U.S. patent application number 11/518701 was filed with the patent office on 2007-03-15 for method and system for evaluating task completion times to data.
This patent application is currently assigned to Key Energy Services, Inc.. Invention is credited to Frederic M. Newman.
Application Number | 20070056727 11/518701 |
Document ID | / |
Family ID | 37853894 |
Filed Date | 2007-03-15 |
United States Patent
Application |
20070056727 |
Kind Code |
A1 |
Newman; Frederic M. |
March 15, 2007 |
Method and system for evaluating task completion times to data
Abstract
The present invention is directed to methods of evaluating the
operations of a well service rig at a well site by evaluating
charts of sensor data obtained from sensors on or associated with
the well service rig. An activity listing or Gantt chart can be
reviewed and each activity verified by viewing charts of sensor
data obtained during that purported activity. In addition service
rig downtimes can be determined and evaluated through the
evaluation of charts of sensor data. Furthermore, activities and
completion times for each activity can be determined by evaluating
charts of sensor data obtained from sensors on the service rig or
at the well site to verify the operations of the service rig, to
improve the efficiency of the operators by identifying long
activities and providing additional instruction, and provide
improved billing to customers by correcting activities and the time
associated therewith.
Inventors: |
Newman; Frederic M.;
(Midland, TX) |
Correspondence
Address: |
KING & SPALDING, LLP
1100 LOUISIANA ST.
STE. 4000
HOUSTON
TX
77002-5213
US
|
Assignee: |
Key Energy Services, Inc.
Houston
TX
|
Family ID: |
37853894 |
Appl. No.: |
11/518701 |
Filed: |
September 11, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60716612 |
Sep 13, 2005 |
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Current U.S.
Class: |
166/250.01 |
Current CPC
Class: |
E21B 47/00 20130101;
E21B 41/00 20130101 |
Class at
Publication: |
166/250.01 |
International
Class: |
E21B 47/00 20060101
E21B047/00 |
Claims
1. A method of determining the accuracy of an activity listing for
activities completed at a well site comprising the steps of: a.
receiving a first activity from an activity listing; b. evaluating
at least one chart of sensor data associated with work completed at
the well site; and c. determining if the sensor data is consistent
with the first activity.
2. The method of claim 1, further comprising the steps of:
determining a start time for the first activity by evaluating the
activity listing; determining a finish time for the first activity
by evaluating the activity listing; and evaluating the sensor data
on the chart between the start time and the finish time of the
first activity.
3. The method of claim 2, further comprising the step of soliciting
information from a rig operator if the sensor data is not
consistent with the first activity.
4. The method of claim 1, further comprising the steps of: d.
repeating steps (b)-(c) for each chart of sensor data associated
with work completed at the well site; and e. repeating steps
(a)-(d) for each additional activity in the activity listing.
5. The method of claim 1, wherein the activity listing comprises an
activity Gantt chart.
6. The method of claim 1, wherein the activity Gantt chart and each
of the charts of sensor data are presented on a monitor.
7. The method of claim 6, further comprising the step of receiving
a request to display the activity Gantt chart on the monitor.
8. The method of claim 1, wherein the activity is selected from a
group consisting of rigging up a service rig, pulling rods, laying
down rods, pulling tubing, laying down tubing, picking up tubing,
running tubing, picking up rods, running rods, rigging down the
workover rig, rigging up an auxiliary service unit, rigging down an
auxiliary service unit, longstroke, cut paraffin, nipple up a blow
out preventer, nipple down a blow out preventer, fishing, jarring,
swabbing, flowback, drilling, clean out, well control activities,
killing a well, circulating fluid within a well, unseating pumps,
setting a release tubing anchor, releasing a tubing anchor, setting
a packer, releasing a packer, picking up drill collars, laying down
drill collars, picking up tools, laying down tools, rigging up
third party servicing equipment, well stimulation, cementing,
logging, perforating, inspecting the well, and traveling to the
well site.
9. The method of claim 1, wherein the sensor data is obtained from
at least one sensor on the well service rig.
10. The method of claim 1, wherein the at least one chart comprises
a rig load chart.
11. The method of claim 1, wherein the at least one chart comprises
a hydraulic pressure chart.
12. The method of claim 1, wherein the at least one chart comprises
an engine speed chart.
13. A method of determining completion times for an activity
completed by a well service rig at a well site comprising the steps
of; evaluating a plurality of charts of sensor data associated with
work completed at the well site; determining a first activity based
on an evaluation of the data in the plurality of charts; evaluating
at least one of the plurality of charts to determine a time to
complete the first activity; and recording the time to complete the
first activity in a computer program.
14. The method of claim 13, further comprising the steps of:
determining if the time to complete the first activity is too long;
and providing additional training for the first activity to a crew
of the well service rig.
15. The method of claim 13, wherein determining the time to
complete first activity comprises the steps of: evaluating at least
one of the charts of sensor data to determine when the first
activity was initiated; evaluating at least one of the charts of
sensor data to determine when a second activity was initiated,
wherein the second activity occurs subsequent to the first
activity; and determining a time difference between the beginning
of the first activity and the beginning of the second activity,
wherein the time difference comprises the time to complete the
first activity.
16. The method of claim 13, wherein determining the time to
complete the first activity comprises the steps of: evaluating at
least one of the chart of sensor data to determine when the first
activity was initiated; evaluating at least one of the charts of
sensor data to determine when the first activity was completed; and
determining a time difference between the beginning of the first
activity and the completion of the first activity, wherein the time
difference comprises the time to complete the first activity.
17. The method of claim 13, wherein the plurality of charts of
sensor data are presented on a monitor.
18. The method of claim 17, further comprising the step of
receiving a request to display the at least one of the plurality of
charts on the monitor.
19. The method of claim 13, wherein the first activity is selected
from a group consisting of rigging up a service rig, pulling rods,
laying down rods, pulling tubing, laying down tubing, picking up
tubing, running tubing, picking up rods, running rods, rigging down
the workover rig, rigging up an auxiliary service unit, rigging
down an auxiliary service unit, longstroke, cut paraffin, nipple up
a blow out preventer, nipple down a blow out preventer, fishing,
jarring, swabbing, flowback, drilling, clean out, well control
activities, killing a well, circulating fluid within a well,
unseating pumps, setting a release tubing anchor, releasing a
tubing anchor, setting a packer, releasing a packer, picking up
drill collars, laying down drill collars, picking up tools, laying
down tools, rigging up third party servicing equipment, well
stimulation, cementing, logging, perforating, inspecting the well,
and traveling to the well site.
20. The method of claim 13, wherein the sensor data is obtained
from at least one sensor on the well service rig.
21. The method of claim 13, wherein the plurality of charts
comprises a rig load chart.
22. The method of claim 13, wherein the plurality of charts
comprises a hydraulic pressure chart.
23. The method of claim 13, wherein the plurality of charts
comprises an engine speed chart.
24. The method of claim 13, further comprising the step of
consolidated the plurality of charts of sensor data associated with
work completed at the well site into one chart for evaluation on a
monitor.
25. A method of determining downtime of a well service rig at a
well site by evaluating a plurality of charts of sensor data
comprising the steps of; a. evaluating a first chart from the
plurality of charts of sensor data associated with work completed
at the well site; b. determining if at least a portion of the data
curve on the first chart is substantially flat for a predetermined
amount of time; c. determining a time period where the data curve
on the first chart is substantially flat based on a positive
determination that the first chart comprises a portion of the data
curve that is substantially flat for a predetermined amount of
time; d. evaluating at least one additional chart from the
plurality of charts of sensor data associated with work completed
at the well site to determine if each additional chart comprises a
data curve that is substantially flat for the time period; and e.
designating the time period as a downtime period.
26. The method of claim 25, further comprising the steps of: f.
determining if the downtime period is an excessive downtime period;
g. soliciting additional information from an operator of the well
service rig to determine the reason for the excessive downtime
period; and h. repeating step (b)-(e) to determine additional
downtime periods.
27. The method of claim 25, wherein the predetermined amount of
time is fifteen minutes.
28. The method of claim 25, wherein the sensor data is obtained
from at least one sensor on the well service rig.
29. The method of claim 25, wherein the plurality of charts
comprises a rig load chart.
30. The method of claim 25, wherein the plurality of charts
comprises a hydraulic pressure chart.
31. The method of claim 25, wherein the plurality of charts
comprises an engine speed chart.
32. The method of claim 25, wherein the plurality of charts of
sensor data are presented on a monitor.
33. The method of claim 25, further comprising the step of
receiving a request to display the at least one of the plurality of
charts on the monitor.
34. A method of determining the accuracy of a written report
comprising a listing of service rig activities conducted at a well
site comprising the steps of: a. determining a first activity from
the written report of service rig activities; b. evaluating at
least one chart of sensor data associated with work completed at
the well site; and c. determining if the sensor data is consistent
with the first activity from the written report.
35. The method of claim 34, further comprising the steps of:
determining a start time for the first activity by evaluating the
written report of service rig activities; determining a finish time
for the first activity by evaluating the written report of service
rig activities; and evaluating the sensor data on the chart between
the start time and the finish time of the first activity.
36. The method of claim 34, wherein determining if the sensor data
is consistent with the first activity from the written report is
completed by a customer receiving the service rig activities.
37. The method of claim 34, further comprising the steps of: d.
repeating steps (b)-(c) for each chart of sensor data associated
with work completed at the well site; and e. repeating steps
(a)-(d) for each additional activity from the written report of
service rig activities.
38. The method of claim 34, wherein the written report of service
rig activities is generated for each work shift completed by a rig
crew operating the service rig.
39. The method of claim 34, wherein each of the charts of sensor
data are presented on a monitor.
40. The method of claim 34, wherein the sensor data is obtained
from at least one sensor on the well service rig.
41. The method of claim 34, wherein the at least one chart
comprises a rig load chart.
42. The method of claim 34, wherein the at least one chart
comprises a hydraulic pressure chart.
43. The method of claim 34, wherein the at least one chart
comprises an engine speed chart.
Description
STATEMENT OF RELATED PATENT APPLICATION
[0001] This non-provisional patent application claims priority
under 35 U.S.C. .sctn. 119 to U.S. Provisional Patent Application
No. 60/716,612, titled Interpretive Techniques Using Sensor Data,
filed Sep. 13, 2005. This provisional application is hereby fully
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The technical field of the present invention relates
generally to evaluation of data concerning servicing hydrocarbon
wells and more specifically to an evaluation of data obtained from
a computerized work over rig adapted to record and transmit data
concerning well servicing activities and conditions at a well
site.
BACKGROUND OF THE INVENTION
[0003] After a well has been drilled, it must be completed before
it can produce gas or oil. Once completed, a variety of events may
occur to the formation, the well and its equipment that requires a
"work-over." For purposes of this application, "work-over" and
"service" operations are used in their very broadest sense to refer
to any and all activities performed on or for a well to repair or
rehabilitate the well, and also includes activities to shut in or
cap the well. Generally, work over operations include such things
as replacing worn or damaged parts (e.g., a pump, sucker rods,
tubing, and packer glands), applying secondary or tertiary recovery
techniques, such as chemical or hot oil treatments, cementing the
well bore, and logging the well bore to name just a few. Service
operations are usually performed by or involve a mobile work-over
or well service rig that is adapted to, among other things, pull
the well tubing or rods and also to run the tubing or rods back in.
Typically, these mobile service rigs are motor vehicle-based and
have an extendible, jack-up derrick complete with draw works and
block. In addition to the service or service rig, additional
service companies and equipment may be involved to provide
specialize operations. Examples of such specialized services
includes: a chemical tanker, a cementing truck or trailer, a well
logging truck, perforating truck, and a hot-oiler truck or
trailer.
[0004] It is conventional for a well owner to contract with a
service company to provide all or a portion of the necessary
work-over operations. For example, a well owner, or customer, may
contract with a service rig provider to pull the tubing from a
specific well, contract with one or more service providers to
provide other specific services in conjunction with the service rig
company so that the well can be rehabilitated according to the
owner's direction.
[0005] It is typical for the well owner to receive individual
invoices for services rendered from each company that was involved
in the work over. For example, if the portable service rig spent
thirty hours at the well site, the customer well owner will be
billed for thirty rig hours at the prevailing hourly rate. The
customer is rarely provided any detail on this bill as to when the
various other individual operations were started or completed, or
how much material was used. Occasionally, the customer might be
supplied with handwritten notes from the rig operator, but such is
the exception, not the rule. Similarly, the customer will receive
invoices from the other service companies that were involved with
working over the well. The customer is often left with little to no
indication of whether the service operation for which it is billed
were done properly, and in some cases, even done at all. Further,
most well owners own more than one well in a given field and the
invoices from the various companies may confuse the well name with
the services rendered. Also, if an accident or some other notable
incident occurs at the well site during a service operation, it may
be difficult to determine the root cause or who was involved
because there is rarely any documentation of what actually went on
at the well site. Of course, a well owner can have one of his
agents at the well site to monitor the work-over operations and
report back to the owner, but such "hands-on" reporting is often
times prohibitively expensive.
[0006] The present invention is directed to ameliorating these and
other problems associated with oil well work-over operations.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to incrementing a well
service rig in such a manner that activity-based and/or time-based
data for the well site is recorded and evaluated. The invention
contemplates that the acquired data can be transmitted in near
real-time or periodically via wired, wireless, satellite or
physical transfer such as by memory module to a data center
preferably controlled by the service rig owner, but alternately
controlled by the well owner or another.
[0008] For one aspect of the present invention, a method of
determining the accuracy of an activity listing for activities
completed by a well service rig at a well site can include
determining a first activity from an activity listing, such as a
Gantt chart. Charts of sensor data can be evaluated. The charts can
be of sensor data obtained from sensors on the well service rig and
the data can be associated with work completed at the well site by
the service rig, other service vehicles or by third party
operators. An evaluation of the charts of sensor data can be
conducted to determine if the activity listed in the Gantt chart
corresponds with the data that is being received from the sensors
and displayed on the data charts.
[0009] For another aspect of the present invention, a method of
determining the completion times for an activity completed by a
well service rig at a well site can be determined by evaluating one
or more charts of sensor data associated with work completed at the
well site. An activity can be determined through the evaluation of
the charts of sensor data and the time to complete that activity
can be determined. Once determined, the completion time can be
recorded in a computer program.
[0010] For yet another aspect of the present invention, method of
determining service rig downtime can be achieved by evaluating one
or more charts of sensor data associated with work completed at the
well site. Each chart of sensor data can be evaluated to determine
if a portion of the data on that particular chart includes a
substantially flat or missing string of data for a predetermined
length of time, for example, fifteen minutes. The time period of
the substantially flat or missing data can be determined and other
charts of sensor data can be evaluated to determined if they have
substantially flat or missing data for the same time period.
BRIEF DESCRIPTION OF DRAWINGS
[0011] For a more complete understanding of the exemplary
embodiments of the present invention and the advantages thereof,
reference is now made to the following description in conjunction
with the accompanying drawings in which:
[0012] FIGS. 1A and 1B are flowcharts of an exemplary process for
of a well servicing activity cycle according to one exemplary
embodiment of the present invention;
[0013] FIG. 2 illustrates one embodiment an activity capture
methodology outlined in tabular form according to one exemplary
embodiment of the present invention;
[0014] FIG. 3 provides a frontal view of an exemplary operator
interface according to one exemplary embodiment of the present
invention;
[0015] FIG. 4 provides an illustration of an exemplary activity
capture map according to one exemplary embodiment of the present
invention;
[0016] FIG. 5 is a side view of a mobile service rig with its
derrick extended according to one exemplary embodiment of the
present invention;
[0017] FIG. 6 is a side view of the mobile service rig illustrating
the raising and lowering of an inner tubing string according to one
exemplary embodiment of the present invention;
[0018] FIGS. 7, 7A, and 8 are exemplary displays that include
activity Gantt charts according to one exemplary embodiment of the
present invention;
[0019] FIG. 9 is a flowchart of an exemplary process for evaluating
and determining the accuracy of an activity Gantt chart according
to one exemplary embodiment of the present invention;
[0020] FIG. 10 is an exemplary electronic display of readings from
sensors on a mobile service rig according to one exemplary
embodiment of the present invention;
[0021] FIG. 11 is a flowchart of an exemplary process for measuring
completion times for jobs completed by evaluating the exemplary
electronic display of readings from sensors on the mobile service
rig according to one exemplary embodiment of the present
invention;
[0022] FIG. 12 is an exemplary electronic display of readings from
sensors on a mobile service rig according to one exemplary
embodiment of the present invention; and
[0023] FIG. 13 is a flowchart of an exemplary process for
determining downtime by evaluating the exemplary electronic display
of readings from sensors on the mobile service rig according to one
exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0024] Because the mobile service rig is typically the center of
work-over or service operations at the well site, the present
invention is directed to incrementing the service rig in such a
manner that activity-based and/or time-based data for the well site
is recorded. The invention contemplates that the acquired data can
be transmitted in near real-time or periodically via wired,
wireless, satellite or physical transfer such as by memory module
to a data center preferably controlled by the service rig owner,
but alternately controlled by the well owner or another. The data
can thereafter be used to evaluate the data and supervise from
off-site the activities of the well service rig. This latter
implementation of the invention permits a service rig owner,
supervisor, or well-owner customer to monitor the work being
completed by the well service rig and other third parties based on
data that is provided and can be reviewed after the fact or
substantially in real-time. As described below in more detail, by
accessing the data through a regularly updated web portal, the
customer may be able to determine in near real time that, for
example, the tubing pull will be completed in approximately two
hours, how long the pull took, and whether to time to complete was
excessive due to other operations or unexpected or wasted downtime.
With such information, the owner or supervisor can provide
customers with more accurate billing and train or discipline
service rig crews based on their activities and their completion
times. Further, the customer will have access to detailed data on
the actual service performed and can then verify its invoices. In
addition, the owner or supervisor can evaluate the data to
determine the efficiency and correctness of the reports generated
by the service rig operator.
[0025] The present invention fosters a synergistic relationship
among the customer and the service companies that promotes a safe
environment by monitoring crew work activities and equipment
speeds, improving productivity, reducing operation expenses through
improved job processes, better data management, and reduced
operational failures.
[0026] Implementation of the invention on a conventional service
rig can be conceptualized in two main aspects: 1) acquisition,
recordation and transmission of transducer data such as hook load,
hydraulic pressure, flow rate, etc. and 2) acquisition,
recordation, and transmission of service-based activity, such as
"Rig Up," "Nipple Up Blow Out Preventer," and "Pull Tubing," among
others. Acquisition of physical transducer or sensor data can be
achieved through automated means, such as a transducer that
converts pressure to an electrical signal being fed to an
analog-to-digital converter and then to a recoding means, such as a
hard drive in a computer or memory in a microprocessor. Acquisition
of service-based activity may be achieved by service rig operator
input into a microprocessor-based system. It is contemplated that
the transducer data and activity data may be acquired by and stored
by the same or different systems, depending the design and
requirements of the service rig.
[0027] In a certain implementation of the invention, it may be
desirable to make the acquisition and storage of the data at the
well site secure to the extent that the service rig operator or
other service company representatives are not able to manipulate or
adulterate the data. One implementation of this inventive concept
is to not allow error correction in the field. In other words, if
the rig operator inadvertently inputs that a tubing pull service
has begun when in fact the operation is nippling up the BOP, the
operator can immediately input that the tubing pull has ended and
input that the nipple up process has started. Additionally or
alternatively, the operator may annotate an activity entry, or
annotation may be restricted to personnel at the data center. It is
also contemplated that the operator (or other inputer) can have
complete editorial control over the data (both transducer data and
activity data) received into the storage system.
[0028] The invention contemplates that transducer sensor data
and/or activity data from third party service providers will also
be input into the service rig data captive system. For example,
third party service vehicles may utilize an identity beacon that
emits a signal, such as an electromagnetic signal that is received
by the instrumented service rig and records the time that the
specific service rig arrived on site. Alternatively, the rig
operator may manually input such information or other means such as
magnetic cards or the like may be used. Once on site, transducer
sensor data associated with the third party service operation, such
as for example, flow rate or pressure, may be communicated to the
instrumented rig via wire or wireless communication busses. The rig
operator can input third-party activity data in a fashion similar
to rig-based activities. In this and similar fashion, the
instrumented service rig of the present invention can acquire,
store and transmit all or substantially all of the physical and
activity-based data that is generated by working over an oil
well.
[0029] The following is a description of one exemplary embodiment
of the present invention. It will be understood that this exemplary
embodiment is but one way of implementing the present invention and
does not necessarily implement all aspects of the invention.
Therefore, the exemplary embodiment described below should not be
construed to limit or define the outer boundaries of the present
invention.
[0030] The amount of time a service rig spends at a well site can
be broken down into discrete activities, each with a measurable
beginning and ending time. One example of a typical series of
service operations that might be performed at a well include moving
onsite and rigging up the workover rig, pulling sucker rods,
nippling up the blow out preventer ("BOP"), pulling tubing, other
specified operations, running tubing, and well stimulation. Each
activity has an identifiable start point which is associated with a
certain time, and an identifiable end point that is associated with
another certain time so that both the customer and the well service
provider can ensure that the work was actually done and done in a
timely manner.
[0031] Capturing the physical activities that take place at the
well site can be determined by an evaluation of the sensor data
from the transducers or by having the operator of the service rig
input what happens at the well site. Operator input is used to
capture and classify what activities are taking place at the well
site, the time the activities are taking place, any exception
events that prevent, restrict, or extend the completion of an
activity, and the primary cause and responsible party associated
with the exception events. Operator input is obtained by having the
operator enter the activity data into a computer or microprocessor
as the different service operations are taking place so that the
customer and the service provider can have an accurate depiction of
what goes on at the well site.
[0032] In one exemplary embodiment, the operator can simply type
the activity information into a computer located at the well site.
In another embodiment, a computer is provided to the operator with
a number of pre-identified activities already programmed therein.
When the operator starts or stops an activity, he can simply push a
button or an area on a touch-screen display associated with the
computer to log the stopping or starting of that pre-identified
service activity. In a further embodiment, the operator is provided
with a hierarchy of service tasks from which to choose from.
Preferably, this service hierarchy is designed to be intuitive to
the operator, in that the hierarchy is laid out in a manner that is
similar to the progression of various service activities at a well
site.
[0033] Service activities at a well site can generally be divided
into three activity identifiers: global day-in/day-out ("DIDO")
well servicing activities, internal routine activities and external
routine activities. DIDO activities are activities that occur
almost every day that a service rig is at a well site. In the case
of a mobile service rig, examples of DIDO activities include
rigging up the service rig, pulling and laying down rods, pulling
and laying down tubing, picking up and running tubing, picking up
and running rods, and rigging down the service rig. Internal
routine activities are those that frequently occur during well
servicing activities, but aren't necessarily DIDO activities.
Examples of internal routine activities include rigging up or
rigging down an auxiliary service unit, longstroke, cut paraffin,
nipple up/down a BOP, fishing, jarring, swabbing, flowback,
drilling, clean out, well control activities such as killing the
well or circulating fluid, unseating pumps, set/release tubing
anchor, set/release packer, and pick up/laydown drill collars
and/or other tools. Finally, external routine activities are
routine activities that are commonly performed by third parties,
such as rigging up/down third party servicing equipment, well
stimulation, cementing, logging, perforating, or inspecting the
well, and other common servicing tasks.
[0034] FIGS. 1A and 1B illustrate one example of a well servicing
activity cycle. The job starts with the typical DIDO activities,
shown in FIG. 1A, of rigging up the service unit, pulling and
laying down rods, pulling and laying down tubing, and the
respective transitions between those activities. After the tubing
is pulled, other service activities are performed, most of which
are selected from the list of internal routine activities and
external routine activities described above and shown in FIG. 1B.
After the selected internal and external routine activities are
performed, the rig completes the job by picking up and running
tubing and rods, and then rigging down the service unit.
[0035] In one embodiment, the operator enters the activity
identifier (i.e. global day-in/day-out (DIDO) well servicing
activities, internal routine activities and external routine
activities) into the computer system. After the activity has been
identified, the activity is classified based on the operator's
subjective determination of how the activity is progressing to
completion. The normal, default activity could be classified as "ON
TASK: ROUTINE" wherein the job is proceeding according to plan. If
for some reason the work is continuing, but not according to plan,
two alternate activity classifications would be available to the
operator to classify what is happening at the wellsite. Two such
classifications could be "ON TASK: EXTEND," in which the job is
proceeding according to plan under conditions that may extend task
times beyond what is normal, and "ON TASK: RE-SEQUENCE," where the
pre-planned job sequence has been interrupted, though work has not
yet ceased. For example, changing from rigging up an auxiliary
service unit to nippling up a BOP before the auxiliary service unit
is completely rigged up would fall within this term. A single
activity can be re-classified at any time while the activity is
being performed. For instance, when a service rig starts rigging
up, the "rig up" activity identifier would likely be classified as
"ON TASK: ROUTINE." However, if problems are encountered causing
the rigging up time to extend beyond what the normal rigging up
time, the "rig up" activity could then be reclassified as "ON TASK:
EXTEND."
[0036] In some instances, work is completely halted, and these
cases, the operator would classify the activity as one of a number
of exceptions. One type of exception classifications is "EXCEPTION:
SUSPEND", in which ongoing work activity has been interrupted due
to a work-site condition and/or event that is temporary, and whose
duration is unlikely to be longer than a set period of time, for
instance, 10 minutes. Such "EXCEPTION: SUSPEND" conditions are
generally non-emergency situations that include anything from a
lunch or work break to a visit from the customer to discuss the
well servicing operations. Another such exception classification is
"EXCEPTION: WAIT" in which the pre-planned work process has been
suspended due to the unavailability of a required resource, such as
unavailable personnel, material, or an unavailable third-party
service. A final type of exception classification is "EXCEPTION:
DOWN," in which the preplanned work process has ceased due to
unplanned events and/or conditions occurring at the well site. Such
unplanned events include change of scope of the service activity,
changed well conditions, mechanical failure, weather, unsafe
conditions, health and safety training events, and other unplanned
events.
[0037] In one exemplary embodiment, for every activity
classification other than "ON TASK: ROUTINE," a variance identifier
is assigned to the activity classification linking the reason for
the non-routine classification to its source. If the activity
classification is "ON TASK: EXTEND," "ON TASK: RESEQUENCE," or
"EXCEPTION SUSPEND," the variance identifier could be any of the
aforementioned reasons for classifying exceptions, such as "SERVICE
AVAILABILITY," "MATERIAL AVAILABILITY," "PERSONNEL AVAILABILITY,"
"SCOPE CHANGE," "WELL CONDITION CHANGE," "MECHANICAL FAILURE,"
"WEATHER, UNSAFE CONDITION," "HEALTH AND SAFETY EVENT," "WORK
BREAK," or other change in the work conditions. As described
earlier, if the activity classification is "EXCEPTION: WAIT," the
variance identifier would be selected from as "SERVICE
AVAILABILITY," "MATERIAL AVAILABILITY," or "PERSONNEL
AVAILABILITY," because "EXCEPTION: WAIT" is the activity
classification in which the pre-planned work process has been
suspended due to the unavailability of a required resource. If the
activity classification is "EXCEPTION: DOWN," the variance
identifier would be selected from the group comprising "SCOPE
CHANGE," "WELL CONDITION CHANGE," "MECHANICAL FAILURE," "WEATHER,
UNSAFE CONDITION," "HEALTH AND SAFETY EVENT," "WORK BREAK," or
other unanticipated change in the work conditions. This is because
the "EXCEPTION: DOWN" activity classification covers exceptions in
which the preplanned work process has ceased due to unplanned
events and/or conditions occurring at the well site.
[0038] After the variance identifier has been selected, the
variance can be classified appropriately so as to be assigned to a
responsible party. Generally, the responsible party will be the
well service provider, a third party, or the customer. In one
embodiment, the variance classification will be selected between
"WELL SERVICE PROVIDER," "CUSTOMER" or "3RD PARTY." After the
variance classification has been selected, the operator is done
entering information in to the computer until the present activity
is completed or the next activity is started.
[0039] Referring to FIG. 2, one embodiment of the aforementioned
activity capture and display system is outlined in tabular form. As
is shown in FIG. 2, an operator first chooses an activity
identifier for his/her upcoming task. If "GLOBAL" is chosen, then,
as shown in FIG. 1A, the operator would choose from rig up/down,
pull/run tubing or rods, or laydown/pickup tubing and rods (options
not shown in FIG. 2). If "ROUTINE: INTERNAL" is selected, then the
operator would choose from rigging up or rigging down an auxiliary
service unit, longstroke, cut paraffin, nipple up/down a BOP,
fishing, jarring, swabbing, flowback, drilling, clean out, well
control activities such as killing the well or circulating fluid,
unseating pumps, set/release tubing anchor, set/release packer, and
pick up/laydown drill collars and/or other tools, as shown in FIG.
1B. Finally, if "ROUTINE: EXTERNAL" is chosen, the operator would
then select an activity that is being performed by a third party,
such as rigging up/down third party servicing equipment, well
stimulation, cementing, logging, perforating, inspecting the well,
and/or other common third party servicing tasks, as shown in FIG.
1B. After the activity is identified, it is classified. For all
classifications other than "ON TASK: ROUTINE," a variance
identifier is selected, and then classified using the variance
classification values.
[0040] As explained above, all that is required from the operator
is that he or she enter in the activity data into a computer, such
as the one shown in FIG. 3. The operator can interface with the
computer using a variety of means, including typing on a keyboard,
using a mouse or other input device, or using a monitor that is
designed as a touch-screen display. In one embodiment, a monitor 48
with pre-programmed buttons 10 is provided to the operator, such as
the one shown in FIG. 3, which allows the operator to simply select
the activity from a group of pre-programmed buttons. For instance,
if the operator were presented with the screen of FIG. 3 upon
arriving at the well site, the operator would first press the "RIG
UP" button. The operator would then be presented with the option to
select, for example, "SERVICE UNIT," "AUXILIARY SERVICE UNIT," or
"THIRD PARTY." The operator then would select whether the activity
was on task, or if there was an exception, as described above.
[0041] An example of an activity capture map for pulling operations
is shown in FIG. 4. If an operator were to select "PULL" from the
top screen, he would then have the option to select between "RODS,"
"TUBING," "DRILL COLLARS," or "OTHER." If the operator chose
"RODS," the operator would then choose from "PUMP," "PART,"
"FISHING TOOL," or "OTHER." The operator would be trained on the
start and stop times for each activity, as shown in the last to
columns of FIG. 4 so that the operator could appropriately document
the duration of the activity at the well site. Each selection would
have its own subset of tasks, as described above, but for ease of
understanding, only those pulling rods or shown in FIG. 4.
[0042] In one embodiment of the present invention, the activity
data is gathered by the computer along with process data from the
well service vehicle, such as is described in U.S. Pat. No.
6,079,490, which is hereby incorporated by reference. Referring to
FIG. 5, a retractable, self-contained mobile service rig 20 is
shown to include a truck frame 22 supported on wheels 24, an engine
26, a hydraulic pump 28, an air compressor 30, a first transmission
32, a second transmission 34, a variable speed hoist 36, a block
38, an extendible derrick 40, a first hydraulic cylinder 42, a
second hydraulic cylinder 44, a first transducer 46, a monitor 48,
and retractable feet 50. Monitor 48, of special importance to the
disclosed invention, receives amongst other things various
parameters measured during the mobile service rig's operation.
[0043] Engine 26 selectively couples to wheels 24 and hoist 36 by
way of transmissions 34 and 32, respectively. Engine 26 also drives
hydraulic pump 28 via line 29 and air compressor 30 via line 31.
Compressor 30 powers a pneumatic slip 84, and the hydraulic pump 28
powers a set of hydraulic tongs. The hydraulic pump 28 also powers
cylinders 42 and 44 that respectively extend and pivot derrick 40
to selectively place derrick 40 in a working position and in a
retracted position. In the working position, the derrick 40 is
pointed upward, but its longitudinal centerline 54 is angularly
offset from vertical as indicated by angle 56 of FIG. 5. This
angular offset 56 provides block 38 access to a well bore 58
without interference from the derrick framework and allows for
rapid installation and removal of inner pipe segments (i.e., inner
pipe strings 62) and sucker rods as shown in FIG. 6.
[0044] Individual pipe segments (of string) and sucker rods are
screwed together using hydraulic tongs. Hydraulic tongs are known
in the art, and refer to any hydraulic tool that can screw together
two pipes or sucker rods, such as those provided by B. J. Hughes
company of Houston, Tex. In operation, the hydraulic pump drives a
hydraulic motor in either forward or reverse directions by way of
valve. The hydraulic motor drives pinions that turn a wrench
element relative to clamp. The wrench element and the clamp engage
flats on mating couplings of a sucker rod or inner pipe string;
however, rotational jaws or grippers that hydraulically clamp on to
a round pipe (i.e., with no flats) can also be used in place of the
disclosed wrench element. The rotational direction of hydraulic
motor determines whether the couplings are assembled or
disassembled.
[0045] A transducer detects by feedback the amount of torque that
is used to assemble or disassemble the string or sucker rods, and
provides an analog or digital signal (e.g., from 0-5 Volts DC)
indicative of that torque value. This signal is provided to a
monitor 48 and is stored in a manner to be described shortly.
[0046] When installing inner pipe string segments, a pneumatic slip
is used to hold the pipe string while the next segment is screwed
on using tongs as just described. A compressor provides pressurized
air through a valve to rapidly clamp and release the slip. A tank
helps maintain constant air pressure. A pressure switch, a type of
transducer or sensor, provides the monitor 48 with a signal that
indirectly indicates that repair unit 20 is in operation.
[0047] Referring back to FIG. 5, weight applied to block 38 is
sensed by way of a hydraulic pad 92 that supports the weight of
derrick 40. Hydraulic pad 92 is basically a piston within a
cylinder such as those provided by M. D. Totco company of Cedar
Park, Tex., but can alternatively constitute a line indicator or a
diaphragm. Hydraulic pressure in pad 92 increases with increasing
weight on the block 38, and this pressure can accordingly be
monitored to assess the weight of the block 38. Thus, the hydraulic
pad 92 constitutes another type of transducer, and it too transmits
a signal (not shown) to the monitor 48.
[0048] In short, and as is well known, the mobile service rig
contains numerous tools for performing various repair tasks, and
most of these tools contain some sort of transducer for providing
an indication of the work being performed. (As used herein,
"transducer" should be understood as any sort of detector, sensor,
or measuring device for providing a signal indicative of the work
being performed by a particular tool). Using such transducers,
important parameters can be measured or monitored, such as hook
load, tong torque, engine RPM, hydrogen sulfide concentration, a
block position encoder for determining where the block is in is
travel, engine oil pressure, clutch air pressure, global
positioning system monitor, and any other sensor that might provide
data worth being monitored by the well service provider.
[0049] As noted above, the signals provide by the various
transducers/sensors associated with the tools are sent to the data
acquisition monitor 48. The primary objective of the monitor 48 is
to gather well maintenance data and save it so that it can be
transferred and subsequently monitored at a site other than the
location of the mobile service rig, such as a central office site,
where a supervisor or owner can view the data on another monitor 48
or other display device known to those or ordinary skill in the
art. The monitor 48 is generally installed in an openly accessible
location on the mobile service rig 20. For example, on a mobile
service rig 20, the monitor 48 is installed somewhere outside the
cab for easy access by human operators who may walk up to the
mobile service rig 20 to interface with the system and collect
data. In an alternative exemplary embodiment, the data can be
transmitted via wireless communication to a computer or other
display device to an evaluator in the same or different location.
In addition to storing the measured data from the tools, the
monitor 48 may also include a screen display for displaying the
data.
[0050] The signals provide by the various sensors associated with
the tools can be sent to the same or a different computer at which
the operator enters the activity data at the will. The computer(s)
can then gather well maintenance data and save it so that it can be
correlated to the activity data entered by the operator. In one
embodiment, the process data can be displayed on a screen for the
operators to review. In yet another exemplary embodiment, the
activity data and the process data can be transferred and
subsequently monitored at a site other than the location of the
mobile service rig 20, such as a centrally located office site. In
one embodiment, the activity and process data is transferred using
a modem and cellular phone arrangement such as is described in U.S.
Pat. No. 6,079,490. In other embodiments, the data is transferred
using other types of wireless communication, such as via a
satellite hookup (Not Shown). The data can also be transferred
using a hard disk medium, wherein the data is saved on a floppy
disk, CD, or other memory storage device and physically transferred
to the central office site. There are a wide variety means to
transfer the data from the well site to the central office site,
and such means are widely known in the art and are considered
within the scope of this invention.
[0051] Processes of exemplary embodiments of the present invention
will now be discussed with reference to FIGS. 9, 11, and 13.
Certain steps in the processes described below must naturally
precede others for the present invention to function as described.
However, the present invention is not limited to the order of the
steps described if such order or sequence does not alter the
functionality of the present invention in an undesirable manner.
That is, it is recognized that some steps may be performed before
or after other steps or in parallel with other steps without
departing from the scope and spirit of the present invention.
[0052] Turning now to FIGS. 7, 7A and 8 an illustration of
exemplary displays 700, 750, 800 that include activity Gantt charts
in accordance with an exemplary embodiment of the present invention
are shown and described within the exemplary operating environment
of FIGS. 5 and 6. Now referring to FIGS. 5, 6, 7, 7A, and 8, the
exemplary display 700 includes an activity Gantt chart 705. The
exemplary display 700 also includes, in one exemplary embodiment,
charts for other sensors on the repair unit 20, including, but not
limited to an engine speed chart 710, a hydraulic pressure chart
715, and a rig load chart 720. The activity Gantt chart 705, engine
speed chart 710, hydraulic pressure chart 715, and rig load chart
720 each include an X-axis represented by time. In one exemplary
embodiment, the activity Gantt chart 705 represents time in hours
and minutes, however other methods of tracking data against time
can be used. The engine speed chart 710 includes a Y-axis
representing engine speed in revolutions per minute ("rpm"). The
hydraulic pressure chart 715 includes a Y-axis representing
hydraulic pressure in pounds per square inch ("psi"). The rig load
chart 720 includes a Y-axis representing weight in pounds.
[0053] In one exemplary embodiment, the operator of the repair unit
20 or an off-site or on-site supervisor may view the display 700 on
the monitor 48 of FIG. 5 or a monitor 48 positioned at another
location that can be on-site or off-site. The repair unit operator
inserts the activities by pressing icons or buttons 10, as shown in
FIG. 3, to tell the system what activity he is performing at any
given time. When they want to view the activity Gantt chart, the
operator or supervisor can select an icon or button requesting its
display on the monitor 48. In one exemplary embodiment, the view is
as shown on the display 700 of FIG. 7, such that the spacing
provided for in a normal view of the four charts 705-720 does not
allow the activity Gantt chart 705 to display the descriptions of
each activity 725, 730.
[0054] The operator can key in or press a button 10 sending an
input to the system to zoom-in on a smaller period of time as shown
in display 750 of FIG. 7A. The activity Gantt chart 705 of FIG. 7A
includes a first activity time period 735. As can be seen in the
Gantt chart 705, the activity for the first activity time period
735 is described as "Nipple up/down BOP". The Gantt chart 705 also
includes a second activity time period 740. In one exemplary
embodiment, the Gantt chart 705 displays each subsequent activity
along the timeline at a position along the Y-axis above the level
of the next preceding activity. The second activity time period 740
includes a description of the activity as "reconfigure
hoisting/handling equipment," which can represent a normal
in-sequence event that a rig crew completes between tasks, such as
changing out rod tongs for tubing tongs, reversing tong heads, etc.
In one exemplary embodiment, the Gantt chart 705 is capable of
graphically representing every activity completed by the repair
unit 20, activities of third parties, as well as reasons for the
repair unit 20 not completing activities as discussed in FIGS.
1-6.
[0055] FIG. 9 is a logical flowchart diagram illustrating an
exemplary method 900 for evaluating and determining the accuracy of
an activity Gantt chart 705 based on a review of sensor data on a
display as shown in FIGS. 7, 7A and 8. Now referring to FIGS. 7,
7A, 8, and 9, the exemplary method 900 begins at the START step and
continues to step 905 where a request is received to display the
activity Gantt chart 705 on the display 700. In step 910, the
activity Gantt chart 705 is displayed along with the engine speed
chart 710, hydraulic pressure chart 715, and rig load chart 720. In
one exemplary embodiment, the charts 705-720 are displayed one on
top of another so that the time periods represented by each chart
are vertically aligned with one another. In one exemplary
embodiment, the charts 705-720 are displayed on the monitor 48 of
FIG. 3 or 5.
[0056] In step 915, the rig operator or supervisor, well owner,
service rig owner, or other evaluator (collectively the
"supervisor") determines the first activity from the activity Gantt
chart 705. As shown in FIG. 7A, the first activity is represented
by the first activity time period 735. In an alternative
embodiment, the first activity can be determined by reviewing a
written report. The written report can be created by a supervisor
or rig crew member, in one exemplary embodiment the service rig
operator, and can be generated daily, per shift, per job, or any
other time interval, for example every hour or twelve-hour period.
In one exemplary embodiment, the written report is generated each
shift by the rig operator. In one exemplary embodiment, the written
report includes the name or identification of the customer and the
well or wells being serviced, the activities that took place during
that shift, or reasons for downtime, and the time that it took to
complete each activity or the amount of downtime based on each
individual cause of the downtime. While the written report does not
look exactly like the Gantt chart 705, those of ordinary skill in
the art, including supervisors and customers are capable of reading
a written report generated by a rig crew conducting service
activities and determining information related to what activities
were conducted at the well during the service period and the time
period for each service activity or downtime activity.
[0057] The start and completion times for the first activity are
determined in step 920. For example, the start time for the first
activity time period 735 is approximately 9:16 and the end time is
approximately 9:58. Counter variable X is set equal to one in step
925. In one exemplary embodiment, counter variable X represents a
chart of sensor data from the rig 20, such as charts 710-720. In
step 930, the supervisor evaluates the data generated in the first
chart during the time period 735 for the first activity. In one
exemplary embodiment, as shown in FIG. 7A, the supervisor
determines the activity listed for the first activity time period
735 and looks at the same time period for the engine speed chart
710 to determine if the data presented by the engine speed chart
710 for that time period 735 is consistent with the activity,
nipple up/down BOP, listed for that time period 735.
[0058] In step 935, an inquiry is conducted to determine if the
data in the first chart is consistent with the first activity in
the Gantt chart 705. If not, the "NO" branch is followed to step
965, where the supervisor solicits additional information from the
rig operator to determine why the Gantt chart 705 did not list the
correct activity. The process then continues from step 965 to step
955. On the other hand, if the data in the first chart is
consistent with the first activity, the "YES" branch is followed to
step 940.
[0059] In step 940, an inquiry is conducted to determine if there
is another chart to evaluate on the display 750. In one exemplary
embodiment, the charts that can be displayed and evaluated by a
supervisor can include one or more charts, of which all or only a
portion of the charts being evaluated may be viewable on the
monitor 48 or display at a single time. In the exemplary display
750 of FIG. 7A, three charts 710-720 are viewable and capable of
being compared to the activity Gantt chart 705. As discussed above
with reference to the engine speed chart 705, the supervisor
compares the time period of the first activity time period 735 to
the same time periods in the hydraulic pressure chart 715 and the
rig load chart 720 to determine if the data from each chart 715,
720 is consistent with data that would be output by sensors
providing that data during the activity listed for the first
activity time period 735. If there is another chart to evaluate,
the "YES" branch is followed to step 945, where the counter
variable X is incremented by one. The process then returns from
step 945 to step 930 to evaluate the data in the next chart for the
first time period 735.
[0060] Returning to step 940, if there are no additional charts to
evaluate, the "NO" branch is followed to step 950, where the time
to complete the activity is evaluated to determine if an excessive
amount of time passed to complete the listed activity. In step 955,
an inquiry is conducted to determine if there is another activity
listed on the activity Gantt chart 705. In the example of FIG. 7A,
a second activity is represented by the second activity time period
740 and the activity was designated as "reconfigure
hoisting/handling equipment. If there is another activity, the
"YES" branch is followed to step 960, where the supervisor selects
the next activity for evaluation. The process then returns from
step 960 to step 920 to determine the start and completion times
for the next activity. If the Gantt chart 705 does not include
additional activities for evaluation, the "NO" branch is followed
to the END step.
[0061] FIG. 8 provides an exemplary display 800 illustrating a
Gantt chart 705 listing activities that do not correspond with the
data provided by sensors on the rig 20 to the charts 710-720.
Referring now to FIG. 8, a third activity time period 805
represents an activity on the Gantt chart 705 listed as
"pump/circulate kill fluid". However, the time period 810 shows
high engine speeds on the engine speed chart 710, fluctuating
levels of high and low hydraulic pressure on the hydraulic pressure
chart 715, and a load of fifty thousand pounds on the rig load
chart 720. The data provided by charts 710-720 for time period 810
is inconsistent with pumping and circulating kill fluid as listed
in the fourth activity time period 805. Instead, an analysis of the
data provided by charts 710-720 for time period 810 is more
consistent with pulling and running rods. Based on this analysis,
as discussed in FIG. 9, the supervisor would solicit information
from the rig operator to determine why the Gantt chart 705 does not
list the correct activity.
[0062] FIGS. 10 and 11 represent an exemplary display 1000 and
method 1100 for measuring transition times by evaluating the
display of readings from sensors on the rig 20 according to one
exemplary embodiment of the present invention. Now referring to
FIGS. 5, 6, and 10, transition times, the time is takes to
accomplish a task, can be identified by examining the data curves
presented in the engine speed chart 710, the hydraulic pressure
chart 715, and the rig load chart 720 or other exemplary charts of
sensor data known to those of ordinary skill in the art from the
rig 20. For example, a first time interval 1005 represents the time
the rig 20 is being driven to a service site. This activity is
determined by evaluating the data provided in the charts 710-720.
The engine speed on the engine speed chart 710 for the first time
interval 1005 shows high engine rpm's while the hydraulic pressure
on the hydraulic pressure chart 715 and the rig load on the rig
load chart 720 for the first time interval 1005 are zero or
substantially zero. This combination of data alerts the supervisor
that the activity being completed at this time is rig 20 being
driven to or from a well site.
[0063] The activity occurring during the second time interval 1010
shown in the rig load chart 720 is the mast 40 being removed from
the head ache rack (Not Shown) on the rig 20 and standing up on the
hydraulic pad indicator 92 of FIG. 5. The activity is determined by
evaluating the charts 710-720, which show that the weight on the
hydraulic pad indicator 92 increases from zero to approximately
twenty thousand pounds at data point 1035, which is generally the
weight of the raised derrick 40 with the leveling jacks (not shown)
still in place, while the engine is operating at approximately
thirteen hundred revolutions per minute at data point 1015, which
is generally the speed of the engine when it is raising the derrick
40. The mast 40 is then extended, or scoped out, and the leveling
jacks are retracted. This part of activity 1010 can be determined
by evaluating the charts 710-720, which show that at data point
1020 the engine of the rig 20 is operating at a speed of
approximately twenty-three hundred revolutions per minute, which is
generally the speed necessary to extend the derrick 40, and the rig
weight on the hydraulic pad indicators 92 had increased from twenty
thousand to approximately forty thousand pounds, which is generally
the weight of the extended derrick 40 on the pad indicators 92
after the leveling jacks (not shown) have been retracted. An
operator of ordinary skill would also know this to be the activity
because the hydraulic pressure in chart 715 stays substantially at
the zero level during the activity 1010.
[0064] The activity occurring during the third time interval 1025,
shown in the rig load chart 720, is the crew of the rig working a
pump loose from a stuck position. The activity is determined by
evaluating the charts 710-720, which show that the maximum weight
limits viewable on the rig load chart 720 and high engine speeds on
the engine speed chart 710 were observed during the third time
interval 1025; however, there is virtually no hydraulic pressure
displayed during the third time interval 1025.
[0065] The activity occurring during the fourth time interval 1030,
shown in the rig load chart 720, is the rig 20 pulling rods out of
the well 58. The activity is determined by evaluating the data on
the charts 710-720, which show the cyclical increases in the engine
speed, hydraulic pressure and rig load weight occurring at the same
time intervals during the fourth time interval 1030 and indicative
of rods being pulled from the well 58.
[0066] Now turning to FIG. 11, an exemplary process for measuring
the completion times for jobs completed by evaluating the exemplary
electronic display 1000 begins at the START step and continues to
step 1105 where the system receives an input selecting the display
of charts 710-720. In one exemplary embodiment, the charts can be
reviewed on the monitor 48 of FIG. 5. In an alternative embodiment,
the charts 710-720 may be viewed by printing them out on a printer
or plotter, or other hard-copy format known to those of ordinary
skill in the art.
[0067] In step 1110, a supervisor evaluates the charts 710-720 on
the display 1000. Counter variable X is set equal to one in step
1115. In one exemplary embodiment, counter variable X represents an
activity conducted by the service rig 20. The supervisor determines
the first activity based on an evaluation of the data curves for
the charts 710-720 in the display 1000 in step 1120. In step 1125,
the supervisor determines the second activity based on an
evaluation of the data curves in the charts 710-720 in the display
1000. In step 1130, the supervisor evaluates the data curves in the
charts 710-720 to determine the beginning of the first activity and
the beginning of the second activity. Returning to the example in
FIG. 10, based on the data that is viewable, the beginning of the
first activity, represented by the first time interval 1005, is
approximately 7:40 while the time at the beginning of the second
activity, represented by the second time interval 1010, is
approximately 8:22.
[0068] In step 1135, the difference between the beginning time of
the first activity and the beginning time of the second activity is
recorded as the time to complete the first activity. In one
exemplary embodiment the completion time can be recorded in a
conventional database in a computer, however, those of ordinary
skill in the art will recognize that many other methods or
recording the data may be used, including, but not limited to,
entering the completion time data onto a data sheet for placement
into a record file. In an alternative embodiment, the completion
time for a task may be determined by determining the beginning time
of a task and the end time of the same task and recording the
difference between those two times as the time to complete the
task. Retuning to the example in FIG. 10, the beginning time for
the first task is approximately 7:40 and the completion time for
the first task is approximately 7:55, which would be a completion
time of approximately fifteen minutes.
[0069] The supervisor determines if the completion time for the
activity is excessive in step 1140. In one exemplary embodiment,
the supervisor can use his personal judgment to make this
determination or he may reference additional data that provides the
average time to complete this task and/or acceptable time ranges
for completing this task and use that information for the
determination. In step 1145, an inquiry is conducted to determine
if the activity completion time is excessive. If so, the "YES"
branch is followed to step 1150, where additional instruction is
provided to the crew related to that activity or disciplinary
action is taken against the crew members for that rig 20. If the
completion time for that activity is not excessive, the "NO" branch
is followed to step 1155.
[0070] In step 1155, an inquiry is conducted to determine if there
is another activity shown on the charts 710-720 in the display
1000. If so, the "YES" branch is followed to step 1160, where
counter variable X is incremented by one. The process then returns
from step 1160 to step 1120 to evaluate the completion time for the
next activity. On the other hand, if there are no additional
activities based on an evaluation of the display 1000, the "NO"
branch is followed to the END step.
[0071] FIGS. 12 and 13 represent an exemplary display 1200 and
method 1300 for measuring wait times or downtimes by evaluating the
display 1200 of readings from sensors on the rig 20 according to
one exemplary embodiment of the present invention. Now referring to
FIGS. 3, 5, and 12, downtimes can be identified by curves on the
charts 710-720 that are inactive or flat. During downtimes, the
engine 26 for the rig 20 may or may not be running and the rig 20
may or may not be registering a load on the rig load chart 720. In
one exemplary embodiment, prior to calling a period a downtime the
data on the charts 710-720 must be examined in sequence with the
other activities shown in the display 1200 to determine what is
happening on the rig 20. For example, nippling up a blow out
preventer often looks like downtime, but that is normally in a
sequence of events prior to pulling tubing from the well.
[0072] In FIG. 12, an evaluation of the charts 710-720 for a first
time period 1205 shows that the rig 20 is pulling rods out of the
well and hanging them in the derrick. During the second time period
1210, the load data in the rig load chart 720 is virtually constant
(flat) and shows a load of approximately forty-six thousand pounds.
For that same time period 1220 on the hydraulic pressure chart 720,
the hydraulic pressure data is substantially zero for the entire
time period 1220. During that same time period 1125 on the engine
speed chart 710, the engine speed is zero for a substantial portion
of that time period. The time period shown by 1210, 1220, 1225 is
considered a downtime based on the data provided by the charts
710-720. This is confirmed by evaluating the third time period
1215, where the supervisor can determined from the data on the
charts that the rig 20 is running rods and a pump back into the
well 58 during that time period 1220. In one exemplary embodiment,
a pump change can be determined by evaluating the time periods and
recognizing that the third time period 1215 is immediately after or
substantially close in time after the third time period, typically
about ten minutes. Generally, any time over the ten minute time
period would be classified as flat or downtime, in one exemplary
embodiment.
[0073] Now turning to FIG. 13, an exemplary process for determining
downtime by evaluating the charts 710-720 on the exemplary
electronic display 1200 begins at the START step and continues to
step 1305 where the supervisor reviews the charts 710-720 on the
display 1200. Counter variable X is set equal to one in step 1310.
In one exemplary embodiment, counter variable X represents a chart
of data from a sensor at the rig 20. In step 1315 the first chart
is evaluated to determine if there is a predetermined amount of
time that the curve for the first chart is off or substantially
flat. In one exemplary embodiment any of the charts 710-720 in FIG.
12 or any other charts of sensor data from the rig 20 may be
considered as the first chart for evaluation purposes. In one
exemplary embodiment, the predetermined amount of time is fifteen
minutes; however, longer and shorter time period are within the
scope of this invention.
[0074] In step 1320, an inquiry is conducted to determine if a
portion of the first chart contains data that is substantially flat
or that is missing for a predetermined amount of time. If the first
chart does not contain an area of data that is substantially flat
or missing, the "NO" branch is followed back to step 1315 where
evaluation of the first chart continues. On the other hand, if
there is a portion of the chart that has data that is substantially
flat or missing, the "YES" branch is followed to step 1325, where
the time period of the flat data is determined. For example, in
FIG. 12, an evaluation of the data in the rig load chart 720 shows
a time period 1210 of data that is substantially flat for more than
fifteen minutes. A review of that time period 1210 shows the start
of the time period 1210 is approximately 11:20 a.m. and the end is
approximately 2:15 p.m.
[0075] In step 1330, an inquiry is conducted to determine if the is
another chart of sensor data from the rig 20. Returning to the
example of FIG. 12, the charts 710 and 715 would satisfy this
inquiry. If there are no additional charts on the display 1200, the
"NO" branch is followed to step 1345, where the time period is
classified as a downtime period. If there are additional charts to
evaluate, the "YES" branch is followed to step 1335, where counter
variable X is incremented by one. In step 1340, an inquiry is
conducted to determine if the next chart, for example the hydraulic
pressure chart 715, has a substantially flat curve or missing data
for the same time period 1210. If the second chart does not have a
substantially flat curve or missing data for that time period 1210,
the "NO" branch is followed to step 1310. Otherwise the "YES"
branch is followed to step 1330. As can be seen in the exemplary
display 1200 of FIG. 12, during the time period 1210, the hydraulic
pressure chart 715 has a time period 1220 that contains data that
is substantially flat, and the engine speed chart 710 contains a
time period 1225 that contains data that is substantially flat.
[0076] In step 1350, an inquiry is conducted to determine if the
downtime period is excessive. If so, the "YES" branch is followed
to step 1355, where the supervisor can solicit additional
information from the rig operator to determine the reason for the
rig 20 downtime or the rig crew can be disciplined for the
excessive downtime. The process then continues from step 1355 to
the END step. On the other hand, if the downtime period is not
excessive, the "NO" branch is followed to the END step.
[0077] Although the invention is described with reference to a
preferred embodiment, it should be appreciated by those skilled in
the art that various modifications are well within the scope of the
invention. Therefore, the scope of the invention is to be
determined by reference to the claims that follow. From the
foregoing, it will be appreciated that an embodiment of the present
invention overcomes the limitations of the prior art. Those skilled
in the art will appreciate that the present invention is not
limited to any specifically discussed application and that the
embodiments described herein are illustrative and not restrictive.
From the description of the exemplary embodiments, equivalents of
the elements shown therein will suggest themselves to those or
ordinary skill in the art, and ways of constructing other
embodiments of the present invention will suggest themselves to
practitioners of the art. Therefore, the scope of the present
invention is to be limited only by any claims that follow.
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