Granted Patent B2

US 9,995,128 · App. 14/926,802 · Granted Jun 12, 2018

Inventors: Edward Curtis Stacy, II (Evansville, IN); Antonio Garcia (Pima, AZ)

Assignee: Flanders Electric Motor Service, Inc.

E21B44/04E21B7/00E21B44/00

Abstract

Claims (35)

1. A system for drilling a borehole, comprising:

a drill rig comprising an air injection system, a water injection system, and a drill, the drill comprising a drill bit;

a control system operatively associated with said drill rig, said control system:

monitoring a plurality of drill parameters during a drilling phase and a retraction phase, the drilling phase ending when the borehole has been drilled to a predetermined depth and the retraction phase beginning following completion of the drilling phase,

receiving information from said drill rig relating to at least one drill parameter,

controlling said drill rig, storing program steps for program control, and processing data; and data,

automatically implementing a collaring routine to form a collar in the borehole; and

said control system processing information relating to the drill parameter, determining whether the drill parameter is within a predetermined specification for the monitored drill parameter, choosing a hole defect mitigation routine based on the monitored drill parameter when the monitored drill parameter is outside the predetermined specification, said hole defect mitigation routine comprising at least one drilling phase defect mitigation routine and at least one retraction phase

mitigation routine, said control system controlling said drill rig to implement the chosen hole defect mitigation routine.

2. The system of claim 1 , wherein said at least one drill parameter comprises air pressure, said drilling phase defect mitigation routine comprises air pressure protection, and said control system implements said air pressure protection routine when said monitored air pressure is outside a predetermined specification for air pressure.

3. The system of claim 2 , wherein said air pressure protection routine comprises:

deactivating the water injection system when the monitored air pressure is outside of the predetermined specification;

retracting the drill bit; and

resuming drilling when the monitored air pressure is nominal.

4. The system of claim 3 , wherein said air pressure protection routine comprises:

continuing to monitor air pressure;

determining whether the monitored air pressure has gone outside of the predetermined specification more than a predetermined number of times within a predetermined time interval; and

retracting the drill bit above the surface of the borehole when the monitored air pressure has gone outside of the predetermined specification more than a predetermined number of times within a predetermined time interval.

5. The system of claim 1 , wherein said at least one drill parameter comprises number of drill retractions, said drilling phase defect mitigation routine comprises end-of-hole spin-out, and said control system implements said end-of-hole spin-out routine when said monitored number of drill retractions during the drilling phase is outside a predetermined specification for number of drill retractions.

6. The system of claim 1 , wherein said at least one drill parameter comprises drill depth, said drilling phase defect mitigation routine comprises end-of-hole water control, and said control system implements said end-of-hole water control routine when said monitored drill depth exceeds a predetermined specification for drill depth.

7. The system of claim 1 , wherein said at least one drill parameter comprises drill rotational speed and hoist speed, said retraction phase defect mitigation routine comprises drill bit hang-up protection, and said control system implements 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.

8. The system of claim 7 , wherein the drill bit hang-up protection routine comprises:

applying maximum torque to the drill bit while applying a pull-up hoist force;

applying alternating pull-down hoist force and pull-up hoist force; and

activating the water injection system.

9. The system of claim 1 , wherein said at least one drill parameter comprises torque, said drilling phase defect mitigation routine comprises torque monitoring, and said control system implements said torque monitoring routine when said monitored drill torque is outside a predetermined specification for drill torque.

10. The system of claim 9 , wherein the torque monitoring routine comprises implementing a hole clean-out routine until monitored torque is no longer outside of the predetermined specification for torque for a predetermined period of time.

11. The system of claim 1 , wherein said at least one drill parameter comprises number of drill retractions, hoist speed and drill torque, said drilling phase defect mitigation routine comprises hole clean-out, and said control system implements 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.

12. A method for using a drill rig to drill a borehole comprising a drill including a drill bit operatively associated with a drill motor system, an air injection system, a water injection system and having a control system operatively associated with said drill rig, comprising:

using sensors associated with the drill motor system, providing drill parameter data to the control system;

at the start of a drilling phase, through the control system, automatically implementing a collaring routine to collar the borehole, using the motor system, air injection system and water control system;

through the control system, using the drill parameter data to monitor at least one drilling phase drill parameter and at least one retraction phase drill parameter;

when the monitored drilling phase drill parameter falls outside of a predetermined specification, through the control system, choosing a drilling phase defect mitigation routine based on the monitored drilling phase parameter and implementing the chosen drilling phase mitigation routine using at least the drill motor system;

after implementing the chosen drilling phase mitigation routine, completing the drilling phase by drilling the borehole to a predetermined borehole completion depth;

during a retraction phase, the retraction phase following the completion of the drilling phase, when the monitored drilling phase drill parameter falls outside of a predetermined specification, through the control system, choosing a retraction phase defect mitigation routine based on the monitored retraction phase parameter and implementing the chosen retraction phase mitigation routine using at least the drill motor system and the water injection system.

Assignments (8)

Continuity (5)