Advanced inground operations, system and associated apparatus
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.
1 . A method for use in conjunction with a horizontal directional drilling system that includes a drill string having a length that extends from a drill rig to a boring tool having a drill bit such that extension of the drill string advances the boring tool through the ground during a drilling operation to form a pilot bore, said method comprising:
during advancement of the boring tool, monitoring a drill bit force that is applied by the drill bit to a face of the pilot bore;
detecting a decrease in the drill bit force; and
initiating a response, using a processor, based at least in part on the detected decrease as being indicative of a potential cross-bore.
2 . The method of claim 1 wherein initiating said response includes at least one of issuing a warning that is indicative of said potential cross-bore and automatically suspending operation of the drill rig.
3 . The method of claim 1 , further comprising:
recording the drill bit force in correlation with the length of the drill string during the advancement of the boring tool.
4 . The method of claim 3 , further comprising:
monitoring a thrust force that is applied by the drill rig to the drill string to produce said advancement; and
recording the thrust force in correlation with the length of the drill string.
5 . The method of claim 4 , further comprising:
responsive to detecting the decrease in the drill bit force and prior to initiating said response, confirming that the drill bit force is less than the thrust force by at least a threshold difference.
6 . The method of claim 1 , further comprising:
responsive to detecting the decrease in the drill bit force and prior to initiating said response, confirming that the drill bit force has dropped to less than 10 pounds in less than 0.1 seconds.
7 . The method of claim 1 , further comprising:
responsive to detecting the decrease in the drill bit force, continuing to monitor the drill bit force to detect a recovery in the drill bit force thereby confirming an interval during which there is essentially no drill bit force.
8 . The method of claim 1 , further comprising:
responsive to detecting the decrease in the drill bit force, initiating a data collection interval to test for a recovery in the drill bit force that evidences a negative going pulse in the drill bit force that is consistent with encountering a cross-bore.
9 . The method of claim 1 wherein the drill string defines a through passage for carrying a pressurized flow of drilling mud from the drill rig to the boring tool for emission from the boring tool at least during advancing of the boring tool, said method further comprising:
correlating the drill bit force with an uphole mud pressure at which the drilling mud is pumped into the drill string; and
confirming that the uphole mud pressure remains constant while the boring tool is advancing at the time of detecting said decrease to enhance confidence in detection of the potential cross-bore.
10 . The method of claim 1 , further comprising:
issuing a warning that is indicative of said potential cross-bore; and
subsequent to issuing said warning, transmitting at least one data log that characterizes the potential cross-bore.
11 . The method of claim 1 wherein the drill string defines a through passage for carrying a pressurized flow of drilling mud from the drill rig to the boring tool for emission from the boring tool at least during advancing of the boring tool, said method further comprising:
correlating the drill bit force with a downhole annular mud pressure surrounding the boring tool; and
at least confirming a decrease in the downhole annular mud pressure corresponding to the decrease in bit force.
12 . An apparatus for use in conjunction with a horizontal directional drilling system that includes a drill string having a length that extends from a drill rig to a boring tool having a drill bit such that extension of the drill string advances the boring tool through the ground during a drilling operation to form a pilot bore, said apparatus comprising:
a monitoring arrangement for monitoring a drill bit force that is applied by the drill bit to a face of the pilot bore during advancement of the boring tool;
a sensor for detecting a decrease in the drill bit force; and
a processor configured for initiating a response based at least in part on the detected decrease being indicative of a potential cross-bore.
13 . The apparatus of claim 12 wherein said processor initiates said response as at least one of a warning that is indicative of said potential cross-bore and automatically suspending operation of the drill rig.
14 . The apparatus of claim 12 wherein the processor records the drill bit force in correlation with the length of the drill string during the advancement of the boring tool.
15 . The apparatus of claim 14 wherein said monitoring arrangement monitors a thrust force that is applied by the drill rig to the drill string to produce said advancement and said processor records the thrust force in correlation with the length of the drill string.
16 . The apparatus of claim 15 wherein responsive to detecting the decrease in the drill bit force and prior to initiating said response, said processor confirms that the drill bit force is less than the thrust force by at least a threshold difference.
17 . The apparatus of claim 12 wherein responsive to detecting the decrease in the drill bit force and prior to initiating said response, said processor confirms that the drill bit force has dropped to less than 10 pounds in less than 0.1 seconds.
18 . The apparatus of claim 12 wherein responsive to detecting the decrease in the drill bit force, said processor continues to monitor the drill bit force to detect a recovery in the drill bit force thereby confirming an interval during which there is essentially no drill bit force.
19 . The apparatus of claim 12 wherein responsive to detecting the decrease in the drill bit force, said processor initiates a data collection interval to test for a recovery in the drill bit force that evidences a negative going pulse in the drill bit force that is consistent with encountering a cross-bore.
20 . The apparatus of claim 12 wherein the drill string defines a through passage for carrying a pressurized flow of drilling mud from the drill rig to the boring tool for emission from the boring tool at least during advancing of the boring tool, and said processor is configured for:
correlating the drill bit force with an uphole mud pressure at which the drilling mud is pumped into the drill string; and
confirming that the uphole mud pressure remains constant while the boring tool is advancing at the time of detecting said decrease to enhance confidence in detection of the potential cross-bore.
21 . The apparatus of claim 12 , wherein said processor initiates said response as a warning that is indicative of said potential cross-bore and subsequent to issuing said warning, said processor is configured for transmitting at least one data log that characterizes the potential cross-bore.
22 . The apparatus of claim 12 wherein the drill string defines a through passage for carrying a pressurized flow of drilling mud from the drill rig to the boring tool for emission from the boring tool at least during advancing of the boring tool and said processor is further configured for:
correlating the drill bit force with a downhole annular mud pressure surrounding the boring tool; and
at least confirming a decrease in the downhole annular mud pressure corresponding to the decrease in bit force.