MACHINES, SYSTEMS, COMPUTER-IMPLEMENTED METHODS, AND COMPUTER PROGRAM PRODUCTS TO TEST AND CERTIFY OIL AND GAS EQUIPMENT
20180179859 ยท 2018-06-28
Inventors
Cpc classification
H04B5/20
ELECTRICITY
E21B43/2607
FIXED CONSTRUCTIONS
E21B41/00
FIXED CONSTRUCTIONS
G06F15/00
PHYSICS
G01V11/002
PHYSICS
E21B44/00
FIXED CONSTRUCTIONS
International classification
E21B41/00
FIXED CONSTRUCTIONS
E21B44/00
FIXED CONSTRUCTIONS
H04B5/00
ELECTRICITY
Abstract
Embodiments of machines, systems, computer-implemented methods, and computer program products certify oil and. gas well equipment. Embodiments identify a selected well equipment device, a device test specification, and testing sequences to be performed by a corresponding testing apparatus. Embodiments select a testing sequence responsive to the selected device. Embodiments control the testing apparatus for the selected testing sequence so that the corresponding testing apparatus performs the sequence responsive to the device test specification. Embodiments generate testing data for the selected testing sequence and link the testing data for the selected testing sequence to the device identifier for the device so that a certificate can be generated. Embodiments generate a certificate for the selected device responsive to the testing sequences having been performed upon the selected device and link the certificate for the selected device to the device identifier so that the certificate can be readily recalled.
Claims
1. (canceled)
2. A system for electronically certifying an oil and gas device, the system comprising: memory accessible by one or more servers, the memory storing a database of associations of device identifiers corresponding to a plurality of oil and gas equipment; and one or more processors programmed for: receiving a device identifier stored on an electronic tag affixed to an oil and gas device from a device of a user testing the oil and gas device, identifying the oil and gas device in the database based on the received device identifier, accessing a history of previous testing of the identified oil and gas device, selecting a sequence of testing operations for the user testing the oil and gas device to perform based on the previous testing of the identified oil and gas device, transmitting the testing operations to the device of the user for instructing the user to perform the testing operations, receiving, from the device of the user, test data responsive to performance of at least one of the testing operations, and storing the received testing data in the database in association with the identified oil and gas device.
3. The system of claim 2, wherein the electronic tag affixed to the oil and gas device comprises an RFID tag storing the device identifier.
4. The system of claim 2, wherein the device of the user comprises an RFID reader for accessing the device identifier from the electronic tag.
5. The system of claim 2, wherein said one or more processors are further programmed for: analyzing the testing data responsive to the performance of the at least one of the testing operations, determining the oil and gas device passed the at least one of the testing operations, and generating a certificate certifying the oil and gas device for operation based, at least in part, on said determination that the oil and gas device passed the at least one of the testing operations.
6. The system of claim 5, wherein said one or more processors are further programmed for storing the generated certificate indicating the oil and gas device is certified for operation in the database linked to the device identifier associated with the oil and gas device.
7. The system of claim 2, wherein said one or more processors are further programmed for: analyzing the testing data responsive to the performance of the at least one of the testing operations, determining the oil and gas device failed the at least one of the testing operations, and generating a certificate certifying the oil and gas device is to be discarded based, at least in part, on said determination that the oil and gas device failed the at least one of the testing operations.
8. The system of claim 7, wherein said one or more processors are further programmed for transmitting the generated certificate indicating the oil and gas device is to be discarded to the device of the user testing the oil and gas device for communication to the electronic tag affixed to the oil and gas device.
9. The system of claim 2, further comprising a band affixed to the oil and gas device for holding the electronic tag.
10. The system of claim 2, wherein the selected oil and gas device comprises at least one member of a group comprising: a slurry blender, a fracturing pump, a pipe, a swivel joint, a pup joint, a plug valve, a check valve, a relief valve, a ball injector, a crow's foot, an air chamber, a crossover, a hose, a pipe, a hose loop, a ball injector tee body, a tee, a wye, a lateral, an ell, a check valve, a plug valve, a wellhead adapter, a swivel joint, a plug, a cross, a valve seat, a valve head, a frac pump, or a cement pump.
11. The system of claim 2, wherein said one or more processors are further programmed for identifying, based on the received device identifier, a testing sequence comprising the testing operations, the testing sequence comprising one or more benchmark parameters to which the testing operations are to be performed.
12. The system of claim 2, wherein said one or more processors are further programmed for: identifying at least one testing apparatus to perform the at least one testing operation, and providing instructions to the device of the user for operating the at least one testing apparatus to perform the at least one testing operation, wherein said testing data originates from the at least one testing apparatus performing the at least one testing operation.
13. A method for electronically certifying an oil and gas device being tested by a testing user, the oil and gas device having an electronic tag affixed thereto that stores a device identifier associated with the oil and gas device, the method comprising: accessing the device identifier from the electronic tag; transmitting the device identifier from a device of the testing user to one or more servers that have access to previous testing data associated with the oil and gas device; receiving one or more testing operations to perform on the oil and gas device, the one or more testing operations selected based on the device identifier and the previous testing data associated with the oil and gas device; instructing the testing user to perform the one or more testing operations; capturing testing data responsive to performance of the one or more testing operations on the oil and gas device; and transmitting the testing data to the one or more servers for use in generating a certificate indicating the oil and gas device is either ready for operation or is to be discarded.
14. The method of claim 13, wherein the one or more testing operations comprise at least one of a wall thickness test, a pressure test, or visual inspection test.
15. The method of claim 13, wherein said instructing the testing user to perform the one or more testing operations comprises performing the wall thickness test before performing the pressure test.
16. The method of claim 13, further comprising: receiving the certificate from the one or more servers; and transmitting the certificate to the electronic tag for storage thereon.
17. The method of claim 13, wherein the electronic tag comprises an RFID tag and said accessing of the device identifier from the electronic tag is performed by a computing device of the testing user.
18. The method of claim 13, further comprising receiving the certificate and presenting the testing user with a notification that the oil and gas device is either ready for operation or is to be discarded.
19. The method of claim 13, further comprising wirelessly transmitting the certificate for storage on the electronic tag affixed to the oil and gas device.
20. One or more non-transitory memory embodied with machine-executable instructions for certifying an oil and gas device being tested by a testing user, the oil and gas device having an electronic tag affixed thereto that stores a device identifier associated with the oil and gas device, comprising: receiving, from the device of the testing user, the device identifier stored on electronic tag of the oil and gas device to be tested; selecting, based on the received device identifier, testing operations for certifying the oil and gas device; notifying the device of the testing user of the selected testing operations; receiving testing data upon performance of the selected testing operations by the testing user; comparing the received testing data against testing criteria for the oil and gas device; generating a certificate for storage on the electronic tag indicating the oil and gas device is either fit or not fit for use based on the comparison of the received testing data against the testing criteria; and transmitting the generated certificate to the device of the testing user for storage on the electronic tag.
21. The one or more non-transitory memory of claim 20, wherein said receiving the upon performance of the selected testing operations by the testing user comprises: identifying a testing apparatus available to the testing user for performing at least one of the selected testing operations; controlling, by the one or more servers, the testing apparatus over a network during performance of the at least one of the selected testing operations; and receiving the testing data over the network from the testing apparatus.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] So that the manner in which the features and benefits of the invention, as well as others which will become apparent, may be understood in more detail, a more particular description of the invention briefly summarized above may be had by reference to the embodiments thereof which are illustrated in the appended drawings, which form a part of this specification. It is also to be noted, however, that the drawings illustrate only various embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it may include other effective embodiments as well.
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DETAILED DESCRIPTION
[0053] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, which illustrate various embodiments of the invention. This invention, however, may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. It is to be fully recognized that the different teachings of the various embodiments discussed below may be employed separately or in any suitable combination to produce desired results. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the various embodiments, and by referring to the accompanying drawings. In the drawings and description that follow, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The prime notation, if used, indicates similar elements in alternative embodiments. The drawings are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness.
[0054] Accordingly, embodiments of the present invention improve safety, effectiveness, and efficiency of operating well equipment by meeting the foregoing objectives to mitigate the likelihood and impact of the failure of such equipment. In embodiments of the present invention, well equipment devices includes the equipment and devices used in hydraulic fracturing for oil and gas wells, i.e. high pressure hydraulic fracturing flow iron, frac iron, or, simply, iron. Frac iron can include, for example, a slurry blender, high pressure/volume fracturing pumps, high pressure treating iron, and other pipes, joints, valves, and fittings. For example, frac iron can include swivel joints, pup joints, plug valves, check valves and relief valves. Furthermore, by way of example, frac iron can include any type of ball injector, crow's foot, air chamber, crossover, hose, pipes/piping, hose loop, ball injector tee body, tee, wye, lateral, ell, check valve, plug valve, wellhead adapter, swivel joint, plug, relief valve, densometer, cross, frac pump, or cement pump. Those skilled in the art will appreciate that embodiments of the present invention are not limited to uses related to in oil and gas wells, but, rather, embodiments of the present invention are applicable to processes for testing or certifying any industrial equipment or device, and at any stage in the lifespan of the equipment, including during or after manufacturing and before, during, or after use or ongoing operations.
[0055]
Central Management Server 100
[0056] An embodiment of a central management server 100, as illustrated in
[0057] I/O 252 connects the central management server 100 to a database 170, a testing interface 150, and one or more testing apparatus 110 (although represented as one block, those of skill in the art will appreciate that a plurality of testing apparatus 110 may include one or more links to the I/O) to thereby allow central management server 100 to send and receive commands and data, I/O 252 can be any I/O including, but not limited to a network card/controller connected by a PCI (Peripheral Component Interconnect) bus to the motherboard, or hardware built into the motherboard of the central management server 100 to connect same to the forgoing database, interface, and apparatus.
[0058] As those of skill in the art will appreciate, I/O 252 can connect the central management server 100 with any other compatible machine, server, system, device, or equipment having a suitable physical interface and that I/O 252 and/or computer program products 210, 220, and 230 on non-transitory memory 240 may be positioned to understand, convert, or translate application or communication protocols of such machines, servers, systems, devices, or equipment irrespective of native protocols. Also, one of skill in the art will understand that I/O 252 can include or otherwise incorporate any logical or physical technology necessary to effect a connection with any of the aforementioned devices, including, for example, hubs, switches, routers, converters, amplifiers, and wireless transceivers. For example, as is further described herein, I/O 252 can also connect the central management server 100 to devices for interacting with radio frequency identification (RFID) devices, such as an RFID reader or interrogator 130 and an RFID writer 140. The central management server 100 can further connect to a remote user interface 160 for interacting with a remote user 161, as is also discussed further herein. Also, the plurality of testing apparatus 110, RFID reader 130, and the RFID writer 140 may be configured as peripherals to the testing interface 150. Also, there a testing apparatus 110 interface 253, such as a programmable logic controller (PLC), an interface between the I/O 252 and the plurality of testing apparatus 110 to control the plurality of testing apparatus 110.
[0059] As can be seen in
[0060] Non-transitory memory 240 stores computer program products 210, 220, and 230 having instructions for execution on the processor 251, and consists of both non-volatile memory, e.g., hard disks, flash memory, optical disks, and the like, and volatile memory, e.g., SRAM, DRAM, and SDRAM as required to support embodiments of the instant invention. As one skilled in the art will appreciate, though the non-transitory memory 240 is depicted on, e.g., a motherboard, of the central management server 100, the non-transitory memory 240 may also be a separate component or device, e.g., FLASH memory, connected to the central management server 100 through the I/O 252. The non-transitory memory 240 may also store applications that various workstations or remote units can access and run on the central management server 100. For example, a testing user 151 may access applications and computer program products stored on the non-transitory memory 240 and run on the processor 251 using the testing interface 150. Importantly, non-transitory memory 240 stores the program products 210, 220, and 230 of the instant invention. As one skilled in the art will understand, the program products 210, 220, and 230, along with one or more databases/tables/fields/records for data associated with the selected well equipment device 101 can be stored either in non-transitory memory 240 or in separate non-transitory memory associated, for example, with a storage medium such as database 170, positioned in communication with the central management server 100.
Database 170
[0061] As seen in
[0062] The database 170 can store therein a data structure or data structures relating to the well equipment devices 101 to be tested and all data generated during the execution of the testing module 211 and certification module 210, as is further discussed herein. In embodiments, database 170 is a relational database positioned to match data by using common data found between data sets, the data sets being organized according to tables 400, 410, 420, 430, 440, and 450 as seen in
Testing Apparatus 110
[0063] As shown in
[0064] Although shown as separate blocks in
[0065] The plurality of testing apparatus 110 and a PC incorporated with a peripheral testing apparatus 110 can be a mobile unit or units having remote or wireless connectivity to central management server 100 using any protocols or standards known in the art, including Wi-Fi, GSM, and WIMAX, for example. Mobile units may also be synchronized with central management server through periodic wired or wireless connections when returning from field use. The PC can be, for example, any suitable PC known in the art and is preferably a Panasonic? Toughbook? or other portable, notebook, laptop, or tablet computer preferably designed to withstand vibration, drops, spills, extreme temperature, and other rough handling and conditions common to industrial use.
[0066] The UT meter can be, for example, an Olympus? MG2DL, or any similar UT meter known in the art. The UT meter can include, for example, features such as B-scan, gain adjust, auto sensitivity optimizations, echo-to-echo, differential mode, hi-low alarm, and live A-scan. The UT meter can also include a file-based alphanumeric data logger and an interface program for transferring data bi-directionally to and from a PC. The testing apparatus 110 can include a PC, such as described above, for enabling data and control functions of a peripheral testing apparatus 110 such as a UT meter.
[0067] The pressure test pump and transducer can be any suitable pressure test pump known in the art. Preferably, embodiments of the invention employ an X45 series model 345 Viatran? test and control pressure sensor, which can, for example, operate in the range of 0-100,000 psi with output in the range of 4-20 mA. As is known in the art, the testing apparatus 110 can include a control interface such as a programmable logic controller (PLC) for communication with and control of the pressure test pump and transducer.
Testing User 151 and Testing Interface 150
[0068] As described above, a testing user 151 may employ embodiments of the present invention, for example, by positioning the frac iron to be tested 101 in a testing station adapted for the test to be performed, and will manually configure the frac iron 101 to safely and effectively interact with the testing apparatus 110 for the intended test. In other embodiments, the testing user may perform testing operations according to instructions provided by the central management server 110 and displayed, for example, on the testing interface 150. The testing user 151 may provide the means of manually gathering testing data 440 as shown in
[0069] Also as described above, the testing interface 150 may be a PC, which may be any desktop, laptop, notebook, tablet, or portable computer known to those in the art. As is known the art, the testing interface 150 can include any number of peripheral devices to interact with the testing user 151, including a keyboard, mouse, control stick/joystick, and memory reader for receiving data input and a display screen, printer, and local storage device for outputting or storing data. Furthermore, embodiments of invention have a testing interface with a touch-sensitive screen (e.g., using a stylus) for interactive display/input so that users can select parts responsive to viewing them on the display of the testing interface 150 and thereafter performing testing operations responsive to the selection, in communication with the testing module 210. The testing interface 150 may connect with the central management server 100 via any communications interface known to those of skill in the art, wired or wireless, and is preferably a secure local Intranet or other authenticated and encrypted communications network, including a VPN over the Internet.
Certificate 500
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[0071] The certificate 500 can reference the well equipment device 101 by a unique device identifier, such as the serial number 501, which can relate to data stored in database 170 in the device information table 400. The certificate 500 can contain a summary indication as to whether certain test sequences were graded as a PASS or a FAIL 502. The grading operation, for example, can be performed by a certification module 220 computer program product operating on the central management server 100. The PASS or FAIL grading 502 can relate to data stored in the database 170, for example, the certificate data 450 and the testing data 440 shown in
[0072] The certificate 500 can also contain a summary indication as to measured qualities of the selected well equipment device 101 and their relation to the qualities demanded by the test specification. For example, measured wall thickness value 505 appears adjacent to demanded wall thickness value 506. Additionally, drawing 504 shows a graphical representation of the parameters measured according to the test specification, as referenced by letter key (e.g., A, B, and C).
[0073] In certain embodiments of the present invention, a certificate can be stored in a proprietary data table format so that a lightweight electronic copy of the certificate, and an RFID certificate can be stored directly onto RFID tag 135 attached to the selected well equipment 101. For example, as understood by those skilled in the art, the RFID certificate can be written to an RFID tag 135 attached to the well equipment so that the certificate can be readily accessed in the field using an RFID reader device 130 capable of recognizing the proprietary data table format. The RFID certificate can include all fields available on the paper certificate 500, including device identifier 501, pass or fail grading 502, tabular summary or rendering of test data 503, drawing 504, measured values 505, and demanded values 506. The tabular summary or rendering 503 and the drawing 504 can be encoded, for example, using lightweight vector-based primitive formats. Also, RFID certificate will allow new schemes for protecting certificate data heretofore unavailable for field use, for example, by having individual cells in the table that are protected according to user access schemes such as read-only, read-write, or no access. For example, the serial number and the certification may be read-only to all; the certificate data may be read-only to many and read-write to few; and custom fields may be user-configurable.
Testing Module 210
[0074] As is shown in
[0075] The testing module 210 can interact with the processor to receive or transmit data, instructions, and other information from or to any of the devices connected to I/O 252. In embodiments discussed below, the testing module 210 at least interacts with the testing interface 150, testing apparatus 110, RFID reader 130, and database 170. Although testing interface 150 has been described to be a personal computer (PC), testing interface 150 can also be implemented in whole or in part as a user terminal interface on the central management server 100 itself, or using a keyboard, display, or media inputs and outputs connecting to the I/O 252. Testing interface 150 can also be a lightweight graphical user interface (GUI) operable over a web browser and viewable on any browser-enabled device, such as a PC, smart phone, or other equipment having a processor and computer functionality. Testing interface 150, for example, can receive user-selected identifiers or other user-selected values or parameters from a testing user as will be described in further detail below and can display identifiers, values, parameters, and other specification data, for example, as can be shown with reference to the selection, input, or display fields 900, 1000, 1100-1101, and 1200-1205 in
[0076] The testing module 210 can receive a device identifier for a selected well equipment device 101, the selected well equipment device being a well equipment device positioned to undergo testing and certification, i.e., in the testing warehouse, on a testing trailer, or otherwise positioned at a testing station. In the embodiment of the present invention, only one well equipment device is tested at any given time using any particular testing apparatus 110. It is possible, however, that multiple instances or threads of the testing module 210 can run on the processor 251 concurrently, with each instance being directed to the testing of a different piece of well equipment positioned for testing. It is also possible that multiple testing apparatus 110 of the same type may be employed to perform the same test sequence in simultaneous testing operations performed on multiple well equipment devices 101.
[0077] The testing module 210 can receive a serial number as a device identifier as shown in
[0078] The testing module 210 can identify the selected well equipment device responsive to the device identifier as shown in and match the selected well equipment to: (i) device library information as shown in
[0079] The test profile as shown in
[0080] Level 1, as set forth in
[0081] Level 2, as set forth in
[0082] Level 3, as set forth in
[0083] Test sequences 1300 can include, for example, visual inspection, wall thickness inspection, disassembly/assembly, magnetic (mag) particle inspection, pressure test, paint, and final inspection. As shown in
[0084] Test sequences as shown in
[0085] Once the testing interface 150 displays the plurality of test sequences 440 available for the well equipment device, the testing user 151 can select a test sequence to be performed. The test sequence should correspond to the testing user positioning the selected well equipment device so that the testing apparatus 110 can perform the testing operations. For example, if the testing user 151 has selected the pressure test sequence, the testing user must also ensure that the appropriate testing apparatus 110 (e.g., the pressure pump and transducer) is positioned upon the selected well equipment device so that the test can be properly performed.
[0086] If the testing user 151 has selected the pressure test sequence or the wall thickness inspection sequence, the testing module 210 will calibrate the testing apparatus 110 as shown in
[0087] According to certain embodiments of the present invention, the testing module 210 systematically controls the performance of testing operations in certain test sequences. For such testing modules having full systematic control of performing the testing operations, e.g., the pressure test sequence, the testing user 151 can initiate the performance of the testing operations to be controlled by the central management server 100, as shown at control deck 1600 in
[0088] In further embodiments of the present invention, the testing module 210 systematically controls the performance of some testing operations and requires manual performance of other testing operations (hybrid systematic/manual). For testing modules having hybrid systematic/manual performance of testing operations, such as for wall thickness inspection, the testing user 151 can initiate the performance of the testing operations to be controlled by the central management server 100, and the central management server 100 can control the testing apparatus 110 as discussed above with respect to fully systematic testing. Also, the testing module 210 can prompt the testing user 151 with instructions for the testing user 151 to perform testing operations pursuant to the test specification. As shown in
[0089] In further embodiments of the present invention, the testing module 210 requires full manual performance of the testing operations for certain test sequences. For testing modules having full manual performance of testing operations, such as for the visual inspection sequence, the testing module 210 can prompt the testing user 151 with instructions for the testing user 151 to perform testing operations pursuant to the test specification. As shown in
[0090] Responsive to systematic, manual, or hybrid systematic/manual performance of the test operation described above, the testing module 210 receives testing data either as captured by the testing apparatus 110 for the corresponding testing sequence or as captured by the testing user 151 and entered into the testing interface 150 according to specific instructions provided by the testing module 210, e.g., at banding menu 2000. As shown in
[0091] Additionally, further embodiments of the present invention include certain test sequences as described in
Certification Module 220
[0092] As is shown in
[0093] The certification module 220 can interact with the processor to receive or transmit data, instructions, and other information from or to any of the devices connected to I/O 252. In addition both the certification module 220 and the testing module 210 are in communication with the processor 251 and the non-transitory memory 240 so that modules can pass or return variables between modules according to a shared API or access global variables being stored on the non-transitory memory 240 to ensure interoperability and open communication between computer program products in communication with the processor 251. Likewise, those skilled in the art will understand that computer program products 220 and 210 are capable of passing, returning, or referencing common variables regardless of whether computer program products are executed on the same processor 251, but that a common API will allow interoperability and open communications. In embodiments discussed below, the certification module 220 at least interacts with the testing interface 150, RFID reader 130, RFID writer 140, and database 170. Although testing interface 150 has been described to be a PC, testing interface 150 can also be implemented in whole or in part as a user terminal interface on the central management server 100 itself, using a keyboard, display, or media inputs and outputs connecting to the I/O 252. The testing interface 150 can also be a lightweight graphical user interface (GUI) operable over a web browser and viewable on any browser-enabled device, such as a PC, smart phone, or other equipment having a processor and computer functionality.
[0094] The certification module 220 can receive a device identifier for a selected well equipment device 101. As described above, well equipment devices includes the equipment and devices used in hydraulic fracturing for oil and gas wells, i.e. high pressure hydraulic fracturing flow iron, frac iron, or, simply, iron. Frac iron can include, for example, a slurry blender, high pressure/volume fracturing pumps, high pressure treating iron, and other pipes, joints, valves, and fittings. For example, frac iron can include swivel joints, pup joints, plug valves, check valves and relief valves. Furthermore, by way of example, frac iron can include any type of ball injector, crow's foot, air chamber, crossover, hose, pipes/piping, hose loop, ball injector tee body, tee, wye, lateral, ell, check valve, plug valve, wellhead adapter, swivel joint, plug, relief valve, densometer, cross, frac pump, or cement pump. The selected well equipment device is a well equipment device that has previously undergone testing, for example, as described above with respect to the testing module 210. The certification module 220 can receive a device identifier, for example, responsive to receiving input from the testing interface 150 as entered therein by a testing user 151. The certification module 220 can also receive a device identifier, for example, responsive to receiving input from a remote user interface as entered therein by a remote user 161. Furthermore, the certification module 220 can receive a device identifier from the testing module 210 responsive to the testing module 210 having completed execution of the testing operations and the generation and linking of the testing data in the database 170. The certification module 220 can identify a selected well equipment device responsive to the device identifier and generate and link certification data in database 170, for example, in certification table 450, responsive to the testing data. For example, the certification data 450 can include all data as can be entered onto certificate 500 as a summary or other rendering of testing data responsive to testing operations being performed on the well equipment device 101, for example, a graphical representation of a pressure test 503. The certification module 220 can include logic to generate charts and data modeling based upon testing data, which is raw data stored, for example, in table 440. Further examples of summaries or renderings of raw testing data responsive to the testing operations appear on the face of certificate 500. As a result of the linking operation, the certification data 440 can be readily accessed or queried according to a serial number for a well equipment device.
[0095] The certification module 220 can also generate certification data in a format responsive the proprietary data table format for the exemplary RFID certificate. For example, certification module 220 may generate certificate data according to specific standards or protocols employed in the proprietary standard, for example, cell size, packet size, header length, payload length, etc. The RFID certificate can be generated so that it is ready to be stored to the media attached to the well equipment without further processing. The certification module 220 may also include logic for rendering graphics stored as certification data, such as the schematics and charts, into a lightweight graphics formats such as vector graphics formats. The RFID certificate, for example, can include all fields available on the paper document, including device identifier 501, pass or fail grading 502, tabular summary or rendering of test data 503, drawing 504, measured values 505, and demanded values 506. The tabular summary or rendering 503 and the drawing 504 can be encoded in lightweight vector graphics formats, for example.
Reporting Module 230 and Enterprise Resource Planning Interface
[0096] As is shown in
[0097] The reporting module 230 can interact with the processor 251 to receive or transmit data, instructions, and other information from or to any of the devices connected to I/O 252. In addition, both the reporting module 230 and the testing module 210 are in communication with the processor 251 and non-transitory memory 240 so that these two modules can pass or return variables between each other according to a common application programming interface (API) or shared global variables being stored on the non-transitory memory 240, thereby enhancing interoperability and open communication between the modules. Likewise, those skilled in the art will understand that computer program products 230 and 220 are capable of passing, returning, or referencing common variables regardless of whether computer program products are executed on the same processor 251 and that a common API will allow interoperability and open communications as described above. In embodiments discussed below, the reporting module 230 at least interacts with the testing module 210, certification module 220, and database 170. Although remote user interface 160 may be a PC as has been described for testing interface 150, remote user interface 160 can also be implemented in whole or in part as a user terminal interface on the central management server 100 itself, using a keyboard, display, or media inputs and outputs connecting to the I/O 252. Remote user interface 160 can also be a lightweight graphical user interface (GUI) operable over a web browser and viewable on any browser-enabled device, such as a PC, smart phone, or other equipment having a processor and computer functionality.
[0098] The reporting module 230 can receive a device identifier for a selected well equipment device 101, the selected well equipment device being a well equipment device that has previously undergone testing, for example, as described above with respect to the testing module 210. The reporting module 230 can receive a device identifier, for example, responsive to receiving input from the testing interface 150 as entered therein by a testing user 151. The reporting module 230 can also receive a device identifier from any other module, as discussed above. In response to receiving the device identifier, the reporting module 230 can match the device identifier to any desired data in the database 170, for example, testing data in the database at testing data table 440, certification data in the certification data table 450, device library data from the device library table 410, and test specification data from the specification library 420. The reporting module, responsive to the device identifier, can return any of the test specification for the selected well equipment device 101, testing data for a plurality of testing sequences performed on the selected well equipment device 101, and certificate data for the selected well equipment device 101, for example, according to the database structure provided in
[0099] The reporting module 230 may also receive an indication or selection of additional variables for reporting purposes, for example, a part number, work order number, etc. In the event that the reporting module 230 receives an additional variable, the reporting module 230 can or expand or refine the matched data with respect to the additional variable. For example, the reporting module 230 may receive a device identifier, a work order number, and the reporting module 230 will return a list of all certifications, tests, or specifications for that device identifier according to the tests performed under the received work order number. On the other hand, a reporting module 230 may receive a device identifier and a part number, and the reporting module 213 will return a list of all certifications, tests, or specifications for either the selected well device 101 or all well devices tested having the selected the part number.
[0100] Embodiments of the present invention employing the reporting module 230 are beneficial in that they transform the task of testing and certificationonce a costly operational hurdleinto a robust data-point in business and operational management decisions. For example, manufacturers may use embodiments of the reporting module in research and development to better understand wear patterns and rates in real-world applications, to build a better product, and to manage customer relations. As those skilled in the art will appreciate, the reporting module 230 can be a powerful tool in achieving management-level value from systematic testing and certifications, which provides a comprehensive and reliable (i.e., consistent) pool of data pertaining to asset management, inventory management, purchasing, risk management, and other business analytics. Exemplary reports generated by the reporting module 13 are shown in
[0101] Furthermore, embodiments of the present invention can employ an ERP (Enterprise Resource Planning) interface (not pictured) connected to the I/O of the central management server 100 to provide the foregoing benefits realized by the reporting module, but in a manner that is more fully integrated into enterprise-wide information systems and providing high levels of cross-functional integration, network scalability, and real-time data synchronization. In particular, embodiments of the present invention employ an ERP interface for the purposes of invoicing the testing and certification operations, for example, responsive to work order information entered by a testing user 151 to the testing interface 150 as shown in
RFID 130, 135, 140
[0102] Furthermore, embodiments of the present invention can achieve some or all of the foregoing objectives by providing a central management server 200 that can communicate with one or more well equipment devices 101. For example, the central management server 200 can be in communication with the one or more well equipment devices using wireless communication technologies, for example, radio frequency identification (RFID) technologies. The one or more well equipment devices 101 can include an RFID tag 135, and the central management server 200 can communicate with the RFID tag 135 on the one or more well equipment devices using an RFID reader 130 in communication with the central management server 200 through the I/O 252. In an embodiment, the RFID tag is a UHF Gen-2 RFID tag that is attached to the frac iron using a clamp designed to be sufficiently robust so that the RFID tag is not affected by the harsh operating conditions of the downhole environment.
[0103] In an embodiment, the RFID reader 130 and RFID 140 are peripherals to the testing interface 150, attaching thereto by known connection means in the art, such as a USB cable or cables. In certain embodiments, the RFID reader and RFID writer may be one unit, such as an RFID reader/writer device.
[0104] The RFID reader 130 can read a device identifier from the RFID tag on a selected well equipment device 101 through radio frequency communication and transmit the device identifier to the central management server 200. The central management server is positioned to receive the device identifier from the RFID reader 130. Any of the computer program products discussed herein, such as the testing module 210, can receive a device identifier responsive to the central management server 200 receiving a device identifier from the RFID reader 130. An embodiment of a computer-implemented method for using the RFID reader 130 includes the testing user 151 having a handheld and/or remote RFID reader 130 in physical proximity to the selected well equipment device 101 and the RFID tag 135 thereon so that the testing user can interrogate the RFID tag 135 and so that the RFID tag can transmit the device identifier to the RFID reader 130.
[0105] The RFID writer 140 can write an RFID certificate to the RFID tag on a selected well equipment device 101 through radio frequency communication and transmit the device identifier to the central management server 200. The RFID certificate can have the qualities and properties as described herein, preferably including at least a serial number. The central management server is positioned to transmit the RFID certificate or any data included therein to the RFID writer 140 responsive to any of the computer program products discussed herein, such as the certification module 220. An embodiment of a computer-implemented method for using the RFID writer 140 includes the testing user 151 having a handheld or remote RFID writer 140 in physical proximity to the selected well equipment device 101 and the RFID tag 135 thereon so that the testing user can establish a communication link with the RFID tag 135 and so that the RFID writer can transmit and store the RFD certificate or the information therein to the RFID tag 135.
[0106] This application claims priority and is related to U.S. Provisional Patent Application No. 61/330,248 filed Apr. 30, 2010 titled Machines, Systems, Computer-Implemented Methods, And Computer Program Products To Test And Certify Oil And Gas Equipment, which is incorporated by reference in its entirety herein.
[0107] The foregoing has broadly outlined certain features, and technical advantages of the present invention and a detailed description of the invention so that embodiments of the invention may be better understood in light of features and advantages of the invention as described herein, which form the subject of certain claims of the invention. It should be appreciated that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized that such equivalent constructions do not depart from the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further advantages are better understood from the description when considered in connection with the accompanying figures. It is to be expressly understood, however, that such description and figures are provided for the purpose of illustration and description only and are not intended as a definition of the limits of the present invention. For example, although the example embodiments discussed herein are directed to oil and gas hydraulic fracturing operations, it should be specifically noted that the systems, machines, methods, and computer program products to test and certify well equipment devices may be employed to carry out similar functions for other equipment or devices requiring routine testing and certification, including without limitation, aircraft maintenance and construction, ship maintenance and construction, facilities maintenance and construction, and so on.