U.S. patent application number 15/043977 was filed with the patent office on 2016-08-18 for bop control systems and related methods.
The applicant listed for this patent is TRANSOCEAN INNOVATION LABS LTD. Invention is credited to John Matthew Dalton, Luis Pereira.
Application Number | 20160237773 15/043977 |
Document ID | / |
Family ID | 56615602 |
Filed Date | 2016-08-18 |
United States Patent
Application |
20160237773 |
Kind Code |
A1 |
Dalton; John Matthew ; et
al. |
August 18, 2016 |
BOP CONTROL SYSTEMS AND RELATED METHODS
Abstract
Some embodiments of the present BOP control systems include a
system controller configured to actuate a first BOP function by
communicating one or more commands to one or more nodes of a
functional pathway selected from one or more available functional
pathways associated with the first BOP function, each node
comprising an actuatable component configured to actuate in
response to a command received from the system controller, each
node having one or more sensors configured to capture a first data
set corresponding to actuation of the component and a processor
configured to analyze the first data set to determine a useful life
remaining of the component and/or compare the first data set to a
second data set corresponding to a simulation of actuation of the
component.
Inventors: |
Dalton; John Matthew;
(Missouri City, TX) ; Pereira; Luis; (Katy,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TRANSOCEAN INNOVATION LABS LTD |
George Town |
|
KY |
|
|
Family ID: |
56615602 |
Appl. No.: |
15/043977 |
Filed: |
February 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62116541 |
Feb 15, 2015 |
|
|
|
62142422 |
Apr 2, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G05B 23/0283 20130101;
G05B 9/03 20130101; E21B 34/16 20130101 |
International
Class: |
E21B 33/064 20060101
E21B033/064; G05B 23/02 20060101 G05B023/02; G05B 13/04 20060101
G05B013/04 |
Claims
1. A blowout preventer (BOP) control system comprising: a system
controller configured to actuate a first BOP function by
communicating one or more commands to one or more nodes of a
functional pathway selected from at least two functional pathways
associated with the first BOP function; each node comprising an
actuatable component configured to actuate in response to a command
received from the system controller, each node having: one or more
sensors configured to capture a first data set corresponding to
actuation of the component; and a processor configured to: analyze
the first data set to determine a useful life remaining of the
component; and communicate the useful life remaining of the
component to the system controller; where the system controller is
configured to: assign a risk level to each of the at least two
functional pathways based, at least in part, on the useful life
remaining of at least one of the one or more nodes of the
functional pathway; and identify at least one of the at least two
functional pathways for actuating the first BOP function based, at
least in part, on the risk levels of each of the at least two
functional pathways.
2. The control system of claim 1, where the risk level of at least
one of the at least two functional pathways is assigned, based, at
least in part, upon one or more of the following: a number of
functional pathways for actuating the first BOP function; a number
of BOP functions for accomplishing a same outcome as the first BOP
function; and a time elapsed since the previous actuation of the
one or more actuatable components of the one or more nodes of the
functional pathway.
3. The control system of claim 1, where the system controller is
configured to communicate the useful life remaining of the
component of each node to a user.
4. The control system of claim 1 or 3, where the processor of each
node is configured to communicate a fault to the system controller
if the useful life remaining of the component is below a
threshold.
5. The control system of any of claims 1-4, where the processor of
each node is configured to: analyze the first data set to identify
an abnormal actuation of the component; and communicate a fault to
the system controller if an abnormal actuation of the component is
identified.
6. The control system of any of claims 1-5, where the processor of
each node is configured to: compare the first data set to a second
data set corresponding to a simulation of actuation of the
component; and communicate a fault to the system controller if
differences between the first data set and the second data set
exceed a threshold.
7. The control system of claim 6, where at least one node comprises
a memory configured to store at least a portion of the second data
set.
8. A blowout preventer (BOP) control system comprising: a system
controller configured to actuate a first BOP function by
communicating one or more commands to one or more nodes of a
functional pathway selected from one or more functional pathways
associated with the first BOP function; each node comprising an
actuatable component configured to actuate in response to a command
received from the system controller, each node having: one or more
sensors configured to capture at least two sensed values during
actuation of the component; and a processor configured to: receive
the at least two sensed valves from at least one of the one or more
nodes; obtain an expected value of a model based on at least one of
the at least two sensed values; compare the expected value to the
other of the at least two sensed values to obtain a difference
between the two values; and communicate to the system controller
one or more of the following: (i) a fault if the difference between
the two values exceeds a threshold; (ii) a useful life remaining of
the actuatable component based at least on the difference between
the two values; (iii) a risk level based at least on the difference
between the two values; or (iv) the difference between the two
values.
9. The control system of claim 8, where at least one node comprises
a memory configured to store at least a portion of the sensed
values.
10. The control system of claim 8 or 9, where the system controller
is configured to communicate the useful life remaining of the
component of each node to a user.
11. The control system of claims 8 to 10, where the processor of
each node is configured to communicate a fault to the system
controller if the useful life remaining of the component is below a
threshold.
12. A blowout preventer (BOP) control system comprising: a system
controller configured to actuate a first BOP function by
communicating one or more commands to one or more nodes of a
functional pathway selected from one or more available functional
pathways associated with the first BOP function; each node
comprising an actuatable component configured to actuate in
response to a command received from the system controller, each
node having: one or more sensors configured to capture a first data
set during an actuation of the component; and a processor
configured to: adjust one or more coefficients of a model such that
the adjusted model approximates one or more values from the first
data set; and communicate to the system controller data based at
least on at least one of the one or more coefficients of the
adjusted model.
13. The control system of claim 12, where the processor is
configure to compare the one or more coefficients of the adjusted
model to the model to obtain a difference between corresponding
coefficients; and communicate to the system controller one or more
of the following: (i) a fault to the system controller if the
difference between one or more corresponding coefficients exceeds a
threshold; (ii) a failure risk level to the system controller based
at least on the difference between one or more corresponding
coefficients; or (iii) the difference between one or more
corresponding coefficients.
14. The control system of claim 12, where at least one node
comprises a memory configured to store at least a portion of the
first data set.
15. The control system any of claims 12 to 13, where the processor
of each node is configured to: analyze the coefficients of the
adjusted model to determine a useful life remaining of the
actuatable component; and communicate the useful life remaining to
the system controller.
16. The control system of claim 15, where the system controller is
configured to communicate the useful life remaining of the
component of each node to a user.
17. The control system of claim 15 or 16, where the processor of
each node is configured to communicate a fault to the system
controller if the useful life remaining of the component is below a
threshold.
18. The control system of any of claims 7 to16, where the system
controller is configured to remove a first functional pathway from
the one or more functional pathways if one or more nodes of the
first functional pathway communicates a fault or a risk level
exceeding a threshold to the system controller.
19. The control system of claim 18, where the system controller is
configured to remove a second functional pathway from one or more
functional pathways associated with a second BOP function if the
second functional pathway includes one or more of the one or more
nodes of the first functional pathway that communicates a fault or
a risk level exceeding a threshold to the system controller.
20. The control system of any of claims 1-19, where the system
controller is configured to select a second BOP function if one or
more nodes of the first functional pathway associated with the
first BOP function communicates a fault or a risk level exceeding a
threshold to the system controller.
21. The control system of any of claims 7-20, where: the one or
more functional pathways comprises a first functional pathway and a
second functional pathway; and the system controller is configured
to actuate the first BOP function by communicating one or more
commands to one or more nodes of the second functional pathway if
one or more nodes of the first functional pathway communicates a
fault or a risk level exceeding a threshold to the system
controller.
22. The control system of any of claims 1-21, where the system
controller is configured to scan the BOP control system for
available functional pathways for actuating the first BOP
function.
23. The control system of any of claims 1-22, where the system
controller is configured to communicate to a user a number of
available functional pathways for actuating the first BOP
function.
24. The control system of any of claims 1-23, comprising a memory
in communication with each node of a functional pathway.
25. The control system of any of claims 1-24, where at least one
node comprises a memory configured to store at least a portion of
the first data set.
26. The control system of any of claims 1-25, where at least one
node comprises a virtual sensor.
27. The control system of any of claims 1-26, where at least one
node is configured to communicate with the system controller
wirelessly.
28. The control system of any of claims 1-27, where at least one
node is configured to communicate with the system controller
through a wired connection.
29. The control system of any of claims 1-28, where at least one
node is configured to communicate with at least one controller
outside of the BOP control system.
30. The control system of any of claims 1-29, where the component
of at least one node comprises a hydraulic manifold including one
or more actuatable valves.
31. The control system of any of claims 1-30, where the component
of at least one node comprises a hydraulic pump.
32. The control system of claim 31, where the hydraulic pump is
battery-powered.
33. The control system of any of claims 1-32, where the first data
set includes data indicative of a number actuation cycles of the
component.
34. The control system of any of claims 1-33, where the first data
set includes data indicative of a response time of the
component.
35. The control system of any of claims 1-34, where the system
controller comprises two or more system controllers.
36. A method for actuating a first blowout preventer (BOP)
function, the method comprising: selecting a first functional
pathway from two or more available functional pathways associated
with the first BOP function; communicating one or more commands to
an actuatable component of each of one or more nodes of the first
functional pathway to actuate the component, where actuation of the
component of each of the one or more nodes of the first functional
pathway actuates the first BOP function; and receiving, from at
least one of the one or more nodes of the first functional pathway,
information associated with actuation of the component.
37. The method of claim 36, where the received information includes
a useful life remaining of the component.
38. The method of claim 37, where the received information
indicates a fault if the useful life remaining of the component is
below a threshold.
39. The method of any of claims 36-38, where the received
information includes an identification of abnormal actuation of the
component.
40. The method of claim 39, where the received information
indicates a fault if an abnormal actuation of the component is
identified.
41. The method of any of claims 36-40, where the received
information includes differences between a first data set
corresponding to actuation of the component and a second data set
corresponding to a simulation of actuation of the component.
42. The method of claim 41, where the received information
indicates a fault if differences between the first data set and the
second data set exceed a threshold.
43. The method of any of claims 36-42, comprising selecting a
second functional pathway from the two or more available functional
pathways associated with the first BOP function if the received
information indicates a fault.
44. The method of any of claims 36-43, comprising removing the
first functional pathway from the two or more available functional
pathways if the received information indicates a fault.
45. The method of any of claims 36-44, comprising removing a second
functional pathway from two or more available functional pathways
associated with a second BOP function if the received information
indicates a fault of a node common to the first functional pathway
and the second functional pathway.
46. The method of any of claims 36-45, comprising selecting a
second BOP function if the received information indicates a
fault.
47. The method of any of claims 36-46, comprising assigning a risk
level to the first BOP function.
48. The method of claim 47, where the risk level is assigned based,
at least in part, on a number of available functional pathways for
actuating the first BOP function.
49. The method of claim 47 or 48, where the risk level is assigned
based, at least in part, on a harm associated with a failure to
actuate the first BOP function.
50. The method of any of claims 47-49, where the risk level is
assigned based, at least in part, on a type of a fault indicated by
the received information.
51. The method of any of claims 36-50, comprising scanning a BOP
control network for available functional pathways for actuating the
first BOP function.
52. The method of any of claims 36-51, comprising communicating to
a user a number of available functional pathways for actuating the
first BOP function.
53. The method of any of claims 36-52, comprising storing the
received information in a memory.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 62/116,541 filed Feb. 15, 2015, and 62/142,422
filed Apr. 2, 2015, which are specifically incorporated herein by
reference without disclaimer.
BACKGROUND
[0002] 1. Field of Invention
[0003] The present invention relates generally to blowout preventer
control systems, and more specifically, but not by way of
limitation, to blowout preventer control systems including
distributed prognostics and/or diagnostics capabilities.
[0004] 2. Description of Related Art
[0005] A blowout preventer (BOP) is a mechanical device, usually
installed redundantly in stacks, used to seal, control, and/or
monitor oil and gas wells. Typically, a blowout preventer includes
a number of devices, such as, for example, rams, annulars,
accumulators, test valves, failsafe valves, kill and/or choke lines
and/or valves, riser joints, hydraulic connectors, and/or the like,
many of which may be hydraulically actuated.
[0006] BOP operational events may account for approximately 50% of
equipment-related non-productive downtime (NPT) for deep-water
drilling rigs. Among such BOP operational events, approximately 55%
may be directly linked to malfunctions in a BOP control system.
[0007] Typically, BOPs and BOP control systems ("BOP systems") are
operated and maintained on a largely trial-and-error basis. For
example, in a typical BOP system, an operator may have to exercise
some degree of subjective judgment as to when a particular BOP
system component should be undergo maintenance, be replaced, and/or
the like. While maintenance plans and other system requirements may
exist for particular components, these plans and requirements are
typically developed after the components have been designed and/or
implemented. Thus, in some instances, components may be
under-maintained and/or implemented beyond their useful life,
leading to component failure, and in other instances, components
may be unnecessarily maintained and/or replaced, increasing
operating costs and/or presenting a risk of self-induced and/or
premature component failure. Additionally, in the event of a BOP
system component failure, such existing BOP systems typically
require costly NPT to adequately identify the failed component in a
process of elimination approach--sometimes necessitating extraction
of the BOP to the surface.
[0008] Recently, some BOP systems have incorporated limited
component monitoring and reporting capability. However, such
incremental improvements fail to address the importance of BOP
system availability, reliability, and fault-tolerance, particularly
when dealing with safety-critical BOP functions.
[0009] Existing BOP systems, including those with limited component
monitoring and reporting capability, may also fail to account for
the operational condition of the BOP system (e.g., whether the
system is under construction, is drilling, is producing, and/or the
like). Such operational conditions may play a crucial role in
making proper operational and/or maintenance choices with respect
to BOP system components.
SUMMARY
[0010] Some embodiments of the present BOP control systems are
configured, through prognostic and/or diagnostic capability
distributed to one or more nodes, each including a BOP system
component, to maximize system availability (e.g., by monitoring for
degradation of one or more BOP system components, anticipating
failure of the one or more BOP system components, and/or the like).
Some embodiments of the present BOP control systems are configured,
through prognostic and/or diagnostic capability distributed to one
or more nodes, each including a BOP system component, redundant
hardware (e.g., two or more redundant BOP system components and/or
two or more redundant BOP functions for accomplishing a same or a
similar outcome, such as, for example, two or more ram-type BOPs,
each with a close function configured to seal a same well bore),
two or more redundant functional pathways for actuating a same BOP
function, and/or the like, to maximize system reliability and/or
system fault tolerance.
[0011] Some embodiments of the present BOP control systems
comprise: a system controller configured to actuate a first BOP
function by communicating one or more commands to one or more nodes
of a functional pathway selected from one or more available
functional pathways associated with the first BOP function, each
node comprising an actuatable component configured to actuate in
response to a command received from the system controller, each
node having one or more sensors configured to capture a first data
set corresponding to actuation of the component and a
processor.
[0012] Some embodiments of the present BOP control systems
comprise: a system controller configured to actuate a first BOP
function by communicating one or more commands to one or more nodes
of a functional pathway selected from at least two functional
pathways associated with the first BOP function; each node
comprising an actuatable component configured to actuate in
response to a command received from the system controller, each
node having one or more sensors configured to capture a first data
set corresponding to actuation of the component; and a processor
configured to analyze the first data set to determine a useful life
remaining of the component; and communicate the useful life
remaining of the component to the system controller; where the
system controller is configured to assign a risk level to each of
the at least two functional pathways based, at least in part, on
the useful life remaining of at least one of the one or more nodes
of the functional pathway; and identify at least one of the at
least two functional pathways for actuating the first BOP function
based, at least in part, on the risk levels of each of the at least
two functional pathways.
[0013] Some embodiments of the present BOP control systems
comprise: a system controller configured to actuate a first BOP
function by communicating one or more commands to one or more nodes
of a functional pathway selected from one or more functional
pathways associated with the first BOP function; each node
comprising an actuatable component configured to actuate in
response to a command received from the system controller, each
node having one or more sensors configured to capture at least two
sensed values during actuation of the component and a processor
configured to receive the at least two sensed valves from at least
one of the one or more nodes; to obtain an expected value of a
model based on at least one of the at least two sensed values; to
compare the expected value to the other of the at least two sensed
values to obtain a difference between the two values; and to
communicate to the system controller one or more of the following:
(i) a fault if the difference between the two values exceeds a
threshold; (ii) a useful life remaining of the actuatable component
based at least on the difference between the two values; (iii) a
risk level based at least on the difference between the two values;
or (iv) the difference between the two values.
[0014] Some embodiments of the present BOP control systems
comprise: a system controller configured to actuate a first BOP
function by communicating one or more commands to one or more nodes
of a functional pathway selected from one or more available
functional pathways associated with the first BOP function; each
node comprising an actuatable component configured to actuate in
response to a command received from the system controller, each
node having one or more sensors configured to capture a first data
set during an actuation of the component and a processor configured
to adjust one or more coefficients of a model such that the
adjusted model approximates one or more values from the first data
set; and communicate to the system controller data based at least
on at least one of the one or more coefficients of the adjusted
model.
[0015] In some embodiments, the component of at least one node
comprises a hydraulic manifold including one or more actuatable
valves. In some embodiments, the component of at least one node
comprises a hydraulic pump. In some embodiments, the hydraulic pump
is battery powered.
[0016] In some embodiments, at least one node comprises a virtual
sensor.
[0017] In some embodiments, the processor of each node is
configured to analyze the first data set to determine a useful life
remaining of the component. In some embodiments, the processor of
each node is configured to communicate the useful life remaining of
the component to the system controller. In some embodiments, the
system controller is configured to communicate the useful life
remaining of the component of each node to a user. In some
embodiments, the processor of each node is configured to
communicate a fault to the system controller if the useful life
remaining of the component is below a threshold.
[0018] In some embodiments, the processor of each node is
configured to analyze the first data set to identify an abnormal
actuation of the component and communicate a fault to the system
controller if an abnormal actuation of the component is
identified.
[0019] In some embodiments, the first data set includes data
indicative of a number of actuation cycles of the component. In
some embodiments, the first data set includes data indicative of a
response time of the component.
[0020] In some embodiments, the processor of each node is
configured to compare the first data set to a second data set
corresponding to a simulation of actuation of the component and
communicate a fault to the system controller if differences between
the first data set and the second data set exceed a threshold.
[0021] In some embodiments, at least one node comprises a memory
configured to store at least a portion of the first data set. In
some embodiments, at least one node comprises a memory configured
to store at least a portion of the second data set. Some
embodiments comprise a memory in communication with each node of a
functional pathway.
[0022] In some embodiments, at least one node is configured to
communicate with the system controller wirelessly. In some
embodiments, at least one node is configured to communicate with
the system controller through a wired connection. In some
embodiments, at least one node is configured to communicate with at
least one controller outside of the BOP control system.
[0023] In some embodiments, the system controller is configured to
scan the BOP control system for available functional pathways for
actuating the first BOP function. In some embodiments, the system
controller is configured to communicate to a user a number of
available functional pathways for actuating the first BOP
function.
[0024] In some embodiments, the system controller is configured to
remove a first functional pathway from the one or more available
functional pathways if one or more nodes of the first functional
pathway communicates a fault to the system controller. In some
embodiments, the system controller is configured to remove a second
functional pathway from one or more available functional pathways
associated with a second BOP function if the second functional
pathway includes one or more of the one or more nodes of the first
functional pathway that communicates a fault to the system
controller. In some embodiments, the system controller is
configured to select a second BOP function if one or more nodes of
the first functional pathway associated with the first BOP function
communicates a fault to the system controller.
[0025] In some embodiments, the system controller is configured to
assign a risk level to the first BOP function. In some embodiments,
the risk level is assigned based, at least in part, on a number of
available functional pathways for actuating the first BOP function.
In some embodiments, the risk level is assigned, based, at least in
part, on a harm associated with a failure to actuate the first BOP
function. In some embodiments, the risk level is assigned based, at
least in part, on a type of fault communicated by one or more nodes
of a functional pathway.
[0026] In some embodiments, the one or more available functional
pathways comprises a first functional pathway and a second
functional pathway, and the system controller is configured to
actuate the first BOP function by communicating one or more
commands to one or more nodes of the second functional pathway if
one or more nodes of the first functional pathway communicates a
fault to the system controller.
[0027] Some embodiments of the present methods for actuating a BOP
function comprise: selecting a first functional pathway from two or
more available functional pathways associated with the first BOP
function, communicating one or more commands to an actuatable
component of each of one or more nodes of the first functional
pathway to actuate the component, where actuation of the component
of each of the one or more nodes of the first functional pathway
actuates the first BOP function, and receiving, from at least one
of the one or more nodes of the first functional pathway,
information associated with actuation of the component. Some
embodiments comprise storing the received information in a
memory.
[0028] Some embodiments comprise scanning a BOP control network for
available functional pathways for actuating the first BOP function.
Some embodiments comprise communicating to a user a number of
available functional pathways for actuating the first BOP
function.
[0029] In some embodiments, the received information includes a
useful life remaining of the component. In some embodiments, the
received information indicates a fault if the useful life remaining
of the component is below a threshold. In some embodiments, the
received information includes an identification of abnormal
actuation of the component. In some embodiments, the received
information indicates a fault if an abnormal actuation of the
component is identified. In some embodiments, the received
information includes differences between a first data set
corresponding to actuation of the component and a second data set
corresponding to a simulation of actuation of the component. In
some embodiments, the received information indicates a fault if
differences between the first data set and the second data set
exceed a threshold.
[0030] Some embodiments comprise selecting a second functional
pathway from the two or more available functional pathways
associated with the first BOP function if the received information
indicates a fault. Some embodiments comprise removing the first
functional pathway from the two or more available functional
pathways if the received information indicates a fault. Some
embodiments comprise removing a second functional pathway from two
or more available functional pathways associated with a second BOP
function if the received information indicates a fault of a node
common to the first functional pathway and the second functional
pathway. Some embodiments comprise selecting a second BOP function
if the received information indicates a fault.
[0031] Some embodiments comprise assigning a risk level to the
first BOP function. In some embodiments, the risk level is assigned
based, at least in part, on a number of available functional
pathways for actuating the first BOP function. In some embodiments,
the risk level is assigned based, at least in part, on a harm
associated with a failure to actuate the first BOP function. In
some embodiments, the risk level is assigned based, at least in
part, on a type of a fault indicated by the received
information.
[0032] The terms "a" and "an" are defined as one or more unless
this disclosure explicitly requires otherwise.
[0033] Further, a device or system (or a component of either) that
is configured in a certain way is configured in at least that way,
but can also be configured in other ways than those specifically
described.
[0034] The terms "comprise" (and any form of comprise, such as
"comprises" and "comprising"), "have" (and any form of have, such
as "has" and "having"), "include" (and any form of include, such as
"includes" and "including"), and "contain" (and any form of
contain, such as "contains" and "containing") are open-ended
linking verbs. As a result, an apparatus or system that
"comprises," "has," "includes," or "contains" one or more elements
possesses those one or more elements, but is not limited to
possessing only those elements. Likewise, a method that
"comprises," "has," "includes," or "contains" one or more steps
possesses those one or more steps, but is not limited to possessing
only those one or more steps.
[0035] Any embodiment of any of the apparatuses, systems, and
methods can consist of or consist essentially of--rather than
comprise/include/contain/have--any of the described steps,
elements, and/or features. Thus, in any of the claims, the term
"consisting of or "consisting essentially of can be substituted for
any of the open-ended linking verbs recited above, in order to
change the scope of a given claim from what it would otherwise be
using the open-ended linking verb.
[0036] The feature or features of one embodiment may be applied to
other embodiments, even though not described or illustrated, unless
expressly prohibited by this disclosure or the nature of the
embodiments.
[0037] Some details associated with the embodiments are described
above and others are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The following drawings illustrate by way of example and not
limitation. For the sake of brevity and clarity, every feature of a
given structure is not always labeled in every figure in which that
structure appears. Identical reference numbers do not necessarily
indicate an identical structure. Rather, the same reference number
may be used to indicate a similar feature or a feature with similar
functionality, as may non-identical reference numbers.
[0039] FIG. 1 is a diagram of a first embodiment of the present BOP
control systems.
[0040] FIGS. 2A and 2B are flow charts that each illustrates an
example of node-based diagnostics.
[0041] FIG. 3 is a partially cutaway and partially cross-sectional
side view of an axial piston pump, which may suitable for use as a
component of a node in some embodiments of the present systems.
[0042] FIG. 4A is a diagram of one example of node-based fault
detection and/or identification.
[0043] FIG. 4B is a diagram of one example of node-based fault
detection and/or identification.
[0044] FIGS. 5A-5D are graphs illustrating one or more examples of
node-based fault detection and/or identification.
[0045] FIG. 6 is a graphical representation of one or more examples
of node-based fault detection and/or identification.
[0046] FIG. 7 is a flow chart of one example of node-based
prognostics.
[0047] FIG. 8 is a graphical representation of one example of
node-based prognostics.
[0048] FIG. 9 is a diagram of a second embodiment of the present
BOP control systems.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0049] As will be described below, some embodiments of the present
BOP control systems include advanced, and in some instances,
process-aware, distributed (e.g., node-based) prognostics and/or
diagnostics capabilities that may ascertain, analyze, and/or
predict performance of a BOP system and/or nodes and/or components
thereof.
[0050] Referring now to the drawings, and more particularly to FIG.
1, shown therein and designated by the reference numeral 10a is a
first embodiment of the present BOP control systems. System 10a
presents an illustrative implementation of the present BOP control
systems and is provided and discussed, in large part, for clarity.
Of course, as can be appreciated, other embodiments of the present
BOP control systems may include substantially more complexity
(e.g., further BOP functions, functional pathways, nodes,
components, and/or the like). In the embodiment shown, system 10a
comprises a system controller 14 configured to actuate one or more
BOP functions (e.g., 18a and/or 18b) of a BOP 20. As used in this
disclosure, the term "blowout preventer" or "BOP" includes, but is
not limited to, a single blowout preventer, as well as a blowout
preventer assembly that may include more than one blowout preventer
(e.g., a blowout preventer stack). BOP functions actuatable with
the present BOP control systems may include any suitable function,
such as, for example, a function associated with a ram, annular,
accumulator, test valve, failsafe valve, kill and/or choke line
and/or valve, riser joint, hydraulic connector, and/or the like
(e.g., ram open, ram close, and/or the like). System controller 14
may comprise a physical machine and may include a housing,
processor, memory, human-machine interface, and/or the like.
[0051] For example, in this embodiment, system controller 14 is
configured to actuate a BOP function (e.g., 18a), at least in part,
by communicating one or more commands to one or more nodes (e.g.,
22a, 22b, 22c, 22d, 22e, and/or 22f) of a functional pathway
(sometimes referred to as a "success path") (e.g., 26a, 26b, or
26c) associated with the BOP function and selected from one or more
available functional pathways (e.g., where available functional
pathways do not include a failed or failing node or a node with a
failed or failing component, as described in more detail below). In
the depicted embodiment, each node comprises an actuatable
component (e.g., 34a, 34b, 34c) configured to actuate, for example,
in response to a command received from system controller 14.
[0052] In the embodiment shown, actuation of one or more components
of each node of a functional pathway may actuate a BOP function
associated with the functional pathway. To illustrate, in this
embodiment, first BOP function 18a is associated with three
functional pathways, 26a, 26b, and 26c. In the depicted embodiment,
functional pathway 26a includes node 22a, which comprises a
hydraulic pump 34a (e.g., which may be powered by an electrical
motor), and node 22b, which comprises a hydraulic manifold 34b
(e.g., which may include one or more actuatable valves). In the
embodiment shown, system controller 14 may command node 22a to
actuate hydraulic pump 34a and node 22b to actuate one or more
actuatable valves of hydraulic manifold 34b to open a hydraulic
fluid pathway to first BOP function 18a, thereby allowing hydraulic
fluid provided by the hydraulic pump to flow through the hydraulic
manifold and to the first BOP function, thus actuating the first
BOP function. Similarly, in this embodiment, functional pathway 26b
includes node 22c, which comprises a hydraulic pump 34a, and node
22d, which comprises a hydraulic manifold 34b. In the depicted
embodiment, system controller 14 may command node 22c to actuate
hydraulic pump 34a and node 22d to actuate one or more actuatable
valves of hydraulic manifold 34b to open a hydraulic fluid pathway
to first BOP function 18a, thus actuating the first BOP
function.
[0053] For further example, in the embodiment shown, functional
pathway 26c includes node 22e, which comprises a hydraulic power
unit 34c (e.g., which may be disposed above-sea), and node 22f,
which comprises a hydraulic manifold 34b. In this embodiment,
system controller 14 may command node 22e to actuate hydraulic
power unit 34c and node 22f to actuate one or more actuatable
valves of hydraulic manifold 34b to open a hydraulic fluid pathway
to first BOP function 18a, thereby allowing hydraulic fluid
provided by the hydraulic power unit to flow through the hydraulic
manifold and to the first BOP function, thus actuating the first
BOP function. Of course, functional pathways 26a, 26b, and 26c,
nodes 22a, 22b, 22c, 22d, 22e, and 22f, and components 34a, 34b,
and 34c are provided only by way of example, as the present BOP
control systems can comprise any suitable number of functional
pathways, which may include any suitable number of nodes having any
suitable component(s).
[0054] In the embodiment shown, system controller 14 is configured
to scan BOP control system 10a for available functional pathways
(e.g., 26a, 26b, 26c, 26d, 26e, and/or 26f) for actuating a BOP
function (e.g., 18a and/or 18b). For example, in the depicted
embodiment, each node (e.g., 22a, 22b, 22c, 22d, 22e, and 22f) may
be directly accessible by system controller 14, and each node may
contain information (e.g., stored in a memory, described in more
detail below) that corresponds to the nodes location and/or
function (e.g., a function of an actuatable component of the node)
within BOP control system 10a. Thus, in this embodiment, system
controller 14 may, by communicating with each of one or more nodes
connected to BOP control system 10a, identify available BOP
function(s), as well as respective functional pathways for
actuating the BOP function(s). In the embodiment shown, system
controller 14 may be in communication with one or more nodes in any
suitable fashion, such as, for example, via a wired and/or wireless
network. In some embodiments, a system controller (e.g., 14) may be
pre-programmed with locations and/or functions of one or more nodes
and/or available functional pathways for actuating a BOP function.
In addition, it is also contemplated that actuation of the BOP
function may further require control over and/or actuation of
components other than component(s) of each node, for example,
components disposed between nodes, between system controller 14 and
one or more nodes, and/or between the BOP function and one or more
nodes.
[0055] In the depicted embodiment, system controller 14 may be
configured to identify one or more functional pathways and/or one
or more BOP functions that are alternate to other functional
pathways and/or other BOP functions (e.g., by assuming a failure of
at least one of the nodes). For example, in the embodiment shown,
to identify functional pathway 26b associated with first BOP
function 18a, system controller 14 may assume a failure of node
22a, 22b, 22e and/or 22f. For further example, in this embodiment,
system controller 14 may identify a BOP function alternate to first
BOP function 18a (e.g., if the first BOP function is a close
function on a ram-type BOP, an alternate BOP function may be a
close function on a separate and redundant ram-type BOP), by
assuming a failure of a node of functional pathway 26a, 26b, and/or
26c. Two BOP functions may be redundant to each other in that each
may be configured to achieve a same or a similar outcome as the
other (e.g., each sealing a same well bore).
[0056] In some embodiments, a system (e.g., 10a) may include two or
more system controllers (e.g., 14). In such embodiments, a second
one of the two or more system controllers may be configured to
perform at least some of the functions of a first one of the two or
more system controllers. In such embodiments, if the first system
controller malfunctions, fails, or otherwise is rendered
inoperable, the second system controller may (e.g., automatically)
perform function(s) of the first system controller.
[0057] In the embodiment shown, each node comprises one or more
sensors 38. Sensors (e.g., 38) of the present BOP control systems
can comprise any suitable sensor, such as, for example, a
temperature sensor (e.g., a thermocouple, resistance temperature
detector (RTD), and/or the like), pressure sensor (e.g., a
piezoelectric pressure sensor, strain gauge, and/or the like),
velocity sensor (e.g., an observation-based sensor,
accelerometer-based sensor, and/or the like), acceleration sensor,
flow sensor, clock, and/or the like, whether physical and/or
virtual (e.g., implemented by a processor 30 of a node).
[0058] At least through respective nodes (e.g., 22a, 22b, 22c, 22d,
22e, and 22f) including respective processors (e.g., 30) and
respective sensor(s) (e.g., 38), some embodiments of the present
BOP control systems (e.g., 10a) may be configured for distributed
(e.g., node-based) diagnostics and/or prognostics capabilities. For
example, in this embodiment, for each of the nodes, one or more
sensors 38 of the node are configured to capture a first data set
corresponding to actuation of an actuatable component of the node,
whether during actual use of the actuatable component (e.g., in
combination with actuatable component(s) of other node(s) of its
respective functional pathway(s) to actuate a BOP function) or
during a performance or function test of the actuatable component,
and such actuation may be in response to a command received from
system controller 14. In the depicted embodiment, the first data
set may include one or more values, which may be indicative of any
suitable parameter(s), such as, for example, a number of actuation
cycles of the actuatable component of the node, a response time of
the actuatable component (e.g., a time required for the component
to complete an actuation), pressure, temperature, flow rate, and/or
the like of hydraulic fluid within the component, and/or the like,
and such value(s) may be included in the first data set as a table
or function over a period of time.
[0059] In the depicted embodiment, processor 30 of each node (e.g.,
22a, 22b, 22c, 22d, 22e, and 22f) is configured to compare the
first data set to a second data set comprising and/or corresponding
to a simulation (e.g., model, mathematical representation, which
may be based on one or more functions, and/or the like) of
actuation of the component of the node (e.g., an example of
node-based diagnostics). Referring now to FIG. 2A and 2B, shown are
flow charts of two examples 200a, 200b of such node-based
diagnostics. In the example shown in FIG. 2A, at step 204, a
detailed model for the component of the node may be provided.
[0060] Referring additionally to FIG. 3, shown is a partially
cutaway and partially cross-sectional side view of an axial piston
pump 300, which may be suitable for use as an actuatable component
of a node. As shown, in this example, axial piston pump 300
comprises an inlet 304 in fluid communication with an inflow volume
308. In the depicted example, axial piston pump 300 includes one or
more cylinders 312, each having a respective one of one or more
pistons 316 slidably disposed therein. In the example shown, each
of one or more pistons 316 is coupled to a rotatable pump shaft 320
via a swash plate mechanism 324 such that, as the pump shaft is
rotated, each of the one or more pistons may axially translate
within a respective one of one or more cylinders 312. In this
example, each of one or more cylinders 312 is in fluid
communication with a respective cylinder filling volume 328 and a
respective cylinder emptying volume 332. In the example shown,
axial piston pump 300 comprises an outlet 340 in fluid
communication with an outflow volume 336. Thus, in this example, as
pump shaft 320 is rotated, each of one or more pistons 316 may
axially reciprocate within a respective one of one or more
cylinders 312, causing fluid communication from inlet 304 to outlet
340.
[0061] In providing a detailed model for axial piston pump 300
(e.g., step 204), it can be shown that:
Q i = A i 2 .rho. i p i - p s ( 1 ) ##EQU00001##
where Q.sub.i is the mass flow rate of fluid flowing into inlet
304, A.sub.i is the flow cross-sectional area the inlet,
.rho..sub.i is the density of fluid flowing into the inlet,
.rho..sub.i is the pressure of fluid flowing into the inlet, and
p.sub.s is the pressure of fluid flowing through inflow volume 308
[1].
[0062] For axial piston pump 300, for a given one of one or more
cylinders 312, it can be shown that:
Q u = A u 2 .rho. u p s - p c ( 2 ) ##EQU00002##
where Q.sub.u is the mass flow rate of fluid flowing through a
cylinder filling volume 328 respective to the given one of the one
or more cylinders, A.sub.u is the flow cross-sectional area of the
respective cylinder filling volume, .rho..sub.u is the density of
fluid flowing through the respective cylinder filling volume, and
p.sub.c is the pressure of fluid flowing through the given one of
the one or more cylinders [1].
[0063] For axial piston pump 300, it can be shown that:
Q o = A o 2 .rho. o p v - p o ( 3 ) ##EQU00003##
where Q.sub.o is the mass flow rate of fluid flowing out of outlet
340, A.sub.o is the flow cross-sectional area of the outlet,
.rho..sub.o is the density of fluid flowing out of the outlet,
p.sub.v is the pressure of fluid flowing through outflow volume
336, and p.sub.o is the pressure of fluid flowing out of the outlet
[1].
[0064] For axial piston pump 300, the rate of change of pressure of
fluid flowing through outflow volume 336, or
p v t = B V c ( .SIGMA. j Q k , j - Q o ) ( 4 ) ##EQU00004##
may be snown as:
p v t , ##EQU00005##
where B is the bulk modulus of portion(s) of the axial piston pump
which define cylinder emptying volume(s) 332, V.sub.c is the sum of
the instantaneous volume of each of one or more cylinders 312, and
Q.sub.k is the mass flow rate of fluid flowing through a cylinder
emptying volume 332 respective to a j one of one or more cylinders
312 [1].
[0065] In the depicted example, at step 204, node and/or component
fault(s) may also be considered (e.g., modeled) in providing the
detailed model. For example, faults associated with a node
including axial piston pump 300 may include gain and/or offset
faults of at least one of sensors(s) 38 of the node (e.g., a speed
sensor configured to capture data indicative of a rotational speed
of pump shaft 320 and/or of a rotational speed of a motor coupled
to the pump shaft, which may also comprise a component of the
node), external fluid leakage (e.g., fluid leakage that may occur
downstream of outlet 340), internal leakage (e.g., due to
clearance(s) between one or more of one or more cylinders 312 and
respective one(s) of one or more pistons 316), and/or the like. To
illustrate, for axial piston pump 300, internal leakage, or
Q.sub.i, may be shown as:
Q l = .pi. D c .DELTA. r 3 12 .eta. x k ( p c - p s ) ( 5 )
##EQU00006##
where D.sub.c is the diameter of a given one of one or more
cylinders 312, .DELTA.r is the radial clearance between a sidewall
of the given one of the one or more cylinders and a respective one
of one or more pistons 312, .eta. is the dynamic viscosity of fluid
flow through the given one of the one or more cylinders, and
x.sub.k is the immediate axial displacement of the respective one
of the one or more pistons relative to the given one of the one or
more cylinders [1].
[0066] Considering Eq. (1)-(5), above, the rate of change of
pressure of fluid flowing through a given one of one or more
cylinders 316, or
p c t , ##EQU00007##
may be shown as:
p c t = B V c ( A c v k + Q i - Q l - Q k ) ( 6 ) ##EQU00008##
where A.sub.c is the flow cross-sectional area of the given one of
the one or more cylinders and v.sub.k is the immediate axial
velocity of one of one or more pistons 312 respective to the given
one of the one or more cylinders [1].
[0067] For a more detailed discussion of Eqs. (1)-(6), above, see
[1] Radovan Petrovi , Mathematical Modeling and Experimental
Research of Characteristic Parameters Hydrodynamic Processes of a
Piston Axial Pump, 55(2009)4 J. of Mech. Eng'g 224 (2009), which is
expressly incorporated by reference in its entirety, and more
specifically, section 1.1, entitled "Mathematical Model of a Pump
Process," which begins on the first column of page 225 and ends on
the first column of page 226.
[0068] In the example shown, at step 208, a reduced-order model of
the component of the node may be provided (e.g., a reduced-order
model based, at least in part, on the detailed model of the
component). For example, the detailed model for axial piston pump
300 provided in Eqs. (1)-(6), above, may be used to derive a
reduced-order model for the axial piston pump that approximates the
detailed model. To illustrate, a reduced-order model (e.g.,
derived, at least in part, by one or more polynomial regressions of
the detailed model) of axial piston pump 300 may be:
Q.sub.pump=a.sub.0N.sub.pump+b.sub.0.DELTA.P.sub.pump+c.sub.0
.DELTA.P.sub.pump+d.sub.0 (7)
where Q.sub.pump is the mass flow rate of fluid flow provided by
the axial piston pump, N.sub.pump may correspond to a rotational
speed of pump shaft 320 of the axial piston pump, .DELTA.P
.sub.pump is the pressure difference between outlet 340 and inlet
304, and a.sub.o, b.sub.o, c.sub.o, and d.sub.o are coefficients
that may be adjusted to fit the reduced-order model to the detailed
model.
[0069] Such mathematical models, whether detailed (e.g., Eqs.
(1)-(6)) and/or reduced-order (e.g., Eq. (7)), may be used to
detect and/or identify node and/or component faults. For example, a
first data set containing values corresponding to actuation of
axial piston pump 300 may be compared with a second data set
corresponding to a simulation or theoretical model of actuation of
the axial piston pump, such as, for example, the reduced-order
model provided in Eq. (7). Referring additionally to FIG. 4A, in
the depicted example, one or more sensors 38 of a node 22g
including axial piston pump 300 may provide signal 404a, which may
be indicative of a pressure difference between outlet 340 and inlet
304 of the axial piston pump, and signal 404b, which may be
indicative of a mass flow rate of fluid flow provided by the axial
piston pump (e.g., and such indicated values may be included in the
first data set). In the example shown, one or more indicated values
(e.g., as indicated by signals 404a and 404b) may be used to
evaluate a model 402. To illustrate, in the example of FIG. 2A, a
pressure difference between outlet 340 and inlet 304 of axial
piston pump 300 (e.g., indicated by signal 404a) may be input into
a model 402 (e.g., Eq. (7))(step 212) to determine an expected
value 408, such as, for example, an expected mass flow rate of
fluid provided by the axial piston pump at the indicated pressure
difference (e.g., and such expected values may be included in the
second data set). In the depicted example, the expected value may
be compared with an indicated value to ascertain differences 412
between the expected and indicated values (step 216). To
illustrate, in this example, an expected mass flow rate of fluid
provided by axial piston pump 300 (e.g., expected value 408) may be
compared to an indicated mass flow rate of fluid provided by the
axial piston pump (e.g., indicated by signal 404b) to determine
differences 412 between the expected and indicated values. In the
example shown, at step 220, component fault(s) may be detected
and/or identified (e.g., if differences 412 exceed a threshold). In
the depicted embodiment, processor 30 of the node may be configured
to communicate differences 412 system controller 14, which in turn,
may be configured to communicate the differences to a user (e.g.,
via a human-machine interface).
[0070] Referring to FIG. 2B, in this example 200b, at step 224, the
reduced-order model may be adjusted based on actuation of the
component of the node (e.g., fit to one or more values from the
first data set). For example, an adjusted or fitted reduced-order
model based upon the reduced-order model provided in Eq. (7) may be
shown as:
Q.sub.pump=aN.sub.pump+{circumflex over
(b)}.DELTA.P.sub.pump+{circumflex over (c)} {square root over
(.DELTA.P.sub.pump)}+{circumflex over (d)} (8)
where a, {circumflex over (b)}, c, and {circumflex over (d)} are
variable coefficients that may be adjusted (e.g., over time) such
that Eq. (8) approximates one or more values from the first data
set. For example, and referring additionally to FIG. 4B,
differences 412 (e.g., between the first data set and the second
data set, as described above) may be provided to a model-fitting
algorithm 416 that is configured to adjust the variable
coefficients such that model 402 (e.g., Eq. (8)) approximates one
or more values from the first data set (e.g., such that differences
between the expected and indicated values are minimized). In these
and similar embodiments, values indicative of the baseline
coefficients (e.g., Eq. (7)) may be included in the second data
set, and values indicative of the variable coefficients (e.g., Eq.
(8)) may be included in the first data set.
[0071] Changes in such variable coefficients may be analyzed or
compared to baseline coefficients (step 228) and used to indicate
whether a node and/or component fault has occurred, as well as
isolate and/or identify the fault (step 232). For example, and
referring additionally to FIGS. 5A-5D, shown are graphs of a.sub.o,
b.sub.o, c.sub.o, and d.sub.o, which may correspond to a modelled
piston pump (e.g., baseline coefficients), and a, {circumflex over
(b)}, c, and {circumflex over (d)}, which may correspond to
actuation of axial piston pump 300 (e.g., variable coefficients).
As shown, the variable coefficients may each be associated with one
or more fault types. For example, FIG. 5A depicts the variable
coefficients versus time for axial piston pump 300 having an
external leakage fault (e.g., with c having the greatest continuous
variance from its respective baseline coefficient, as shown). FIG.
5B depicts the variable coefficients versus time for one of one or
more sensors 38 (e.g., a pump speed sensor) having a gain fault
(e.g., with a having the greatest continuous variance from its
respective baseline coefficient, as shown). FIG. 5C depicts the
variable coefficients versus time for axial piston pump 300 having
an internal leakage fault (e.g., with b having the greatest
continuous variance from its respective baseline coefficient, as
shown). FIG. 5D depicts the variable coefficients versus time for
one of one or more sensors 38 (e.g., a pump speed sensor) having an
off-set bias fault (e.g., with a having the greatest continuous
variance from its respective baseline coefficient, as shown). Thus,
in the example shown, at step 220, differences between the baseline
coefficients and the variable coefficients may be used to identify
a type of fault in a node and/or a component of the node. This may
be visualized in FIG. 6, in which one or more faults may be
identified when differences between baseline coefficients and
respective variable coefficients exceed a threshold.
[0072] For further example, and referring back to FIG. 1, in the
embodiment shown, node 22b may receive a command from system
controller 14 to close one or more valves of manifold 34b of the
node, and one or more sensors 38 of the node may capture a first
data set corresponding to closing of the one or more valves, such
as hydraulic fluid pressures and/or flow rates within the manifold.
In this embodiment, processor 30 of the node may compare the first
data set to a second data set corresponding to a simulation or
model of closing of the one or more valves of the manifold, such as
expected hydraulic fluid pressure and/or flow rates within the
manifold. Similarly, in this embodiment, node 22b may receive a
command from system controller 14 to open one or more valves of
manifold 34b of the node, and processor 30 of the node may compare
a first data set corresponding to opening of the one or more valves
with a second data set corresponding to a simulation or model of
opening of the one or more valves (e.g., modelling and/or
simulation may be command-specific).
[0073] In some embodiments, simulations or models may be refined
based on historic one or more sensor 38 data (e.g., stored in a
memory, such as, for example, memory 42, memory 46, and/or the
like). At least through such distributed diagnostics capabilities,
some embodiments of the present BOP control systems may be
configured to maximize system availability (e.g., by monitoring for
degradation of BOP system components, anticipating failure of the
BOP system components, identifying faulty components, and/or the
like), system reliability, and/or system fault tolerance.
[0074] In the embodiment shown, a processor 30 of each node (e.g.,
22a, 22b, 22c, 22d, 22e, 22f) is configured to analyze a first data
set to determine a useful life remaining (e.g., a prognostic
parameter) of a component of the node. Referring now to FIG. 7,
shown is a flow chart of one example 700 of such node-based
prognostics. In the example shown, at step 704, one or more
variable coefficients of a reduced-order model (e.g., Eq. (8)) may
be adjusted such that the reduced-order model approximates the
first data set (e.g., in a same or a similar fashion to as
described for step 212, above). In this example, at step 708,
future behavior of the component may be anticipated based, at least
in part, on the adjusted reduced-order model. For example, and as
shown in FIG. 8, one or more variable coefficients (e.g., a,
{circumflex over (b)}, c, and/or {circumflex over (d)}) of the
adjusted reduced-order model may be monitored over a period of time
(e.g., up until an instant time 804). In this example, trends in
the one or more variable coefficients may be extrapolated to
approximate a failure time 808 (e.g., a time when at least one of
the one or more variable coefficients is anticipated to fall above
or below a threshold), and thus a useful life remaining 812 of the
component. In this embodiment, processor 30 of the node may be
configured to communicate the useful life remaining of the
component of the node to system controller 14, which in turn, may
be configured to communicate the useful life remaining of the
component to a user (e.g., via a human-machine interface).
[0075] For further example, a processor 30 of the node may compare
a value in the first data set, such as a number of actuations of
the component of the node, to another value, such as a maximum
number of actuations of the component, to determine a useful life
remaining of the component.
[0076] In this embodiment, each node, and more particularly, a
processor 30 of each node, may be configured to communicate node
and/or component faults to system controller 14. For example, in
the depicted embodiment, a processor 30 of each node is configured
to communicate a fault to system controller 14 if the useful life
remaining (e.g., 812) of a component of the node is below a
threshold. For further example, in the embodiment shown, a
processor 30 of each node is configured to analyze the first data
set to identify an abnormal actuation of a component of the node
and communicate a fault to system controller 14 if an abnormal
actuation of the component is identified (e.g., if at least one of
one or more sensors 38 of the node indicates that the component
failed to fully actuate, the component had a response time that
exceeds a threshold, and/or the like). Such abnormal actuations may
also be identified by non- and/or partial-responsiveness of a node
and/or a processor 30 of the node (e.g., when the node and/or
processor are experiencing communications faults). For yet further
example, a processor 30 of each node may communicate a fault to
system controller 14 if differences between the first data set and
the second data set (e.g., as described above) exceed a threshold.
Such faults may indicate that a node and/or a component of the node
has failed, may fail, and/or the like. In this embodiment, system
controller 14 may be configured to communicate node faults to a
user (e.g., via a human-machine interface). In the embodiment
shown, at least one of the nodes is configured to communicate with
at least one controller outside of BOP control system 10a (e.g., in
the event that system controller 14 is unavailable, for example,
after an emergency disconnect sequence).
[0077] For example, some embodiments of the present methods for
actuating a BOP function (e.g., 18a) comprise selecting a first
functional pathway (e.g., 26a) from two or more available
functional pathways (e.g., 26a, 26b, and 26c) associated with the
first BOP function, communicating one or more commands to an
actuatable component of each of one or more nodes (e.g., component
34a of node 22a and component 34b of node 22b) of the first
functional pathway to actuate the component, where actuation of the
component of each of the one or more nodes of the first functional
pathway actuates the first BOP function, and receiving, from at
least one of the one or more nodes of the first functional pathway,
information associated with actuation of the component.
[0078] In some embodiments, the received information includes a
useful life remaining of the component. In some embodiments, the
received information indicates a fault if the useful life remaining
of the component is below a threshold. In some embodiments, the
received information includes an identification of abnormal
actuation of the component. In some embodiments, the received
information indicates a fault if an abnormal actuation of the
component is identified. In some embodiments, the received
information includes differences between a first data set
corresponding to actuation of the component and a second data set
corresponding to a simulation of actuation of the component. In
some embodiments, the received information indicates a fault if
differences between the first data set and the second data set
exceed a threshold.
[0079] In some embodiments, a processor (e.g., 30), one or more
sensors (e.g., 38), a memory (e.g., 42), and/or the like may be
retrofitted onto an actuatable component to create a node. In some
embodiments, one or more nodes may each correspond to a lowest
replaceable unit ("LRU") (e.g., the one or more nodes may be
configured to be replaced rather than repaired.). In some
embodiments, a node may be tested for faults (e.g., for proper
functioning of a processor 30, one or more sensors 38, memory 42,
actuatable component, and/or the like) before implementation in a
BOP control system (e.g., 10a). Such testing may be performed
offshore and/or onshore using an automated (e.g., hydroelectric)
test unit configured to functionally test the processor, one or
more sensors, memory, component and/or the like of the node and
communicate results of the functional test, for example, to a
service provider. In some embodiments, if the functional test
indicates one or more faults in a node, the node may be rendered
inoperable (e.g., by the node itself, the automated test unit,
and/or the service provider) until the fault(s) of the node are
addressed (e.g., and the node has been reset by the node itself,
the automated test unit, and/or the service provider).
[0080] System controller 14, in response to one or more faults of
one or more nodes of a functional pathway associated with a BOP
function, may be configured to advise and/or alert an operator
(e.g., at a human-machine interface), propose alternate functional
pathways and/or BOP functions, and/or automatically select
alternate functional pathways and/or BOP functions (e.g., based, at
least in part, on a risk level assigned to the BOP function, as
described below). For example, in the embodiment shown, system
controller 14 is configured to remove a functional pathway from two
or more available functional pathways associated with a BOP
function if one or more nodes of the functional pathway communicate
a fault to the system controller or has a risk level assignment
that is above a threshold, is relatively high, and/or the like
(discussed below). For example, in this embodiment, if node 22a or
node 22b of functional pathway 26a communicates a fault to system
controller 14, functional pathway 26a may be removed from the
functional pathways associated with first BOP function 18a (e.g.,
leaving functional pathways 26b and 26c in the available functional
pathways). In the embodiment shown, if one or more nodes of a first
functional pathway (e.g., nodes 22a and 22b of functional pathway
26a) associated with a BOP function (e.g., 18a) communicates a
fault to system controller 14, the system controller may be
configured to actuate the first BOP function by communicating one
or more commands to one or more nodes of a second functional
pathway (e.g., nodes 22c and 22d of functional pathway 26b or nodes
22e and 22f of functional pathway 26c).
[0081] For example, some embodiments of the present methods
comprise selecting a second functional pathway (e.g., 26b) from two
or more available functional pathways associated with a first BOP
function (e.g., 18a) if information received from at least one of
one or more nodes of a first functional pathway associated with the
first BOP function (e.g., nodes 22a and/or 22b of functional
pathway 26a) indicates a fault. Some embodiments comprise removing
the first functional pathway from the two or more available
functional pathways if the received information indicates a
fault.
[0082] In the depicted embodiment, system controller 14 is
configured to remove a functional pathway (e.g., 26d) from one or
more available functional pathways (e.g., 26d, 26e, and 26f)
associated with a second BOP function (e.g., 18b) if the functional
pathway associated with the second BOP function includes one or
more nodes of a first functional pathway (e.g., node 22a of
functional pathway 26a) associated with a first BOP function (e.g.,
18a) that communicates a fault to system controller 14.
[0083] For example, some embodiments of the present methods
comprise removing a second functional pathway (e.g., 26d) from two
or more available functional pathways (e.g., 26d, 26e, and 26f)
associated with a second BOP function (e.g., 18b) if the received
information indicates a fault of a node common to the first
functional pathway and the second functional pathway (e.g., node
22a is common to functional pathway 26a associated with first BOP
function 18a and functional pathway 26d associated with second BOP
function 18b).
[0084] In the embodiment shown, system controller 14 is configured
to assign a risk level (e.g., a failure risk level) to one or more
BOP functions (e.g., 18a and/or 18b), to one or more functional
pathways (e.g., 26a, 26b, 26c, 26d, 26e, and/or 26f) associated
with the BOP function(s), and/or to one or more nodes (e.g., 22a,
22b, 22c, 22d, 22e, and/or 22f) associated with the functional
pathway(s). A risk level of a BOP function may be assigned based
upon a risk level assigned to one or more functional pathways
and/or one or more nodes associated with the BOP function. A risk
level of a functional pathway may be assigned based upon a risk
level assigned to one or more nodes associated with the functional
pathway. In some embodiments, a functional pathway for actuating a
BOP function may be selected by choosing the functional pathway
that is assigned the lowest risk level. In some embodiments, a node
having a risk level at or above a threshold risk level may be
considered faulty.
[0085] Assignment of a risk level to a BOP function, a functional
pathway, and/or a node can be based upon one or more factors. Such
factor(s) may include, for example, sensed value(s), value(s)
associated with the importance of the BOP function, functional
pathway, and/or node to safe drilling or production operations
(e.g., considering the magnitude of potential loss in the event of
a failure of the BOP function, functional pathway, and/or node), a
level of confidence in the factor(s) (e.g., a time elapsed since
sensed value(s) were last acquired), and/or the like, and some
factor(s) may be given more weight than other(s) of the factor(s).
Such a risk level assignment may be facilitated using known risk
assessment techniques, such as, for example, probabilistic risk
assessment, a failure mode and effects analysis, a fault tree
analysis, a hazard analysis, and/or the like.
[0086] For example, in this embodiment, a risk level may be
assigned to a BOP function, a functional pathway, and/or a node
based, at least in part, on a number of available functional
pathways for actuating the BOP function (e.g., where less available
functional pathways for actuating the BOP function corresponds to a
higher risk level assigned to the BOP function). For further
example, in the depicted embodiment, a risk level may be assigned
to a BOP function, a functional pathway, and/or a node based, at
least in part, on a harm associated with a failure to actuate the
BOP function (e.g., failure to actuate a close function on a
shear-type BOP may result in a well blowout, and thus such a
function may be assigned elevated risk levels relative to less
safety-critical BOP functions). For yet further example, in the
embodiment shown, a risk level may be assigned to a BOP function, a
functional pathway, and/or a node based, at least in part, on a
type of fault communicated by one or more nodes of a functional
pathway associated with the BOP function (e.g., a node
communicating a slowed response time, but otherwise operating at an
acceptable capacity, may result in a lower risk level assignment
than a node communicating operations at a reduced capacity, a node
communicating the potential for an imminent failure may result in a
higher risk level assignment than a node communicating the
potential for a less-imminent failure). For yet further example, in
this embodiment, a risk level may be assigned to a BOP function, a
functional pathway, and/or a node based, at least in part, on a
number of redundant BOP functions available for accomplishing a
same or a similar outcome as the BOP function (e.g., where less
available redundant BOP functions corresponds to a higher risk
level assigned to the BOP function). For yet further example, in
the depicted embodiment, a risk level may be assigned to a BOP
function, a functional pathway, and/or a node based, at least in
part, on a designation of the BOP function, the functional pathway,
and/or the node as an emergency (e.g., last resort) option. For yet
further example, in the embodiment shown, a risk level may be
assigned to a BOP function, a functional pathway, and/or a node
based, at least in part, on a useful life remaining of one or more
nodes (e.g., actuatable component(s) thereof). For yet further
example, in this embodiment, a risk level may be assigned to a BOP
function, a functional pathway, and/or a node based, at least in
part, on a time elapsed since the most recent actuation (e.g.,
actual use or performance or function test) of one or more nodes
(e.g., actuatable component(s) thereof). Such a time-based risk
level may be reset or reduced upon actuation of the node(s) (e.g.,
which may be pursuant to a pre-determined schedule).
[0087] In the embodiment shown, at least one of the one or more
nodes (e.g., 22b) comprises a memory 42. In this embodiment, memory
42 may be configured to store at least a portion of the first data
set and/or the second data set. In the depicted embodiment, system
10a comprises a memory 46 in communication with each of one or more
nodes of a functional pathway (e.g., in some embodiments, with each
of one or more nodes of each functional pathway). In these and
similar embodiments, a data recording and health monitoring
subsystem may be implemented to collect data captured by one or
more sensors 38, store at least a portion of the captured data in
memory 46, and/or provide the captured data to system controller
14.
[0088] In this embodiment, system 10a is configured to be
process-aware. For example, system 10a, and more particularly,
system controller 14, may be aware of BOP functions selected for
actuation during a given process. To illustrate, if system 10a is
implemented during a drilling process, system controller 14 may be
aware that a first BOP function (e.g., 18a) has been selected for
actuation (e.g., a first BOP function to close a first shear-type
BOP). In the embodiment shown, system controller 14 may be
configured to alert and/or advise a user and/or select a second BOP
function (e.g., 18b) for actuation (e.g., a second BOP function to
close a second shear-type BOP) if one or more nodes (e.g., 26a,
26b, 26c, 26d, 26e, and/or 26f) of a functional pathway (e.g., 26a,
26b, and 26) associated with the first BOP function communicates a
fault to the system controller. For example, some embodiments of
the present methods comprise selecting a second BOP function (e.g.,
18b), if information received from at least one of one or more
nodes (e.g., 26a, 26b, 26c, 26d, 26e, and/or 26f) of a functional
pathway (e.g., 26a, 26b, and 26c) associated with the first BOP
function indicates a fault.
[0089] Referring now to FIG. 9, shown therein and designated by the
reference numeral 10b is a second embodiment of the present BOP
control systems. System 10b may be substantially similar to system
10a, with the primary exceptions described below. In FIG. 9, dashed
lines and solid lines each represent functional pathway(s) or
portion(s) thereof, and the dashed lines are only dashed for
readability. As shown, system 10b includes at least 18 functional
pathways for actuating a first BOP function. Also as shown, the
same, similar, or other functional pathway(s) may be provided for
actuating a second and/or third BOP function. In this embodiment,
the first, second, and third BOP functions may be functions of an
annular BOP and/or ram BOP.
[0090] Provided below, by way of illustration, is a list of
functional pathways shown in FIG. 9 that include the nodes
represented by boxes having thicker borders.
[0091] Surface Power Assembly A--Subsea Reservoir A--Subsea Pump
Assembly A--Manifold C--First BOP function;
[0092] Surface Power Assembly A--Subsea Reservoir B--Subsea Pump
Assembly A--Manifold C--First BOP function;
[0093] Surface Power Assembly A--Subsea Reservoir A--Subsea Pump
Assembly B--Manifold D--First BOP function;
[0094] Surface Power Assembly A--Subsea Reservoir B--Subsea Pump
Assembly B--Manifold D--First BOP function;
[0095] Surface Power Assembly B--Subsea Reservoir B--Subsea Pump
Assembly B--Manifold D--First BOP function;
[0096] Surface Power Assembly B--Subsea Reservoir B--Subsea Pump
Assembly A--Manifold C--First BOP function;
[0097] Surface Power Assembly B--Subsea Reservoir A--Subsea Pump
Assembly B--Manifold D--First BOP function; and
[0098] Surface Power Assembly B--Subsea Reservoir A--Subsea Pump
Assembly A--Manifold C--First BOP function.
[0099] As shown, though rigid conduits A and B are components that
must be operable in order to actuate a BOP function using certain
functional pathway(s), rigid conduits A and B are not considered
nodes.
[0100] If implemented in firmware and/or software, the functions
described above may be stored as one or more instructions or code
on a non-transitory computer-readable medium. Examples include
non-transitory computer-readable media encoded with a data
structure and non-transitory computer-readable media encoded with a
computer program. Non-transitory computer-readable media are
physical computer storage media. A physical storage medium may be
any available medium that can be accessed by a computer. By way of
example, and not limitation, such non-transitory computer-readable
media can comprise RAM, ROM, EPROM, EEPROM, CD-ROM or other optical
disk storage, magnetic disk storage or other magnetic storage
devices, or any other physical medium that can be used to store
desired program code in the form of instructions or data structures
and that can be accessed by a computer. Disk and disc includes
compact discs (CD), laser discs, optical discs, digital versatile
discs (DVD), floppy disks, and Blu-ray discs. Generally, disks
reproduce data magnetically, and discs reproduce data optically.
Combinations of the above are also be included within the scope of
non-transitory computer-readable media. Moreover, the functions
described above may be achieved through dedicated devices rather
than software, such as a hardware circuit comprising custom VLSI
circuits or gate arrays, off-the-shelf semiconductors such as logic
chips, transistors, or other discrete components, all of which are
non-transitory. Additional examples include programmable hardware
devices such as field programmable gate arrays, programmable array
logic, programmable logic devices, and/or the like, all of which
are non-transitory. Still further examples include application
specific integrated circuits (ASIC) or very large scale integrated
(VLSI) circuits. In fact, persons of ordinary skill in the art may
utilize any number of suitable structures capable of executing
logical operations according to the described embodiments.
[0101] The above specification and examples provide a complete
description of the structure and use of illustrative embodiments.
Although certain embodiments have been described above with a
certain degree of particularity, or with reference to one or more
individual embodiments, those skilled in the art could make
numerous alterations to the disclosed embodiments without departing
from the scope of this invention. As such, the various illustrative
embodiments of the systems and methods are not intended to be
limited to the particular forms disclosed. Rather, they include all
modifications and alternatives falling within the scope of the
claims, and embodiments other than the ones shown may include some
or all of the features of the depicted embodiments. For example,
elements may be omitted or combined as a unitary structure and/or
connections may be substituted. Further, where appropriate, aspects
of any one of the examples described above may be combined with
aspects of any other one(s) of the examples described above to form
further examples having comparable or different properties and/or
functions and addressing the same or different problems. Similarly,
it will be understood that the benefits and advantages described
above may relate to one embodiment or may relate to several
embodiments.
[0102] The claims are not intended to include, and should not be
interpreted to include, means-plus- or step-plus-function
limitations, unless such a limitation is explicitly recited in a
given claim using the phrase(s) "means for" or "step for,"
respectively.
REFERENCES
[0103] These references, to the extent that they provide details
related to those set forth herein, are specifically incorporated by
reference. [0104] [1] Radovan Petrovi , Mathematical Modeling and
Experimental Research of Characteristic Parameters Hydrodynamic
Processes of a Piston Axial Pump, 55(2009)4 J. of Mech. Eng'g 224
(2009).
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