Process control architecture with hydrodynamic correction

• US 7,415,364 B2
• Filed: 10/10/2006
• Issued: 08/19/2008
• Est. Priority Date: 10/10/2006
• Status: Expired due to Fees

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Dykstra, Jason D., Mazrooee, Mehdi
• Primary Examiner(s): Raymond; Edward
• Application Number:
  US11/545,750
• Publication Number:
  US 20080114554A1
• Time in Patent Office: 679 Days
• Field of Search: 702/55, 702182-185, 702/188, 324/306, 73/10.1, 73/10.2, 73/11.6, 73/15.7, 731/521.8, 361/281
• US Class Current: 702/55
• CPC Class Codes: B28C 7/0418 control systems therefor
• CPC Class Codes: B28C 9/004 Making slurries, e.g. with discharging means for injecting in a well or projecting against a wall
• CPC Class Codes: E21B 33/13 Methods or devices for cementing, for plugging holes, crevices or the like
• CPC Class Codes: G01F 23/804 containing circuits handling parameters other than liquid level

Abstract

Methods and systems for controlling processes related to the amount of fluid in a container subjected to externally-excited motions. Fluid level sensor measurements in processing tanks on-board boats are confused by ocean waves and swells. A hydrodynamic model of a fluid in a tank can be constructed using non-linear dynamic model algorithms with inputs such as multi-axis accelerations, fluid viscosity, and apparent level measurements. The model can be used to filter-out boat motion disturbances to obtain a corrected level of the fluid in the tank. The corrected fluid level signal can be further processed using a dynamic model of the tank and associated input and output flow rates in a closed loop observer. The methods and systems are especially advantageous for offshore equipment such as cementing and fracturing ships.

Claims

1. A process control method, comprising the actions of:

a) monitoring the amount of a fluid in a container;

b) monitoring movements of the fluid and/or the container; and

c) combining results of the actions (a) and (b) using a hydrodynamic model of the container to generate a resultant output, wherein the hydrodynamic model simulates modes and frequencies of the container at different heights of the fluid in the container, and/or different viscosities of the fluid.

2. The method of claim 1 wherein the container is mounted on a water-borne apparatus.

3. The method of claim 1 wherein the fluid in the container is water, an aqueous solution, an aqueous slurry, a mixture of cement and water, or a mixture of cement and an aqueous solution.

4. The method of claim 1 wherein the action (a) results in measurements selected from the group consisting of the fluid'"'"'s level in the container, the fluid'"'"'s mass in the container, the fluid'"'"'s weight in the container, the fluid'"'"'s volume in the container, static force exerted by the fluid, down-force exerted by the fluid, and the fluid'"'"'s height at a particular point or points in the container.

5. The method of claim 1 wherein the action (b) results in measurements selected from the group consisting of accelerations in one or more axes of direction, velocities in one or more axes of directions, or position along one or more axes.

6. The method of claim 1 wherein the hydrodynamic model uses a neural network.

7. The method of claim 1 wherein inputs to the hydrodynamic model include two or more inputs selected from the group consisting of accelerations in two or more axes, velocity in two or more axes, position in two or more axes, the fluid'"'"'s viscosity, dynamic measurements of the fluid'"'"'s viscosity, the fluid'"'"'s density, dynamic measurements of the fluid'"'"'s density, the fluid'"'"'s yield value, the fluid'"'"'s gel strength, the fluid'"'"'s temperature, amount of water in the fluid, amount of solids in the fluid, amount of cement in the fluid, and amount of air in or entrained in the fluid.

8. The method of claim 1 wherein the resultant output is used to control at least one or more flow streams connected to the container.

9. The method of claim 1 wherein the hydrodynamic model is integrated with a dynamic process system model.

10. The method of claim 1 further comprising dynamic modeling of a process system including the container wherein a closed loop observer modifies the measured variable related to the amount of the fluid in the container.

11. A process control method, comprising the actions of:

a) measuring the amount of a fluid in a container which is subject to externally-excited motion;

b) measuring at least one spatial movement parameter of the fluid and/or the container;

c) modifying the result of the action (a) to more closely represent the actual amount of the fluid using the action (b) as an input to a hydrodynamic model of the behavior of the fluid, wherein said hydrodynamic model includes simulating modes and frequencies of the container at different heights of the fluid in the container, and/or different viscosities of the fluid; and

d) controlling a process using the result of the action (c).

12. The method of claim 11 wherein the container is mounted on a water-borne apparatus.

13. The method of claim 11 wherein the hydrodynamic model uses a neural network.

14. The method of claim 11 wherein inputs to the hydrodynamic model include two or more inputs selected from the group consisting of accelerations in two or more axes, velocity in two or more axes, position in two or more axes, the fluid'"'"'s viscosity, dynamic measurements of the fluid'"'"'s viscosity, the fluid'"'"'s density, dynamic measurements of the fluid'"'"'s density, the fluid'"'"'s yield value, the fluid'"'"'s gel strength, the fluid'"'"'s temperature, amount of water in the fluid, amount of solids in the fluid, amount of cement in the fluid, and amount of air in or entrained in the fluid.

15. The method of claim 11 wherein the resultant output is used to control at least one or more flow streams connected to the container.

16. The method of claim 11 further comprising dynamic modeling of a process system including the container wherein a closed loop observer modifies the measured variable related to the amount of the fluid in the container.