Distributed control system

• US 20040182574A1
• Filed: 03/18/2003
• Published: 09/23/2004
• Est. Priority Date: 03/18/2003
• Status: Active Grant

• Current Assignee: Schlumberger Technology Corporation (Schlumberger NV)
• Original Assignee: Schlumberger Technology Corporation (Schlumberger NV)
• Inventors: Adnan, Sarmad, Zheng, Shunfeng, Rouse, Matthew D., Opel, Kent C., Lu, Weibin
• Granted Patent: US 6,968,905 B2
• Time in Patent Office: Days
• US Class Current: 166/250.01
• CPC Class Codes: E21B 44/00 Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
• CPC Class Codes: G05B 15/02 electric

Abstract

A distributed control system permits local or remote control of equipment. The distributed control system provides a communication bridge through a local control panel between a non-real-time network, such as an Ethernet, and a real-time network, such as a controller area network. Both soft real-time and hard real-time networks are suitable, but hard real-time is preferred. The system uses multiple distributed control units to control various equipment components and is thus highly expandable. The distributed control system may be applied in any environment. When applied to a skid-mounted coiled tubing unit, the distributed control system reduces the amount of hydraulic hose required and therefore makes set up and take down shorter and more economical.

Claims

1. A method for distributed control of equipment comprising:

operating an input device at a master control station to transmit control signals from the master control station across a non-real-time network to at least one local control panel (LCP);

converting and transmitting the control signals from the master control station across a real-time network to at least one distributed control unit (DCU) to control the operation of the equipment;

sensing sensor data and transmitting the sensor data across the real-time network from the at least one DCU to the LCP; and

converting and transmitting the sensor data from the LCP across the non-real-time network to at least one output device at the master control station.

2. The method of claim 1, further comprising observing operation of the equipment from an ancillary control station.

3. The method of claim 1, further comprising:

operating an input device at an ancillary control station to transmit control signals from the ancillary control station across the non-real-time network to the at least one LCP;

converting and transmitting the control signals from the ancillary control station across the real-time network to the at least one DCU to control the operation of the equipment;

sensing sensor data and transmitting the sensor data across the real-time network from the at least one DCU to the LCP; and

converting and transmitting the sensor data from the LCP across the non-real-time network to at least one output device at the ancillary control station.

4. The method of claim 1, further comprising transmitting video signals of the equipment to an electronic display proximate the master control station.

5. The method of claim 4, further comprising transmitting sound signals from the equipment to a sound output device proximate the master control station.

6. The method of claim 1, wherein the real-time network includes a hard real-time network.

7. The method of claim 1, wherein the real-time network includes a soft real-time network.

8. A system for distributed control of equipment comprising:

a master control station, including at least one input device and at least one output device, to operate the equipment;

at least one local control panel (LCP);

at least one distributed control unit (DCU);

a non-real-time network to transmit signals between the master control station and the LCP; and

a real-time network to transmit signals between the at least one LCP and the at least one DCU.

9. The system of claim 8, wherein the master control station is positioned proximate the equipment allowing an operator to visually observe operation of the equipment.

10. The system of claim 9, further comprising at least one video input device positioned proximate the equipment to send video signals to at least one electronic display located proximate the master control station.

11. The system of claim 9, further comprising at least one sound input device proximate the equipment to transmit sound signals from the equipment to at least one sound output device proximate the master control station.

12. The system of claim 8, further comprising an ancillary control station to monitor operation of the equipment.

13. The system of claim 8, wherein the master control station is located remote from the equipment so an operator cannot observe operation of the equipment without the further assistance of a video camera or other optical apparatus.

14. The system of claim 13, further comprising at least one video input device positioned proximate the equipment to send video signals to at least one electronic display located proximate the master control station.

15. The system of claim 13, further comprising at least one sound input device proximate the equipment to transmit sound signals from the equipment to at least one sound output device proximate the master control station.

16. A method for distributed control of a coiled tubing unit comprising:

operating an input device at a control station to transmit control signals from the control station across a non-real-time network to a local control panel (LCP);

converting and transmitting the control signals from the control station across a real-time network to at least one distributed control unit (DCU);

transmitting the control signals from the at least one DCU to at least one piece of coiled tubing unit equipment;

sensing sensor data from at least one piece of coiled tubing unit equipment and transmitting the sensor data across the real-time network from at least one DCU to the LCP; and

converting and transmitting the sensor data from the LCP across a non-real-time network to at least one output device at the control station.

17. The method of claim 16, further comprising observing operation of the at least one piece of coiled tubing equipment from an ancillary control station.

18. The method of claim 16, further comprising transmitting sound signals from the coiled tubing unit to a sound output device proximate the control station.

19. The method of claim 16, further comprising transmitting video signals of the coiled tubing unit to an electronic display proximate the control station.

20. The method of claim 16, further comprising:

positioning the control station at a location that is remote from the coiled tubing unit; and

transmitting sound signals from the coiled tubing unit to a sound output device proximate the remotely located control station to enable an operator to hear the operation of the coiled tubing unit.

21. The method of claim 16, further comprising:

positioning the control station to a location that is remote from the coiled tubing unit; and

transmitting video signals of the coiled tubing unit to an electronic display proximate the remotely located control station to enable an operator to observe operation of the coiled tubing unit.

22. The method of claim 16, further comprising:

sensing a non-real-time network signal failure; and

transmitting control signals to the at least one DCU when the non-real-time network signal failure is sensed.

23. The method of claim 16, wherein the at least one DCU comprises a power pack DCU, a coiled tubing reel DCU, and an injector head/BOP DCU, the method further comprising:

sensing a non-real-time network signal failure; and

transmitting control signals to one or more of the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU when the non-real-time network signal failure is sensed.

24. The method of claim 16, further comprising:

sensing a real-time network signal failure; and

transmitting control signals to the at least one DCU when the real-time network signal failure is sensed.

25. The method of claim 16, wherein the at least one DCU comprises a power pack DCU, a coiled tubing reel DCU, and an injector head/BOP DCU, the method further comprising:

sensing a real-time network signal failure; and

transmitting control signals to one or more of the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU when the real-time network signal failure is sensed.

26. The method of claim 16, further comprising:

sensing a sensor data signal failure; and

transmitting control signals to at least one DCU when the sensor data signal failure is sensed.

27. The method of claim 16, wherein the at least one DCU comprises a power pack DCU, a coiled tubing reel DCU, and an injector head/BOP DCU, the method further comprising:

sensing a sensor data signal failure; and

transmitting control signals to one or more of the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU when the sensor data signal failure is sensed.

28. The method of claim 16, wherein the coiled tubing unit comprises a power pack to supply power to other components of the coiled tubing unit, a coiled tubing reel, an injector head, a stripper, and a BOP, and wherein the at least one DCU comprises a power pack DCU, a coiled tubing reel DCU, and an injector head/BOP DCU, the method further comprising:

converting and transmitting the control signals from the control station across a real-time network to one or more of the power pack DCU to control the operation of the power pack, a coiled tubing reel DCU to control operation of the coiled tubing reel, and an injector head/BOP DCU to control the operation of the injector head, the stripper, and the BOP; and

sensing sensor data and transmitting the sensor data across the real-time network from one or more of the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU to the LCP.

29. The method of claim 16, further comprising:

generating automated control signals; and

transmitting the automated control signals to the coiled tubing unit.

30. The method of claim 16, further comprising:

generating automated control signals in the LCP; and

transmitting the automated control signals to at least one DCU to automatically control the coiled tubing unit.

31. The method of claim 16, further comprising:

generating automated control signals in at least one DCU; and

transmitting the automated control signals from the at least one DCU to automatically control the coiled tubing unit.

32. The method of claim 16, wherein the at least one DCU comprises a power pack DCU, a coiled tubing reel DCU, and an injector head/BOP DCU, the method further comprising:

transmitting and sharing the sensor data among one or more of the power pack DCU, the coiled tubing reel DCU, the injector head/BOP DCU, and the local control panel; and

calculating fail-safe parameters and comparing against a pre-loaded operating envelope and automatically transmitting control signals from the local control panel to one or more of the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU when the pre-loaded operating envelope is violated.

33. The method of claim 16, further comprising:

transmitting and sharing the sensor data among one or more of the at least one DCU and the local control panel; and

calculating fail-safe parameters and comparing against a pre-loaded operating envelope and automatically transmitting control signals from the LCP to at least one DCU when the pre-loaded operating envelope is violated.

34. The method of claim 16, further comprising:

transmitting and sharing the sensor data among one or more of the at least one DCU and the LCP; and

calculating fail-safe parameters and comparing against a pre-loaded operating envelope and automatically transmitting control signals from at least one DCU to another DCU on the real-time network or the LCP when the pre-loaded operating envelope is violated.

35. The method of claim 16, wherein the at least one DCU comprises a power pack DCU, a coiled tubing reel DCU, and an injector head/BOP DCU, the method further comprising:

transmitting and sharing the sensor data among one or more of the power pack DCU, the coiled tubing reel DCU, the injector head/BOP DCU, and the LCP; and

calculating fail-safe parameters and comparing against a pre-loaded operating envelope and automatically transmitting control signals from one or more of the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU, to other DCU'"'"'s on the real-time network and the LCP when the pre-loaded operating envelope is violated.

36. The method of claim 16, wherein the at least one DCU comprises a power pack DCU, a coiled tubing reel DCU, and an injector head/BOP DCU, the method further comprising:

storing sensor data from one or more of the power pack DCU, the coiled tubing reel DCU, the injector head/BOP DCU, and the LCP in a memory storage device; and

calculating fail-safe parameters based on the stored sensor data and comparing against a pre-loaded operating envelope and automatically transmitting control signals to one or more of the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU when the pre-loaded operating envelope is violated.

37. The method of claim 16, further comprising:

storing sensor data from at least one DCU and the local control panel in a memory storage device; and

calculating fail-safe parameters based on the stored sensor data and comparing against a pre-loaded operating envelope and automatically transmitting control signals to at least one DCU when the pre-loaded operating envelope is violated.

38. The method of claim 16, wherein the at least one DCU comprises a power pack DCU, a coiled tubing reel DCU, and an injector head/BOP DCU, the method further comprising:

loading an operating envelope in the local control panel;

transmitting and sharing the sensor data among one or more of the power pack DCU, the coiled tubing reel DCU, the injector head/BOP DCU, and the LCP; and

transmitting control signals from the LCP to one or more of the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU when the operating envelope is violated.

39. The method of claim 16, wherein the at least one DCU comprises a power pack DCU, a coiled tubing reel DCU, and an injector head/BOP DCU, the method further comprising:

loading an operating envelope in a memory storage device;

transmitting and sharing the sensor data among one or more of the power pack DCU, the coiled tubing reel DCU, the injector head/BOP DCU, and the LCP; and

transmitting control signals to one or more of the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU when the operating envelope is violated.

40. The method of claim 16, further comprising:

monitoring sensor data involving performance of the coiled tubing unit;

storing and accumulating the sensor data involving performance; and

generating maintenance notices and incorporating this sensor data into fail-safe operating envelopes.

41. A system for distributed control of a coiled tubing unit, the coiled tubing unit including a power pack and associated components, a coiled tubing reel and associated components, an injector head and associated components, and a BOP and associated components, the system comprising:

a master control station, including at least one input device and at least one output device, to operate the coiled tubing unit;

a local control panel (LCP);

a power pack distributed control unit (DCU) to control operation of the power pack and associated components;

a coiled tubing reel DCU to control operation of the coiled tubing reel and associated components;

an injector head/BOP DCU to control operation of the injector head and associated components, and the BOP and associated components;

a non-real-time network to send signals between the master control station and the LCP; and

a real-time network to send signals between the LCP, the power pack DCU, the coiled tubing reel DCU, and the injector head/BOP DCU.

42. The system of claim 41, wherein the non-real-time network is an Ethernet.

43. The system of claim 41, wherein the non-real-time network is a token ring.

44. The system of claim 41, wherein the real-time network is a controller area network (CAN).

45. The system of claim 41, wherein the real-time network also uses a sensor network to send sensor signals from sensors to the LCP.

46. The system of claim 45, wherein the sensor network is selected from the group consisting of a Smart Distributed System (SDS), DeviceNet, PROFIBUS, and CANopen.

47. The system of claim 41, wherein the master control station is positioned proximate the coiled tubing unit allowing an operator to visually observe operation of the coiled tubing unit.

48. The system of claim 47, further comprising at least one video input device positioned proximate the coiled tubing unit to send video signals to at least one electronic display located proximate the master control station.

49. The system of claim 47, further comprising at least one sound input device proximate the coiled tubing unit to transmit sound signals from the coiled tubing unit to at least one sound output device proximate the master control station.

50. The system of claim 41, further comprising an ancillary control station to monitor operation of the coiled tubing unit.

51. The system of claim 41, wherein the master control station is located remote from the coiled tubing unit so an operator cannot observe operation of the coiled tubing unit without the assistance of a video camera or other optical apparatus.

52. The system of claim 51, further comprising at least one video input device positioned proximate the coiled tubing unit to send video signals to at least one electronic display located proximate the control station.

53. The system of claim 51, further comprising at least one sound input device proximate the coiled tubing unit to transmit sound signals from the coiled tubing unit to at least one sound output device proximate the master control station.