How operators can learn drilling basics before stepping on a machine

With horizontal directional drilling (HDD) in such high demand, there simply aren’t enough experienced drillers available to keep up with the amount of work ahead. To solve this labor challenge, some contractors have promoted laborers from within their ranks, while others have hired novices — and some companies have done both. Whatever solution is selected, contractors are then faced with the issue of training these new operators.

Companies might be tempted to rely on on-the-job HDD training as the primary method to teach operators the intricacies of drilling, enabling them to learn while producing results. However, this approach has its drawbacks. The stress of avoiding mistakes while operating a drill is not an ideal learning environment. For example, new operators might focus more on operating the drill rather than absorbing the information.

This is why more HDD contractors are turning to their equipment dealers for alternative methods to help train their teams. Training options, like simulators, can be tailored to best fit an operation’s needs while getting operators up to speed quickly in a low-stress working environment.

“HDD simulators solve a specific challenge in our industry — a lack of high-level, consistent training opportunities for new drill operators,” said Chad Comer, Vermeer brand experience specialist. “It’s a training aid that goes further in preparing HDD operators for the jobsite by training employees to operate drills correctly without adding wear and tear on actual drilling equipment. This can result in time savings, as well as increased productivity.”

Realistic learning experience

A key factor that makes HDD training simulators different from other types of training is that they offer operators the chance to learn in an environment designed to maximize information retention. For that reason, Comer said, Vermeer dealers have significantly invested in the Vermeer HDD Simulator that helps train their customers to operate Vermeer directional drills, all without running a machine in the field.

Like other training programs, the Vermeer HDD Simulator features simulated real-time drilling, bore planning and monitoring of underground conditions — all critical proficiencies on an HDD jobsite. According to Comer, what makes the Vermeer HDD Simulator is the level of realism it brings to the training process. For example, the virtual reality (VR) system provides an immersive, authentic experience with detailed animations that help better prepare the trainee. It also incorporates the Vermeer S3 HDD controls, exactly like those found on the Vermeer drill lineup.

“VR can completely immerse users in an environment, truly placing operators in the moment,” said Comer. “And the realistic seat and joystick controls are crucial in reinforcing muscle memory for operator training on these machines. It’s been transformative for us to observe the rapid evolution of students, even over a half-hour period, as they learn to correctly install rods in the ground.”

Other advantages of simulated training

According to Comer, the Vermeer HDD Simulator also provides multiple learning levels and tutorials, which serve as a baseline for initial training and offer a path for ongoing education. That’s because simulations allow users to learn how to operate the machine correctly, which prevents wear and tear on the machine.

“New operators often struggle with mastering the necessary series of movements,” said Comer. “But these sequences are repeatable and can be learned without the stress of engine noise and machine operation.”

“When a user oversteers the rods, it will show up in the simulator’s report card in the rod-by-rod evaluation section,” continued Comer. “It’s just like drilling — everything functions just like you were sitting on a drill. This training is valuable regardless of previous experience, as it ensures all operators are functionally learning how the drill is supposed to operate. Once learned, operators can consistently apply the skills they’ve gained running the drill simulator in the field.”

Learning the basics

Comer stated that the learning path on the simulator originates from the fundamentals of HDD. It’s grounded in the information provided in the machine’s operator manual and reflects the curriculum used by Vermeer factory programs and Vermeer dealers for in-person and classroom training.

“It starts with the vital need to verify utility locations and the importance of potholing,” Comer said. “Then, it moves on to bore planning and highlights the machine’s crucial safety features. Other topics, such as mix systems, reamer theory and tooling, are addressed separately before operators begin using the machine.”

As Comer mentioned, this training method benefits all experience levels. The simulator is not only used for initial training but also for continuing education. For example, many experienced operators have developed habits over the years, like they don’t grease rods as frequently as they should. The simulator will catch this type of error.

The simulator also assesses whether the individual can operate the machine correctly, thus helping to prevent unnecessary wear and tear on parts. For example, if a less experienced operator under torques a joint, the simulator will catch it and let them know. These types of corrections can maximize the life of machine components, such as sub savers and drill rods.

No matter who the operator is, the simulator grades each action, from handling drill rods to understanding the connection between the display screen and underground steering. Furthermore, it checks if the operator can replace a rod after sending out the first one. If they can’t, they may not be as skilled as they claim. Once an operator has completed a bore, the Vermeer HDD Simulator generates a detailed, rod-by-rod report that provides in-depth feedback and highlights the trainee’s proficiencies in areas of operation, steering accuracy and rod cycle times.

“The system is a true measure of an operator’s experience,” said Comer.

He continued, “We’ve observed an increase in efficiency when trainees use the simulator before fieldwork. The simulator helps reduce the learning curve for new operators before operating a machine. This is particularly beneficial during the startup phase for new contractors, as it allows them to familiarize themselves with our machines before actual use.”

Simulations don’t solve all training challenges. Operators still need to handle variables such as weather conditions and machine noise. Despite these factors, trainees can approach their tasks in the field with more confidence after simulator training.

In support of simulated training

Operators enrolled in one of the Vermeer HDD Circuit® training programs aren’t the only ones reaping the benefits of using a simulator before operating real machines. Vermeer dealers also recognize these advantages. As Comer explained, “Most of the Vermeer dealer network have HDD certified trainers who can fluently run Vermeer HDDs. As a result, they can use these simulators to promote and propagate their knowledge, helping customers be successful.”

Adding alternative training methods, like HDD simulation, Comer concluded, promotes growth in the training process and contributes to the productivity of the industry.

How simulated training works

Training with the Vermeer HDD Simulator begins with fundamental lessons where operators are introduced to the equipment’s controls. A transparency mode allows them to visualize the internal mechanisms of the drill, such as the rod loader arms and sub saver, which enhances their understanding of the machine’s operation.

Then, operators are taken to the next level, where they learn how the drill head steers underground. Using VR (virtual reality), they can follow the drill head’s movement and understand its deflection pattern. This feature, in combination with the display screen, helps them avoid overbending the rod and provides a comprehensive understanding of the drilling process.

As operators progress, the transparency mode is disabled, challenging them to rely on the machine indicators. This stage prepares them for situations where they can’t visually verify what’s happening inside the machine.

In the final stage, operators — assuming the roles of both the locator and the driller — are given the task of plotting their bore path. They are presented with a situation that mimics real-life conditions, where they need to avoid underground utilities. The driller executes the commands given by the locator, and together, they navigate the bore path.

This stage emphasizes communication between the driller and the locator, addressing a common challenge experienced on jobsites. The goal is to ensure that the driller understands the locator’s commands and that the locator comprehends the driller’s queries.

“Through this simulated training, operators not only learn how to run the equipment but also gain a deeper understanding of the drilling process,” Comer explained. “This includes the science of mud, how technology works and how to plan a bore.”

“The comprehensive approach of these programs allows operators to be well-prepared to work efficiently in the field,” Comer concluded. With today’s labor shortages, being able to provide additional training to both new and experienced drillers is crucial to complete jobs efficiently. By using the Vermeer HDD Simulator, operators and locators can become better equipped to tackle unique jobsite challenges by learning HDD basics in a low-stress and realistic environment. For more information on HDD training tools, reach out to your local Vermeer dealer.

Vermeer Corporation reserves the right to make changes in engineering, design and specifications; add improvements; or discontinue manufacturing at any time without notice or obligation. Equipment shown is for illustrative purposes only and may display optional accessories or components specific to their global region. Please contact your local Vermeer dealer for more information on machine specifications.

Vermeer, the Vermeer logo and Vermeer HDD Circuit are trademarks of Vermeer Manufacturing Company in the U.S. and/or other countries. © 2024 Vermeer Corporation. All Rights Reserved. 

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