Patent Publication Number: US-2022235656-A1

Title: Utilizing cobots for lab procedures for the purpose of testing and gathering data

Description:
BACKGROUND 
     The present invention relates to a system and method for performing laboratory tests suitable for wellbore operations and, in particular, to a system and method for automated testing of fluids from a wellbore. 
     In the field of drilling and completions fluids, cementing, and other oil field operations in which fluids are involved, mud checks and routine laboratory tests are conducted to determine properties and composition of fluids retrieved from a wellbore. These tests are typically conducted with the use of several specially designed testing devices and can be conducted at a rig site, or in a suitable laboratory. Testing is limited to the time during which personnel are actively working, i.e., during work hours. Also, due to the number, complexity and coordination required among these tests, there is the possibility of error on the part of the lab personnel. Accordingly, there is a need to be able to automate the performance and scheduling of these tests. 
     SUMMARY 
     Disclosed herein is a testing system for a wellbore operation. The testing system includes a first robot arm for performing a test on a fluid sample at a first test station, the fluid sample obtained from the wellbore operation, and a controller that receives data on the wellbore operation, selects the test based on the data and controls the first robot arm to perform the test, wherein a result of the test is used to adjust a parameter of the wellbore operation. 
     Also disclosed herein is a method of testing a fluid sample from a wellbore. The method includes receiving the fluid sample at a first test station, the first test station having a first robot arm for performing a test on the fluid sample, receiving data on a wellbore operation at a controller, selecting, at the controller, the test based on the data, and controlling the first robot arm via the controller to perform the test. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG. 1  shows a wellbore system in an illustrative embodiment; 
         FIG. 2  shows a schematic diagram illustrating operation of the testing laboratory of the wellbore system, in an embodiment; 
         FIG. 3  shows a detailed view of the cobot in an illustrative embodiment; 
         FIG. 4  shows the end actuator of a cobot in an illustrative embodiment; 
         FIG. 5  shows a first laboratory arrangement for a cobot with respect to a plurality of fluid test stations; 
         FIG. 6  shows a second laboratory arrangement for a cobot with respect to a plurality of test stations; 
         FIG. 7  shows a collaborative cobot system including a plurality of cobots working in collaboration with one another; and 
         FIG. 8  shows a fluid testing system  800  including interactive fluid sample delivery. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     Referring to  FIG. 1 , a wellbore system  100  is shown in an illustrative embodiment. The wellbore system  100  can be a drilling system, as shown in  FIG. 1 , or any other suitable system, such as a completion system, etc. The wellbore system  100  includes a drill string  102  for drilling a wellbore  104  in a formation  106 . The drill string  102  includes a drill bit  108  at an end thereof and defines an inner bore  114  and an annulus  116  between the drill string  102  and a wall of the wellbore  104 . 
     The wellbore system  100  further includes a mud pit  120  at a surface location  110  having a fluid  112  stored therein. Fluid  112  can include a drilling fluids or drilling mud, a completion fluid, a cementing fluid, a displacement fluid or other fluid used downhole or any combination thereof. A standpipe  122  serves as a conduit for flow of the fluid  112  from the mud pit  120  to an entry of the drill string  102  at a top of the drill string  102 . A return line  126  allows for flow of fluid  112  and any wellbore fluids and cuttings entrained in the fluid  112  from the drill string  102  to the mud pit  120 . Various devices (not shown) can be used to separate cuttings from the fluid  112  at the return line  126 . During drilling, a mud pump  124  in the standpipe  122  pumps the fluid  112  from the mud pit  120  through the standpipe  122  and into the drill string  102 . The fluid  112  flows downhole through the inner bore  114  of the drill string  102  and exits the drill string  102  via the drill bit  108  at the bottom of the wellbore  104 . The fluid  112  then flows upward to the surface through the annulus  116  and returns to the mud pit  120  via the return line  126 . 
     The return line  126  includes an inlet or valve  128  that allows the fluid  112  returning from the wellbore  104  to be collected or diverted to a testing laboratory  130 . Alternatively, fluids  112  may be collected or diverted from mud pit  120 . The testing laboratory  130  includes various equipment, disclosed in further detail herein, for performing tests on wellbore fluid, which includes the fluid  112  and/or any other fluids obtained from the wellbore  104 . The results of the tests performed at the testing laboratory  130  can be sent to a system controller  140 . 
     The system controller  140  includes a processor  142  and a memory storage device  144 . The memory storage device  144  can be a solid-state device. A set of programs  146  are stored on the memory storage device  144 . The processor  142  accesses the programs  146  in order to perform the methods disclosed herein. In various embodiments, the programs  146  can provide instructions to be used at the testing laboratory  130  to perform various tests, as disclosed herein. The system controller  140  can adjust a parameter of the wellbore system  100  based on the test results. In various embodiments, the system controller  140  can adjust a parameter of the fluid  112 , such as chemical composition, density, etc. The system controller  140  can also adjust other parameters of the wellbore operation, such as a pumping rate of mud pump  124 , etc. 
       FIG. 2  shows a schematic diagram  200  illustrating operation of the testing laboratory  130  of the wellbore system  100 , in an embodiment. The testing laboratory  130  includes a controller  202  and a test station  204 , which can be one of a plurality of test stations at the testing laboratory  130 . The test station  204  is set up to receive a fluid sample  206  and can include tools used to perform a designated test on the fluid sample obtained from the wellbore  104 . The designated test can be, for example, API filtration, HPHT (High Pressure High Temperature testing), fluid loss, titration, rheology, electrical stability, pH, VSST (Viscometer Sag Shoe Test), PPT (Particle Plugging Test), or any test or fluid test requested by an operator. The controller  202  receives data concerning a wellbore operation and determines a test that is suitable to perform on the fluid sample  206  at the test station  204  based on the data. In one embodiment, the controller  202  sends instructions to a cobot  210  (collaborative robot) to perform the test. The cobot  210  can be one of a plurality of cobots at the testing laboratory  130 . The cobot  210  operates various working devices for performing the test and obtaining test results. The test results can be communicated from the cobot  210  to the controller  202 . The controller  202  can determine an adjustment to be made to the wellbore operation based on the test results and communicates that adjustment to the system controller  140  to be implemented by the system controller  140 . Alternatively, the controller  202  can pass the test results to the system controller  140 , which determines the adjustment to the wellbore operation based on the test results and makes the adjustment. 
       FIG. 3  shows a detailed view of the cobot  210  in an illustrative embodiment. The cobot  210  includes a robot arm  304  supported by a base  302 . The robot arm  304  can include an upper arm  306 , a forearm  308  and end actuator  310 . The upper arm  306  is coupled to the base  302  via a base joint  312  that allows the upper arm  306  to rotate with respect to the base  302  along several angular directions, including up/down and circumferentially around the base  302 . The upper arm  306  is coupled to the forearm  308  via an elbow joint  314  that allows rotation of the forearm  308  about any of several axes through a selected angle with respect to upper arm or base joint. The forearm  308  is coupled to the end actuator  310  via a wrist joint  316 . Rotation about any of several axes of the wrist joint  316  changes an angular relation between the end actuator  310  and the forearm  308  along several angular directions. Coordinated operation of the base joint  312 , elbow joint  314  and wrist joint  316  can place the end actuator  310  at a selected location and orientation with respect to the base  302 . 
       FIG. 4  shows the end actuator  310  in an illustrative embodiment. The end actuator  310  can be designed to perform various operations suitable to the tests performed at the laboratory. The end actuator  310  includes a coupler  402  and a multifunctional interchangeable end-of-arm tool (MIET  404 ) that can be attached and separated from the coupler  402 . In various embodiments, the MIET  404  is a 3D printed device. The coupler  402  can grasp or couple to the MIET  404  upon receiving a coupling command from the controller  202  or can release the MIET  404  upon receiving a release command from the controller  202 . The robot arm  304  can thereby switch between MIETs based on testing requirements. Once the coupler  402  and MIET  404  are coupled, signals can be communicated between the controller  202  and the MIET  404  to operate the MIET and receive a test result from the MIET. 
     Each MIET  404  includes a plurality of support faces, such as side support surface  406  and front support surface  408 . For example, the side support surface  406  supports a first working device  410  and the front support surface  408  supports a second working device  412 . Each support face is capable having a working device attached or detached, thereby allowing the MIET  404  to have a plurality of configurations. A working device can be a device that performs a direct test on the fluid sample, such as a titration device, thermometer, etc. Alternatively, the working device can be a manipulation device that is capable of manipulation of the fluid sample or a component at the test station, such as a container, a knob, a control setting, etc. In various embodiments, the manipulation device includes a gripper for lifting and moving, a rotating collar to actuate valves, a rotating tool for fastening screws or other hardware, etc. Several working devices can be disposed on the same MIET, allowing the robot arm  304  to select a working device for use by rotating the MIET accordingly. 
     In one embodiment, the working device tool is a modified viscometer attachment for measuring the rheological properties of several preparations of fluids and a cleaning device for cleaning the viscometer between tests. In another embodiment, the working device is a pipette tool for conducting titrations, with cleanable or disposable pipettes suitable for handling different products. In other embodiments, the working device tool can include a scooping tool suitable for handling dry products, a fastener driver head for turning mechanical fasteners, etc. This list of tools is not intended to limit the scope of application of this invention. 
     Specific working devices of the MIET can vary from test station to test station. The robot arm  304  can be manipulated to rotate either of the first working device  410  and the second working device  412  into position with respect to a sample or test station to perform a test on a fluid sample using the tool. 
       FIG. 5  shows a first laboratory arrangement  500  for a cobot  210  with respect to a plurality of fluid test stations. The first laboratory arrangement  500  includes a first test station  502   a , second test station  502   b , third test station  502   c  and fourth test station  502   d , which are aligned in a row. The cobot  210  includes the robot arm  304  supported by a base  302 . The base  302  is placed on a track  504  that runs parallel to the test stations  502   a - 502   d  and is capable of moving along the track  504  under control of the controller  202 . In an illustrative example, the cobot  210  can perform a first test at the first test station  502   a  and then move to the second test station  502   b  to perform a second test. The cobot  210  can move back and forth between test stations in order to perform an action at one test station while waiting for results from another test station or during a waiting period in the test being performed at the other test station. 
       FIG. 6  shows a second laboratory arrangement  600  for a cobot  210  with respect to a plurality of test stations. The second laboratory arrangement  600  includes the plurality of test stations  602   a - 602   h  forming a group or cluster around the base  302  the cobot  210 . The robot arm  304  is capable of rotating and/or swiveling from between test stations, such as between first test station  602   a  and second test station  602   b , for example, as commanded by the master controller (not shown) to perform the tests at the respective test stations. A first MIET can be used at one first test station and then interchanged with a second MIET for use at another second test station. Alternatively, the first MIET can be used at both the first test station and the second test station. 
       FIG. 7  shows a collaborative cobot system  700  including a plurality of cobots working in collaboration with one another. The collaborative cobot system  700  includes a master controller  702 , cobot network controller  704  and the plurality of cobots  706   a - 706   d . The master controller  702  coordinates the management of tasks and data. The cobot network controller  704  manages the individual actions and movements of each cobot  706   a - 706   d . The cobot network controller  704  can prioritize tasks and determine an order of their execution, while keeping track of timed intervals and other considerations of the simultaneous tests. For example, the cobot network controller  704  can optimize when overlapping portions of simultaneous tests are to be executed. In various embodiments, this includes coordinating tasks using a time required for a cobot to perform a movement. The cobot network controller  704  can also operate one cobot to collaborate with another cobot in order to produce a test result. 
     In operation, the master controller  702  can send a requests or instruction to the cobot network controller  704 , which sends an acknowledgement of receipt of the instructions to the master controller  702 . The cobot network controller  704  then prioritizes, sequences, and executes individual tasks and records data to fulfill the request from the master controller  702 . The cobot network controller  704  then sends confirmation, data, response, or other relevant information to the master controller  702  to close the original request. 
       FIG. 8  shows a fluid testing system  800  including interactive fluid sample delivery. The fluid testing system  800  includes a testing laboratory  130  and a delivery system  802 . The testing laboratory  130  includes a controller  202  and a cobot  210 , which can be a plurality of cobots. The delivery system  802  includes a delivery controller  804  and a delivery vehicle  806  which can be a plurality of vehicles. The delivery vehicle  806  can be an autonomous terrain vehicle, remote controlled terrain vehicle, a drone, etc. The delivery vehicle  806  can include instrumentation for collection, grabbing and/or holding a test sample in order to transport the test sample. In addition to controlling operation of the cobot  210 , the controller  202  can communicate a delivery request to the delivery controller  804 . The delivery controller  804  then sends a command to the delivery vehicle  806  to pick up and deliver a fluid sample to the cobot  210  or an associated test station, thereby fulfilling the delivery request. 
     Set forth below are some embodiments of the foregoing disclosure: 
     Embodiment 1. A testing system for a wellbore operation, including: a first robot arm for performing a test on a fluid sample at a first test station, the fluid sample obtained from the wellbore operation, and a controller that receives data on the wellbore operation, selects the test based on the data and controls the first robot arm to perform the test, wherein a result of the test is used to adjust a parameter of the wellbore operation. 
     Embodiment 2. The testing system of any prior embodiment, further comprising a delivery system in communication with the controller, the delivery system configured to fulfill a delivery request from the controller to deliver the fluid sample to the first test station. 
     Embodiment 3. The testing system of any prior embodiment, further comprising an interchangeable end-of-arm tool attachable to the first robot arm for performing the test. 
     Embodiment 4. The testing system of any prior embodiment, wherein the test includes at least one selected from the group consisting of: (i) API filtration; (ii) High Pressure High Temperature testing; (iii) fluid loss; (iv) titration; (v) rheology; (vi) electrical stability; (vii) pH; (viii) Viscometer Sag Shoe Test; (ix) Particle Plugging Test; (x) any other fluid test requested by an operator. 
     Embodiment 5. The testing system of any prior embodiment, wherein the interchangeable end-of-arm tool includes a plurality of working devices disposed thereon. 
     Embodiment 6. The testing system of any prior embodiment, wherein the first robot arm is configured to move along a track between the first test station and a second test station. 
     Embodiment 7. The testing system of any prior embodiment, wherein the first robot arm is configured to rotate between the first test station and a second test station. 
     Embodiment 8. The testing system of any prior embodiment, further comprising a second robot arm, wherein the controller operates the second robot arm to collaborate with the first robot arm. 
     Embodiment 9. A method of testing a fluid sample from a wellbore, including receiving the fluid sample at a first test station, the first test station having a first robot arm for performing a test on the fluid sample, receiving data on a wellbore operation at a controller, selecting, at the controller, the test based on the data, and controlling the first robot arm via the controller to perform the test. 
     Embodiment 10. The method of any prior embodiment, further comprising communicating a delivery request from the controller to a delivery system and fulfilling the delivery request at the delivery system to deliver the fluid sample to the first test station. 
     Embodiment 11. The method of any prior embodiment, further comprising performing the test use an interchangeable end-of-arm tool attached to the first robot arm. 
     Embodiment 12. The method of any prior embodiment, wherein the test includes at least one selected from the group consisting of: (i) API filtration; (ii) High Pressure High Temperature testing; (iii) fluid loss; (iv) titration; (v) rheology; (vi) electrical stability; (vii) pH; (viii) Viscometer Sag Shoe Test; (ix) Particle Plugging Test; (x) any other fluid test requested by an operator. 
     Embodiment 13. The method of any prior embodiment, wherein the interchangeable end-of-arm tool includes a working device, further comprising removing the working device from the interchangeable end-of-arm tool. 
     Embodiment 14. The method of any prior embodiment, further comprising moving the first robot arm along a track between the first test station and a second test station. 
     Embodiment 15. The method of any prior embodiment, further comprising rotating the robot arm between the first test station and a second test station. 
     Embodiment 16. The method of any prior embodiment, further comprising controlling, via the controller, the first robot arm and a second robot arm to collaborate with each other. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity). 
     The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. 
     While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.