Abstract:
A control system for a well site, the well site includes connectable elements configured for inserting down a well. An explosion hazard zone surrounds the well site. A first electronics enclosure is remote from the explosion hazard zone and houses a first electronics module. A remote electronics control module is spaced apart from the first electronics housing and a remote hydraulics module removed from the first electronics module and the hazard zone module. The control system includes a human machine interface including a display and input. A central communications module is in wireless communication with the first electronics control module, the remote electronics module, and a remote location. A processor is in one or more of the first electronics module, the communications module or the human machine interface.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a control system and control method for an oil well site and in particular to a system for providing automation and automatic wireless control of operations at a well site. 
         [0003]    2. Description of the Prior Art 
         [0004]    Management of elements used for drilling and pumping oil from well sites has historically been largely performed manually. The harsh conditions and hazards present special challenges for connecting and protecting control electronics. Moreover, areas around the well head require certain explosion proof rated components in many uses. Wiring, switches and other connections are subject to extremely harsh and often corrosive conditions and are subject to a higher failure rate. Moreover, control equipment is also subject to harsh operating conditions and also has a higher incidence of problems. 
         [0005]    In addition, the information gathered relating to various parameters of drilling and connecting elements such as tubing or sucker rods has been limited for prior art systems. Even if such information exists, accessing and analyzing the information for modifying operations have also been limited. 
         [0006]    It can be seen then that a new and improved control and data system for oil well sites is needed. Such a system should provide for wireless communication between various components to avoid the harsh conditions and possible damage to components and connections. Moreover, the components that are at the well site should be protected in enclosures and where necessary, in explosion proof enclosures. Such a system should also provide for collecting data and real time control and reporting of various conditions associated with the well site. The data should also be storable for further analysis at a later time and should also be accessible at remote locations. The present invention addresses these as well as other problems associated with controls at oil well sites. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is directed to a wireless and automatic control and data system for oil well site control and operations. The control system includes various subsystems disposed as modules in enclosures and where possible, placed remotely from a hazardous explosion zone surrounding the well head. Wireless communication through Bluetooth, Ethernet, cellular connections or other systems provides for communication and avoids damage to wiring and other components that conventional systems are prone to. 
         [0008]    One control module is placed proximate the tong for the drill rig in a hazardous explosion zone. Explosion proof valves and control components are utilized and in communication with the tong and to control the tong. The various module elements may be enclosed in an explosion rated housing. 
         [0009]    The first electronics module is located outside the hazardous explosion zone in a sealed enclosure and is connected to the tong control system module. The first electronics control module includes an Ethernet programmable controller and provides for wireless communication to other control modules. 
         [0010]    A remote hydraulics module and a remote electronics module are spaced away from the well head at an opposite end of the drill rig. The two enclosures include wireless communication, such as Bluetooth and cellular connections. The remote electronics module is in communication with the first electronics module and includes additional controls, relays and processors. By positioning the modules away from the explosion zone, less protection is required at the remote location. The remote electronics module provides a cellular connection, radio or other wireless communication method for providing data and receiving instructions from a remote location. The remote electronics module acts as a central hub to coordinate control. 
         [0011]    A human machine interface includes a screen suitable for use even in sunlight such as an industrial touch screen so that operations may be monitored at the well site and various data from pressure transducers, load sensors and flow sensors provide information on operations is displayed to operators. The human machine interface also includes a processor and may be connected to a further enclosure providing emergency stops and other switches. The interface is preferably mounted outside the hazardous zone but within sight of the well head and tong so that operators may observe operations while also monitoring the view screen. 
         [0012]    The wireless technologies also provide for automation of the operations at the well site. The tong is controllable by processors in the electronics modules, actuating control valves and flow controls based on sensors, transducers and meters. Moreover, pressure transducers provide information regarding the stresses on the rig and provide alerts and alarms should problems be encountered. The present system also provides for acquiring data in multiple aspects of operations and provides for making real time adjustments. The information may be stored as well as being transmitted to remote locations or portable electronic devices. With such a system, improved operations are possible with operations automated as compared to conventional manually operated rigs. In addition to efficiency, safety and reliability are also improved as various components are removed from areas near the well head with control accomplished remotely. 
         [0013]    These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings that form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    Referring now to the drawings, wherein like reference letters and numerals indicate corresponding structure throughout the several views: 
           [0015]      FIG. 1  is a diagrammatic view of a system for controlling well equipment according to the principles of the present invention; 
           [0016]      FIG. 2  is a diagrammatic view showing the layout of the system of  FIG. 1 ; 
           [0017]      FIG. 3  is a flow diagram for operating the system shown in  FIG. 1 ; 
           [0018]      FIGS. 4A ,  4 B and  4 C are diagrammatic views of a first housing for electronics for the system shown in  FIG. 1 ; 
           [0019]      FIGS. 5A ,  5 B,  5 C,  5 D and  5 E are views of a second housing containing explosion rated components for the system shown in  FIG. 1 ; 
           [0020]      FIGS. 6A and 6B  are diagrammatic views of a third housing containing hydraulic equipment for the system shown in  FIG. 1 ; 
           [0021]      FIG. 6C  is an interior view of the third housing and the hydraulic equipment shown in  FIGS. 6A and 6B ; 
           [0022]      FIG. 6D  is a detail view of the hydraulic equipment shown in  FIG. 6C ; 
           [0023]      FIG. 6E  is a wiring diagram for controlling the hydraulic equipment shown in  FIGS. 6A-6D ; 
           [0024]      FIGS. 7A ,  7 B and  7 C are diagrammatic views of a fourth housing for electronic equipment located remote from the hazardous explosion zone for the system shown in  FIG. 1 ; 
           [0025]      FIGS. 8A ,  8 B and  8 C are diagrammatic views of a fifth housing containing interface equipment for the system shown in  FIG. 1 ; 
           [0026]      FIG. 9A  is a perspective view of a first embodiment of a human machine interface utilized with the fifth housing; 
           [0027]      FIG. 9B  is a front view of a second embodiment of a human machine interface utilized with the fifth housing; 
           [0028]      FIG. 10  is a side elevational view of a rig including the system shown in  FIG. 1 ; and 
           [0029]      FIG. 11  is a side elevational view of a trailer mounted system for the system shown in  FIG. 1  configured for use with a rig. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0030]    Referring now to the drawings and in particular to  FIGS. 1 and 2 , there is shown a control system  100  for acquiring and analyzing data to control equipment at a well site. The control system  100  includes multiple protected subsystems or modules. A tong hydraulics module  106  within the hazardous explosion zone  122  is protected in an explosion rated box  106 A. Other components are located remotely from the hazardous explosion zone  122 . The other control components are placed in enclosures to protect them from the elements and communicate via Bluetooth or other wireless communication. Therefore, problems associated with corrosion or other damage to wiring, relays and switches are eliminated. Moreover, the various components provide for automatic control of the tong  102  and automatic recording of operational data. The information is forwarded to a human machine interface  112  with a processor and may also be transmitted to remove locations for real time monitoring and automation of the various processes at the well site. The data and information may be sent to any type of computer readable medium including a database, a website and/or cloud storage. It can be appreciated that the hydraulic enclosure  104 A for the tong  102  is typically within the hazardous explosion zone but the other subsystems or modules are removed from the zone, so that this equipment need only comply with lower hazard ratings and standards. 
         [0031]    As shown in  FIG. 10 , the system  100  is mounted to a conventional rig  120  in one embodiment. The rig  120  typically includes a frame or floor  124  serving as a base for all other components. Such a rig  120  includes wheels  128  for driving the rig to the well site. A cab  126  is typically at one end of the rig  120  while the mast or derrick  130  is raised at the opposite end. The hydraulic enclosure  108 A and electronics enclosure  110 A are mounted for example, on the front of the rig  120 . The main electronics enclosure  104 A may be hard wired to the tong hydraulic enclosure  106 A. The human machine interface  112  may have a screen and a keypad accessible within visual range of the well head and also includes an emergency stop box  114  often mounted to the human machine interface  112  or within reach of an operator. The communication between the various subsystems are wireless except for the explosion rated hard wiring required for connection to the tong hydraulic module  106  in the explosion zone. Bluetooth Ethernet type communications  118  are provided between the components to eliminate hard wiring and associated drawbacks, but other wireless technologies could also be used. Moreover, the electronics module  110  may have equipment with a cellular connection for transmitting and receiving data, commands and other information to and from a remote control center at another location. Such a configuration provides for monitoring by owners, customers and others at locations remote from the well site and decreases the number of personnel required at the well site. 
         [0032]    The control module  104  is typically mounted so as to be in direct electrical communication with the enclosed tong hydraulic module  106  and its various components. Referring to  FIGS. 4A ,  4 B and  4 C, the first electronics subsystem  104  includes a sealed cable  142  extending to the tong  102  and the components in the tong hydraulic enclosure  106 A. Moreover, the enclosure  104 A of module  104  houses a bidirectional Bluetooth communication system  146 , a relay bank  148  and one or more power supplies  150 . Moreover, also within the box is an Ethernet system  152  and a relay bank  148 . Pressure transducers  140  are positioned to sense various weights and fluid pressures associated with the well site operations. An Ethernet programmable controller such as may be available from Wago® Corporation is combined with the other components and provides for a system that can be controlled remotely and can also be programmed for automatic control of operations. 
         [0033]    For some environments and/or applications the tong hydraulic enclosure  106 A is needed that is explosion rated. The tong hydraulic module  106  connects to the tong  102  and supplies power to hydraulic motors and to actuate and stop the tong  102 . As shown in  FIGS. 5A-5E , the tong hydraulic enclosure  106 A includes pneumatic actuators  158  as well as explosion proof valves  156 . The actuators  158  provide for operation of the tong within the hazardous explosion zone. The enclosure  106 A has an explosion proof housing that meets Class 1 standards. Moreover, the actuators  158  and valves  156  are controlled and directly connected to the electronics module  104 , which is outside the hazardous explosion zone. 
         [0034]    Referring to  FIGS. 6A-6E , the remote hydraulics subsystem  108  is located in a remote enclosure  108 A. The remote hydraulic module  108  includes a flow meter  166  and a hydraulic flow controller  162  for the tong  102  and a resistive thermal device (RTD). It can be appreciated that the flow controller may be a proportional flow controller  162  with a proportional driver  174 . A dump valve  168  and a valve bank or a single unit multifunction valve  170  also direct and control hydraulic fluid flow. Pressure transducers  172  provide additional information on operating conditions and performance. 
         [0035]    The remote hydraulics subsystem  108  is in a sealed enclosure  108 A next to or near the enclosure for the remote electronics module  110 . The remote electronics enclosure  110 A is shown in  FIGS. 7A-7C . The module  110  acts as a central processor and is the central communication hub for the control system  100 . The remote electronics system  110  includes a Bluetooth transmitter receiver and a cellular modem. The system also includes a global positioning system  180  and one or more power supplies  182 . The remote electronics subsystem  110  also includes a relay bank  186  and one or more pressure transducers  188 . An Ethernet programmable controller  184  is connected to the other components. With such a configuration, the communication and control of the other components is automated and wireless. Moreover, data can be provided both to the human machine interface  112  as well as to a remote location for analysis and/or controlling remotely well site operations of the tong  102  and the rig  120 . Information can be provided in either direction and control inputs may be received to modify operations parameters. 
         [0036]    The emergency stop module  114  shown in  FIGS. 8A ,  8 B and  8 C has a box  114 A mounting to or near the human machine interface  112 . The emergency stop enclosure  114 A includes explosion rated switches  198  and emergency stop  200 . Power supplies  202  provide power at different voltages to the module  114 . Ethernet  204  provides for communication with the remote electronics module  110 . The emergency stop module  114  also includes relays  206  and is in direct communication with the human machine interface  112 . 
         [0037]    The human machine interface  112 , such as the model shown in  FIG. 9A , may be an industrial rated computer touch screen or keyboard  212  in a frame  210 . The human machine interface  112  is preferably positioned so that it is outside the hazardous zone  122  while providing a view of the well head so an operator is able to view operations while monitoring the human machine interface  112 . The operating conditions and parameters may be monitored by an operator on the screen  212  and the operations may be modified by user input through the touch screen or other appropriate keyboard or controller. 
         [0038]    In an alternate embodiment shown in  FIG. 9B , the human machine interface  112  is mounted in a dedicated enclosure  112 A. In some embodiments the emergency stop module  114  is also housed in the enclosure  112 A. The human machine interface in the dedicated enclosure  112 A also includes a touch screen  212  and ports  214  for providing the human interface. 
         [0039]    The use of Bluetooth and Ethernet communication systems as well as other connections provide for inputs and displays to the human machine interface  112  as well as to remote monitoring locations and for storage and memory. However, operators may also utilize portable electronic devices such as telephones, PDA&#39;s, tablets, laptops etc., to receive information and give commands. 
         [0040]    As shown in  FIG. 11 , for rigs that do not have the various control modules, but have a tong, a portable trailer  300  may be utilized to provide the various remote modules. The trailer  300  includes a frame  304 , a hitch  302  and wheels  306 . A remote control module compartment  308  includes the modules shown in  FIG. 1 , except for the human machine interface. The communication to the tong may be direct with all other modules being remote and in communication with one another. This configuration also provides for safe operation as the trailer is positioned outside the hazardous zone  122 . Equipment storage  310  is also provided. 
         [0041]    Referring now to  FIG. 3 , a setup for the system is illustrated. To provide the automatic operation, inputs are made as to the type of rod or tubes being utilized including make, model, size or grade. The human machine interface  112  also provides for pulling up different screens for calibrating the various pieces of equipment prior to operation and for leading operators through equipment checks and diagnostics. Weights and other information from the pressure transducers may also be utilized to set initial conditions prior to operation. However, once all parameters have been input, the human machine interface  112 , which may include a processor loaded with appropriate software or connected to a controller with appropriate software in the remote electronics module  110 , is able to provide automatic control and operation of the tong and the rig at the well site. Moreover, information and modifications of the tong may be provided to and from remote locations or portable electronic devices. The present system  100  is also able to verify and certify the correctness of connections for tubing and/or rods and that the connecting equipment, such as the tong, is properly calibrated. 
         [0042]    It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.