1. Field of the Invention
The present invention is directed to choke systems for oil rigs and, in one particular aspect, to diagnostic/control systems for such choke systems.
2. Description of Related Art
In the drilling of oil wells a drill pipe is introduced into the wellbore with a bit on the lower end thereof and, as the bit is rotated, to circulate a drilling fluid, drilling “mud”, down through the interior of the drill string, out through the bit, and up the annulus of the well bore to the surface. Fluid circulation removes cuttings from the wellbore, cools the bit, and maintains hydrostatic pressure in the well bore to control formation gases and prevent blowouts, and the like. Additional backpressure is applied on the drilling fluid at the surface when the weight of the drilling fluid is not sufficient to contain the bottom hole pressure in the well to keep the well under control. In some instances, a backpressure control device is mounted in a return flow line for the drilling fluid.
Backpressure control devices or “chokes” are also used for controlling “kicks” in the system caused by the intrusion of salt water, oil, or formation gases into the drilling fluid, which may lead to a blowout condition. In these situations, sufficient additional backpressure must be imposed on the drilling fluid such that the formation fluid is contained and the well controlled until heavier fluid or mud can be circulated down the drill string and up the annulus to kill the well. It is also desirable to avoid the creation of excessive back pressures which could cause a drill string to stick, or cause damage to the formation, the well casing, or the well head equipment.
Maintenance of an optimum backpressure on the drilling fluid can be complicated by variations in certain characteristics of the drilling fluid as it passes through the backpressure control device. For example, the density of the fluid can be altered by the introduction of debris or formation gases, and/or the temperature and volume of the fluid entering the control device can change. Therefore, the desired backpressure is not achieved until appropriate changes have been made in the throttling of the drilling fluid in response to these changed conditions. Conventional devices generally require manual control of and adjustments to a choking device orifice to maintain the desired backpressure. However, manual control of the throttling device or choke involves a lag time and generally is inexact.
U.S. Pat. No. 4,355,784 discloses an apparatus and method for controlling backpressure of drilling fluid in the above environment in a system in which a balanced choke device moves in a housing to control the flow and the backpressure of the drilling fluid. One end of the choke device is exposed to the pressure of the drilling fluid and its other end is exposed to the pressure of a control fluid.
Conventional choke control systems can be difficult to utilize accurately or efficiently and can require a great deal of experience to operate properly. Some typical conventional choke control mechanisms have a needle valve to control the rate of hydraulic fluid flow and a direction lever for controlling the direction of an open/close valve in a choke device. For example, to make an adjustment to slowly increase the backpressure, an operator shuts down the needle valve supplying hydraulic fluid to a hydraulically actuated choke to reduce supply of hydraulic fluid to a minimum so that the choke element moves slowly in the direction selected by the open/close valve. The operator relies on his experience in interpreting the familiar sounds and physical feedback associated with manipulating the choke controls and physical feedback during choke manipulation. Resistance and vibration of a joystick and the sound of the air-over-hydraulic pump kicking can indicate to the operator that the choke control is engaged and operating. The operator looks at the backpressure and determines if a new desired backpressure was achieved. If the operator has missed a pressure target, another adjustment is needed using the open/close valve and the needle valve to adjust the choke until the desired backpressure is achieved. Proper adjustment of the choke element to achieve desired backpressure level can be an iterative procedure requiring multiple attempts. This is a time consuming, inefficient and relatively inaccurate procedure for adjusting a choke.
Prior art oil recovery systems have a vast network of various and assorted oilrigs platforms which can be widespread geographically. It is expensive to physically patrol, inspect and diagnose equipment failures, and to attempt to perform operational optimization in a fleet of hundreds or even thousands of oilrigs comprising a regional or global oil recovery system. There is a need for a remote monitoring and diagnostic and notification service for a wide area oil recovery system and a need for an automated process running on a plurality of oilrigs comprising an oil recovery system that performs a Health Check monitoring function of an oil recovery system.
The present invention, in certain embodiments, discloses a system for determining the operational state of a choke control system and an associated choke mechanism. Such a system, in certain aspects, determines the existence of an appropriate operational state for testing and diagnostics, e.g. a state in which operation of the choke control system is not imminent. In certain aspects, such a system according to the present invention performs periodic ad hoc choke system diagnostics, tests, and checks on a permission basis; and, in certain embodiments a secondary level test on the choke system determines when a primary level diagnostic, test or check can be run to verify the operational integrity of the electronic choke system. In certain embodiments, such periodic and ad hoc intelligent diagnostics, tests, and checks insure that the choke system is fully operational and completion of such diagnostics, tests, and checks provides a high degree of confidence that the choke system will work properly when called upon, e.g. on demand or in an emergency scenario. Choke systems according to the present invention may have one choke mechanism or a plurality of choke mechanisms, one of which is operational while at least one other choke of the plurality is in standby mode and can be diagnosed, tested, and exercised (e.g., selectively periodically operated).
In certain aspects, systems according to the present invention verify that required choke monitoring and control sensors are operational and that the choke mechanism works as intended. Degradation and failure rate data are recorded and stored in appropriate recording and storage devices, e.g. computers, so that degradation data can be correlated with failure data to predict failures from degradation data before the failures occur. In one aspect the choke system tests, checks, and diagnostic reports generated by a system according to the present invention inform a user as to the choke system readiness. The reports and intelligent diagnostics can address a user's well-founded concern whether a long idle choke system will work when called upon, e.g. to handle a high pressure kick in a wellbore.
In certain embodiments, systems according to the present invention provide tests, checks, and intelligent diagnostics specific to choke operational scenarios which enhance oil rig safety and efficiency of oil field drilling operations, in certain particular aspects when applied to an electronic choke control system associated with drilling chokes to ensure continuous and proper choke system availability during downhole operations. In certain systems according to the present invention failures, performance degradation and/or predicted failures are reported to service personnel that perform additional diagnostics or dispatch field personnel to replace or repair the choke systems as necessary.
The present invention provides a method and apparatus for remotely monitoring, analyzing and affirmatively notifying appropriate personnel of problems and events associated with an oil recovery system comprising hundreds of oil rigs over a vast geographic area. The present invention provides a monitoring and reporting system that is referred to as a Health Check system. The present invention provides a variety of performance monitoring sensors at each oilrig in an oil recovery system. The results of selected diagnostics, which are run on each oilrig, are reported to a central server. The central server automatically populates a database for the oil recovery system and displays a red/yellow/green/gray color-coded report for an entire oil recovery system. The present invention also affirmatively alerts appropriate personnel of actions required to address events associated with an oilrig in an oil recovery system. The diagnostics performed at each oilrig are configurable at the individual rig. The central server need not change its reporting and display program when changes are made to a heath check at an oilrig. The present invention provides a dynamic oilrig status reporting protocol that enables construction and display of a tree node structure representing an entire oil recovery system status on a single screen. Preferably, top level information is presented on a single screen, and detailed information presented when one drills down in to other screens. Thus, the present invention enables rapid visual affirmation of a system Health Check.
A Health Check is an automated test that is running on the rig and monitoring something for acceptable performance, indication of problems, etc. These tests could be applied to equipments, drilling processes, or an operator's usage of particular drilling equipment. The results are then communicated to a central server located in a service center through a unique protocol, which allows automatic distribution and display of information. A test program on a rig can be modified and that change will flow automatically through communication, storage and display of the resulting Health Check data for the rig.
The service center based web server allows secure access to Health Check results. The results are presented in “top down tree” mode with red/yellow/green/gray colors. The red color indicates the failure of a test or flagging an event of interest, the yellow color indicates that the health test has found some abnormality that may need attention, green indicates successful completion of a test, and gray color indicates inability to conduct a test. The bottom-most node of the “top down tree” contains the results of a Health Check. The work-case result is successively carried up to the next level, until topmost node (which in most cases is the drilling rig, group of rigs or oil recovery system) is reached.
Each Health Check result can be configured to generate a message (email, phone call, PDA, etc.) to alert single or multiple persons in case of test failure. The data transfer protocol is well defined, such that other development groups or third parties can easily develop Health Check tests, generate results and feed information to the central server. Test results are transferred from the rig to the server using a novel data protocol that dynamically defines the structure of the data, that is, the node tree structure of the data by the naming convention of the protocol. Thus, the results are simply stored and displayed using the structural definition provided in the communication protocol. This allows for extreme flexibility in the definition of new programs and results to run and report at oilrigs without requiring a change in the communication protocol, notification function or the display and storage functions at the central server. The bottom-most nodes in the tree structure contain test results. Each test comes into the central server as a record containing node information as to where the information fits within the tree structure, an identifier for the test, a test result (red/yellow/green/gray) and intermediate data such as error codes, operator entry data and test data description. Thus, no results processing need occur at the central server. The central server only archives and display results and issues affirmative (with acknowledgement) and regular notifications as required.
Events or conditions can be set for notification, thus, once the event or condition occurs and after it is set for notification, a notification is sent to a designated person reporting the event of condition. A list of persons can be associated with each oilrig and event or condition. A notification can be sent to a cell phone, PDA or other electronic device. A notification can comprise a text, audio or video message to a user. A notification tells the rig status color code, text, aural or video. A user can call into the central server to check the status of an oilrig or oil recovery system. The status returned is a notification message indicating that the rig is okay or that a problem or condition of interest has occurred. Thus, the Health Checks are different than alarms, although alarms (including those alarms generated by prior or legacy systems) can be used as inputs to a Health Check where the alarms are processed and considered by Health Check rather than sending an alarm immediately to oilrig personnel. Health Check may indicate that piece of equipment is out of range and should be replaced in the near future, however, supercritical alarms can be processed by Health Checks to generate an immediate notification.
What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, other objects and purposes will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide new, unique, useful, and nonobvious systems and methods of their use—all of which are not anticipated by, rendered obvious by, suggested by, or even implied by any of the prior art, either alone or in any possible legal combination.
Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures and functions. Additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods.
The present invention recognizes and addresses the previously-mentioned problems and long-felt needs and provides a solution to those problems and a satisfactory meeting of those needs. To one skilled in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, other purposes and advantages will be appreciated from the following description of preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later disguise it by variations in form or additions of further improvements.
The Abstract that is part hereof is to enable the United States Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limited of the scope of the invention in any way.
A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments that are shown in the drawings which form a part of this specification. These drawings illustrate certain embodiments and are not to be used to improperly limit the scope of the invention that may have other equally effective or legally equivalent embodiments.
As shown in
The choke control system 2100 operates in various “system control” modes or “system states.” The choke control system 2100 recognizes states of the system and commands the performance of intelligent choke mechanism diagnostics on the choke system 2106 appropriate to the system state. Control modes include: Local Control, Automatic Mode, Manual Override Mode, and Standby Mode. In the Local Control mode, the choke control system 2100 is under the command of a local user who directly controls the choke system 2106; or with a computer system 2116 e.g. any suitable programmable apparatus, apparatuses, system, systems, devices or device via a user interface, e.g., a panel system 2117. In the Automatic Mode, an Automatic Supervisory Control Function existing in a controller 2118 takes over the choke control system 2100. In the Automatic Supervisory Control Mode, operation of the choke control system 2100 is directed by an Automatic Control function in accordance with a data set of user-specified parameters (e.g. for using either a “drillers” method and “wait-and-weight” method). In the Manual Override Mode, the choke control system 2100 is under the control of a local or remote user who manually directs operation of the choke control system 2100. A kill line 2110d with a kill line valve 2110c serves as an emergency backup system and provides an alternate flow path for injecting fluids into the wellbore or for allowing wellbore fluids to flow out of the wellbore in a controlled manner. Blowout preventers 2110b provide blowout control.
The Standby Mode allows initiation of tests, checks and diagnostics to determine the operational viability of the choke control system 2100. In standby mode, the choke isolation valve 2104 is closed to remove the choke system 2106 from the mud pressure line so that choke operation has no influence on the well pressure. The computer system 2116 determines when the choke control system 2100 is in standby mode (or a user can put in standby mode) and whether it is appropriate to stay in standby mode based on system conditions (system conditions e.g. from sensors, gauges, systems indicating, e.g. the position of valves, the status of BOP's, the annular pressure, the drill pipe pressure, and/or pump rate). The computer system 2116 also determines when the system can enter standby mode and who can command entry into standby mode. In the standby mode, the system can perform intelligent diagnostics; e.g. determining the state of choke control system sensors 2121 in communication with the control system and/or computer system, (sensors 2121R—choke isolation valve, sensor; 2121S—choke position sensor, e.g. the sensors 2808, 2810,
Diagnostics for the choke system 2106, such as positional cycling, mechanism movement rate and positional feedback and monitoring, are performed during standby mode. These intelligent diagnostics enable a user or processor to determine whether the choke is operational or whether a failure has or will soon occur. The positional diagnostics move the mechanism of the choke system 2106 back and forth. This movement prevents the choke system 2106 from remaining idle and motionless for the extended periods of time. The positional and/or periodic cycling and/or operation of the choke system 2106 occurs when the choke is under electronic control (by the system 2100).
The choke system specific diagnostics include a scheduled performance including checks, tests, and intelligent diagnostics. These checks, tests and intelligent diagnostics evaluate all aspects of choke control system operation. In one example of a secondary choke control system diagnostic, the choke mechanism speed, direction, and positional accuracy are tested to determine the state and operational viability of the choke control system 2100. The performance of choke mechanism movement is monitored and evaluated. If the results of the choke control mechanism diagnostic are unacceptable or return suspect results, the choke control system 2100 conducts more detailed evaluation including additional checks, tests, and diagnostics to provide further insight into problem. The results of each diagnostic are stored in memory database and compared to a stored historical database for previous diagnostic results (e.g. stored in a database 2804,
The choke system 2106 can be exercised and monitored to ensure that it is operational. For example, in one choke control diagnostic, the system commands the choke mechanism to move in small, medium, and/or large increments. The choke control mechanism is tracked and the resultant positioning accuracy and speed are evaluated. The choke control mechanism diagnostic moves the choke mechanism through its full travel distance and compares travel endpoint position feedback values. This test ensures that the choke system 2106 is operational and in good working order.
A significant advantage of the present invention is that the mechanism of the choke system 2106 is moved periodically (e.g. every 12 hours) so that it is not left idle for long periods of time or left in a fully closed position for extended periods. When the choke mechanism of the system 2106 is left idle or closed for a long period of time, adjacent choke mechanism elements or element seals, which are pressed together when the choke mechanism is closed, can bond closed as the choke mechanism elements may stick together. Upon opening, stuck choke mechanism seals may pull apart and be destroyed preventing the mechanism of the choke system 2106 from operating properly. Moreover, after the mechanism has been sitting idle for an extended period, its components may become stuck together preventing it from opening and make proper operation impossible. The seals on each end of a choke mechanism can also stick to each other so that they are pulled apart when the choke is operated. This periodic manipulation also prevents the user from leaving the choke mechanism closed or static in one position for extended periods of time, thereby destroying the choke mechanism operability and the necessity for an otherwise unnecessary service call to repair the damage.
The next function 2206 (“CHOKE IN STANDBY”) determines if the choke is in standby mode. If the choke is in standby mode, the event proceeds to function 2214 (“SELECT SCHEDULED DIAGNOSTIC”) where a diagnostic is selected from a list of diagnostics in a database of the processor 2804 (see
If the system is not in standby mode at step 2206, then it is determined if Standby Mode has been requested at 2208 (“STANDBY REQUESTED”). If Standby Mode has not been requested, as determined in step 2208 then a report 2204 (“REPORT TO HEALTH CHECK”) is sent to the health check commander. If Standby Mode has been requested, then the event proceeds to step 2210 (“OK TO ENTER STANDBY”) to determine if it is appropriate to enter into Standby Mode. This process of determining whether it is appropriate to enter standby mode is detailed further in
Upon completion of the selected diagnostic, the results are analyzed in step 2218 (“ANALYZE DIAGNOSTIC RESULTS”) and a report is generated in step 2220 (“GENERATE REPORT”). The Run Diagnostic is exited in step 2222. The analysis of the diagnostic result is detailed more fully in
As shown in
The process and functions for reviewing system diagnostic results is illustrated in
In an embodiment 2800 shown in
Either choke system 2910 or 2920 can be used. When one system is in use, one choke system can be in standby mode while mud is flowing through the line 2930 and/or through the other choke system. The choke system in standby mode can be diagnosed, analyzed, and checked (e.g. as is done for the choke system 2106, e.g. as described for
While a hydraulic-actuated choke has been used for example purposes above, the present invention principles apply to any choke with any type of actuation. As noted above, the present invention confirms (by evaluation of the state of the choke mechanism control, the hydraulic control valve and other related choke sensors) that it is safe to enter into the standby mode. Unless that confirmation is present, the choke system should not enter into standby mode. This confirmation can be determined from the status of the choke and kill line valves (e.g. the valves 2104 and 2110c in
In another embodiment, the present invention (and any and all steps and/or events described above for
The present invention is described herein by the following example for use on drilling rigs, however, numerous other applications are intended as appropriate for use in association with the present invention. In a preferred embodiment the present invention replaces conventional choke control methods and apparatuses with an improved digital choke control system that provides a more accurate and faster response choke control than prior systems while maintaining the look and feel of prior known choke control systems. The user adapts to perceive the present invention as the preferred manner of controlling the choke versus known conventional choke control methodologies and apparatuses. The present invention also enables direct control of both pressure and position associated with a choke.
The present invention is a replacement for any application requiring the use of a choke (e.g., but not limited to chokes used in wellbore operations, e.g., but not limited to drilling, unloading, flow testing, pressure testing, fluid changeovers such as in cementing and completion operations). Preferably the user relies on the conventional known choke control methods only as emergency manual backup stations used to back up the improved choke control method and apparatus provided by the present invention. It is expected that the user population will eventually develop enough familiarity and confidence in the choke controlling method and apparatus of the present invention that the user interface provided by the present invention will become the only choke-control-related component located on the rig floor. Eventually, it is expected that in order to simplify rig operations and create more space on the rig floor, that users will exclusively utilize the present invention to the exclusion of conventional choke control methodologies and configure rigs without conventional choke control equipment on the rig floor. That is, all conventional choke control equipment (such as choke console for hydraulic actuators, remote manual station for electric actuators, etc) will be either removed or initially omitted from a rig floor configuration design. It is expected that the drilling industry will eventually gravitate to the exclusive use of method and apparatus of the present invention as the only choke control function on the rig floor.
As shown in
An improved choke control user interface according to the present invention is shown in
As shown in
As shown in
Examples of choke/actuator combinations supported by the present invention comprise: M/D Totco drilling choke with hydraulic actuator; Power drilling choke with worm-gear hydraulic actuator; and Chimo Willis choke with electric actuator, with either open/close or position-set point actuator controller (integral to actuator). The present invention is extendable to virtually any other choke/actuator combination.
The present invention provides for the control of a variety of remotely-actuated drilling chokes. The quality and presentation of the overall design is preferably consistent with different choke mechanisms and thus will not be intentionally reduced by the constraints of any specific actuator or choke as the control methods and apparatus provided by the present invention are independent of actuation methods and choke performance curves. Preferably a consistent user view is provided to maintain intuitive operation between configurations provided for the various choke mechanisms.
For hydraulic-actuated chokes, the present invention provides an interface with existing actuators and choke consoles, with following functions provided at the user's console: Quick-connects for pressurized hydraulic supply and return lines for quick retrofitting of the present invention into existing choke installations; Emergency Manual Backup button and a “Station in Control” indicator light. As discussed below, the operator interface comprises aural, visual and physical feedback to the user in a simulation of traditional choke control methodologies.
For electric-actuated chokes, the present invention provides an interface with the existing actuators and choke consoles, with following functions added to console: Interface and electrical devices as needed to interface with specific actuator comprising, for example, the Emergency Manual Backup functionality as implemented in present invention.
The base configuration for the preferred embodiment of the present invention comprises Dual chokes; Position- and pressure-set control; a “Full choke console” integrated display; and a User interface connected to controller with wires.
The initial list of configuration options for the present invention preferably comprises: Inclusion of each actuator/choke combination on the supported list; Single choke only; Position-set control only; Limited display; High-availability system; Additional user interface stations; Wireless user interface station and wireless controller. The present invention provides an emergency manual backup method and apparatus, which includes the traditional choke control methodologies with which the users are intuitively and extensively familiar. Thus, operator's wealth of experience and expertise are not diminished by introduction of a new product with which they have no experience and would have to traverse a possibly steep and costly learning curve. The present invention, in certain aspects, looks and feels and sounds like the conventional choke control device with which they are familiar. All currently known pressure control techniques are usable with present invention. The currently-known choke control methods are available for inclusion, if desired, as an emergency manual backup method and apparatus.
The activation of the emergency manual backup method of control will be initiated at the emergency manual control station located off the rig floor. When the emergency manual backup method is activated, notice of this activation becomes evident at the operators console 1200 via a perceptible aural, visual or physical operator notification signal at the console as part of the user interface for the present invention, such as 1222. When the emergency manual backup is activated, it takes over through the emergency manual backup user interface and the control functionality of the present invention user interface will be disabled.
In a preferred embodiment, a duplicate display is provided of the operator console lights on the rig floor choke control console 1220 and 1222 at the emergency manual back up console to inform the user via the emergency manual back up console user interface and show the activation state of the emergency manual backup on a separate display at the emergency manual backup station.
In one aspect of an arrangement for the present invention provides a user interface on the rig floor and all other components are located near the actual chokes. An alternative arrangement is provided to accommodate cases wherein a user customer prefers a different arrangement; e.g. at initial introduction or initial use of a system according to the present invention in critical well conditions.
The present invention is compatible with locating an alternate and already accepted control method on the rig floor. Typically, for hydraulic-actuated chokes this would be the choke console, and for electric-actuated chokes this would be a remote open/close control station.
All of the functionality of the present invention, except for the pressure-set control mode, is easily usable by any choke operator with previous experience on a conventional choke with the same type of actuation (e.g. hydraulic or electric). The pressure-set control mode functionality is easily usable by a similarly-experienced choke operator after a brief (i.e. less than 15 minutes) introductory training period, which might be a video, a rig-site simulator, a web-based introduction, exposure in a well control school, hands-on training by service personnel, etc.
The present invention provides physical user controls (such as joysticks, buttons, etc.) in all cases where there is extensive or high frequency use of the control. The simulation of the traditional choke control experience bolsters user confidence as it provides an experience close to, if not identical to, existing choke control methods. The emulation of traditional methods provided by certain systems according to the present invention enables experienced operators to operate the choke control method and apparatus of the present invention by feel, that is, without looking at the controls. In an alternative embodiment, other types of controls are provided, such as graphical touch screen controls and membrane-type buttons.
A neural network is provided and trained to learn the conventional choke control method and physical feedback associated therewith. The neural network can reproduce physical feedback given a set of operational parameters.
The present invention, in certain aspects, provides all user controls, regardless of type, designed for maximum usability. The control choices and how to execute them are evident and unambiguously clear. Conventional physical feedback is provided for all operator actions and system actions which enable presentation of an intelligible conceptual model with which the operator is familiar.
Both types of control functionality (i.e., position-set and pressure-set control) are provided to the user as discrete and as continuous actions. A discrete action is provided in response to a single crisp user action, for example, pressing a button or pressing and releasing a button or moving a joystick to a specific position. A continuous action is provided when a user maintains a control in one state, for example, holding a button down or maintaining a joystick within a specific position range. The continuous control action is carried out on a regular basis, which is managed by the user. Accelerating-type continuous control actions are not allowed by the present invention and are overridden by the processor. Both types of control actions are provided to the user in a three-value range (example—small/medium/large magnitudes of change).
The position-control functionality is provided to the user in the form of relative position movements in the open and closed directions. For example, the values offered may be 0.1%, 1% and 10% change in the position of the choke element inside of the choke. The new position set point is computed using the relative position increment and the current position. Thus, the position set point is not allowed to “race ahead” to values far from the current position.
The relative position increment is initially fixed for all chokes and actuators. The present invention enables tuning the relative position increment to the specific choke characteristics (loosely), the benefits of which would include increased operator convenience and improved control performance.
When the pressure control mode is selected, the pressure set point will be set to measured choke pressure. The user will be offered the opportunity to raise or lower the pressure set point by a selected pressure increment. For example, the range of pressure set point change values offered may be 25 psi, 100 psi and 500 psi. The new pressure set point is computed using the relative pressure increment and the current pressure. Thus, the pressure set point is not allowed to “race ahead” to values far from the current pressure.
In a preferred embodiment, the pressure set point value is visible to the user, however, knowledge of the pressure set point value is not in any way required to operate the pressure-set point control mode, just as a driver can operate a car with cruise control and never sees the speed set point value.
Any set of control set point incremental change values (whether position or pressure) offered to the user (i.e. the three-value ranges noted above) are limited to values which are within the measurable and controllable limits of the specific configuration of equipment of the present invention.
The present invention provides emulation-enhanced dual controls so that the user should be able to use the same control to operate with either control mode, and the operation of the control is consistent with the user's previous choke control experience. In one aspect, the experience of operating the controls associated with the choke element movement is consistent between both control modes. For example, closing the choke in position-set control mode and raising the pressure set point in pressure-set control require similar control actuation movements and produce a similar physical experience for the operator.
When the user is in a given control mode provided by the present invention, either position-set point or pressure-set point control mode, the control device provides the user suitable physical feedback so that he can continue to exercise control based on physical feedback without looking at the control device. The control device provides an emulation of the traditional choke control experience with sufficient tactile, aural, visual and/or physical feedback of sufficiently obvious orientation such that at any time the choke control operator can tell where the current control command is and how to select other commands based solely on the perceived feedback or feel from the emulation of the traditional choke control experience associated with the control device. In one aspect this experience is provided by a physical simulation or emulation of the conventional choke control experience, so that the controls look, sound and feel comfortable and familiar much like the conventional choke control experience. Simulating the conventional choke control experience enhances the safety of an operation while increasing an operator's ability to effectively operate the improved choke control method and apparatus of the present invention and avail himself of its benefits.
One embodiment of the present invention has sensors for the items shown in Table 1.
The electric actuator performance indicator(s) are any data items that provide insight into the state and proper operation of the actuator, comprising, but not limited to, torque, temperature, current and supply of power to an actuator. Note that sensors may not be required for all of the listed inputs. For example, an electric actuator may provide position feedback via an analog output current or a network-communicated data value. The user interface displays data to the user and provides and offers control actions.
The activation state of the emergency manual backup method and apparatus of the present invention control state will be displayed in a manner that is easily perceptible from across the rig floor. In one embodiment, a light and sound meter are provided to determine whether and what level of a light or sound notification to the operator is appropriate but must be available over 100 decibels. For example, if the noise level at the rig is below a set level, for example 100 decibels, then an aural notification signal is appropriate. Otherwise the aural notification may be swamped with ambient noise and become imperceptible to the operator. At any given time, one of these states must be true and the other false. The emergency manual backup activation state of true will be a red light and when appropriate, an aural notification. The present invention control state of true will be a green light and, when appropriate, an aural notification.
The use of a yellow light and associated aural notification to show if a given station has control is also provided. The notification light states are as follows: Red—emergency manual backup method is active; Yellow—the present invention control is active, but this station is not in control; and Green—the present invention control is active, and this station is in control. An operator interface enables a station to take control, for example, when any control-related operator input occurs.
The following data will be displayed in a text format at the rig floor console: All of the sensor inputs, except for emergency manual switch state and pump stroke counter; Control mode state in effect (position-set point or pressure-set point); Pump speed(s) in strokes per minute (SPM); Cumulative pump stroke count; and Pressure set point value, when a pressure-set point control is in effect.
Graphical display of selected data is also provided. As shown in
The present invention, in certain aspects, provides a system with a user interface that provides aural, physical and visual feedback for movement of the choke element. This feedback includes an emulated sound similar to the traditional sound of the current air-over-hydraulic pump and electric actuator, as appropriate, or can be a new sound, such as a clicking. The sound will alert the user to the smallest detectable movement of the choke element. The sound is preferably expressive for any movement, as the sound also communicates the relative speed of movement of the choke element. The user will be able to adjust the volume of the sound at the user interface, from silent to loud (easily audible within five feet of the user interface with typical rig floor background noise). The emulated sound will be heard sooner than the sound it emulates and thus provides a rapid and more accurate means for enabling the operator to determine when the choke element is moving and to enhance operator's experience (knowledge) by building an enhanced mental model of choke movement.
In a conventional choke control system, the operator issues a command to move the choke element, the choke element moves and the air-over-hydraulic pump starts up to build up hydraulic pressure diminished by the choke element movement. The operator uses the sound of the air-over-hydraulic pump starting up to confirm that the choke element has moved. Thus, there is a feedback delay in the conventional system, that is, there is a delay between the time that the choke element moves and the time the air-over-hydraulic pump starts up and the operator hears the sound of the pump. In the preferred embodiment of the present invention, the emulated sound of the air-over-hydraulic pump starts up immediately when the operator moves the choke control joystick without the physical feedback delay encountered by operators in conventional choke control systems. Thus, in on embodiment of the present invention, the operator receives immediate aural feedback that the choke control command is being executed by the choke control system.
The control performance of the present invention is more accurate and quicker than the best control performance attainable by an expert operator under similar flow conditions using the conventional known choke control equipment. The present invention enables an operator to rapidly, accurately and directly control the pressure drop across a choke. One evaluation of the control performance of the present invention is a set of pre-defined control exercises, which are repeatable and can be performed by a human operator with current equipment and a human operator utilizing the present invention. Examples of these exercises are: Starting at a given position, on command move the choke to different relative positions; and Starting at a given pressure and maintaining a fixed flow rate through the choke, change the pressure to different values.
The schedule of positions and pressures in the pre-defined control exercises covers a range of typical operations, such as small changes and large changes, and with the choke element at various initial control positions. The schedule rigorously challenges the capabilities of the human operator, the present invention, the actuator and the choke, within the allowable physical limits of the operational scenario. The evaluation system prompts the human operator at a console user interface provided by the present invention. Voice operator notifications are preferable for delivering the commands.
Installation of certain embodiments of the present invention requires a minimum of tuning/calibration. The tuning/calibration procedure is easily understandable and unambiguous to any qualified service person. A confirmation procedure is provided, in which the service person verifies that the present invention is properly installed and meets all performance requirements. The service person documents the quality of the installation. The verification procedure is automatic and self-documenting. Once the present invention is installed and working properly, there will be no tuning requirements of any kind, nor will any user adjustments be required to maintain high quality control performance over any well conditions encountered.
The present invention provides a user interface, which, in one aspect, is preferably mounted to existing rig floor structure and also provides a pedestal mount with adjustable height, for convenient choke operation. A wireless version is also provided.
The present invention supports real-time two-way data communication, e.g., with Varco International, Inc.'s RigSense and DAQ JVM, and with other commercially available information systems. In one aspect any sensors whose data is used by the present invention (for control and/or display) are directly connected to the present invention.
In one aspect, when the RigSense system is present in an embodiment of the present invention, the RigSense system provides data archiving and expanded data displays functionality to the present invention. The present invention provides a user interface integrated into other systems such as the RigSense system, DAQ JVM and VICIS; Real-Time Well Control, supervisory control specific to well control tasks; and Automated well control, which may be entire process or selected sub-tasks. One of the primary impacts perceived on existing products and services in which integration and/or implementation of the present invention is performed is additional capability for taking control of and/or being in control of the choking operation via a distinct intervention, so that control is clearly being exercised by users at other stations and by automated controllers.
A key factor for efficient utilization and integration of the present invention into the operator's working environment is the present invention's provision of manual controls for high-frequency user control actions in lieu of touch screen control consoles. Additional automated functionality is provided such as automatic pressure-set control for use in association with the touch screen and provides benefit in the control area, particularly in emergency stations.
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In another embodiment, the present invention is implemented as a set of instructions on a computer readable medium, comprising ROM, RAM, CD ROM, Flash or any other computer readable medium, now known or unknown that when executed cause a computer to implement the method of the present invention.
The present invention provides a method and apparatus for remotely monitoring, analyzing and affirmatively notifying appropriate personnel of problems and events of interest associated with an oil recovery system comprising hundreds of oil rigs over a vast geographical area or a single rig. The present invention provides a monitoring and reporting system that is referred to as a Health Check system. The present invention provides a variety of performance, process and equipment monitoring Health Checks and equipment sensors at each oilrig in an oil recovery system. The results of selected diagnostics, which are run on each oilrig, are reported to a central server. The central server populates a data base for the oil recovery system, displays a red/yellow/green/gray color coded report for an entire oil recovery system and affirmatively alerts appropriate personnel of actions required or advisories to address events associated with an oilrig in an oil recovery system. The Health Checks performed at each oilrig are configurable at the individual rig and from the central server or other processor associated with either the oilrig or central server. The central server need not change its reporting and display program when changes are made to a health check at an oilrig. The present invention provides a dynamic oilrig status reporting protocol that enables population and display of a tree node structure representing an entire oil recovery system or single oilrig status on a single screen. Thus, the present invention enables rapid visual or aural affirmation of a system Health Check.
Health Checks are not the same as alarms. An alarm is an immediate notification to an operator that a known unacceptable condition has been detected, requiring the operator's awareness of it and often some action by the operator. A Health Check may use alarms in its logic, but it is by nature different than an alarm. A heath check is more general and more diagnostic than an alarm, and does not require immediate action, at least not on the oilrig. In the present invention, a problem is reported to a central server for reporting and diagnosis to service personnel. A Health Check can apply to any equipment component or process, sensors, control systems, operator actions, or control processes, etc.
The Health Check system comprises software containing test logic. The logic is configurable so that inputs, outputs and logic can be selected by a user to test and look for any condition or event associated with an oilrig or oil recovery system. The overall system comprises Health Checks running in real time on a computer at an oilrig and a communications network connecting the oilrig to a central server to move data from the rig of a group of rigs to the server. The server displays the results in hierarchical form. The server sends commands, application programs and data to the rig from the server.
The Health Check system of the present invention further comprises a central database populated with dynamic status reported from oilrigs comprising an oil recovery system. The present invention further comprises a web page display for efficiently displaying Health Check results associated with a test, a rig, an area or an oil recovery system. The web page results can be displayed on a computer, cell phone, personal data assistant (PDA) or any other electronic display device capable of receiving and displaying or otherwise alerting (e.g., sound notification) a user of the status of the data. The preferred screen is a color screen to enable red/green/yellow/gray display results. Results can also be audio, video or graphically encoded icons for severity reports, e.g., an audio message may state audibly, “situation green”, “situation red” or “situation yellow” or display a particular graphical icon, animation or video clip associated with the report to demonstrate a Health Check severity report. The present invention enables drilling down (that is, traversing a hierarchical data structure tree from a present node toward an associated child or leaf node), into a tree of nodes representing diagnostic status, to a node or leaf level to access additional information regarding a color-coded report.
The present invention also provides a notification system to immediately inform service personnel of problems as necessary, such as a message or email to a cell phone or pager or computer pop up message. There is also a receipt affirmation function that confirms that a notification message was received and acknowledged. Secondary and tertiary notifications are sent when a primary recipient does not acknowledge an affirmative notification within a configurable time limit. A severity report associated with a given problem is represented by a blinking color when it is unacknowledged and remains a blinking color until the given problem is cleared and returns to green or clear status. Severity reports once acknowledged change from blinking to a solid color. Reports that have been acknowledged by one user may be transferred or reassigned to another user upon administrative permission by a system supervisor or by requesting permission to transfer a second user and receiving permission from the second user. A system supervisor can also display a list of users and severity reports being handled by the user, that is, a list of acknowledged and in progress severity reports assigned to a particular user to view and enable workload distribution to facilitate reassignments for balancing the work load.
A dispatch may assign a work order to a group of particular severity reports. Once the work order is completed the system checks to see if the nodes associated with the work order have been cleared. The work order provides a secondary method for determining if nodes associated with a work order have been cleared after a work is complete. The system administrator software program can also automatically check the work order against the node state for a system check.
The advantages provided to the customer of a preferred Health Check system are substantially less down time due to the present invention's Health Check's ability to find or anticipate problems earlier and fixing the problems faster, ideally before the customer becomes aware that a problem has occurred. The present invention reassures the customer that the Health Check system is always on the job and monitoring and reporting on the oil recovery system twenty-four hours a day, seven days a week. A customer or system user can always call in and confirm the status of an entire oil recovery system or single rig with a single call to the central server or a rig and receive a situation report, that is situation red, yellow, green or gray for the oil recovery system or single rig, as requested. The present invention enables more efficient use of operational service personnel. The present invention finds and reports problems, potential problems and trigger events of interest, which enables rapid response and recovery in case of actual and/or potential equipment or operator malfunctions or the occurrence of a particular event. The present invention also helps to find problems at an early stage when the problems are often easier to fix, before catastrophic failure, thus creating less impact on the customer's oil recovery system or individual oilrig. Health Checks according to the present invention provide a method and apparatus for providing an application program that acts as an ever-vigilant set of eyes watching an entire oil recovery system or single rig to ensure that everything is okay, that is, operational.
In certain embodiments, all results for each oilrig in an oil recovery system or individual oilrig or equipment are worst-case combined so that the worst-case severity report bubbles to the top of the reporting tree and is reported as the status for an entire oil recovery system, oilrig(s), event of interest, process, or equipment being analyzed. As discussed above, red is a worst-case severity report, followed by yellow severity report and then green is the least severe report. Gray indicates no data available. Thus, if one or more tests reporting a red status is received from an oilrig, the red status bubbles up past all yellow and green status reports and the status for the rig and the entire oil recovery system in which the rig resides is shown as red. Once the red report is cleared, yellow reports, if any, bubble up and the status of the oil recovery system, rig or equipment being viewed is shown as yellow, if a yellow report is in a node tree transmitted from any oilrig in an oil recovery system. The status for a single oilrig bubbles up the worst-case report as well, however, localized to the single rig or rigs under investigation, unless grouped. When grouped the worst-case status for the group is reported. For example, if three rigs were reporting the following scenario is possible: Rig 1 reports red, rig 2 reports yellow and rig 3 reports green. The status for a group selected to include rigs 1, 2 and 3 would be red. The status for a group selected to include rigs 2 and 3 would be yellow. The status for a group selected to include rig 3 only would be green. Subsections within a rig can also be selected for a color-coded status report. Preferably, the gray is not cleared. Usually, if the test were not conducted for any reason, the status would take gray color.
The present invention enables testing at the nodes of a bottom up tree structure representing an oil recovery system, a single rig therein, or an equipment in an oilrig, wherein the nodes carry the results to the top for easy visualization and use. The present invention also provides a dynamic reporting protocol for data transfers from an oilrig to a central server wherein level identifiers are provided to transfer data and its structure in a single packet transfer, thus enabling dynamic data base population and display of reports from an oilrig. The results are presented on a web page or reported to cell phones, computers, pagers, personal data assistants or otherwise affirmatively reported other wise to appropriate personnel. In a preferred embodiment, reports are acknowledged by a first recipient or a second recipient is selected for receipt of the report when the first recipient does not acknowledge receipt, and so on, until a recipient has received and acknowledged the report. Alternatively multiple recipients may simultaneously get the notification.
The present invention is automatically scaleable and extensible due to the modular and dynamic nature of its design. Tests can be easily created, added or deleted and parameters added or modified on an oilrig equipment test or Health Check without reprogramming or changing the central server's database population, data reporting and data display applications. The reporting can vary between broad coverage and specific coverage, that is, a status report can included data for an entire oil recovery system comprising over 100 oilrigs and/or specifically report status for a single oilrig of interest concurrently.
The present invention provides early warning of potential and actual failures and also provides confirmation of product performance and usage. A set of automated Health Checks and diagnostic tests is selected to run in real time on an oilrig. Status from the test is reported continuously via a communication link between the oilrig and a central server. The present invention provides insight and analysis of equipment, processes and equipment usage on an oilrig. The present invention monitors alarms and parameter limits to assess necessary action and perform affirmative notification of appropriate personnel.
The present invention provides quick response, real-time monitoring and remote diagnostics of the automation and control systems running on oilrigs comprising a fleet of oilrigs or an oil recovery system to achieve maximum rig performance while maintaining optimum personnel allocation. A service center is connected to the oilrigs through an Internet based network. System experts make real-time data and logged data from the oilrigs available for perusal and analysis in a central facility or at distributed locations. The web site of the present invention provides access to current operational status as well as to historical operation and performance data for each of the rigs comprising an oil recovery system.
Health Check tests are configurable so that new tests can be created, added or deleted and parameters changed for execution at an oilrig without the necessity of programming. A simple user interface is provided wherein a user at the central server or at an oilrig can select a test from a library of existing tests, or create a new test using a scripting language, natural language interface or pseudo language is provided which generates a script defining inputs, outputs and processing logic for a test. The script is compiled and sent to the rig for addition to existing Health Checks running on the rig. The user interface also enables modification or addition and deletion of parameters associated with a Health Check or test.
Notifications can be an immediate message when a problem is detected or an advisory notification. The notification is sent to expert service personnel associated with the central server or can be directed to a service manager or local service person closest to the rig needing service. For each rig and problem type, a particular person or service personnel category is designated for receipt of a notification. Secondary and tertiary backup personnel and personnel categories are designated as a recipient for each notification. Affirmative notifications must be acknowledged by the recipient so that the problem is acknowledged and someone has taken responsibility for the problem. If an affirmative notification is not acknowledged within a configurable time period, then a secondary or tertiary recipient is notified until the problem is acknowledged. Reliability reports are generated by the present invention showing performance summaries for oilrigs, comprising up time, response, problems detected and solutions provided. These reports provide an objective basis for formulating an evaluation of the Heath Check system's efficiency.
The results from a rig include processed inputs from the rig. No processing is required at the central server, other than display, storage and alerts to appropriate personnel. The oilrig Health Checks and tests are configurable so no programming is required to implement a new test or change logic or parameters for an existing test. A field engineer or central server personnel can add a new test without requiring a user to perform a programming change. The present invention provides a local or remote user interface, which provides a simple interface for describing a test and logic. The interface comprises an iconic presentation, pseudo language, script or a natural language interface to describe a test's input(s), processing logic and output(s). The user interface interprets a user's inputs and converts the user's input into a scripting language. The script language is compiled and sent to the rig on which the new or augmented test is to be performed. The new test is added to a library of tests from which a user may choose to have run at a rig. Test modules can be deleted, added, parameters changed, and updated from the oilrig, the central server or from a remote user via a remote access electronic device.
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The present invention is also useful for Process Monitoring, that is, to determine that equipment is being used properly to perform a designated process. For example, if rig operators are using an “override” during a certain system state indicative of a certain process, which is supposed to be run automatically rather than manually overridden, the present invention can perform a health check to detect this event of interest and report it to the central server. Knowledge of this occurrence enables central server personnel to detect and correct the inappropriate action of the operators. Moreover, the test to detect the inappropriate override stays in the system so that if new operators recreate the problem or trained operators backslide into using the manual override inappropriately, the central server personnel will be notified so that the problem can be address again. Thus, the Health Check system builds a cumulative base of operational checks to insure that a process on a rig or oil recovery system runs in optimal fashion.
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Changes to the Health Checks running on any or all rigs does not require changes to the display or data base population application because the preferred communication protocol defines the data base layout and display layout. The leaf nodes of the tree structure represent Health Check results. Each node contains a test identifier, test result (red/yellow/green/gray), intermediate data, user-entered data and test description. Trouble shooting comments are provided at the central server based on reported errors. Test error codes are included in the node so that messages associated with the error codes are displayed to the appropriate user. Alternately, trouble shooting and other information can also be generated and appended to the results of the tests at rig site. Thus, no processing to determine rig status is done at the central server. Notifications are sent when deemed necessary by the application. Notification logic is configurable by service personnel at the central server or at the oilrig. Notification logic dictates that notifications are sent when an event occurs and the event has been selected for reporting as a notification to a user. The notification logic and a list of appropriate notification recipients in order of priority, that is, who to contact first, is retained at the central server. The event can be a report on an equipment status, process execution or an operational item. A user can check in with the central server of present invention to obtain a real time report of the status of an oilrig or multiple oilrigs. The requesting user will receive a severity report message indicating the status of the rig, for example, “okay” or “red/yellow/green/gray.”
The following are examples of Health Checks in a preferred embodiment of the present invention. In this example, VICIS-ED is a drilling rig information and control system; it includes control of the drawworks via a joystick.
Rig Health Check: Auto-Drilling Performance
Auto-drilling Performance: In a preferred embodiment of the present invention, an autodriller in VICIS-ED controls ROP, WOB, torque and/delta-p parameters of the drilling process; it does this by controlling rate of line payout on the drawworks to limit the controlled parameters to setpoints specified by the driller. This health check tests verifies that the auto-driller is maintaining these parameters within acceptable limits. Acceptable control ranges typically have the following default values:
At any given time during drilling, only one controller is in control. If no drilling occurred or auto drilling is not active during the last 24 hours this check is not possible and will not be included in the report. For each of the four controllers, the DCQA application computes the percent of time the feedback is within the allowable range. For each controller, this test is performed once a second when the controller has been in control for a minimum of 10 seconds. A count of acceptable and total test results is accumulated for each controller. At 6 am for the previous 24 hours, this test computes the percent of time each controller's feedback was within the specified range, for all valid tests. If at least twenty tests for a controller were not done in the last 24 hours (which includes when there was no drilling or if the autodriller was not used), that controller's health check result is gray. Otherwise, the percentage of acceptable control counts is compared to pre-set values to categorize the result as red, yellow or green.
Health Check: Use of System Keyed Override Switch
VICIS-ED provides a keyed override switch, whose use should not be required for routine operation of the system. In 24-hour periods, the status of this switch is monitored once a second, resulting in a count of times the switch was activated. A count greater than zero produces a red result for this health check, otherwise it is green. If this switch is used, this check is deemed failed and the number of engagements of this switch is documented in the command center log. This test monitors the state of the keyed override switch once a second and counts the number of times the switch has been pressed. If the switch is on when the test starts, that is counted as a key press. At 6 am for the previous 24 hours, the health check is conducted, which consists of comparing the number of switch activations to a count of zero. If the switch has been pressed one time or more, the health check result is red; otherwise, it is green.
Health Check: “Joystick Control”
Joystick Control: The joystick controls the movement of the block; when hoisting it controls engine speed and when lowering it controls application of brake. For each 24-hour period, joystick movement and the resulting block velocity changes are observed. This test uses a comparison between joystick position (hoist, lower or neutral) and block velocity. In general, both parameters should be moving in the same direction. This test consists of identifying times where the joystick and the block are moving in opposite directions. The rules for this test procedure are specific to the joystick position.
Health Check: Joystick in Hoist/Lower Position
This Health Check watches for a minimum of three consecutive joystick positions in same direction (i.e. all hoisting or all lowering) and compares the joystick position and block velocity in the third sample. If the joy stick position and the block velocity are in opposite directions, the Health Check increments the appropriate joystick hoist or lowers the error count. This test is not performed while the system is in keyed override or in a slip-and-cut mode.
Health Check: Joystick in Neutral Position
This Health Check detects watches for a minimum of three consecutive joystick positions in neutral direction. If the block is rising or falling in the third sample, it increments the joystick neutral error count. This Health Check is not performed while the system is in keyed override or in slip-and-cut mode. The “block falling” portion of this test is not performed when the auto driller is on. If the sum of the error counts for all of the above tests are greater than zero for the previous 24 hours, the health check result is red; otherwise, it is green. The joystick position is determined using the hoist and lower switches in the joystick assembly. The test also uses the following parameters:
Sign Conventions and Tolerances:
Block velocity >1.0 ft/min upward block movement.
Block velocity <−1.0 ft/min downward block movement.
Health Check: Use of Auto-Drilling
It is assumed that the autodriller should be used and provide optimal performance during most drilling operations.
To conduct this test, the Health Check monitors the bit-on-bottom state and auto-driller state from the drill logic in the drilling instrumentation system. It computes the percent of drilling time when the auto driller is in use on a one-second sampling as follows:
At 6 am for the previous 24 hours, the test outputs the percent of drilling time the auto driller was used and this health check. This Health Check consists of comparing this percentage against a threshold of 98%. If the percentage is <98%, the health check result is red; otherwise it is green. If no drilling was done, the health check result is gray. The percent of time on-bottom drilling is also computed, based on bit-on-bottom status.
Health Check: System Settings Changes
A large number (more than 100) of system setting parameters exist in VICIS-ED; some are initial system settings, some are expert tuning adjustments and some are operational in nature and driller-specified. Many of these parameters preferably do not require changing on a daily basis, and knowledge of which parameters changed and how is vital for providing support to maintain system performance and ensure optimal usage. This test monitors all tuning parameters and maintains a count of changes by parameters and by groups of parameters (example—driller-initi-ated parameters). The following parameters are monitored, grouped as follows:
The following are User/Driller-Adjustable Tuning Parameters: Large Piston Bias for Tripping; Large Piston Bias for Drilling; Driller ROP Gain Factor-Adjust; Driller WOB Gain Factor-Adjust; Driller Torque Gain Factor-Adjust; and Driller DeltaP Gain Factor-Adjust.
Driller-Adjustable Operational Parameters: Drill Stop Point; Low Set Point; High Set Point; Swab Speed for Trip Out; Surge Speed for Trip In; Stand Lowering Time; Surge Speed for Run Casing; Joint Lowering Time; Connection Lowering Speed; Connection Hoisting Speed; Trip In Kick Out Alert; Trip Out Height Alert; ROP Set point; WOB Set point; Delta P Set point; Torque Set point; Engine Cut Slip Speed Set point; Lines Strung; and Bail Length.
The following are Password-Protected Parameters: Block weight; Brake horsepower; Encoder resolution; Brake air supply alarm low limit; Brake air supply alarm high limit; Engine tuning gain; Engine tuning integral; Brake hoisting tuning gain; Brake hoisting tuning integral; Brake lowering tuning gain; Brake lowering tuning integral; ROP loop tuning gain; ROP loop tuning integral; WOB loop tuning gain; WOB loop tuning integral; Torque loop tuning gain; Torque loop tuning integral; Delta P loop tuning gain; and Delta P loop tuning integral.
This test records the value for each parameter upon startup. On a 24-hour basis starting at 6 am CST, the test maintains a count of the number of times each parameter's value is changed, and if a parameter was outside the preferred range.
The application outputs the following at 6 am CST: a “value has changed” state for each parameter; a “value was out of range” state for each parameter; count of parameters changed per group; color-coded test result for each group; and color-coded test result for System Settings.
The test results for each parameter are color-coded in the following order:
Based on the above results, the System Settings test status is color-coded in the following order:
The BCS (block control system) limits the driller's operation of the block such that it does not exceed safe limits of operation. This check tests the operation of block control system compared to the preset limits it is required to enforce. To pass the test, the block should operate within the position/velocity envelope enclosed by upper and lower set points and maximum velocity set points. Pre-determined tolerance ranges are specified upon installation. The specification for VICIS-ED BCS operation is as follows:
The health check is not done if either the range override or the keyed over ride are on, or if in slip-and-cut mode. These counts are reset to zero at 6 am and are maintained on a 24-hour basis. At 6 am, the counts will be summed. If this sum is greater than zero, the health check result is red; otherwise, it is green.
These health checks include rules to qualify inputs as valid. Examples of these rules are:
In another embodiment, the present invention is implemented as a set of instructions on a computer readable medium, comprising ROM, RAM, CD ROM, Flash or any other computer readable medium, now known or unknown that when executed cause a computer to implement the method of the present invention.
The present invention is described herein for use on drilling rigs, however, numerous other applications are intended as appropriate for use in association with the present invention. In a preferred embodiment the present invention replaces conventional choke control methods and apparatuses with an improved digital choke control system that provides a more accurate and faster response choke control than prior systems while maintaining the look and feel of prior known choke control systems. The user adapts to perceive the present invention as the preferred manner of controlling the choke versus known conventional choke control methodologies and apparatuses. The present invention also enables direct control of both pressure and position associated with a choke.
The present invention is a replacement for any application requiring the use of a choke. Preferably the user relies on the conventional known choke control methods only as emergency manual backup stations used to back up the improved choke control method and apparatus provided by the present invention. It is expected that the user population will eventually develop enough familiarity and confidence in the choke controlling method and apparatus of the present invention that the user interface provided by the present invention will become the only choke-control-related component located on the rig floor. Eventually, it is expected that in order to simplify rig operations and create more space on the rig floor, that users will exclusively utilize the present invention to the exclusion of conventional choke control methodologies and con Fig. rigs without conventional choke control equipment on the rig floor.
The present invention, therefore, in at least some, but not necessarily all embodiments, provides a system for diagnosing and controlling a choke, the choke used for choking in wellbore operations associated with a wellbore in the earth, the system including a positioner for moving a choke mechanism of a choke, a choke isolation valve connected to the choke for selectively isolating the choke, a processor for controlling the positioner and for selectively commanding the positioner to move the choke mechanism while the choke is in standby mode. Such a system may have one or some (in any possible combination) of the following; wherein the processor automatically commands the positioner to move the choke mechanism into standby mode; wherein the system includes sensor apparatus for sensing conditions of the wellbore operations, the sensor apparatus for producing signals indicative of said conditions and for transmitting said signals to the processor, the sensor apparatus in communication with the processor, and the processor includes a computer readable medium with computer executable instructions for commanding the choke to remain in standby mode based on said conditions; wherein the system includes sensor apparatus for sensing conditions of the wellbore operations, the sensor apparatus for producing signals indicative of said conditions and for transmitting said signals to the processor, the sensor apparatus in communication with the processor, and the processor includes a computer readable medium with computer executable instruction for commanding the choke to enter standby mode based on said conditions; wherein the processor includes a computer readable medium with computer executable instructions for scheduling periodic operation of the choke and for then periodically operating the choke; wherein the processor includes a computer readable medium with computer executable instructions for diagnosing the choke; wherein the system includes sensor apparatus for sensing conditions of the wellbore operations, the sensor apparatus for producing signals indicative of said conditions and for transmitting said signals to the processor, the sensor apparatus in communication with the processor; wherein the system includes sensor apparatus for sensing conditions of the wellbore operations, the sensor apparatus for producing signals indicative of said conditions and for transmitting said signals to the processor, the sensor apparatus in communication with the processor, and the processor includes a computer readable medium with computer executable instructions for commanding the choke to exit the standby mode based on user input or on said conditions; a mode sensor connected to the choke for determining when the choke is in a standby mode, the mode sensor in communication with the processor; a choke position sensor connected to the choke for determining the position of the choke mechanism, the choke position sensor in communication with the processor; a processor memory in the processor and containing diagnostic instructions for performing a choke diagnostic; the processor including a computer readable medium with computer executable instructions for producing a result based on a diagnostic performed by the system; the processor including a computer readable medium with computer executable instructions for producing an analysis for determining whether a choke failure has occurred; the processor including a computer readable medium with computer executable instructions for producing an analysis for predicting that a choke failure will occur; a pressure sensor for measuring a pressure of fluid circulating through the wellbore to produce a pressure measurement, the pressure sensor in communication with the processor, the processor including a computer readable medium with computer executable instructions for determining if said pressure measurement relative to a pre-determined pressure threshold indicates that standby mode is appropriate; the processor including a computer readable medium with computer executable instructions for performing a choke mechanism speed diagnostic; and/or the processor including a computer readable medium with computer executable instructions for performing a choke mechanism position diagnostic.
The present invention, therefore, provides in some, but not necessarily all, embodiments a system for diagnosing and controlling a choke, the choke used for choking in wellbore operations associated with a wellbore in the earth, the system including a positioner for moving a choke mechanism of a choke, a choke isolation valve connected to the choke for selectively isolating the choke, and a processor for controlling the positioner and for selectively commanding the positioner to move the choke mechanism, the processor for diagnosing the choke, transmitting information regarding a diagnosis to a control system, and for selectively periodically activating the choke. Such a system may have a processor that enables operation of the choke during the selective periodic actuation of the choke, confirms acceptable status of the choke, provides notice of potential problems with the coke, and/or provides notice of existing problems with the choke.
The present invention, therefore, provides in some, but not necessarily all, embodiments a system for diagnosing and controlling a choke system, the choke system used for choking in wellbore operations associated with a wellbore in the earth, the system including a plurality of chokes, valve apparatus and associated conduit apparatus for selectively operating a first choke of the plurality of chokes, while at least one non-operational choke is maintained in standby mode, each of the chokes of the plurality of chokes further including a positioner for moving a choke mechanism of a choke, a choke isolation valve for selectively isolating the choke, and a processor for controlling the positioner and for selectively commanding the positioner to move the choke mechanism while the choke is in standby mode. In such a system the plurality of chokes can be a first choke and a second choke either of which may be operational while the other is in standby mode.
The present invention, therefore, provides in some, but not necessarily all, embodiments a method for diagnosing and controlling a choke used in wellbore operations, the method including placing a choke mechanism of a choke in a standby mode, controlling the choke mechanism with a processor, and the processor including a computer readable medium with computer executable instructions for producing instructions commanding the choke to operate to place the choke mechanism in the standby mode, to remain in standby mode, or to exit standby mode. Such a method may include one or some of the following, in any possible combination: the processor can include a computer readable medium for automatically placing the choke in standby mode and the system includes sensor apparatus for sensing conditions of the wellbore operations, the sensor apparatus for producing signals indicative of said conditions and for transmitting said signals to the processor, the sensor apparatus in communication with the processor, and the method further including with the processor, and based on said conditions, automatically placing the choke in standby mode; with the processor, commanding the choke to enter standby mode; with the processor, commanding the choke to remain in standby mode; with the processor, commanding the choke to exit standby mode; wherein the processor includes a computer readable medium with computer executable instructions for scheduling periodic operation of the choke and for then periodically operating the choke, the method further including with the processor, periodically operating the choke; wherein the system includes sensor apparatus for sensing conditions of the wellbore operations, the sensor apparatus for producing signals indicative of said conditions and for transmitting said signals to the processor, the sensor apparatus in communication with the processor, the method further including with the processor, preventing the choke from operating based on said conditions; wherein the choke includes a choke isolation valve and the method further includes determining with the processor when the choke isolation valve is in a standby mode; wherein the choke includes a choke isolation valve, a choke position sensor for determining the position of the choke mechanism, the choke position sensor in communication with the processor, and the method further including with the choke position sensor determining the position of the choke mechanism; wherein the processor has a processor memory containing diagnostic parameters for performing a choke diagnostic, the method further including with the processor, performing a choke diagnostic; producing with the processor a result based on a diagnostic performed by the system; determining with the processor whether a choke failure has occurred; predicting with the the processor that a choke failure will occur; wherein a pressure sensor for measuring pressure of fluid circulating through the wellbore is in communication with the processor, the method further including producing a signal indicative of a measured pressure of fluid with the pressure sensor, and determining with the processor if standby mode is appropriate in view of said measured pressure, and, if so, with the processor, entering the choke into standby mode; performing with the processor a choke mechanism speed diagnostic; and/or performing with the processor a choke mechanism position diagnostic.
The present invention, therefore, provides, in at least certain embodiments a method for diagnosing and controlling a choke used in wellbore operations, the method including placing a choke mechanism of a choke in a standby mode, controlling the choke mechanism with a processor, and the processor including for commanding the choke to operate to place the choke mechanism in the standby mode, to remain in standby mode, or to exit standby mode.
The present invention, therefore, provides, in at least certain embodiments, a method for diagnosing and controlling a choke used in wellbore operations, the method including placing a choke mechanism of a choke in a standby mode, controlling the choke mechanism with a processor system, and with the processor system selectively operating the choke and analyzing the choke's operation. Such a method may include communicating results of said analyzing to a health check system, and producing at least one health check result with the health check system.
The present invention, therefore, provides in at least certain embodiments, a computer readable medium containing instructions that, when executed, cause a processor to control operation of a choke mechanism of a choke, the choke for choking drilling fluid flow in wellbore operations, and instructions for controlling a positioner of a choke mechanism of a choke, the choke including a choke isolation valve for selectively placing the choke in standby mode, for controlling the choke isolation valve, and for selectively placing the choke in standby mode.
This is a continuation-in-part of U.S. application Ser. No. 10/373,216 filed Feb. 24, 2003; 60/424,262 filed Nov. 6, 2002; 60/546,241 filed Feb. 20, 2004; and Ser. No. 10/353,650 filed Jan. 29, 2003, all co-owned with the present invention, all fully incorporated herein for all purposes, and with respect to all of which the present invention claims priority under the Patent Laws.
Number | Date | Country | |
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60546241 | Feb 2004 | US |
Number | Date | Country | |
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Parent | 10373216 | Feb 2003 | US |
Child | 11056951 | Feb 2005 | US |
Parent | 10353650 | Jan 2003 | US |
Child | 11056951 | Feb 2005 | US |