/sec and distinguishing compares a measured rate of change to the selected threshold value.

16. An apparatus for use in conjunction with a horizontal directional drilling system that includes a drill string that extends from a drill rig to an inground tool such that extension and retraction of the drill string generally produces corresponding movements of the boring tool through the ground during an inground operation, said drill string defining a through passage for carrying a pressurized flow of drilling mud from the drill rig to the inground tool for emission from the inground tool, said apparatus comprising:

a sensor for sensing an annular mud pressure in the ground surrounding the inground tool during the inground operation to produce a sensor output; and

a processor receiving the sensor output and configured for monitoring the annular mud pressure based on the sensor output and for continuing to monitor the annular mud pressure subsequent to detecting said decrease for a recovery in the annular mud pressure such that a negative going pulse is defined in the annular mud pressure and issuing a warning responsive to identification of the negative going pulse.