System and Method for Remote Real-Time Surveillance and Control of Pumped Wells
A system and method is provided for facilitating remote real-time surveillance, management, optimization, and control of pumping systems at a wellsite. A variety of sensors are deployed along pumping systems, such as electric submersible pumping systems, positioned in wellbores. Data from the sensors is output in real-time to a remote location via a network. The system analyzes the data to identify problems and potential problems in the pumping systems and suggest possible causes and corrective measures. The network can be used to provide two-way communication such that control signals may then be sent from the remote location to the pumping systems. Alarms may also be triggered when sensor data or data trends fall outside predetermined ranges.
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1. Field of the Invention
The present invention generally relates to well systems, and in particular to the management and optimization of well systems that use pumps, such as electric submersible pump (ESP) systems or pumping systems located at the earth's surface, for pumping hydrocarbon-based fluids.
2. Description of Related Art
In many artificially lifted wells, pumping systems are used to produce a desired fluid, e.g. petroleum, to a collection point. For example, a wellbore may be drilled into a subterranean reservoir, and the pumping system is used to lift fluid from the reservoir location to the collection point. Pumps are used to intake fluid from the wellbore and to pump the fluid upwardly or laterally through the wellbore via, for example, production tubing. Instrumentation can be deployed in the wellbore to monitor operation of the pumping system, which may be submersible or surface-mounted.
Although wellbore pumping monitoring and diagnostics systems have been in use for many years, the ability to transfer the data and/or utilize the data in controlling and optimizing pumping system operation has heretofore been limited.
BRIEF SUMMARY OF THE INVENTIONIn general, the present invention provides an improved system and method for cost effective real-time surveillance, management, optimization, and control of wellbore pumping systems at one or more wellsites. The technique utilizes real-time surveillance of wellbore pumping systems, transfer of data to one or more remote locations, provision of warnings based on the data, analysis of the data, and control over the one or more wellsites, and is designed to make the identification of wells with performance deficiencies highly efficient. A communications network is used to carry surveillance data and control signals in two-way communication.
BRIEF DESCRIPTION OF THE DRAWINGSCertain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
The present invention generally relates to a system and method for remote real-time surveillance, control, and optimization of wellbore pumping systems, e.g. electric submersible pumping systems, at a wellsite. The technique enables a well operator or well field manager to better manage and optimize operation a plurality of pumping systems without physically attending the wellsite. For example, the system and methodology enhances the monitoring, surveillance, diagnostics, and optimization of electric submersible pumps using real-time and on-time data in a cost efficient manner.
Referring generally to
Surveillance and control system 20 further comprises a remote control center 26 where surveillance data is obtained from wellsite 22 and pumping systems 24 on a real-time and on-time basis. Control center 26 may comprise one or more processor-based control systems 28, such as computer-based workstations where wellsite operators or managers can observe data obtained from wellsite 22 and pumping systems 24. This data is used for analysis, planning, and decision-making with respect to operation of pumping systems 24 and the overall wellsite. Additionally, control systems 28 can be used to provide control instructions to wellsite 22 along with, for example, action updates, data polling, and queries.
Either at remote control center 26 or at another remote location, surveillance and control system 20 comprises a data storage system 30 for retaining historical data. Data storage system 30 also can be used to provide user security controls, alarm and alert management, business process management, and other functionality in cooperation with remote control center 26. For example, remote control center 26 and data storage system 30 enable a multidiscipline collaboration and historical interrogation of wellsite data to aid in diagnostic analysis and optimization of pumping system operation.
Control system 28 in cooperation with data storage system 30 also can be used to instigate alarms/alerts when real-time data or data trends indicate changes causing concern with respect to operation of wellsite 22, e.g. movement of parameter values into a sub-optimal range or beyond a predetermined threshold value. The alerts can be provided at control system 28 and/or at a variety of other monitoring locations. For example, the alerts may be provided to remote handheld devices 32, such as cellular telephones 34 or personal digital assistants 36.
The two-way communication between wellsite 22 and the various remote locations, e.g. remote control center 26, data storage system 30, and remote handheld devices 32, is accomplished over a network 38. Network 38 can be established via a variety of transmission mechanisms, including wired and wireless mechanisms 40. For example, the two-way communication of data between wellsite 22 and the remote locations can be sent at least in part over the Internet. Portions of the network may be hardwired, may comprise satellites 42 for satellite transmission, may comprise cellular or radio towers 44 for wireless transfer, or may comprise a variety of other data transmission technologies for conveying data, including real-time data, between the wellsite 22 and the various remote locations of surveillance and control system 20.
Control system 28 is designed to automate processing of much of the data flow within surveillance and control system 20. In the present example, control system 28 is a computer-based system having a central processing unit (CPU) 46, as illustrated in
As illustrated by the flowchart of
The use of communication tools, such as network 38, control system 28, remote handheld devices 32, data storage systems 30, and other potential devices coupled into network 38, enables a well operator to facilitate surveillance and optimization of well behavior without traveling to the specific wellsite. As illustrated in the flowchart of
Furthermore, the well operator can program control system 28 and CPU 46 to provide alerts/warnings when well-related parameters fall outside a desired range or cross a specific set point, as illustrated by block 68. In many applications, the set points can be changed by sending appropriate control signals to wellsite 22 from a remote location, e.g. from remote control center 26 or from remote handheld devices 32. The use of network 38 also enables a well operator to control multiple well systems from one or more remote locations, as illustrated by block 70. Additionally, the storage of data by data storage system 30 and the processing of both real-time and historical data on control system 28 enables a wide variety of analyses to be performed by the well operator and/or others to better plan and optimize well operation, as illustrated by block 72. In some applications, the combination of real-time monitoring and data analysis, either automatic analysis at control center 26 or human analysis, ensures optimum performance of wellsite equipment, including electric pumping systems, variable speed drive controllers, multisensor artificial lift monitoring systems, and a variety of other components and systems.
One example of a wellsite 22 and welisite equipment used in the production of hydrocarbon-based fluids is illustrated in
In addition to sensor devices and other surveillance equipment, surveillance and control system 20 may comprise a variety of controllable devices 82 which regulate operation of each electric submersible pumping system 78. Controllable devices 82 are controlled remotely via control signals sent over network 38 from one or more remote locations, such as remote control center 26. One example of a controllable device 82 is a variable speed drive that can be controlled remotely. However, controllable devices 82 may comprise a variety of other controllable devices, including valves, heaters, and other components that may be used in cooperation with the electric submersible pumping systems 78. Each of the controllable devices 82 responds to specific control instructions input at a remote location, e.g. control center 26.
In the embodiment illustrated, controllable devices 82, e.g. pump controllers, and sensor devices 80, interface with a site communications box 84 which is used to relay signals between the various wellsite devices and network 38. By way of example, the site communications box 84 may comprise a satellite radio and process-assisted communicator 86 for relaying signals to and from satellite 42. The data from wellsite 22, for example, can be transferred to a remote management system 88 that provides Internet access to the data from a variety of Internet accessible remote locations 90, as illustrated in
As illustrated in
In one embodiment, surveillance and control system 20 comprises a web-based application that allows individuals to monitor and control equipment at one or more wellsites 22 from virtually anywhere in the world. In this embodiment, an operator requires only a web browser and an Internet connection to gain access at a variety of remote locations 90. With the use of, for example, a graphical user interface, the operator can simply click on-screen buttons and select drop-down menus to easily access any monitored and/or control points, as discussed more fully below. Of course, access to the system can be controlled by various security measures, including user profile permissions as set by, for example, a project supervisor.
Examples of graphical user interfaces and of functionality available at these remote locations is illustrated in
Another example of the functionality of surveillance and control system 20 is illustrated in
In
The functionality of surveillance and control system 20 also enables an operator to set and monitor specific alarm parameters for one or more wells and wellsites 22, as illustrated in
The adaptability of surveillance and control system 20 further enables use of an “overview” screen that provides an operator with a field map 146 of multiple wells, as illustrated in
As discussed previously, the ability to conduct real-time surveillance and control from remote locations combined with the programmability of control system 28 provides great potential for adapting and customizing the overall surveillance and control system 20. In some applications, for example, it may be desirable to closely track the performance of individual electric submersible pumping systems 78. Data obtained from sensor devices 80 can be automatically processed by CPU 46 to determine pump performance and graphically display such performance via graphical user interface 96. As illustrated in
A wide variety of other automatic analyses can be performed by one or more CPU's 46 deployed at one or more remote locations. In
Other data observed in real-time at wellsite 22 and transmitted to one or more remote locations via network 38 can be used to construct, for example, pressure gradients, as illustrated by the graph 166 of
Referring to
Surveillance and control system 20 greatly enhances the adaptability, functionality and cost effectiveness of well management. The system enables the generation of a wide variety of reports, reduces wellsite visits, decreases costs associated with installation, maintenance, and administration of the control system, improves pump operation, facilitates prioritization of well work, reduces well interventions, extends pump run life, and increases pump and well uptime. All of these characteristics of surveillance and control system 20 enable the cost efficient optimization of production at one or more wellsites 22.
Although, only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Accordingly, such modifications are intended to be included within the scope of this invention as defined in the claims.
Claims
1. A method of operating a pumping system at a welisite, comprising:
- sensing at least one parameter related to the pumping system in real-time;
- outputting a signal that corresponds with the sensed parameter to a distribution network;
- transmitting the signal over the distribution network to a location remote from the wellsite;
- processing the signal and displaying information related to the signal on a graphical user interface disposed at the remote location; and
- triggering an alert when the parameter indicates an operational concern.
2. The method as recited in claim 1, wherein the at least one sensed parameter comprises voltage, current, pressure, temperature, or vibration.
3. The method as recited in claim 1, wherein when an alert is triggered the graphical user interface identifies the symptom, the probable cause or causes, and suggests a corrective action.
4. The method as recited in claim 1, wherein sensing comprises sensing downhole parameters related to a plurality of electric submersible pumping systems.
5. The method as recited in claim 1, wherein outputting comprises outputting data from sensors deployed along a wellbore in which the pumping system is deployed.
6. The method recited in claim 1, wherein transmitting comprises transmitting the signal via satellite.
7. The method as recited in claim 1, wherein transmitting comprises transmitting the signal via cellular network.
8. The method as recited in claim 1, wherein transmitting comprises transmitting the signal via the Internet.
9. The method as recited in claim 1, wherein processing comprises processing the signal with a microprocessor-based system remote from the well.
10. The method as recited in claim 1, wherein triggering further comprises providing the alert at a computer workstation.
11. The method as recited in claim 1, wherein triggering further comprises providing the alert at a handheld communication device.
12. A method, comprising:
- operating downhole pumping equipment in a wellbore to pump a fluid;
- sensing a plurality of different parameters related to pumping of the fluid;
- outputting data, related to the plurality of different parameters, through a network;
- analyzing the data at a remote site via a control system connected to the network; and
- sending control signals to the downhole pumping equipment via the network.
13. The method as recited in claim 12, wherein outputting comprises making all data obtained from sensing available over the Internet.
14. The method as recited in claim 12, wherein outputting comprises routing the data through a site communications box located proximate the wellbore.
15. The method as recited in claim 12, further comprising displaying the data via a graphical user interface of the control system.
16. The method as recited in claim 15, wherein displaying comprises displaying all current parameter values from a plurality of input/output points.
17. The method as recited in claim 15, wherein displaying comprises displaying historical parameter values.
18. The method as recited in claim 15, wherein displaying comprises displaying pump performance data.
19. The method as recited in claim 12, wherein sending comprises setting specific alarm parameters for a specific wellsite.
20. The method as recited in claim 12, wherein sending comprises changing set points of the control system.
21. A system for facilitating operation of a wellsite, comprising:
- a plurality of electric submersible pumping systems deployed in a plurality of wellbores;
- a plurality of sensor devices deployed to sense pumping related parameters of each electric submersible pumping system;
- a site communications box to receive data from the plurality of sensors and to output control signals to the plurality of electric submersible pumping systems;
- a control center located at a remote location to receive data from the site communications box and to output control instructions to the site communications box; and
- a handheld device to receive alerts based on data sent from the site communications box regarding sub-optimal well parameters.
22. The system as recited in claim 21, wherein the site communications box and the control center are connected via the Internet.
23. A method of constructing a well management system, comprising:
- establishing a sensor system at a wellsite to detect pumping-related parameters along a plurality of electric submersible pumping systems;
- surveilling the plurality of electric submersible pumping systems in real-time, via the sensor system, at a remote location from the wellsite;
- controlling operation of the plurality of electric submersible pumping systems from the remote location;
- utilizing the sensor system in determining when well-related parameters fall outside a desired range, upon which event an alert is automatically output to a remote location; and
- analyzing data obtained from surveillance of the plurality of electric submersible pumping systems to enable planning for optimization of electric submersible pumping system operation from the remote location.
24. The method as recited in claim 23, wherein establishing comprises deploying pressure sensors, temperature sensors, and vibration sensors along each electric submersible pumping system.
25. The method as recited in claim 23, wherein controlling comprises providing control over a variable speed drive and over a remote start and stop capability for each electric submersible pumping system.
26. The method as recited in claim 23, wherein utilizing comprises providing alerts to a remote handheld device over a network.
27. The method as recited in claim 23, wherein analyzing comprises establishing historical data trends and displaying the historical data trends graphically on a graphical user interface at the remote location.
Type: Application
Filed: Jan 30, 2006
Publication Date: Aug 2, 2007
Applicant: SCHLUMBERGER TECHNOLOGY CORPORATION (Sugar Land, TX)
Inventors: Alexandre Kosmala (Royston), Charles Cosad (Balcombe), Lance Fielder (Sugar Land, TX), Albert Ollre (Sugar Land, TX), Bertrand Theuveny (Cambridge)
Application Number: 11/307,263
International Classification: E21B 43/12 (20060101);