Method of, and a system for, controlling a drilling operation

Patent metadata

Field	Value
Publication number	US-10746012-B2
Application number	US-201816165151-A
Country	US
Kind code	B2
Filing date	Oct 19, 2018
Priority date	May 8, 2013
Publication date	Aug 18, 2020
Grant date	Aug 18, 2020

Abstract

A system 10 for controlling a drilling operation by a drill rig 12 includes a receiver 16 for receiving sensed data related to the drilling operation. A processor 18 is in communication with the receiver 16, the processor 18 processing the sensed data to estimate at least one geological property of interest of a zone 20 in which the drill rig 12 is active. The processor 18 is configured to operate as a decision engine 22 to optimize the drilling operation automatically by changing at least one drilling related parameter during the drilling operation based on the at least one geological property of interest.

First claim

The invention claimed is:

1. A method of controlling a drilling operation of a drill rig, wherein the drill rig includes:
a platform supporting a drill mast, the drill mast carrying a drill string, wherein an operative lower end of the drill string includes a replaceable drill bit;
an auto bit changer module having a plurality of receptacles, each receptacle being adapted to receive a drill bit, wherein when activated the auto bit changer module changes the replaceable drill bit on the drill string;
a controller for controlling operation of the drill rig, the controller including an operating system that includes:
a database for storing a geological model of a bench on which a drilling operation is to be performed,
a receiver,
a processor in communication with said receiver, and
a decision engine;

wherein the method comprises the steps of:
the receiver receiving sensed data relating to the drilling operation carried out by the drill rig and sending the sensed data to the processor;
the processor processing the sensed data to estimate at least one geological property of interest of a zone of the bench in which the drill rig is active;
the decision engine automatically optimizing the drilling operation, based on said at least one geological property of interest, by changing at least one of: (a) said replaceable drill bit at said lower end of the drill string, and (b) a drill model comprising an order in which holes are to be drilled by the drill rig during the drilling operation; and
the controller causing the drill rig to operate under the optimized drilling operation to maximize at least one metric of interest relating to the drilling operation.

2. The method according to claim 1 , wherein the auto bit changer module is configured to operate automatically under control of said controller.

3. The method according to claim 1 , wherein the sensed data is selected from the group consisting of: mechanical drill data, geophysical data, geochemical data, and any combination of the foregoing.

4. The method according to claim 1 , further comprising:
sensing, by a sensor pack, mechanical drilling parameters as said sensed data.

5. The method according to claim 4 , wherein said mechanical drilling parameters are selected from the group consisting of: rotation speed of the drill bit, rotation direction of the drill bit, pull down speed, pull down pressure, pull up speed, depth, air pressure, water fluid flow rate, rotation pressure, and bit pressure.

6. The method according to claim 1 , wherein the at least one geological property of interest is selected from the group consisting of strata boundaries and metrics related to substrate hardness.

7. The method according to claim 1 , wherein the decision engine optimizes the drilling operation in respect of at least one specified criterion.

8. The method according to claim 7 , wherein the at least one specified criterion is selected from the group consisting of: maximizing rate of penetration of the drill bit, minimizing time taken to drill a hole, maximizing bit life, maximizing the rate of drilling the zone by changing an order in which holes of a drill pattern for the zone are to be drilled, and any combination of the foregoing.

9. The method of claim 1 , wherein said decision engine, when optimizing the drilling operation, factors in the time taken to change the drill bit in determining whether or not changing the drill bit optimizes the drilling operation.

10. A drill rig comprising:
a platform supporting a drill mast, the drill mast carrying a drill string, wherein an operative lower end of the drill string includes a replaceable drill bit;
an auto bit changer module having a plurality of receptacles, each receptacle being adapted to receive a drill bit, wherein when activated the auto bit changer module changes the replaceable drill bit on the drill string;
a controller for controlling operation of the drill rig, the controller including an operating system that includes:
a database for storing a geological model of a bench on which a drilling operation is to be performed,
a receiver for receiving sensed data relating to the drilling operation carried out by the drill rig,
a processor in communication with said receiver, said processor operative to process the sensed data to estimate at least one geological property of interest of a zone of the bench in which the drill rig is active, and
a decision engine for automatically optimizing the drilling operation, based on said at least one geological property of interest, by changing at least one of: (a) said replaceable drill bit at said lower end of the drill string, and (b) a drill model comprising an order in which holes are to be drilled by the drill rig during the drilling operation;

wherein said controller causes the drill rig to operate under the optimized drilling operation to maximize at least one metric of interest relating to the drilling operation.

11. The drill rig of claim 10 , wherein the auto bit changer module is configured to operate automatically under control of said controller.

12. The drill rig of claim 10 , wherein the sensed data is selected from the group consisting of: mechanical drill data, geophysical data, geochemical data, and any combination of the foregoing.

13. The drill rig of claim 10 , wherein the at least one geological property of interest is selected from the group consisting of strata boundaries and metrics related to substrate hardness.

14. The drill rig of claim 10 , wherein the decision engine optimizes the drilling operation in respect of at least one specified criterion.

15. The drill rig of claim 14 , wherein the at least one specified criterion is selected from the group consisting of: maximizing rate of penetration of the drill bit, minimizing time taken to drill a hole, maximizing bit life, maximizing the rate of drilling the zone by changing an order in which holes of a drill pattern for the zone are to be drilled, and any combination of the foregoing.

16. The drill rig of claim 10 , wherein said decision engine, when optimizing the drilling operation, factors in the time taken to change the drill bit in determining whether or not changing the drill bit optimizes the drilling operation.

17. The drill rig of claim 10 , wherein said decision engine changes said replaceable drill bit in dependence on a mode of drilling of the drill rig selected to optimize the drilling operation.

18. The drill rig of claim 17 , wherein the mode of drilling is one of rotary drilling and percussive drilling.

19. The drill rig of claim 10 , further comprising:
a sensor pack for providing sensed mechanical drilling parameters as said sensed data to said receiver.

20. The drill rig of claim 19 , wherein said mechanical drilling parameters are selected from the group consisting of: rotation speed of the drill bit, rotation direction of the drill bit, pull down speed, pull down pressure, pull up speed, depth, air pressure, water fluid flow rate, rotation pressure, and bit pressure.

Assignees

• Tech Resources Pty Ltd

Inventors

• Mchugh Charles Benjamin
• Nettleton Eric William

Classifications

• E21B7/02 Primary

  Drilling rigs characterised by means for land transport {with their own drive}, e.g. skid mounting or wheel mounting · CPC title

• E21B44/02 Primary

  Automatic control of the tool feed ({E21B44/005,} E21B44/10 take precedence) · CPC title

• G05B13/021

  in which a variable is automatically adjusted to optimise the performance · CPC title

• E21B49/003

  by analysing drilling variables or conditions (E21B49/005 takes precedence; systems specially adapted for monitoring a plurality of drilling variables or conditions E21B44/00) · CPC title