Differential Marine Drill Sensor Configuration for High-Definition Rate of Penetration
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Solution Overview
Problem
Conventional marine drilling systems face inaccuracies in monitoring the crown block position due to indirect measurement methods, which introduce systematic errors and are affected by temperature and load-induced deformations in steel wire ropes, necessitating improved measurement techniques for precise control and safety.
Innovation Solution
A differential sensor configuration is implemented, with sensors installed on the drill floor and top drive of a marine drill, allowing for simultaneous data collection and processing to calculate physical parameters such as high-definition rate of penetration, drilling level bubble, and out-of-straightness, using a combination of accelerometers, gyroscopes, and compasses, and employing a processor to apply algorithms like the Error State Kalman Filter for accurate pose estimation and error compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rotary encoder is mounted on the shaft of the draw works, then installation and maintenance become easy, but systematic errors are produced due to indirect measurement
Solution Approach 1:
The patent introduces an intermediary measurement approach by using a string encoder that directly measures the block position through the steel wire rope, eliminating the need for indirect measurement through the draw works shaft. This intermediary measurement method resolves the contradiction by providing both easy installation (similar to rotary encoder mounting) and direct measurement (eliminating systematic errors).
Solution Approach 2:
The patent replaces the mechanical rotary encoder system with a string encoder system that uses a string or cable attached to the block. This substitution allows direct measurement of block position without relying on the mechanical transmission through the draw works shaft, thereby eliminating the systematic errors while maintaining ease of installation.
2Measurement precision
If a string encoder is used to measure block position, then direct measurement eliminates systematic errors, but the measurement is affected by steel wire rope deformation due to temperature and load
Solution Approach 1:
The patent implements feedback mechanisms to compensate for the harmful effects of temperature and load on the string encoder measurement. By continuously monitoring the block position and comparing it with expected values, the system can detect and correct for deformation effects, maintaining measurement precision despite environmental and operational variations.
Solution Approach 2:
The patent employs parameter changes to compensate for wire rope deformation. By measuring additional parameters such as temperature and load, and using these to calculate correction factors, the system adjusts the block position measurement to account for the deformation effects, thereby maintaining accuracy despite the harmful factors.
3Device complexity
If conventional encoder placement is used, then the measurement system is simple, but it cannot provide high-definition rate of penetration and precise pose estimation
Solution Approach 1:
The patent segments the measurement system into multiple independent sensor components: a string encoder for block position, accelerometers for vibration measurement, and gyroscopes for orientation measurement. Each sensor type is optimized for its specific function, and the results are combined through signal processing to achieve high-definition rate of penetration and pose estimation, resolving the contradiction between simplicity and precision.
Solution Approach 2:
The patent creates a multi-functional measurement system where the string encoder, accelerometers, and gyroscopes work together to provide both block position measurement and vibration/orientation data. This universal approach allows a single integrated system to perform multiple measurement functions simultaneously, achieving high precision without requiring separate dedicated systems for each parameter.
4Device complexity
If single sensor placement is used, then the system is simple, but it cannot differentiate between vessel motion and drill floor vibrations
Solution Approach 1:
The patent segments the measurement function by placing separate sensors at different locations: accelerometers on the drill floor to measure local vibrations and gyroscopes on the top drive to measure vessel motion. This spatial segmentation allows the system to independently measure and differentiate between the two types of motion, resolving the contradiction by using multiple sensors in a coordinated manner.
Solution Approach 2:
The patent adds the spatial dimension to the measurement system by placing sensors at different locations (drill floor and top drive). This dimensional approach allows the system to distinguish between motions occurring at different positions, thereby separating vessel motion from drill floor vibrations through spatial differentiation rather than temporal or signal-processing alone.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances measurement accuracy, reduces systematic errors, and provides precise control and monitoring of marine drilling operations by differentially combining sensor data to account for vessel motion and drill floor vibrations, leading to improved precision and operational efficiency.
Implementation Method 1
The first sensor and the second sensor are set-up in a differential configuration. There is at least one processor configured to calculate a physical parameter based, in part, on the first information received from the first sensor and the second information received from the second sensor.
Implementation Method 2
employing a processor to apply algorithms like the Error State Kalman Filter for accurate pose estimation and error compensation
Implementation Method 3
using a combination of accelerometers, gyroscopes, and compasses
Implementation Method 4
using a combination of accelerometers, gyroscopes, and compasses
Implementation Method 5
using a combination of accelerometers, gyroscopes, and compasses
Data Source
AI summary
Two sensors may be installed on a marine drill to improve measurements used for monitoring and operating the marine drill. The sensors may be installed in a differential configuration with one sensor located on a top block of the marine drill and a second sensor located on a drilling floor of the marine drill. Various calculations may be performed using measurements obtained from the two sensors such as, for example, rate of penetration of the marine drill, drilling level bubble for the marine drill, out of-straightness values for the marine drill, and vibration motion for the marine drill.