Drillbotics 2018 2018 Team Members Jack Borer Team Captain - PowerPoint PPT Presentation

Drillbotics 2018

2018 Team Members  Jack Borer Team Captain  Patrick Dolan MVP Mechanical/Safety  Aditya Sharma Electrical  Ali Mehdi Naqvi Drilling  Chad Meadows Remote Monitoring  Dr. Ramadan Ahmed Advising Professor  VimleshBavadiya Advising Liason 2

Presentation Outline I. Safety Tailgate II. 2017 Recap III. Mechanical Systems IV. Drill Pipe Connections V. Remote System Control VI. Electrical/Downhole Sensor VII. Control System VIII. Capital Expenditures IX. Drillbotics Events 3

I. Safety Tailgate 4

I. Safety Tailgate 5

II. 2017 Recap – Spaghetti Style 6

III. Mechanical Systems - Hoisting  Pneumatically controlled top drive  Manual control added for safety and usability  Raised rails 8 inches to allow for greater drilling depth 7

III. Mechanical Systems – Hoisting : Pneumatics Height of top drive controlled electronically by pneumatic converters or manual valve. 8

III. Mechanical Systems – Hoisting : Pneumatics Flowsheet Top Pneumatic Converter Pilot Top of air operated cylinder check Directional Bottom valve Pneumatic Converter Toggle Air supply Regulator valve Directional Bottom of Manual Pilot valve control operated air valve check cylinder 9

III. Mechanical Systems – Hoisting : Pneumatics - AirPilot Check Valves  Valve prevents flow out of cylinder Air Signal unless air signal from opposite side of cylinder is provided  Air cylinder holds position even when supply is disconnected  Free flow is allowed when air is From Air supplied in automatic mode Supply  When electrical signal is lost pneumatic converters reduce WOB to less than 5lbs From Air Cylinder 10

III. Mechanical Systems - Circulation  Circulation system space efficiency increased  New system working pressure is 400 psig 11

III. Mechanical Systems – Circulation Flowsheet 12

III. Mechanical Systems - Conduits and Carriers  All cables and wires secured  3” ID conduit connects all boxes  Rig mast can be laid down without crushing cables 13

III. Mechanical Systems – Hammer Motor Hammer motor location moved to rig  Enables rig to be laid down without breaking connections Flow to swivel through cable carrier through flexible nylon tubing 14

III. Mechanical Systems - Instrumentation Pressure gauges added for:  Compressed air supply  Top air cylinder  Bottom air cylinder  Stand pipe 15

III. Mechanical Systems – Rig Supplies Connections for:  120 VAC, single phase  230 VAC 3-phase  Quick connect 150 psig compressed air  Quick connect city water hose 16

IV . Drill Pipe Connections – Phase I Inspiration for new connection:  Last year compression fitting failure  Increased pipe thickness – allows increased load capacity, requiring stronger connection Ideas discussed in Design report  Raw threaded pipe (A)  Threaded Pipe with Permanent Box (B)  Square Kelly Connection (C) A B C 17

IV . Drill Pipe Connections – Phase II Raw Threaded Pipe Threaded Pipe with Permanent Box (Aluminum)  Attempted to thread NPT connection on the pipe  Used 1” 6061 Aluminum rod  Pipe thickness not sufficient  Machined 3/8” tapered NPT box at one end  Machined 1” deep housing for 0.375” OD drillpipe  Used Loctite Marine epoxy to bond the pipe & the connection  Successfully tested the connection to a torque of 50 in-lb 18

IV . Drill Pipe Connections – Phase II Threaded Pipe with Permanent Pin (Brass)  More efficient & cost effective solution  Slimmer pre-threaded brass connections  Machined 1” deep housing for 0.375” OD drillpipe  Used Loctite Marine epoxy to bond the pipe & connection  Used the same connection on both ends of the pipe 19

V . Remote System Control Remote system surveillance and control keeps people out of harm’s way Key Components:  2 Samsung 4K Monitors  Off-site mission control center  Security Camera System  Two 4K IP cameras with 8X optical zoom  One 4K Pan Tilt Zoom (PTZ) IP camera with 16X optical zoom  Microphone  Real time rig site audio  Remote Desktop Connection  Access to system controls from remote location  2-Way Audio Conversation 20

V . Remote System Control Remote Desktop Connection Benefits  Allows remote user to have full control of the remote computer  2-Way Audio  Stop work authority is given to offsite team members 21

V . Remote System Control 22

V . Remote System Control West PTZ North IP South IP RIG 23

V . Remote System Control  The 8 channel Sibell receiver is housed on the rig in a waterproof electric box  Power supply built into box 24

V . Remote System Control Sibell Network Video Recorder (NVR) can be accessed through: 1. Downloaded Sibell Software 2. Internet Explorer Browser 3. Sibell Mobile Viewer App 25

V . Remote System Control Sibell Network Video Recorder (NVR) can be accessed through: 1. Downloaded Sibell Software 2. Internet Explorer Browser 3. Sibell Mobile Viewer App All 3 system interface methods allow zoom control of the cameras as well as access to real-time on site audio 26

V . Remote System Control PTZ Camera Zoom Capabilities 27

VI. Electrical – Rig Sensors 28

VI. Electrical – DAQ Circuitry 29

VI. Electrical – Analog Input/Output Block 30

VI. Electrical – Power 31

VI. Electrical – Kill Switch 32

VI. Electrical – VFDs 33

VII. Control System - Control Structure 2017 Look Back Driven by Dependencies  Raise and lower functionality was dependent upon the pneumatic voltage pressure relationship  No use of PID control  Code structure was “spaghetti style” with zero notes or documentation Poor Program Structure  No intuitive execution structure  Minimal error feedback control  Lack of tuned control structures  Boolean logic 34

VII. Control System – Control Structure Sections Data Collection and Display  Collected from Ni-DAQ analog inputs Data Processing and Filtering  Backward weighted boxcar filters Auto Driller  Dual layer PID control Analog Outputs  Drives variable output actuators Digital Outputs  Drives actuator relays 35

VII. Control System – Drilling Execution Sequence Raise Top Drive Lower Top Drive Rotating Auto Driller Rotating Raise Top Drive Equipment Start Control Equipment Stop • Height • Velocity • Solenoid On • Torque • Solenoid Off • Height Control Control Control Control • Hammer • Hammer • Boolean Start • WOB Motor Start • Mechanical Motor Stop • Ends Command Threshold RPM Limits Program • Pump Warm • Pump Cool Execution Up • WOB Down Mechanical • Return to • Top Drive • Top Drive Limits Manual Start Stop Control 36

VII. Control System – Rig Sensors and Actuators Sensors Actuators  Load Cell  Bottom Pneumatic  RPM  Top Drive  Torque  Top Pneumatic  Vibration  Pump  Depth  Hammer Motor  Pressure  Solenoid Valve  Flow Meter Auto Driller Controls 37

VII. Control System – Auto Driller Structure WOB Control Torque Control RPM Control 38

VII. Control System – Torque Control PID Torque Control Setpoint Torque Driller Control Term True Torque Gains Output P: .01 High: 1 I: 0.0 Low: -1 D: 0.0 39

VII. Control System – WOB and RPM Control PID WOB WOB Control + Setpoint Bottom Pneumatic Voltage True WOB Proportional x Output Gains Error Term P: -0.086 High: 55 I: 0.009 Low: 2 Driller Control Term D: 0.0 RPM Control RPM + Setpoint Top Drive VFD Voltage True RPM Proportional x Gains Output Error Term P: 0.003 High: 400 I: 0.02 Low: 1100 D: 0.0 Driller Control Term 40

VIII. Capital Expenditures Category Expenditures Circulation $1,298 Electrical $1,083 Hoisting $899 Remote System Control $1,759 Rotation $1,242 Other $850 TOTAL $7,131 41

IX. Drillbotics Events Awards Banquet Open House 42