Drilling or work-over rig comprising an operational control and/or state unit and a computer-implemented method of providing operational control and/or state

Abstract

A drilling or work-over vessel (10) is disclosed comprising a number of operational equipment (300), wherein the drilling or work-over vessel comprises at least one operational control and/or state unit (100) comprising at least one processing unit (102), wherein the at least one operational control and/or state unit (100) comprises or are in connection with a memory and/or storage (103), and at least one sensor unit (200), wherein the at least one sensor unit (200) is adapted to obtain one or more measured physical values and to provide data representing the one or more measured physical values and/or derived values thereof to the at least one operational control and/or state unit (100), the memory and/or storage (103) comprises a data representation of a computational physics model of at least a part of the drilling or work-over rig, and the at least one processing unit (102) is adapted to derive data representing an estimation of one or more physical states (such as defined by limits of forces, relative motion between operational equipment and vessel, or between other two pieces of operational equipment) estimated to act on at least one operational equipment (300) in response to the data representing the one or more measured physical values and/or derived values thereof as provided by the at least one sensor unit (200).

Claims

1. A drilling or work-over vessel, comprising; sensor units configured to obtain measured physical values wherein at least some of the sensor units are configured to obtain physical values associated with the vessel itself, and to provide data representing the measured physical values, and the obtained physical values; multiple operational equipment configured for use in drilling or work-over operations; and a control system configured to receive data representing the measured physical values from the sensor units; and further configured to use a computational physics model of at least part of the vessel so as to derive data representing an estimation of one or more physical states of the operational equipment based at least in part on the data received from the sensor units; wherein the physical states of the multiple operational equipment are presented to an operator with a plurality of indicators wherein the plurality of indicators are configured to indicate the operability of the multiple operational equipment and the plurality of indicators indicates whether the multiple operational equipment is operable in normal operation or in one of: cautionary operation; reduced operation; stop operation; or a disconnect operation, and wherein at least one of the sensor units is remote from the multiple operational equipment and the control system is configured to use the computational physics model to translate data representing measured physical values at the sensor unit remote from the multiple operational equipment in order to estimate physical values experienced at a particular operational equipment.

2. The vessel according to claim 1, wherein the computational physics model comprises limitations for the operational equipment so that based on motions of the vessel and the operation at hand said indication is determined based on the computational physics model.

3. The vessel according to claim 1, wherein the control system is configured to derive data representing an optimized operation for at least one of the vessel and the operational equipment.

4. The vessel according to claim 1, wherein the control system is configured to estimate one or more future physical states of the operational equipment.

5. The vessel according to claim 1, wherein the control system is configured to estimate one or more future physical states of the operational equipment and the control unit is configured to derive the data representing at least one of an optimized operation for the vessel and an optimized operation for the operational equipment, based on the estimated future physical state.

6. The vessel according to claim 3, wherein the optimized operation defines or redefines a particular sequence of operation, a particular orientation or positional movement of the vessel.

7. The vessel according to claim 1, wherein at least one of the operational equipment is permanently installed with the vessel.

8. The vessel according to claim 1, wherein the control system is configured to use the computational physics model to derive data representing an estimation of the present physical state of the operational equipment in real time.

9. The vessel according to claim 1, wherein the control system is configured to derive data representing the physical states from an estimation as to relative motion between one or more of operational equipment and vessel, and between two or more operational equipment.

10. The vessel according to claim 9, wherein the physical state are based, at least in part, on the likelihood of equipment clashing, either with other equipment or the vessel.

11. The vessel according to claim 4, wherein, the control system is configured to derive an expected duration of state for operation equipment.

12. The vessel according to claim 4, wherein the control system is configured to estimate the future physical states of the operational equipment using present data received from the sensor units together with previous data.

13. The vessel according to claim 1, wherein the control system is further configured to use a weather forecast to derive data representing one or more future physical states of the operational equipment.

14. The vessel according to claim 1, wherein some or all of the sensor units are configured to obtain physical values associated with the vessel itself.

15. The vessel according to claim 1, wherein each of the sensor units is selected from the group of: a pitch and roll sensor, a motion reference unit, a gyroscope, an accelerometer, a global positioning system or other positioning sensor, a weather station, a wind sensor, an inertial measurement unit, a near surface water current measurement unit, a near seabed water current measurement unit, a Doppler water current sensor, a single-point water current meter, a water current profiler unit, a vessel water current sensor, a water current sensor located on a marine riser, Riser management system, Doppler radar, Data, and state information of control systems.

16. The vessel according to claim 1, wherein the operational equipment is one or more selected from the group of: pipe racking equipment, tubular handling equipment tubular guiding equipment, a crane, hoisting equipment, a blowout preventer, a Xmas tree, active or passive heave compensation equipment.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1a schematically illustrates a side view of a vessel, such as a drilling or work-over vessel/rig; and FIG. 1b schematically illustrates a plan view of that vessel;

(2) FIG. 2 schematically illustrates one embodiment of a work-over or drilling rig comprising at least one operational control and/or state unit, at least one sensor unit, and at least one operational equipment, and

(3) FIG. 3 schematically illustrates a functional block diagram of one embodiment of an operational control and/or state unit, such as the one shown in FIG. 2.

DETAILED DESCRIPTION

(4) Various aspects and embodiments of a vessels, control systems, and methods will now be described with reference to the figures. Some examples described a drilling or work-over vessel comprising at least one control system having an operational control and/or state unit and a computer-implemented method of providing operational control and/or state.

(5) For ease of explanation, the following examples have been described with reference to oil and gas drilling or work-over rigs/vessels. However, it will readily be appreciated that the systems and methods described herein may be equally used and may be applicable in respect of vessels used for other offshore operations (e.g. pipe laying, or the like). A skilled reader will readily be able to implement those various alternative embodiments accordingly. It will also be apparent to a skilled reader that the term vessel may include platforms, semi-submersibles, mobile offshore drilling units, and other such mobile sea-going vessels.

(6) When relative expressions such as upper and lower, right and left, horizontal and vertical, clockwise and counter clockwise or similar are used in the following terms, these refer to the appended figures and not necessarily to an actual situation of use. The shown figures are schematic representations for which reason the configuration of the different structures as well as their relative dimensions are intended to serve illustrative purposes only.

(7) Some of the different components are only disclosed in relation to a single embodiment of the invention, but is meant to be included in the other embodiments without further explanation.

(8) FIG. 1a shows a simplified side representation of a vessel 10, and in particular a drilling or work-over vessel 10. It will be appreciated that during offshore operations, the vessel 10 may be fitted with operational equipment for use during those operations. Typically, some of the operational equipment is permanently installed at the vessel 10, whereas there may also be bespoke or dedicated equipment depending on the expected operation. Further some of the operational equipment may be relocatable about the vessel 10, depending on operations.

(9) Here, in FIG. 1a, the vessel 10 is shown havingas operational equipmenta derrick 20 (which may be dynamic), a crane 30, a pipe rack 40; heave compensation equipment 60, and a riser section 70 (e.g. for drilling or work-over operations), which passes through a moonpool 80, in a known manner. The vessel 10 here also comprises a control tower 50 where, for example, a driver such as a captain, or other operational crew may be located. Additionally, the vessel 10 comprises a plurality of sensor units 200 that, as will be explained, are configured to obtain measured physical values, and to provide data representing those measured physical values.

(10) Some of the sensor units 200 may be configured to obtain physical values associated with the vessel 10 itself, such as pitch and roll, acceleration, positional information (e.g. from GPS, or the like). In such cases, those sensor units 200 may be provided with the vessel 10 for further vessel sub-systems, such a navigation, control, etc. In other words, those sensor units 200 may be considered to have been installed/incorporated with the vessel 10 itself.

(11) Similarly, in some examples, some of the sensor units 200 may be configured to obtain physical values relating to environmental conditions associated with the vessel, such as near-water current values, wind speeds, etc., as would be appreciated by a skilled reader. Again, those sensor units 200 may be installed/incorporated irrespective of the operational equipment at the vessel. In this example, and as shown in FIG. 1a, some of the sensors units 200 are also provided with operational equipment, in this case the derrick 20 and heave compensation equipment 60. Here, those sensor units 200 are configured to provide data specifically regarding the conditions at that operational equipment 20, 60.

(12) FIG. 1b shows a plan view of the vessel 10 of FIG. 1a. As is apparent, the operation equipment at the vessel 10 has a spatial relationship (e.g. relative to the each other, the vessel 10 and the sensor units 200). As mentioned above, some of the operational equipment may be permanently installed with the vessel 10, while some may be temporary, and so the relative position or the type of equipment may vary depending on application.

(13) In FIGS. 1a and 1b, the vessel 10 here further comprise a control system 100 configured to receive data representing the measured physical values from the sensor units 200. As will be explained in further detail below, the control system 100 is configured to use a computational physics model of at least part of the vessel 10 so as to derive data representing an estimation of one or more physical states of the operational equipment.

(14) FIG. 2 schematically illustrates a simplified representation of the work-over or drilling rig/vessel 10 comprising the control system 100, sensor units 200, and operational equipment 300 (e.g. riser 70, crane 30, etc.). In this example, the control system 100 may be considered to be an operational control and/or state unit. The operational control and/or state unit 100 comprises or are in connection with a memory and/or storage (see e.g. 103 in FIG. 3).

(15) FIG. 3 schematically illustrates a functional block diagram of one embodiment of an operational control and/or state unit, such as the one shown in FIG. 2. Shown is an operational control and/or state unit 100 suitable for carrying out one or more of the functionalities described throughout this description comprising one or more processing units 102 connected via one or more communications and/or data buses 101 to a memory and/or storage 103, one or more transmitter and receiver communications elements 104 for communicating via a suitable communications network, an optional display 110, and optionally one or more (physical) user interface elements 120 (e.g. for positioning at the control tower 50). It should be noted, that the operational control and/or state unit 100or another appropriate processing unitmay receive data from a computer readable medium (as indicated in connection with FIG. 2) to be able to execute the method (also indicated in connection with FIG. 2).

(16) As mentioned, the sensor unit 200 is adapted to obtain one or more measured physical values and to provide data representing the one or more measured physical values and/or derived values thereof to the operational control and/or state unit(s). Here, the memory and/or storage (see e.g. 103 in FIG. 3) comprises a data representation of the computational physics model of at least a part of the drilling or work-over vessel 10. This enables physical modelling of the drilling or work-over vessel in response to a number of supplied parameters (e.g. measured physical values) whereby it is possible to estimate present or (e.g. near-)future states of the drilling or work-over vessel 10 or parts thereof. In particular, it is possible also to estimate present or future states of one or more of the operational equipment 300.

(17) The model may comprise information relating specifically to the present operational equipment 300 installed at the vessel 10, which may include the operating envelopes or limitations for operational equipment. The model may comprise information relating specifically to the relative positioning of operational equipment 300 (e.g. relative to either other, relative to the vessel, etc.). For example, the model may define the spatial relationship of operation equipment 300, e.g. the spatial relationship between a riser 70 and moonpool 80. Such a computational physics model may be usable to translate data representing measured physical values at a sensor unit 200 remote from particular operational equipment to physical values that may be experienced at that operational equipment. Such a computational physics model may be usable to provide an estimation of the dynamic operation of operational equipment 300 at the vessel 10, e.g. forces, position or displacements, velocities, and/or accelerations of equipment.

(18) In particular, the at least one processing unit 102 of the control system 100 can be adapted to derive data representing an estimation of one or more physical forces estimated to act on at least one operational equipment 300 presently or within a predetermined near-future period of time using the data representing the one or more measured physical values and/or derived values thereof as provided by the at least one sensor unit 200.

(19) By placing one or more sensor units 200 on operational equipment and/or receiving information from one or more sensor units 200 already typically located on a rig and using that data with the mathematical model it is possible to derive or estimate what forces or the like will act on the given operational equipment and/or what state it will be in, presently or in the (near-)future. From that it is possible to derive a suggested or recommended operational state for the given operational equipment presently or for the (near-)future that takes actual measured physical values and/or conditions into account.

(20) This enables more optimal use of the operational equipment while still maintaining safety. Specifically, an operational equipment may accordingly be used safely at full speed, safely at reduced speed/load, etc. whereas it perhaps would not have been used according to other schemes not deriving/estimating the present or actual (near-) future state of the operational equipment (and/or the forces estimated to act on it). This enables greater usage of the operational equipment.

(21) The at least one operational control and/or state unit 100 may derive data representing a state of at least one given operational equipment 300 in response to the data derived from the mathematical model. In some embodiments, the state is derived for an operation using one but often multiple operational equipments 300. The state may be presented to a controller and/or an operator e.g. at the operational equipment 300 and/or at a control centre (e.g. at the control tower 50). The state may comprise one or more selected from the group of: normal operation (e.g. associated with a green light indicator), cautionary operation (e.g. associated with a white light indicator), stop operation (e.g. associated with a yellow light indicator), and disconnect operation (e.g. associated with a red light indicator).

(22) In some examples, at least one operational control and/or state unit 100 may derive data representing a state of proceeding operation with a lower than normal operational speed/load. For example, the system 100 may permit decisions to derate equipment for reduced speed/loading as necessary to reduce wear and tear. This may allow for an extension of time intervals between overhaul or maintenance of operational equipment 300.

(23) In some embodiments, the at least one processing unit 102 is adapted to provide data representing a control signal for at least one given operational equipment 300 in response to the derived data representing an estimation. In this way, a given operational equipment may be controlled (at least to some extent).

(24) In some embodiments, the at least one processing unit 102 is adapted to provide data representing a state and/or a control signal for at least one operation involving a plurality of operational equipments 300. This enables state and/or control of operations, tasks, etc. involving several operational equipments 300 working in conjunction. Such operations, tasks, etc. may e.g. be a drilling operation, blowout preventer (BOP) landing operation, Crane operations, ROV operations, Riser and BOP operations, landing and other handling of subsea X-mas trees etc.

(25) In some embodiments, the at least one processing unit 102 is adapted to provide data representing a maximum operational speed and/or load limit for a given operational equipment 300. This governs and ensures safe operation.

(26) The input supplied to the at least one operational control and/or state unit 100 may e.g. be one or more selected from the group of sensors and/or data from control systems below (or derived data based on these), the vessel model and operational limits of the equipment and current position of the equipment if it moves relative to the rig. Some equipment may be added for specific operations so its data must be provided whereas other equipment is substantially permanently installed but the operational limits may have to be revised as the equipment ages or if it is replaced or upgraded.

(27) The output supplied from the at least one operational control and/or state unit 100 may e.g. be one or more selected from the group of: serial interface to another system, analog interface to another system, digital interface to another system, HMI to another system. This interface can control equipment or group of equipment to safe operation mode. This interface can be used as guidance and indication to operator to go to safe operation mode.

(28) Furthermore, condition based maintenance (CBM) may utilize the data from the at least one operational control and/or state unit which can provide a record of the forces to which the equipment 300 has been exposed thus enabling better prediction of when the equipment may require maintenance.

(29) In some embodiments, the at least one sensor unit 200 is/are one or more selected from the group of: a pitch and roll sensor, a motion reference unit, a gyroscope, an accelerometer, a global positioning system or other positioning sensor, a weather station, a wind sensor, an inertial measurement unit, a near surface water current measurement unit, a near seabed water current measurement unit, a Doppler water current sensor, a single-point water current meter, a water current profiler unit, a vessel water current sensor, a water current sensor located on a marine riser, Riser management system Doppler radar, Motion Reference Units (MRU (s), gyro compass, current measurements surface, current measurement in ocean down to 4000 m or beyond, wave high measurements, Doppler radar, weather station, shock sensor(s), equipment behaviour measurements, Data and/or state information of control systems such as the ballast system, dynamic positioning system, active heave compensation systems of the hoisting system for the well centre(s) (e.g. an active heave compensation drawworks, hydraulic cylinders hoisting system, crown mounted heave compensators etc.), active heave compensation systems for cranes, Dynamic Position (DP) system, Drilling Control Network (DCN), Mud control system (MCS) and similar measurements and control systems interfacing to the controller.

(30) In some embodiments, the at least one operational equipment 300 is/are one or more selected from the group of: a pipe racking equipment, a crane or other lifting and/or hoisting equipment, a blowout preventer, at least one equipment hanging off of the drilling or work-over rig and in the water (such as in a splash zone, at certain depths such as about 10 to about 100 meters+interval op till 3 km or beyond), near the seabed (such as about within 1 meter, within 5 meters, within 10 meters, within 20 meters, within about 50 to about 100 meters), blowout preventer, marine riser, and/or X-mas tree, active or passive heave compensation equipment.

(31) The computational physics model of the rig/vessel 10 may be customised or may alternatively be based on models already used somewhere on the vessel for certain embodiments. As one example of such an existing system already incorporating a vessel 10 a model is the control system for the dynamic positioning (DP) system. Accordingly, the at least one operational control and/or state unit may in one embodiment be incorporated into the control system for the DP system. In some embodiments, the at least one operational control and/or state unit is arranged to predict maximum dynamic forces on the operational equipment based on the pattern in the sensor measurements e.g. wind, vessel motions and/or currents.

(32) Examples of systems that may apply MRU sensors and in which the at least one operational control and/or state unit may be incorporated or connected includes Active heave compensation system for winch (s), active heave compensation system for crane(s), Crown Mounted Compensator (CMC), Active heave compensation for drawwork.

(33) According in some examples, there is a computer-implemented method of providing operational control and/or state in a drilling or work-over rig 500, wherein the method comprises obtaining one or more measured physical values from at least one sensor unit 200, providing data representing the one or more measured physical values and/or derived values thereof to at least one operational control and/or state unit 100, deriving, by at least one processing unit 102, data representing an estimation of one or more physical states (such as defined by limits of forces, relative motion between operational equipment and vessel, or between other two pieces of operational equipment) estimated to act on at least one operational equipment 300 presently or within a predetermined near-future period of time in response to the data representing the one or more measured physical values and/or derived values thereof as provided by the at least one sensor unit 200, and a data representation of a computational physics model of at least a part of the drilling or work-over vessel stored in a memory and/or storage 103 accessible by the at least one processing unit 102.

(34) In some embodiments, the method carries out one or more functions of a drilling or work-over rig/vessel 10 as described above.

(35) In some examples, features and methods described above may be provided on to a computer readable medium comprising encoded instructions for carrying out the method listed above.

(36) The at least one operational control and/or state unit 100 may e.g. also provide operational control and/or state data in response to the relative movement between one or more operational equipment 300 and the rig.

(37) In use, and as generally described, the control system 100 can obtain data from sensor units 200, whereby that data represents measured physical values. The control system 100 can then use the computational physics model of at least part of the vessel so as to derive data representing an estimation of one or more physical states of the multiple operational equipment at the vessel.

(38) As mentioned, the physical states of the operational equipment may provide an indication as to the operability of the operational equipment, based on data received from the sensor units 200, for example, whether, or to what extent, the operational equipment 300 may be operable within an operational window (e.g. a safe/optimal window). Further, the physical states may comprise an indication as to whether the equipment 300 is operable in normal operation; cautionary operation; reduced operation (e.g. reduced speed and/or load); stop operation; disconnect operation, or the like.

(39) As has been described, in some examples, the physical state may be derived from an estimation as to the limits of forces experienced by certain equipment, relative motion between operational equipment and rig, or between two or more operational equipment. In similar words, the physical state may include an indication of any interaction with the other operational equipment or the vessel. In practical terms, this may mean that the physical state is based on the likelihood of clashing or bottlenecks with other equipment or the vessel. For example, this may be based on the potential clashing between a riser 70 and the moonpool 80, based on data from sensor units. It will be appreciated that the riser angle may be influenced by current. Therefore, the control system 100 may be configured to use data from sensor units 200 measuring water current and vessel motion, together with the physical model.

(40) As highlight above also, while in some cases, the control system may provide an output indicating states in real time, it may additionally provide an indication as to the future physical state of operation equipment 300. For example, the future state may relate to an estimation as to the state of that equipment in a predefined time in the future, such as in 30 mins, 1 hour, 2 hours, 4 hours, 6 hours, 12 hours, or the like. This may be presented to an operator (e.g. at the control tower 50).

(41) In doing so, the control system 100 may be configured to estimate, using the present data received from the sensor units 200 for example, the present state and/or the future state of the equipment. In some cases, additional data may be used, such a weather forecast or the like, which may help provide the estimation of future state. The control system 100 may also be configured to derive an expected duration of state for operation equipment by deriving data indicating how long a particular operational equipment is expected to remain in a particular state.

(42) In some cases, the control system 100 may be configured to estimate, using the present data received from the sensor units together with previous data (e.g. from sensor units), one or more future physical states/duration of state of the operational equipment. In other similar words, the control system may be configured to forecast the future state based on the present data together with historical data. For example, the control system 100 may be configured to extrapolate present data and historical data in order to forecast the future state. In some cases, tidal and/or weather forecast may be used by the control system in order to predict future states.

(43) Throughout the description, the used symbols in the drawings may have a different meaning than what they traditionally may represent. In such cases, the meaning is then the meaning as written in the description.

(44) In the claims enumerating several features, some or all of these features may be embodied by one and the same element, component or item. The mere fact that certain measures are recited in mutually different dependent claims or described in different embodiments does not indicate that a combination of these measures cannot be used to advantage.

(45) It should be emphasized that the term comprises/comprising when used in this specification is taken to specify the presence of stated features, elements, steps or components but does not preclude the presence or addition of one or more other features, elements, steps, components or groups thereof. However, on the other hand the term comprises/comprising is intended to also include embodiments where the particular articles is formed entirely by the comprised features.