BR112015032970B1 - MONITOR FOR A WELL HOLE ERUPTION PREVENTIVE CONTROLLER, AND, METHOD FOR MONITORING A WELL HOLE ERUPTION PREVENTIVE CONTROLLER penetrating an underground formation - Google Patents

Abstract

MONITOR FOR A PREVENTIVE CONTROLLER OF ERUPTION OF A WELL HOLE, MONITORING SYSTEM FOR A WELL HOLE TO PENETRATE AN UNDERGROUND FORMATION, AND, METHOD FOR MONITORING A PREVENTIVE ERUPTION CONTROLLER. The present description relates to a monitor for a wellbore blowout preventive controller. The blowout preventive controller includes a housing, rams and an actuator comprising a cylinder with a piston. The piston is operatively connectable with the ram movable therewith. The monitor includes a monitor base operably attachable to the cylinder (the monitor base having an inside side of the cylinder and an outside side outside the cylinder), an interior plate positionable inside the cylinder on the inside side of the base (the inner plate operatively connectable to the piston and movable therewith), an outer plate that can be positioned outside the cylinder on the outer surface of the monitor base (outer plate attached by magnets to the inner plate and rotatable therewith), and a sensor operably connectable trigger on the monitor base and the outer plate for detecting the rotation thereof whereby a ram position (...).

Description

FUNDAMENTALS

[001] The present description generally refers to techniques for performing wellsite operations. More specifically, the present disclosure relates to techniques, such as blowout preventative controllers (BOPs), plugs and/or ram blocks, for sealing well holes.

[002] Oil field operations can be undertaken to locate and gather valuable downhole fluids. Oil rigs are positioned in the wells and downhole tools, such as drilling tools, are positioned deep into the ground to reach subsurface reservoirs. Once the downhole tools form a wellbore to reach a desired reservoir, casing tubes can be cemented into position within the wellbore and the wellbore completed to begin producing fluids from the reservoir. Piping or tubes can be positioned in the well to allow passage of subsurface fluids to the surface.

[003] Leakage of subsurface fluids can present a significant environmental threat if the fluid is released from the well. Equipment such as blowout preventive controllers (BOPs) can be positioned around the wellbore to form a seal around the pipes there to prevent fluid leakage as it is brought to the surface. In some cases, BOPs employ rams and/or ram blocks that seal off the wellbore. Some examples of BOPs and/or ram blocks are provided in the U.S. Patent Application. Us. 4647001, 6173770, 5025708, 7051989, 5575452, 6374925, 2008/0265188, 5735502, 5897094, 7234530, 8544538, 8136247, 2010/0265126 and 023926. The location of the ram and/or ram block of a BOP can be visually measured by looking at the propeller axis of the ram blocks. Ram position sensors may be provided as described, for example, in US Application/Patent No. 2008/0197306, 4922423, 5320325, 5407172 and 7274989.

SUMMARY

[004] In at least one aspect, the description refers to a monitor for a wellbore explosion preventive controller. The blowout preventive controller includes a housing, at least one ram slidably positionable in the housing to form a seal around the wellbore, and a driver. The actuator comprises a cylinder with a piston slidably movable therein. The piston is operatively connectable with the ram and movable with it. The monitor includes a monitor base operably attachable to the cylinder (the monitor base having an inner side inside the cylinder and an outer side outside the cylinder), an inner plate positionable inside the cylinder, around the inner side of the base (the operatively connectable to the piston and movable with it), an outer plate positionable outside the cylinder around the external surface of the monitor base (the outer part coupled by magnets to the inner plate and rotatable with it) and an operably connectable trip sensor on around the monitor base and the outer plate to detect its rotation, whereby the ram position can be determined.

[005] The monitor may include a cable operatively connecting the inner plate to the piston. The inner plate may include a pulley wheel, with the cable available around the pulley wheel. The inner plate may include a cover with a hole to pass the cable through and/or rotating spring. The monitor base may have an internal cavity to receive the inner plate and may have a shaft operably connectable to the inner plate. The trigger sensor may include a sensor base and a trigger, the sensor base may be operatively connectable to the monitor base and have a rod extending into the outer plate, and the trigger may be positionable around the outer plate to deflect the rod to an offset position, detectable by the sensing base when the outer plate rotates, whereby the ram position can be determined.

[006] The outer plate may have an actuator cavity to receive the actuator, the actuator may include a spring and a plunger, as a plunger propelled by the spring against the rod, the actuator sensor may include an actuator positionable on the outer plate and having a hole through it to receive the rod, with the trigger attachable with the bracket to deflect the rod, and/or the sensor base can be fixedly positioned in a sensor receptacle of the monitor base with the rod extending and flexing it. if from the sensor base. The stem tip of the stem can extend from the sensor base into the actuator cavity and the stem tip can be movable within the actuator cavity when the inner plate is rotated.

[007] The trigger sensor may include a sensor base, operably connectable to the monitor base and having a stem extending into the outer plate, to detect keys along its periphery. Keys may include teeth and/or black and white parts. The outer plate may include the base plate and the ring and a rotating disc operably connectable to the base plate and movable therewith. The outer plate can be rotated via the magnets with the inner plate and the outer wall can have a rotating disk with the inner plate. The trigger sensor may include a strain gauge. The magnets may include internal magnets, operatively connectable between the internal board and the monitor base. The magnets may include external magnets, operatively connectable between the external board and the monitor base. The monitor base may include an end cylinder cap. The monitor may also include at least one seal and/or an accelerometer.

[008] In yet another aspect, the description refers to a monitoring system for a wellbore penetrating an underground formation. The system includes a blowout preventer, positionable around the wellbore and a monitor operatively connectable to the blowout preventer. The blowout preventive controller includes an enclosure, at least one ram slidably positionable in the enclosure to form a seal around the wellbore, and an actuator comprising cylinders with slidably movable pistons therein. The piston is operatively connectable with the at least one ram and movable therewith. The monitor includes a monitor base, an internal board, an external board and a trigger sensor. The monitor base is operatively connectable to the cylinder and has an inside side inside the cylinder and an outside side outside the cylinder. The inner plate is positioned inside the cylinder, around the inner side of the base, and is operatively connectable to and movable with the piston. The outer plate is positioned outside the cylinder, around the outer surface of the monitor base, and is magnet-coupled to the inner plate and is movable with it. The trigger sensor is operably connectable to the monitor base and has a rod positionable around the outer plate to detect its rotation, whereby the ram position can be determined. The system may include an inspector and/or controller operably connectable to the trigger sensor. The inspector can be a remote operated vehicle and/or an operator.

[009] In yet another aspect, the description relates to a method of monitoring a wellbore blowout preventive controller penetrating an underground formation. The blowout preventive controller includes an enclosure, at least one ram slidably positionable in the enclosure to form a seal around the wellbore, and an actuator comprising cylinders with slidably movable pistons therein. The piston is operatively connectable with at least one ram and movable therewith. The method involves operatively connecting a monitor including a monitor base, an inner plate, an outer plate and a trigger sensor to the blowout preventive controller, operatively connecting the monitor base to the cylinder, an inner plate around an inner surface of the monitor base, and an outer plate around the outer surface of the monitor base. The method further involves rotating the inner plate with the rams via a cable, rotating the outer plate with the inner plate via the magnets, and determining the position of the rams by reading the rotation of the outer plate with the trigger sensor.

[0010] The method may also include collecting trigger sensor data, passing trigger sensor data to a surface unit, and/or adjusting the flare preventive controller based on the determination. The trigger sensor may include a sensor base positionable on the monitor base and a rod extending from the sensor base into the outer plate, and the determination may involve detecting the position of the outer plate by deflecting the rod and measuring the position of the rod. with the sensor base during rotation. The trigger sensor may include a sensing base, positionable on the monitor base, and a rod extending from the sensing base into the outer plate, and the determination may involve detecting the position of the outer plate by detecting keys along the periphery of the outer plate. with the trigger sensor.

[0011] In another aspect, the invention relates to a blowout preventive controller for sealing a borehole tubular. The well hole penetrates the underground formation. The blowout preventer has an enclosure having a hole therethrough for receiving the tubular, at least one ram slidably positionable in the enclosure (each ram having a ram block for sealing engagement around the tubular), a driver for selectively actuating the ram block (the driver having a piston slidably positionable in a cylinder) and a monitor for detecting the piston therein. The monitor includes a visual indicator on the outside of the cylinder. The visual indicator is operatively coupled to the piston to display a position of the piston as the piston moves within the cylinder, whereby the position to the ram can be determined.

[0012] The visual indicator may have a cable operatively connected to the piston. The cable may be operatively connectable to a rotating disc via a pulley and rotating therethrough as the piston moves within the cylinder. The visual indicator may also have at least one gear for operatively coupling the pulley to the rotating disc. The visual indicator may have a magnetic coupler to couple the rotating disc to the pulley. The visual indicator may have an integral housing with the cylinder. The visual indicator may also have a plurality of beacons positioned on a beacon rod. The plurality of flags can be selectively raised when the piston passes adjacent to them. The visual indicator may have a magnet slidably positionable in a guide, in response to a magnet over the piston passing adjacent to it. The visual indicator may have a transparent housing, with a plurality of metal filings, movably positionable therein, in response to a magnet over the piston passing adjacent thereto. The visual indicator may have a transparent housing with a movably positionable magnetic indicator therein, in response to a magnet over the piston passing adjacent to it. The eruption preventive controller may also have a visual sensor to detect the visual indicator.

[0013] The blowout preventive controller may also have an electrical indicator to detect a piston position. The electrical indicator may have a slidably positionable magnet on a guide, in response to a magnet over the piston passing adjacent to it, and at least one Hall effect sensor, to detect the position of the magnet on the guide. The electrical indicator may be an inductive resistance sensor, comprising a coil arranged around the cylinder. The electrical indicator may have a top end ultrasonic sensor at the top end of the cylinder and a bottom end ultrasonic sensor at the bottom end of the cylinder to detect the piston when adjacent to it. The electrical indicator may have an ultrasonic limit sensor. The electrical indicator can be a laser sensor. The electrical indicator may have a capacitive displacement sensor. The electrical indicator can be a sonar sensor, to emit sonar waves and sense the waves bounced off the piston. The electrical indicator may have at least one proximity sensor. The electrical gauge may have a flow sensor to detect the flow of fluid through the cylinder chamber as the piston passes there.

[0014] In yet another aspect, the invention relates to a system for sealing a borehole tubular. The system has an eruption preventive controller and an inspector to inspect the visual indicator. The blowout preventer has an enclosure having a hole therethrough, for receiving the tubular, at least one ram slidably positionable in the enclosure (each ram having a ram block for sealing meshing around the tubular), a driver for selectively driving the ram block (the driver having a piston slidably positionable in a cylinder) and a monitor for detecting the piston therein. The monitor includes a visual indicator on the outside of the cylinder. The visual indicator is operatively coupled to the piston to display the position of the piston as the piston moves within the cylinder, whereby the ram position can be determined.

[0015] The blowout preventer has an enclosure having a hole through it, to receive the tubular, at least one ram slidably positionable in the enclosure (each ram having a ram block to seal the meshing around the tubular ), a driver for selectively driving the ram block (the driver having a piston slidably positionable in a cylinder) and a monitor for detecting the piston therein. The monitor includes a visual indicator on the outside of the cylinder. The visual indicator is operatively coupled to the piston to display the position of the piston as it travels within the cylinder, whereby the ram position can be determined.

[0016] The inspector can be a human or a remote operated vehicle (ROV). The system may also have a surface unit for receiving data from the monitor, an electrical indicator for sensing the position of the piston, a receiver for transmitting signals with the electrical indicator, and/or at least one sensor for sensing the well parameters.

[0017] In yet another aspect, the invention relates to a method of monitoring a flare preventive controller. The method involves positioning the blowout preventer around a tubular, activating at least one of the monitor's visual indicators when the piston passes adjacent to it, and inspecting the visual indicators. The blowout preventer has an enclosure having a hole therethrough, for receiving the tubular, at least one ram slidably positionable in the enclosure (each ram having a ram block for sealing meshing around the tubular), a driver for selectively driving the ram block (the driver having a piston slidably positionable in the cylinder) and a monitor for detecting the piston therein. The monitor includes a visual indicator on the outside of the cylinder. The visual indicator is operatively coupled to the piston for displaying the position of the piston as it moves within the cylinder, whereby the position of the ram can be determined. The method may also involve reading the piston position with an electrical indicator, manually viewing the visual indicators, reading the visual indicator for activation and/or passing data from the monitor to the surface unit.

[0018] Finally, in yet another aspect, the invention relates to a blowout preventative controller for sealing the wellbore. The blowout preventive controller includes an enclosure having a hole therethrough for receiving the tubular, at least one ram slidably positionable in the enclosure (each of the at least one ram having a ram block for sealing engagement around the tubular) , an actuator for selectively actuating the ram block (the actuator comprising a piston slidably positionable in a cylinder) and a monitor for detecting the piston. The monitor has an enclosure with a cable in it. The cable is operatively connectable to the piston and movable with it to activate the visual indicator on the outside of the enclosure, whereby the ram position can be displayed.

[0019] The monitor may also have an operably connected sensor to detect cable movement and/or a communication link to pass data from the sensor to the surface unit. The visual indicator may have a rotating disk rotationally movable by the handle. The monitor may also have a magnetic coupler within the enclosure for attaching the cable to the rotating disk. The monitor also has at least one gear operatively coupling the cable to the rotating disk. The monitor may also have at least one pulley. The enclosure can be integral with the cylinder.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The drawings illustrate exemplary embodiments of this description and are therefore not to be considered limiting its scope, as the description may admit of other equally effective embodiments. Figures are not necessarily to scale and certain details and certain views of figures may be shown exaggerated to scale or schematically in the interest of clarity and brevity.

[0021] Figure 1 shows a schematic view of a well away from the coast, having a blowout preventive controller (BOP) to seal a tubular.

[0022] Figure 2 shows a schematic perspective view of the BOP of Figure 1.

[0023] Fig. 3 shows a schematic side view of the BOP of Figure 2, having one or more actuator(s) and a BOP monitoring system.

[0024] Figs. 4A - 4N show schematic cross-sectional views of various versions of a part of an actuator and a monitoring system operatively connected thereto.

[0025] Figs. 5A - 5D show schematic cross-sectional views of additional versions of an actuator and a monitoring system operatively connected to it.

[0026] Fig. 6 represents a method of monitoring a BOP.

[0027] Fig. 7 represents a schematic view of a BOP with triggers and a BOP monitor.

[0028] Fig. 8 is a schematic view of a part of the BOP depicting a BOP monitor therein, the BOP monitor including a monitor base, inner and outer plates, and a trigger sensor.

[0029] Fig. 9A is a schematic diagram depicting the trigger sensor of the BOP monitoring system. Fig. 9B is a schematic diagram depicting the operation of the trigger sensor at various angles.

[0030] Figures 10A and 10B show outer end and inner end views, respectively, of a BOP monitor. Fig. 10C shows a partial cross-sectional view of the BOP monitor.

[0031] Figures 11A - 11C show partial cross-section, external exploded and internal exploded views, respectively, of a BOP monitor. Figure 11D shows an exploded view of an alternate version of the BOP monitor.

[0032] Figures 12A1 and 12A2 are schematic views of a BOP monitor in an initial position. Figures 12B1 and 12B2 are schematic views of the BOP monitor in a rotated position.

[0033] Figure 13A is a cross-sectional view of the BOP monitor of Figure 12A1, taken along line 13A - 13B. Figure 13B is a cross-sectional view of the BOP monitor of Figure 12A2, taken along line 13B - 13B.

[0034] Figure 14 is a flow diagram depicting a method of monitoring a BOP.

DETAILED DESCRIPTION OF THE INVENTION

[0035] The description that follows includes exemplary apparatus, methods, techniques and/or instructional sequences, which embody techniques of the present subject. However, it is understood that the described modalities can be practiced without these specific details.

[0036] The invention is directed to techniques to provide monitoring and/or measurement of the operation of the blowout preventive controller (BOP). The BOP may be provided with a monitor to detect, for example, the position (or location) of a ram of the BOP. These techniques can be used to provide monitoring, such as visual or electrical monitoring, of the BOP (eg from the surface), such as when the BOP is in use on the seabed. Such monitoring techniques involve one or more of the following, but are not limited to: determining the function of the BOP, determining the ram position, determining the sealed position, constantly monitoring the ram position within the BOP, adaptability to well equipment (e.g. various tube diameters).

[0037] Blowout preventive controllers (BOPs) may include an enclosure positioned around a wellbore to receive a pipeline through it and to provide a seal around it, for example, during a blowout. The BOP also has movably shaped rams positioned in the enclosure to fit into the tubular and/or form a seal around the wellbore. A BOP monitor can be provided around the BOP to detect the movement of the rams and determine their position. The BOP monitor may include a monitor base available inside the cylinder, an inner plate cabled to the ram, an outer plate magnetically coupled to the inner plate, and sensors (e.g. strain gauges) to detect the rotation of the BOPs. plates and, therefore, displacement and position of the rams.

PREVENTIVE ERUPTION CONTROLLER

[0038] Figure 1 depicts an offshore well 100 having a sealing unit 102 configured to seal a wellbore 105 extending into a seabed 107. As shown, the sealing unit 102 is positioned on a blowout preventive controller (BOP), which is part of a subsea system 106 positioned on the seabed 107. The subsea system 106 may also comprise a tube (or tubular) 104 extending from the wellbore 105, a wellhead 110 and around the wellbore 105, a conduit 112 extending from the wellbore 105, and other subsea devices such as an extractor and a transport supply system (not shown). BOP 108 can have a BOP monitoring system (or BOP monitor) 103, to monitor the operation of BOP 108. Although well 100 is represented as a subsea operation, we note that well 100 can be either land-based or water-based. and the sealing unit 102 can be used in any well environment.

[0039] A surface system may be used to facilitate operations at the offshore well 100. The surface system 120 may include a rig 122, a platform 124 (or ship) and a surface controller 126. In addition, it may there may be one or more subsea controllers 128. Although surface controller 126 is shown as part of surface system 120 at a surface location and subsea controller 128 is shown as part of subsea system 106 at a subsea location, we observe that one or more more controllers can be located at various locations to control surface and/or subsea systems.

[0040] To operate one or more sealing units 102 and monitor the BOP monitoring system 103 and/or other devices associated with the well 100, the surface controller 126 and/or the subsea controller 128 can be brought into communication with them. . Surface controller 126, subsea controller 128 and/or any devices in the well 100 may communicate via one or more communication links 134. Communication links 134 may be any suitable means of communication, such as hydraulic lines, pneumatics, wiring, fiber optics, telemetry, acoustics, wireless communication, any combination thereof, etc. The sealing unit 102, the BOP monitoring system 103, the BOP 108 and/or other well devices 100 may be automatic, manual and/or selectively operated via the surface and subsea controllers 126 and/or 128, respectively.

[0041] A remote operated vehicle (ROV) 121 may optionally be provided to travel below the surface and inspect the BOP monitoring system 103. The ROV 121 may be provided with a camera 135 to display images from the BOP monitoring system 103 and/or electrical communicators (eg, communication link 134) to couple to the monitoring system BOP 103. The ROV 121 can be in communication with the surface unit 126 and/or BOP 108, via a link of communication 136. In some cases, a diver or other inspector may be used to visually inspect the BOP 103 monitoring system.

[0042] Figure 2 shows a schematic view of a BOP 108 that can be used like the BOP 108 of Figure 1. The BOP 108 is schematically represented as a cuboidal-shaped device, having a hole (or channel) 220 through it, to receive the tube 104. The BOP 108 is also provided with a channel 222 therethrough to receive the sealing unit 102. Although the BOP 108 is represented as having a specific configuration, we note that the BOP 108 can have a variety of shapes. and be provided with other devices, such as sensors (not shown). An example of a BOP that can be used is described in US Patent No. 5735502, the entire contents of which are hereby incorporated by reference.

[0043] The sealing unit 102 comprises one or more rams 202 for sealing the BOP 108. The rams 202 can be any device for sealing the interior of the BOP 108 and/or cutting the tube 104. For example, rams, ram blocks and/or cutting blades. On driving the rams 202 of the sealing unit 102, the rams 202 can move along the channel 222 towards the tube 104. The sealing unit 102 can seal the tube 104 within the BOP 108, thereby preventing fluids, such as wellbore fluids and/or seawater, pass through the BOP 108. In addition, the sealing unit 102 can cut the pipe 104 if the sealing unit 102 has cutting blades.

[0044] Figure 3 shows a schematic side view of the BOP 108 of Figure 2 having a driver 300 coupled to each of the rams 202. The driver 300 may be configured to move the rams 202 between a non-actuated position, where the rams 202 are not meshed with tube 104, and a driven position (as shown in Figure 3), in which rams 202 are meshed with tube 104. In the non-actuated position, tube 104 can move through the BOP 108 and into and out of the wellbore 105 (see, for example, Figure 1). In the driven position, the tube 104 and/or the central hole 220 of the BOP 108 can be sealed around the tube 104 by the rams 202.

[0045] Actuator 300, as shown, is a hydraulic actuator configured to move a piston 304 within a cylinder 306, employing hydraulic fluid supplied by actuator 300. Cylinder 306 has a side 307, a head 309 and a rear 311 The piston 304 is slidably movable within the cylinder 306 by, for example, hydraulic pressure selectively supplied to it. Piston 304 may couple to a rod 308 (or ram shaft), which is configured to move the rams 202 as the pistons move. While driver 300 is shown as a hydraulic, cylindrical piston, driver 300 can be any driver suitable for moving rams 202 between the driven and non-driven positions.

[0046] When the piston 304 moves within the cylinder 306, the BOP monitoring system 103 can monitor the location of the piston 304. With the location of the piston 304 determined, the location of the rams 204 within the BOP can be determined. The data collected by the BOP 103 monitoring system can be sent, via the communication links 134, to the surface and subsea controller(s) 126/128, in order, for example, to determine how the BOP 108 is doing. operating. The BOP monitoring system 103 may be any system suitable for determining the location of pistons 304, rods 308 and/or rams 202 within the BOP 108. Monitoring system 103 may also be capable of determining other borehole parameters. BOP 108 well, its components and/or associated wellbore conditions.

ERUPTION PREVENTIVE CONTROLLER MONITORING SYSTEMS

[0047] Figures 4A-4N represent cross-sectional views of a part of the 300a-m driver, having various versions of a 103a-m monitoring system, usable as the 300 driver and 103 BOP monitoring system of Figure 3. As shown in each of these figures, the piston 304 is slidably movable within the cylinder 306. Each of the monitoring systems 103a-m is positionable around the cylinder 306 and has devices for detecting the position of the piston 304 therein. Each piston 304 is operatively connectable to a ram 202 (see Figures 2 and 3) and therefore a position of the rams 202 (and/or its components) can also be determined. A visual indicator sensor S can optionally be positioned around monitoring systems to detect activation, position or other well parameters and/or components, such as the 103a-m monitoring system.

[0048] Figure 4A depicts a driver 300a with a BOP monitoring system 103a as an inductive resistance sensor 400. The inductive resistance sensor 400 may have one or more coils 402, which wrap around the outside of the side. 307 of cylinder 306. A current can be supplied to coils 402 and resistance in the coils can be measured during operation of driver(s) 300a.

[0049] The piston 304 moves within the cylinder 306 between the cylinder head 309 and the cylinder back 311 of the BOP 108. The resistance of the coils 402 changes as a function of the location of the piston 304. The coils 402 can individually change when the piston 304 passes through them, thus indicating that the piston 304 is adjacent to a certain coil 402. The changes in resistance can be used to determine the location of the piston 304 and the rod 308. Thus, the location of the rams 202 (as shown in Figure 3) can also be determined. The inductance of the coils may be measured and received by the ROV 121 and/or the surface unit 126 (Figure 1) to provide an electrical indication of the location of piston 304 and ram 202. Sensor S may be provided to pass signals from the coils 402 to a receiver positioned around the well 100. A visual indicator, such as those provided herein, may also optionally be coupled to the monitoring system 103a to provide a visual indication of position on activation by the monitoring system 103a.

[0050] Figure 4B depicts a driver 300b with a BOP monitoring system 103b as a magnetic beacon sensor 410. The magnetic beacon sensor 410 may have one or more magnetic beacons 412 located on the outside of a side 307 of cylinder 306. Each of the magnetic beacons 412 may be attached to the cylinder 306 on an axis 414, which allows the magnetic beacon 412 to rotate around it in response to a piston magnet 416 passing in the vicinity. Each magnetic beacon 412 can be magnetic or have a magnet on it. Each magnetic beacon 412 may be in a downward position gravitationally, and rise as the piston magnet 416 passes therethrough.

[0051] Piston magnet 416 can be any magnet attached to or near piston 304. When piston 304 moves within cylinder 306, between cylinder rear 311 and cylinder head 309, piston magnet 416 lifts magnet flags 412 near piston 304. Raised magnet flags 412 can be used to provide a visual indication of the location of piston 304 and rod 308. Thus, the location of rams 202 (as shown in Figure 3) can also be be indicated. Sensor S may also be operatively coupled to one or more beacons, to provide an electrical and/or visual indication of the activation of a given beacon. Sensor S can pass the signal to various components to communicate the position of piston 304.

[0052] Figure 4C depicts an actuator 300c with a BOP monitoring system 103c as a sliding magnetic sensor 418. The sliding magnetic sensor 418 may have one or more sliding magnets 420 attached to a guide rod 422 located on the outside of the side 307 of cylinder 306. Each of slide magnets 420 may be attached to guide rod 422 in a manner that allows slide magnet 420 to translate along guide rod 422 in response to movement of piston magnet 416.

[0053] As the piston 304 moves within the cylinder 306, between the rear of the cylinder 311 and the cylinder head 309, the piston 304, with a magnet 416 on it, translates the sliding magnet 420 close to the piston 304. The location of the slide magnet 420 may provide a visual indicator of the piston 304. Limit switches or other devices, such as an S sensor, may also be used to sense and/or transmit the position of the slide magnet 420 along the guide rod 422. The location of slide magnet 420 can be used to determine the location of piston 304 and rod 308. Thus, the location of rams 202 (as shown in Figure 3) can also be determined.

[0054] Figure 4D represents an actuator 300d and a BOP monitoring system 103d as an ultrasonic sensor 424. The ultrasonic sensor 424 may have one or more ultrasonic inductors 426 located around the outer side of side 307 of cylinder 306. Each one of the ultrasonic inductors 426 produces ultrasonic waves 428, which are directed into the cylinder 306 and then detected by the receiver 429. As shown, the receiver 429 is positioned on the BOP 108.

[0055] Changes in ultrasonic waves 428 may indicate the location of piston 304 near one or more of the ultrasonic inductors 426. When piston 304 moves within cylinder 306, between cylinder back 311 and cylinder head 309, the changes detected in the ultrasonic waves 428 can be used to determine the location of piston 304 and rod 308. Thus, the location of rams 202 (as shown in Figure 3) can also be determined. The ultrasonic waves detected by receiver 429 may be passed to ROV 121 and/or surface unit 126 (Figure 1) to provide an indication of the location of piston 304 and ram 202. Sensor S may also be operably coupled to one or more ultrasonic inductors 426, to provide an electrical and/or visual indication of activation of a given ultrasonic inductor. Sensor S may pass the signal to various components, such as receiver 429, to communicate the position of piston 304. A visual indicator, such as those provided here, may also optionally be coupled to monitoring system 103d, to provide an Visual indication of position on activation by 103d monitoring system.

[0056] Figure 4E represents a trigger 300e and a BOP monitoring system 103e as a 430 ultrasonic limit sensor. The 430 ultrasonic limit sensor can have two ultrasonic inductors 426, 427, each located close to a travel limit of the piston 304 within the cylinder 306. For example, one of the ultrasonic inductors 426 may be located near the rear of the cylinder 311 and the second ultrasonic inductor 427 may be located adjacent to the side 307 of the cylinder 306. The second ultrasonic inductor 427 on the side 307 may be located near the limit of travel adjacent to cylinder head 309 of piston 304.

[0057] Each of the ultrasonic inductors 426, 427 produces the ultrasonic waves 428, which are directed into the cylinder 306 and then detected by a receiver 429. Changes in the ultrasonic waves 428 may indicate the location of the piston 304 near the ultrasonic inductor. 426, 427. As piston 304 travels within cylinder 306, between the rear of cylinder 311 and cylinder head 309, the detected changes in the ultrasonic waves 428 indicate when piston 304 reaches travel limits in the non-actuated position. or in the activated position. Therefore, the detected changes in the ultrasonic waves 428 can be used to determine the position of the piston 304 and the rod 308. Thus, the location of the rams 204 (as shown in Figure 3) can also be determined. The ultrasonic waves detected by receiver 429 may be passed to ROV 121 and/or surface unit 126 (Figure 1) to provide an indication of the location of piston 304 and ram 202. Sensor S may also be operatively coupled to a or more ultrasonic inductors 426, 427, to provide an electrical and/or visual indication of activation of a given ultrasonic inductor. Sensor S may pass the signal to various components, such as receiver 429, to communicate the position of piston 304. A visual indicator, such as those provided herein, may also optionally be coupled to monitoring system 103e, to provide a visual indicator. position on activation by monitoring system 103e.

[0058] Figure 4F represents a driver 300f and a BOP monitoring system 103f as a laser sensor 432. The laser sensor 432 may have one or more laser inductors 434 located near the end of the driver 300f. As shown, laser inductors 434 are located near the rear of cylinder 311. Laser inductor 434 can direct a laser 436 through an opening 438 of cylinder 306.

[0059] Laser 436 may fit a portion of piston 304. Laser 436 may have conventional range finding capabilities, which can be used to determine the distance between cylinder rear 311 and piston 304 as piston moves inside the cylinder 306. The location of piston 304, as determined by laser sensor 432, can be used to determine the location of piston 304 and rod 308. Thus, the location of rams 202 (as shown in Figure 3) can also be be determined. The location detected by laser sensor 432 may be passed to ROV 121 and/or surface unit 126 (Figure 1) to provide an indication of the location of piston 304 and ram 202. Sensor S may also be operably coupled to the monitoring system 103f to provide an electrical and/or visual indication of the position detected by laser 436. Sensor S may pass the signal to various components to communicate the position of piston 304. A visual indicator, such as those provided herein, may also optionally be coupled to monitoring system 103f, to provide a visual indication of position on activation by monitoring system 103f.

[0060] Figure 4G represents a trigger 300g and a BOP monitoring system 103g as a linear magnetic sensor 440. The linear magnetic sensor 440 may have a sensing magnet 442 attached to the rear of cylinder 311. The sensing magnet 442 may couple to a linear sensor 444, which is placed into the cylinder 306 through an opening 438 of the cylinder rear 311. The linear sensor 444 can detect the movement of a piston magnet 416 as the piston 304 moves. As shown, piston 304 may have a cavity 446 to allow piston 304 to pass linear sensor 444 without engaging linear sensor 444.

[0061] When the piston 304 moves within the cylinder 306, between the cylinder back 311 and the cylinder head 309, the linear sensor 444 detects the location of the piston magnet 416. The location of the piston magnet 416 can be used to determine the location of piston 304 and rod 308. Thus, the location of rams 202 (as shown in Figure 3) can also be determined. The location detected by linear sensor 444 may be passed to ROV 121 and/or surface unit 126 (Figure 1) to provide an indication of the location of piston 304 and ram 202. Sensor S may also be operably coupled to the system. sensor 103g, to provide an electrical and/or visual indication of the position detected by linear sensor 444. Sensor S may pass the signal to various components to communicate the position of piston 304. A visual indicator, such as those provided herein, it may also, optionally, be coupled to the monitoring system 103g, to provide a visual indication of the position on activation by the monitoring system 103g.

[0062] Figure 4H represents a trigger 300h and a BOP 103h monitoring system as a Hall Effect sensor. The Hall Effect sensor 448 may have one or more sliding magnets 420 attached to the guide rod 422 located on the outside of the side 307 of the cylinder 306. Each of the sliding magnets 420 may be attached to the guide rod 422 in a manner that permits that slide magnet 420 translates along guide rod 422 in response to movement of piston magnet 416 over piston 304. As piston 304 moves within cylinder 306, between cylinder rear 311 and cylinder head 309 , piston magnet 416 translates sliding magnet 420 close to piston 304.

[0063] Proximity sensors 421 can be positioned on either side of the slide magnet 420 to detect the position of the slide magnet. The magnet 420 can be detected by the proximity sensors 421 as the magnet approaches, thereby indicating the position of the piston 304. Therefore, the Hall Effect sensor 448 can provide a specific electrical and/or visual indication of the piston 304 and the position or location of rod 308. Thus, the location of rams 202 (as shown in Figure 3) can also be determined. The location detected by Hall Effect sensor 448 can be passed to ROV 121 and/or surface unit 126 (Figure 1), to provide an indication of the location of piston 304 and ram 202. Sensor S can also be operatively coupled to monitoring system 103h, to provide an electrical and/or visual indication of position detected by proximity sensor 421. Sensor S may pass the signal to various components to communicate a position of Hall Effect sensor 448.

[0064] Figure 41 represents a 300i trigger and a 103i BOP monitoring system as a magnetic motion sensor. Magnetic motion sensor 450 may have one or more magnetic indicators (or filings) 452 located within a transparent housing 454. Transparent housing 454 may be, for example, a tube located on the outside of side 307 of cylinder 306. Each one of the magnetic indicators 452 may be secured within the transparent housing 454, proximate the cylinder 306, in a manner that allows the magnetic indicator 452 to translate within the transparent housing 454 in response to the movement of the piston magnet 416. As shown in Figure 41, magnetic indicator 452 is a plurality of magnetic fragments. However, the magnetic indicator 452 can be any suitable indicator, such as one or more magnetic ball(s) (as shown in Figure 4J).

[0065] Transparent housing 454 may be of any suitable shape to allow magnetic indicator 452 to move. The magnetic housing 454 may be transparent to allow visual inspection of the location of the magnetic indicator 452 as the magnetic indicator 452 travels within the transparent housing 454. The magnetic indicator 452 may be used to provide a visual indication of the location of the piston 304 and of the rod 308. As the piston 304 moves within the cylinder 306, between the cylinder rear 311 and the cylinder head 309, a piston magnet 416 of the piston 304 translates the magnetic indicator 452 through the transparent housing 454 to a position proximate of the piston 304. The location of the magnetic indicator 452 can be used to determine the location of the piston 304 and the rod 308. Thus, the location of the rams 202 (as shown in Figure 3) can also be determined. Sensor S may also be operatively coupled to monitoring system 103i to provide an electrical and/or visual indication of position detected by magnetic indicator 452. Sensor S may pass the signal to various components to communicate the position of piston 304.

[0066] Figure 4J represents an actuator 300j with a BOP monitoring system 103j as another magnetic motion sensor 453. Monitoring system 103j is similar to monitoring system 103i, except that the transparent housing 454, as shown in Figure 4J, can be a clear channel (or tube) to receive the magnetic indicator 453 and allow it to translate there. The magnetic sensor 453 can be, for example, a ball that rolls through the transparent groove as the piston moves within the cylinder 306.

[0067] When piston 304 moves within cylinder 306, between cylinder head 309 and rear 311 of BOP 108, piston magnet 416 translates magnetic indicator 453 near piston 304. The location of magnetic indicator 453 within of the clear tube can be used to provide a visual indication of the location of piston 304 and rod 308. Thus, the location of rams 202 (as shown in Figure 3) can also be determined. The location of magnetic indicator 453 can be used to determine the location of piston 304 and rod 308. Thus, the location of rams 202 (as shown in Figure 3) can also be determined. Sensor S may also be operatively coupled to monitoring system 103j to provide an electrical and/or visual indication of position detected by magnetic indicator 453. Sensor S may pass the signal to various components to communicate the position of piston 304.

[0068] Figures 4K-4N represent various configurations of a 103k,l,l' pulley monitor. Figures 4K-4M represent longitudinal cross-sectional views of an actuator 300k,1,1' and Figure 4N represents an end view thereof. Figure 4K represents a 300k drive and a 103k BOP monitoring system as a 456 gear drive sensor. The 456 gear drive sensor may have a 458 gear drive enclosure coupled to the rear of cylinder 311. Gear drive 458 may have a cable (or flexible member) 460 which is placed in cylinder 306 through an opening 438 therein. Cable 460 may couple with piston 304 and travel with it as piston 304 moves within cylinder 306. A pulley 469 may be provided to drive gears 462 when cable 460 moves with piston 304.

[0069] When the piston 304 moves from the non-actuated position to the actuated position, the cable 460 can be pulled by the piston 304. The movement of the cable 460 can rotate one or more gears 462, located within the gear drive enclosure. 458. One of gears 462 can couple with and/or rotate a first portion of a magnetic coupler 464 located within gear drive enclosure 458. The first portion of magnetic coupler 464 can magnetically couple with a second portion of the gear. magnetic coupler 466, located outside the gear drive enclosure 458.

[0070] The rotation of the second part of the magnetic coupler 466 can be measured and used to determine the location of the piston 304 as it travels within the cylinder 306. An indicator arrow 467 can be positioned on the magnetic coupler 466 and rotated therewith. The position of the indicator arrow 467 can be used as an electrical and/or visual indicator to indicate the position of the piston 304. As shown in Figure 4N, the indicator arrow can rotate to a position along the second part of the magnetic coupler 466. A rotational position of the indicator arrow 467 can correlate with the position of the piston within the cylinder 306.

[0071] Gears 462 may be spring-wound in order to retract the cable when the piston 304 moves from the driven position to the non-driven position. The location of piston 304, as visually indicated by indicator arrow 467, can be used to determine the location of piston 304 and rod 308. Thus, the location of rams 202 (as shown in Figure 3) can also be determined.

[0072] Figure 4L represents drive 3001 as a monitoring system of BOP 1031 as a pulley drive. In system 1031, as shown in Figure 4L, cable 460 wraps around a first pulley 469 and a second pulley 468 within pulley housing 458. Thus, as piston 304 moves within cylinder 306, pulley 468 is rotated. The pulley 468 can couple with the first part of the magnetic coupler 464 located inside the pulley housing 458. .

[0073] The rotation of the second part of the magnetic coupler 466 can be measured and used to determine the location of the piston 304 and the rod 308 as they move within the cylinder 306 in a manner similar to that described in Figure 4K. As also described with respect to Figure 4K, the indicator arrow 467 can be used to provide an electrical or visual indication of the piston 304. Thus, the location of the rams 202 (as shown in Figure 3) can also be determined.

[0074] Figure 4M represents a 3001' drive with a 1031' BOP monitoring system as a pulley drive. Driver 3001' is similar to driver 3001, except that pulley housing 458 and contents are rotated 90 degrees and pulley housing 458 is integral with cylinder 306. As indicated by Figure 4M, the visual indicators (or displays) here they can be positioned in various locations around cylinder 306 for easy viewing. As also indicated by Figure 4M, the visual indicators (or displays) can be positioned integrally with cylinder 306 (or separate, as shown by Figures 4K and 4L).

[0075] The rotation of the second part of the magnetic coupler 466 can be measured and used to determine the location of the piston 304 and the rod 308 as it travels within the cylinder 306 in a manner similar to that described for Figure 4K. As also described with respect to Figure 4K, the indicator arrow 467 can be used to provide a visual indication of the piston 304. Thus, the location of the rams 202 (as shown in Figure 3) can also be determined.

[0076] The movement of arrow 467 may be detected by an S sensor. The S sensor may also be operatively coupled to the 103k-m monitoring system to provide an electrical or visual indication of the position of arrow 467. The S sensor may pass the signal to various components to communicate a position of piston 304.

[0077] Figures 5A-5D represent schematic alternative views, in cross-section of a 300 m-p trigger, having various versions of a 103m-p monitoring system usable as trigger 300 and BOP monitoring system 103 of Figure 3 and representing your operation. As shown in each of these figures, piston 304 is slidably movable within cylinder 306. In these figures, for simplicity, rod 308 is not shown. Monitoring systems 103m-p are positionable around cylinder 306 and have devices to detect the position of piston 304 there. Each piston 304 is operatively connectable to a ram 202 (see Figures 2 and 3) and therefore the position of the rams 202 (and/or their components) can also be determined. In each of these monitoring systems 103m-p, a sensor S may also be operatively coupled to the monitoring system 103m-p to provide an electrical and/or visual indication of the detected position of the piston 304. Sensor S may pass the signal to various components to communicate a position of piston 304. A visual indicator, such as those provided here, may also optionally be coupled to monitoring system 103m-p to provide a visual indication of position in the activation by the monitoring system.

[0078] Figure 5A represents a driver 300m and a BOP monitoring system 103m as a capacitive displacement sensor 506. Capacitive displacement sensor 506 can flow a current 502 into cylinder 306. Current 502 can be sent in. cylinder 306 with one or more source electrodes 504 coupled to the rear of cylinder 311.

[0079] A sensing electrode 506 can detect the current after it has coupled with piston 304. Changes in the current sensed by sensing electrode 506 can be used to determine the distance of piston 304 from the rear of cylinder 311. The location of piston 304 can be used to determine the location of piston 304 (and rod 308, not shown). Thus, the location of the rams 202 (as shown in Figure 3) can also be determined.

[0080] Figure 5B represents a trigger 300n and a BOP monitoring system 103n as a sonar sensor 508. The sonar sensor 508 can produce a sonic wave 510 inside the cylinder 306. The sonic wave 510 can be propagated into the cylinder 306 and reflected off piston 304. The reflected sonic wave 510 can be detected by a receiver 512.

[0081] Changes in the detected sonic wave 510 can be used to determine the distance of piston 304 from the rear of cylinder 311. Piston location 304 can be used to determine the location of piston 304 (and rod 308, not shown). Thus, the location of the rams 202 (as shown in Figure 3) can also be determined.

[0082] Figure 5C represents a trigger 300o and a BOP monitoring system 103o as one or more proximity sensor(s) 514. The proximity sensor(s) 514 can be any detection sensor which determines the location of piston 304 within cylinder 306. For example, proximity sensor 514 can be a mechanical sensor, such as a button or switch, an electrical sensor, such as a strain gauge, a sonar sensor, etc. . Proximity sensor 514 can be coupled, for example, to ROV 121 or surface unit 126.

[0083] Proximity sensor(s) 514 can detect the location of piston 304 when piston 304 is in the triggered and/or non-actuated position. There may also be multiple proximity sensor(s) 514 along the cylinder 306 to provide the location of the piston 304 as the piston 304 translates into the cylinder 306. The location of the piston 304 can be used to determine the location of the piston. 306 (and rod 308, not shown). Thus, the location of the rams 202 (as shown in Figure 3) can also be determined.

[0084] Figure 5D represents a 300p trigger and a 103p BOP monitoring system such as the flow sensor 516. The flow sensor 516 can be, for example, a totalizing mechanical flow meter configured to measure inward flow and/or out of cylinder 306 as piston 304 is extended and retracted. Flow sensor 516 may be coupled to a source of fluid, such as a tank (not shown). Pumps, flow lines or other fluid devices may be provided to assist in manipulating the flow of fluid through the 516 flow sensor.

[0085] With the internal volume of the cylinder known, the hydraulic flow into the cylinder can be used to calculate the position of piston 304 within the cylinder. Alternatively, when piston 304 is retracted to the non-actuated position, the mechanical flow meter may return back to zero instead of measuring outflow. The location of piston 304 can be used to determine the location of piston 304 (and rod 308, not shown). Thus, the location of the rams 202 (as shown in Figure 3) can also be determined.

[0086] Each of the displays 103a-p, shown in Figures 4A-4N, 5A-5D, can be used to indicate the position of piston 304. These displays 103a-p may be coupled via a communication link (e.g. 134 of Figure 1), to the ROV 121 and/or surface unit 126, to pass signals between them. Such signals may contain data that may indicate (or be analyzed to indicate) the position of piston 304. Some of the displays 103a-p may provide visual indicators (e.g., displays 103b-c,i-l), such as the flags 412 of the Figure 4B, magnets 420 of Figures 4C and 4H, magnetic indicators 452, 453 of Figures 41 and 4J, which can be visually inspected by an operator, ROV, camera, or other devices, to determine the position of the piston. Visual indicators may also be provided with visual indicator sensors to electrically indicate the position of the sensors. Some of the monitors 103a-p may provide actuation sensors having electrical indicators (eg, monitors 103a,d-h,m-p) which can send signals to the surface unit indicating the position of the piston. One or more cylinders 306 of a BOP 108 may be provided with one or more of the monitors 103a-p around various locations.

[0087] Figure 6 is a flow diagram depicting a method (600) for monitoring a blowout preventive controller. The method (600) involves positioning (680) the blowout preventive controller around a tubular, activating (682) at least one of the monitor's visual indicators as the piston passes adjacent to it, inspecting (684) the visual indicators, and reading (686) the piston position with an electrical indicator. Inspection may also involve manually viewing the visual indicators and/or reading the visual indicators for activation. The method may also involve additional steps, such as passing data from the monitor to the surface unit. The steps can be performed in an order and repeated as desired. BURST PREVENTIVE CONTROLLER MONITOR WITH ACTIVATION SENSOR

[0088] Figure 7 is another view of the BOP 108. This version includes a BOP housing 701, with multiple rams 202 (Figure 3), with corresponding drivers 300. Each driver 300 includes cylinder 306 with an end cap (or door). ram) 711 removable around one end thereof. One top of the 711 end caps has been replaced with a BOP monitor (or ram position indicator) 703. In some cases, the BOP monitor 108 is a BOP monitoring system or a part of it.

[0089] The BOP monitor 703 can track the movement of a BOP ram 202 passing through the BOP 108, in the same manner shown in Figures 2 and 3. When the ram 202 moves to mesh with the tubular 104, the BOP monitor 703 is activated to monitor your movement and/or to determine your position. The BOP monitor 703 can be used to determine the displacement of the ram 202 and thus its position on the BOP 108.

[0090] Figure 8 shows a portion of BOP 108 representing actuator 300, including piston 304 slidably positionable in cylinder 306. End cap 711 (Figure 7) of cylinder 306 has been removed and replaced by BOP monitor 703. The BOP monitor 703 is detachably positionable around the outer end of the cylinder 306, with a part thereof positioned inside the cylinder 306 and a part positioned outside the cylinder 306.

[0091] The BOP monitor 703 includes a monitor base 851, an inner plate 868, an outer plate 866, and a trigger sensor 857. The monitor base 851 is detachably positioned around the end of the cylinder 306. monitor base 851 may be, for example, of a threaded shape disposed on or secured to cylinder 306. Monitor base 851 can seal cylinder 306 in the same manner as end cap 711 removed therefrom.

[0092] Inner plate 868 may be rotationally coupled along the inner surface of monitor base 851. Inner plate 868 may include a pulley wheel 869 with a cable 360 disposed around its perimeter. Cable 360 can couple piston 304 to inner plate for translational movement therebetween. The movement of piston 304 within cylinder 306 can extend and retract handle 360. As handle 360 extends and retracts, inner plate 868 may rotate with it.

[0093] Because base 851 replaces end cap (ram port) 711, outer plate 866 and inner plate 868 can be connected to base 851 on either side. The outer plate 866 may be disposed outside the end cap (ram port) 711 of the ram cylinder 306 of the BOP 108. The inner plate 868 may be disposed inside the end cap (ram port) 711. The outer plate 866 and internal 868 can rotate about base 851 when ram 202 (Figures 2 or 3) of BOP 108 moves there.

[0094] The outer and inner plates 866, 868 can be positioned on opposite sides of the base 851 and move axially relative to each other for some distance. The outer plate 866 and the inner plate 868 may be axially secured so that they do not move in the axial direction and so that they are free to independently rotate about a centerline axis Z. The outer plate 866 and the inner plate 868 may be, for example, metal plates (e.g. steel), which are circular in shape. However, the outer and inner boards 866, 868 may be shaped differently in other embodiments. The axial centerline Z of the outer plate 866 and the inner plate 868 may be aligned as shown in Figure 8 by the single axial centerline Z.

[0095] The outer plate 866 may be rotationally coupled along the outer surface of the monitor base 851. The magnets 864a-d may be combinatorially positioned around the inner plate 868 and outer plate 866 for magnetic interaction between them. The magnets 864a,c of the outer plate 866 and magnets 864b,d of the inner plate 868 are magnetically attachable through the monitor base 851 to provide magnetic coupling therebetween. The magnetic coupling can be used to transfer the rotation from the inner plate 868 through the monitor base 851 to the outer plate 866, as indicated by the double rotational arrows. Magnets 864a-d can be any magnets capable of transferring rotation between outer plate 866 and inner plate 868, such as N50/52 magnets or other functionally equivalent types of magnets.

[0096] The monitor base 851 can be used to fluidly isolate the trigger sensor 857 on the outside of the cylinder 306. The inner plate 868 is coupled to the piston 304 inside the cylinder 306. The outer plate 866 is on the outside of the cylinder and magnetically coupled to inner plate 868 via magnets 864 a-d. This configuration can be used to allow rotation of outer plate 866 outside of cylinder 306 (and BOP 108), employing a mechanically separate coupling, such as magnets 864a-d, for translational movement from the inner side of cylinder 306 to the outside. of cylinder 306.

[0097] Figure 9A shows another view of the BOP monitor 703, representing the trigger sensor 857. As shown in Figures 8 and 9, the trigger sensor 857 is arranged around the outer plate 806 and the monitor base 851. representing the trigger sensor 857, the external board 866 and the monitor base 851 have been shown in a dashed line. Actuation sensor 857 includes a sensor base 859 with a rod 861 extending therefrom, a driver (or load device) 865 with a plunger (or push block) 867 extending therefrom, and a bracket 855. sensor base 859 is positioned in a sensor cavity 863 extending into the outer surface of the monitor base 851. The rod 861 extends from the sensor base 859 and into an actuator cavity 869 of the outer plate 866. The bracket 855 is positioned in the actuator cavity 869 and has a hole to receive the sensor rod tip 861 therefrom. Holder 855 may have an outer ring positionable on outer plate 866, engageable by plunger 867, and an inner ring for receiving rod tip 861. Driver 865 is positioned on outer plate 866 with plunger 867 engageable with bearing 855.

[0098] The 857 trigger sensor can, as shown, be a voltage rosette or strain gauge. Actuation sensor 857 senses movement of outer plate 866 to provide a measurable signal to determine the position of the piston and therefore the rams. Trigger sensor 857 is coupled to outer plate 866 at its center point around the Z geometry axis. Trigger sensor 857 has a known X and Y direction. The resulting directional vector V can be determined based on a magnitude and direction of the stress detected by the trigger sensor 857 in the X and Y direction. The load/force of the trigger 865 is assumed to be approximately constant. The force produced by actuator 865 is transferred to sensor base 859 via plunger 867, bracket 855 and sensor rod 861.

[0099] Sensor rod 861 deflects in the direction of the force produced by driver 867 and this deflection is measured at sensor base 859 via strain gauge methods. A change in the force direction also changes the direction that the sensor rod 861 deflects, which is measurable by the sensor base 859, when the outer plate 866 rotates. This change of direction can be used to determine the vector angle of the load, which can be used to determine the angle of the outer plate 866. Given the known geometry of the BOP monitor 703, the angle of the outer plate 866 can be used to determine the ram position.

[00100] The trigger sensor 857 can be, for example, a strain gauge capable of measuring strain along multiple geometric axes, such as three geometric axes, as schematically illustrated in Figure 9B. The 0o strain gauge measures strain along the Y-axis, 90o measures strain along the X-axis, and 45o measures a combination of the two and is used to increase accuracy. The combination of the three, 0o, 90o and 45o, allows tracking of voltage - magnitude and direction - when outer plate 866 rotates due to any rotation of inner plate 868. Other settings and angles can be used.

[00101] As also shown, the accelerometer (or other additional sensor) A can optionally be provided. External forces (e.g., forces other than those associated with magnets 864a-d) can impact inner plate 868, causing vibration or shock loads on outer plate 866, which can be felt by actuation sensor 857. For example, gravity can cause a downward pull on outer plate 866 and vibration can affect the directional load of outer plate 866 in either direction. Failure to consider these forces can result in inaccurate determinations of the rotation of the outer plate 866 and thus the displacement and position of the ram.

[00102] To compensate for or correct potential errors, which may be caused by external forces (eg, gravity and vibration), which may impact the 866 outer plate and, in turn, be sensed by the 857 trigger sensor, various forces can be considered. Data from accelerometer A can be correlated with readings from the 857 drive sensor to provide accurate rotational position by factoring the gravity and vibration experienced through the accelerometer A. The 857 drive sensor and accelerometer A measurements can be transferred to a controller, surface unit or other device (see eg 126, 128 of Figure 1) to collect and/or analyze data.

[00103] Motion of piston 304 extends and retracts handle 360. Motion of handle 360 rotates inner plate 868. Inner plate magnets 864b,d are coupled to magnets 864a.c to translate inner plate motion 868 to the outer plate 866. The tip of the sensor rod 861 extends into the holder 855 of the outer plate 866. The plunger 867 of the driver 865 pushes the holder 855 and the tip of the rod 861 so that the rod 861 is displaced. of the geometry axis Z along an offset geometry axis Z'.

[00104] Bending/deflecting sensor rod 861 provides measurements detectable by sensor base 859. Sensor base 859 can be coupled to BOP 108, controllers 126, 128 and/or other devices to transfer sensed measurements to it. The drive sensor 857 detects the movement of the outer and inner plates 866, 868 to provide a signal measurement to determine the direction vector that can be used to determine the position of the piston.

[00105] Figures 10A and 10B show various views of the BOP monitor 703. Figure 10A shows an outer end view of the BOP monitor 703. Figure 10B shows the inner end view of the BOP monitor 703.

[00106] As shown in Figure 10A, the BOP monitor 703 is represented as a circular member, connectable to the cylinder 306, for example, by screws. Outer plate 866 also has a visual indicator in the form of rotating disc (or arrow) 871 rotating with outer plate 866. Rotating disc 871 may be similar to rotating disc 467 of Figures 4K-4N. Rotating disc 871 and outer plate 866, as shown, are rotatable between an open and a closed position, as indicated by the arrow. Markers 881a,b may be provided to represent open and closed positions, respectively, along the outer face of the BOP monitor 703.

[00107] Figure 10A also represents another view of trigger sensor 857. Trigger sensor 857 is shown on outer plate 866 with stem 861 extending into trigger cavity 869. Trigger 865, plunger 867 and bracket 855 are depicted on the outer plate adjacent to rod 861. As shown in this view, driver 865 is a spring or flat bar 881 extending between fixed brackets 885. Receiving spring engages plunger 867 and presses plunger 867 toward rod 861, as indicated by the arrow. Spring 882 may include a brace extending between the brackets and a tooth extending from each bracket parallel to the brace. The fixed bar keeps your teeth straight. Plunger 867 is positioned midway between the two teeth and is biased by the teeth to apply a force to bracket 855 and rod 861 to push/deflect rod 861 off center Z axis (Figure 8). As also shown in this view, magnets 864a,b and 864c,d are aligned around outer plate 866 and inner plate 868 (Figures 8 and 9A). Magnets 864a-d are at the same distance from the Z axis.

[00108] As shown in Figure 10B, the inner plate 868 is positioned adjacent the base 851 and includes a pulley (or wheel) 873 and a separate cover 875. The wheel 873 has a positionable outer surface adjacent the monitor base 851 and a perimeter to receive the cable 360 around it. Cover 875 is provided around the inner surface of pulley 873 and has a hole 870 through it for passing cable 360 through it to connect with piston 304 (Figure 8).

[00109] Figure 10C shows another version of the BOP monitor 703'. This version is the same as shown in Figure 10A, except that a modified external board 866' and sensor 865' are provided. Outer plate 866' is available around outer cover 891 and spacer 890. Outer plate 866' has visual indicator 871 on it and has teeth 889 along its periphery, mating with sensor 865'. Although teeth 889 are shown in this example, other detectable features, such as alternating bands of light and dark, along the periphery of outer plate 866', can be used.

[00110] Sensor 865' extends through spacer 890 and teeth 889 onto the outside of plate 866'. Sensor 865' can detect teeth 889 as they rotate further, thereby indicating a rotational position of outer plate 866'. A known angle between the teeth 889 and the size of the rotating outer plate 866' can be used to determine the linear displacement of the rams.

[00111] Figures 11A, 11B and 11C show partial cross-sectional, exterior exploded and interior exploded views, respectively, of the BOP monitor 703. These views show the BOP monitor 701 in an assembled and a disassembled configuration. These views also show the components of Figures 8, 9 and 10A, plus additional optional components such as seals 879, a spring 880, rotating disc cover 887 and additional connectors (e.g. screws) 877.

[00112] Seals 879 may be used to prevent fluid leakage through the BOP monitor 703. Spring 880 may be a rotational spring, which biases inner plate 868 into a retracted position to retract handle 360 from piston 304 and to keep the cable 360 taut (Figure 8). Rotating disc cover 887 may be a transparent cover, to protect outer plate 886 and rotating disc 871 and/or seal sensor 865 from outer cover 891. Various connectors, such as screws, may be provided between various parts of the rotation sensor. BOP 703, to hold such parts in place. Sensor base 859 with rod 861 on it can be adjustably mounted to monitor base 851 by screws.

[00113] As also shown in Figure 11B, the outer plate 866 may crimp in a bracket 893, which is crimped in an adapter 892, which is screwed to the monitor base 851. The outer plate 866 is free to rotate around the sensor rod 861 using bracket 893. Rotating disc (or visual indicator) 871 is positioned on outer plate 866. As also shown in Figure 11C, monitor base 851 is provided with an inner cavity 883 and a shaft 885 on its inner side, to receive the 868 inner board.

[00114] Figure 11D also shows an alternate configuration of the BOP monitor 703”, which is similar to the BOP monitor 703 of Figures 11A and 11B, except that the outer plate 866 includes two outer covers 866a, a rotating disk plate 866b and an 866c spacer”.

[00115] Figures 11A1, 12A2, 12B1, 12B2, 13A and 13B show schematic views of another version of the BOP 703"' monitor. Figures 12A1 and 12A2 show views of the BOP 703"' monitor in a zero or home position. Figures 12B1 and 12B2 show views of the BOP 703"' monitor rotated α degrees (eg, about 45 degrees clockwise). The BOP monitor 703"' of Figures 12A2 and 12B2 is the same as the BOP monitor 703 of Figure 10A, except the magnets have been moved to an offset position. Figures 12A1 and 12B1 are schematic views of the BOP monitor 703"' of Figures 12A2 and 12B2. Figure 13A shows the BOP monitor of Figure 12A1 taken along lines 13A-13A. Figure 13B shows the BOP monitor of Figure 12A2, taken along lines 13B - 13B.

[00116] As shown in these views, magnets 864a-d are in an offset position around inner plate 868 and outer plate 866 to translate movement between them. One or more pairs of magnets, such as magnets 864a-d, as shown, may be magnetically coupled to translate rotation between outer plate 866 and inner plate 868.

[00117] As with the magnets depicted in the aligned position of Figure 10A, the magnets 864a,c on the outer plate 806 enable the outer plate 866 of Figures 12A and 12B to remain aligned with the inner plate 868 so that the center lines Z axials of plates 866, 866 match. Likewise, the magnets 864b,d of the inner plate 868 allow the inner plate 868 to remain aligned with the outer plate 868 so that the axial Z center lines of the plates 866, 868 coincide. Opposing magnets 864a,c on the outer plate 868 and inner plate 866, closer together due to their proximity, are attracted to each other.

[00118] In the offset configuration of Figures 12A1 - 12B2, the magnets 864a,c on the outer plate 806 are radially offset from the center line Z. In the exemplary embodiment, the magnets 864b,d on the inner plate 868 may be radially offset from the line central Z in different degrees. In other words, the radial distance Da between the magnet 864a and the axis Z is different from the radial distance Dc between the magnet 864c and the axis Z. In the exemplary embodiment, the magnets 864b,c are also radially offset from the axis Z. in different degrees. In other words, the radial distance between magnet 864b and the Z-centerline is different from the radial distance between magnet 864d and the Z-centerline.

[00119] The displacement of magnets 864a-d creates a lateral force between the outer plate 866 and the sensing rod 861 (or intermediate components transfer the lateral force to the sensing rod 861). The lateral force is created when the displaced magnets 864a,b attempt to pull each other into axial alignment. Similarly, magnets 864c,d attempt to pull each other into axial alignment. The magnets 864a-d are displaced in such a way as to cause the pulling force between each set of magnets to be in the same direction. The axis of rotation of the outer plate 866 and of the present invention 868 and the center line of the sensor rod 861 are aligned with the center line Z when the magnets are in the offset position. A hole, cavity or intermediate device of the outer plate 866 is positioned to contact the sensing rod 861.

[00120] The pulling force of the displaced magnet array acts to move the outer plate 866 away from the Z centerline. The outer plate 866 will rotate in conjunction with the present invention 868 due to the magnetic attraction between 864a,b and 864c,d . The rotation of the plates also causes the lateral force exerted on the sensing rod 861 to rotate, which can be felt and measured by the sensing base 859. The sensed tension can then be used to determine the rotation of the plate 868 and in turn , the displacement and position of the ram. The relative positions of magnets 864a,c and magnets 864b,d cause a net lateral force through outer plate 866 on sensor rod 861, shown in Figure 12A, to be in a downward direction. This lateral force direction will rotate with the rotation of plates 866 & 868.

[00121] As also shown by Figures 13A and 13B, the trigger sensor 858 is coupled to the monitor base 851. However, various sensors can be used, so the bezel can be on the outer cover 891, rotating disc cover 887 or 890 spacer.

[00122] Figure 14 represents a method 1400 of monitoring the position of a ram of a BOP, such as the BOP provided herein. The method involves 1491 - operatively connecting the monitor comprising a monitor base, an inner plate, an outer plate and a trigger sensor to the blowout preventive controller, operatively connecting the monitor base to the cylinder, an inner plate around the surface of the monitor base and an outer plate around the outer surface of the monitor base, 1493 - rotating the inner plate with the rams via a cable, 1495 - rotating the outer plate with the inner plate via the magnets, and 1496 - determining the position of the rams by reading the rotation of the outer plate with the trigger sensor.

[00123] The trigger sensor comprises a sensor base positionable on the monitor base and a rod extending from the sensor base into the outer plate and the 1496 determination may involve detecting the position of the outer plate by deflecting the rod and measuring the rod position with sensor base during rotation. The trigger sensor may include a sensing base positionable on the monitor base and a rod extending from the sensing base into the outer plate, and the 1496 determination may involve detecting the position of the outer plate by detecting keys along the periphery of the plate. external, with the trigger sensor.

[00124] The method may also involve additional steps such as 1497 - collect (or pass) trigger sensor data, 1498 - pass trigger sensor data to the surface unit, 1499 - adjust the blowout preventive controller based on in the determination. The steps can be performed in order and repeated as desired.

[00125] It will be appreciated by those skilled in the art that the techniques described here can be implemented for automated stand-alone applications, via software configured with algorithms, to perform the desired functions. These aspects can be implemented by programming one or more computers for suitable general purposes, having appropriate hardware. Programming may be accomplished through the use of one or more program storage devices, readable by the processor(s) and encoding one or more computer-executable instruction programs to perform the operations described herein. The program storage device may take the form of, for example, one or more floppy disks; a CD ROM or other optical disc; a read-only memory (ROM) chip; and other forms of the kind well known in the art or subsequently developed. The instructional program can be “object code”, that is, in binary form that is executable more or less directly by the computer, in “source code”, which requires compilation or interpretation before execution; or in some other intermediate form, such as partially compiled code. The precise shapes of the program storage device and instruction encoding are negligible here. Aspects of the invention may also be configured to perform the described functions (via appropriate hardware/software) solely locally and/or remotely controlled, via an extended communication network (eg wireless, internet, satellite etc.).

[00126] Although the modalities are described with reference to various implementations and exploits, it will be understood that these modalities are illustrative and that the scope of the inventive subject is not limited thereto. Many variations, modifications, additions and improvements are possible. For example, one or more monitors (with one or more sensors, pairs of magnets, and/or other components) can be positioned around one or more cylinders of a blowout preventive controller. Also the monitoring devices described herein can detect positions of the piston 304 (and other parts of the ram 202) in a non-actuated position, an activated position and/or other positions in between. Various parts of sensors, monitors, BOPs and other devices here can be combined.

[00127] Several examples can be provided for components, operations or structures described here as a single example. In general, frameworks and functionality presented as separate components from exemplary configurations can be implemented as a combined framework or component. Similarly, structures and functionality presented as a single component can be implemented as separate components. These and other variations, modifications, additions and improvements may fall within the scope of the inventive subject.

Claims (29)

1. Monitor (703) for a blowout preventive controller (108) of a wellbore (105), the blowout preventive controller (108) comprising a housing, at least one ram (202) slidably positionable in the housing for forming a seal over the wellbore (105) and an actuator (300) comprising a cylinder (306) with a piston (304) slidably movable therein, the piston (304) operably connectable to at least one ram (202) ) and movable therewith, the monitor (703) characterized in that it comprises: a monitor base (851) operably connectable to the cylinder (306), the monitor base (851) having an inner side inside the cylinder (306) ) and an outer side outside the cylinder (306); an inner plate (868) positionable within the cylinder (306) on the inner side of the monitor base (851), the inner plate (868) operably connectable to and movable with the piston (304); an outer plate (866) positionable outside the cylinder (306) on the outer surface of the monitor base (851), the outer plate (866) coupled by magnets (864a-d) to the inner plate (868) and rotatable with the same; and a trigger sensor (857) operably connectable to the monitor base (851) and the outer plate (866) for detecting rotation thereof whereby the position of the ram (202) can be determined. 2. Monitor (703) according to claim 1, characterized in that it additionally comprises a cable (360) that operatively connects the inner plate (868) to the piston (304). 3. Monitor (703) according to claim 2, characterized in that the inner plate (868) comprises a pulley wheel (869), the cable (360) available on the pulley wheel (869). 4. Monitor (703) according to claim 3, characterized in that the inner plate (868) additionally comprises a cover with a hole for passing the cable (360) through it. 5. Monitor (703) according to claim 3, characterized in that the inner plate (868) additionally comprises a rotating spring (882). 6. Monitor (703) according to claim 1, characterized in that the monitor base (851) has an interior cavity (883) to receive the interior plate (868). 7. Monitor (703) according to claim 1, characterized in that the monitor base (851) has a tree (855) operatively connected to the inner plate (868). 8. Monitor (703) according to claim 1, characterized in that the trigger sensor (857) comprises a sensor base (859) and a trigger (865), the sensor base (859) operatively connectable to the monitor base (851) and having a rod (861) extending into the outer plate (866), the trigger (865) positionable on the outer plate (866) to deflect the rod (861) to a detectable displacement position by the sensor base (859) while the outer plate (866) is rotated, whereby a position of the ram (202) can be determined. 9. Monitor (703) according to claim 8, characterized in that the outer plate (866) has a trigger cavity (869) therein to receive the trigger (865). 10. Monitor (703) according to claim 8, characterized in that the trigger (865) comprises a spring (882) and a plunger (867), the plunger (867) driven by the spring (882) against the rod (861). 11. Monitor (703) according to claim 8, characterized in that the trigger sensor (857) comprises a support (855) positionable on the outer plate (866) and having a hole through it to receive the rod ( 861), the trigger (865) engages with the support (855) to deflect the rod (861). 12. Monitor (703) according to claim 8, characterized in that the sensor base (859) is fixedly positioned in a sensor receptacle of the monitor base (851) and the rod (861) extends deflectively from the sensor base (859). 13. Monitor (703) according to claim 12, characterized in that a rod tip of the rod (861) extends from the sensor base (859) into the trigger cavity (869), the tip of the movable rod in the trigger cavity (869) while the inner plate (868) is rotated. 14. Monitor (703) according to claim 1, characterized in that the trigger sensor (857) comprises a sensor base (859) operably connectable to the monitor base (851) and having a rod (861) that extends to the outer plate (866) to detect keys along a periphery thereof. 15. Monitor (703) according to claim 14, characterized in that the keys comprise at least one of the teeth, black and white portions and combinations thereof. 16. Monitor (703) according to claim 1, characterized in that the outer plate (866) comprises a base plate and the at least one ring, and a rotating disc operatively connected to the base plate and movable with the same. 17. Monitor (703) according to claim 1, characterized in that the outer plate (866) is rotatable by means of magnets (864a-d) with the inner plate (868), the outer plate (866) having a rotating disc therein that can rotate with the inner plate (868). 18. Monitor (703) according to claim 1, characterized in that the trigger sensor (857) comprises a strain gauge. 19. Monitor (703) according to claim 1, characterized in that the magnets (864a-d) comprise inner magnets (864a-d) operatively connectable between the inner plate (868) and the monitor base (851) . 20. Monitor (703) according to claim 1, characterized in that the magnets (864a-d) comprise outer magnets (864a-c) operatively connectable between the outer plate (866) and the monitor base (851) . 21. Monitor (703) according to claim 1, characterized in that the monitor base (851) comprises an end cap of the cylinder (306). 22. Monitor (703) according to claim 1, characterized in that it additionally comprises at least one seal. 23. Monitor (703) according to claim 1, characterized in that it additionally comprises an accelerometer. 24. Method for monitoring (703) a blowout preventative controller (108) from a wellbore (105) penetrating an underground formation, the blowout preventative controller (108) comprising a housing, at least one positionable ram (202) of slidingly in the housing to form a seal over the wellbore (105), and an actuator (300) comprising cylinders (306) with pistons slidably movable therein, the piston (304) operably connectable with at least one ram (202) movable therewith, the method characterized in that it comprises: operatively connecting a monitor (703) comprising a monitor base (851), an inner plate (868), an outer plate (866) and a sensor trigger (857) for the blowout preventive controller (108) by operatively connecting the monitor base (851) to the cylinder (306), an inner plate (868) on an inner surface of the monitor base (851), and an outer plate (866) on an outer surface or of the monitor base (851); rotating the inner plate (868) with the rams (202) through a cable; rotating the outer plate (866) with the inner plate (868) through the magnets (864a-d), and determining a ram position (202) by sensing rotation of the outer plate (866) with the trigger sensor (857). ). 25. Method according to claim 24, characterized in that it additionally comprises collecting data from the trigger sensor (857). 26. Method according to claim 24, characterized in that it additionally comprises passing the trigger sensor data (857) to a surface unit. 27. Method according to claim 24, characterized in that it additionally comprises adjusting the eruption preventive controller (108) based on the determination. 28. Method according to claim 24, characterized in that the trigger sensor (857) comprises a sensor base (859) positionable on the monitor base (851) and a rod (861) extending from the base of the sensor (859). sensor (859) for the outer plate (866) and wherein the determination comprises detecting a position of the outer plate (866) by deflecting the stem (861) and measuring a position of the stem (861) with the base of sensor (859) during rotation. 29. Method according to claim 24, characterized in that the trigger sensor (857) comprises a sensor base (859) positioned in the monitor base (851) and a rod (861) extending from the base of the monitor (859). sensor (859) for the outer plate (866) and wherein the determination comprises detecting a position of the outer plate (866) by detecting keys along a periphery of the outer plate (866) with the trigger sensor ( 857).

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