MARINE RISER MANAGEMENT SYSTEM AND AN ASSOCIATED METHOD

In accordance with one aspect of the present technique, a method is disclosed. The method includes receiving sensor data from a first set of sensors mechanically coupled to a first riser joint of a marine riser. The method also includes analyzing the sensor data to determine a condition of the first riser joint and determining whether the condition satisfies a transmission criterion. The method further includes sending a notification including the condition to an on-vessel monitor communicatively coupled to the marine riser in response to determining that the condition satisfies the transmission criterion.

BACKGROUND

The subject matter disclosed herein generally relates to a marine riser management system. More specifically, the subject matter relates to a system and a method for analyzing sensor data received from sensors coupled to a marine riser and transmitting the sensor data to an on-vessel monitor based on the analysis.

Marine risers are components used in offshore drilling of hydrocarbons and production operations conducted from a vessel on the ocean surface. Marine risers are vertical structures that extend miles in length connecting the vessel and a well head on the ocean floor. The marine riser needs to be successfully deployed into the ocean and maintained over their lifespan (e.g., 20 years) in challenging environments while meeting safety and regulatory requirements.

Existing riser management systems include sensors that are coupled to a marine riser. Such systems have numerous problems due to limitations in the retrieval of sensor data by monitors deployed on the vessel. For example, the monitor receives sensor data from loggers coupled to the sensors. Such systems are disadvantageous as the loggers include large amounts of non-readily interpreted sensor data. Moreover, the retrieval of sensor data from the loggers typically occurs post-process, i.e., after the drilling or production operation is complete. In another example, the monitor receives sensor data via data transmission systems (e.g., acoustic data transmission) that are coupled to the sensors. Such systems are disadvantageous as the sensor data received by the monitor is semi real-time (e.g., once a day, once in 12 hours, and the like) due to low transmission rates and power constraints of the data transmission system.

Thus, there is a need for an enhanced marine riser management system.

BRIEF DESCRIPTION

In accordance with one aspect of the present technique, a method includes receiving sensor data from a first set of sensors mechanically coupled to a first riser joint of a marine riser. The method also includes analyzing the sensor data to determine a condition of the first riser joint and determining whether the condition satisfies a transmission criterion. The method further includes sending a notification including the condition to an on-vessel monitor communicatively coupled to the marine riser in response to determining that the condition satisfies the transmission criterion.

In accordance with one aspect of the present systems, a system includes a communication module configured to receive sensor data from a first set of sensors mechanically coupled to a first riser joint. The system also includes an analysis module configured to analyze the sensor data to determine a condition of the first riser joint. The system also includes a decision module configured to determine whether the condition satisfies a transmission criterion. The system further includes a notification module configured to send a notification including the condition to an on-vessel monitor communicatively coupled to the marine riser in response to determining that the condition satisfies the transmission criterion.

In accordance with one aspect of the present technique, a computer program product encoding instructions is disclosed. The instructions when executed by a processor, causes the processor to receive sensor data from a first set of sensors mechanically coupled to a first riser joint of a marine riser. The instructions further cause the processor to analyze the sensor data to determine a condition of the first riser joint and determine whether the condition satisfies a transmission criterion. The instructions further cause the processor to send a notification including the condition to an on-vessel monitor communicatively coupled to the marine riser in response to determining that the condition satisfies the transmission criterion.

DETAILED DESCRIPTION

As used herein, the terms “software” and “firmware” are interchangeable, and may include any computer program stored in memory for execution by devices that include, without limitation, mobile devices, clusters, personal computers, workstations, clients, and servers.

As used herein, the term “computer” and related terms, e.g., “computing device”, are not limited to integrated circuits referred to in the art as a computer, but broadly refers to at least one microcontroller, microcomputer, programmable logic controller (PLC), application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein.

A system and method for transmitting sensor data of a marine riser is described herein.FIG. 1illustrates a block diagram of a riser management system100according to one embodiment. In the illustrated embodiment, the riser management system100includes a vessel110, a marine riser120, and a well head140. The vessel110may be any type of ship or platform floating on the ocean surface configured to perform offshore drilling of hydrocarbons and production operations. In the illustrated embodiment, the vessel110further includes an on-vessel monitor115configured to receive a condition and/or sensor data of the marine riser120via a transceiver (not shown). The on-vessel monitor115may include a processor, a memory, and a display device for further processing and displaying the condition and/or sensor data to, for example, a drilling contractor, an administrator of the riser management system100, and the like. In one embodiment, the on-vessel monitor115may be further configured to send the condition and/or sensor data to an on-shore monitor (not shown) for further analytics of, for example, an oil leak situation, a riser replacement requirement, and the like. The sensor data and the condition are described below in further detail with reference toFIG. 2.

The marine riser120may be a vertical structure that acts as a sealed pathway between the vessel110and the well head140on the ocean surface. In one embodiment, the marine riser120may be a drilling riser that is used for, for example, pumping down lubricants, extracting drilling mud and drill cuttings, and the like, during drilling operations. In another embodiment, the marine riser120may be a production riser that is used for, for example, extracting hydrocarbons from the ocean floor. In the illustrated embodiment, the marine riser120includes a plurality of riser joints130,132and134that are connected to the each other by, for example, bolted flanges. Each riser joint130,132, and134is mechanically coupled to a plurality of sensors (218,220, and222respectively) and a data transmission device (228,230, and232respectively) for sending a condition and/or sensor data of the riser joint130,132, and134to the on-vessel monitor115.

FIG. 2illustrates a plurality of sensors220and a data transmission device230mechanically coupled to the riser joint132according to the embodiment ofFIG. 1. The data transmission device230and the plurality of sensors220are communicatively coupled to each other via a network290. The network290may be a wired or wireless communication type, and may have any number of configurations such as a star configuration, token ring configuration, or other known configurations. Furthermore, the network290may include a local area network (LAN), a wide area network (WAN) (e.g., the Internet), and/or any other interconnected data path across which multiple devices may communicate. In one embodiment, the network290may be a peer-to-peer network. The network290may also be coupled to or include portions of a telecommunication network for transmitting data in a variety of different communication protocols. In another embodiment, the network290includes Bluetooth communication networks or a cellular communications network for transmitting and receiving data such as via a short messaging service (SMS), a multimedia messaging service (MMS), a hypertext transfer protocol (HTTP), a direct data connection, WAP, email, and the like. While only one network290is shown coupled to the plurality of sensors220and the data transmission device230, a plurality of networks290may be coupled to the entities.

The plurality of sensors220may include any type of sensors that are configured to measure one or more physical parameters of the riser joint132. In one embodiment, the plurality of sensors220includes one or more strain gauges configured to measure the strain of the riser joint132. In another embodiment, the plurality of sensors220includes an accelerometer/motion sensor configured to measure, for example, a displacement, velocity, an acceleration, and the like, of the riser joint132. In yet another embodiment, the plurality of sensors220includes a curvature sensor/inclinometer configured to measure a roll and pitch angle of the riser joint132. The plurality of sensors220is further configured to send the sensor data (i.e., strain data, displacement, pitch angle, and the like) to the data transmission device230via the network290. The plurality of sensors220are coupled to the network290via a signal line225. Although in the illustrated embodiment, a plurality of sensors220are shown, in other embodiments, a single sensor may be coupled to the riser joint132.

The data transmission device230may be any device that is configured to analyze the sensor data received from the plurality of sensors220and transmit the sensor data and/or a condition of the riser joint132to the on-vessel monitor115. The data transmission device230includes a decisioning application240, a processor250, a memory260, and a transceiver270. The decisioning application240includes a communication module242, an analysis module244, a decision module246, and a notification module248. The plurality of modules of the decisioning application240, the processor250, the memory260, and the transceiver270may be coupled to a bus (not shown) for communication with each other. The data transmission device230is coupled to the network290via a signal line235. Although in the illustrated embodiment, one data transmission device230is shown, in other embodiments, a plurality of data transmission devices may be coupled to the riser joint132.

The processor250may include at least one arithmetic logic unit, microprocessor, general purpose controller or other processor arrays to perform computations, and/or retrieve data stored on the memory260. In another embodiment, the processor250is a multiple core processor. The processor250processes data signals and may include various computing architectures including a complex instruction set computer (CISC) architecture, a reduced instruction set computer (RISC) architecture, or an architecture implementing a combination of instruction sets. The processing capability of the processor250in one embodiment may be limited to supporting the retrieval of data and transmission of data. The processing capability of the processor250in another embodiment may also perform more complex tasks, including various types of feature extraction, modulating, encoding, multiplexing, and the like. In other embodiments, other type of processors, operating systems, and physical configurations are also envisioned.

The memory260may be a non-transitory storage medium. For example, the memory260may be a dynamic random access memory (DRAM) device, a static random access memory (SRAM) device, flash memory or other memory devices. In one embodiment, the memory260also includes a non-volatile memory or similar permanent storage device, and media such as a hard disk drive, a floppy disk drive, a compact disc read only memory (CD-ROM) device, a digital versatile disc read only memory (DVD-ROM) device, a digital versatile disc random access memory (DVD-RAM) device, a digital versatile disc rewritable (DVD-RW) device, a flash memory device, or other non-volatile storage devices.

The memory260stores data that is required for the decisioning application240to perform associated functions. In one embodiment, the memory260stores the modules (e.g., the communication module242, the decision module246, and the like) of the decisioning application240. In another embodiment, the memory260stores transmission criteria (e.g., a stress threshold value, a criterion mode shape, a fatigue threshold value, and the like) that are defined by, for example, a drilling operator, an administrator of the data transmission device230or the riser management system100. The transmission criteria are described below in further detail with reference to the decisioning application240.

The transceiver270is any device configured to receive any sensor data from the plurality of sensors220and send the sensor data and/or condition of the riser joint132to the on-vessel monitor115. The transceiver270may include any type of data communication, for example, acoustic communication, optical communication, electromagnetic communication, hardwired communication, and the like.

The communication module242includes codes and routines configured to handle communications between the plurality of sensors220and the other modules of the decisioning application240. In one embodiment, the communication module242includes a set of instructions executable by the processor250to provide the functionality for handling communications between the plurality of sensors220and the other modules of the decisioning application240. In another embodiment, the communication module242is stored in the memory260and is accessible and executable by the processor250. In either embodiment, the communication module242is adapted for communication and cooperation with the processor250and other modules of the decisioning application240.

In one embodiment, the communication module242receives sensor data from the plurality of the sensors220via the network290. For example, the communication module242receives the sensor data in real-time at a data sampling rate of at least 10 hertz. In another example, the communication module242receives the sensor data in response to sending a request for sensor data to the plurality of sensors220. The sensor data received from the plurality of sensors220includes, for example, strain data, a displacement, a velocity, an acceleration, a roll angle and a pitch angle of the riser joint132. In another example, the communication module242further receives sensor data associated with one or more neighboring riser joints130and134of the marine riser120. In such an embodiment, the communication module242sends the received sensor data to the analysis module244. The communication module242may also perform analog to digital conversion, noise filtering, and the like, prior to sending the sensor data to the analysis module244. In another embodiment, the communication module242receives a notification including, for example, a condition of the riser joint132from the notification module248. In such an embodiment, the communication module242sends the notification to the on-vessel monitor via the transceiver270.

The analysis module244includes codes and routines configured to determine a condition of the riser joint132based on the received sensor data. In one embodiment, the analysis module244includes a set of instructions executable by the processor250to provide the functionality for determining a condition of the riser joint132. In another embodiment, the analysis module244is stored in the memory260and is accessible and executable by the processor250. In either embodiment, the analysis module244is adapted for communication and cooperation with the processor250and other modules of the decisioning application240.

The analysis module244analyzes the sensor data received from the communication module242to determine a condition of the riser joint132. In one embodiment, the analysis module244is further configured to remove noise from the received sensor data prior to determining a condition of the riser joint132. In one embodiment, the analysis module244analyzes the sensor data to determine a stress level as the condition of the riser joint132. For example, the analysis module244calculates the stress level of the riser joint132based on the strain data received from the communication module242. In another example, the analysis module244calculates the stress level of the riser joint132based on the strain data, the curvature (i.e., the roll and the pitch angle) of the riser joint132. In a further example, the analysis module244calculates the stress level of the riser joint132based on a stress amplification factor. The analysis module244retrieves the stress amplification factor from the memory260. The stress amplification factor is dependent on the position/depth of the riser joint132in the ocean and is defined by, for example, an administrator of the data transmission device230.

In another embodiment, the analysis module244analyzes the sensor data to determine a vibrational characteristic as the condition of the riser joint132. The analysis module244determines the vibrational characteristic based on at least one of the displacement, the velocity, the acceleration, and the strain data of the riser joint132. The vibrational characteristic of the riser joint132includes, for example, a vibrational frequency, a vibrational mode shape, and the like. For example, the analysis module244determines the vibrational frequency and the vibrational mode shape of the riser joint132based on the strain data, using finite element analysis.

Referring now toFIG. 3, a graphical representation300of vibrational mode shapes of a marine riser illustrated according to one embodiment. In the illustrated embodiment, the graph300includes curves representing five different vibrational mode shapes (i.e., mode-1310, mode-2320. mode-3330, mode-4340, and mode-5350) of a marine riser during drilling operation.

Referring back toFIG. 2, in another embodiment, the analysis module244analyzes the sensor data to determine a fatigue level as the condition of the riser joint132. The analysis module244calculates the fatigue level of the riser joint132based on at least one of the strain data, the stress level, and the vibrational characteristic of the riser joint132. In yet another embodiment, the analysis module244receives additional sensor data from a plurality of sensors218,222coupled to one or more neighboring riser joints130,134. In such an embodiment, the analysis module244analyzes the additional sensor data and the sensor data received from the plurality of sensors220to determine a condition of the riser joint132. For example, the analysis module244calculates the strain level of the riser joint132based on the strain data received from the plurality of sensors220and the strain data received from the plurality of sensors218,222coupled to the riser joints130,134. In the above described embodiments, the analysis module244is further configured to send the condition and the sensor data used to determine the condition, to the decision module246.

The decision module246includes codes and routines configured to determine whether a condition of the riser joint132satisfies a transmission criterion. In one embodiment, the decision module246includes a set of instructions executable by the processor250to provide the functionality for determining whether the condition of the riser joint132satisfies the transmission criterion. In another embodiment, the decision module246is stored in the memory260and is accessible and executable by the processor250. In either embodiment, the decision module246is adapted for communication and cooperation with the processor250and other modules of the decisioning application240.

The decision module246receives the condition of the riser joint132and determines whether the received condition satisfies the transmission criterion. The decision module246retrieves the transmission criterion from the memory260. The transmission criterion is defined by, for example, a drilling contractor, an administrator of the data transmission device230, and the like. If the decision module246determines that the condition satisfies the transmission criterion, the decision module246sends a message to the notification module248for sending a notification to the on-vessel monitor115. The message includes the condition and the sensor data used by the analysis module244to determine the condition.

In one embodiment, the decision module246receives a stress level of the riser joint132and determines whether the received stress level exceeds a stress threshold value (i.e., the transmission criterion). For example, the decision module246receives the stress level of the riser joint132as 70%. In such an example, the decision module246determines that the received stress level exceeds a stress threshold value of 65% and sends a message to the notification module248.

In another embodiment, the decision module246receives a vibrational characteristic of the riser joint132and determines whether the vibrational characteristic satisfies a transmission criterion. For example, the decision module246receives the vibrational frequency as 7 hertz. In such an example, the decision module246determines that the received vibrational frequency is within a frequency threshold range of 5 hertz-10 hertz and sends a message to the notification module248. In another example, the decision module246receives the vibrational mode shape of the riser joint132as mode-4340(See,FIG. 3). In such an example, the decision module246does not send the message to the notification module248, since the received vibrational mode shape does not match mode-2320(See,FIG. 3), i.e., the criterion mode shape.

In yet another embodiment, the decision module246receives the fatigue level of the riser joint132and determines whether the received fatigue level satisfies a transmission criterion. For example, the decision module246receives a fatigue level of the riser joint132as 80%. In such an example, the decision module246determines that the received fatigue level exceeds a fatigue threshold value of 50% and sends a message to the notification module248.

The notification module248includes codes and routines configured to send a notification to the on-vessel monitor115. In one embodiment, the notification module248includes a set of instructions executable by the processor250to provide the functionality for sending the notification to the on-vessel monitor115. In another embodiment, the notification module248is stored in the memory260and is accessible and executable by the processor250. In either embodiment, the notification module248is adapted for communication and cooperation with the processor250and other modules of the decisioning application240.

The notification module248receives a message from the decision module246and sends a notification to the on-vessel monitor115via the transceiver270. In one embodiment, the notification includes the condition (e.g., stress level, a vibrational mode shape, and the like) of the riser joint132that satisfies the transmission criterion. In another embodiment, the notification includes the condition of the sensor data and the sensor data used by the analysis module244to determine the condition. In yet another embodiment, the notification includes an instruction based on the condition of the riser joint132. For example, if the decision module246determines that the stress level of the riser joint132exceeds the threshold stress value (i.e., transmission criteria), the notification module248sends a notification including the stress level of the riser joint132, the sensor data, and an instruction to the on-vessel monitor115. In such an example, the instruction instructs the on-vessel monitor115to adjust the tension of the marine riser120.

In yet another embodiment, the notification module248generates data for providing a user interface including the condition of the riser joint132to, for example, a drilling contractor. In such an embodiment, the notification module248sends the notification to a display device included in the on-vessel monitor115. The display device renders the data and graphically displays actionable information to the user interface.

FIG. 4illustrates a flow diagram400of a method for transmitting sensor data of a riser joint according to one embodiment. The communication module receives sensor data from a first set of sensors coupled to a first riser joint of a marine riser402. For example, the communication module receives strain data and the displacement of the riser joint132(See,FIG. 1) from the plurality of sensors in real-time at a data sampling rate of at least 10 hertz. The communication module also receives additional data from a second set of sensors coupled to a second riser joint of the marine riser404. For example, the communication module receives strain data and displacement of the riser joint134(See,FIG. 1) in real-time.

The analysis module analyzes at least one of the sensor data and the additional data to determine a condition of the riser joint406. In the above example, the analysis module calculates a stress level and a vibrational mode shape of the riser joint132(See,FIG. 1) in real-time based on the received sensor data and the additional data. The decision module determines whether the condition of the riser joint satisfies a transmission criterion408. In the above example, the decision module determines whether the calculated stress level of the riser joint132(See,FIG. 1) exceeds a threshold stress value. The decision module further determines whether the calculated vibrational mode shape of the riser joint matches a criterion mode shape. The notification module sends a notification including the condition to an on-vessel monitor communicatively coupled to the marine riser in response to determining that the condition satisfies the transmission criterion410. In the above example, the notification module sends a notification to the on-vessel monitor as the decision module determines that the calculated vibrational mode shape of the riser joint132(See,FIG. 1) matches mode-2320(See,FIG. 3), i.e., the criterion mode shape.

The above described riser management system is advantageous compared to conventional riser management systems, as the sensor data is analyzed in real-time for determining a condition of each riser joint of a marine riser. Additionally, instead of sending large amounts of non-interpreted sensor data to the on-vessel monitor, transmitting the condition that satisfies a transmission criterion and the sensor data used to determine the condition, is advantageous due to the low data transmission rates and high power consumption of the existing data transmission systems.

It is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

While the subject matter has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the inventions are not limited to such disclosed embodiments. Rather, the subject matter can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the inventions. Additionally, while various embodiments of the subject matter have been described, it is to be understood that aspects of the inventions may include only some of the described embodiments. Accordingly, the inventions are not to be seen as limited by the foregoing description, but are only limited by the scope of the appended claims. What is claimed as new and desired to be protected by Letters Patent of the United States is: