U.S. patent application number 12/259386 was filed with the patent office on 2010-04-29 for hydraulic system and method of monitoring.
Invention is credited to Sarmad Adnan, Evgeny Khvoshchev.
Application Number | 20100101785 12/259386 |
Document ID | / |
Family ID | 42116371 |
Filed Date | 2010-04-29 |
United States Patent
Application |
20100101785 |
Kind Code |
A1 |
Khvoshchev; Evgeny ; et
al. |
April 29, 2010 |
Hydraulic System and Method of Monitoring
Abstract
A technique involves monitoring a hydraulic system having a
hydraulic pump coupled to a hydraulic motor which can be used to
drive well related equipment. The system and methodology utilize
sensors positioned to monitor parameters related to operation of
the hydraulic pump and the hydraulic motor. A processor system is
coupled to the sensors to obtain data output by the sensors. The
processor system analyzes the sensor data for failure signatures
that can be used to determine a failure or potential failure in the
hydraulic system.
Inventors: |
Khvoshchev; Evgeny; (Sugar
Land, TX) ; Adnan; Sarmad; (Sugar Land, TX) |
Correspondence
Address: |
SCHLUMBERGER TECHNOLOGY CORPORATION;David Cate
IP DEPT., WELL STIMULATION, 110 SCHLUMBERGER DRIVE, MD1
SUGAR LAND
TX
77478
US
|
Family ID: |
42116371 |
Appl. No.: |
12/259386 |
Filed: |
October 28, 2008 |
Current U.S.
Class: |
166/250.01 ;
166/53 |
Current CPC
Class: |
F04B 51/00 20130101;
E21B 33/13 20130101; E21B 34/16 20130101; E21B 43/25 20130101 |
Class at
Publication: |
166/250.01 ;
166/53 |
International
Class: |
E21B 47/00 20060101
E21B047/00; E21B 43/12 20060101 E21B043/12 |
Claims
1. A method of monitoring a hydraulic system, comprising: coupling
a hydraulic pump with a hydraulic motor via a hydraulic line;
deploying a pressure sensor to measure pressure in the hydraulic
line; processing consecutively recorded data points of a hydraulic
pressure signal received from the pressure sensor to decompose the
consecutively recorded data points into a series of data subsets
representing scaled base functions localized in frequency and time;
using a processor to search the series of data subsets for failure
signatures; and outputting an indication as to whether a failure
condition is found.
2. The method as recited in claim 1, wherein coupling comprises
coupling the hydraulic pump with the hydraulic motor in a closed
loop configuration.
3. The method as recited in claim 1, wherein deploying comprises
deploying a plurality of pressure sensors along the hydraulic
line.
4. The method as recited in claim 1, wherein processing comprises
processing the consecutively recorded data points on a
computer-based system.
5. The method as recited in claim 1, wherein processing comprises
processing data on pump speed and motor speed.
6. The method as recited in claim 5, wherein processing comprises
processing data on motor load.
7. The method as recited in claim 1, wherein processing comprises
processing data on one of pump vibration and motor vibration.
8. The method as recited in claim 1, wherein using the processor
comprises searching for the failure signatures in frequency bands
and at time points that depend on speeds of the hydraulic pump and
the hydraulic motor.
9. The method as recited in claim 1, wherein outputting comprises
displaying information related to a failure signature on a computer
display.
10. The method as recited in claim 1, wherein outputting comprises
displaying information indicating operation of the hydraulic system
within acceptable parameters.
11. A method, comprising: deploying pressure sensors in a hydraulic
system having a hydraulic motor powered by a hydraulic pump;
operatively coupling the pressure sensors to a processing system;
using the pressure sensors to obtain a certain number of
consecutively recorded data points based on hydraulic pressure
signals; and processing the consecutively recorded data points on
the processor system so that the consecutively recorded data points
are decomposed into a series of data subsets representing scaled
base functions that can be used to determine a failure signature
related to operation of the hydraulic system.
12. The method as recited in claim 11, further comprising
operatively coupling additional sensors to the processing
system.
13. The method as recited in claim 12, wherein operatively coupling
additional sensors comprises coupling a hydraulic pump speed
sensor, a hydraulic motor speed sensor, at least one vibration
sensor, and a motor load sensor to the processing system.
14. The method as recited in claim 11, wherein processing comprises
processing in real-time the consecutively recorded data points so
the consecutively recorded data points are decomposed into the
series of data subsets representing scaled base functions localized
in frequency and time.
15. The method as recited in claim 14, further comprising searching
the series of data subsets for the failure signature in frequency
bands and at time points that depend on hydraulic pump speed and
hydraulic motor speed.
16. The method as recited in claim 11, further comprising
outputting an indication as to an operational state of the
hydraulic system.
17. The method as recited in claim 16, wherein outputting comprises
outputting a warning indicating a failure condition based on the
failure signature.
18. The method as recited in claim 11, further comprising
performing an oilfield services operation with the hydraulic
system.
19. A system, comprising: a hydraulic pump; a hydraulic motor
coupled to the hydraulic pump via a hydraulic line; a plurality of
sensors positioned to monitor parameters related to operation of
the hydraulic pump and the hydraulic motor; and a processor system
coupled to the plurality of sensors to obtain data from the
sensors, the processor system having a processor unit to analyze
the data for failure signatures in frequency and time domains.
20. The system as recited in claim 19, wherein the hydraulic pump
comprises a piston based pump.
21. The system as recited in claim 19, wherein the plurality of
sensors comprises a pressure sensor to monitor pressure in the
hydraulic line.
22. The system as recited in claim 19, wherein the plurality of
sensors comprises a hydraulic pump speed sensor and a hydraulic
motor speed sensor.
23. The system as recited in claim 19, wherein the plurality of
sensors comprises a hydraulic motor load sensor.
24. The system as recited in claim 19, wherein the plurality of
sensors comprises at least one pump vibration sensor and at least
one motor vibration sensor.
25. The system as recited in claim 19, wherein the processor system
comprises an output device through which a warning, based on a
failure signature, is automatically provided to an operator.
26. A method, comprising: measuring hydraulic pressure in a
hydraulic line connecting a hydraulic motor with a hydraulic pump;
monitoring hydraulic pump speed with a hydraulic pump speed sensor;
monitoring hydraulic motor speed with a hydraulic motor speed
sensor; outputting data on the hydraulic pressure, hydraulic pump
speed, and hydraulic motor speed to a processor system; and using
the processor system to automatically monitor the data for a
failure condition related to operation of the hydraulic motor and
the hydraulic pump by searching for failure signatures in the
data.
27. The method as recited in claim 26, wherein using comprises
searching for failure signatures in frequency and time domains.
28. The method as recited in claim 26, wherein using comprises
using in real-time consecutively recorded data points, on hydraulic
pressure, decomposed into a series of data subsets representing
scaled base functions localized in frequency and time.
29. The method as recited in claim 26, wherein using comprises
using in real-time consecutively recorded data points, on pump or
motor vibration, decomposed into a series of data subsets
representing scaled base functions localized in frequency and
time.
30. The method as recited in claim 26, wherein searching comprises
one of wavelet analysis, pattern analysis, and Fourier analysis.
Description
BACKGROUND
[0001] A variety of hydraulic systems are used in oilfield service
equipment. Hydraulic systems often utilize a hydraulic pump coupled
to and powering a hydraulic motor used to drive specific well
equipment. For example, the hydraulic systems can be employed in
well cementing operations, well stimulation operations, and coiled
tubing services to drive centrifugal pumps, high-pressure
reciprocating pumps, coiled tubing injector heads, and other types
of equipment. The hydraulic systems often are used in important
applications and their dependability can have a direct impact on
the success of the well service. However, there are no adequate
methods or devices for monitoring operation of the existing
hydraulic systems to determine potential failure conditions.
SUMMARY
[0002] In general, the present invention provides a system and
method of monitoring a hydraulic system having a hydraulic pump
coupled to a hydraulic motor. The system and methodology utilize
sensors positioned to monitor parameters, such as pressure, related
to operation of the hydraulic pump and the hydraulic motor. A
processor system is coupled to the sensors to obtain data output by
the sensors. The processor system comprises a processor unit
designed to analyze the sensor data for failure signatures that can
be used to determine a failure or potential for failure in the
hydraulic system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Certain embodiments of the invention will hereafter be
described with reference to the accompanying drawings, wherein like
reference numerals denote like elements, and:
[0004] FIG. 1 is a schematic front elevation view of a well system
having a hydraulic system utilizing a hydraulic motor and a
hydraulic pump, according to an embodiment of the present
invention;
[0005] FIG. 2 is a schematic illustration of one example of a
hydraulic pumping system, according to an embodiment of the present
invention;
[0006] FIG. 3 is a schematic representation of an example of a
monitoring and control system that can be used in the hydraulic
pumping system illustrated in FIG. 2, according to an embodiment of
the present invention;
[0007] FIG. 4 is a flow chart representing an example of a
methodology for implementing monitoring and control of the
hydraulic system, according to an embodiment of the present
invention;
[0008] FIG. 5 is a flow chart representing another example of a
methodology for implementing monitoring and control of the
hydraulic system, according to an alternate embodiment of the
present invention; and
[0009] FIG. 6 is a flow chart representing another example of a
methodology for implementing monitoring and control of the
hydraulic system, according to an alternate embodiment of the
present invention.
DETAILED DESCRIPTION
[0010] In the following description, numerous details are set forth
to provide an understanding of the present invention. However, it
will be understood by those of ordinary skill in the art that the
present invention may be practiced without these details and that
numerous variations or modifications from the described embodiments
may be possible.
[0011] The present invention relates to a system and method
involving the use of a hydraulic system in a well related
operation. The hydraulic system generally comprises a hydraulic
pump operated to power a hydraulic motor which can be used to drive
a variety of well related systems or components. For example, the
hydraulic system can be used to drive centrifugal pumps,
high-pressure reciprocating pumps, coiled tubing injector heads,
and other components in carrying out a variety of well service
operations, such as well cementing, well stimulation, coiled tubing
services and other well related services. The hydraulic system may
comprise either a closed loop hydraulic system or an open loop
hydraulic system using, for example, a piston based hydraulic pump,
such as an axial-piston or radial-piston type hydraulic pump.
[0012] Additionally, the hydraulic system comprises a monitoring
and control system that obtains data on one or more parameters
related to operation of the hydraulic system. The monitoring and
control system may be a processor based system able to process the
data in a manner that enables determination of failure signatures
in the data. The failure signatures can be analyzed to determine
the presence of a failure condition indicative of a failure or
potential failure in the hydraulic system.
[0013] In one embodiment, the system and methodology comprise
automatically monitoring the health of the hydraulic pump and
hydraulic motor in a hydraulic system. The automatic health
monitoring can be done in real time. By way of example, the
automatic health monitoring can be accomplished based on an
analysis of hydraulic pressure signals obtained from one or more
pressure sensors. The system and methodology further enables
generation of automatic warnings stating or predicting failures of
the hydraulic system. The warnings can be provided audibly and/or
visually through visual indicators, such as icons, graphs, or text
indicating the failure or potential failure. The warnings allow the
monitored hydraulic system or portions of the hydraulic system to
be taken out of service before the occurrence of more serious
conditions.
[0014] Referring generally to FIG. 1, an example of a well system
20 is illustrated according to embodiment of the present invention.
The well system 20 comprises a surface structure 22, such as a rig,
positioned above a wellbore 24 that extends into a subterranean
region 26. The well system 20 further comprises a hydraulic system
28 used in performing an oilfield service operation, such as, but
not limited to, well cementing, a well trement operation such as
well stimulation, coiled tubing services, or for powering wellsite
surface equipment, such as a wireline drum for wireline logging,
and/or auxiliary equipment such as centrifugal pumps and cooling
fans, or the like. The hydraulic system 28 can be coupled to a
variety of components and systems depending on the specific
oilfield service operation to be conducted. As described above, the
hydraulic system 28 can be used to drive coiled tubing injector
heads, a variety of pumps, and other well components, equipment,
and systems.
[0015] Generally, hydraulic system 28 comprises a hydraulic pump 30
coupled to a hydraulic motor 32 to power the hydraulic motor. The
hydraulic motor, in turn, can be connected to the appropriate well
component, e.g. coiled tubing injector head, centrifugal pump,
high-pressure reciprocating pump, a hydraulic power cylinder, or
other component. By way of example, hydraulic pump 30 may comprise
a piston-type pump, e.g. an axial-piston hydraulic pump or a
radial-piston hydraulic pump, driven by a suitable power source
33.
[0016] Referring generally to FIG. 2, one embodiment of hydraulic
system 28 is schematically illustrated. In this embodiment,
hydraulic pump 30 is coupled to hydraulic motor 32 via one or more
hydraulic lines 34 which may be arranged in a closed loop or open
loop configuration. The hydraulic pump 30 may be operated by
rotation of a pump shaft 36 which may be rotated via, for example,
power source 32. Operation of hydraulic pump 30 serves to pump
hydraulic fluid to hydraulic motor 32, as illustrated by arrows 38.
As the hydraulic fluid is pumped through hydraulic motor 32, the
hydraulic motor is rotated and outputs power via hydraulic motor
shaft 40.
[0017] In the embodiment illustrated, hydraulic system 28 further
comprises a processing system 42, such as a monitoring and control
system, coupled to a plurality of sensors disposed throughout
hydraulic system 28. By way of example, the plurality of sensors
may comprise one or more hydraulic sensors 44 for measuring
pressure in the hydraulic line or hydraulic lines 34. In one
embodiment, the hydraulic sensors 44 are positioned along the
hydraulic lines 34, although the specific position of the hydraulic
sensors can vary depending on the hydraulic system configuration.
For example, one or more hydraulic pressure sensors 44 can be
installed in the hydraulic line 34 on the hydraulic pump discharge
side near the hydraulic pump, and one or more additional hydraulic
pressure sensors 44 can be installed in the hydraulic line 34 on
the hydraulic motor pressure side near the hydraulic motor 32.
[0018] The plurality of sensors also may comprise a variety of
additional sensors to detect and monitor a variety of other
hydraulic system related parameters. By way of example, the sensors
may comprise a pump speed sensor 46, a motor speed sensor 48, and a
motor load sensor 50. The pump speed sensor 46 may be installed on
the hydraulic pump input shaft 36 to measure the rotational
frequency of the hydraulic pump 30. Similarly, the motor speed
sensor 48 may be installed on the hydraulic motor output shaft 40
to measure the rotational frequency of the hydraulic motor 32.
Motor load sensor 50 is designed to measure the load on hydraulic
motor 32 and may comprise a motor torque sensor, a pump discharge
pressure sensor (if the hydraulic motor drives a positive
displacement pump), a coiled tubing weight sensor for an injector
head motor drive, or another type of suitable load sensor. The
system 28 may further comprise at least one pump vibration sensor
49 operatively coupled to the pump 30 and at least one motor
vibration sensor 51 operatively coupled to the motor 32. The
vibration sensors 49 and 51 may be, but are not limited to, an
accelerometer, a vibration speed sensor, and a vibration
displacement sensor. The vibration sensors 49 and 51 may be
attached directly to the body or housing of the pump 30 and motor
32, respectively. Alternatively, the vibration sensors 49 and 51
are attached at any location suitable for measuring vibration of
the pump 30 and motor 32 or other mechanical components of the
system 28.
[0019] The plurality of sensors 44, 46, 48, 49, 50, and 51 are
operatively coupled with processing system 42 via a plurality of
communication lines 52. The type of communication line may vary
within the hydraulic system 28 depending on the specific type of
sensor used to monitor the desired hydraulic system parameter. By
way of example, the communication lines 52 may comprise hydraulic
lines, electrical lines, fiber optic lines, wireless communication
lines, and other suitable communication lines for conveying signals
from the sensors to processing system 42 in real-time. Processing
system 42 is able to process and analyze the real-time data
obtained from the one or more hydraulic system pressure sensors,
vibration sensors, and other parameter sensors to monitor the
health of hydraulic system 28. For example, processing system 42
can be utilized to analyze a series of hydraulic pressure data to
look for failure signatures in frequency and time domains, as
discussed in greater detail below.
[0020] Processing system 42 may comprise a variety of monitoring
and/or control configurations, however one embodiment of processing
system 42 is a computer-based processing system, as illustrated
schematically in FIG. 3. The methodology described herein may be
carried out by a computer-based controller 54 able to automate the
data accumulation, processing, analysis, and/or control functions
related to hydraulic system 28. The computer-based controller 54
comprises a processing unit 56 such as a central processing unit
(CPU). The CPU 56 may be operatively coupled to sensors 44, 46, 48,
50 through communication lines 52 and to other components of
computer-based controller 54. For example, the CPU 56 may be
operatively coupled to a memory 58, an input device 60 and an
output device 62.
[0021] Input device 60 may comprise a variety of devices, such as a
keyboard, mouse, voice-recognition unit, touchscreen, other input
devices, or combinations of such devices. Output device 62 may
comprise a visual and/or audio output device, such as a monitor
having a graphical user interface to present information to an
operator. For example, information can be provided to indicate
hydraulic system 28 is operating within desired parameters or to
indicate a failure condition that reflects an actual or potential
failure in the hydraulic system. Additionally, the processing may
be done on a single device or multiple devices at the well
location, away from the well location, or with some devices located
at the well and other devices located remotely.
[0022] In FIG. 4, a flow chart is provided to illustrate a general
functionality of processing system 42 that may be carried out on
the computer-based controller 54. In this example, processing
system 42 is used to monitor parameters related to hydraulic system
28, as illustrated by block 64. The monitoring is accomplished by
processing data from system parameter sensors, e.g. hydraulic
sensors 44, to determine the occurrence of a failure condition, as
illustrated by block 66. If a failure condition is determined, the
processing system 42 automatically outputs a warning signal
indicating a failure or potential failure, as illustrated by block
68. The warning signal can be provided through output device 62
via, for example, visual information and/or audio information.
[0023] The processing system 42 can be designed and programmed to
determine the occurrence of failure conditions by processing data
from one or more of the hydraulic system sensors. One approach is
illustrated by the flowchart of FIG. 5. In this embodiment,
hydraulic pressure data is obtained by monitoring hydraulic
pressure via the one or more hydraulic pressure sensors 44, as
indicated by block 70. The hydraulic pressure data is sent to
processing system 42, and the data is processed for failure
signatures in frequency and time domains, as illustrated by block
72. The automatic analysis of hydraulic pressure data enables the
processing system 42 to determine potential, or actual, failure
conditions in hydraulic system 28, as illustrated by block 74. If a
failure condition is determined, the processing system 42
automatically outputs data to a user regarding the potential
failure condition, as illustrated by block 76. For example,
information can be output in the form of a warning via output
device 62 which may comprise a computer display, e.g. a computer
monitor. It also should be noted that processing system 42 can
output data indicating hydraulic system 28 is operating properly
within desired parameters.
[0024] A specific example of the use of processing system 42 (in
cooperation with sensors 44, 46, 48, 49, 50, and 51) during
operation of hydraulic system 28 is provided by the flowchart
illustrated in FIG. 6. In this embodiment, processing system 42 is
used to measure hydraulic pressure throughout the hydraulic system
28, as illustrated by block 78. Hydraulic sensors 44 can be
disposed along the one or more hydraulic lines 34 and/or within
hydraulic pump 30 and hydraulic motor 32. By way of example, one
hydraulic pressure sensor 44 can be disposed in a pump discharge
segment of hydraulic line 34, and another hydraulic pressure sensor
44 can be installed in a hydraulic motor pressure section of
hydraulic line 34.
[0025] As illustrated, processing system 42 also is designed to
monitor hydraulic pump speed and vibration via one or more
hydraulic pump speed sensors 46 and vibration sensors 49, as
illustrated by block 80. Similarly, system 42 receives data from
one or more hydraulic motor speed sensors 48 and vibration sensors
51 to monitor hydraulic motor speed and vibration, has illustrated
by block 82. Those skilled in the art will appreciate that speed
and vibration need not be measured concurrently as illustrated by
blocks 80 and 82 but may be performed separately, in sequence, or
independently. In some applications, the load on hydraulic motor 32
also can be measured via motor load sensor 50, as indicated by
block 84. Signals output by the hydraulic sensors, speed sensors,
load sensors, and vibration sensors are sent to the computer-based
controller 54 of processing system 42, as represented by block 86.
In this embodiment, the signals are provided to processing system
42 in real-time.
[0026] Once the sensor signal data is received by processing system
42, the signal data is converted into digital form and recorded in
a suitable memory, such as memory 58, as illustrated by block 88.
By way of example, the processing system 42 can be designed to
record data at a rate of a hundred times per second or more. In
this embodiment, processing system 42 comprises an algorithm
designed to select a certain number of consecutively recorded data
points, as illustrated by block 90. The consecutively recorded data
points are decomposed by the processing system 42 into a series of
subsets representing scaled base functions localized in frequency
and time, as illustrated by block 92. The data subsets can then be
searched for failure signatures, as illustrated in block 94. The
failure signatures can be found in frequency bands and at time
points based on hydraulic pump and hydraulic motor speeds provided
by speed sensors 46 and 48, respectively. The scaled base functions
may be selected depending on type of failure that the system 42 is
to detect and one base function may be used for detecting one or
more failure signatures. The base function may be one of many
wavelets and the searching of data subsets in block 94 may be
wavelet analysis. The scaled base function may be a simple sine
wave so the process of block 94 is Fourier analysis. Alternatively,
the searching of block 94 may be pattern analysis. During
operation, the system 42 preferably cycles through all available
base functions to detect different failure signatures.
[0027] If the processed data provides signatures indicative of
failure, those signatures are analyzed via processing system 42 to
determine the severity of actual or potential failure conditions,
as illustrated by block 96. If a failure has occurred or if there
exists sufficient potential for failure, processing system 42
automatically outputs a warning, as illustrated by block 98. For
example, the visual and/or audible warning may be provided via
output device 62. In some applications, processing system 42 also
may be programmed with suitable control features to automatically
adjust operation of the hydraulic system 28 based on the determined
potential for failure, as illustrated by block 100. The adjustments
are subject to hydraulic motor load information provided by motor
load sensor 50.
[0028] The overall well system 20 can be constructed in a variety
of configurations for use in many environments and applications.
For example, various types of hydraulic pumps and hydraulic motors
can be combined in hydraulic system 28. Additionally, the hydraulic
pump 30 can be rotated via a variety of power sources, and the
hydraulic motor 32 can be connected to drive various well
components or systems. Furthermore, the hydraulic system 28 can be
designed as a closed-circuit or open circuit system with hydraulic
sensors located at various positions along the hydraulic system.
Many types of additional sensors also can be incorporated into the
system to detect and monitor a variety of parameters related to
operation of the hydraulic system 28. The processing system 42 can
be designed and programmed according to different forms, and the
system can be physically positioned at one or more locations. A
variety of programs, algorithms, and other processing tools can be
used in processing system 42 to carry out the methodology described
herein.
[0029] Accordingly, although only a few embodiments of the present
invention have been described in detail above, those of ordinary
skill in the art will readily appreciate that many modifications
are possible without materially departing from the teachings of
this invention. Such modifications are intended to be included
within the scope of this invention as defined in the claims.
* * * * *