NO20151737A1 - Drilling system - Google Patents

Description

DRILLING SYSTEM

FIELD

The present invention relates to a system for operating equipment used in a drilling operation, and in particular to a system for monitoring and controlling such equipment from a remote operating station.

BACKGROUND

Drilling operations, in particular those carried out offshore, have very high safety requirements for all equipment used in such operations. There are potential major consequences of failures or damage to equipment, both in terms of personnel safety and environmental impact. There is therefore a continuous need to improve and optimize the operation of offshore drilling equipment, both on individual machines and on a system level.

A key requirement for equipment used in drilling operations is their suitability to operate in areas with explosion or fire risks. Electrical equipment and electrical cables must in particular be designed with high safety standards. During such operations, there nevertheless exists a risk that tools or objects being handled, for example, a drill pipe, comes into mechanical contact with and damages electrical equipment and/or cables. Damage can also occur during maintenance of the equipment when workers need access to different parts of, for example, a machine.

SUMMARY

An object of the present invention is to remove drawbacks of known technology and to provide improved systems and solutions for the operation of, and, in particular, the monitoring of equipment used in drilling operations.

In an embodiment, the present invention provides a system for use in a drilling operation which includes a machine, a hydraulic supply line comprising a hydraulic fluid, at least one sensor configured to measure at least one operating parameter of the machine and to produce a sensor signal based thereon, and a monitoring unit. The hydraulic supply line is connected to the machine so that the machine can be operated with the hydraulic fluid from the hydraulic supply line. The monitoring unit comprises a power generator unit connected to the hydraulic supply line, a first data processor configured to receive the sensor signal from the at least one sensor and produce an output signal based thereon, and a first wireless communication unit configured to receive the output signal. The power generator unit comprises a hydraulic motor configured to drive an electric generator so as to produce electric power. The data processor and the first wireless communication unit are each configured to receive the electric power from the electric generator.

BRJEF DESCRIPTION OF THE DRAWINGS

Fig. 1 shows a machine operating on a drilling plant; Fig. 2 shows a machine used with an embodiment of the present invention; Fig. 3 shows further detail of the system illustrated in Fig. 2; Fig. 4 shows a local power supply unit according to an embodiment of the present invention; Fig. 5 shows another machine used with an embodiment of the present invention; and

Fig. 6 shows an embodiment of according to the present invention.

DETAILED DESCRIPTION

In an embodiment, the present invention provides a system for use in a drilling operation which comprises a machine, a hydraulic supply line, the machine being connected to and operable with hydraulic fluid from the hydraulic supply line, at least one sensor operable to measure at least one operating parameter of the machine, and a monitoring unit. The monitoring unit comprises a power generator unit, a data processor configured to receive a sensor signal from the at least one sensor and to produce an output signal, and a first wireless communication unit configured to receive the output signal. The power generator unit is connected to the hydraulic supply line. The power generator unit comprises a hydraulic motor driving an electric generator. The data processor and the first wireless communication unit are adapted to receive electric power from the electric generator.

It can be advantageous if the system obviates the need for a dedicated electric power supply to be provided to the machine for powering the data processor and the wireless communication unit, and dedicated electronic signal lines to be provided to the machine for communicating measurement data from the machine.

In an embodiment of the present invention, the system can, for example, further comprise a server unit, the server unit comprising a data processor, a data storage unit, and a second wireless communication unit. The second wireless communication unit is configured to communicate with the first wireless communication unit.

In an embodiment of the present invention, the data processor can, for example, be configured to generate an output signal comprising at least one of: (i) a single value of a data set contained in the sensor signal over a pre-defined time interval; (ii) an average value of a data set contained in the sensor signal over a pre-defined time interval; (iii) a median value of a data set contained in the sensor signal over a pre-defined time interval; and (iv) a value representing the rate of change for a variable of a data set contained in the

sensor signal over a pre-defined time interval.

It can be advantageous if this reduces the required data transmission requirement because not all sensor data needs to be transferred by the first wireless communication unit.

In an embodiment of the present invention, the power generator unit can, for example, further comprise a battery. The battery is adapted to provide electric power to the data processor and the first wireless communication unit.

It can be advantageous if the battery permits operation of the data processor, sensors, and wireless communication unit also when the hydraulic mains are de-energized and the machine is in a stand-by state.

In an embodiment of the present invention, the system can, for example, further comprise an actuator which operates a valve controlling the operation of the machine. The actuator can, for example, be controlled by a controller. The actuator and the controller can, for example, be powered by the electric generator.

It can be advantageous if the electric generator obviates the need for a dedicated power supply for the actuator.

In an embodiment of the present invention, the monitoring unit can, for example, be provided within an enclosure.

In an embodiment of the present invention, the enclosure can, for example, be explosion-and/or fire-proof.

The present invention is described in greater detail below on the basis of embodiments and of the drawings.

Fig. 1 illustrates a machine operating on a drilling plant, for example, an offshore drilling rig. The machine 100 is a lower guiding arm (LGA) for handling drilling pipes. The LGA 100 comprises a guide head assembly 104 and a telescopic arm assembly 105. The LGA 100 is mounted on a guide rail (not shown) by a trolley assembly 106. Conventionally, electric and hydraulic interfaces to the LGA are provided via the guide rail and the trolley assembly. Hydraulic main lines 107 further distribute hydraulic power to the various subcomponents on the LGA, such as the guide head 104 and telescopic arm 105. The LGA further comprises a monitoring and control unit 103 which is described in further detail below.

Fig. 1 further shows a control station 101, for example, a driller's cabin, in which a drilling operator controls the operation of the LGA and other equipment. The control station 101 further comprises a server unit 102, which is also described further below. Fig. 2 illustrates a second type of machine which is suitable for use with the present invention and which would also be present on a drilling plant such as that shown in Fig. 1. Fig. 2 shows, schematically, a drilling machine 200, which may, for example, be a top drive. The drilling machine 200 is movable along a rail 201 on a drilling rig and is provided with hydraulic power through hydraulic main lines 207 from a hydraulic power unit 208. The drilling machine comprises hydraulic motors 21 la and 21 lb which are configured to rotate a drill string 210 via gearbox 209.

The drilling machine 200 further comprises a monitoring and control unit 103. The monitoring and control unit 103 is connected to the hydraulic main lines 207 and to a set of sensors 212a-c in a manner described in further detail below.

Fig. 3 shows further detail of the system illustrated in Fig. 2 along with a server unit 102 positioned in a control station 101 (see Fig. 1). The hydraulic main lines to the drilling machine 200 comprise a supply line 207a and a return line 207b. The monitoring and control unit 103 comprises a local power supply 320, described in more detail below, and in relation to Fig. 4. The local power supply 320 is coupled to, and receives hydraulic fluid from, the hydraulic lines 207a and 207b via hydraulic bleed-off lines 331a and 33 lb. The local power supply utilizes bleed-off hydraulic fluid from the hydraulic main lines 207 to generate and provide electric power to a local data processor 321 via electric supply line 322.

The local data processor 321 receives input from sensors 212a, 212b and 212c via sensor signal lines 213a, 213b and 213c. The local data processor 321 is further connected to a wireless communication unit 323, for example, a Bluetooth sender and receiver. The local data processor 321 is configured to send sensor data to the server unit 102 via the wireless communication unit 323. For this purpose, the server unit 102 is provided with a wireless communication unit 324 to receive the sensor data. The server unit 102 is further provided with a data processor 325 and a data storage unit 326, for example, a hard drive dise. From the data storage unit 326, the sensor data can be extracted for display, for example, on an operations screen (not shown) for a human operator in the control station 101.

The sensors 212a, 212b and 212c may be any sensor type related to operating parameters of the machine in question, for example, sensors measuring temperature, power, torque, vibration, or other operating parameters. In the example shown in Figs 2 and 3, the sensors 212a and 212c are torque sensors for measuring the torque provided by hydraulic motors 212a and 212c, whereas sensor 212b is an acceleration sensor to measure the vibration of the gear box 209. The sensors may be analogue or digital, and the communication with local data processor 321 may be in any manner known in the art.

In an embodiment of the present invention, the data processor (321) can, for example, be configured to carry out pre-processing of the signals from sensors 212a, b, c such as to generate a reduced set of sensor data. This reduces the data transmission requirements for the system in that not all sensor data need be transferred via the wireless communication unit. For one measured operational parameter, for example, the speed of the drilling machine 200, the reduced set of sensor data generated and transmitted may comprise: (i) a single value of the speed over a pre-defined time interval, for example, one second prior to the generation of the reduced set of sensor data; (ii) an average value of the speed over the time interval;

(iii) a median value of the speed over the time interval; and/or

(iv) the rate of change of the speed over the time interval.

Fig. 4 shows the local power supply 320. As shown above, the local power supply 320 is coupled to the hydraulic bleed-off lines 331a and 331b. Bleed-off hydraulic power from hydraulic main lines 207 is used to drive a hydraulic motor 401, which drives an electric generator 402 via a shaft 404. The electric power generated is provided to electric supply line 322. The local power supply may optionally include a battery 403. Since the power requirements for most standard sensor systems will be very low, the local power supply

320 can be designed small and compact. The amount of hydraulic power required for the local power supply will be very low compared to that used in the regular operation of the machine. Fig. 5 illustrates an embodiment according to the present invention. The embodiment comprises certain elements equivalent to those described above, which will not be repeated here, including a hydraulic supply line 207a, hydraulic return line 207b, hydraulic bleed-off lines 331a and 331b, monitoring and control unit 103, local power supply 320, electric supply line 322, and a wireless communication unit 323. Fig. 5 further shows a hydraulic cylinder 501 for the guide head assembly 104 of the LGA shown in Fig. 1. The hydraulic cylinder 501 is thus part of the LGA machine. The hydraulic cylinder 501 is provided with hydraulic power from the hydraulic main lines 107, i.e., a hydraulic supply line 207a, return line 207b, through cylinder supply line 500a, and cylinder return line 500b. Operation of the hydraulic cylinder 501 is controlled by hydraulic valve 502. The hydraulic valve 502 is controlled by electro-mechanical actuator 503. A data processor and controller 521 is provided in the monitoring and control unit 103. The data processor and controller 521 is provided with electric power through electric supply line 322, and the data processor and controller 521 controls the electro-mechanical actuator 503 via the electric power supplied through electric supply line 322. The data processor and controller 521 can, for example, be a programmable logi cal controller (PLC) of conventional design.

A linear encoder 504 is provided in association with the hydraulic cylinder 501 to provide a sensor signal representing the position of the cylinder and thus the position of the gripper of the guide head assembly 104. The sensor signal from the linear encoder 504 is provided to the data processor and controller 521 through signal line 505.

The data processor and controller 521 is connected to, and may both send to and receive data from, the wireless communication unit 323. The monitoring and control unit 103, located locally on the LGA, may therefore both send sensor data to a server unit 102, and receive control instructions for the operation of the LGA via a wireless communication link from an operator in a control station 101.

Fig. 6 shows an embodiment of the present invention. The embodiment in Fig. 6 is equivalent to that shown in Fig. 5, but with the monitoring and control unit 103 being provided within an enclosure 600. The enclosure 600 is provided locally on the LGA, and is provided as a unit which is fire- and/or explosion-proof. This may, for example, be ATEX compliant (including the feed-through for the cables and leads) for use in atmospheres with high explosion risks, such as those found on drilling rigs. The local power supply 320 will be shielded from the operating atmosphere of the LGA by providing the enclosure 600. The generation of electric power locally through the generator 402 will thus not present a safety risk.

By providing a system according to the present invention, operational data from machines on a drilling rig can be measured and provided to a control station without the need to run extensive electric cabling to and from the machines. By providing a local power supply according to the present invention, the power necessary to drive the sensors can advantageously be extracted from the (already present) main hydraulics supply. An enclosed, fire-/explosion-proof system can also advantageously be obtained.

The present invention is not limited to embodiments described herein; reference should be had to the appended claims.

Claims (7)

1. A system for use in a drilling operation, the system comprising: a machine; a hydraulic supply line comprising a hydraulic fluid, the hydraulic supply line being connected to the machine so that the machine can be operated with the hydraulic fluid from the hydraulic supply line; at least one sensor configured to measure at least one operating parameter of the machine and to produce a sensor signal based thereon; and a monitoring unit (103) comprising: a power generator unit (320) connected to the hydraulic supply line, the power generator unit comprising a hydraulic motor configured to drive an electric generator so as to produce electric power, a first data processor (321) configured to receive the sensor signal from the at least one sensor and produce an output signal based thereon, and a first wireless communication unit (323) configured to receive the output signal; wherein, the data processor (321) and the first wireless communication unit (323) are each configured to receive the electric power from the electric generator.

2. The system as recited in claim 1, further comprising a server unit (102) comprising a second data processor (325), a data storage unit (326), and a second wireless communication unit (324), the second wireless communication unit being configured to communicate with the first wireless communication unit.

3. The system as recited in any of claims 1 and 2, wherein the output signal of the first data processor (321) comprises at least one of: (i) a single value of a data set contained in the sensor signal over a predefined time interval; (ii) an average value of the data set contained in the sensor signal over the predefined time interval; (iii) a median value of the data set contained in the sensor signal over the predefined time interval; and (iv) a value representing a rate of change for a variable of the data set contained in the sensor signal over the pre-defined time interval;

4. The system as recited in any one of claims 1 to 3, wherein the power generator unit (320) further comprises a battery (403), the battery being configured to provide electric power to the first data processor and the first wireless communication unit.

5. The system as recited in any one of claims 1 to 4, further comprising: a valve (502) configured to control the operation of the machine; an actuator (503) configured to operate the valve (502); and a controller (521) configured to control the actuator (503), wherein, each of the actuator (503) and the controller (521) are powered by the electric generator.

6. The system as recited in any one of claims 1 to 5, further comprising an enclosure (600) configured to enclose the monitoring unit (103).

7. The system as recited in claim 6, wherein the enclosure (600) is provided so as to be at least one of explosion proof and fire proof.