Patent Grant
7657376
The subject invention generally pertains to equipment used for repairing wells that have already been drilled. More specifically the present invention pertains to an analysis of rig load data received from well service rigs to determine different aspects of the service provided.
After a well has been drilled, it must be completed before it can produce gas or oil. Once completed, a variety of events may occur to the formation causing the well and its equipment to require a “work-over.” For purposes of this application, “work-over” and “service” operations are used in their very broadest sense to refer to any and all activities performed on or for a well to repair or rehabilitate the well, and also includes activities to shut in or cap the well. Generally, work-over operations include such things as replacing worn or damaged parts (e.g., a pump, sucker rods, tubing, and packer glands), applying secondary or tertiary recovery techniques, such as chemical or hot oil treatments, cementing the well bore, and logging the well bore, to name just a few. Service operations are usually performed by or involve a mobile work-over or well service rig (collectively hereinafter “service rig” or “rig”) that is adapted to, among other things, pull the well tubing or rods and also to run the tubing or rods back in. Typically, these mobile service rigs are motor vehicle-based and have an extendible, jack-up derrick complete with draw works and block. In addition to the service rig, additional service companies and equipment may be involved to provide specialized operations. Examples of such specialized services include: a chemical tanker, a cementing truck or trailer, a well logging truck, perforating truck, and a hot-oiler truck or trailer.
It is conventional for a well owner to contract with a service company to provide all or a portion of the necessary work-over operations. For example, a well owner, or customer, may contract with a service rig provider to pull the tubing from a specific well and contract with one or more service providers to provide other specific services in conjunction with the service rig company, so that the well can be rehabilitated according to the owner's direction.
It is typical for the well owner to receive individual invoices for services rendered from each company that was involved in the work-over. For example, if the portable service rig spent thirty hours at the well site, the customer well owner will be billed for thirty rig hours at the prevailing hourly rate. The customer is rarely provided any detail on this bill as to when the various other individual operations were started or completed, the speed at which the operations took place, how much material was used, or whether any problems were encountered in the well. Occasionally, the customer might be supplied with handwritten notes from the rig operator, but such is the exception, not the rule. Similarly, the customer will receive invoices from the other service companies that were involved with working over the well. The customer is often left with little to no indication of whether the service operations for which it is billed were done properly, and in some cases, even done at all. Further, most well owners own more than one well in a given field and the invoices from the various companies may confuse the well name with the services rendered. Also, if an accident or some other notable incident occurs at the well site during a service operation, it may be difficult to determine the root cause or who was involved because there is rarely any documentation of what actually went on at the well site. Of course, a well owner can have one of his agents at the well site to monitor the work-over operations and report back to the owner, but such “hands-on” reporting is often times prohibitively expensive.
The present invention is directed to evaluating rig load data provided to a chart in a display from sensors on the service rig to determine the activities accomplished by the service rig, the hook load carried during an activity by the service rig and well bore conditions evaluated by reviewing the rig load data during the removal of tubes and rods from a well or well bore.
The present invention is directed to incrementing a well service rig in such a manner that activity-based and/or time-based data for the well site is recorded and evaluated. The invention contemplates that the acquired data can be transmitted in near real-time or periodically via wired, wireless, satellite or physical transfer such as by memory module to a data center preferably controlled by the service rig owner, but alternately controlled by the well owner or another.
For one aspect of the present invention, a method of determining the activity completed by a service rig at a well site can be achieved by analyzing a rig load chart comprising rig load data. The rig load chart can be displayed on a monitor or provided in hard copy and can be evaluated by a rig operator, supervisor, rig owner, well owner, or other interested party. A grouping of rig load data can be identified and determined to be a first activity. The first activity on the rig load data chart can be evaluated to determine what the activity is. Once determined the activity can be recorded in a computer storage medium, such as a hard drive, compact disc, floppy disc or other storage medium known to those or ordinary skill in the art.
For another aspect of the present invention, a method of determining well bore conditions can be achieved by analyzing rig load data on a rig load data chart. The rig load chart can be displayed on a monitor or provided in hard copy and can be evaluated by a rig operator, supervisor, rig owner, well owner, or other interested party. A grouping of rig load data can be identified and determined to be a first activity. The first activity on the rig load data chart can be evaluated to determine what the activity is. If the first activity is determined to be pulling at least one string of tubing from the well bore, and evaluation can be conducted to determine if there are any rig load data points on the rig load chart that are abnormally high. In one exemplary embodiment, a determination of whether a rig load data value is abnormally high is based on a determination of whether the rig load data value is substantially above an average upper value for the rig loads during that activity. If there are not abnormally high rig load data values, the well bore status can be designated as normal.
For yet another aspect of the present invention, a method of determining the hook load on a well service rig can be achieved by analyzing rig load data curves on a rig load data chart. The rig load chart can be displayed on a monitor or provided in hard copy and can be evaluated by a rig operator, supervisor, rig owner, well owner, or other interested party. A first rig load level can be selected from a data point that is substantially along a peak of the rig load data curve on the display. A second rig load level can be selected from a data point that is substantially along a trough of the rig load data curve immediately preceding or subsequent to the peak of the first rig load level. The hook load can then be calculated by taking the difference of the first rig load level and the second rig load level.
For a more complete understanding of the exemplary embodiments of the present invention and the advantages thereof, reference is now made to the following description in conjunction with the accompanying drawings in which:
Referring to
The engine 26 selectively couples to the wheels 24 and the hoist 36 by way of the transmissions 34 and 32, respectively. The engine 26 also drives the hydraulic pump 28 via the line 29 and the air compressor 30 via the line 31. The compressor 30 powers a pneumatic slip (Not Shown), and pump powers a set of hydraulic tongs (Not Shown). The Pump 28 also powers the cylinders 42 and 44 which respectively extend and pivot the derrick 40 to selectively place the derrick 40 in a working position, as shown in
Individual pipe segments (of string 62) and sucker rods are screwed to themselves using hydraulic tongs. The term “hydraulic tongs” used herein and below refer to any hydraulic tool that can screw together two pipes or sucker rods. An example would include those provided by B. J. Hughes company of Houston, Tex. In operation, the pump 28 drives a hydraulic motor (Not Shown) forward and reverse by way of a valve. Conceptually, the motor drives the pinions which turn a wrench element relative to a clamp. The element and clamp engage flats on the mating couplings of a sucker rod or inner pipe string 62 of one conceived embodiment of the invention. However, it is well within the scope of the invention to have rotational jaws or grippers that clamp on to a round pipe (i.e., no flats) similar in concept to a conventional pipe wrench, but with hydraulic clamping. The rotational direction of the motor determines assembly or disassembly of the couplings.
While not explicitly shown in the figures, when installing the inner pipe string segments 62, the pneumatic slip is used to hold the pipe string 62 while the next segment of pipe string 62 is screwed on using tongs. A compressor 30 provides pressurized air through a valve to rapidly clamp and release the slip. A tank helps maintain a constant air pressure. Pressure switch provides monitor 48 (
Referring back to
In the embodiment of
Returning to
A telephone accessible circuit 124, referred to as a “POCKET LOGGER” by Pace Scientific, Inc. of Charlotte, N.C., includes four input channels 126, 128, 130 and 132; a memory 96 and a clock 134. The circuit 124 periodically samples inputs 126, 128, 130 and 132 at a user selectable sampling rate; digitizes the readings; stores the digitized values; and stores the time of day that the inputs were sampled. It should be appreciated by those skilled in the art that with the appropriate circuit, any number of inputs can be sampled and the data could be transmitted instantaneously upon receipt.
An supervisor at a computer 100 remote from the work site at which the service rig 20 is operating accesses the data stored in the circuit 124 by way of a PC-based modem 98 and a cellular phone 136. The phone 136 reads the data stored in the circuit 124 via the lines 138 (RJ11 telephone industry standard) and transmits the data to the modem 98 by way of antennas 140 and 142. In an alternative embodiment the data is transmitted by way of a cable modem or WiFi system (Not Shown). In one exemplary embodiment of the present invention, the phone 136 includes a CELLULAR CONNECTION.™. provided by Motorola Incorporated of Schaumburg, Ill. (a model S1936C for Series II cellular transceivers and a model S1688E for older cellular transceivers).
Some details worth noting about the monitor 48 is that its access by way of a modem makes the monitor 48 relatively inaccessible to the crew at the job site itself. However the system can be easily modified to allow the crew the capability to edit or amend the data being transferred. The amplifiers 122, 144, 146 and 148 condition their input signals to provide corresponding inputs 126, 128, 130 and 132 having an appropriate power and amplitude range. Sufficient power is needed for RC circuits 150 which briefly (e.g., 2-10 seconds) sustain the amplitude of inputs 126, 128, 130 and 132 even after the outputs from transducers 46, 102 and 80 and the output of the generator 118 drop off. This ensures the capturing of brief spikes without having to sample and store an excessive amount of data. A DC power supply 152 provides a clean and precise excitation voltage to the transducers 46, 102 and 80; and also supplies the circuit 124 with an appropriate voltage by way of a voltage divider 154. A pressure switch 90 enables the power supply 152 by way of the relay 156, whose contacts 158 are closed by the coil 160 being energized by the battery 162.
Processes of exemplary embodiments of the present invention will now be discussed with reference to
Turning now to
In the third activity, the rig 20 is pulling tubing 62 out of the well 58. Since tubing is not hung, but is instead racked or stacked on the ground, the tubing pull does not exhibit the increasing baseline 630 like in the first activity 605. Each joint of tubing is pulled and stacked so the mast looses the weight of each stand after it has been pulled out of the well 58. The upper level of the rig load data for the third activity 615 is steadily decreasing. This is caused because after each stand of tubing 62 is removed, the rig load of the next stand is less.
The second activity 610 represents the unseating of the tubing anchor catcher (“TAC”). Unseating of the TAC typically occurs between pulling rods out of a well 58 and pulling tubing out of the well 58. This activity 610, typically displays data on the rig load chart 600 that includes a baseline rig load 625 that is substantially constant and upper level rig loads that are random in nature and do not show a steady increase of decline.
In the third activity, the rig 20 is inserting rods 62 into the well 58. Since the rods 62 were hanging in the derrick 40, each stand of rods 62 inserted into the well 58 reduces the total weight on the pads 92 thereby causing the baseline 720 to steadily decline. In addition, when inserting rods 62 into the well, the upper level of the rig load data for the third activity 715 is substantially constant.
The second activity 710 represents setting the TAC. Setting the TAC typically occurs between inserting tubing into the well 58 and inserting rods into the well 58. This activity 710, typically displays data on the rig load chart 700 that includes a baseline rig load 730 that is substantially constant and upper level rig loads that are random in nature and do not show a steady increase of decline.
In step 808, counter variable X is set equal to one. In one exemplary embodiment, counter variable X represents an activity completed by a rig 20 during which time the rig load chart 600 was collecting and displaying data on the monitor 48. The supervisor identifies the first activity on the rig load chart 600 in step 810. In one exemplary embodiment, the supervisor identifies an activity by viewing data on the rig load chart 600 and determining how certain portions of the data may likely represent an activity being accomplished by the rig 20.
In step 812, an inquiry is conducted to determine if the upper level of the rig load data on the rig load chart 600 is substantially flat for the first activity. In
In step 820, an inquiry is conducted to determine if the baseline for the rig load data on the rig load chart 600 is substantially flat for the first activity. In
In step 822, an inquiry is conducted to determine if the upper level of the rig load data for the first activity is increasing or decreasing over time. As seen in
If the upper level of the rig load data on the rig load chart 600 is neither substantially increasing nor decreasing, the “NO” branch is followed to step 828. In step 828, an inquiry is conducted to determine if the first activity is positioned between activities for pulling rods and tubing or inserting rods and tubing. As can be seen in
In step 830, an inquiry is conducted to determine if the first activity is between a pair of pulling or insertion activities. If the first activity is between activities of the rods and tubing being pulled, the “Pulling” branch is followed to step 832, where the activity is identified as unseating the TAC and recorded in the computer 100. The process then continues from step 832 to step 838. If the first activity is between activities of the rods and tubing being inserted into the well 58, the “Inserting” branch is followed to step 834, where the supervisor identifies the activity as setting the TAC and records it in the computer 100. The process then continues to step 838.
In step 838, an inquiry is conducted to determine if there is another activity to evaluate on the rig load chart 600. If so, the “YES” branch is followed to step 840, where the counter variable X is incremented by one. The process then returns from step 840 to step 810. On the other hand, if the rig load chart 600 does not have any additional activities, the “NO” branch is followed to the END step.
Turning now to
When the rods 62 are resting on the rod elevators on the wellhead (Not Shown) during the rod pull, the hook load is substantially zero, or nulled because in one exemplary embodiment the operator nulls or offsets the empty rig weight so that the chart will read substantially near zero when the rig is not bearing rod or tubing loads. This time in the rod pull provides the baseline 925 for the rig load of this activity and is generally represented by the trough portion of the data, such as the second data point 910 and the fourth data point 920. These data points 910, 920 typically include a portion of the weight of the rig 20 and the load of the rods 62 hanging on the derrick 40. Thus the hook load can be calculated by subtracting the second data point 910 from the first data point 905 or the fourth data point 920 from the third data point 915.
The exemplary display 1000 of
In step 1120, the supervisor determines the first rig load at a data point on a data curve. In
The second rig load data chart 1210 also displays rig load data during the removal of tubing 62 from the well 58. By positioning an average load level decline 1230 line on the second rig load chart 1210 it can be determined that there is a single area 1235 where rig load data was substantially above the average load level decline. When there is a single area of the data representing a load level that is abnormal, as is the data at 1235, the problem is typically diagnosed as a bad or narrow spot in the well 58. To determine the position of the bad or narrow spot in the well 58, the supervisor can count the peaks of data after the abnormal peak 1235 on the monitor 48 until all the tubing has been removed from the well 58 and multiply that number by the length of each stand of tubing 62 to determine the depth of the bad or narrow spot in the well 58.
The third rig load data chart 1215 also displays rig load data during the removal of tubing 62 from the well 58. The chart 1215 further includes an average load level decline 1240 line. A view of the rig load data on the monitor 48 at the computer 100 alerts the supervisor that there are several data points that are substantially above the average load level decline 1240, including data points 1245, 1250, and 1255. When the abnormal spikes in rig load data occur several times at random intervals, it is unlikely that the well 58 would have this many tight spots in the casing 186. Instead, the activity causing this type of data typically occurs when the TAC does not properly release and the rig operator is dragging it out of the well 58 with the dogs of the TAC not fully retracted.
The second rig load data chart 1410 also displays rig load data during the removal of rods 62 from the well 58. The chart 1410 further includes an average load level increase 1420 line. A view of the rig load data on the monitor 48 of the computer 100 alerts the supervisor that there are several data points that are substantially above the average load level decline 1420, including data points 1425. This rig load data indicates that the rods 62 are dragging in the tubing 186. When the abnormal spikes in rig load data occur in a relatively small area and are tightly bunched, as shown in the second rig load data chart 1410, it is likely that the pump (Not Shown) is being pulled into a paraffin buildup interval within the tubing and the pump is acting as a paraffin swab.
Paraffin is temperature sensitive and typically remains in solution until the oil cools off as it travels from downhole in the well 58 to the surface. At some temperature associated with the geothermal gradient, paraffin drops out and adheres to the tubing 62. The supervisor can determine the location of the paraffin by reviewing rig load data on the monitor 48 and counting the number of peaks of rig load data that occur after the abnormal data caused by the paraffin and multiplying that number by the length of a stand of rods 62.
In step 1308, counter variable X is set equal to one. In one exemplary embodiment, counter variable X represents an activity completed by the service rig 20. In step 1310, the supervisor views the monitor 48 and identifies an activity on the rig load chart. In one exemplary embodiment, the supervisor identifies the activity on the chart in the manner described in
In step 1316, an inquiry is conducted by the supervisor to determine if there are any data points on the chart 1205-1215 that represent abnormal load levels that are substantially above the average load decline 1220, 1230, 1240. If not, the “NO” branch is followed to step 1316 to continue looking for abnormal rig load levels. Otherwise, the “YES” branch is followed to step 1318. In the example of
In step 1318, an inquiry is conducted by the supervisor to determine if there are several data spikes above the average load decline. In
In step 1322, the supervisor determines the location of the tight or bad spot in the well. In one exemplary embodiment, the supervisor evaluates the monitor 48 to determine the location by counting the number of peaks in the data chart 1210 that occur after the abnormally high rig load data spike 1235 until all the tubing is pulled from the well 58. The supervisor then multiplies that number by the length of the tubing 62 being pulled from the well 58 to determine where the tight or bad spot is located. In step 1324, the supervisor records the location of the tight or bad spot in the well 58 and, if not previously identified, schedules service for that section of the well 58.
Returning to step 1318, if there are several data spikes above the average load decline, the “YES” branch is followed to step 1326. In step 1326, an inquiry is conducted by the supervisor to determine if the abnormal load spikes are occurring at random intervals. As shown in the rig load chart 1215 of
Returning to step 1312, if the activity is determined by the supervisor to be pulling rods, the “Rod” branch is followed to step 1330 to determine the average upper load level for the charted load data. For example, in
In step 1334, an inquiry is conducted to determine if the abnormally high load levels are generally confined to one area of the rod pull data. As shown in
In step 1338, the supervisor views the monitor 48 and counts the remaining number of load peaks for this activity that are subsequent to the abnormally high load peaks caused by the paraffin 1425. In step 1340, the supervisor calculates the paraffin level by multiplying the number of load peaks subsequent to the peaks caused by the paraffin level 1425 by the length of the rods 62 being pulled from the well 58. In step 1342, an inquiry is conducted to determine if there is another activity to analyze on the rig load chart. If so, the “YES” branch is followed to step 1344, where counter variable X is incremented by one. The process returns from step 1344 to step 1310 to identify the next activity. If the rig load chart does not contain any additional activities to analyze, the “NO” branch is followed to the END step.
In step 1515, the sum of the data peaks 1025 on the display 1000 within the time period 1020 is divided by the number of minutes selected in the time period 1020. In the exemplary embodiment shown in
Although the invention is described with reference to a preferred embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope of the invention. Therefore, the scope of the invention is to be determined by reference to the claims that follow. From the foregoing, it will be appreciated that an embodiment of the present invention overcomes the limitations of the prior art. Those skilled in the art will appreciate that the present invention is not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the exemplary embodiments, equivalents of the elements shown therein will suggest themselves to those or ordinary skill in the art, and ways of constructing other embodiments of the present invention will suggest themselves to practitioners of the art. Therefore, the scope of the present invention is to be limited only by any claims that follow.
This application is a divisional of and claims priority to U.S. patent application Ser. No. 11/516,105, filed Sep. 5, 2006, now U.S. Pat. No. 7,359,801 entitled, “Method and System for Evaluating Weight Data From a Service Rig” which claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 60/716,612, titled Interpretive Techniques Using Sensor Data, filed Sep. 13, 2005, the entire contents of both being herein incorporated by reference.
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| Child | 11827052 | US |
