APPARATUS AND METHODS FOR EVALUATING SYSTEMS ASSOCIATED WITH WELLHEADS

• US 20130317750A1
• Filed: 05/23/2013
• Published: 11/28/2013
• Est. Priority Date: 05/25/2012
• Status: Active Grant

• Current Assignee: SPM Oil & Gas Incorporated (Caterpillar Incorporated)
• Original Assignee: SPM Flow Control Inc. (Caterpillar Incorporated)
• Inventors: Hunter, Scott
• Granted Patent: US 9,417,160 B2
• Time in Patent Office: Days
• US Class Current: 702/6
• CPC Class Codes: E21B 33/03 Well heads; Setting-up thereof
• CPC Class Codes: E21B 41/00 Equipment or details not covered by groups E21B15/00 - E21B40/00
• CPC Class Codes: E21B 43/2607 Surface equipment specially adapted for fracturing operations
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: G01M 99/00 Subject matter not provided for in other groups of this subclass
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06

Abstract

According to one aspect, data identifying a component is received, wherein the component is part of a system associated with a wellhead. A location at which the component is positioned relative to one or more other components is identified. The useful remaining operational life of the component is predicted based on at least an operational parameter specific to the location, and the operational history of the component or one or more components equivalent thereto. According to another aspect, a model representing at least a portion of a proposed system associated with a wellhead is generated, the model comprising a plurality of objects, each of which has a proposed location and represents an existing component. The useful remaining operational life for each object is predicted based on an operational parameter at the corresponding proposed location, and data associated with the respective operational history of the existing component.

Claims

1. A method, comprising:

receiving, using a computer, data identifying a first component in a first plurality of components,

wherein the first plurality of components is part of a system associated with a wellhead, and

wherein the first component has a useful remaining operational life;

identifying, using the computer, a first location at which the first component is positioned relative to one or more other components in the first plurality of components;

receiving, using the computer, data associated with a first operational parameter specific to the first location;

receiving, using the computer, data associated with an operational history of the first component or one or more components equivalent thereto; and

predicting, using the computer, the useful remaining operational life of the first component based on at least;

the first operational parameter, and

the operational history of the first component or one or more components equivalent thereto.

2. The method of claim 1, wherein the system associated with the wellhead is a system for pumping fluid to the wellhead.

3. The method of claim 1, wherein receiving the data identifying the first component comprises receiving data associated with a first reading of a first identifier that is coupled to the first component.

4. The method of claim 3, wherein receiving data associated with the first reading of the first identifier comprises:

coupling the first identifier to the first component;

positioning at least one reader in the vicinity of the first component;

reading the first identifier using the at least one reader to thereby obtain the first reading; and

transmitting the data associated with the first reading to the computer.

5. The method of claim 4, wherein the first identifier comprises an RFID tag;

and

wherein the at least one reader is an RFID reader.

6. The method of claim 3, wherein the first reading is part of a first plurality of readings to be taken in a first predetermined order, each place in the first predetermined order corresponding to a respective location of one component in the first plurality of components;

and

wherein identifying the first location at which the first component is positioned comprises determining the place in the first predetermined order at which the first reading was made.

7. The method of claim 1, wherein the first operational parameter is selected from the group consisting of a fluid flow rate through the first component, a fluid pressure within the first component, a volume of media within the first component, a volume of proppant within the first component, a volume of sand within the first component, and a time period during which fluid is to be pumped through the first component.

8. The method of claim 1, wherein the first operational parameter specifies a value or range of values;

and

wherein receiving data associated with the operational history comprises;

receiving data associated with measurements of one or more wear life attributes of the first component or one or more components equivalent thereto taken against time and under one or more operational parameters, the one or more operational parameters having the same, or different, values or ranges of values than that specified by the first operational parameter; and

storing the data associated with the wear life attribute measurements and the one or more operational parameters made thereunder; and

querying the stored data.

9. The method of claim 1, wherein predicting the useful remaining operational life of the first component comprises:

determining a wear trend for the first component based on at least the first operational parameter and the data associated with the operational history of the first component or one or more components equivalent thereto; and

predicting the useful remaining operational life of the first component using the wear trend.

10. The method of claim 1, further comprising:

(a) receiving, using the computer, data identifying another component in the first plurality of components, wherein the another component has a useful remaining operational life;

(b) identifying, using the computer, another location at which the another component is positioned relative to one or more other components in the first plurality of components;

(c) receiving, using the computer, data associated with another operational parameter specific to the another location;

(d) receiving, using the computer, data associated with an operational history of the another component or one or more components equivalent thereto;

(e) predicting, using the computer, the useful remaining operational life of the another component based on at least;

the another operational parameter, and

the operational history of the another component or one or more components equivalent thereto; and

(f) repeating (a)-(e) until the respective useful remaining operational lives of all the components in the first plurality of components have been predicted.

11. The method of claim 1, further comprising:

receiving, using the computer, data identifying a second component in a second plurality of components,

wherein the second plurality of components is part of the system associated with the wellhead, and

wherein the second component has a useful remaining operational life;

identifying, using the computer, a second location at which the second component is positioned relative to one or more other components in the second plurality of components;

receiving, using the computer, data associated with a second operational parameter specific to the second location;

receiving, using the computer, data associated with an operational history of the second component or one or more components equivalent thereto; and

predicting, using the computer, the useful remaining operational life of the second component based on at least;

the second operational parameter, and

the operational history of the second component or one or more components equivalent thereto.

12. An apparatus, comprising:

a non-transitory computer readable medium; and

a plurality of instructions stored on the non-transitory computer readable medium and executable by a processor, the plurality of instructions comprising;

instructions that cause the processor to receive data identifying a first component in a first plurality of components,

wherein the first plurality of components is part of a system associated with a wellhead, and

wherein the first component has a useful remaining operational life;

instructions that cause the processor to identify a first location at which the first component is positioned relative to one or more other components in the first plurality of components;

instructions that cause the processor to receive data associated with a first operational parameter specific to the first location;

instructions that cause the processor to receive data associated with an operational history of the first component or one or more components equivalent thereto; and

instructions that cause the processor to predict the useful remaining operational life of the first component based on at least;

the first operational parameter, and

the operational history of the first component or one or more components equivalent thereto.

13. The apparatus of claim 12, wherein the system associated with the wellhead is a system for pumping fluid to the wellhead.

14. The apparatus of claim 12, further comprising:

a first identifier adapted to be coupled to the first component; and

at least one reader adapted to read the first identifier and transmit the data identifying the first component.

15. The apparatus of claim 14, wherein the first identifier is an RFID tag;

and

wherein the at least one reader is an RFID reader.

16. The apparatus of claim 12, wherein the instructions that cause the processor to receive the data identifying the first component comprise instructions that cause the processor to receive data associated with a first reading of a first identifier that is coupled to the first component.

17. The apparatus of claim 16, wherein the first reading is part of a first plurality of readings to be taken in a first predetermined order, each place in the first predetermined order corresponding to a respective location of one component in the first plurality of components;

and

wherein instructions that cause the processor to identify the first location at which the first component is positioned comprises instructions that cause the processor to determine the place in the first predetermined order at which the first reading was made.

18. The apparatus of claim 12, wherein the first operational parameter is selected from the group consisting of a fluid flow rate through the first component, a fluid pressure within the first component, a volume of media within the first component, a volume of proppant within the first component, a volume of sand within the first component, and a time period during which fluid is to be pumped through the first component.

19. The apparatus of claim 12, wherein the first operational parameter specifies a value or range of values;

and

wherein the operational history indicates a wear life of the first component or one or more components equivalent thereto as a function of time and the first operational parameter; and

wherein instructions that cause the processor to receive data associated with the operational history comprises;

instructions that cause the processor to receive data associated with measurements of one or more wear life attributes of the first component or one or more components equivalent thereto taken against time and under one or more operational parameters, the one or more operational parameters having the same, or different, values or ranges of values than that specified by the first operational parameter; and

instructions that cause processor to store the data associated with the wear life attribute measurements and the one or more operational parameters made thereunder; and

instructions that cause the processor to query the stored data.

20. The apparatus of claim 12, wherein the instructions that cause the processor to predict the useful remaining operational life of the first component comprise:

instructions that cause the processor to determine a wear trend for the first component based on at least the first operational parameter and the data associated with the operational history of the first component or one or more components equivalent thereto; and

instructions that cause the processor to predict the useful remaining operational life of the first component using the wear trend.

21. The apparatus of claim 12, wherein the plurality of instructions further comprises instructions that cause the processor to:

(a) receive data identifying another component in the first plurality of components, wherein the another component has a useful remaining operational life;

(b) identify another location at which the another component is positioned relative to one or more other components in the first plurality of components;

(c) receive data associated with another operational parameter specific to the another location;

(d) receive data associated with an operational history of the another component or one or more components equivalent thereto;

(e) predict the useful remaining operational life of the another component based on at least;

the another operational parameter, and

the operational history of the another component or one or more components equivalent thereto; and

(f) repeat (a)-(e) until the respective useful remaining operational lives of all the components in the first plurality of components have been predicted.

22. The apparatus of claim 12, wherein the plurality of instructions further comprises:

instructions that cause the processor to receive data identifying a second component in a second plurality of components,

wherein the second plurality of components is part of the system associated with the wellhead, and

wherein the second component has a useful remaining operational life;

instructions that cause the processor to identify a second location at which the second component is positioned relative to one or more other components in the second plurality of components;

instructions that cause the processor to receive data associated with a second operational parameter specific to the second location;

instructions that cause the processor to receive data associated with an operational history of the second component or one or more components equivalent thereto; and

instructions that cause the processor to predict the useful remaining operational life of the second component based on at least;

the second operational parameter, and

the operational history of the second component or one or more components equivalent thereto.

23. A method, comprising:

generating, using a computer, a model that represents at least a portion of a proposed system associated with a wellhead, the model comprising a plurality of objects,

wherein each of the objects has a proposed location within the model,

wherein each of the objects represents an existing component proposed to be part of the proposed system, and

wherein each of the existing components has a useful remaining operational life;

specifying, using the computer, at least one operational parameter at each of the respective proposed locations of the objects;

receiving, using the computer, data associated with respective operational histories of the existing components; and

predicting, using the computer, the useful remaining operational life for each object,

wherein the prediction of the useful remaining operational life for each object is based on at least;

the respective at least one operational parameter at the corresponding proposed location, and

the data associated with the respective operational history of the existing component represented by the each object.

24. The method of claim 23, wherein the proposed system associated with the wellhead is a proposed system for pumping fluid to the wellhead.

25. The method of claim 23, further comprising:

rearranging the objects in the model and/or replacing one or more of the objects in the model with one or more other objects,

wherein each of the other objects has a proposed location within the model, and

wherein each of the other objects represents another existing component proposed to be part of the proposed system;

and

predicting, using the computer, the useful remaining operational life of each rearranged object and/or other object, wherein the prediction of the useful remaining operational life of the each rearranged object and/or other object is based on at least;

the respective at least one operational parameter at the corresponding proposed location, and

the data associated with the respective operational history of the existing component represented by the each rearranged object and/or other object.

26. The method of claim 23, further comprising optimizing, using the computer, at least one of the objects in the model by maximizing the respective useful remaining operational life of the at least one object, comprising:

(a) moving, using the computer, the at least one object to another proposed location in the model;

(b) after moving the at least one object to the another location in the model, predicting, using the computer, the useful remaining operational life of the at least one object,

wherein the prediction of the useful remaining operational life of the at least one object is based on at least;

the respective at least one operational parameter at the another proposed location, and

the data associated with the respective operational history of the existing component represented by the at least one object;

(c) repeating (a) and (b) until the another location at which the useful remaining operational life of the at least one object is at a maximum is determined;

(d) if the at least one object is not at the another location at which the useful remaining operation life of the at least one object is at the maximum, then moving, using the computer, the at least one object to the another location at which the useful remaining operational life of the at least one object is at the maximum.

27. The method of claim 23, wherein the at least one operational parameter is selected from the group consisting of a proposed fluid flow rate, a proposed fluid pressure, a proposed volume of media, a proposed volume of proppant, a proposed volume of sand, and a proposed time period during which fluid is to be pumped.

28. The method of claim 23, wherein each at least one operational parameter specifies a value or range of values;

and

wherein receiving data associated with each respective operational history comprises;

receiving data associated with measurements of one or more wear life attributes of the corresponding existing component or one or more components equivalent thereto taken against time and under one or more operational parameters, the one or more operational parameters having the same, or different, values or ranges of values than that specified by the corresponding at least one operational parameter at the proposed location of the object that represents the corresponding existing component.

29. The method of claim 23, wherein predicting the useful remaining operational life for each object comprises:

determining a wear trend for the corresponding existing component based on at least;

the at least one operational parameter at the proposed location of the each object, and

the data associated with the operational history of the existing component that is represented by the each object;

and

predicting the useful remaining operational life of the each object using the wear trend.

30. An apparatus, comprising:

a non-transitory computer readable medium; and

a plurality of instructions stored on the non-transitory computer readable medium and executable by a processor, the plurality of instructions comprising;

instructions that cause the processor to generate a model that represents at least a portion of a proposed system associated with a wellhead, the model comprising a plurality of objects,

wherein each of the objects has a proposed location within the model,

wherein each of the objects represents an existing component proposed to be part of the proposed system, and

wherein each of the existing components has a useful remaining operational life;

instructions that cause the processor to specify at least one operational parameter at each of the respective proposed locations of the objects;

instructions that cause the processor to receive data associated with respective operational histories of the existing components; and

instructions that cause the processor to predict the useful remaining operational life for each object, wherein the prediction of the useful remaining operational life for each object is based on at least;

the respective at least one operational parameter at the corresponding proposed location, and

the data associated with the respective operational history of the existing component represented by the each object.

31. The apparatus of claim 30, wherein the proposed system associated with the wellhead is a proposed system for pumping fluid to the wellhead.

32. The apparatus of claim 30, wherein the plurality of instructions further comprises:

instructions that cause the processor to rearrange the objects in the model and/or replace one or more of the objects in the model with one or more other objects,

wherein each of the other objects has a proposed location within the model, and

wherein each of the other objects represents another existing component proposed to be part of the proposed system;

and

instructions that cause the processor to predict the useful remaining operational life of each rearranged object and/or other object, wherein the prediction of the useful remaining operational life of the each rearranged object and/or other object is based on at least;

the respective at least one operational parameter at the corresponding proposed location, and

the data associated with the respective operational history of the existing component represented by the each rearranged object and/or other object.

33. The apparatus of claim 30, wherein the plurality of instructions further comprises instructions that cause the processor to optimize at least one of the objects in the model by maximizing the respective useful remaining operational life of the at least one object, comprising instructions that cause the processor to:

(a) move the at least one object to another proposed location in the model;

(b) predict, after moving the at least one object to the another location in the model, the useful remaining operational life of the at least one object, wherein the prediction of the useful remaining operational life of the at least one object is based on at least;

the respective at least one operational parameter at the another proposed location, and

the data associated with the respective operational history of the existing component represented by the at least one object;

(c) repeat (a) and (b) until the another location at which the useful remaining operational life of the at least one object is at a maximum is determined;

(d) if the at least one object is not at the another location at which the useful remaining operation life of the at least one object is at the maximum, then move the at least one object to the another location at which the useful remaining operational life of the at least one object is at the maximum.

34. The apparatus of claim 30, wherein the at least one operational parameter is selected from the group consisting of a proposed fluid flow rate, a proposed fluid pressure, a proposed volume of media, a proposed volume of proppant, a proposed volume of sand, and a proposed time period during which fluid is to be pumped.

35. The apparatus of claim 30, wherein each at least one operational parameter specifies a value or range of values;

and

wherein instructions that cause the processor to receive data associated with each respective operational history comprises;

instructions that cause the processor to receive data associated with measurements of one or more wear life attributes of the corresponding existing component or one or more components equivalent thereto taken against time and under one or more operational parameters, the one or more operational parameters having the same, or different, values or ranges of values than that specified by the corresponding at least one operational parameter at the proposed location of the object that represents the corresponding existing component.

36. The apparatus of claim 30, wherein the instructions that cause the processor to predict the useful remaining operational life for each object comprise:

instructions that cause the processor to determine a wear trend for the corresponding existing component based on at least;

the at least one operational parameter at the proposed location of the each object, and

the data associated with the operational history of the existing component that is represented by the each object;

and

instructions that cause the processor to predict the useful remaining operational life of the each object using the wear trend.