Universal rig controller interface

A rig control interface includes a plurality of interface systems. Each of the interface systems is configured to manipulate a rig control based on a signal received from an automated rig control system. The interface systems includes a mechanical control interface. The mechanical control interface includes an actuator configured to mechanically move a control handle from a first position to a second position responsive to the signal.

BACKGROUND

Rigs, such as drilling rigs or production rigs, used in exploration and production of oil and gas, apply a variety of tools and rig systems to implement the operations performed by the rig. For example, a drilling rig includes a draw works to raise and lower a drill string, a top drive or rotary table to rotate the drill string, pumps to circulate drilling fluid in the bore hole, and various other tools. The rig includes controls that an operator uses to manipulate the tools.

SUMMARY

A rig control interface includes a plurality of interface systems. Each of the interface systems is configured to manipulate a rig control based on a signal received from an automated rig control system. The interface systems includes a mechanical control interface. The mechanical control interface includes an actuator configured to mechanically move a control handle from a first position to a second position responsive to the signal.

A method for controlling a rig includes measuring, by an automated rig control system, a rig control parameter. Based on the measured rig control parameter, the automated rig control system, determines to change the value of the rig control parameter. A motor is activated, by the automated rig control system, responsive to the determining. Rotation of the motor is applied to mechanically move a control handle of the rig. A position of the control handle is measured by a sensor coupled to the control handle.

A method for automating control of a rig includes mounting a coupler on a mechanical control handle of a rig. Movement of the mechanical control handle changes a signal that controls a tool of the rig. An electric motor is connected to the coupler. An automated rig control system is electrically connected to the electric motor. A sensor that measures a value of a parameter of the tool is monitor by the automated rig control system. A control signal to change the value of the parameter of the tool is generated by the automated rig control system. The electric motor is activated responsive to the signal. The control handle is moved by the electric motor to change the value of the parameter of the tool.

DETAILED DESCRIPTION

Modern rigs include features that allow automated control of rig operations and implementation of variety of advanced control features, such as stick-slip mitigation, drilling optimization, drill pipe oscillation, etc. that can be implemented using automated control. Older rigs may not include automated control systems that allow for implementation of advanced control features. For example, older rigs may provide only manual control over the rig's tools which generally precludes the implementation of advanced control features. Consequently, in a competitive market, older rigs may suffer a significant disadvantage.

The rig control interface disclosed herein can be added to an older rig to provide an interface between the rig's tools and an automated control system. A rig that has been updated to include the rig control interface of the present disclosure can implement various advanced control features, which in turn, make the rig more desirable when compared with other rigs. Implementations of the rig control interface disclosed herein may include a mechanical control interface, an analog control interface, a pneumatic control interface, and/or a digital control interface each of which is coupled to an automated rig control system that controls the rig's tools via the rig control interface. The mechanical control interface mechanically manipulates, under control of the automated rig control system, a control handle, such as a rotary knob, a slider, or a switch, that controls a tool, e.g., a knob on an operator's console. The analog control interface selectively routes, under control of the automated rig control system, an analog control signal generated under the control of the automated rig control system to a tool controller, or routes an analog signal generated by a legacy rig control system to the tool interface. The pneumatic control interface selectively routes, under control of the automated rig control system, a pneumatic control signal generated under the control of the automated rig control system to a tool controller, or routes a pneumatic signal generated by a legacy rig control system to the tool interface. The digital control interface includes a digital control bus master that allows the automated rig control system to communicate with a tool controller via a digital control bus.

FIG.1shows an example rig100that includes a universal rig interface in accordance with the present disclosure. In the rig100, a drilling platform102supports a derrick104having a draw works136for raising and lowering a drill string108. A kelly110supports the drill string108as it is lowered through a rotary table112. In some embodiments, a top drive is used to rotate the drill string108in place of the kelly110and the rotary table112. A drill bit114is positioned at the downhole end of the tool string126, and is driven by rotation of the drill string108or by a downhole motor (not shown) positioned in the tool string126up hole of the drill bit114. The drill string108includes a plurality of lengths (or joints) of drill pipe118that are coupled end-to-end. As the bit114rotates, it removes material from the various formations and creates the borehole116. A pump120circulates drilling fluid through a feed pipe122and downhole through the interior of drill string108, through orifices in drill bit114, back to the surface via the annulus140around drill string108, and into a retention pit124. The drilling fluid transports cuttings from the borehole116into the pit124and aids in maintaining the integrity of the borehole116.

The rig100includes an automated rig control system132that provides automated control of various rig systems, such as the draw works136, the rotary table112(or a top drive), and the pump120. By controlling the operations of the various rig systems, the automated rig control system132can automate at least some drilling processes, and provide advance control functionality (such as stick-slip mitigation) that is generally possible only via automated control. The automated rig control system132interfaces with the various rig systems via a universal rig interface134. The universal rig interface134couples the automated rig control system132to rig systems and translates control signals generated by the automated rig control system132to a form suitable for control of the rig systems. For example, in an implementation of the rig100, the draw works136, the rotary table112, and/or the pump120may be controlled by mechanical manipulation of knobs, slider, switches, etc. (referred to herein as control handles) that are manually manipulated by an operator (i.e., a human user) to change an operation of the draw works136, the rotary table112, and/or the pump120. Control means (such as control handles) provided in the rig100prior to inclusion of the universal rig interface134into the systems of the rig100are referred to herein as “legacy” controls. The universal rig interface134adapts the automated rig control system132to manipulate legacy controls of the rig100, such as control handles. Legacy controls may take a variety of forms. In addition to control handles, the universal rig interface134may provide interfaces that allow the automated rig control system132to control rig systems via electrical analog control signals, pneumatic control signals, and/or a digital control bus.

FIG.2shows a block diagram for an example of rig systems200including a universal rig interface in accordance with the present disclosure. The rig systems200include an automated rig control system202, a universal rig interface204, legacy rig control and tool controllers, an operator interface208, and sensors210. The automated rig control system202is an example of the automated rig control system132, and the universal rig interface204is an example of the universal rig interface134. The automated rig control system202includes a processor, such as a microprocessor, a digital signal processor, etc. that executes instructions that cause the processor to monitor the operation of a rig's tools (e.g., the draw works136, the rotary table112, and/or the pump120) and provide control signals that change the operation of the rig's tools. In some implementations, the automated rig control system202may be implemented using a computer or computing device as known in the art. The legacy rig control and tool controllers206includes the legacy controls of a rig (e.g., the rig100) and tool controllers that directly control the rig's tools. For example, a tool controller for the electric motor of the draw works136may set the direction and amount of current flow to the electric motor to control the direction and speed of drum rotation. Tool controllers for the rotary table112(or a top drive) and the pump120may provide similar functionality. The legacy controls of the rig may include mechanical control handles, electrical analog signal generators, pneumatic signal generators, and/or a digital control bus.

The universal rig interface204translates control signals generated by the automated rig control system202to a form suitable for communication with the legacy rig control and tool controllers206. For example, the universal rig interface204may translate digital signals generated by the automated rig control system202to mechanical motion or pneumatic signals to communicate with a tool controller via the legacy rig controls. In some implementations, the universal rig interface204translates signals from the legacy rig control and tool controllers206to a form suitable for input to the automated rig control system202. For example, the universal rig interface204may translate physical position information for mechanical control handles or pneumatic signals from legacy rig controls to electrical signals suitable for input to the automated rig control system202.

The sensors210measure operational parameters of the rig's tools and provide the measurements to the automated rig control system202for use in controlling the rig's tools. For example, the sensors210may measure the weight on the drill bit114, which is a function of operation of the draw works136, measure the rotation rate of the drill string108, which is a function of the operation of the rotary table112or top drive, and/or measure the pressure of drilling fluid in the borehole116, which is a function of the operation of the pump120. The automated rig control system202may apply such measurements in execution of an automated control program to determine whether to adjust the operation of the rig's tools (e.g., to change the speed of the pump120). The sensors210may include transducers in the drill string108, on the draw works136, on the pump120, on the rotary table112, and/or at other location of the rig100as needed to monitor and measure operation of the tools of the rig100.

The operator interface208may include a display device, such as a computer monitor, or other device to communicate information from the automated rig control system202to an operator of the rig100. The operator interface208may also include an input device, such as keyboard, a mouse, a trackball, a touchscreen, a microphone, etc. to allow an operator to provide control information to the automated rig control system202. In some implementations, the operator interface208may be embodied in a computer or computing device as known in the art. The operator interface208may be located on-site with (i.e., at a same location as) the automated rig control system202, or be remote (i.e., located at different site) from the automated rig control system202.

FIG.3shows a block diagram for an example of a universal rig interface300in accordance with the present disclosure. The universal rig interface300is an implementation of the universal rig interface134and/or the universal rig interface204. The universal rig interface300includes one or more control interfaces. The implementation of the universal rig interface300shown inFIG.3includes four types of control interfaces, other implementations of the universal rig interface300may include a different number of types of control interfaces and/or may include more than one of each type of control interface. The universal rig interface300includes a mechanical control interface302, an analog control interface304, a pneumatic control interface306, and a digital control interface308. The mechanical control interface302interfaces the automated rig control system132to mechanical control handles, such as rotary knobs, linear sliders, or switches mounted on an operator control panel. The analog control interface304interfaces the automated rig control system132to a signal line that provides communication with a tool controller via a conductor carrying an analog electrical signal. The pneumatic control interface306interfaces the automated rig control system132to a pneumatic line that provides a pneumatic control signal to a tool controller. The digital control interface308interfaces the universal rig interface134to a digital control bus, such as Modbus or Profibus, which is used to communicate digital data, such as commands and parameters, to a tool controller.

FIGS.4-6show block diagrams for example mechanical rig control interfaces in accordance with the present disclosure.FIG.4shows a block diagram for a first example of a mechanical control interface400. The mechanical control interface400is an implementation of the mechanical control interface302. The mechanical control interface400includes a coupler402, gears404, a motor406, and a sensor408. The coupler402engages a control handle of the legacy rig controls. For example, a surface of the coupler402may be in contact with a surface of the control handle so that rotational motion of the coupler402induces rotational motion in the control handle or linear motion of the coupler402induces linear motion of the control handle. That is, the coupler402adapts the control handle to be manipulated by operation of the motor406. For example, if the control handle is a rotary knob, such as a rotary knob attached to a potentiometer or switch, the coupler402may include an engaging structure that retains the coupler402to the knob and a splined shaft that extends from the engaging structure. The engaging structure may include two plates that sandwich the knob (e.g., the plates connected by screws such that the plates exert pressure on a front side and a back side of the knob). The splined shaft extends from one of the plates, engages the gears404, and is in-turn rotated by operation of the motor406. In another implementation, the coupler402includes a boot or sheath formed of a flexible material (e.g., plastic) that securely fits over and engages the control handle. A splined shaft extends from the boot and engages the gears404.

The gears404are driven by the motor406, and in turn, drive the coupler402. The gears404may provide a rotational output that is a fraction of the rotational rate of the motor406. For example, a gear ratio of the gears404may produce an output rotation rate that 1/100thof the rotation rate of the motor406. Some implementations of the gears404may include a mechanism, such as a moveable rack or a slider-crank mechanism, which converts rotation to linear motion. The motor406is an actuator (such as a stepper motor) that rotates responsive to a control signal received from the automated rig control system132. The control signal may indicate direction of rotation, speed of rotation, time of rotation, number of rotation cycles, etc. In some implementations, the gears404and the motor406may located on or at the legacy rig controls with the coupler402and the control handle manipulated by the mechanical control interface400.

The sensor408senses the position of the control handle and provides a signal indicative of the position of the control handle to the automated rig control system132. The sensor408may include a rotary encoder in some implementations of the mechanical control interface400.

In some implementations of the mechanical control interface400, the control handle may be manually manipulated by disengaging the coupler402from the control handle. For example, moving a knob (e.g., pushing or pulling) from a first position to a second position may disengage the coupler from the control handle and allow the control handle to be moved manually.

FIG.5shows a block diagram for a second example of a mechanical control interface500. The mechanical control interface500is an implementation of the mechanical control interface302. The mechanical control interface500is similar to the mechanical control interface400, and includes a flexible shaft502coupled to the gears404and the coupler402. The flexible shaft502transfers rotational force from the motor406and the gears404to the coupler402. In implementations of the mechanical control interface500, the motor406and the gears404may be isolated from the coupler402, so that the likelihood of ignition in the vicinity of the coupler402caused by operation of the motor406is reduced. For example, the coupler402is disposed on or at the control handle (e.g., on a control panel), and the motor406is disposed in a first safe container.

FIG.6shows a block diagram for a third example of a mechanical control interface600. The mechanical control interface600is an implementation of the mechanical control interface302. The mechanical control interface600is similar to the mechanical control interface500, and transfers force from the motor406and the gears404to the coupler402via hydraulic fluid602. For example, the motor406, through the gears404, may drive a piston that moves the hydraulic fluid602in a tube coupling the gears404to the coupler402. At the end of the tube proximate the coupler402, movement of the hydraulic fluid induces motion (e.g., rotational or linear motion) of the coupler402to move the control handle. In implementations of the mechanical control interface600, the motor406and the gears404may be isolated from the coupler402, so that the likelihood of ignition in the vicinity of the coupler402caused by operation of the motor406is reduced.

FIG.7shows a block diagram for an example analog control interface700in accordance with the present disclosure. The analog control interface700is an implementation of the analog control interface304. The analog control interface700includes a relay702that switches one of analog electrical control signal704, provided by the automated rig control system132, and an analog electrical control signal706, provided by the legacy rig controls, to a tool controller. That is, the automated rig control system132may be coupled to a first terminal of the relay702, the legacy rig controls coupled to a second terminal of the relay702, and the tool controller coupled to a third terminal of the relay702, wherein the relay702(e.g., under control of the automated rig control system132) switchably connects the first terminal or the second terminal to the third terminal. The relay702may be implemented as an electromechanical device or a semiconductor device. Implementations of the analog control interface700may include additional components. For example, the analog control interface700may include a digital-to-analog converter to generate the analog electrical control signal704from a digital value provided by the automated rig control system132, amplifiers, and other components. The analog control interface700may also route the analog electrical control signal706to the universal rig interface134.

FIG.8shows a block diagram for an example pneumatic control interface800in accordance with the present disclosure. The pneumatic control interface800includes pneumatic-to-voltage converter802, a voltage-to-pneumatic converter804, and a pneumatic valve806. The pneumatic-to-voltage converter802converts a pneumatic signal816provided by the legacy rig controls to an electrical signal810that is provided to the universal rig interface134. The voltage-to-pneumatic converter804converts an electrical signal814provided by the universal rig interface134to a pneumatic signal808. A first inlet of the pneumatic valve806is coupled to the legacy rig controls for receipt of the pneumatic signal816, a second inlet of the pneumatic valve806is coupled to the voltage-to-pneumatic converter804for receipt of the pneumatic signal808, and an outlet of the pneumatic valve806is coupled to a tool controller. The pneumatic valve806switchably routes (under control of the universal rig interface134) the pneumatic signal816or the pneumatic signal808to the tool controller as the pneumatic signal812.

FIG.9shows a block diagram for an example digital control interface900in accordance with the present disclosure. The digital control interface900includes a digital control bus master circuit902. The digital control bus master circuit902is coupled to a digital control bus904, and transfers information received from the automated rig control system132to a tool controller via the digital control bus904. Similarly, the digital control bus master circuit902transfers information from the tool controller to the automated rig control system132via the digital control bus904in some implementations. The digital control bus904may be, for example, Profibus, Modbus, or other digital control bus.

FIG.10shows a flow diagram for an example method1000for controlling a rig in accordance with the present disclosure. Though depicted sequentially as a matter of convenience, at least some of the actions shown can be performed in a different order and/or performed in parallel. Additionally, some implementations may perform only some of the actions shown. Operations of the method1000may be performed by the automated rig control system132.

In block1002, the automated rig control system132receives a measurement value from a sensor210of the rig100that is related to a control parameter of the rig100. The control parameter may specify, for example, rotation speed of the drill string108, pressure of the drilling fluid in the116, weight on the drill bit114, or other control parameter of the rig100.

In block1004, the automated rig control system132compares the measured value to one or more threshold values or applies the measured value in a control algorithm to determine whether the value of the control parameter should be changed.

If the value of the control parameter is to be changed, then in block1006, the automated rig control system132provides a signal to the universal rig interface134, and the universal rig interface134translates the signal to a form suitable for use by the legacy rig controls of the rig100. Further information regarding the operations performed by the universal rig interface134to translate the signal for use by the legacy rig controls of the rig100is provided inFIGS.11-14.

FIG.11shows a flow diagram for an example method1100for automated manipulation of a mechanical control handle for controlling a rig in accordance with the present disclosure. Though depicted sequentially as a matter of convenience, at least some of the actions shown can be performed in a different order and/or performed in parallel. Additionally, some implementations may perform only some of the actions shown. Operations of the method1100may be performed by implementations of the mechanical control interface302, including the mechanical control interface400, the mechanical control interface500, or the mechanical control interface600.

In block1102, the mechanical control interface400receives a signal from the automated rig control system132indicating that a legacy mechanical control handle of the rig100is to be moved. The signal may specify the direction, speed, and/or other parameters of motor operation. The mechanical control interface400activates the motor406to move the control handle.

In block1104, rotation of the motor406induces movement of the gears404, which in turn moves the coupler402and the control handle. In various implementations, force may be transferred from the motor406to the coupler402via the flexible shaft502or hydraulic fluid602.

In block1106, the sensor408measures the position of the control handle and transfers the measurement to the automated rig control system132.

In block1108, the coupler402is disengaged from the motor406to allow the control handle to be moved manually.

In block1110, a rig operator manually moves the control handle.

FIG.12shows a flow diagram for an example method1200for controlling a rig using an analog signal in accordance with the present disclosure. Though depicted sequentially as a matter of convenience, at least some of the actions shown can be performed in a different order and/or performed in parallel. Additionally, some implementations may perform only some of the actions shown. Operations of the method1200may be performed by the analog control interface700.

In block1202, the automated rig control system132sets the relay702to connect an input terminal of the relay702that is coupled to the automated rig control system132to the output terminal of the relay702, which is coupled to the tool controller.

In block1204, the relay702routes the analog electrical control signal704provided by the automated rig control system132to the tool controller.

In block1206, the automated rig control system132sets the relay702to connect an input terminal of the relay702that is coupled to a legacy rig control to the output terminal of the relay702, which is coupled to the tool controller.

In block1208, the relay702routes the analog electrical control signal706provided by the legacy rig control to the tool controller.

FIG.13shows a flow diagram for an example method1300for controlling a rig using a pneumatic signal in accordance with the present disclosure. Though depicted sequentially as a matter of convenience, at least some of the actions shown can be performed in a different order and/or performed in parallel. Additionally, some implementations may perform only some of the actions shown. Operations of the method1300may be performed by the pneumatic control interface800.

In block1302, the automated rig control system132sets the pneumatic valve806to connect an inlet of the pneumatic valve806that is coupled to the automated rig control system132to the outlet of the pneumatic valve806that is coupled to the tool controller.

In block1304, the voltage-to-pneumatic converter804converts the electrical signal814provided by the automated rig control system132to the pneumatic signal808, and the pneumatic valve806routes the pneumatic signal808to the tool controller.

In block1306, the automated rig control system132sets the pneumatic valve806to connect an inlet of the pneumatic valve806that is coupled to a legacy rig control to the outlet of the pneumatic valve806that is coupled to the tool controller.

In block1308, the pneumatic valve806routes the pneumatic signal816provided by the legacy rig control to the tool controller.

FIG.14shows a flow diagram for an example method1400for controlling a rig using a digital control bus in accordance with the present disclosure. Though depicted sequentially as a matter of convenience, at least some of the actions shown can be performed in a different order and/or performed in parallel. Additionally, some implementations may perform only some of the actions shown. Operations of the method1400may be performed by the digital control interface900.

In block1402, the automated rig control system132sets the digital control bus master circuit902to operate as a master device for accessing the digital control bus904.

In block1404, the digital control bus master circuit902transfers one or more digital values received from the automated rig control system132to the tool controller via the digital control bus904.

FIG.15shows a flow diagram for an example method1500for automating control of a rig using a universal rig interface in accordance with the present disclosure. Though depicted sequentially as a matter of convenience, at least some of the actions shown can be performed in a different order and/or performed in parallel. Additionally, some implementations may perform only some of the actions shown.

In block1502, a coupler402is mounted to a control handle of a legacy rig control. The coupler402may engage a knob to rotate the knob, or engage a slider or switch to induce linear motion.

In block1504, a motor406is attached to the coupler402. Attachment of the motor406to the coupler402may be via the gears404, the flexible shaft502, and/or the hydraulic fluid602.

In block1506the automated rig control system132is connected to the motor406.

In block1508, the automated rig control system132monitors a sensor210of the rig100.

In block1510, the automated rig control system132determines that a parameter of a tool controlled by the mechanical control interface400is to be changed, and generates an electrical control signal. The electrical control signal controls operation of the motor406.

In block1512, electrical control signal activates the motor406.

In block1514, rotation of the motor406moves the control handle via the coupler402.

In block1516, the sensor408measures the position of the control handle and provides the measurement to the automated rig control system132.

In block1518, an output terminal of the relay702is coupled to a tool controller.

In block1520, a first input terminal of the relay702is coupled to the automated rig control system132.

In block1522, a second input terminal of the relay702is coupled to a legacy rig control.

In block1524, a pneumatic outlet of the pneumatic valve806is connected to a tool controller.

In block1526, a first pneumatic inlet of the pneumatic valve806is connected to the pneumatic outlet of the voltage-to-pneumatic converter804.

In block1528, the voltage-to-pneumatic converter804is electrically coupled to the automated rig control system132.

In block1530, a second pneumatic inlet of the pneumatic valve806is connected to a pneumatic outlet of a legacy rig control, such as an outlet of a pneumatic knob or switch.

In block1532, the pneumatic outlet of a legacy rig control is connected to the pneumatic inlet of the pneumatic-to-voltage converter802.

In block1534, the pneumatic-to-voltage converter802is electrically coupled to the automated rig control system132.

In block1536, the digital control bus master circuit902is coupled to the digital control bus904and to the automated rig control system132.