Patent Publication Number: US-9845664-B2

Title: System and method for communicating with a drill rig

Description:
FIELD OF THE INVENTION 
     The present invention generally involves a system and method for communicating with a drill rig. In particular embodiments, the system and method may be incorporated into land-based or offshore drill rigs used for gas production and/or well service operation. 
     BACKGROUND OF THE INVENTION 
     Drill rigs are commonly used in oil and gas production and well service operations and include heavy duty machinery to bore substantial distances below the earth&#39;s surface. The drill rigs are often located in remote locations, and the heavy duty machinery is expensive to maintain and can cause significant personnel and equipment damage in a short period of time. In addition, changes in environmental conditions and/or the location of the drill rig may adversely affect operations and maintenance of the heavy duty machinery. As a result, local personnel are often required to monitor the operations, identify operating trends and/or imminent events, and take appropriate actions to prevent or mitigate personnel and/or equipment damage. 
     In some cases, remote monitoring of the drill rig may supplement the knowledge, training, resources, and/or experience of the local personnel to enhance the safe and efficient operation of the heavy duty equipment. For example, remote monitoring may enable more accurate and sophisticated analysis of operating parameters to improve trend analysis, facilitate maintenance scheduling, and/or anticipate imminent equipment failures or unsafe operating practices. As a result, an improved system and method for communicating with drill rigs would be useful. 
     BRIEF DESCRIPTION OF THE INVENTION 
     Aspects and advantages of the invention are set forth below in the following description, or may be obvious from the description, or may be learned through practice of the invention. 
     One embodiment of the present invention is a system for communicating with a drill rig that includes a data acquisition board on the drill rig. A plurality of sensors are on the drill rig, and each sensor transmits data associated with the drill rig to the data acquisition board. A processor on the data acquisition board is configured to execute first logic stored in a first memory that causes the processor to format the data, store the data, and transfer the data to a mobile communications device. 
     Another embodiment of the present invention is a method for communicating with a drill rig that includes sensing an operating parameter on the drill rig and transmitting data reflective of the operating parameter to a data acquisition board on the drill rig. The method further includes formatting the data with the data acquisition board and transferring the formatted data from the data acquisition board to a mobile communications device. 
     In yet another embodiment of the present invention, a method for communicating with a drill rig includes sensing an operating parameter on the drill rig and transmitting data reflective of the operating parameter to a data acquisition board on the drill rig. The method further includes formatting the data with the data acquisition board and transferring the formatted data from said data acquisition board to a database server remote from the drill rig. 
     Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the specification. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which: 
         FIG. 1  is a block diagram of an exemplary system and method for communicating with a drill rig according to one embodiment of the present invention; 
         FIG. 2  is a block diagram of a communications protocol within the scope of various embodiments of the present invention; 
         FIG. 3  is an exemplary screen shot showing data available to a customer; and 
         FIG. 4  is an exemplary screen shot showing data available to a customer. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference will now be made in detail to present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     Various embodiments of the present invention provide a system and method for communicating with a drill rig. The system generally includes one or more sensors that monitor conditions associated with the drill rig and generate data reflective of the conditions. The data may include, for example, temperature, pressure, speed, depth, weight, volume, or other operating parameters for various equipment on the drill rig. Alternately or in addition, the data may include environmental information associated with the drill rig, such as weather conditions, weather forecasts, location of the drill rig, and attitude (e.g., pitch and yaw) of the drill rig. The sensors transmit or otherwise communicate the data to a data acquisition board on the drill rig, and the data acquisition board formats the data for temporary storage. Periodically or continuously, the data acquisition board synchronizes the stored data with a portable communications device such as a smart phone or a tablet, and the portable communications device transmits the stored data to a database server remote from the drill rig. Alternately or in addition, the data acquisition board may transmit the stored data directly to the database server. The database server allows a customer to access the data. Alternately or in addition, the database server may compare the data to a predetermined baseline parameter or operating limit and notify the customer when the data approaches or exceeds one or more predetermined baseline parameters or operating limits. In this manner, the systems and methods described herein enable a customer to remotely communicate with the drill rig to receive real time or near real time data from the drill rig. 
     The present disclosure refers to sensors, processors, database servers, logic, memory, and other computer-based systems, as well as actions taken and information sent to and from such systems. One of ordinary skill in the art will recognize that the inherent flexibility of computer-based systems allows for a great variety of possible configurations, combinations, and divisions of tasks and functionality between and among components. For instance, methods discussed herein may be implemented using a single server or multiple servers working in combination. Similarly, databases and logic for manipulating the databases may be implemented on a single system or distributed across multiple systems sequentially or in parallel. Data transferred between components may travel directly or indirectly. For example, if a first device accesses a file or data from a second device, the access may involve one or more intermediary devices, proxies, and the like. The actual file or data may move between the components, or one device may provide a pointer or metafile that the other device uses to access the actual data from a still further device. 
     The various computer systems discussed herein are not limited to any particular hardware architecture or configuration. Embodiments of the methods and systems set forth herein may be implemented by one or more general-purpose or customized computing devices adapted in any suitable manner to provide desired functionality. The device(s) may be adapted to provide additional functionality complementary or unrelated to the present subject matter, as well. For instance, one or more computing devices may be adapted to provide desired functionality by accessing logic or software instructions rendered in a computer-readable form. When software is used, any suitable programming, scripting, or other type of language or combinations of languages may be used to implement the teachings contained herein. However, software need not be used exclusively, or at all. For example, some embodiments of the systems and methods set forth herein may also be implemented by hard-wired logic or other circuitry, including, but not limited to application-specific circuits. Of course, combinations of computer-executed software and hard-wired logic or other circuitry may be suitable, as well. 
     Embodiments of the systems and methods disclosed herein may be executed by one or more suitable computing devices. Such system(s) may comprise one or more computing devices adapted to perform one or more embodiments of the methods disclosed herein. As noted above, such devices may access one or more computer-readable media that embody computer-readable instructions which, when executed by at least one computer, cause the computer(s) to implement one or more embodiments of the methods of the present subject matter. Additionally or alternately, the computing device(s) may comprise circuitry that renders the device(s) operative to implement one or more of the methods of the present subject matter. Furthermore, components of the presently-disclosed technology may be implemented using one or more computer-readable media. Any suitable computer-readable medium or media may be used to implement or practice the presently-disclosed subject matter, including, but not limited to, diskettes, drives, and other magnetic-based storage media, optical storage media, including disks (including CD-ROMs, DVD-ROMs, and variants thereof), flash, RAM, ROM, and other memory devices, and the like. 
     Referring now to the drawings, wherein identical numerals indicate the same elements throughout the figures,  FIG. 1  provides a block diagram of an exemplary system and method  10  for communicating with a drill rig  12  according to one embodiment of the present invention. As shown in  FIG. 1 , the system and method  10  may include a communication link  14  that operably connects one or more sensors  16  to a data acquisition board  18  on the drill rig  12 . The communications link  14  may include one or more wired, wireless, or other suitable communication links known to one of ordinary skill in the art for transferring data between components. 
     The sensors  16  monitor parameters associated with the drill rig  12 , equipment on the drill rig  12 , and/or the environment of and around the drill rig  12 . Examples of suitable sensors  16  within the scope of the present invention include a GPS sensor  20 , a block and tackle sensor  22 , a sand line sensor  24 , a weather sensor  26 , and even a user-defined sensor  28 . The user defined sensor  28  enables a customer to identify another sensor to transmit data to the data acquisition board  18 . In addition, logic  36  on the data acquisition board  18  and/or database server  38  may enable the customer to define and/or modify the baseline parameter or operating limit for one or more of the sensors  16 . Each sensor  16  may transmit a specific type of data  30  associated with the drill rig  12  through the communications link  14 . The data  30  may thus include information related to rig safety, equipment maintenance requirements, rig operating parameters, and other data of interest to rig management personnel. 
     The data acquisition board  18  may be contained within a protective housing on the drill rig  12  to insulate the data acquisition board  18  from the environment. The degree and type of protection the housing provides is dictated by the environment in which the data acquisition board  18  is used (e.g., weather proof, hermetically sealed, etc.). The data acquisition board  18  generally includes a processor  32  and memory  34  for receiving the data  30  associated with the drill rig  12  from the sensors  16 . The processor  32  is configured to execute logic  36  stored in the memory  34  that causes the processor  32  to perform various functions on the data  30 . For example, execution of the logic  36  may cause the processor  32  to format and store the data  30  for later transfer to a database server  38  remote from the drill rig  12 . In this manner the data acquisition board  18  may concatenate all of the data  30  from each sensor  16  by converting the data  30  to a desired format and size before transferring the data  30  to the database server  38  remote from the drill rig  12 . 
     Alternately or in addition, execution of the logic  36  may enable to the processor  32  to perform or participate in a communications protocol that enables the processor  32  to transfer the data  30  to a mobile communications device  40  such as a smart phone or tablet on the drill rig  12  for subsequent transfer to the database server  38  when communications are available.  FIG. 2  provides a block diagram of an exemplary communications protocol within the scope of various embodiments of the present invention that may be incorporated into an application installed in the mobile communications device  40 . At block  42 , the mobile communications device  40  interfaces or connects to the processor  32  through a wired or wireless connection  44 . This interface or connection may be at scheduled times or at predetermined intervals. For example, the mobile communications device  40  may initiate a Bluetooth® wireless connection to the data acquisition board  18  at 6 a.m., 12 p.m., 6 p.m., etc. or every 10 minutes since the last successful connection. Once communication with the data acquisition board  18  is established, the mobile communications device  40  and/or the processor  32  may identify the most recent data  30  transfer either to the database server  38  directly or to the mobile communications device  40 , and the processor  32  may then transfer or synchronize all additional data  30  received from the sensors  16  and formatted since that time. 
     At block  46 , the mobile communications device  40  may continuously or periodically check for internet access, and when internet access becomes available, the mobile communications device  40  may transfer all of the formatted data  30  through the internet to the database server  38 , indicated by block  48 . At block  50 , the mobile communications device  40  may wait for confirmation that the data  30  transfer was complete. If the confirmation is received, the mobile communications device  40  returns to block  42  to wait for the next scheduled communication with the data acquisition board  18 . Otherwise, the mobile communications device  40  returns to block  46  to check for internet access again. 
     Returning to  FIG. 1 , the database server  38  is configured to receive the formatted data  30  directly from the data acquisition board  18  or indirectly from the mobile communications device  40 . The database server  38  may be, for example, a Redhat™ Linux server executing logic  52  to receive the formatted data  30  from multiple sources simultaneously, reconcile the data  30  to eliminate duplicate data  30 , and/or convert the formatted data  30 , as desired, to ASCII or another high level language for incorporation into a database. At block  54 , the logic  52  may also cause the database server  38  to compare the data  30  to a predetermined limit and generate a notification  56  when one or more pieces of data  30  associated with a particular piece of equipment deviate from a baseline parameter or operating limit. The notification  56  may be assigned a priority level based on severity of the deviation from the baseline parameter or operating limit. For instance, a warning notification  56  may indicate that a relatively minor deviation from a baseline parameter or operating limit has occurred. In contrast, an alarm notification  56  may indicate that a significant deviation from a baseline parameter or operating limit has occurred. 
     As further shown in  FIG. 1 , the notifications  56  may be transmitted to a graphical user interface (GUI)  58  selected by a customer. The GUI  58  may be, for example, a smart phone, tablet, computer, or other communications device selected by the customer for receiving notifications  56  from the database server  38 . In this manner, the customer may select the method (e.g., e-mail, text, dashboard alert, etc.) by which the customer may receive notifications  56  from the database server  38 . Alternately or in addition, the GUI  58  may enable the customer to directly access data  30  and/or notifications  56  stored in the database server  38  for each drill rig  12  in the customer&#39;s account, and  FIGS. 3 and 4  provide exemplary screen shots of the GUI  58  showing the data  30  available to the customer. As shown in  FIG. 3 , for example, the GUI  58  may display “RIG INFORMATION”  60  to identify the particular drill rig  12  and “WEATHER DATA”  62  local to that particular drill rig  12 . In this exemplary screen shot, the GUI  58  may additionally display real time or near real time equipment readings  64 , video streams  66 , and/or GPS data  68 . Alternately or in addition, the GUI  58  may display a record of previous notifications  70  and/or graphs of various selected operating parameters over time  72  to enable the customer to promptly respond to previous notifications  56  and/or anticipate and avoid future notifications  56 . 
     As previously discussed with respect to  FIG. 1 , the logic  36  in the data acquisition board  18  may enable the customer to create one or more user-defined sensors  28  to monitor particular equipment and/or conditions on the drill rig  12 . In addition, the logic  36  in the data acquisition board  18  and/or the logic  52  executed by the database server  38  may enable the customer to enable (i.e., turn on) a particular sensor  16  and/or adjust the baseline parameter or operating limit used to generate notifications  56 . Referring to the screen shot shown in  FIG. 4  , for example, the customer has enabled or selected several sensors  80 —i.e., engine temperature, oil pressure, fuel levels, fuel temperature, transmission temperature and pressure, battery and alternator voltages, etc.—for the data acquisition board  18  to monitor and display on the GUI  58 . In addition, the customer has adjusted or enabled various baseline parameters or operating limits  82  for one or more of the user-defined sensors  28  to generate desired notifications  56  that enhance the customer&#39;s real time or near real time monitoring of events and conditions on the drill rig  12 . 
     The system and method  10  described and illustrated with respect to  FIGS. 1-4  enhances a customer&#39;s ability to efficiently receive and analyze data  30  associated with a particular drill rig  12 . For example, the system and method  10  of the present disclosure include the ability to provide real time or near real time updates from the drill rig  12  with no manual action by the customer, thereby enhancing on-time detection and diagnosis of anomalies. Alternately or in addition, the customer may configure different types of sensors  16 , baseline parameters, and/or operating limits for each drill rig  12 , depending on various factors specific to each drill rig  12 , such as the prevailing issues, history, and/or personnel associated with each drill rig  12 . 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.