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

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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

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• I. Safety Tailgate

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• I. Safety Tailgate

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• II. 2017 Recap – Spaghetti Style

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• 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

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• III. Mechanical Systems – Hoisting : Pneumatics

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Height of top drive controlled electronically by pneumatic converters or manual valve.

• III. Mechanical Systems – Hoisting : Pneumatics

Flowsheet

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Air supply

Regulator Manual control valve Toggle valve Top Pneumatic Converter Bottom Pneumatic Converter Pilot

• perated

check Pilot

• perated

check

Top of air cylinder Bottom of air cylinder

Directional valve Directional valve

• III. Mechanical Systems – Hoisting : Pneumatics -

AirPilot Check Valves

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• Valve prevents flow out of cylinder

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

supplied in automatic mode

• When electrical signal is lost

pneumatic converters reduce WOB to less than 5lbs

From Air Supply Air Signal From Air Cylinder

• III. Mechanical Systems - Circulation
• Circulation system

space efficiency increased

• New system

working pressure is 400 psig

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• III. Mechanical Systems – Circulation Flowsheet

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• 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

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• 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

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• III. Mechanical Systems - Instrumentation

Pressure gauges added for:

• Compressed air supply
• Top air cylinder
• Bottom air cylinder
• Stand pipe

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• 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

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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)

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A B C

IV . Drill Pipe Connections – Phase II

Raw Threaded Pipe

• Attempted to thread NPT connection on

the pipe

• Pipe thickness not sufficient

Threaded Pipe with Permanent Box (Aluminum)

• Used 1” 6061 Aluminum rod
• 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

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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

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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

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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
• ffsite team members

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V . Remote System Control

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V . Remote System Control

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RIG

South IP North IP West PTZ

V . Remote System Control

• The 8 channel Sibell

receiver is housed on the rig in a waterproof electric box

• Power supply built into box

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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

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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

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All 3 system interface methods allow zoom control of the cameras as well as access to real-time on site audio

V . Remote System Control

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PTZ Camera Zoom Capabilities

• VI. Electrical – Rig Sensors

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• VI. Electrical – DAQ Circuitry

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• VI. Electrical –

Analog Input/Output Block

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• VI. Electrical – Power

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• VI. Electrical – Kill Switch

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• VI. Electrical – VFDs

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• 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

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• 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

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• VII. Control System –

Drilling Execution Sequence

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Raise Top Drive

• Height

Control

• Boolean Start

Command Lower Top Drive

• Velocity

Control

• WOB

Threshold Rotating Equipment Start

• Solenoid On
• Hammer

Motor Start

• Pump Warm

Up

• Top Drive

Start Auto Driller Control

• Torque

Control

• Mechanical

RPM Limits

• WOB

Mechanical Limits Rotating Equipment Stop

• Solenoid Off
• Hammer

Motor Stop

• Pump Cool

Down

• Top Drive

Stop Raise Top Drive

• Height

Control

• Ends

Program Execution

• Return to

Manual Control

• VII. Control System –

Rig Sensors and Actuators

Sensors

• Load Cell
• RPM
• Torque
• Vibration
• Depth
• Pressure
• Flow Meter

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Actuators

• Bottom Pneumatic
• Top Drive
• Top Pneumatic
• Pump
• Hammer Motor
• Solenoid Valve

Auto Driller Controls

• VII. Control System –

Auto Driller Structure

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Torque Control WOB Control RPM Control

• VII. Control System –

Torque Control PID

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Torque Control

Setpoint Torque True Torque Driller Control Term

P: .01 I: 0.0 D: 0.0

Gains

High: 1 Low: -1

Output

• VII. Control System –

WOB and RPM Control PID

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WOB Control

True WOB

P: -0.086 I: 0.009 D: 0.0 Gains High: 55 Low: 2 Output

Bottom Pneumatic Voltage

RPM Control

True RPM

P: 0.003 I: 0.02 D: 0.0 Gains High: 400 Low: 1100 Output

Top Drive VFD Voltage Driller Control Term

x

Proportional Error Term

+

WOB Setpoint Driller Control Term Proportional Error Term

+

RPM Setpoint

x

• 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

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• IX. Drillbotics Events

Awards Banquet Open House

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