US20140100819A1 - Oil field system data recorder for failure reconstruction - Google Patents
Oil field system data recorder for failure reconstruction Download PDFInfo
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- US20140100819A1 US20140100819A1 US14/122,398 US201114122398A US2014100819A1 US 20140100819 A1 US20140100819 A1 US 20140100819A1 US 201114122398 A US201114122398 A US 201114122398A US 2014100819 A1 US2014100819 A1 US 2014100819A1
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- oil field
- field system
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B41/00—Equipment or details not covered by groups E21B15/00 - E21B40/00
- E21B41/0021—Safety devices, e.g. for preventing small objects from falling into the borehole
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0221—Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
Definitions
- Oil field system failures are sometimes catastrophic and result in the complete destruction of the system.
- the personnel working on such an oil field system when such a failure occurs are sometimes killed or injured so that they are unavailable afterwards to help reconstruct the events that led to the failure.
- the intense scrutiny that sometimes follows such a failure may cause such personnel, either intentionally or unintentionally, to remember events differently than they actually occurred. Reconstruction such failures is important to avoid making the same mistakes in the use of future oil field systems.
- FIG. 1 is a block diagram of a black box.
- FIG. 2 illustrates a plan for an oil field system.
- FIG. 3 is a flow chart.
- an oil field system is defined to be a drilling rig (on shore or off shore), a production rig, a workover rig (wireline, coiled tubing (wired or unwired)), or any other similar system. While many of the examples described in this application relate to offshore rigs, it will be understood that the techniques and apparatuses described herein could be used on any oil field system.
- an oil field system data recorder (or “black box” or “apparatus”) is a secure repository that records detailed activity in the oil field system in the form of data generated by sensors, cameras, microphones (including those recording discussions taking place during decision-making meetings), and data considered useful in evaluating the health status of the oil field system and associated systems.
- the black box records sufficient information to reconstruct or reenact catastrophic failures, fires, blow outs, etc. that the oil field system might experience.
- the black box is a self-contained apparatus 100 that is engineered to survive fire, heat, explosion, and water submersion.
- the black box is an enclosure that satisfies one or more of the standards set by The Association of Electrical and Medical Imaging Equipment Manufacturers (“NEMA”) for enclosures.
- NEMA The Association of Electrical and Medical Imaging Equipment Manufacturers
- the black box 100 includes a primary power source 105 , such as a standard power supply.
- the primary power source 105 receives power from the oil field system 110 in the form of line voltage, such as 110 VAC 60 Hz power.
- the primary power source 105 receives power from another source, such as a solar panel, a wind mill, a power source using power generated by the motion of waves, or a similar source.
- the black box 100 includes a battery backup system 115 .
- the battery backup system 115 is charged by the primary power source 105 using techniques necessary to prolong the life of any battery included in the battery backup system 115 .
- the battery-life-prolonging techniques are practiced by the battery backup system 115 in addition to, or instead of, the primary power source 105 .
- the battery backup system 115 includes circuitry to recognize a failure in the primary power source 105 and transition the load of the black box 100 to the battery backup system 115 .
- the black box 100 includes a processor 120 .
- the processor 120 can be a microprocessor, a microcontroller, a programmable logic array, or any other similar device that is capable of controlling the other components in the black box 100 .
- the black box 100 includes a memory 125 .
- the memory includes random access memory (“RAM”), programmable read only memory (“PROM”), erasable programmable read only memory (“EPROM”), flash memory, volatile memory, nonvolatile memory, or any other type of memory.
- the memory includes a digital recorder, a flash memory, a dynamic memory, and/or a mag memory (e.g., magnetic tape).
- the processor 120 communicates with the memory 125 and with other components in the black box 100 through a bus or busses 130 that allows the processor to selectively communicate with components in the black box 100 .
- the black box 100 includes a global positioning system antenna, receiver, and decoder (“GPS”) 135 that receives signals from the Global Positioning System satellites and uses those signals to locate the black box on the earth's surface.
- GPS global positioning system antenna, receiver, and decoder
- the processor 120 receives position reports from the GPS 135 via the bus 130 and records those reports, thereby maintaining a “track” of the location of the black box over a period of time.
- an input device 140 conditions input signals received from the oil field system for presentation to the processor 120 .
- the input device 140 has a connection to the processor 120 that is separate from the bus 130 .
- the input device 140 communicates with the processor 120 through the bus 130 .
- the input device 140 accepts signals not limited to the following formats:
- the input device 140 converts the signal or signals, which can be received via a wire, fiber, wirelessly, via radio, via a telephone connection, or via a connection to a cellular network, into data that can be accepted by the processor 120 and provides the results to the processor either directly as shown in FIG. 1 , or by way of the bus 130 .
- the input device 140 transmits all data that it receives from the oil field system 110 to the processor 120 .
- the input device 140 selects some data for transmission to the processor 120 .
- the input device 140 summarizes data before transmitting it to the processor 120 .
- the input device 140 passes raw data to the processor 120 and any summarization is performed by the processor 120 .
- the input device 140 samples the signals from the oil field system 110 with the sample rate for each signal being set by the processor 120 .
- the processor 120 recognizes stages, including “failure stages” of the oil field system 110 based on the data provided by the input device 140 . For example, in one embodiment, the processor recognizes four stages of operation, although additional stages of operation are envisioned:
- the processor controls the rate the input device 140 samples the signals from the oil field system depending, at least in part, on the stage of operation the oil field system 110 is currently in.
- the processor 120 only records audio from the control room when a voice or voices can be detected on the audio.
- the processor records the audio continuously.
- the processor samples downhole pressure once every 10 seconds.
- the processor samples downhole pressure once every second.
- the black box 100 includes software that is stored on the memory 125 and executed by the processor 120 .
- the software includes a process that prevents the original format of the sampled form of one of the inputs that is stored in memory from being modified.
- this process operates similarly to a configuration management tool, in that it maintains a record of the format of data as it is received and prevents the modification of the format of that data by anyone other than a person with the proper privileges. This process also maintains a record of the people that have made such modifications or have attempted such modifications.
- the software includes a voice recognition process that accepts an audio signal containing a voice signal and executes an algorithm to identify the speaker from a set of known speakers.
- the memory contains a set of speaker voice recognition profiles created as personnel arrive at the oil field system 110 . In one embodiment, a newly arriving person is asked to speak into a microphone when he or she first arrives at the oil field system and the voice recognition profile is created based on that interaction.
- one audio input to the input device 140 is from a microphone or microphones through which personnel can comment on the procedures being followed on the oil field system, other personnel, other companies, vendors, or any other topic the speaker feels is worthy of comment.
- the processor 120 stores a digitized version of these comments along with the identity of the speaker, which in one embodiment is determined by the voice recognition process, in the memory 125 .
- an audio input to the input device 140 is from the public address system that personnel use in the oil field system 110 to make announcements regarding the status of operations on the oil field system 110 or to give directions to accomplish oil field system 110 tasks.
- the processor 120 stores a digitized version of these communications along with the identity of each speaker, which in one embodiment is determined by the voice recognition process, in the memory 125 .
- microphones and cameras are distributed around the oil field system 110 work areas. Signals from these microphones and cameras are inputs to the input device 140 .
- the processor 120 stores a digitized version of these signals, along with the identity of speakers where they can be determined by the voice recognition process, in the memory 125 .
- the input device receives data from:
- the processor 120 has access to and can execute the MAXACTIVITYTM rig floor activity monitoring software available from the assignee of this application, or other similar software.
- the MAXACTIVITY software tracks and times rig floor activities such as trips in and out of the rig's bore hole, circulating, drilling, and connection operations based on rig floor sensor information collected through the input device 140 .
- the MAXACTIVITY software can be run on real-time or historical data, can export data to a spreadsheet program, allows users to override or edit data, produces reports concerning rig operations, and can export data to, for example, the remote system 155 through the remote system interface 160 .
- MAXACTIVITY collects the following sensor data:
- health monitoring systems of a drilling rig such as systems monitoring well string vibration, weight on bit (“WOB”), rate of penetration (“ROP”), pressure, and the like, are given priority and are sampled and processed at higher priorities than other inputs to the input device 140 .
- the processor 120 selects portions of the data it receives from the input device 140 , processes it, and stores it in the memory 125 .
- the stored data provides a record of the data received.
- the stored data is sufficient to reconstruct faults that occur on the oil field system 110 .
- the data stored in the memory 125 is periodically overwritten on a first-in-first-out (“FIFO”).
- FIFO first-in-first-out
- a plan is being monitored as discussed below.
- the data associated with that milestone is decimated, leaving enough data that essential data can be gathered and interrogated to evaluate primary conditions, i.e., conditions that are sufficient to understand the state of the well.
- some or all of the data collected regarding critical operations are encrypted.
- the processor provides data sufficient to reconstruct faults through an analysis interface 145 to a failure analysis system 150 .
- the failure analysis system 50 is able to select the data to receive by interacting with the processor 120 through the analysis interface 145 .
- the failure analysis system 150 is outside the black box 100 .
- data collected through the input device 140 is forwarded to a remote system 155 through a remote system interface 160 .
- data is forwarded to the remote system 155 during normal operations, which allows the remote system to replicate the processing being performed by the processor 120 .
- a dashboard interface 165 provides a real-time view of the data being collected to the oil field system 110 .
- the oil field system 110 includes a screen that illustrates the current status of the oil field system 110 according to the black box 100 .
- the real-time view of the data that is provided through dashboard interface 165 includes an identification of problems that the black box 100 perceives.
- the black box 100 is mechanically coupled to the oil field system in normal operations.
- the black box 100 includes a mechanical release mechanism 170 that releases the black box 100 from the oil field system 110 .
- the purpose of the release caused by the mechanical release mechanism is to allow the black box 100 to move a distance away from the oil field system 110 in the event that the oil field system 110 is undergoing a catastrophic failure that might destroy the black box 100 if it is left in its attached position.
- the mechanical release mechanism 170 is a simple release that simply drops the black box 100 from the oil field system 110 into, for example, the sea.
- the mechanical release mechanism 170 is a launching device that launches the black box 100 away from the oil field system using an explosive device, a rocket, or a large spring.
- the black box 100 continues to record data until the mechanical release mechanism 170 is activated or the black box 100 is otherwise released from the oil field system 110 . In one embodiment, even after the black box 100 is released it maintains a connection to the oil field system 110 through a tether, such as a wire, fiber, or wireless connection. In one embodiment, the tether is on a spool that is attached to the black box 100 or to the oil field system 110 and pays out as the black box 100 moves away from the oil field system. In one embodiment, the black box 100 has a way to sever or otherwise release the tether if the black box 100 is no longer receiving data from the oil field system 110 , the tether is fully extended, or some other similar event occurs.
- a tether such as a wire, fiber, or wireless connection.
- the tether is on a spool that is attached to the black box 100 or to the oil field system 110 and pays out as the black box 100 moves away from the oil field system.
- the black box 100 has a way to
- the processor 120 uses the data stored in the memory to detect such catastrophic events and, when they occur, actuates the mechanical release mechanism 170 .
- the mechanical release mechanism can be activated in one of the following ways:
- the black box 100 includes a beacon 175 , such as a radio transmitter, that transmits a beacon signal that allows the black box 100 to be located by searchers, for example, after the mechanical release mechanism has been activated and it has been released from the oil field system 110 .
- the beacon signal includes a status message conveying information concerning the event that caused the black box 100 to be released.
- the beacon 175 is automatically activated upon the occurrence of one of the activation events described above.
- the beacon 175 and memory 125 are part of a separate module 180 within the black box 100 .
- the battery backup system 115 is included in the module 180 .
- the beacon 175 has its own battery.
- the beacon's battery is charged by the primary power source 105 or by the battery backup system 115 .
- module 180 is the only part of the black box 100 that is jettisoned from the oil field system when the mechanical release mechanism 170 is activated.
- a processor 120 upon detecting a condition that either will or might cause the black box to be released from the oil field system, the processor 120 initiates a power decay tree, in which the processor automatically, for example through the dashboard interface 165 , turns off successively less important sensors.
- a set of high importance sensors i.e., last to be turned off
- the processor automatically, for example through the dashboard interface 165 , turns off successively less important sensors.
- a set of high importance sensors includes public address system sensors, microphone sensors, BOP status sensors, riser sensors, and well position sensors.
- a set of medium importance sensors includes standpipe pressure sensors, sensors monitoring the flow of mud in and out of the well, engine sensors, and temperature sensors.
- a set of low importance sensors includes gamma ray resistivity sensors, survey sensors, and drilling parameter sensors.
- the battery backup system 115 performs some or all of the power decay tree functionality.
- the location of the black box 100 on the oil field system 110 is chosen to enhance its survivability.
- the black box 100 is mounted on the oil field system's life rafts.
- the black box 100 is located a sufficient distance away from the oil field system 110 that it is unlikely to be affected by any failures of the oil field system 110 while still being connected to the oil field system 110 either wirelessly or through a tether, as described above.
- the black box 100 maintains a plan for the oil field system 110 to follow, tracks actual progress against the plan, and reports deviations from the plan to the oil field system 110 through the dashboard interface and, in one embodiment, to the remote system 155 through the remote system interface 160 .
- the plan is shown on the left side of the page and the actual is shown on the right side of the page.
- the plan includes milestones, labeled Milestone 1 through Milestone M, although only Milestone N ⁇ 1, Milestone N, and Milestone N+1 are shown.
- the milestones are represented in FIG. 2 by diamond-shaped symbols.
- Each milestone is broken down into tasks.
- Milestone N includes 4 tasks: Task N:1, Task N:2, Task N:3, and Task N:4.
- Milestone N+1 includes 3 tasks: Task N+1:1, Task N+1:2, and Task N+1:3.
- Milestone N+2 (not shown) includes at least task N+2:1.
- Other Milestone N+2 tasks are not shown because they are outside the timeframe shown in FIG. 2 .
- the task or tasks included in Milestone N ⁇ 1 are outside the timeframe shown in FIG. 2 .
- milestones that have not yet been completed are represented on the “plan” side of FIG. 2 by black diamond-shaped symbols. Completed milestones are indicated on the “actual” side of FIG. 2 by circles around the black diamond-shaped symbols. In the example shown in FIG. 2 , Milestones N ⁇ 1 and Milestone N have been completed.
- uncompleted tasks are represented on both sides of FIG. 2 by dashed boxes and completed tasks are shown on the “actual” side of FIG. 2 by solid-lined boxes.
- Task N:1, Task N:2, Task N:3, and Task N:4 are completed and Task N+1:1 is incomplete and presumably underway.
- data collected during each task is associated with each task. This is represented in FIG. 2 by solid-lined boxes to the left of each task. For example, Data N:1 is associated with Task N:1, Data N:2 is associated with Task N:2, Data N:3 is associated with Task N:3, and Data N+1:1 is associated with Task N+1:1, etc.
- each task has associated with it “expected data” represented on the “plan” by a solid box to the left of the task box.
- Task N:1 has an associated Expected Data N:1, etc.
- not all tasks have expected data and not all tasks have collected data.
- tasks can be divided into sub-tasks, for example, and into even finer levels of detail. It will also be understood that milestones can be grouped into super-milestones, for example and even greater levels of summary.
- the processor 120 detects this deviation and reports it to the oil field system 110 through the dashboard interface 165 . In one embodiment, the processor 120 reports the deviation to the remote system 165 through the remote system interface 160 .
- the processor 120 compares some or all of the data collected during each task to data that was expected during that task. In one embodiment, the processor 120 compares the data collected during a task (e.g., Data N:1) to the data that was expected to be collected when the plan was created (e.g., Expected Data N:1). In one embodiment, the processor reports significant deviations of the collected data from the expected data to the oil field system 110 through the dashboard interface 165 . In one embodiment, the processor reports such data deviations to the remote system 165 through the remote system interface 160 . In one embodiment, the significance of the deviation necessary to report the deviation to the oil field system 110 and/or to the remote system 165 is included in the definition of the expected data. For example, the plan may specify that the rate of penetration (“ROP”) during Task N:3 should be 1 meter per minute and that deviations away from this number by more than one half meter per minute should be reported.
- ROP rate of penetration
- the information shown in FIG. 2 is, in whole or in part, shown in the dashboard view provided through the dashboard interface 165 ( FIG. 1 ).
- the dashboard view is color coordinated. In one embodiment, for example, parts of the plan that are on schedule or that are being performed according to plan are shown in green. In one embodiment, for example, parts of the plan that are not on schedule or that are not being performed according to plan but that are still within threshold limits of deviation from the plan are shown in yellow. In one embodiment, for example, parts of the plan that are not on schedule or that are not being performed according to plan and that are outside threshold limits of deviation from the plan are shown in red.
- the black box (or “releasable apparatus”) 100 which is attached to the oil field system, receives an oil field system signal (block 305 ).
- the black box 100 digitizes the oil field system signal to produce a digitized signal (block 310 ).
- the black box 100 stores the digitized signal in a memory (e.g., memory 125 ) in the black box 100 (block 315 ).
- the black box 100 forwards the digitized signal to a location remote (e.g., remote system 155 ) from the oil field system 110 (block 320 ).
- the black box 100 determines from the digitized signal that a failure in the oil field system 110 has occurred and, in response, is released (or releases itself) from the oil field system 110 (block 325 ). In one embodiment, the black box 100 is retrieved (block 330 ). In one embodiment, the digitized signal is extracted from the memory in the black box 100 (block 335 ). In one embodiment, the digitized signal is used to analyze the failure in the oil field system (block 340 ).
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Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/US2011/038725 WO2012166132A1 (fr) | 2011-06-01 | 2011-06-01 | Enregistreur de données de dispositif de champ pétrolifère pour la reconstruction de défaillance |
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US20140100819A1 true US20140100819A1 (en) | 2014-04-10 |
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US14/122,398 Abandoned US20140100819A1 (en) | 2011-06-01 | 2011-06-01 | Oil field system data recorder for failure reconstruction |
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US (1) | US20140100819A1 (fr) |
WO (1) | WO2012166132A1 (fr) |
Cited By (2)
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US20160277136A1 (en) * | 2014-06-10 | 2016-09-22 | Halliburton Energy Services, Inc. | Synchronization of receiver units over a control area network bus |
US20230196480A1 (en) * | 2021-12-16 | 2023-06-22 | Halliburton Energy Services, Inc. | Assisted business intelligence on performance of complex assets with taxonomy of real time systems |
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- 2011-06-01 WO PCT/US2011/038725 patent/WO2012166132A1/fr active Application Filing
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US20090295367A1 (en) * | 2007-05-08 | 2009-12-03 | Eric Fauveau | Method to Communicate With Multivalved Sensor on Loop Power |
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US9641267B2 (en) * | 2014-06-10 | 2017-05-02 | Halliburton Energy Services Inc. | Synchronization of receiver units over a control area network bus |
US20230196480A1 (en) * | 2021-12-16 | 2023-06-22 | Halliburton Energy Services, Inc. | Assisted business intelligence on performance of complex assets with taxonomy of real time systems |
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WO2012166132A1 (fr) | 2012-12-06 |
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