Note: Descriptions are shown in the official language in which they were submitted.
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METHODS AND APPARATUS FOR INTERACTIVE COMMUNICATIONS
WITH SERVICE AND SUPPORT PERSONS
The invention relates to communication systems. More particularly, the
invention relates to an interactive communication system for off site service
and support
personnel.
Complex industrial equipment can be found at wellsites and platforms; nuclear
and fossil fuel power generating plants; oil refineries; petroleum and
chemical
processing plants, and manufacturing facilities. All of the equipment requires
periodic
inspection, maintenance, and troubleshooting by service personnel. In the oil
and gas
industry for example, service and support personnel include engineers,
technicians,
specialists, and consultants that are called upon to interact with on-site
personnel.
Because the profits that such a complex systems can generate may run into the
millions
of dollars per day, the pressures to keep the systems operating continuously
and
efficiently is often immense. The nature of the problems requiring service and
support
however, create difficulties in providing services in a time and cost
effective manner.
Most service and support personnel are based at a home base or office, and
each person
often services multiple sites. The actual time that these service personnel
spend
performing their specialised task at a particular location is frequently a
very small
portion of the total time associated with the job. This is due to the
transportation time to
and between the various sites to be serviced, which are frequently located in
distant
parts of the world. Another reason for the relatively small amount of actual
work-time
is that, due to the specialised nature of the equipment and training of the
service
persoxmel, each service person frequently services a small piece of the
overall complex
system. Once on-site, the service person's schedule is often affected by
unscheduled
delays in othex parts of that overall system. For example, it is not uncommon
for
service personnel to be on-site at a remotely located oil platform for several
days before
beginning a task that requires only a day once they gain exposure to the
system. Also,
due to distances and logistical issues associated with transportation to these
remote
locations, the service persormel often cannot return to their home bases
temporarily or
do other productive work at the location.
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Off site, specialised service personnel are needed immediately when there are
malfunctions or failures in equipment, particularly when the malfunction or
failure has
slowed or shut dome a major or important part of an overall operation.
Currently,
service persoimel are not always readily available when such emergencies arise
due to
the geographic distance between service personnel and the operation or because
of other
professional or personal conflicts. Further, service personnel often require
written
procedures in order to effectively carry out their function in relation to a
certain piece of
complex machinery. For example, service personnel often have to be onsite to
evaluate
which procedure is to be performed and then must arrange access to the
procedures
which are usually dispatched for the home office. The procedures are typically
needed
and utilised in some written format and it can be difficult at times to access
a certain
procedure at certain times, such as at night or during weekends. Another
problem
associated with conventional methods of servicing remote equipment relates to
records
that must be prepared describing an operation performed on machinery.
Preparation of
the records is essential as a historical document and also is utilised to
prepare an invoice
of services. Currently, the record is created either during or after the work
is performed
and is a separate, time consuming task.
There is a need therefore, for a portable, interactive communication system
for
use between the location of complex equipment and the home office of service
personnel, whereby service personnel can monitor, diagnose and provide advice
and
solutions to problems arising with and around the equipment. There is a
further need
for a portable, interactive communication system for use between the location
of
complex equipment and the home office of service personnel, whereby service
personnel located at the complex equipment can interact directly with their
own office,
transmitting and receiving information therefrom. There is a further need for
a portable,
interactive communication system for use between the location of complex
equipment
and the home office of service personnel, whereby locally situated service
personnel can
interact directly with more experienced or more specially trained personnel at
their
home office, transmitting and receiving information therefrom. Using the
communication system and through a less-trained on-site person, experienced
personnel
can make informed evaluations about the on-site situation, and prescribe an
appropriate
remedy for a problem.
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There is a further need for a portable, interactive communication system for
use
in servicing complex equipment whereby personnel at the location of the
equipment can
send and receive detailed information relating to the equipment to and from a
variety of
remote locations where persons having additional or more specialised training
are
stationed. In this manner, the situation on-site could be analysed more
effectively with
input from a variety of skilled service personnel.
There is a further need for an interactive communication system to be used for
the service and support of complex industrial equipment that is remotely
located from
qualified service personnel. There is an additional need for an interactive
communication system to permit equipment to be serviced and supported by
highly
trained personnel without the need for the personnel to travel to the physical
location of
the equipment. There is yet a further need for an interactive communication
system that
is light-weight and portable and can be utilised by service personnel either
at a home
office or a remote location of equipment to be serviced and supported. There
is a
further need for an interactive communication system capable of providing
information
in a variety of digital and analogue forms including voice, video and data.
There is yet
a further need for an interactive communication system permitting various
skilled
personnel at a variety of different locations to interact together and
independently to
provide support and service to remotely located equipment. There is yet a
further need
for an interactive communication system permitting the monitoring of
conditions at
remotely located equipment. There is yet a further need for an interactive
communications system that is easy for a remotely located person to use and
which
transmits data without undue involvement by the person at the on-site
equipment.
The present invention provides methods and apparatus as set out in the claims.
In one aspect of the invention, a method of communicating between an on-site
location and an off site location is provided. The method comprises providing
a
communications attachment that can be positioned at the on-site location. A
two or
more-way communication system is established between the on-site location and
the
off site location. The actions of the on-site location can be remotely
monitored by input
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from the off site location and the actions of the on-site location are relayed
back to the
off site location to ensure directions have been carried out as directed. In
another aspect
of the invention, an apparatus comprises an off site service computer, a
communications
attachment, and a communications system. The communications attachment is
typically
located at an on-site location. A communication system is supplied between the
communications attachment and the off site service computer. In one
embodiment, the
communications attachment is secured to an article worn by on-site personnel,
like a
hardhat. The communications attachment facilitates communication between
personnel
by supplying visual data.
Some preferred embodiments of the invention will now be described by way of
example only and with reference to the accompanying drawings, in which:
Figure 1 shows a block diagram of one embodiment of communication system
of the invention;
Figure 2 shows a detailed block diagram of one embodiment of the on-site
module, the remote module, and the downhole sensor/control module of the
communication system shown in Figure l;
Figure 3 shows a side elevational view of a hard hat attached to one
embodiment
of communications attachment of the communication system;
Figure 4 shows a front view of one embodiment of display integrated in the
hard
25- hat shown in Figure 3;
Figure 5, consisting of Figs. 5A and SB, shows a flow chart of one embodiment
of a method performed by the communication system shown in Figure 1;
Figure 6 shows a schematic diagram of a plurality of well platforms in which
the
communication system may be used; and
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Figure 7 shows a detailed block diagram of one embodiment of communication
networlc including the remote module, the off site module, and the connections
therebetween.
5 To facilitate understanding, identical reference numerals have been used,
where
possible, to designate identical elements that are common to the figures.
After considering the following description, those skilled in the art will
clearly
realise that the teachings of this invention can be readily utilised in
interactive
cormnunication systems between service persons and people located at remote on-
site
locations. This disclosure focuses on the use of the communication system in
the oil
and gas industry in particular. It is envisaged however, that the
communication system
may also be used in nuclear and fossil fuel power generating plants, oil
refineries,
petroleum and chemical processing plants, metal producing plants, and plants
with
heavy machinery. The on-site module portion of the communication system is
preferably located at an oil well or drilling platform or rig. The off site
module portion
of the communication system is preferably located at the location of a service
person or,
if the service person is on-site, at a home office supporting the service
person.
Communications System Overview
One embodiment of communication system 100 is shown in Figure 1. The
communication system 100 comprises an on-site module 102, a communications
link
120, a remote module 104, a communication network 106 (that may be the
Internet, an
intranet, or any other known appropriate network), and an off site module 108.
The on-
site module 102 comprises a communications attachment 110 (that is secured to
an on-
site person 114, for example to a hardhat 112) and an on-site computer 116.
The on-site
computer 106 may be a personal computer, a laptop, a mainframe, a networked
computer, or any known type of computer, but is preferably a laptop due to the
remote
locations and difficult environment that the on-site computer 106 is likely to
encounter.
The on-site computer 116 may be associated with the operation of the wellsite
as
described below. Alternatively, the an-site computer 116 may be associated
primarily
with the communication link 120. A local link 118 preferably transmits
information by
RF signals between the communications attachment 110 and the on-site computer
116.
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The commmications link 120 is established between the on-site computer 116
and the remote module 104. In one embodiment, the communication link 120
includes
a first link 124, a communication satellite 122, and a second link 126. The
first link 124
and the second link 126 are preferably wireless communication links.
Information such
as audio, video, still pictures, text, and other data may be transmitted using
such
protocols as code division multiple access (CDMA), time division multiple
access
(TDMA), and frequency division multiple access (FDMA) as is known in the art.
The
communications satellite 122 may be a geostationary satellite or a low earth
orbit
satellite (LEOS). In an alternate embodiment, the communications link 120
comprises a
land-link 128 that is configured to transmit wire communications in a full-
duplex
manner between the on-site computer 116 and the remote module 104.
The off site module 108 comprises a plurality of off site service computers
109a, 109b, and 109c. Though three off site computers are shown, any number
may be
used, and each off site computer can be located at a different geographic
location. Each
off site service computer 109a, 109b, and 109c is in communication with the
communication network 106 via a direct connection. Alternatively, each of the
off site
service computers 109a, 109b, and 109c may be attached to the communication
network
106 by a hub or switch 702 (see Figure 7). Off site service persons (not
shown) may
access the communication system 100 via any one of the off site service
computers
109a, 109b, and 109c. The on-site module 102, the communications link 120, the
communication network 106, and the off site module provide a broadband two-way
pathway between the communications attachment 110 and the off site service
computers 109a, 109b, and 109c.
The embodiment of communication system 100 as physically described above is
able to transmit video, audio, still image, and/or data information between
the
communications attachment 110, the off site service computers 109a, 109b, and
109c,
and the remote computer 104. Certain embodiments of the communication systems
also
provide a position deriving system 150 comprising a first Global Positioning
System
(GPS) link 152, a communication satellite 122, a second GPS link 154, and a
remote
module 104. The remote module 104 is capable of deriving positional
information
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about the location of the on-site person 114 using the positional deriving
system 150.
Such positional information can be transmitted from the remote module 104 to
the off
site service computers 109a, 109b, and 109c over the communication network
106, if
necessary. The first GPS link 152 is depicted as extending from the
communications
attachment 110 to the communications satellite 122. In an alternate
embodiment, the
first GPS linlc 152 can extend from the on-site computer 116 to the
communication
satellite 122. If the on-site person is located in close enough proximity to
the on-site
computer 116 to be able to communicate thereto, it is assumed that the on-site
person is
working on that worksite or platform associated with that on-site computer.
Therefore,
the positional information that is derived from either the on-site person 114
or the on-
site computer 116 can be used to provide positional, billing, work code, and
other
similar information relative to the on-site person as described below.
The position deriving system 150 indicated in the embodiment shown in Figure
1 may utilise the same communication satellite 122 to transmit the positional
information as communications link 120 uses to transmit the video, still
images, audio,
text, data, etc. Alternatively, another communication satellite 122' can be
used to
transmit the positional information, or any other known device that transmits
positional
information may also be used in the same manner as described relative to the
communication satellite 122. The second GPS link 154 is shown as extending
from the
communications satellite 122 to the remote module 104. Positional information
is
transmitted between the remote module 104 to the off site module 108 via the
communication network 106. Alternately, the second GPS link 154 may extend
directly
from the communication satellite 122 to the off site module 108 where one or
more of
the off site service computers 109a, 109b, or 109c can receive the positional
information transmitted from the communications attachment 110 via the first
GPS link
152.
As indicated above, a variety of types of information can be transmitted
between
the communications attachment 110, the remote module 104, and the off site
module
108 using the communication link 120 and/or the communications network 106.
Many
of the information types are broadband in nature. Such broadband network
protocols as
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Asynchronous Transfer Mode (ATM) or Frame Relay may be used to provide this
information transfer.
Figure 2 shows an expanded block diagram of one embodiment of the on-site
module 102 shovnm in Figure 1 comprising the communications attachment 110,
the on-
site computer 116, and the downhole sensor/control module 250. The
communications
attachment 110 may comprise a video/still image/audio camera 210, a user input
device
212, a GPS receiver 214, a transmitter 216, a receiver 218, a video/still
image display
304, an audio speaker 222, and a user input prompt and instruction display
224. It is
envisioned that other components may be contained in the communications
attachment
110. The transmitter 216 receives information from the video/still imagelaudio
camera
210, the user input device 212, and/or the GPS receiver 214. The transmitter
transfers
information from the communications attachment 110 to the on-site computer 116
over
the data link 118. The receiver 218 receives signals that contain information
from the
on-site computer 116 over the data link 118. The receiver 218 outputs the data
received
from the on-site computer to the video/still image display 304, the audio
speaker 222,
and/or the user input prompt and instruction display 224.
The type of information transmitted from the video/still image/audio camera
210, from the user input device 212, and from the GPS receiver 214 is
different, and
typically is formatted differently. The transmitter 216 may combine all of
these distinct
information types into a form that can be transmitted into a common signal
using such
protocols as ATM, frame relay, CDMA, FDMA, or TDMA. In one embodiment, the
video/still image/audio camera 210 is a camcorder or similar device that is
specially
designed for external and other tough applications. The video/still
image/audio camera
210 (as well as the remainder of the communications attachment 110) is
intended to
able to withstand the types of physical shocks, abrasions, exposure to dust,
salt, or dirt,
and varied temperatures to which the communications attachment is likely to be
exposed.
The data input 215 may be used to receive information or data such as video
streams from external sources, such as contained in the downhole
sensor/control module
250. For example, data generated by the flow sensors 252 may be input directly
into the
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data input 215 either by an electric cable connected directly from the sensor,
by a
wireless link connected to the sensor, or via a data acquisition and control
(DAC) unit
266 of the on-site computer 116 and the local link 118. This data is then
transmitted
from the communications attaclnnent 110 to the remote computers) 109a to 109c
over
the communication system 100, and the data can be displayed in a useful format
or
stored for access when desired. As such, the operational parameters of the
downhole
sensor/control module 250 can be monitored, analysed, and/or stored.
In this disclosure, the term "monitor" is intended to apply to a person, e.g.
a
service person, visually monitoring a display screen or output indicator
displaying the
data transmitted from the communications attachment 110, or from some other
sensor or
source of information located on-site.
A particular communication between an on-site person and an off site service
person may be commenced by either person. If the on-site person commences the
communication, there has to be some type of user input device that permits the
on-site
person to select which area of service expertise, or which service person, is
sought. If
the off site service person commences the communication, software must be
included in
the off site service computer 109a, 109b, or 109c that permits remote
accessing of the
communications attachment 110.
The user input device 212 has multiple input devices that may include one or
more of the following: a keypad, a multiple press-buttons, a bar-code reader,
or a
parameter measuring device. The user input device 212 provides physical
communication from the on-site person 114 to one or more of the off site
service
computers 109a, 109b, or 109c. The on-site person 114 may have to key in a
prescribed
code before they can utilise the communications attachment 110. The user can
input the
identity their identity using the off site service computer 109a, 109b, or
109c by
entering a password in the keypad input. Another user input device is a bar
code
scanner that enables tools, parts, or equipment to be uniquely numbered and
recorded
prior to their use. The bar code scanner preferably interacts with a database
that is
capable of retrieving a checklist stored in the off site module 108 or the
remote module
104. The database contains the desired information relating to that particular
tool or
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part. The off site module 108 or the remote module 104 can, in response,
return a
simple schematic of a part or tool along with a prompt for critical
dimensions/features
to be checked for that particular tool.
5 The GPS receiver 214 provides information about the position of the
communications attaclnnent 110 upon the earth, and is based upon interaction
between
the GPS receiver 214 and communication satellites 122. Since the
communications
attachment is presumably close to the on-site person 114 (for example,
attached to
hardhat worn by the on-site person), the positional information also indicates
the
10 location or worksite of the on-site person. Any other known device that
provides geo-
positional information such as Loran may be used in place of the GPS receiver
214. As
the on-site person 114 traverses the work-site with the communications
attachment 110
secured to his hardhat (or some other connection), the GPS receiver transmits
the
location of the on-site persons 114. The remote module 104 or the off site
module 108
contains database 747 and 737 (shown in the embodiment of Figure 7 and
described
below), that stores the geographic locations and other data associated with
each
particular worksite. For instance, as soon as the off site person leaves the
vicinity of the
worksite, his billing associated with that particular worksite ceases. In this
disclosure,
the term billing can also include those billings associated with the off site
service
personnel who utilise the off site service computers 109a, 109b, and 109c as
well as the
on-site person 114. Additionally, this positional information could be used to
locate a
lost, missing, or hurt on-site person.
The analogue or digital information from the video/still image/audio camera
210, the input information from the user input device 212, and the positional
information from the GPS receiver information 214 are all combined and
transmitted
over the local link 118. The on-site computer can store the particular
information that it
desires on, for example, memory 232 that may comprise ROM, RAM, a disk drive,
a
magnetic memory, or an alternate farm of memory. This information can provide
a
record of a particular activity. The on-site computer 116 then transmits the
desired
information over the communications link 120 to the remote module 104. The
remote
module can store whatever information is desired based upon the input from the
user,
and the program performed by the remote module 104. The remote computer can
then
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transmit the information to the off site service module 108 via the
communications
network 106 that is envisioned to be the Internet.
In response, considerable information is transmitted from the off site module
108, the remote module 104, or the on-site computer 116 to the communications
attachment 110. The communications attachment 110 shown in Figure 2 can
receive
information from the above sources that relates to video display information,
audio
information, user input prompt information, measurement or calibration
information,
instructional information, or alternate information. All of these types of
information are
received by the receiver 218 of the communications attachment 110. The
receiver 218
receives information, and based upon the header information associated with
the
particular information, determines the type of information that it is
receiving. Based
upon the type of information, the receiver forwards the information to either
the
video/still image display 304, the audio speaker 222, or the user input prompt
and
instruction display 224.
There are typically at least three computers that interact within the
communication system 100. These computers are located at the on-site computer
116,
the remote module 104 (that is preferably configured as a server), and one of
the off site
service computers 109a, 109b, or 109c at the off site module 102. The
components of
each of these computers is now described in order.
The on-site computer 116 comprises a CPU 230, a memory 232, circuits 234,
input/output (I/O) circuits 236, a database 239, and the DAC unit 266. The on-
site
computer 116 may be a. general-purpose computer, a microprocessor, a
microcontroller,
or any other known type of computer. The CPU 230 performs the processing and
aritlnnetic operations for the on-site computer 116. CPU 230 is preferably of
a type
produced by Intel, Texas Instruments, Advanced Micro Devices, Motorola, or
other
such companies and whose operation is generally known to those skilled in the
art.
The memory 232 includes random access memory (RAM) and read only
memory (ROM) that together store the computer programs, operands, operators,
and
other parameters that relate to the communication of the communication system
100. A
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bus (not shown) provides for digital information transmissions between CPU
230,
circuit portion 234, memory 232, IIO 236, database 239, DAC unit 266, and
other
portions of the communication system 100. The database 239 may utilise RAM,
memory from disk drives (not shown), memory from magnetic tape drives, or any
other
types) of memory that is capable of maintaining a database.
I/O 236 provides an interface to control the transmissions of digital
information
between the on-site computer 116 and other portions of the communication
system 100.
I/O 236 also provides an interface between the components of the on-site
computer 116.
Circuit portion 234 comprises all of the other user interface devices (such as
display and
keyboard), system devices, and other accessories associated with the on-site
computer
116. While one embodiment of digital on-site computer 116 is described herein,
other
digital computers as well as analogue computers could function well in this
application,
and are within the intended scope of the invention.
The remote module 104, shown in the embodiment of Figure 7 includes another
computer, and comprises a CPU 740, a memory 742, circuits 744, I/O circuits
746, a
database 747, and a browser 748. The remote module 104 may be a general-
purpose
computer, a microprocessor, a micro-controller, or any other known type of
computer.
The CPU 740 performs the processing and arithmetic operations for the remote
module
104. CPU 740 is preferably of a type produced by Intel, Texas Instruments,
Advanced
Micro Devices, Motorola, or other such companies and whose operation is
generally
known to those skilled in the art.
The memory 742 includes random access memory (RAM) and read only
memory (ROM) that together store the computer programs, operands, operators,
and
other parameters that relate to the remote module 104 interacting with the
communication system 100. A bus (not shown) provides for digital information
transmissions between CPU 740, circuit portion 744, memory 742, IIO 746,
database
747, browser 748, and other portions of the communication system 100. The
database
747 may utilise RAM, memory from disk drives (not shown), memory from magnetic
tape drives, or any other types) of memory that are configured to maintain a
database.
The browser 748 is the software stored in the memory 742 that enables the CPU
740 (as
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well as the remainder of the remote module 104) to communicate over the
Internet 106.
Examples of browsers are NETSCAPE NAVIGATOR° (a trademark of
Netscape
Communications Corporation) and INTERNET EXPLORER" (a trademark of
Microsoft Corporation).
I/O 746 provides an interface to control the transmissions of digital
information
between the remote module 104 and other portions of the communication system
100.
I/O 746 also provides an interface between the components of the remote module
104.
Circuit portion 744 comprises all of the other user interface devices (such as
display and
keyboard), system devices, and other accessories associated with the remote
module
104. While one embodiment of remote module is described herein, other digital
computers as well as analogue computers could function well in this
application, and
axe within the intended scope of the invention.
Each of the off site service computers 109x, 109b, or 109c, shown in the
embodiment of Figure 7, comprises a CPU 730, a memory 732, circuits 734, I/O
circuits
736, a database 737, and a browser 73~. The off site service computer 109a,
109b, or
109c may be a general-purpose computer, a microprocessor, a microcontroller,
or any
other known type of computer. The CPU 730 performs the processing and
arithmetic
operations for the off site service computer 109a, 109b, or 109c. CPU 730 is
preferably
of a type produced by Intel, Texas Instruments, Advanced Micro Devices,
Motorola, or
other such companies and whose operation is generally known to those skilled
in the art.
The memory 732 includes random access memory (RAM) and read only
memory (ROM) that together store the computer programs, operands, operators,
and
other parameters that relate to the off site service computer 109a, 109b, or
109c
interacting with the communication system 100. A bus (not shown) provides for
digital
information transmissions between CPU 730, circuit portion 734, memory 732,
I/O 736,
database 737, browser 73~, and other portions of the communication system 100.
The
database 737 may utilise RAM, memory from disk drives (not shown), memory from
magnetic tape drives, or any other types) of memory that are configured to
maintain a
database. The browser 73~ is the software stored in the memory 732 that
interacts with
the CPU 730 (as well as the remainder of the off site service computer 109a,
109b, or
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109c) to allow the off site service computer to communicate over the Internet
106.
Since both the off site service computer 109a, 109b, or 109c and the remote
module 104
each have a respective browser 738 and 748, the off site service computer
109a, 109b,
or 109c can communicate with the remote module 104 using known techniques.
I/O 736 provides an interface to control the transmissions of digital
information
between the off site service computer 109a, 109b, or 109c and other portions
of the
communication system 100. I/O 736 also provides an interface between the
components of the off site service computers 109a, 109b, or 109c. Circuit
portion 734
comprises all of the other user interface devices (such as display and
keyboard), system
devices, and other accessories associated with the off site service computer
109a, 109b,
or 109c. While one embodiment of off site service computer is described
herein, other
digital computers as well as analogue computers could function well in this
application,
and are within the intended scope of the invention.
The on-site computer 116, the remote module 104, and the off site computer
109a, 109b, or 109c provide a framework by which an on-site person 114
positioned at
the on-site computer can effectively interact with a service person located at
the off site
computer. Additionally, information such as video, still images, text, data
audio, etc.
that is stored in one of the several databases within communication system 100
can also
be accessed as necessary to provide prior recorded information about
performing the
task at hand.
Oil and Gas Industry Applications
The communication system 100 of Figure 1 can be applied to a variety of
applications in which the service person can be located at a variety of off
site locations.
The off site location includes his home office as well as, for example,
another oil
drilling platform, an oil rig, a nuclear or fossil fuel powered generating
plant, or a
chemical or petroleum plant. In all cases, the on-site person can interact
with a variety
of remotely located service persons, computers, and databases. In such
applications, the
on-site computer 116 is preferably a computer that controls the operation of
that
particular platform, rig, worksite, etc. For example, Figure 6 is a schematic
diagram of
one offshore oil drilling system in which the operation of at least one well
platform is
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controlled or monitored by on-site computer 116. Each well platform 660 is
typically
associated with a plurality of well pipes 614 that extend from the platform
through
water to the ocean floor and then downwardly into formations under the ocean
floor.
Although the invention is illustrated in relation to offshore platforms, the
inventors
5 contemplate that the invention could also be utilised with land based wells.
Each platform 612 is typically associated with a plurality of wells 614, and a
given well 614 is divided into a plurality of separate production zones 616.
Each
production zone isolates specific areas of a well for purposes of producing
selected
10 fluids, preventing blowouts, and avoiding water intake. Such zones 616 may
be
positioned in a single vertical well, or result when portions of different
wells are located
in a common region. The oilfield depicted in Figure 6 includes features of
well
production such as the drilling and completion of lateral or branch wells that
extend
from a particular primary wellbore. These lateral or branch wells can be
completed
15 such that each lateral well constitutes a separable production zone and can
be isolated
for selected production. Each well 614 can include a plurality of production
zones 616
that are monitored and/or controlled for efficient production and management
of the
well fluids.
The embodiment of on-site module 102 depicted in Figure 2 includes the DAC
unit 266 that interacts with a downhole sensor/control module 250. In the
embodiment
depicted in Figure 2, the downhole sensor/control module 250 comprises a
sensor
portion 251 and a driver portion 253. The sensor portion 251 includes flow
sensors 252,
stress information sensors 257, formation evaluation sensors 254, fishing
equipment/operation sensors 255, electro-mechanical positioning sensors 256,
and
seismic sensors 258. The driver portion 253 comprises electromechanical
drivers 260
and electro-mechanical devices 262. The list of components in the sensor
portion 251
and the driver portion 253 is intended to be exemplary, and not exhaustive.
The
downhole sensors, electronics, and electromechasucal modules that axe
associated with
each downhole sensor/control module 250 can be placed in different zones in a
well.
Preferably, each zone 616 of each well 614 includes a distinct downhole
sensor/control
module 250 dedicated to monitor and control production and operating
parameters for
that particular zone 616.
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Each downhole sensor/control module 250 preferably communicates with a
DAC unit 266 located in the on-site computer via a hardwired electrical cable
contained
within the production tubing. Other embodiments of communications techniques
may
be used to transfer data between the downhole sensorlcontrol module 250 and
the on-
site computer 116. These embodiments of communication techniques include
wireless
transmissions such as low frequency radio transmission from a surface or
subsurface
location (with corresponding radio transmission feedback from the downhole
components to the surface location or subsurface location); acoustic
transmission and
reception; electromagnetic wave transmission and reception; microwave
transmission
and reception; fibre optic communications through a fibre optic cable carried
by the
production tubing from the surface to the downhole components; and electrical
signalling from a wire line carried transmitter to the downhole components
with
subsequent feedback, and the use of fluid lines to provide signals. The
communication
system 100 may also use various modulation types such as frequencies,
amplitudes,
codes or variations or combinations of these parameters. Additionally, a
transformer or
inductive coupled technique may be used in which a transformer primary or
secondary
coil transforms signals to a downhole tool may be used by the communication
system
100. Either the primary or secondary of the transformer is conveyed on a wire
line with
the other half of the transformer residing within the downhole tool. When the
two
portions of the transformer are mated, data and electrical power can be
interchanged.
The DAC unit 266 preferably interfaces with all of the zoneslwells of a well
platform or location. As such, it polls each sensor 252, 254, 255, 256, 257,
or 258
within sensor portion 251. In general, the DAC unit 266 allows the operator to
control
the position, seal status, and/or fluid flow in each zone of the well by
sending a
command to the electromechanical drivers 260 and the electro-mechanical
devices 262
in each downhole sensorlcontrol module 250. An important function of the on-
site
computer 116 is thereby to monitor, control and optimise the fluid or gas flow
from the
formation into the wellbore and from the wellbore to the surface.
To optimise the production of hydrocarbon-containing fluids from each zone
616, well 614, or the entire oilfield, DAC unit 266 can access one or more
remote server
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computers using the Internet, satellite transceivers and communications
systems, or
other networking technologies and systems as shown in the embodiment of FIGURE
1.
This Internet access allows the input of critical geological data, data
gathered during the
exploratory drilling operation, 3D seismic, economic data such as hydrocarbon
product
prices, mapping and topological data for the geographical area of the field,
climate data,
operating parameter data on downhole system components, etc. This data can be
fed to
an optimisation software package that can be included in the DAC unit 266.
Control software packages, such as the Vertex 1000 software, are available
from
Vertex Petroleum Systems of Englewood, Colorado, or the CS Lift software
available
from Case Services Inc., of Houston, Texas are optimisation software packages
that can
be used by the DAC unit 266. Such optimisation software packages can include
mathematical models of a single zone 616, multiple zones, a complete well 614,
or even
an entire oilfield. The DAC units 266 can then perform flow predictions for
zone 616,
well 614, or the entire field flow. Changes in downhole flow parameters in
zone 616,
well 614, or an entire field can then be modelled as a function of time and
their effects
on ultimate hydrocarbon production amount. The DAC unit 266 can thereby
optimise
hydrocarbon production to any desired set of parameters via the on-site
computer.
The optimisation software of the DAC unit 266 also may be utilised to
automatically monitor and control the activities in the wellbore by monitoring
data
collected from the sensor portion 251. This optimisation software can respond
to
changes in the well/zone field conditions by changing the downhole mechanics
according to the programmed response optimised for a particular set of
operating
conditions. The DAC unit 266 provides commands to downhole tools such as
packers,
sliding sleeves or valves to open, close, change state or perform whatever
other action is
appropriate if certain sensed parameters are outside the normal or pre-
selected. An
operator can override the operating parameters by entering an external or
surface
command from the DAC unit 266.
The on-site 116 computer can be used to process, store and display the
information acquired from downhole, and also to interface with an operator or
on-site
person 114. The on-site computer 116 can be used to compare the status of
different
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wells, compare past and present operating conditions, and to get formation
evaluation
logs. The DAC unit 266 preferably comprises analogue and digital inputs and
outputs,
computer bus interfaces, high voltage interfaces and signal processing
electronics as is
well known in the art.
The DAC unit 266 interfaces with the downhole sensor modules to acquire data
from the wellbore, to control the status of the downhole devices, and to
control the fluid
flow from the well or from the formation. A depth measurement system (not
shown)
preferably interfaces with the DAC unit 266 and also provide information
related to the
depth of the tools as the tool string is lowered into the borehole. The DAC
unit 266 also
includes one or more surface sensors for monitoring well parameters such as
pressure,
rig pumps, and heave. All of these sensors provide the operator with
additional
information on the status of the well.
The DAC unit 266 preferably controls the activities of the downhole control
modules by requesting sensor measurement data on a periodic basis, and then
commanding the downhole modules. Such downhole modules act by opening or
closing electromechanical devices such as seals or valves in response to
changes in long
term borehole conditions. The DAC unit 266 sends a control signal to a
downhole
electromechanical control device 262 which then actuates a downhole component
such
as a sliding sleeve, packer seal or other type of flow or pressure control
valve. The
present invention can automatically control a downhole component in response
to
sensed selected downhole parameters. Alternatively, the downhole control
module 250
is programmed to respond to other received information. For this alternative,
the DAC
unit 266 can provide an overnde command to change the downhole control
module's
programmed responses.
The DAC unit 266 also acquires and processes data sent from surface sensors
and downhole sensors. The DAC unit 266 preferably pre-processes the analogue
and
digital sensor data and formats it for transfer to the remainder of the on-
site computer
116. Included among the data received from the DAC unit 266 is data from flow
sensors 252, formation evaluation sensors 254, seismic sensors 258 and
electromechanical position sensors 256 that provide information on position,
orientation
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and status of the downhole components and the well. The data received from the
formation evaluation sensors 254 is processed for the determination of well
reservoir
parameters. The data received from flow sensors 252 is evaluated to determine
whether
the operation of the electromechanical devices 262 should be modified. The
data
gathered from seismic sensors 25~ is also processed to determine, for example,
there is
sand or debris impingement on the casing/tubing annulus. The automatic control
executed by the DAC unit 266 can be initiated without the need for any control
from the
surface or from any other external source. Thus the DAC unit 266 can, if
desired,
provide a closed loop system for well, zone or field optimisation. While the
DAC unit
266 is shown integrated within the on-site computer 116, it is envisioned that
a DAC
unit 266 may also be contained within the data input 215 of the communications
attachment 215. Alternatively, raw data is transmitted form the downhole
sensor/control module 250 to the data input 215 of the communication
attachment 110.
The raw data is then transmitted from the transmitter 216 to the on-site
computer 116,
and the raw data is acquired and processed into processed data or information
by the
combination of the DAC unit 266 and the CPU 230 of the on-site computer 116
using
known computer techniques. The processed data is then transmitted from the on-
site
computer 116 via the communication system 100 to the remote computers 109a to
109c.
The downhole sensors associated with flow 252 and formation evaluations
sensors 254 may include (but are not limited to) sensors for pressure, flow,
temperature,
oillwater content, geological formation parameters (such as porosity or
density), gamma
ray detectors and formation evaluation sensors (which utilise acoustic,
nuclear,
resistivity and electromagnetic technology). Typically the pressure, flow,
temperature
and fluid/gas content sensors will be used to monitor the production of
hydrocarbons
while the formation evaluation sensors 254 will measure, among other things,
the
movement of hydrocarbons and water in the formation. Additionally, sensors
specifically designed to be used in retrieving strings of tubular or tools
that have
because stuck in a wellbore can be utilised as hereinafter described. As such,
sensors
related to those activities can include logging tools, ultrasound cameras and
hydrophones for determining the location and condition of downhole devices.
The
DAC unit 266 executes automatic commands for actuating electromechanical
drivers
260 or other electronic control apparatus. In turn, the electromechanical
driver 260 will
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actuate an electromechanical device 262 that controls a downhole tool such as
a sliding
sleeve, shut off device, valve, variable choice, smart shunt screen, smart
screen chokes,
penetrator valve, perforator valve, or gas lift tool (all of which are known
in the art).
The DAC unit 266 may also control other electronic control apparatus such as
apparatus
5 that may effect flow characteristics of the fluids in the well.
The downhole sensor system includes a power source (not shown) for operation
of the system. Power source can be generated in the borehole, at the surface,
or by
energy storage devices such as batteries. Power is used to provide electrical
voltage and
10 current to the electronics and electromechanical devices connected to a
particular sensor
in the borehole. Power for the power source may come from the surface through
hardwiring or may be provided in the borehole such as by using a turbine
generator.
Other power sources include chemical reactions, flow control, thermal,
borehole
electrical potential differential, solids production or hydraulic power
methods.
The DAC unit 266 controls the electromechanical systems, monitors formation
and flow parameters, processes data acquired in the borehole, and transmits
and receives
commands and data to and from the CPU 260. The DAC can be an integral part of
on-
site computer 116, or a separate system that interfaces with the on-site
computer 116.
Though the DAC unit 266 has been described as interacting with elements
utilised in
the oil industry, the concepts and structure can be modified to apply to
control virtually
any process or machine.
The communications attachment 110 can be used in combination with the
downhole sensor/control module 250 to transmit information or data derived by
the
latter to a remote location. For example, a person located on-site can direct
the
video/audio camera 210 at an output meter from one of the flow sensors 252,
fishing
equipment/operation sensors 255, stress information sensors 257,
electromechanical
devices 262, or another component such as those indicated within the downhole
sensor/control module 250. The output from the sensors or equipment is then
transmitted via the data input 215 of the communications attachment 110 over
the
communication system 100 to one of the off site service computers 109a to
109c.
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21
Alternatively, the communications attachment 110 can obtain data directly from
the sensors or other components of the downhole sensor/control module 250. For
instance, the user input device 212 of the communications attachment caxz be
configured
to receive data during oil exploration, drilling, pumping, troubleshooting, or
other oil
related or industrial operations. As such, the data input 215 from the
communications
attachment 110 is configured to receive input directly from, e.g., the flow
sensors 252,
the electromechanical devices 262, or an alternate component of the downhole
sensor/control module. Such data may include operational level sensor data,
video
information, fluid level, positional data relating to location of equipment
within the
wellbore or on-site location, etc. An electric cable or wireless link may be
connected to
transmit the data obtained from the component of the downhole sensor/control
module
250 to the data input 215, including a DAC, of the communications attachment.
Alternatively, the data from the downhole sensor/control module 250 can be
transmitted
over the on-site computer 116, using the DAC 266, to the conununications
attachment
110. As such, the communications attachment can be used to transmit data
generated
by the downhole sensor/control module either by reading data generated by the
downhole sensor/control module 250 over the operational gauges that exist at
the on-
site location, or by transmitting the data directly from the sensors via the
cormnunications attachment 110 and the communication system 100.
Communications Attachment Confi~nration
Figure 3 shows one embodiment of communications attachment 110 that is
attached to an outer (usually side) surface of a hardhat 300. The
communications
attachment 110 comprises a sidemount attachment portion 302, a display portion
304,
and an audio insert 222. The audio insert is positioned within the hardhat 300
in a
position that the wearer can hear the audio output. The display 304 may be a
liquid
crystal display (LCD), a light emitting diode (LED), a heads up display of the
type used
in many modern aircraft, or any of a variety of applicable displays that are
known. The
display 304 may be "flipped up" to remove the display from obstructing the
view of the
on-site person when the display is not being used. The components of the
conununications attachment 110 are shown .
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22
The side-mount attachment 302 comprises an audio/video camera portion 306
(including a camera eye 308 and a speaker 310), a pushbutton portion 312, a
barcode
reader 314, a local link transceiver 316, a GPS receiver 318, and a parameter
measuring
device 330. The local link transceiver 316 is electrically connected t~ the
other
components of the sidemount attachment 302 such that information generated by
these
components can be transmitted over local link 118. Similarly, the information
received
over the local link 118 can be received by the appropriate individual
components. The
audio/video camera may use any known type of video including digital or
analogue
video, and/or still image transfer. Any type of camera that projects an image
(moving
or still) is intended to be within the scope of the term "video". The camera
eye 308
receives the video input for the audio/video camera portion 306. The speaker
310
receives the audio input for the audio/video camera portion 306.
The embodiment of haxdhat 300 shown in Figure 3 is the type of hardhat worn
on a site such as a drilling rig, an off shore oil platform, power generation
site, chemical
plant or other suitable location. The hardhat electronics would need to be
intrinsically
safe and is preferably battery powered. The hardhat 300 itself must conform to
all
hardhat safety standards. The attaclunent of the communications attachment 110
to the
hardhat 300 cannot compromise the structural qualities of the hardhat 300, or
make the
hardhat impossible, unwieldy, or uncomfortable to wear. Additionally, the
communications attaclnnent cannot make the hard hat excessively bulky or
heavy. The
display 304 cannot be positioned in the hard hat 300 in a manner that limits
normal
vision required for the on-site wearer of the hardhat.
In one embodiment, the communications attachment 110 is secured to the
hardhat by some permanent attachment such as epoxy, another adhesive, or some
fastener. In this configuration, the video camera tracks the direction of the
head of the
on-site person. In an alternate embodiment, a removable clip, fastener,
adhesive, or
fabric such as VELCROTM (VELCO is a registered trademark of Velcro Industries
B.V.
LIMITED LIABILITY COMPANY NETHERLANDS) connects the communications
attachment to the hardhat. The on-site person can therefore remove the
communications
attachment from the hardhat and position the communications attachment at some
difficult-to-reach or awkward location. An off site service person can direct
the on-site
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person about the desired positioning of the communications attachment, if
necessary. A
hardwire connection or a wireless link may connect the hardhat to the
communications
attachment to provide for such removal of the communications attachment.
Though the communications attachment is attached to a hardhat 300 in the
embodiment shown in Figure 3, it is envisioned that certain embodiments of the
communications attachment 110 may be used in environments where the use of
hardhats is unnecessary. Therefore, the communications attachment 110 may be
attached to the on-site person by, for example, a strap-on headband or other
suitable
harness. Examples of such professions where the use of hard hats is not
required, but
the use of the communications attachment may be desirable include plumbers,
electricians, explorers, etc.
The video/still image display 304 and the audio speaker 222 display the video
received from either the off site module 10~, the remote module 104, or the on-
site
computer 116. A front exemplary view of one embodiment of the display is
illustrated
in Figure 4 that comprises prompt screen portion 404 of the video/still image
display
304 and a user input prompt and instruction display portion 406. Light sensor
and light
may be applied to the video/still image display to provide an enhanced video
image.
The video/still image portion may show a video image of the service person, an
assembly drawing, a picture of a part that is being described, a video of an
installation
procedure, a training session, or whatever information is desired to provide
to the on-
site person I14 to perform the task at hand. The user input prompt and
instruction
display portion 406 provides text or data relating to the on-site person.
Examples of the
user input prompt and instruction display portion include a checklist of
operations to
perform, request for logon procedure, options for the on-site person to
select, and
instructions from an off site person. An example of a logon procedure includes
prompts
for a user to input a personal identification code. Audio instructions to the
on-site
person 114 to be used during the user input prompt or other communications can
also be
provided by the audio speakers 222.
The pushbutton portion 312 of the side-mount attachment allows the on-site
person 114 to select a variety of choices from the display. The pushbutton
portion may
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be configured in whichever format is desired. For example, an alphanumeric
pushbutton input may be provided, even though the size of the sidemount
attachment
may limit the number and size of buttons. The user may also enter a password
into the
pushbutton portion when he starts using the hardhat 300 to identify the user
of the
hardhat, and to provide correct billing and positional information.
One scenario envisions that the hardhat 110 could be rented, so a number of
users may use the same hardhat. Not only can the haxdhat with the
communications
attachment be rented, but access to the professional or technical expertise
associated
with the off site service computers can also be considered as being rented. As
such,
individual passwords may also indicate the user of the hardhat for connection,
options,
or billing purposes. The pushbutton portion 312 also can be used to select the
appropriate off site service computer 109a, 109b, or 109c. The selection of a
particular
off site service computer may relate to the area of expertise of the service
personnel
who are at each of the off site service computers. For example, a construction
specialist
may be located at off site service computer 109a, an engineer may be located
at off site
service computer 109b, and a piping specialist may be located at the off site
service
computer 109c. The on-site person 114 can select which of the specialists to
communicate by selecting a prescribed code in the pushbutton portion 312.
The barcode reader 314 is any of the known variety of barcode readers, and is
used to input information to the corninunications attachment 110. For a
particular on-
site person to sign on, he may have a unique barcode strip to slide across the
barcode
reader. The barcode reader 314 may thus be used to input similar information
as the
pushbutton portion 312, described above. Additionally, the on-site person 114
may
have a distinct barcode strip to select a particular user. For example, the
user may swipe
a unique barcode strip to connect to an engineer who is located at off site
service
computer 109b. The barcode reader 314 thereby forwards this information to
select the
particular service person or consultant.
The barcode reader 314 can also be used to assemble a relatively complex
structure. For example, in the oil industry, the on-site person 114 may be
installing a
series of drill pipes for the oil drilling. The user can swipe the barcode
reader across a
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unique barcode affixed to each length of pipe being inserted for the drilling
process.
The lengths of the drill pipes can therefore be monitored and/or recorded by
the on-site
computer 116. This information can then be forwarded to the remote module 104
and/or the off site module 108. This automatic recording of drill pipe lengths
limits the
5 possibility errors in the total length of drill pipe or other tubulars that
are inserted in the
well. Tubulars can be provided with bar codes located thereupon having any
number of
data types. Additionally, the tubulars could be provided with tags known
generally as
RFID tags that permit quick scanning while permitting personnel to remain a
safe
distance of the tubulars being scanned. The use of the bar code reader 314 can
be
10 highly desirable for the accurate performance of other mundane or
repetitive tasks.
While the bar code reader 314 is shown as being attached to the hardhat 300,
it can also
be a temporarily removable hand-held item that provides for greater
accessibility in
some application. Any type of optical, electromagnetic, or other reader that
can be used
to detect the identity of a part, product, person, etc. can be used in place
of, or in
15 addition to, the barcode reader.
The parameter measuring device 330 may use laser, ultrasound, or other known
measuring, diagnostic, or calibration technique. The parameter measuring
device can
precisely measure tools, equipment, or parts with which the on-site person is
interacting.
20 It may be important for the on-site person to calibrate certain critical
dimensions on-site
before it is used. For example, in the drilling technologies, it is vital to
ensure that the
dimensions (e.g. diameter) of the drill rod connections are correct before the
drill rod
length is inserted in the drill hole. Also, a parameter measuring device 330
that is
distinct from the communications attachment 110 may be used by the on-site
person
25 114, and its output "read" by the video/still image/audio camera 306.
Alternatively, the
value indicated by the parameter measuring device 330 may be manually input
into
pushbutton portion 312 by the communications attachment 110.
The local link transceiver 316 is configured to transmit data over a wireless
link
between the communications attachment 110 and the on-site computer 116. The
local
link transceiver may utilise any type of wireless communication link that is
used to
transmit data between local sites, but preferably is a radio frequency (RF)
transceiver
that directs an omni-directional beam that is not blocked by obstructions.
Using a signal
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that is not bloclced is important since the on-site user is likely to be
positioned at
different locations on such equipment as a drilling rig, an off sea platform,
a large piece
of machinery, etc. The local link transceiver 316 comprises an antenna (not
shown) that
transmits a signal to, and receives a signal from, a similar antenna located
at the on-site
computer 116 in a manner that provides the local link 118.
The remote module 104 communicates with the off site module 108 over the
communication network 106 as shown in expanded detail in Figure 7. The
Internet is
selected as the preferred communications network since many sites are located
at
remote sites that can be most easily accessed by the Internet. The expense of
providing
a distinct broadband communications network between the off site module 108
and the
remote module 104 would be prohibitive for most remote locations.
The GPS receiver 318 is provided to indicate the position of the on-site
person
114 based upon the location of the helmet 200. GPS receivers are well known
and used
to provide positional information in such applications as aircraft, missiles,
hikers, etc.
The cost of GPS receivers has recently decreased to make them commercially
viable for
a wide variety of users. The positional data provided by the GPS receiver 318
can be
transmitted over the local link 118 to the on-site computer 116 (or over
communication
system 100 to the remote module 104 or the off site service computer 108) to
the
respective database. The GPS positional values stored in the database for a
specific
worksite can be compared with those for a plurality of work sites, and the
location of
the on-site person 114 can be the off site modules 108. The billing or
technical data can
be directed at the remote module 104 or the off site module 108 automatically
based
upon the positional GPS information received from the on-site person 114.
Additionally, such positional information may be used to locate a lost or
injured on-site
person.
Computer Operations
Figure 5 (including Figs. 5A and SB) illustrate one embodiment of an exemplary
method that may be performed by the communication system 100 of Figure 1. A
considerable amount of the information may be stored in, or retrieved from,
databases
737, 747 (see Figure 7), or 239 (see Figure 2). The method 500 starts with
decision
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block 502 in which the on-site computer 116 determines whether there is a
request to
establish a communication session with an off site service person located at a
specific
off site service computer 109a, 109b, or 109c. Alternatively, the off site
service
computers could establish the comlection to an on-site person 114 at the on-
site module
116. If the answer to decision block 502 is NO, then the method 500 continues
to block
504, and loops back through decision block 502 until a person positioned at
either the
on-site module 102, the remote module 104, or the off=site module 108 wishes
to
establish a communication session.
If the answer to decision block 502 is YES, then the method 500 continues to
block 506 in which the on-site computer 116 determines with which off site
service
computer 109a, 109b, or 109c communications should be established (each off
site
service computer is associated with a different service person). The addresses
of the
desired service person may be stored in either the database 239 of the on-site
computer
116 or the database 747 of the remote module 104. Following block 506, the
method
continues to block 508.
In block 508, the communication system 100 attempts to establish a connection
between the on-site computer 116 and the off site service computers 109a,
109b, and
109c. Typical network connection protocols (such as ATM, Frame Relay, CDMA,
FDMA, TDMA, etc.) are used to establish the connection. Method 500 then
continues
to decision block 510 in which the on-site computer 116 determines whether the
connection has been established. If the answer to decision block 510 is NO,
then the
method 500 loops through block 508 and decision block 510. If the answer to
decision
block 510 is YES, then the method 500 continues to block 511.
In block 511, either the communications attachment 110 or the on-site computer
116 or the on-site module 102 contains a receiver that receives positional
(e.g., GPS)
information. The GPS information indicates the physical position of the GPS
receiver.
The GPS information is transmitted over the connection between the on-site
computer
116 and the desired off site service computer 109a, 109b, or 109c to identify
the
location of the on-site person. This positional information can be used for
the purposes
of supplying technical data, billing, rental of equipment from a rental centre
to certain
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work sites, locating lost or injured persons, etc. In this disclosure, the
rental centre is a
location where the job is dispatched or the location where persons with
expertise or
information based upon expertise resides. Following block 511, method 500
continues
to block 512.
In block 512, the on-site module 102 comprises the communications attachment
110 and the on-site computer 116. The on-site module derives and transfers
input
information that pertains to the specific part or machine that is involved to
the remote
module 104 and/or the off site module 108. This information may include input
information from the barcode reader 314, input to the pushbutton portion 312,
viewing a
unique part or machine with the video portion 306, or some other manner known
in the
art to identify the part or machine. The input information is transferred over
the
communications link 120 to the remote module 104. The remote module 104
receives
the input information. Either the remote module 104 or one of the off site
service
computers 109a, 109b, or 109c locates the appropriate the instruction
information
respectively in databases 747 or 737 (see Figure 7). The instruction
information may
include such items as a schematic drawing of the part ommachine, critical
dimensions of
the part or machine, checklists of, or video clips showing, how to utilise or
operate the
part or machine, or any other information that may be of use to the on-site
person in
using the part or machine.
Some of the instructional information can also be provided by the service
person
located at the off site service computer 109a, 109b, or 109c. For example, the
service
person may either provide verbal instructions, or may select which one of a
plurality of
instructions stored as files in the databases 737 or 747 should be provided to
the on-site
person 114. The service person then forwards the above information (plus
information
that may be added automatically by the computer based upon the question or
query) to
the communications attachment 110. If the remote module 104 stores the
instruction
information corresponding to the input information, then the instruction
information is
retrieved and returned it to the on-site computer 106 (over communications
link 120) in
block 514. If one of the off site service computers 109a, 109b, or 109c stores
the
instruction information corresponding to the input information, then the
remote module
104 transfers the input information from the desired off site service computer
109a,
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109b, or 109c to the on-site computer 106 via remote module. The remote module
104
transmits the instruction information over the communication link 120 to the
on=site
computer 116.
When the on-site computer receives the instruction information in block 516,
the
instruction information is forwarded over the local link 118 to the
communications
attachment 110. The instruction information received by the communications
attachment is of the type that can be read by the video/ still image display
304, the audio
speaker 222, or the user input prompt and instruction display 224 as described
above.
An example of the information may be instructions for the on-site person to
measure a
desired measurement of the casing in an oil drill. A schematic diagram of the
casing
may be provided over the video/still image display 304, as well as an
identifying
characteristic of the part used to measure the casing, and an indication of
the allowable
ranges of allowable measurements or test results. A verbal description of the
instructions may be recited over audio speakers 222. A video record of a
similar prior
operation may be included. Other values, instructions, calibration
measurements,
weights, shapes, etc. could also be stored in the databases in the remote
module 104 or
the off site service computers 109a, 109b, or 109c, could be transferred to
the on-site
module 102 upon demand. Following block 516, the method 500 continues to block
S 18.
In block 518, the on-site person follows the operation indicated by the
instruction information received by the communications attachment 110. If the
communications attachment indicates to make a casing measurement using a
particular
tool, then the on-site person performs this operation. In this manner, the
communications system provides a set of interactive multimedia instructions
that
demonstrate how to perform a specific operation on a specific part or machine.
The
results of the specific measurement, calibration, or other operation to be
performed by
the on-site person as a response to the instruction information is referred to
as "result
information".
Following block 518, the method continues to optional block 520 in which the
result information derived in block 518 is combined with actual measurements
from the
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downhole sensor/control module 250 and is processed by the DAC unit 266. The
DAC
unit 266 provides an output in data format that may be used by the remote
module 104
or the off site service computers 109a, 109b, or 109c to determine whether the
specific
measured or calibrated part is applicable for the present operation based upon
specific
5 conditions. The combined information is transmitted over the communications
link 120
to the remote module 104, and possibly (if the off site service computers
109a, 109b, or
109c instead of the remote module I04.
The method 500 continues to block 524 in which the remote module and/or the
10 off site computer 129a, 129b, or 129c receives and processes the combined
information
to determine if the part or machine is suitable for operation under measured
condition.
Block 524 is performed using computer programs associated with the specific
operation. For example, a computer program may input the measured dimensions
of a
casing in an oil drill to determine if the casing is structurally adequate or
sufficiently
15 contoured considering the present condition of the drill string, as
determined by the
DAC unit 266 of the on-site computer. The results from the processing of the
combined
information in block 524 are returned to the on-site person 114, as well to
the off site
service computers 109a. 109b, or 109c where the service personnel are located.
20 Operation of the Communication System
Certain operational aspects of the communication system 100 are now detailed.
The communication system 100 can be worn by an on-site person 114 and one or
more
service persons located at computers 109a, 109b, or 109c located at the off
site module
108. The communication system can also be used with downhole sensing devices
that
25 operate in conjunction with the communications attachment to provide data
to an off
site location and thereby permit monitoring and direction of activities at an
on-site
location. The local link 118 that transmits data between the on-site person
and an on-
site computer 116 is wireless (preferably a RF link), and thereby does not
impede free
movement of the on-site person 114. Using present integrated circuit or solid
state
30 technologies, the communications attachment may be light (e.g. less than a
pound) such
that the hard hat 300 that the communications attachment is secured to is
comfortable to
wear.
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The use of the GPS receiver 318 provides an accurate position information of
the on-site person 114 who is wearing the hardhat 300. The positional
information is
useful for automatic reporting of status, usage, location and other
technically useful
data. For example, if an off site person is working where there are multiple
sites in a
close vicinity, then the positional information can automatically determine
his specific
site, and indicate the activities performed at that worksite or platform.
Much of the equipment used in downhole drilling is very large and extremely
complex. Often workers, even those skilled in the specific area, become
confused based
upon the variety of components such as parts, equipment, tools, etc. For
example, many
components used in downhole drilling, such as drill pipe, appear similar after
long
periods of operation in a hostile environment. As such, any positional
information that
provides an indication of the identity of a specific part or tool may be
useful in proper
identification thereof.
The oil industry has a variety of functions associated with exploring for oil,
maintaining the oil drilling and pumping equipment, and repairing damaged oil
drilling
and pumping equipment that can benefit from the interactive communication of
the
invention. One such example is the assembly of tubular strings for insertion
into a
wellbore. Each length of casing or other tubular includes a male joint fitting
and a
female joint fitting that permit joining of adjacent pieces of tubular to form
the string.
To add a new piece of tubular to the drill string, either the male joint
fitting or the
female joint fitting in the new piece is positioned in threaded contact with
the mating
joint fitting of the adjacent piece of tubular. The new tubular is then
rotated until the
mating joint fittings are threaded together to an acceptable torque. The
rotation between
adj acent pieces of tubular is typically applied by a hydraulically driven
tong. The
torque applied to the joints is determined by standards that ensure the
tubular pieces will
remain fixed together during well operations. Typically, the tongs are
electrically
connected to sensors that determine the amount of torque present in the joint
and the
value is fed back to an on-site computer that can determine when the
appropriate
amount of torque in the joint has been established. Because the tubulars with
their male
and female portions are manufactured according to the same standards, the
number of
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angular turns needed to establish an acceptable torque in the joint should be
almost the
same for each subsequent joint.
According to the present invention, an site computer, 116, can be used to
establish, display, and/or retransmit data associated with the number of turns
of a
tubular and the amount of torque associated with a joint at any one time.
Allowable
torque versus turns curves are stored in the on-site computer 116, the remote
module
104, or the off site service computer 109a, 109b, or 109c. The allowable
torque versus
turns curves plot acceptable ranges of torque versus the number of turns for a
drill
length joint are plotted for different types of drill lengths. The actual
torque versus
turns curves can be compared to the allowable torque versus turns curves to
determine
the quality and acceptability of the joint between tubulars. The joint may be
considered
unacceptable if during the tightening for example, the amount of torque
generated for
than number of turns falls outside of the acceptable limits of the allowable
torque versus
turns curve.
If the actual torque versus turn curves fall considerably far outside of
allowable
limits indicated by the allowable torque versus turn curves, then the on-site
operator
may determine that the piece of tubular is unacceptable and it can be taken
out of
service without consultation with service personnel. If the actual torque
versus turn
curves produced for a specific joint are marginally outside the value of the
allowable
torque versus turn curves, then the on-site person may wish to consult with
off site
service personnel using the communication system 100. Alternatively, the
communication system 100 allows for off site service personnel to monitor
and/or
provide input for the tightening of joints in the drill length and provide
input to
determine whether the tightening of the drill length falls outside of the
acceptable limits
based upon actual torque versus turns curves produced by sensors associated
with the
tongs.
Another service function associated with the oil industry that can benefit
from
the methods and apparatus of the invention is "fishing". Fishing is part of
troubleshooting a well and can be required at virtually any time during the
drilling,
completion or operation of an oil well. The fishing operation utilises data or
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information received from the fishing equipment/operation sensors 255 of the
downhole
sensor/control module 250. For example, during drilling, a wellbore can
collapse and
bury a portion of the drill string in place. Applying a rotational force to
the unburied
portion of the drill string when a portion of the drill string is buried can
result in
twisting and damaging the unburied portion of the drill string. By using the
fishing
equipment and methods and the received data and information from the fishing
equipment, the damaged drill string can be removed without damaging other
equipment
or parts of the well.
Fishing equipment may include electronic sensors that are configured to detect
problems and conditions downhole. The fishing equipment is often connected to
a wire,
pipe, or flexible tubing, and is initially used in the wellbore to deterniine
the location of
a problem, like a buried, damaged, or obstructed string of tubular. For
example, if the
bottom of the drill string contacts an obstruction at a certain depth, the
electronic
information from the fishing tool provides an indication of the type and
location of the
obstruction. Once the location of the problem is determined, a solution can be
carried
out. Upon determination that the drill string is buried, damaged, or
obstructed, there are
often multiple possible alternatives to remedy the problem. For example, if a
drill string
is buried at a specific depth, it may be possible to un-thread the drill pipe
at a depth near
where the drill string is buried and divert the drill string to drill a new
wellbore, thereby
abandoning the buried drill lengths of the drill string. It may alternatively
be desired to
drill around the buried drill string. Multiple such alternatives are often
presented to
fishing personnel for their consideration and solution. The communication
system 100
of the invention allows for the on-site persons to consult with one or more
remotely
located service persons or experts (such as fishers) very quickly without the
need for the
service persons to travel to the wellsite. The service persons can obtain
sufficient
information from the communication system 100 to provide an informed opinion
of
how to deal with the drill string being damaged, buried, or obstructed. Based
upon this
information a skilled operator can analyse the data during the "fishing"
expedition and
determine how to proceed. The description of the fishing operation and
equipment is
intended to be exemplary and not exhaustive. The oiI drilling operation in
particular
and industrial operations in general, are replete with examples of on-site/off
site
examples that could utilise the communications attachment 110 as described.
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The various operations related to oil wells and drilling require skilled
service
persomlel to monitor the operations at the on-site location. Using the above
communication system 100, the skilled operator can be located at one of the
remote
computers 109a, 109b, or 109c. The communication system 100 allows an off site
service personnel to interact with on-site persons and the on-site location to
monitor the
performance of the operation. Additionally, the off site service personnel can
receive
sufficient information to be sure that the equipment is performing properly
and/or
repairs are being done correctly.
The parameter measuring device 330 can provide precise measuring or
calibration of tools, equipment, or parts with which the on-site person is
interacting. An
example of a drill part that requires precise dimensioning is a full gauge
window mill
that has a very tight clearance with the inner diameter of the pipe in which
the mill is
being run. For example, in a 7" casing pipe, there may be less than 1l8" of
clearance
between either side of the casing and the mill. In practice, the casing is
exposed to hard
wear and may be bent, twisted, or otherwise deformed such that it is not
perfectly round
as it is inserted down the hole which also decreases the clearance. With small
diameter
casings, an even smaller diameter mill may be required. Often such tools as
mills
having uncommon diameters are shipped from remote warehouse locations and a
trained technician is required to provide input on the operation of the tools.
Using the
communication system 100, the input can come from specialists located at the
off site
computers 109a, 109b, and 109c.
A standard procedure may be to run a gauge ring on that mill to check to
ensure
that it is in dimensional conformance (similar tests may be run for other
tools, parts,
machines, etc.). The communication system 100 will prompt the on-site person
114 to
check the required dimensions using the parameter measuring device 330 to
ensure
proper operation. The barcode reader 314 may be used to identify the part, as
described
below, and then the computer retrieves the special measurements, procedures,
and
characteristics associated with that part, tool, or machine from the
applicable data bases.
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The bar code reader enables tool bar codes to be recorded prior to their use.
For
example, a unique bar code strip (or other similar identification element)
could be
located on each of the different parts and components as stored in the
database. The
databases (e.g. 239, 737, 747) located throughout the communication system 100
can
5 retrieve a suggested checklist for the specific activity to be performed
related to each
part or component. Additionally, drawings or video can be provided on the
video
display 304 to provide an indication of how to perform the activity. Other
information
such as a simple schematic of the part or tool with prompting of critical
dimensionslfeatures to be checked can be stored in the databases, and
retrieved upon
10 reading of the bar code.
Depending on operations being performed, different predetermined views of
relevant information could be broadcast to the on-site person 114. For
example, custom
displays would be devised for operations relative to drilling, liner running,
cementing,
15 fishing, logging, well testing, perforating, fracturing, etc. operations
used in the oil
industry, or other activities, to which the communication system is being
applied.
The communication system 100 provides a technique to perform service
delivery utilising the Internet. This technique of providing service delivery
from remote
20 locations via the Internet enables effective and precise collaboration
between the on-site
personnel and the off site service personnel and specialists. If a person with
specific
skills or experience is required, the on-site person, could access those
skills of the
service person without the expense and time required for transportation of the
service
personnel to the site.
Another aspect of the communication system 100 is that it provides a semi-
permanent record of the activities performed by an on-site person, and which
can be
used for case history collection. When accidents or errors occur, the actions
of each
individual can be reviewed. Additionally, the activities of a skilled person
can be
recorded to indicate how the activity "should be performed" for training
purposes. Less
skilled on-site persons can view the recording as a means to improve their
performance.
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The communication system 100 uses the Internet, or other known network, to
provide timely interaction with service personnel. The service person has
experience,
and also access to all kinds of information. Additionally, service persons
with different
skills are relatively simple to access for multi-disciplinary information.
A large drilling or service company would normally require a large staff of
experienced service personnel. Using the communication system, however, these
service personnel could become more centralised and effectively used because
they
would spend less time travelling or waiting to perform their duties at a
wellsite. The
companies could therefore better utilise service personnel and avoid some
expenses
related to extended travel time and the associated transportation expenses. If
a specific
platform or work site needs expertise for a brief period, the company could
interact with
the service personnel over the Internet, and provide extremely detailed
information and
an accurate image of what is occurring on-site. If a platform or work site has
a
malfunction or failure, assistance from a suitable service person can be
provided
immediately.
The hardhat 300 could also be provided as a rental item from a company such as
a rental centre that also rents the services of personnel. Service personnel
typically bill
out at a day rate and tools rent out at an hourly or day rate. Instead of
sending both the
tools and the service persons to the worksite, the use of the communication
system 100
allows sending only the tools out. An on-site person can rent a hardhat 112
having a
communications attaclunent 110, and obtain the experience of the service
personnel
without the necessity of having the off site service personnel transported to
the site.
The on-site persons could then use the tools as instructed by the service
personnel. Data
related to use of the hardhat and communication systems can be stored and/or
permanently transmitted back to the rental centre for accounting and billing
purposes.
