U.S. patent application number 15/500839 was filed with the patent office on 2017-08-10 for monitoring health of additive systems.
The applicant listed for this patent is Schlumberger Technology Corporation. Invention is credited to Lewis CALLAWAY, Jonathan Wun Shiung CHONG, Liang DU, Rajesh LUHARUKA, Chuong NGUYEN, Gregoire OMONT, Corey RAY.
Application Number | 20170226842 15/500839 |
Document ID | / |
Family ID | 55218339 |
Filed Date | 2017-08-10 |
United States Patent
Application |
20170226842 |
Kind Code |
A1 |
OMONT; Gregoire ; et
al. |
August 10, 2017 |
MONITORING HEALTH OF ADDITIVE SYSTEMS
Abstract
A monitoring system operable to monitor an oilfield additive
system having multiple components. The oilfield additive system is
operable to transfer an additive-containing substance for injection
into a wellbore. The monitoring system includes sensors each
associated with, and operable to generate information related to an
operational parameter of, a corresponding one of the oilfield
additive system components. The monitoring system also includes a
monitoring device in communication with the sensors and operable to
record the information generated by the sensors to generate a
database. The database includes information indicative of
maintenance aspects of the oil-field additive system and/or the
oilfield additive system components.
Inventors: |
OMONT; Gregoire; (Houston,
TX) ; LUHARUKA; Rajesh; (Katy, TX) ; RAY;
Corey; (Houston, TX) ; CHONG; Jonathan Wun
Shiung; (Sugar Land, TX) ; NGUYEN; Chuong;
(Richmond, TX) ; CALLAWAY; Lewis; (Sugar Land,
TX) ; DU; Liang; (Sugar Land, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Schlumberger Technology Corporation |
Sugar Land |
TX |
US |
|
|
Family ID: |
55218339 |
Appl. No.: |
15/500839 |
Filed: |
July 31, 2015 |
PCT Filed: |
July 31, 2015 |
PCT NO: |
PCT/US15/43062 |
371 Date: |
January 31, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62032158 |
Aug 1, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 44/005 20130101;
G06Q 50/02 20130101; E21B 33/138 20130101; E21B 43/247 20130101;
E21B 21/062 20130101; E21B 21/16 20130101; E21B 43/267 20130101;
E21B 43/162 20130101; E21B 43/255 20130101; E21B 33/13 20130101;
E21B 43/40 20130101; G06Q 10/20 20130101; E21B 43/26 20130101 |
International
Class: |
E21B 44/00 20060101
E21B044/00; E21B 43/40 20060101 E21B043/40; E21B 43/16 20060101
E21B043/16; E21B 33/138 20060101 E21B033/138; E21B 43/267 20060101
E21B043/267; E21B 43/25 20060101 E21B043/25; E21B 43/247 20060101
E21B043/247 |
Claims
1. An apparatus, comprising: a monitoring system operable to
monitor an oilfield additive system, wherein the oilfield additive
system is operable to transfer an additive-containing substance for
injection into a wellbore, wherein the oilfield additive system
comprises a plurality of components each associated with a
corresponding operational parameter, and wherein the monitoring
system comprises: a plurality of sensors each associated with, and
operable to generate information related to the operational
parameter of, a corresponding one of the plurality of components;
and a monitoring device in communication with each of the plurality
of sensors and operable to record the information generated by the
plurality of sensors to generate a database indicative of a
maintenance aspect of an item, wherein the item is at least one of:
the oilfield additive system; at least one of the plurality of
components; and/or a combination thereof.
2. The apparatus of claim 1 wherein the maintenance aspect is, or
is indicative of, an estimated remaining functional life of the
item.
3. The apparatus of claim 1 wherein the maintenance aspect is, or
is indicative of, a health of the item.
4. The apparatus of claim 1 wherein the plurality of components
comprises a prime mover and a material-transfer device operable in
conjunction with the prime mover, and wherein the plurality of
sensors comprises: a first sensor operable to generate information
related to the operating parameter of the prime mover; and a second
sensor operable to generate information related to the operating
parameter of the material-transfer device.
5. The apparatus of claim 4 wherein the material-transfer device is
operable to transfer subterranean formation fracturing fluid and/or
wellbore casing cement.
6. The apparatus of claim 1 wherein: the oilfield additive system,
the additive-containing substance, the wellbore, the plurality of
components, the plurality of sensors, the information, and the
operational parameter are, respectively, a first oilfield additive
system, a first additive-containing substance, a first wellbore, a
first plurality of components, a first plurality of sensors, first
information, and a first operational parameter; the monitoring
system is further operable to monitor a second oilfield additive
system operable to transfer a second additive-containing substance
for injection into a second wellbore; the second oilfield additive
system comprises a second plurality of components each associated
with a corresponding second operational parameter; the monitoring
system further comprises a second plurality of sensors each
associated with, and operable to generate second information
related to the second operational parameter of, a corresponding one
of the second plurality of components; and the maintenance aspect
of the item is based on a comparison of at least portions of the
first information and the second information.
7. The apparatus of claim 6 wherein: the first plurality of
components comprises a first material-transfer device; the second
plurality of components comprises a second material-transfer
device; the item is the first material-transfer device; the
compared portion of the first information is indicative of a first
efficiency of the first material-transfer device; and the compared
portion of the second information is indicative of a second
efficiency of the second material-transfer device.
8. The apparatus of claim 7 wherein: the first efficiency is based
on a first ratio of a first actual material transfer rate of the
first material-transfer device to a first theoretical material
transfer rate of the first material-transfer device; and the second
efficiency is based on a second ratio of a second actual material
transfer rate of the second material-transfer device to a second
theoretical material transfer rate of the second material-transfer
device.
9. The apparatus of claim 1 wherein the information generated by
one of the plurality of sensors comprises information related to
one or more of performance, efficiency, and accuracy of the
corresponding one of the plurality of components.
10. The apparatus of claim 1 wherein the information generated by
one of the plurality of sensors comprises information related to a
property of the additive-containing substance.
11. A method, comprising: transferring an additive-containing
substance for injection into a wellbore with an oilfield additive
system, wherein the oilfield additive system comprises a plurality
of components each associated with a corresponding operational
parameter; generating information related to the operational
parameter of each of the plurality of components with a
corresponding one of a plurality of sensors; and recording the
information generated by the plurality of sensors with a monitoring
device to generate a database indicative of a maintenance aspect of
an item, wherein the item is at least one of: the oilfield additive
system; at least one of the plurality of components; and/or a
combination thereof.
12. The method of claim 11 wherein the maintenance aspect is, or is
indicative of, an estimated remaining functional life of the item,
and wherein the estimated remaining functional life is an estimate
of remaining operational time until failure of the item and/or
operational efficiency of the item falling below a predetermined
threshold.
13. The method of claim 11 further comprising comparing the
information related to the operational parameter of a selected one
of the plurality of components with the database to determine the
maintenance aspect of the item.
14. The method of claim 11 wherein monitoring the oilfield additive
system further comprises: comparing the information generated by
the plurality of sensors to predetermined thresholds; and
generating an output signal based on the comparison.
15. The method of claim 11 wherein the oilfield additive system,
the additive-containing substance, the wellbore, the plurality of
components, the plurality of sensors, the information, and the
operational parameter are, respectively, a first oilfield additive
system, a first additive-containing substance, a first wellbore, a
first plurality of components, a first plurality of sensors, first
information, and a first operational parameter; and the method
further comprises: transferring a second additive-containing
substance for injection into a second wellbore with a second
oilfield additive system, wherein the second oilfield additive
system comprises a second plurality of components each associated
with a corresponding second operational parameter; generating
second information related to the second operational parameter of
each of the second plurality of components with a corresponding one
of a second plurality of sensors; and comparing at least portions
of the first information and the second information to determine
the maintenance aspect of the item.
16. The method of claim 15 wherein: the first plurality of
components comprises a first material-transfer device; the second
plurality of components comprises a second material-transfer
device; the item is the first material-transfer device; the
compared portion of the first information is indicative of a first
efficiency of the first material-transfer device; the compared
portion of the second information is indicative of a second
efficiency of the second material-transfer device; and the method
further comprises: determining a first ratio of a first actual
material transfer rate of the first material-transfer device to a
first theoretical material transfer rate of the first
material-transfer device to determine the first efficiency; and
determining a second ratio of a second actual material transfer
rate of the second material-transfer device to a second theoretical
material transfer rate of the second material-transfer device to
determine the second efficiency.
17. The method of claim 11 wherein the oilfield additive system
further comprises a communication system operable to facilitate
communication between the plurality of components, wherein the
communication system comprises: an input/output module in
communication with the plurality of sensors and the plurality of
components; a controller in communication with the input/output
module; and a human/machine interface in communication with the
controller; and wherein monitoring the oilfield additive system
further comprises: detecting a defect in communications between the
input/output module, the controller, and the human/machine
interface; and generating an output signal when the defect is
detected.
18. A system, comprising: an oilfield additive system operable to
transfer a material for injection into a wellbore, wherein the
oilfield additive system comprises a plurality of components; a
monitoring system operable to monitor the oilfield additive system,
wherein the monitoring system comprises: a plurality of sensors
each associated with, and operable to generate information related
to operational parameters of, a corresponding one of the plurality
of components; and a monitoring device in communication with each
of the plurality of sensors and operable to record the information
generated by the plurality of sensors to generate a database,
wherein the database is indicative of a maintenance aspect of the
oilfield additive system and/or at least one of the plurality of
components.
19. The system of claim 18 wherein the maintenance aspect is, or is
indicative of, an estimated remaining functional life of the
oilfield additive system and/or at least one of the plurality of
components.
20. The system of claim 18 wherein the maintenance aspect is, or is
indicative of, a health of the oilfield additive system and/or at
least one of the plurality of components.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S.
Provisional Application No. 62/032,158, entitled "Prognosis and
Health Management (PHM) Implementation on Additive Systems," filed
on Aug. 1, 2014, the entire disclosure of which is hereby
incorporated herein by reference.
BACKGROUND OF THE DISCLOSURE
[0002] In oilfield operations, additive systems are utilized at
wellsites to blend and/or inject additives or other material into a
wellbore. Such operations may include drilling, cementing,
acidizing, water jet cutting, and hydraulic fracturing of
subterranean formations. In some additive systems, several pumps or
other material transfer devices may be connected in parallel and/or
in series to transfer the material from a storage container into
the wellbore. Additive systems further include valves, actuators,
flow meters, and/or mixing devices that facilitate the transfer and
combining of the materials, while in solid and/or liquid form,
prior to being injected into the wellbore.
[0003] The success of the additive system operations may be related
to many factors, including failure rates. Due to high frequency of
use, high pressures, and abrasive properties of certain materials,
portions of the additive systems may wear out and fail. Such
failures result in operation stoppages and severe damage to other
components. In some instances, oilfield operations may have to be
repeated at large monetary costs and loss of production time.
SUMMARY OF THE DISCLOSURE
[0004] This summary is provided to introduce a selection of
concepts that are further described below in the detailed
description. This summary is not intended to identify indispensable
features of the claimed subject matter, nor is it intended for use
as an aid in limiting the scope of the claimed subject matter.
[0005] The present disclosure introduces an apparatus that includes
a monitoring system that monitors an oilfield additive system. The
oilfield additive system transfers an additive-containing substance
for injection into a wellbore, and includes multiple components
each associated with a corresponding operational parameter. The
monitoring system includes sensors and a monitoring device. Each
sensor is associated with, and generates information related to the
operational parameter of, a corresponding one of the oilfield
additive system components. The monitoring device is in
communication with each of the sensors, and records the information
generated by the sensors to generate a database indicative of a
maintenance aspect of the oilfield additive system and/or one or
more of the oilfield additive system components.
[0006] The present disclosure also introduces a method that
includes transferring an additive-containing substance for
injection into a wellbore with an oilfield additive system. The
oilfield additive system includes components each associated with a
corresponding operational parameter. The method also includes
generating information related to the operational parameter of each
of the oilfield additive system components with corresponding
sensors. The information generated by the sensors is recorded with
a monitoring device to generate a database indicative of a
maintenance aspect of the oilfield additive system and/or one or
more of the oilfield additive system components.
[0007] The present disclosure also introduces a system that
includes an oilfield additive system and a monitoring system that
monitors the oilfield additive system. The oilfield additive system
includes multiple components, and is operable to transfer a
material for injection into a wellbore. The monitoring system
includes sensors each associated with, and operable to generate
information related to operational parameters of, a corresponding
one of the oilfield additive system components. The monitoring
system also includes a monitoring device in communication with each
of the sensors. The monitoring device records the information
generated by the sensors to generate a database indicative of a
maintenance aspect of the oilfield additive system and/or one or
more of the oilfield additive system components.
[0008] These and additional aspects of the present disclosure are
set forth in the description that follows, and/or may be learned by
a person having ordinary skill in the art by reading the materials
herein and/or practicing the principles described herein. At least
some aspects of the present disclosure may be achieved via means
recited in the attached claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present disclosure is understood from the following
detailed description when read with the accompanying figures. It is
emphasized that, in accordance with the standard practice in the
industry, various features are not drawn to scale. In fact, the
dimensions of the various features may be arbitrarily increased or
reduced for clarity of discussion.
[0010] FIG. 1 is a schematic view of at least a portion of
apparatus according to one or more aspects of the present
disclosure.
[0011] FIG. 2 is a schematic view of at least a portion of an
apparatus according to one or more aspects of the present
disclosure.
[0012] FIG. 3 is a schematic view of at least a portion of an
apparatus according to one or more aspects of the present
disclosure.
[0013] FIG. 4 is a schematic view of at least a portion of an
apparatus according to one or more aspects of the present
disclosure.
[0014] FIG. 5 is a block diagram of diagnostic tools according to
one or more aspects of the present disclosure.
[0015] FIG. 6 is a flow-chart diagram of at least a portion of a
method according to one or more aspects of the present
disclosure.
DETAILED DESCRIPTION
[0016] It is to be understood that the following disclosure
provides many different embodiments, or examples, for implementing
different features of various embodiments. Specific examples of
components and arrangements are described below to simplify the
present disclosure. These are, of course, merely examples and are
not intended to be limiting. In addition, the present disclosure
may repeat reference numerals and/or letters in the various
examples. This repetition is for simplicity and clarity, and does
not in itself dictate a relationship between the various
embodiments and/or configurations discussed. Moreover, the
formation of a first feature over or on a second feature in the
description that follows may include embodiments in which the first
and second features are formed in direct contact, and may also
include embodiments in which additional features may be formed
interposing the first and second features, such that the first and
second features may not be in direct contact.
[0017] FIG. 1 is a schematic view of at least a portion of an
example additive system 100 according to one or more aspects of the
present disclosure. The figure depicts a wellsite surface 102
adjacent to a wellbore 104 and a partial sectional view of the
subterranean formation 106 penetrated by the wellbore 104 below the
wellsite surface 102. The additive system 100 may be operable to
transfer an additive or other material from a source location to a
destination location for blending or mixing with another additive
or material and eventual injection into the wellbore 104. The
additive system 100 may comprise a first mixer 108 connected with
one or more first containers 110 and a second container 112. The
second container 112 may contain a first additive and the first
containers 110 may contain water or another liquid comprising
water. When the additive system 100 is operable as a fracturing
system, the first additive may be or comprise a hydratable material
or gelling agent, such as guar, a polymer, a synthetic polymer, a
galactomannan, a polysaccharide, a cellulose, and/or a clay, among
other examples, and the liquid may be or comprise an aqueous fluid,
which may comprise water or an aqueous solution comprising water,
among other examples. When the additive system 100 is operable as a
cementing system, the first additive may be or comprise cement
powder.
[0018] The liquid may be transferred from the first containers 110
to the first mixer 108 by a first material transfer device 114,
such as may be driven by a first prime mover 115. The first
material transfer device 114 may be or comprise a pump, while the
prime mover 115 may be or comprise an electric motor, an engine, or
another rotary actuator. The first additive may be transferred from
the second container 112 to the first mixer 108 by a second
material transfer device 116, such as may be driven by a second
prime mover 117. The second material transfer device 116 may be or
comprise a conveyer, a bucket elevator, or a feeding screw, while
the second prime mover 117 may be or comprise an electric motor, an
engine, or another rotary actuator. The first mixer 108 may be
operable to receive the first additive and the liquid via two or
more conduits 118, 120, and mix or otherwise combine the first
additive and the liquid to form a base fluid. The first mixer 108
may then discharge the base fluid via one or more conduits 122.
[0019] The first mixer 108 and the second container 112 may each be
disposed on corresponding trucks, trailers, and/or other mobile
carriers 124, 126, respectively, such as may permit their
transportation to the wellsite surface 102. However, the first
mixer 108 and/or second container 112 may be skidded or otherwise
stationary, and/or may be temporarily or permanently installed at
the wellsite surface 102.
[0020] The additive system 100 may further comprise a second mixer
128 fluidly connected with the first mixer 108 and a third
container 130. The third container 130 may contain a second
additive that may be substantially different than the first
additive. When the additive system 100 is operable as the
fracturing system, the second additive may be or comprise a
proppant material, such as sand, sand-like particles, silica,
quartz, and/or propping agents, among other examples. When the
additive system 100 is operable as the cementing system, the second
additive may be or comprise accelerators, retarders, fluid-loss
additives, dispersants, extenders, weighting agents, lost
circulation additives and/or other chemicals or materials operable
to modify the characteristics of the base fluid. The second
additive may be a solid material (e.g., particulate material,
powder) or a liquid.
[0021] The second additive may be transferred from the third
container 130 to the second mixer 128 by a second material transfer
device 131 driven by a third prime mover 132. The third material
transfer device 131 may be or comprise a pump when the second
additive is a liquid, or the third material transfer device 131 may
be or comprise a conveyer, a bucket elevator, or a feeding screw
when the second additive is a solid material. The third prime mover
132 may be or comprise an electric motor, an engine, or another
rotary actuator. The second mixer 128 may be operable to receive
the base fluid from the first mixer 108 via one or more conduits
122, and a second additive from the third container 130 via one or
more conduits 133, and mix or otherwise combine the base fluid and
the second additive to form a mixture. The mixture may comprise a
fracturing fluid when the additive system 100 is operable as the
fracturing system, or the mixture may comprise a cement slurry when
the additive system 100 is operable as the cementing system. The
second mixer 128 may then discharge the mixture via one or more
conduits 134.
[0022] The second mixer 128 and the third container 130 may each be
disposed on corresponding trucks, trailers, and/or other mobile
carriers 136, 138, respectively, such as may permit their
transportation to the wellsite surface 102. However, the second
mixer 128 and/or third container 130 may be skidded or otherwise
stationary, and/or may be temporarily or permanently installed at
the wellsite surface 102.
[0023] The mixture may be communicated from the second mixer 128 to
a fourth container 140, which may be or comprise a mixing,
displacement, or storage tank for the mixture prior to being
injected into the wellbore 104. The mixture may be communicated
from the fourth container 140 to a common manifold 142 via the one
or more conduits 144. The common manifold 142 may comprise a
combination of valves and/or diverters, as well as a suction line
146 and a discharge line 148, such as may be collectively operable
to direct flow of the mixture in a selected or predetermined
manner. The common manifold 142, which may be known in the art as a
missile or a missile trailer, may distribute the mixture to a pump
fleet. The pump fleet may comprise multiple pump assemblies 150
each comprising a pump 152, a prime mover 154, and a heat exchanger
156. Each pump assembly 150 may receive the mixture from the
suction line 146 of the common manifold 142, via one or more
conduits 158, and discharge the mixture under pressure to the
discharge line 148 of the common manifold 142, via one or more
conduits 160.
[0024] The pump assemblies 150 may each be mounted on corresponding
trucks, trailers, and/or other mobile carriers 164, such as may
permit their transportation to the wellsite surface 102. However,
the pump assemblies 150 may be skidded or otherwise stationary,
and/or may be temporarily or permanently installed at the wellsite
surface 102.
[0025] The mixture may then be discharged from the common manifold
142 into the wellbore 104 via one or more conduits 162, such as may
include various valves, conduits, and/or other hydraulic circuitry
fluidly connected between the common manifold 142 and the wellbore
104. During operations, the mixture and/or wellbore fluid may be
ejected from the wellbore 104 and communicated to a fifth container
166 via one or more conduits 168. Although the additive system 100
is shown comprising a fourth container 140, it is to be understood
that the fourth container 140 may not be included as part of the
additive system 100, such that the mixture may be communicated from
the second mixer 128 directly to the common manifold 142. The
additive system 100 may also omit the common manifold 142, and the
conduits 160 may be fluidly connected to the wellbore 104 via a
wellhead (not shown) and/or other means.
[0026] The additive system 100 may also comprise a control center
170, which may be operable to monitor and control at least a
portion of the additive system 100 during operations. Signals may
be communicated between the control center 170 and other components
of the additive system 100 via a local network. For example, the
control center 170 may be operable to monitor and/or control the
production rate of the mixture, such as by increasing or decreasing
the flow of the liquid from the first containers 110, the first
additive from the second container 112, the base fluid from the
first mixer 108, the second additive from the third container 130,
and/or the mixture from the second mixer 128. The control center
170 may also be operable to monitor health and/or functionality of
the additive system 100. For example, the control center 170 may be
operable to monitor and/or control operational parameters
associated with the containers 110, 112, 130, 140, 166, the first
and second mixers 108, 128, the material transfer assemblies 114,
116, 130, and/or the pump assemblies 150. The control center 170
may also be operable to monitor temperature, viscosity, density,
and composition of the liquid contained in the first containers
110, the first additive, the second additive, and/or the
mixture.
[0027] The control center 170 may be disposed on a corresponding
truck, trailer, and/or other mobile carrier 172, such as may permit
its transportation to the wellsite surface 102. However, the
control center 170 may be skidded or otherwise stationary, and/or
may be temporarily or permanently installed at the wellsite surface
102.
[0028] FIG. 1 depicts the additive system 100 as being operable to
transfer additives and produce mixtures that may be pressurized and
injected into the wellbore 104 during hydraulic fracturing or
cementing operations. However, it is to be understood that the
additive system 100 may be operable to transfer other additives and
produce other mixtures that may be pressurized and injected into
the wellbore 104 during other oilfield operations, such as
drilling, acidizing, chemical injecting, and/or water jet cutting
operations, among other examples.
[0029] FIG. 2 is a schematic view of at least a portion of an
example implementation of the additive system 100 shown in FIG. 1,
designated in FIG. 2 by reference numeral 200, according to one or
more aspects of the present disclosure. FIG. 2 also depicts an
example implementation of a control and monitoring (CAM) system 300
according to one or more aspects of the present disclosure. At
least portions of the additive system 200 shown in FIG. 2 may be
substantially similar to corresponding portions of the additive
system 100 shown in FIG. 1 and/or other additive systems within the
scope of the present disclosure. The depicted implementation of the
additive system 200 shown in FIG. 2 includes generic examples of
the subsystems, components, and/or other portions of an additive
system that may be in communication with the CAM system 300
according to one or more aspects of the present disclosure.
[0030] For example, the additive system 200 may comprise one or
more monitored subsystems 202. Examples of the monitored subsystem
202 depicted in FIG. 2 may include the containers 110, 112, 130,
140 and/or other components and/or subsystems of the additive
system 100 shown in FIG. 1 that may be monitored but not controlled
via operation of the CAM system 300. Each monitored subsystem 202
comprises one or more sensors 204 each operable to monitor one or
more parameters associated with that monitored subsystem 202. Each
sensor 204 is operable to generate a signal or information related
to operational parameters of the monitored subsystem 202, which may
then be communicated to the CAM system 300 via a local network
302.
[0031] The local network 302 may be or comprise Ethernet, digital
subscriber line (DSL), telephone, coaxial, cellular, and/or other
types of networks. However, the local network 302 is implemented
entirely at the wellsite, and does not include network nodes or
other components that are located remote from the wellsite. The
local network 302 may form a portion of the CAM system 300 and/or
otherwise facilitate communication between one or more components
of the CAM system 300 and one or more components of the additive
system 200.
[0032] The additive system 100 may also comprise one or more
wellsite-controlled (WC) subsystems 212. Each WC subsystem 212
comprises one or more sensors 214 each operable to monitor one or
more parameters associated with that WC subsystem 212. For example,
each sensor 214 may be operable to generate a signal or information
related to operational parameters of one or more controllable
devices 216 and/or other components or aspects of the WC subsystem
212, which may then be communicated to the CAM system 300 directly
via the local network 302 or indirectly via a communication
interface 218.
[0033] Examples of the WC subsystem 212 depicted in FIG. 2 may
include the material transfer devices 114, 116, 131, the prime
movers 115, 117, 132, and/or other components and/or subsystems of
the additive system 100 shown in FIG. 1 that may be monitored via
operation of the CAM system 300, and that have one or more
controllable devices 216 that may be controlled via operation of
the CAM system 300, but that do not include a subsystem
human-machine interface (HMI) as described below. Thus, while the
monitored subsystems 202 and the WC subsystems 212 each include at
least one sensor 204, 214 that is monitored via operation of the
CAM system 300, the monitored subsystems 202 and the WC subsystems
212 are distinguishable from each other in that the WC subsystems
212 each also include at least one controllable device 216
controlled via operation of the CAM system 300, whereas the
monitored subsystems 202 do not include devices that are controlled
via operation of the CAM system 300.
[0034] The communication interface 218 facilitates communication
between the controllable devices 216 and the CAM system 300 via the
local network 302. The communication interface 218 may also
facilitate communication between the sensors 214 and the CAM system
300 via the local network 302, although communication between the
sensors 214 and the CAM system 300 may be directly via the local
network 302. The communication interface 218 may be, comprise, or
be implemented by various types of standard interfaces, such as an
Ethernet interface, a universal serial bus (USB), a third
generation input/output (3GIO) interface, a wireless interface,
and/or a cellular interface, among other examples, although
non-standard interfaces may also be utilized. The communication
interface 218 may also comprise a communication device, such as a
modem or network interface card, to facilitate exchange of data via
the local network 302. One or more portions of the communication
interface 218 may also be or comprise one or more of the
input/output (I/O) modules described below.
[0035] The additive system 100 may also comprise one or more
HMI/network-controllable (HNC) subsystems 220. Each HNC subsystem
220 comprises one or more sensors 222 each operable to monitor one
or more parameters associated with that HNC subsystem 220. For
example, each sensor 222 may be operable to generate a signal or
information related to operational parameters of one or more
controllable devices 224 and/or other components or aspects of the
HNC subsystem 220, which may then be communicated to the CAM system
300 directly via the local network 302 or indirectly via a
communication interface 226. The communication interface 226 may
have the same or similar structure and/or function as the
communication interface 218 described above. The signal or
information generated by each sensor 222 may also be communicated
to a subsystem HMI 228.
[0036] The subsystem HMI 228 may permit a human operator to monitor
and/or enter control commands or other information operable to
control the operation of the controllable devices 224 and/or other
portions of the HNC subsystem 220. The subsystem HMI 228 may
comprise one or more input devices, one or more output devices, and
one or more communication interfaces, as described below. The
subsystem HMI 228 may also communicate with the communication
interface 226.
[0037] Examples of the HNC subsystem 220 depicted in FIG. 2 may
include the mixers 108, 128, the pump assemblies 150, and/or other
components and/or subsystems of the additive system 100 shown in
FIG. 1 that may be monitored via operation of the CAM system 300,
that have one or more controllable devices 224 that may be
controlled via operation of the CAM system 300, and that include a
subsystem HMI 228. Thus, while the WC subsystems 212 and the HNC
subsystems 220 each include at least one sensor 214, 222 monitored
via operation of the CAM system 300, and each include at least one
controllable device 216, 224 controlled via operation of the CAM
system 300, the WC subsystems 212 and the HNC subsystems 220 are
distinguishable from each other in that the HNC subsystems 220 each
also include a subsystem HMI 228, whereas the WC subsystems 212 do
not include an HMI.
[0038] The CAM system 300 includes a system control/monitoring
(SCM) device 306 in communication with the monitored subsystems
202, the WC subsystems 212, and the HNC subsystems 220 via the
local network 302. The SCM device 306 is operable to receive
information generated by the sensors 204, 214, 222 and, based at
least in part on such information, generate and send control
signals to the controllable devices 216, 224. For example, the SCM
device 306 may be operable to utilize the information generated by
the sensors 204, 214, 222 and other data and execute coded
machine-readable instructions to implement at least a portion of
one or more of the example methods and/or processes described
herein, and/or to implement a portion of one or more of the example
systems described herein.
[0039] The SCM device 306 comprises a communication interface 308
and/or other means operable to facilitate communication between the
SCM device 306 and the one or more subsystems 202, 212, 220 of the
additive system 200 via the local network 302. The communication
interface 308 may have the same or similar structure and/or
function as the communication interface 218 described above.
[0040] The SCM device 306 may further comprise a system HMI 310
permitting a human operator to monitor and/or enter control
commands or other information operable to control the operation of
one or more of the subsystems 202, 212, 220 of the additive system
200 via the local network 302. The system HMI 310 may comprise one
or more input devices, one or more output devices, and one or more
communication interfaces, as described below. Communication between
the system HMI 310 and the additive system 200 may be via the
communication interface 308 and the local network 302.
[0041] The control and monitoring system 300 may further comprise a
remote access device 312 operable for communication with the
additive system 200 from a remote location not at the wellsite. For
example, the remote access device 312 may be located at a
substantial distance from the wellsite, and may therefore
communicate with the local network 302 via an external network 304.
Thus, the remote access device 312 may be operable to communicate
with and/or control the operation of one or more portions of the
subsystems 202, 212, 220 via the external network 304 and the local
network 302.
[0042] The external network 304 may be or comprise DSL, telephone,
cellular, satellite, and/or other types of networks. At least a
portion of the external network 304 is implemented remote from the
wellsite, and includes network nodes or other components that are
located remote from the wellsite. The external network 304 may form
a portion of the CAM system 300 and/or otherwise facilitate
communication with the local network 302 and, thus, communication
between the remote access device 312 and one or more components of
the CAM system 300 and/or one or more components of the additive
system 200.
[0043] The remote access device 312 may be operable to receive
information generated by the sensors 204, 214, 222 and, based at
least in part on such information and/or information input by a
human operator via a remote HMI 316, generate and send control
signals to the controllable devices 216, 224 via the external
network 304 and the local network 302. For example, based on the
received information, the user input, and/or other data, the remote
access device 312 may execute coded machine-readable instructions
to implement at least a portion of one or more of the example
methods and/or processes described herein, and/or to implement a
portion of one or more of the example systems described herein. The
remote access device 312 may also be operable to access or
otherwise communicate with the SCM device 306, such as to enter
control commands or other information operable to control the
operation of one or more of the subsystems 202, 212, 220 of the
additive system 200.
[0044] The remote access device 312 may comprise a communication
interface 314 operable to facilitate communication between the
remote access device 312 and the external network 304. The
communication interface 314 may have the same or similar structure
and/or function as the communication interface 218 described
above.
[0045] The remote HMI 316 may permit a human operator to monitor
and/or enter control commands or other information operable to
control the operation of one or more of the subsystems 202, 212,
220 of the additive system 200. The remote HMI 316 may comprise one
or more input devices, one or more output devices, and one or more
communication interfaces, as described below.
[0046] FIG. 3 is a schematic view of at least a portion of an
example implementation of an additive system 201 according to one
or more aspects of the present disclosure. The additive system 201
shown in FIG. 3 provides an example of the generic additive system
200 shown in FIG. 2 when implemented in the environment of the
additive system 100 shown in FIG. 1. That is, the additive system
201 shown in FIG. 3 comprises components of the additive system 100
shown in FIG. 1 implemented as the various subsystems 202, 212, 220
of the additive system 200 shown in FIG. 2. However, a person
having ordinary skill in the art will readily appreciate that other
implementations of the generic additive system 200 shown in FIG. 2,
including in environments other than the example additive system
100 shown in FIG. 1, are also within the scope of the present
disclosure.
[0047] The following description refers to FIGS. 1-3,
collectively.
[0048] The additive system 201 may comprise a container 240, such
as may be or comprise one or more of the containers 110, 112, 130,
140 shown in FIG. 1. The container 240 may be an implementation of
the monitored subsystem 202, and may thus comprise one or more
sensors 204, such as material quantity sensors operable to generate
information related to level, volume, and/or mass of the material
within the container 240 and/or the output transfer rate of
material from the container 240. The material quantity sensors may
comprise conductive, capacitive, vibrating, electromechanical,
ultrasonic, microwave, nucleonic, and/or other material height or
level detection means, which may be further utilized to calculate
material volume. The material quantity sensors may further comprise
mass measuring means, such as load cells, pressure sensors, and/or
other weight measuring means. The material within the container 240
may be transferred or otherwise communicated through a plurality of
subsystems of the additive system 201 until the material is
injected or discharged into a material destination 270, as
described below.
[0049] For example, another subsystem 242 of the additive system
201 may comprise a valve 244 operable to control the transfer of
the material from the container 240 to a subsequent subsystem 252
via one or more material conduits 246. The valve 244 may be
disposed with or near the container 240, or further downstream from
the container 240 along the conduit(s) 246, and may be or comprise
a check valve, a flow control valve, a directional control valve, a
diverter valve, a shut-off valve, a ball valve, a butterfly valve,
a gate valve, a globe valve, and/or other types of valves. The
valve 244 may be actuated or otherwise moved between valve
positions by an actuator 248, which may be or comprise a manual
operator (such as a handle or lever), a pneumatic or hydraulic
actuator (such as a cylinder), an electric motor, or a solenoid,
among other examples.
[0050] The subsystem 242 may be an implementation of an instance of
the WC subsystem 212 or the HNC subsystem 220, such that the valve
244 and/or the actuator 248 may be implementations of the
controllable devices 216, 224. Accordingly, the sensors 214, 222
may be disposed or otherwise utilized in association with the valve
244 and/or the actuator 248, such as for generating information
related to operational parameters of the valve 244 and/or the
actuator 248. For example, the one or more sensors 214, 222 may be
operable to generate information related to temperature, pressure,
electrical current, power consumption, proximity, linear position,
rotational position, operating speed, operating frequency, torque,
elapsed operating time, and/or other operational parameters
associated with the valve 244, the actuator 248, and/or other
monitored and/or controlled components of the subsystem 242. The
information generated by the sensors 214, 222 may then be
communicated to the CAM system 300 via the local network 302, as
described above. When the subsystem 242 is implemented as an
instance of the HNC subsystem 220, the information generated by the
sensors 222 in association with the valve 244, the actuator 248,
and/or other components of the subsystem 242 may also be
communicated to the subsystem HMI 228 for review and/or action
thereon by a human operator at the subsystem 242, as described
above.
[0051] The example subsystem 252 that may receive the material
transferred from the container 240 via the subsystem 242 may
comprise a material transfer device 254 operable to receive and
transfer the material from the first subsystem 242 to another
subsystem 262, such as via one or more material conveyors and/or
other conduits 258. The material transfer device 254 may be or
comprise one of the material transfer devices 114, 116, 131 or
pumps 152 shown in FIG. 1. Thus, the subsystem 252 may also
comprise a prime mover 256 operable to drive the material transfer
device 254. The prime mover 254 may be or comprise a corresponding
one of the prime movers 115, 117, 132, 154 shown in FIG. 1. The
subsystem 252 may also comprise a prime mover control device (not
shown), such as may power and/or control the prime mover 256. For
example, in implementations in which the prime mover 256 comprises
an electric motor, the prime mover control device may be a drive,
and in implementations in which the prime mover 256 comprises an
engine, the prime mover control device may be a throttle
device.
[0052] The subsystem 252 may be an implementation of an instance of
the WC subsystem 212 or the HNC subsystem 220, such that the
material transfer device 254 and/or the prime mover 256 may be
implementations of the controllable devices 216, 224. Accordingly,
the sensors 214, 222 may be disposed or otherwise utilized in
association with the material transfer device 254 and/or the prime
mover 256, such as for generating information related to
operational parameters of the material transfer device 254 and/or
the prime mover 256. For example, the one or more sensors 214, 222
may be operable to generate information related to temperature,
pressure, electrical current, power consumption, proximity, linear
position, rotational position, operating speed, operating
frequency, torque, elapsed operating time, and/or other operational
parameter associated with the material transfer device 254, the
prime mover 256, and/or other monitored and/or controlled
components of the subsystem 252. The information generated by the
sensors 214, 222 may then be communicated to the CAM system 300 via
the local network 302, as described above. When the subsystem 252
is implemented as an instance of the HNC subsystem 220, the
information generated by the sensors 222 in association with the
material transfer device 254, the prime mover 256, and/or other
components of the subsystem 252 may also be communicated to the
subsystem HMI 228 for review and/or action thereon by a human
operator at the subsystem 252, as described above.
[0053] The additive system 201 may also comprise one or more
material sensors 260 operable to generate information related to
properties of the material communicated via the one or more
material conduits 246, 258. Each material sensor 260 may be an
implementation of the monitored subsystem 202. Thus, each material
sensor 260 may be or comprise the one or more sensors 204 operable
to generate information related to one or more parameters
associated with the material transferred via the one or more
material conduits 246, 258. The information generated by the
material sensor(s) 260 may then be communicated to the CAM system
300 via the local network 302, as described above.
[0054] Each material sensor 260 may be located along one or more of
the material conduits 246, 258. For example, one or more material
sensors 260 may be located downstream (i.e., on the outlet or
pressure side) and/or upstream (i.e., on the inlet or suction side)
of the material transfer device 254, among other possible locations
within the additive system 201. For example, at least one of the
material sensors 260 may be or comprise a flow meter operable to
generate information relate to the flow rate of material being
transferred via the one or more material conduits 246, 258. If the
material being transferred comprises a fluid, the corresponding
material sensor(s) 260 may be or comprise a fluid flow meter
operable to measure the volumetric and/or mass flow rate of the
fluidic material. If the material comprises a solid or particulate
material, the corresponding material sensor(s) 260 may be or
comprise a dry or particulate flow meter operable to measure the
volumetric and/or mass flow rate of the dry or particulate
material. One or more of the material sensors 260 may also or
instead be or comprise a mechanical flow meter, such as gear or
turbine meter, a pressure-based meter (such as a Venturi or
pitot-static tube meter), an optical flow meter, a mass flow meter,
and/or other types of flow meters operable to measure rate of
movement of a liquid or solid material.
[0055] One or more of the material sensors 260 may also or instead
be operable to generate other information related to properties of
the material transferred via the one or more conduits 246, 258. For
example, such material sensors 260 may be operable to generate
information related to temperature, pressure, viscosity, density,
composition, and/or other physical parameters of the material being
transferred.
[0056] The example implementation of the additive system 201 shown
in FIG. 3 also includes another instance of the subsystem 242,
designated in FIG. 3 by the reference numeral 262. The subsystem
262 comprises a valve 264 operable for controlling the transfer of
material from the subsystem 252 to the material destination 270 via
one or more of the material conduits 258. As above, the valve 264
may be actuated or otherwise moved between valve positions by an
actuator 266. The valve 264 and actuator 266 may be as described
above with respect to the valve 244 and the actuator 248 of the
subsystem 242.
[0057] As also described above, the subsystem 262 may be an
implementation of the WC subsystem 212 or the HNC subsystem 220,
such that the valve 264 and/or the actuator 266 are implementations
of the controllable devices 216, 224. Accordingly, the sensors 214,
222 may be disposed or otherwise utilized in association with the
valve 264 and/or the actuator 266, such as may be operable to
generate information related to operational parameters of the valve
264 and/or the actuator 266. For example, the one or more sensors
214, 222 may be operable to generate information related to
temperature, pressure, electrical current, power consumption,
proximity, linear position, rotational position, operating speed,
operating frequency, torque, elapsed operating time, and/or other
operational parameters associated with the valve 264 and/or the
actuator 266. The information generated by the sensors 214, 222 may
then be communicated to the CAM system 300 via the local network
302, as described above. Where the subsystem 262 is an
implementation of the HNC subsystem 220, the information generated
by the sensors 222 in association with the valve 264 and/or the
actuator 266 may also be communicated to the subsystem HMI 228, as
described above.
[0058] The subsystem 262 may discharge the material into the
material destination 270. The material destination 270 may be or
comprise the first or second mixing device 108, 128. The material
destination 270 may instead be the fourth container 140 in
implementations in which the material transfer device 254 is or
comprises one of the material transfer devices 114, 116, 131. The
material destination 270 may also or instead be or comprise the
common manifold 142 in implementations in which the material
transfer device 254 is or comprises the pump 152.
[0059] The material destination 270 may be in communication with
the CAM system 300. For example, each mixing device 108, 128 may
comprise one or more motors and other actuators (not shown)
operable to receive control signals from the CAM system 300 to
control or otherwise operate each mixing device 108, 128. Each
mixing device 108, 128 may also comprise one or more sensors (not
shown) operable to generate a signal or information related to
operational parameters of each mixing device 108, 128 and
communicate such signal or information to the CAM system 300.
Likewise, the common manifold 142 may comprise one or more
actuators (not shown) operable to receive control signals from the
CAM system 300, such as to control or otherwise operate flow
through the common manifold 142. The common manifold 142 may also
comprise one or more sensors (not shown) operable to generate a
signal or information related to operational parameters of or
associated with the common manifold 142 and communicate such signal
or information to the CAM system 300.
[0060] Various portions of the additive systems 100, 200, 201
and/or the CAM system 300 may comprise various control hardware.
For example, the control hardware may be implemented as cards,
modules, circuits, and/or other devices forming at least portions
of the subsystems 202, 212, 220 of the additive system 200 and the
control devices 306, 312 of the CAM system 300. FIG. 4 is a
schematic view of at least a portion of an example implementation
of such control hardware 400 according to one or more aspects of
the present disclosure.
[0061] In the example implementation shown in FIG. 2, components of
the local network 302, components of the external network 304,
components of each subsystem 202, 212, 220 of the additive system
200 (such as each of the HMIs 228 and the communication interfaces
218, 226), components of the SCM device 306 (such as each of the
HMI 310 and the communication interface 308), and components of the
remote access device 312 (such as each of the remote HMI 316 and
the communication interface 314) may each be implemented as an
instance of the control hardware 400 shown in FIG. 4, or a subset
of the various components of the control hardware 400 described
below. Thus, for example, various instances of the control hardware
400 may be operable to facilitate communication between the
additive system 200 and the CAM system 300, including communication
between one or more components of various instances of the
subsystems 202, 212, 220 and the SCM device 306 via the local
network 302, and communication between one or more components of
various instances of the subsystems 202, 212, 220 and the remote
access device 312 via the local network 302 and the external
network 304.
[0062] Each instance of the control hardware 400 may be or comprise
one or more processors, special-purpose computing devices, servers,
personal computers, personal digital assistant (PDA) devices,
smartphones, Internet appliances, and/or other types of computing
devices. As depicted in FIG. 4, the various instances of the
control hardware 400 may each include one or more instances of each
of a processor 412, a volatile memory 418, a non-volatile memory
420, an interface circuit 424, an input device 426, an output
device 428, and/or a mass storage device 430, and may include or be
operable or otherwise associated with an external storage medium
434. However, each instance of the control hardware 400 that is
implemented as or within the various components of the additive
system 200 and the CAM system 300 may not include each of the
components depicted in FIG. 4, but may instead include a subset of
the depicted components.
[0063] For example, an instance of the control hardware 400 that is
implemented as or within the SCM device 306 may include each of the
components depicted in FIG. 4 (although perhaps without the
external storage medium 434), whereas instances of the control
hardware 400 that are implemented as or within instances of the
remote access device 312 and/or the HNC subsystem 220 may not
include the mass storage device 430 and/or the external storage
medium 434. As another example, instances of the control hardware
400 that are implemented as or within instances of the WC subsystem
212 may not include the mass storage device 430, the external
storage medium 434, the input device 426, and/or the output device
428. In another example, instances of the control hardware 400 that
are implemented as or within instances of the monitored subsystem
202 may not include the mass storage device 430, the external
storage medium 434, the input device 426, the output device 428,
and/or the interface circuit 424. However, the monitored subsystem
202 may not be implemented utilizing an instance of the control
hardware, but may instead be implemented utilizing components other
than those depicted in FIG. 4, such as components conventionally
utilized in mesh, radio-frequency identification (RFID), and/or
other sensor networks, including those utilizing PROFIBUS, Modbus,
Highway Addressable Remote Transducer (HART), Fieldbus, and/or
other industrial standard communication protocols.
[0064] Moreover, the above-described examples of the different
subsets of the components depicted in FIG. 4 that may form the
various instances of the control hardware 400 are indeed merely
examples, and other examples of different subsets of the components
depicted in FIG. 4 that may be included in the various instances of
the control hardware 400 for implementing the various components of
the additive system 200 and the CAM system 300 are also within the
scope of the present disclosure. Nonetheless, it should be
understood that reference hereafter to an instance of the control
hardware 400 contemplates instances including each of the
components depicted in FIG. 4 as well as instances including a
subset of the depicted components.
[0065] Each instance of the control hardware 400 may be operable to
execute coded machine-readable instructions to implement at least a
portion of one or more of the example methods and/or processes
described herein, and/or to implement a portion of one or more of
the example systems described herein. For example, various
instances of the control hardware 400 may receive information
generated by the sensors 204, 214, 222, information input by a
human operator via one or more of the HMIs 228, 310, 316, and/or
information retrieved from internal or external memory of that
instance of the control hardware 400, among other possible
information sources. Each instance of the control hardware 400 may
execute programs, routines, and/or other coded instructions based
on such information, perhaps resulting in the generation of output
information. For example, the executed instructions and/or
generated output information may be for controlling the
controllable devices 216, 224, and/or for monitoring the sensors
204, 214, 222 and/or other operational aspects of the additive
system 200, whether by another instance of the control hardware 400
and/or a human operator utilizing one or more of the HMIs 228, 310,
316.
[0066] The processor 412 may be a general-purpose programmable
processor, among other examples. The processor 412 may comprise a
local memory 414, and may execute programs or coded instructions
432 present in the local memory 414 and/or another memory device.
The processor 412 may execute, among other things, machine-readable
instructions or programs to implement the methods and/or processes
described herein.
[0067] The coded instructions 432 stored in the local memory 414
may include program instructions or computer program code that,
when executed by an associated processor, facilitate the
controllable devices 216, 224, or the additive system 200 as a
whole, to perform at least portions of the methods and/or processes
described herein. The coded instructions 432 stored in the local
memory 414 may further include program instructions or computer
program code that, when executed by the processor 412, facilitate
one or more instances of the control hardware 400 to record the
information generated by the sensors 204, 214, 222, such as for
determining efficiency, accuracy, and/or other operational aspects
of one or more components of the additive system 200 based, for
example, on the information generated by the sensors 204, 214, 222.
For example, the coded instructions 432 stored in the local memory
414 may also include program instructions or computer program code
that, when executed by the processor 412, facilitate one or more
instances of the control hardware 400 to determine remaining
functional life of one or more components of the additive system
200, determine remaining operational time until failure of one or
more components of the additive system 200, and/or determine health
of one or more components of the additive system 200 based on the
information generated by the sensors 204, 214, 222.
[0068] The processor 412 may be, comprise, or be implemented by one
or more processors of various types suitable to the local
application environment, and may include one or more of
general-purpose computers, special-purpose computers,
microprocessors, digital signal processors (DSPs),
field-programmable gate arrays (FPGAs), application-specific
integrated circuits (ASICs), and processors based on a multi-core
processor architecture, among other examples. However, other
processors from other families are also appropriate.
[0069] The processor 412 may be in communication with a main
memory, such as may include the volatile memory 418 and/or the
non-volatile memory 420, perhaps via a bus 422 and/or other
communication means. The volatile memory 418 may be, comprise, or
be implemented by random access memory (RAM), static random access
memory (SRAM), synchronous dynamic random access memory (SDRAM),
dynamic random access memory (DRAM), RAMBUS dynamic random access
memory (RDRAM), and/or other types of random access memory devices.
The non-volatile memory 420 may be, comprise, or be implemented by
read-only memory, flash memory, and/or other types of memory
devices. One or more memory controllers (not shown) may control
access to the volatile memory 418 and/or the non-volatile memory
420. One or more instances of the control hardware 400 may be
operable to store or record the signals or other information
generated by the sensors 204, 214, 222 on the main memory.
[0070] The communication interface 424 may have the same or similar
structure and/or function as the communication interface 218
described above. The communication interface 424 may facilitate
communication between the control hardware 400 instance and other
portions of the additive system 200 and/or the CAM system 300. One
or more portions of the communication interface 424 may be or
comprise one or more of the I/O modules described below.
[0071] The input device 426 may also be connected to the
communication interface 424. The input device 426 may permit a
human operator to enter data and commands into the processor 412.
The input device 426 may be, comprise, or be implemented by a
keyboard, a mouse, a touchscreen, a track-pad, a trackball, an
isopoint, and/or a voice recognition system, among other
examples.
[0072] The output device 428 may also be connected to the
communication interface 424. The output device 428 may permit a
human operator to visually, audibly, or otherwise perceive
information generated by the control hardware 400 instance, such as
the information received from the sensors 204, 214, 222. The output
device 428 may be, comprise, or be implemented by a display device
(e.g., a light-emitting diode (LED) display, a liquid crystal
display (LCD), and/or cathode ray tube (CRT) display, among
others), a printer, and/or speakers, among other examples.
[0073] The mass storage device 430 may store the coded instructions
432 and/or other data. Examples of such mass storage devices 430
include floppy disk drives, hard drive disks, compact disk (CD)
drives, digital versatile disk (DVD) drives, and flash drives,
among other examples. The coded instructions 432 may be stored in
the mass storage device 430, the volatile memory 418, the
non-volatile memory 420, the local memory 414, and/or the removable
or external storage medium 434. The external storage medium 434 may
be or comprise a hard drive disk, CD, DVD, and/or flash drive,
among other examples.
[0074] At least portions or components of various instances of the
control hardware 400 may be implemented in one or more integrated
circuit chips (e.g., an application specific integrated circuit, or
ASIC), such as may be mounted to a printed circuit board, a
removable plug-in card, or other electronics device. However, at
least portions or components of various instances of the control
hardware 400 may instead be implemented as software or firmware for
execution by one or more processors. Such implementations may be
provided as a computer program product including a computer
readable medium or storage structure embodying computer program
code (i.e., software or firmware) thereon for execution by the
processor 412.
[0075] The coded instructions 432 of the SCM device 306 and/or
other portion of the CAM system 300 may include instructions or
program code for implementing several layers of diagnostic tools
operable to perform diagnostics of the additive system 200 and/or
the CAM system 300. For example, the diagnostic tools may
facilitate monitoring various properties and/or parameters
associated with the health of one or more components or other
portions of the additive system 200 and/or the CAM system 300. The
diagnostic tools may also cause various instances of the control
hardware 400 to generate output signals or information indicative
of the health of one or more components or other portions of the
additive system 200 and/or the CAM system 300. For example, one or
more instances of the control hardware 400 may initiate outputs
perceivable to human operators, such as may include alarms, visual
indicators, error codes, and/or other diagnostic information to be
perceived by human operators via one or more of the output devices
428 of one or more of the HMIs 228, 310, 316.
[0076] Possible human operators may include electronic technicians
(ET), field supervisors, software engineers, control engineers,
reliability engineers, EPA representatives, mechanics, researchers,
and field service managers, among other examples. Each group of
human operators may be interested in different information related
to the additive system 200 and/or the CAM system 300. Thus, the
diagnostic tools may be divided into several levels, each operable
to address different classes of problems associated with different
portions or components of the additive system 200 and/or the CAM
system 300. FIG. 5 is a block diagram of at least a portion of an
example implementation of the diagnostic tools 500 according to one
or more aspects of the present disclosure. The following
description refers to FIGS. 1-5, collectively.
[0077] The diagnostic tools 500 include an I/O diagnostic tool 505,
a hardware level tool 510, a sensor diagnostic tool 515, a process
diagnostic tool 520, a communication diagnostic tool 525, an
automation diagnostic tool 530, a health check diagnostic tool 535,
an error code diagnostic tool 540, a watchdog diagnostic tool 545,
an application diagnostic tool 550, a wireless diagnostic tool 555,
a logging tool 560, and a predictive maintenance tool 565. However,
other implementations of the diagnostic tools 500 are also within
the scope of the present disclosure, including implementations that
do not include one or more of the diagnostic tools 500 depicted in
FIG. 5, as well as implementations that include diagnostic tools
other than those depicted in FIG. 5.
[0078] The I/O diagnostic tool 505 performs I/O level diagnostics,
such as for monitoring I/O cards, modules, and/or other I/O
hardware (such hardware hereafter collectively referred to as
"modules") of the communication interfaces 218, 226, 308, 314, 424
and/or other I/O devices. The I/O diagnostic tool 505 is operable
to detect defects and/or error conditions in the communication
interfaces 218, 226, 308, 314, 424. Information generated by the
I/O diagnostic tool 505, such as input/output states, faults,
warnings, and/or errors, may be visually or otherwise perceivable
by human operators via the HMI 310, and/or may be logged or
otherwise recorded to internal or external memory, including as
described below with regard to the logging tool 560.
[0079] The I/O diagnostic tool 505 may perform diagnostics for
analog input modules to indicate configuration errors, missing
external load voltage errors, reference voltage errors, common-mode
errors, overvoltage warnings, open circuit detections,
short-circuit detections, and/or exceeded upper/lower limit
detections, among other examples. The I/O diagnostic tool 505 may
also perform diagnostics for analog output modules to indicate
configuration errors, missing external load voltage errors, open
circuit detections, short-circuit detections, and/or exceeded load
voltage upper/lower limit detections, among other examples.
[0080] The I/O diagnostic tool 505 may also perform diagnostics for
digital input modules to indicate input states, ground fault
detections, missing sensor supply detections, blown fuse
detections, short-circuit detections, and/or overvoltage
detections, among other examples. The I/O diagnostic tool 505 may
also perform diagnostics for digital output modules to indicate
output states, missing load voltage errors, blown fuse detections,
short-circuit detections, overvoltage detections, ground fault
detections, and/or over-temperature detections, among other
examples.
[0081] The I/O diagnostic tool 505 may also perform diagnostics for
thermocouple input modules to indicate configuration errors,
exceeded upper/lower limit detections, and/or open circuit
detections, among other examples. The I/O diagnostic tool 505 may
also perform diagnostics for frequency input modules to indicate
configuration errors, exceeded upper/lower limit detections, open
circuit detections, and/or faulty encoder power supply detections,
among other examples.
[0082] The I/O diagnostic tool 505 for digital input and output
modules may generate diagnostic messages related to faults or
errors and display them via the HMI 310. Examples of diagnostic
messages identifying a problem with a digital input module may
include messages indicating that an external load voltage is
missing, and/or messages indicating the existence of a
configuration error, a programming error, a common-mode error, a
wire break, an underflow, and/or an overflow. Example diagnostic
messages identifying possible causes for the problem with an input
module may include messages indicating a potential difference
between inputs of the module and a reference potential of a
measuring circuit, and/or messages indicating that a load voltage
of the module is missing, faulty parameters were transferred to the
module, the resistance of a transducer circuit is too high, an open
circuit exists between the module and a sensor, a channel is not
connected (open), an input value is below a predetermined range, a
measuring range setting is wrong, a sensor polarity is reversed,
and/or an input value exceeds an overshoot range. Example
diagnostic messages identifying possible solutions to a problem
with an input module may include messages recommending connecting a
corresponding supply, checking a measuring range of the module,
programming the module, using a different type of sensor,
connecting a cable, disabling a channel group, wiring a channel,
programming a different measuring range, checking connectors,
and/or programming a different measuring range.
[0083] Examples of diagnostic messages identifying a problem with
an output module may include messages indicating that an external
load voltage is missing, and/or messages indicating the existence
of a configuration error, a programming error, a short circuit,
and/or a wire break. Example diagnostic messages identifying
possible causes for a problem with an output module may include
messages indicating that a load voltage of the module is missing,
faulty parameters were transferred to the module, an overload
exists at an output, a short circuit exists at an output, an
actuator impedance is too high, a wire break exists between the
module and an actuator, and/or a channel is not being used. Example
diagnostic messages identifying possible solutions to a problem
with an output module may include messages recommending connecting
a supply, assigning new module parameters, eliminating an overload,
eliminating a short circuit, using a different type of actuator,
modifying the corresponding wiring, connecting a cable, and/or
disabling a channel group.
[0084] The hardware diagnostic tool 510 performs hardware
diagnostics, such as for monitoring various hardware components to
diagnose usage issues, configure problems, and/or detect hardware
failures. Examples of hardware diagnostics include monitoring
processor usage, stack usage, memory usage, IP address, firmware
version, unit type, card level faults, over-temperature events, RAM
faults, EEPROM faults, and lost hardware interrupts.
[0085] One or more instances of the control hardware 400 may
include a self-test mechanism operable to run a self-diagnostic
operation between jobs, such as may permit a human operator to
perform troubleshooting of hardware problems. The self-test
mechanism may be accessible via one or more of the HMIs 228, 310,
316. As described above, one or more instances of the control
hardware 400 may be operable to provide an external network
connection via the external network 304, thus permitting remote
access to hardware diagnostics performed by the hardware diagnostic
tool 510. However, the bandwidth sufficient to perform such
diagnostic operations may be limited during wellsite operations.
Thus, such remote access to diagnostic data may be coordinated in a
controlled manner. For example, remote access to the hardware
diagnostics performed by the hardware diagnostic tool 510 may be
limited to periods during which wellsite operations are not being
performed. The hardware diagnostics data may, however, be
communicated directly (i.e., not through the external network 304)
to one or more instances of the control hardware 400 and/or the
HMIs 228, 310 at the wellsite, such as may permit access to
relevant data, and/or to control the communication mechanism
utilized to acquire the hardware diagnostics data, during wellsite
operations.
[0086] It is also noted that the capabilities and compatibility of
various instances of the control hardware 400 may be tied to the
corresponding firmware and/or software versions. Thus, such
versions may also be displayed via the HMI 310. Such version
information may also permit automatic update of the firmware and/or
software, as well as confirmation of compatibility between
instances of the control hardware 400 and functionality of the HMIs
228, 310, 316.
[0087] Issues may also occur when human operators input information
related to hardware type or configuration. Thus, such information
may be provided automatically in that the hardware may identify
itself via a "type" parameter. The type parameter information may
be displayed for various instances of the control hardware 400 via
the HMI 310, such as may provide configuration feedback and/or
facilitate automatic detection. Additionally, if the hardware type
is known, further diagnostics may be implemented, such as matching
of I/O modules to hardware type, or verifying that proper hardware
types are implemented for certain jobs. If unrecognized hardware
types or responsiveness issues are detected, such issues may be
also indicated via the HMI 310.
[0088] The hardware diagnostics may be implemented, for example,
when an electronic technician (ET) replaces an I/O module due to a
failure, when the ET mistakenly installs the wrong I/O module type
and operates the additive system 200, when the CAM system 300
compares the installed I/O module types to the known
configurations, and/or when the hardware diagnostic tool 510
generates an error message indicating that a problem exists. The
hardware diagnostics may also address situations in which an
instance of the control hardware 400 has the wrong hardware type
set due to improper configuration by a human operator, when a human
operator failed to set the hardware type, when there is a
mechanical failure (such as when cables disconnect from an input
module), or when an output to a solenoid or relay is
short-circuited, among other examples.
[0089] External power supplies with status contacts that indicate
when a fault has occurred may also be utilized to provide power to
digital outputs. Thus, the hardware diagnostics may monitor the
status contacts and, when fault condition occurs, generate an error
message indicating a power supply fault exists.
[0090] The hardware diagnostics information displayed via the HMI
310 may include firmware version, processor usage, stack usage,
memory usage, IP address, unit type, disk usage, hardware level
faults, warnings, errors, power supply status, proper card
configuration test results for hardware type, and/or hardware type
information. While this information is monitored, an alarm may be
generated when an output signal is outside a selected threshold, or
when a hardware level fault, warning, and/or error is detected.
This information may also be logged or otherwise recorded to
internal or external memory, including as described below with
respect to the logging tool 560.
[0091] The sensor diagnostic tool 515 performs sensor diagnostics
for monitoring the sensors 204, 214, 222. The sensor diagnostic
information may also be logged or otherwise recorded to internal
and/or external memory, including as described below with respect
to the logging tool 560.
[0092] The sensor diagnostics may include confirming that the
sensors 204, 214, 222 are set to an intended range and/or do not
have excessive zero shift. The range checking may be performed in
conjunction with the I/O diagnostic tool 505 with proper selection
of hardware. The zero shift checking may be utilized to notify
human operators that the sensors 204, 214, 222 are being utilized
in a condition that is out of specification. One or more of the
sensors 204, 214, 22 may also be a smart sensor that is able to
generate information related to its health and communicate such
information to one or more of the HMIs 228, 310, 316.
[0093] Examples of sensor diagnostics include monitoring discharge
pressure sensors on fracturing pumps and cement units to detect
excessive zero drift. Upon such detection, the sensor diagnostic
tool 515 may then issue a warning message, via the HMI 310,
indicating which pressure sensor is out of specification. Sensor
diagnostics may also include monitoring a fracturing pump suction
pressure sensor, such as to compare an amperage or other parameter
associated with the sensor to a predetermined threshold to verify
that the sensor is present and functioning and issue a warning
message that the sensor is defective or not present if the
parameter fails to meet the predetermined threshold.
[0094] The process diagnostic tool 520 performs process diagnostics
for monitoring raw sensor data and/or other process parameters
values to, for example, confirm that such values meet predetermined
thresholds or are within predetermined ranges. Such information may
be displayed via one or more of the HMIs 228, 310, 316, such as may
facilitate identification of problems associated with the wellsite
operation process. The process diagnostic tool 520 may also permit
configuration of thresholds for alarms, whether preprogrammed or
via the HMI 310, such that changes in the sensors 204, 214, 222,
variations in components of the additive system 200, and changes in
process knowledge may be easily incorporated. Such alarms may be
enhanced by adding a troubleshooting guide or a list of suggestions
related to potential root causes of each alarm. One example of
process diagnostics includes comparing the power end oil pressure
on a pump 152 to a threshold value while the associated prime mover
154 is driving the pump 152. For example, if the pressure falls
below the threshold value, the process diagnostic tool 520 may
issue a low power end oil pressure warning, via the HMI 310. Other
examples of process diagnostics may include comparing an air
pressure of the pump 152 to a threshold value. For example, if the
air pressure falls below the threshold value, the process
diagnostic tool 520 may issue a low air pressure warning and
display a list of potential resolutions, such as checking the air
supply, compressor, filter, or hoses (e.g., for leaks) of the pump
152. The process diagnostic information may also be logged or
otherwise recorded to internal and/or external memory, including as
described below with respect to the logging tool 560.
[0095] The communication diagnostic tool 525 performs communication
diagnostics for monitoring communication between the sensors 204,
214, 222, various instances of the control hardware 400, other
components of the additive system 200 and the CAM system 300, the
local network 302, and perhaps the external network 304.
Information related to the communication diagnostics, such as
response times to polling requests and warnings, errors, and/or
faults related to communication loss, may be logged or otherwise
recorded to internal and/or external memory, including as described
below with respect to the logging tool 560.
[0096] Communication diagnostics may include detecting different
types of communication failures between such components, because
loss of actuation and sensor signals may disable control loops
and/or otherwise disable the automated control aspects of the
additive system 200 and the CAM system 300. Accordingly, upon
detection of different types of communication failures, a human
operator may be notified so that manual control may be initiated,
and/or an appropriate safe state may be entered. Communication
diagnostics may also monitor for loss of communication with
external systems, which may compromise control or input data.
Communication diagnostics may also include monitoring for errors
and/or faults related to Modbus, PROFIBUS, HART, Controller Area
Network (CAN), and/or other communication protocols.
[0097] Communication diagnostics may include periodically checking
for the presence of the I/O module of various components of the
additive system 200. If one of the I/O modules is not present, a
warning may be issued (via the HMI 310) to indicate that
communication with that I/O module has been lost. Communication
diagnostics may also utilize a handshake mechanism to transfer
and/or synchronize information between the HMIs 228, 310, 316,
various I/O modules, and/or other components of the additive system
200, such as to periodically check perform the handshake to verify
that communication is present with the corresponding component. If
the handshake value has not been updated, a warning may be issued,
and the missing component may be set to an offline mode.
[0098] For example, each pump 152 may include a master distributed
control unit (DCU), a slave DCU, and an I/O module. The master and
slave DCUs may each be implemented via an instance of the control
hardware 400. The SCM 306 may ordinarily communicate with the
master DCU but not the slave DCU. The master DCU may periodically
check for the presence of the slave DCU and the I/O module. If
either piece of hardware is not present, the master DCU may
communicate such occurrence to the SCM 306, such that a warning may
be issued via the HMI 310 to indicate that communication has been
lost.
[0099] The automation diagnostic tool 530 performs automation
diagnostics for monitoring automatic operations of the additive
system 200 without human operator knowledge or participation. For
example, during a tub calibration procedure in cementing
operations, the automation diagnostics may monitor a rise in tub
level to complete a calibration process. If the tub level rise does
not meet certain criteria, the tub level calibration may not
complete and a human operator may not be aware of it. Therefore,
automation diagnostics may provide status information and the
criterion for success related to various automation steps and/or
sequences. If an automation sequence is not functioning properly,
step information for troubleshooting may be displayed via one or
more of the HMIs 228, 310, 316. The automation diagnostics may also
include providing a message identifying the reason for an abort of
automation or failure, instead of a generic "aborted" or "failed"
message. For example, such message may be "aborted due to gate
time-out."
[0100] Another example of automation diagnostics includes sand
blender gate calibration during the course of fracturing
operations, such as for an automatic calibration routine to
identify parameters to control the gate. During the calibration
routine, the gate may open to various degrees while the results are
analyzed in real-time, and this process may be repeated until the
gate responds as intended. For example, the automation diagnostics
may provide diagnostic messages to indicate the current step in the
calibration process, such as "gate opening to 10%," and if the
calibration fails, the reason for the failure may also be
provided.
[0101] The automation diagnostics may provide status information
indicating what the additive system 200 is doing, awaited actions
of the additive system 200 (e.g., the closing of a valve or a
material level obtaining a predetermined level), and information
related to aborted or failed steps along with the reason for or a
description of the abort or failure. This and other information
related to automation diagnostics may also be logged or otherwise
recorded to internal and/or external memory, including as described
below with respect to the logging tool 560.
[0102] The health check diagnostic tool 535 performs health check
diagnostics for monitoring the relationships between sensors 204,
214, 222. Such relationships, along with knowledge of the process
being performed by the additive system 200, may aid in detecting
additional problems with the additive system 200, such as problems
that are sensor related, mechanical in nature, and/or process
related. Health check diagnostics may provide an early warning to a
human operator that, although the additive system 200 is
functioning, something is wrong with the operation of the additive
system 200, and may facilitate identification of the root cause.
Relationships of impossible combinations may also be utilized to
flag problems, such as feedback indicating that a valve is open and
closed at the same time. Information related to the health check
diagnostics, such as warnings, errors, and/or faults, may also be
logged or otherwise recorded to internal and/or external memory,
including as described below with respect to the logging tool
560.
[0103] During operation of the additive system 200, health check
diagnostics may verify the open or closed status of valves, check
redundant sensors against one another within an error tolerance,
and check sensors to verify a process condition, among other
examples. In an example pertaining to cementing system
implementations, a surge can weight, gate position, output flow,
and tub level may be related. If the gate is open, there is cement
in the surge can, and the flow of cement out of the cementing
system is known, then the tub level reaction may be determined.
Health check diagnostics may also be utilized with cementing pumps.
For example, if a triplex pump is stroking and the valve positions
are known, then the rate measurements from proximity switches and a
downhole flow meter may be determined. The health check diagnostics
may be utilized in determining these and other relationships,
and/or identifying related problems with cementing and other
implementations of the additive system 200.
[0104] The error code diagnostic tool 540 performs error code
diagnostics operable to provide a human operator with information
related to problems with the additive system 200 by displaying
predefined error codes. The I/O modules, transmission control
modules (TCMs), engine control modules (ECMs), VFDs, and/or other
components of the additive system 200 may generate various error
codes that may be communicated to one or more of the HMIs 228, 310,
316, such that the code number and a meaningful message may be
displayed to a human operator. Displaying both the error code and
the meaning of each error code may facilitate understanding of the
problem without accessing a separate manual or interpreting tool.
For example, the error code diagnostic tool 540 may monitor various
components of the additive system 200 for error codes and, when an
error code is detected, the error code number, the type of error,
and the number of occurrences may be provided as diagnostic
information, perhaps with a textual description of the error code
to assist with troubleshooting.
[0105] Error code diagnostics may also include firmware
diagnostics. If an instance of the control hardware 400 does not
include an output device 428, control related errors (e.g., divide
by zero, default case statement, default else statement, logic
error condition) may not be communicated to a human operator.
Without knowledge of the errors, control related problems may be
difficult to diagnose. Therefore, firmware errors may be stored in
variables, which may be manually read. The errors may be captured
and presented to a human operator via one or more of the HMIs 228,
310, 316. For example, the error numbers and messages may be
transmitted as a predefined string and an unsigned integer. A human
operator may then utilize the error numbers and messages to
diagnose the corresponding component of the additive system 200 and
correct the problem that led to the error code being generated. A
real-time operating system may also provide errors and/or warnings
related to tasks that run too long and/or that a scheduling problem
exists.
[0106] The error code diagnostics information may include hardware
error codes, ECM error/fault codes, TCM error/fault codes, VFD
error/fault codes, and actuator sensor interface (AS-i) master
error/fault codes, among other examples. The error code diagnostics
information may also be logged or otherwise recorded to internal
and/or external memory, including as described below with respect
to the logging tool 560.
[0107] The watchdog diagnostic tool 545 performs watchdog
diagnostics for monitoring communications and identifying problems
with various instances of the control hardware 400 of the additive
system 200 and the CAM system 300. For example, the watchdog
diagnostics may be utilized to check communications by periodically
checking the status of a counter that is passed back and forth
between instances of the control hardware 400. Watchdog diagnostics
may also be utilized to permit two instances of the control
hardware 400 to monitor the health of each other. Watchdog
diagnostics may also generate time-out alarms for actuators and/or
other components of the additive system 200, such as by comparing a
set point with state feedback, such that when an actuator or other
process control command is issued and the feedback signal does not
reflect the intended action after a set period of time, then an
alarm may be triggered. Such errors may be triggered by faulty
instances of the sensors 204, 214, 222, the controllable devices
218, 226, a power source, and/or other examples. Identified
possible root causes may also be listed in a troubleshooting guide
and/or displayed via one or more of the HMIs 228, 310, 316.
[0108] Watchdog diagnostics may also provide valve control and
monitoring. For example, when a valve is commanded to open or
close, a watchdog timer may be initiated such that after a
predetermined period of time (e.g., about five seconds) the actual
valve status or position may be checked. If the valve is not in the
intended position, the watchdog diagnostic tool 545 may trigger a
valve actuator time-out alarm for the particular valve. During
operations of the additive system 200, watchdog diagnostics may
also verify whether the actual valve position is within an error
tolerance of the set point. Watchdog diagnostics may also monitor
hardware for fault conditions. For example, position-controlled
valves may have a configurable error tolerance, and the results of
tests that may be performed as part of the watchdog diagnostics may
be made available to human operators via one or more of the HMIs
228, 310, 316.
[0109] The watchdog diagnostics information, including information
relating to warnings, errors, and/or faults, may be logged or
otherwise recorded to internal and/or external memory, including as
described below with respect to the logging tool 560.
[0110] The application diagnostic tool 550 performs application
diagnostics for monitoring health of software and/or firmware
applications of the additive system 200 and/or the CAM system 300.
Examples of application diagnostics information may include
processor usage, memory usage, disk usage, error codes, and crash
reports, among others. The application diagnostics information may
be logged in a file and viewed by a software engineer when problems
with the application are detected. Crash reports may contain
pertinent information about the state of the application, such as
the line where the problem occurred and the call stack information
when the problem occurred. Application diagnostics may also include
items related to the functionality of the additive system 200
and/or the CAM system 300. For example, if communication with a
material transferring device 254 is lost, information such as
handshake value, time between the handshake send and receipt,
processor load, network load, and memory usage may be logged to
help identify possible causes. The application diagnostics
information may also be logged or otherwise recorded to internal
and/or external memory, including as described below with respect
to the logging tool 560.
[0111] The wireless diagnostic tool 555 performs wireless
diagnostics for monitoring the health of the local network 302. For
example, the local network 302 may comprise a master node and
multiple slave nodes, wherein each master and slave node may be
implemented via an instance of the control hardware 400. Wireless
diagnostics may include analyzing and logging information such as
node temperature, up time, link time, firmware version, service set
identifier (SSID), internet protocol (IP) address, and/or mode
(e.g., master, repeater, slave), as well as signal strength,
current data transfer rate (i.e., modulation and coding scheme
(MCS) value), and signal to noise ratio (SNR).
[0112] The wireless diagnostic tool 555 may be operable to inform a
human operator that a wireless communication path is or may be
compromised, such as when the wireless signal is weak or wireless
signal interference exists, in which case a wired communication
path may be established to replace the faulty wireless
communication path. The wireless diagnostic tool 555 may include or
control lights and/or other indicators viewable via one or more of
the HMIs 228, 310, 316, such as in implementations utilizing
indicators of different colors to inform a human operator as to the
degree of the problem. Wireless diagnostics may also include
detecting wireless communication transmission rates, such as may be
indicative of bandwidth limitations of the additive system 200, the
CAM system 300, the local network 302, and/or the external network
304. For example, a specific amount of data (e.g., packets) may be
transmitted per unit of time, depending on the specific
implementation of the additive system 200, the CAM system 300, the
local network 302, and/or the external network 304, and such
transmission rate may be utilized to estimate whether a master or
other network node will be able to transmit sufficient data to the
connected hardware. Wireless diagnostics may also include detecting
additional master network nodes, such as for determining whether
the master network node at a wellsite is sufficiently close to
another master network node in the general vicinity to cause
interference and/or other communication problems, which may be the
case if both master network nodes have the same SSID, among other
potential problems.
[0113] The wireless diagnostic information may also be logged or
otherwise recorded to internal and/or external memory, including as
described below with regard to the logging tool 560.
[0114] The logging tool 560 performs logging activities of various
operational parameters associated with various components of the
additive system 100 and the CAM system 300. For example, the
monitoring, control, and/or other diagnostic information described
above may be utilized to provide support to human operators during
the various operational failures, issues, and problems described
above (among others). Such support may include the generation of a
"ticket," whether automatically by one of the diagnostic tools,
manually by a human operator, or otherwise. The ticket may then be
referred to appropriate personnel having expertise related to the
process being performed by the additive system 200, the control
thereof, the particular component of the additive system 200 that
is exhibiting the problem, and/or other areas. The ticket may
include electronic records such as job files, data acquisition
files, and other examples of diagnostic information as described
above. For example, the contents of the job and acquisition files
may include modes (e.g., manual, automatic, remote), settings
(e.g., what type of component, engine, transmission, gate type),
process/sensor readings, process/control set points,
firmware/software versions, and/or other information generated by
the diagnostic tools. Each job and/or acquisition file may be a log
of such information, spanning the time period extending from start
to finish of the operation, process, utilization of an application,
etc., because if some of such information is not logged, subsequent
issues may be unresolvable, which may lead to repeated job
incidents and lost time.
[0115] The logging tool 560 may also provide a repository for
information that may be utilized for later analysis in the event of
an incident or audit. For example, the logging tool 560 may log
pump fuel rates, engine speeds, engine loads, and/or other
information that the U.S. Environment Protection Agency may request
for determining emissions data. Another example is in the event of
an overpressure incident, in which case knowledge of the highest
pressure achieved by one or each component of the additive system
200 may be a basis to remedying the overpressure and/or preventing
similar incidents in the future. As another example, the logging
tool 560 may record the highest raw value pressure to which a
treating iron has been subjected in the last ten seconds, such as
to assess whether the life of the treating iron has been
diminished.
[0116] The logging tool 560 may also be operable to consolidate or
otherwise combine various different logs into a single file or a
single view/display. Such combination of logs may eliminate the
burden of a human operator having to know the location of the
individual log files and/or manually combine the data using time
stamps before the complete job log file is compiled after
operations have ended.
[0117] The logging tool 560 may also be utilized for verifying
reliability. From a single location point of view, the logging tool
560 may query and/or consolidate various log files to show
diagnostic and alarm information, which may aid in quantifying
reliability. From a project point of view, the logging tool 560 may
aid in consolidating the diagnostic and alarm information, which
may then be communicated via the external network 304 to remote
components for reliability analysis.
[0118] The predictive maintenance tool 565 performs predictive
maintenance operations, such as for providing remaining functional
life estimates. Predictive maintenance operations may facilitate
greater reliability of the additive system 200 by utilizing the
logged information associated with various components of the
additive system 200 to generate functional life profiles for
predicting or otherwise determining remaining functional life of
the components. Predicting remaining functional life of components
may permit in-time servicing and maintenance of the components,
such as to avoid costly failures or extend the lifetime of these
components. In contrast to condition monitoring, predicting
remaining functional life according to one more aspects of the
present disclosure may aid in preventing failures before they
occur, rather than detecting failures after they occur.
[0119] The predictive maintenance tool 565 may include or control
various maintenance alarms to inform human operators of a
predetermined maintenance schedule, a remaining functional life,
and/or other maintenance-related aspects of certain components of
the additive system 200. For example, the alarms may be triggered
when values of certain monitored and perhaps logged parameters
exceed, fall below, or fall within a predetermined or selected
threshold and/or range. The predictive maintenance operations may
also utilize certain monitored and logged parameter values over the
functional life of components for the creation of a historical
database of functional life profiles of the various components,
which may be utilized to obtain the predetermined or selected
threshold and/or range associated with the alarms. The historical
database of functional life profiles may also aid in identifying
those parameters that have greater affect on the functional life of
such components and/or those parameters that more accurately and/or
reliably indicate remaining functional life. As the database
progressively expands, the increase in functional life profiles may
facilitate an increasingly more accurate process for estimating the
remaining functional life of the components and/or the additive
system 200 as a whole.
[0120] Examples of the components for which predictive maintenance
operations may be performed via the predictive maintenance tool 565
include the prime movers described above, such as motors or
engines, which may be monitored via communication with a drive,
throttle, and/or other controllable device(s) utilized to control
the prime mover via the SCM device 306 and/or other portions of the
CAM system 300. For example, feedback signals from the prime mover,
the associated sensors, and/or other components may be utilized
during predictive maintenance operations to provide human operators
with operating rates, frequencies, and/or other operational
parameters of the prime mover in real-time. Other examples of
logged parameters that are associated with the prime mover may
include bearing temperature, hot spot temperature, current draw,
time-based voltage, power consumption, rotational position, torque
output, frame acceleration, and operating time. Additional examples
of logged parameters associated with the prime mover may indicate
dates of engine oil, transmission fluid, and other fluid changes,
as well as servicing of filters, air systems, and other components,
including with respect to date, operating hours (i.e., elapsed
functional life), and/or other factors.
[0121] Additional examples of the components for which predictive
maintenance operations may be performed via the predictive
maintenance tool 565 include the material transferring devices
described above, such as pumps, conveyers, bucket elevators,
feeding screws, and other material transfer devices, as well as
metered distribution means of dry or particulate material. For
example, the predictive maintenance operations may include
predicting the remaining functional life of a pump based on logged
or calculated slip increase or efficiency loss, such as may be
caused by wear. Similar approaches may be utilized for other
material transferring and/or metering means, as the efficiency of
such means decreases with wear.
[0122] The predictive maintenance operations may also be performed
with respect to the efficiency of various pumps of the additive
system 200. Pump efficiency may be defined as the ratio of the
actual pump displacement to a theoretical pump displacement, such
as may be described by related pump specification documents. Such
definition of the pump efficiency may be utilized during predictive
maintenance operations for real-time monitoring and failure
prediction of one or more pumps. Pump displacement may be
determined from real-time feedback relating to speed of the
associated prime mover and information obtained via one or more
from the material sensor and/or other sensors. Thus, pump
efficiency may be determined utilizing Equation (1) set forth
below:
PE = Q RPM .times. TPD .times. 100 ( 1 ) ##EQU00001##
wherein PE denotes pump efficiency in percent (%), Q denotes flow
rate in gallons per minute (GPM), RPM denotes speed of the
associated prime mover in revolutions per minute (RPM), and TPD
denotes theoretical pump displacement in gallons per revolution
(gal/rev).
[0123] A similar formula may be utilized to determine efficiency of
a solid material transfer device. For example, such efficiency may
be determined as the ratio of the quantity of solid material
actually displaced, per revolution of a component of the transfer
device or associated prime mover, to the quantity that would be
displaced with a new instance of the solid material transfer device
(i.e., at the beginning of its functional life). When transferring
solid material, additional data may also be logged with respect to
parameters that affect the displacement of the solid material, such
as humidity, motor speed, and particle size.
[0124] Pump displacement may also differ for different fluids. For
example, viscous fluids create less slip and are therefore
displaced differently by a pump. In the case of non-Newtonian
fluids, for which viscosity depends on the shear rate, the pump
displacement may further depend on the pump speed. Therefore, for
shear-thinning fluids, additional parameter data may be logged to
determine pump displacement for different types of fluids and at
different pump speeds. However, for solid material, parameter data
may also be logged at different transfer device (or associated
prime mover) speeds to account for various dynamics of the transfer
process, such as variations in friction of the moving solid
material.
[0125] When transferring Newtonian fluids, pump displacement may be
calculated for each Newtonian fluid at different temperatures. Pump
efficiency may then be monitored and logged over time for each such
fluid to create a database. For example, during operations
conducted with the additive system, pumps may be run up to the
point of inefficient, or even to the point of failure, which may
facilitate creation of efficiency loss profiles spanning the
functional life of the pump. These efficiency loss profiles may
then be utilized to estimate remaining functional life of that
and/or other similar pumps. For example, current use, conditions,
and/or sensor readings associated with the pump may be compared to
an efficiency loss profile in the database generated under the same
or similar use, conditions, and/or sensor readings. The position
along the efficiency loss profile where a match is made with
current sensor readings may be indicative of the remaining
functional life of the pump under the same or similar
conditions.
[0126] When additive systems are utilized to transfer non-Newtonian
fluids, pump speed may also be logged for creating efficiency loss
profiles, because viscosity and, therefore, pump displacement,
depends on pump speed. Thus, theoretical or initial pump
displacement may be collected for each fluid at different
temperatures and different pump speeds. Thereafter, pump efficiency
may be monitored and logged over time for each such fluid at
different temperatures and flow rates to create the database of
efficiency loss profiles.
[0127] More advanced monitoring may also be achieved by acquiring
the same data at different discharge pressures, because discharge
pressure affects pump displacement for both Newtonian and
non-Newtonian fluids. Therefore, discharge pressure changes may
also affect the determination of pump efficiency.
[0128] Another method for calculating pump efficiency may include
monitoring suction pressure measurements during priming operations.
For example, when pump slip increases (i.e., when pump efficiency
decreases), the pump may not achieve the same vacuum levels as a
new pump, thereby indicating an efficiency loss.
[0129] Other logged parameters associated with the material
transfer devices may include temperature, pressure, power
consumption, proximity, linear position, rotational position,
operating rate or frequency, material transfer rate, total material
transferred, torque, acceleration, and operating time. However,
other examples of such parameters are also within the scope of the
present disclosure.
[0130] The predictive maintenance operations may also include
generating similar functional life profiles for other components of
the additive system based on other parameters. Above-described
examples of such other components may include the material
container 240, the valves 244, 264, the actuators 248, 266, the
material sensor 260, and the material destination 270, among
others. For example, these components may also be run up to the
point of inefficiency, or to the point of failure, while logging
information generated by the sensors 204, 214, 222. The logged
sensor and/or other information may then be utilized to generate
functional life loss profiles spanning the life of the components.
The functional life profiles may then be utilized to estimate
remaining functional life of the components. For example, current
use, conditions, and/or sensor readings associated with the
components may be compared to the functional life profile in the
database generated under the same or similar use, conditions,
and/or sensor readings. The position along the functional life
profile where a match is made with current sensor readings may be
indicative of the remaining functional life of the component under
the same or similar use and/or conditions.
[0131] It follows from the above discussion that predicting or
determining remaining functional life of some components may depend
on accuracy of various material sensors, such as the material
sensor 260 depicted in FIG. 3 when implemented as a flow meter.
Therefore, to obtain a robust remaining functional life prediction,
the monitoring and logging methods described above may also be
applied to the flow meter. For example, some flow meters and other
such material sensors may include built-in, embedded, or otherwise
associated health management means, such as may utilize additional
sensors included with or otherwise associated with the material
sensor, and such health management means may also be operable to
generate corresponding functional life profiles of the material
sensors. The data generated by the associated health management
means may also be utilized to predict the impact that the measuring
operations have on the measuring performance over time. The health
management means may also be utilized to schedule servicing time,
and/or to monitor product quality, such as by detecting gas pockets
in the various materials being utilized during operation of the
additive systems. Generating such prediction, servicing, and/or
monitoring information may also include comparing factory values
associated with the material sensor to current values generated by
the health management means. Differences between the current values
and the factory values may thus be utilized to service the material
sensor over time, and/or to determine remaining functional life of
the material sensor.
[0132] Other methods for monitoring the material sensors may
include utilizing information obtained via other sensors associated
with the upstream source of material from which material is being
transferred past the material sensor. For example, in the example
additive system 201 shown in FIG. 3, such information may be
obtained via the sensors 204 associated with the container 240 in
which fluidic or solid material is stored before being transferred
by the material transfer device 254. One or more known material
quantity sensing methods may be utilized to measure the quantity of
material in the container 240, wherein the material quantity
sensing methods may utilize the level measuring means, the volume
measuring means, and the weight measuring means, as described
above. After calibration, readings from the sensors 204 may be
related to the level, volume, and/or weight of material remaining
in the container 240. However, while the accuracy of the sensors
204 and the size of the container 240 alone may not permit
real-time flow measurement, material quantity readings may be taken
before and after a job, and such readings may permit the
determination of the cumulative volume and/or mass of material that
has been transferred out of the container 240. The cumulative value
may then be compared to the cumulative value obtained from the flow
meter, which may then permit detection of inaccuracies of the
material sensor 260. Therefore, for example, if the calibration of
the material sensor 260 becomes offset, such as because an inner
tube or other component of the material sensor 260 has suffered
corrosion, the comparison of the total quantities of the material
transferred may permit recalibration of the material sensor 260.
Moreover, discrepancies between the two readings that exceed
predetermined thresholds may be utilized by the predictive
maintenance operations to indicate that maintenance or replacement
of the material sensor 260 may be in order.
[0133] One or more instances of the material sensors 260 may also
include one or more pressure transducers operable to monitor
suction and discharge pressure within the additive system. In a
manner similar to that described above with respect to other
components of the additive system, the predictive maintenance
operations may also include monitoring and/or logging data from the
pressure transducers to predict their remaining functional life.
Monitoring and logging fluid characteristics, such as density,
viscosity, temperature, composition, pumping rate, and time spent
at high pressure, for example, through the functional lifetime of
the pressure transducers may also be utilized to generate a
database of functional life profiles, which may then be utilized to
determine remaining functional life of same or similar pressure
transducers when utilized under same or similar conditions.
[0134] Various parameters associated with valves and actuators,
such as the valves 244, 264 and actuators 248, 266 depicted in FIG.
3, may also be monitored and logged to create functional life
profiles, which may then be utilized to determine remaining
functional life of same or similar valves and actuators when
utilized under same or similar conditions. The monitored and logged
parameters may include material temperature, pressure, material
transfer rate, number of cycles, cycling frequency, number of times
an associated controller times out (e.g., because the valve is
stuck), and actuation time (i.e., time between the command and the
end of the action), among other examples.
[0135] If several additive systems are operated at the same
wellsite, or at different wellsites in the same general vicinity,
cross checking among the additive systems may also be utilized to
monitor the health of the additive systems. For example, a flow
meter associated with a first additive system may be utilized to
measure the efficiency of a material transfer device of a second
additive system. The accuracy of the remaining functional life
determinations may also increase with additional functional life
profiles. However, some profiles will not be available at the
beginning of a job, so the above-described monitoring and logging
may be first implemented when pumping water at the beginning and
the end of a job.
[0136] Other logged information that may also be available to human
operators via one or more of the HMIs 228, 310, 316 during
operation of the additive system may include hours of operation of
various components of the additive system, number of cycles of the
components, and amounts of material transferred by material
transfer devices. Human operators may also have the ability to
select additional parameters to be monitored and logged for one or
more components of the additive system.
[0137] FIG. 6 is a flow-chart diagram of at least a portion of a
method (600) according to one or more aspects of the present
disclosure. The method (600) may be performed utilizing at least a
portion of one or more implementations of the apparatus shown in
one or more of FIGS. 1-5 and/or otherwise within the scope of the
present disclosure.
[0138] The method (600) comprises transferring (605) an
additive-containing substance for injection into a wellbore with an
oilfield additive system. The oilfield additive system may be an
instance of the generic additive system 200 shown in FIG. 2, such
as may be implemented in the context of the additive system 100
shown in FIG. 1 in the manner depicted in FIG. 3, although other
examples are also within the scope of the present disclosure. In
each such example, however, the oilfield additive system includes a
plurality of components each associated with a corresponding
operational parameter.
[0139] Information related to the operational parameter of each of
the plurality of components is generated (610) with a corresponding
one of a plurality of sensors, such as sensors of or otherwise
associated and/or communicable with the oilfield additive system.
The information generated (610) by the plurality of sensors are
recorded and/or otherwise monitored (615) via a monitoring device,
such as the SCM device 306 and/or other component of the CAM system
300 shown in FIGS. 2 and 3, to generate a database indicative of a
maintenance aspect of an item, wherein the item is the oilfield
additive system as a whole, at least one of the plurality of
components of the oilfield additive system, and/or a combination
thereof.
[0140] The maintenance aspect may be, or may be indicative of, an
estimated remaining functional life of the item. As described
above, the estimated remaining functional life may be an estimate
of remaining operational time until failure of the item and/or an
estimate of remaining operational time until operational efficiency
of the item falls below a predetermined threshold. The maintenance
aspect may also be, or be indicative of, the health of the item.
The method (600) may also comprise comparing (620) the information
related to the operational parameter of a selected one of the
oilfield additive system components with the database to determine
the maintenance aspect of the item.
[0141] As described above, the oilfield additive system components
may include a prime mover and a material transfer device operable
in conjunction with the prime mover. Thus, generating (610) the
information related to the operational parameter of each of the
oilfield additive system components may include generating
information related to the operational parameter of the prime mover
with a first sensor, and generating information related to the
operational parameter of the material transfer device with a second
sensor.
[0142] The information generated (610) by one of the sensors may
include information related to performance of the corresponding one
of the oilfield additive system components. The information
generated (610) by one of the sensors may also include information
related to a property of the additive-containing substance, such as
in implementations in which the property is temperature, viscosity,
density, composition, and/or other properties. The operational
parameter may also be temperature, pressure, flow rate, electrical
current, power consumption, operating speed, operating frequency,
torque, position, elapsed operating time, and/or other operational
parameters.
[0143] The monitoring (615) may also include comparing (625) the
information generated by the sensors to predetermined thresholds,
and generating (630) an output signal based on the comparison
(625). For example, the generated (630) output signal may be for
controlling one or more oilfield additive system component, and/or
may be displayed to human operators via an HMI, such as one or more
of the HMIs 228, 310, 316 shown in FIG. 2.
[0144] As also described above, the oilfield additive system may
include or be operable in conjunction with a communication system
operable to facilitate communication between the oilfield additive
system components. For example, such communication system may
include one or more I/O modules each communicable with one or more
of the sensors and/or oilfield additive system components, a
controller or other processor communicable with one or more of the
I/O modules, and an HMI communicable with the processor. Thus, the
monitoring (615) may also or instead include detecting (635) a
defect in communications between two or more of the I/O modules,
the processor, and the HMI, and generating (640) an output signal
when the defect is detected (635).
[0145] In an example implementation, the additive system, the
additive-containing substance, the wellbore, the additive system
components, the sensors, the generated (610) information, and the
operational parameter may be a first additive system, a first
additive-containing substance, a first wellbore, first additive
system components, first sensors, first information, and a first
operational parameter, respectively, and the method (600) may also
include transferring (645) a second additive-containing substance
for injection into a second wellbore with a second additive system
comprising second additive components each associated with a
corresponding second operational parameter, generating (650) second
information related to the second operational parameter of each of
the second additive system components with a corresponding one of a
plurality of second sensors, and comparing (655) at least portions
of the first information and the second information to determine
the maintenance aspect of the item. In such implementations, the
first and second additive-containing substances may be
substantially the same or different, and the first and second
wellbores may be the same or different wellbores.
[0146] For example, the first additive system components may
include a first material transfer device, the second additive
system components may include a second material transfer device,
the item may be the first material transfer device, the compared
(655) portion of the first information may be indicative of a first
efficiency of the first material transfer device, and the compared
(655) portion of the second information may be indicative of a
second efficiency of the second material transfer device. Such
implementations of the method (600) may also include calculating
(660) a first ratio of a first actual material transfer rate of the
first material transfer device to a first theoretical material
transfer rate of the first material transfer device to determine
the first efficiency, and calculating (665) a second ratio of a
second actual material transfer rate of the second material
transfer device to a second theoretical material transfer rate of
the second material transfer device to determine the second
efficiency.
[0147] In view of the entirety of the present disclosure, including
the claims and the figures, a person having ordinary skill in the
art should readily recognize that the present disclosure introduces
an apparatus comprising a monitoring system operable to monitor an
oilfield additive system, wherein the oilfield additive system is
operable to transfer an additive-containing substance for injection
into a wellbore, wherein the oilfield additive system comprises a
plurality of components each associated with a corresponding
operational parameter, and wherein the monitoring system comprises:
a plurality of sensors each associated with, and operable to
generate information related to the operational parameter of, a
corresponding one of the plurality of components; and a monitoring
device in communication with each of the plurality of sensors and
operable to record the information generated by the plurality of
sensors to generate a database indicative of a maintenance aspect
of an item, wherein the item is at least one of: the oilfield
additive system; at least one of the plurality of components;
and/or a combination thereof.
[0148] The maintenance aspect may be, or may be indicative of, an
estimated remaining functional life of the item. The estimated
remaining functional life may be an estimate of remaining
operational time until failure of the item. The estimated remaining
functional life may be an estimate of remaining operational time
until operational efficiency of the item falls below a
predetermined threshold.
[0149] The maintenance aspect may be, or may be indicative of, a
health of the item.
[0150] The plurality of components may comprise a prime mover and a
material-transfer device operable in conjunction with the prime
mover, and the plurality of sensors may comprise: a first sensor
operable to generate information related to the operating parameter
of the prime mover; and a second sensor operable to generate
information related to the operating parameter of the
material-transfer device. The material-transfer device may be
operable to transfer a fluid, a solid material, or a mixture
comprising a fluid and a solid material. For example, the
material-transfer device may be operable to transfer subterranean
formation fracturing fluid and/or wellbore casing cement.
[0151] The oilfield additive system, the additive-containing
substance, the wellbore, the plurality of components, the plurality
of sensors, the information, and the operational parameter may,
respectively, be a first oilfield additive system, a first
additive-containing substance, a first wellbore, a first plurality
of components, a first plurality of sensors, first information, and
a first operational parameter. In such implementations, among
others within the scope of the present disclosure, the monitoring
system may be further operable to monitor a second oilfield
additive system operable to transfer a second additive-containing
substance for injection into a second wellbore. The second oilfield
additive system may comprise a second plurality of components each
associated with a corresponding second operational parameter. The
monitoring system may further comprise a second plurality of
sensors each associated with, and operable to generate second
information related to the second operational parameter of, a
corresponding one of the second plurality of components. The
maintenance aspect of the item may be based on a comparison of at
least portions of the first information and the second information.
The first and second additive-containing substances may be
substantially the same. The second wellbore may be the first
wellbore. The first plurality of components may comprise a first
material-transfer device, the second plurality of components may
comprise a second material-transfer device, the item may be the
first material-transfer device, the compared portion of the first
information may be indicative of a first efficiency of the first
material-transfer device, and the compared portion of the second
information may be indicative of a second efficiency of the second
material-transfer device. The first efficiency may be based on a
first ratio of a first actual material transfer rate of the first
material-transfer device to a first theoretical material transfer
rate of the first material-transfer device, and the second
efficiency may be based on a second ratio of a second actual
material transfer rate of the second material-transfer device to a
second theoretical material transfer rate of the second
material-transfer device.
[0152] The information generated by one of the plurality of sensors
may comprise information related to performance, efficiency, and/or
accuracy of the corresponding one of the plurality of
components.
[0153] The information generated by one of the plurality of sensors
may comprise information related to a property of the
additive-containing substance. The property may be selected from
the group consisting of: temperature, viscosity, density, and
composition.
[0154] The operational parameter may be selected from the group
consisting of: temperature, pressure, flow rate, electrical
current, power consumption, operating speed, operating frequency,
torque, position, and elapsed operating time.
[0155] The monitoring device may be further operable to: compare
the information generated by the plurality of sensors to
predetermined thresholds; and generate an output signal based on
the comparison.
[0156] The apparatus may further comprise a communication system
operable to facilitate communication between the plurality of
components and the monitoring system. The communication system may
comprise: an input/output module in communication with the
plurality of sensors and the monitoring device; and a human/machine
interface in communication with the monitoring device. In such
implementations, among others within the scope of the present
disclosure, the monitoring system may be further operable to:
detect a defect in communications between the input/output module,
the monitoring device, and the human/machine interface; and
generate an output signal when the defect is detected.
[0157] The present disclosure also introduces a method comprising:
transferring an additive-containing substance for injection into a
wellbore with an oilfield additive system, wherein the oilfield
additive system comprises a plurality of components each associated
with a corresponding operational parameter; generating information
related to the operational parameter of each of the plurality of
components with a corresponding one of a plurality of sensors; and
recording the information generated by the plurality of sensors
with a monitoring device to generate a database indicative of a
maintenance aspect of an item, wherein the item is at least one of:
the oilfield additive system; at least one of the plurality of
components; and/or a combination thereof.
[0158] The maintenance aspect may be, or may be indicative of, an
estimated remaining functional life of the item. The estimated
remaining functional life may be an estimate of remaining
operational time until failure of the item. The estimated remaining
functional life may be an estimate of remaining operational time
until operational efficiency of the item falls below a
predetermined threshold.
[0159] The maintenance aspect may be, or may be indicative of, a
health of the item.
[0160] The method may further comprise comparing the information
related to the operational parameter of a selected one of the
plurality of components with the database to determine the
maintenance aspect of the item.
[0161] The plurality of components may comprise a prime mover and a
material-transfer device operable in conjunction with the prime
mover, and generating information related to the operational
parameter of each of the plurality of components with the
corresponding one of the plurality of sensors may comprise:
generating information related to the operational parameter of the
prime mover with a first sensor; and generating information related
to the operational parameter of the material-transfer device with a
second sensor.
[0162] The oilfield additive system, the additive-containing
substance, the wellbore, the plurality of components, the plurality
of sensors, the information, and the operational parameter may,
respectively, be a first oilfield additive system, a first
additive-containing substance, a first wellbore, a first plurality
of components, a first plurality of sensors, first information, and
a first operational parameter. In such implementations among others
within the scope of the present disclosure, the method may further
comprise: transferring a second additive-containing substance for
injection into a second wellbore with a second oilfield additive
system, wherein the second oilfield additive system comprises a
second plurality of components each associated with a corresponding
second operational parameter; generating second information related
to the second operational parameter of each of the second plurality
of components with a corresponding one of a second plurality of
sensors; and comparing at least portions of the first information
and the second information to determine the maintenance aspect of
the item. The first and second additive-containing substances may
be substantially the same. The second wellbore may be the first
wellbore. The first plurality of components may comprise a first
material-transfer device, the second plurality of components may
comprise a second material-transfer device, the item may be the
first material-transfer device, the compared portion of the first
information may be indicative of a first efficiency of the first
material-transfer device, and the compared portion of the second
information may be indicative of a second efficiency of the second
material-transfer device. The method may further comprise:
determining a first ratio of a first actual material transfer rate
of the first material-transfer device to a first theoretical
material transfer rate of the first material-transfer device to
determine the first efficiency; and determining a second ratio of a
second actual material transfer rate of the second
material-transfer device to a second theoretical material transfer
rate of the second material-transfer device to determine the second
efficiency.
[0163] The information generated by one of the plurality of sensors
may comprise information related to performance, efficiency, and/or
accuracy of the corresponding one of the plurality of
components.
[0164] The information generated by one of the plurality of sensors
may comprise information related to a property of the
additive-containing substance. The property may be selected from
the group consisting of: temperature, viscosity, density, and
composition.
[0165] The operational parameter may be selected from the group
consisting of: temperature, pressure, flow rate, electrical
current, power consumption, operating speed, operating frequency,
torque, position, and elapsed operating time.
[0166] Monitoring the oilfield additive system may further
comprise: comparing the information generated by the plurality of
sensors to predetermined thresholds; and generating an output
signal based on the comparison.
[0167] The oilfield additive system may further comprise a
communication system operable to facilitate communication between
the plurality of components, wherein the communication system
comprises: an input/output module in communication with the
plurality of sensors and the plurality of components; a controller
in communication with the input/output module; and a human/machine
interface in communication with the controller. In such
implementations, among others within the scope of the present
disclosure, monitoring the oilfield additive system may further
comprise: detecting a defect in communications between the
input/output module, the controller, and the human/machine
interface; and generating an output signal when the defect is
detected.
[0168] The present disclosure also introduces a system comprising:
an oilfield additive system operable to transfer a material for
injection into a wellbore, wherein the oilfield additive system
comprises a plurality of components; a monitoring system operable
to monitor the oilfield additive system, wherein the monitoring
system comprises: a plurality of sensors each associated with, and
operable to generate information related to operational parameters
of, a corresponding one of the plurality of components; and a
monitoring device in communication with each of the plurality of
sensors and operable to record the information generated by the
plurality of sensors to generate a database, wherein the database
is indicative of a maintenance aspect of the oilfield additive
system and/or at least one of the plurality of components.
[0169] The maintenance aspect may be, or may be indicative of, an
estimated remaining functional life of the oilfield additive system
and/or at least one of the plurality of components. The estimated
remaining functional life may be an estimate of remaining
operational time until failure of the oilfield additive system
and/or at least one of the plurality of components. The estimated
remaining functional life may be an estimate of remaining
operational time until operational efficiency of the oilfield
additive system and/or at least one of the plurality of components
falls below a predetermined threshold.
[0170] The maintenance aspect may be, or may be indicative of, a
health of the oilfield additive system and/or at least one of the
plurality of components.
[0171] A comparison between the information related to the
operational parameters of a selected one of the plurality of
components and the database may be indicative of the maintenance
aspect of the oilfield additive system and/or at least one of the
plurality of components.
[0172] The plurality of components may comprise a prime mover and a
material-transfer device operable in conjunction with the prime
mover, and the plurality of sensors may comprise: a first sensor
operable to generate information related to the operating parameter
of the prime mover; and a second sensor operable to generate
information related to the operating parameter of the
material-transfer device.
[0173] The oilfield additive system, the additive-containing
substance, the wellbore, the plurality of components, the plurality
of sensors, the information, and the operational parameter may,
respectively, be a first oilfield additive system, a first
additive-containing substance, a first wellbore, a first plurality
of components, a first plurality of sensors, first information, and
a first operational parameter. In such implementations, among
others within the scope of the present disclosure, the monitoring
system may be further operable to monitor a second oilfield
additive system operable to transfer a second additive-containing
substance for injection into a second wellbore. The second oilfield
additive system may comprise a second plurality of components each
associated with a corresponding second operational parameter. The
monitoring system may further comprise a second plurality of
sensors each associated with, and operable to generate second
information related to the second operational parameter of, a
corresponding one of the second plurality of components. The
maintenance aspect of the first oilfield additive system and/or at
least one of the first plurality of components may be based on a
comparison of at least portions of the first information and the
second information. The first and second additive-containing
substances may be substantially the same. The second wellbore may
be the first wellbore. The first plurality of components may
comprise a first material-transfer device, the second plurality of
components may comprise a second material-transfer device, the
compared portion of the first information may be indicative of a
first efficiency of the first material-transfer device, and the
compared portion of the second information may be indicative of a
second efficiency of the second material-transfer device. The first
efficiency may be based on a first ratio of a first actual material
transfer rate of the first material-transfer device to a first
theoretical material transfer rate of the first material-transfer
device, and the second efficiency may be based on a second ratio of
a second actual material transfer rate of the second
material-transfer device to a second theoretical material transfer
rate of the second material-transfer device.
[0174] The information generated by one of the plurality of sensors
may comprise information related to performance, efficiency, and/or
accuracy of the corresponding one of the plurality of
components.
[0175] The information generated by one of the plurality of sensors
may comprise information related to a property of the
additive-containing substance. The property may be selected from
the group consisting of: temperature, viscosity, density, and
composition.
[0176] The operational parameter may be selected from the group
consisting of: temperature, pressure, flow rate, electrical
current, power consumption, operating speed, operating frequency,
torque, position, and elapsed operating time.
[0177] The monitoring device may be further operable to: compare
the information generated by the plurality of sensors to
predetermined thresholds; and generate an output signal based on
the comparison.
[0178] The system may further comprise a communication system
operable to facilitate communication between the plurality of
components and the monitoring system. The communication system may
comprise: an input/output module in communication with the
plurality of sensors and the monitoring device; and a human/machine
interface in communication with the monitoring device. In such
implementations, among others within the scope of the present
disclosure, the monitoring system may be further operable to:
detect a defect in communications between the input/output module,
the monitoring device, and the human/machine interface; and
generate an output signal when the defect is detected.
[0179] The foregoing outlines features of several embodiments so
that a person having ordinary skill in the art may better
understand the aspects of the present disclosure. A person having
ordinary skill in the art should appreciate that they may readily
use the present disclosure as a basis for designing or modifying
other processes and structures for carrying out the same functions
and/or achieving the same benefits of the embodiments introduced
herein. A person having ordinary skill in the art should also
realize that such equivalent constructions do not depart from the
spirit and scope of the present disclosure, and that they may make
various changes, substitutions and alterations herein without
departing from the spirit and scope of the present disclosure.
[0180] The Abstract at the end of this disclosure is provided to
comply with 37 C.F.R. .sctn.1.72 (b) to permit the reader to
quickly ascertain the nature of the technical disclosure. It is
submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims.
* * * * *