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  • 专利说明
  • 权利要求
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    • 专利摘要:
    SYSTEM FOR MONITORING SUBMARINE EQUIPMENT AND METHODS FOR MONITORING SUBMARINE DRILLING AND FOR DETECTING LEAKS IN SUBMARINE EQUIPMENT "Systems and methods for monitoring subsea equipment are described in this document. In one embodiment, such a system may include a plurality of acoustic sensor arrangements that include, each, at least two acoustic sensors, in which at least a first acoustic sensor array is mounted on an external surface of subsea equipment being monitored and at least a second acoustic sensor array is positioned remotely from the subsea equipment. The system can also include a digital data processor in communication with the plurality of acoustic sensor arrays, the digital data processor can be configured to process data from selected sensors from the plurality of acoustic sensor arrays for both focusing selectively on a portion of the sub equipment marino and to determine a point of origin of an acoustic signal. The system can be particularly usable in detecting leaks and other events in subsea drilling equipment.
    公开号:BR102014031037B1
    申请号:R102014031037-1
    申请日:2014-12-11
    公开日:2020-12-22
    发明作者:Svein A. Haugen；Geir K. Nilsen；Jens Abrahamsen
    申请人:General Electric Company；
    IPC主号:
    专利说明:

    FIELD OF THE INVENTION
    [001] The present invention relates to subsea industrial activities and, in particular, systems and methods for monitoring subsea equipment, such as oil and gas extraction equipment. BACKGROUND OF THE INVENTION
    [002] For many years, certain industrial activities, such as oil and gas extraction, have been increasingly expanding to underwater locations, as the number of available terrestrial sites has decreased. The seabed, however, is a harsh and inaccessible environment, and many activities, for example, drilling operations, involve a considerable risk of environmental contamination. In some cases, an oil or gas well can be located thousands of meters below the surface of the water that no human can reach. As a result, monitoring the safety and efficiency of drilling equipment can be difficult.
    [003] For example, in many cases, the instruments used to monitor underwater drilling equipment (or other types of equipment) fail more often than the equipment itself. Failure to monitor instruments can create false positive warnings of drilling equipment failure, and may require excessive maintenance procedures to repair the monitoring system. In addition, traditional monitoring instruments are often incorporated into drilling equipment and, as a result, repairing the instruments may require costly operation to bring the piece of equipment up from the seabed. Furthermore, even when the monitoring instruments are operating correctly, they provide few details, for example, allowing operators to determine only when a major event (for example, a catastrophic component failure) has occurred.
    [004] State of the art systems have tried to address the above issues, but with little success. For example, acoustic monitoring of subsea equipment has been attempted with the use of sensors mounted remotely from subsea equipment, but these systems suffer from the same lack of detail discussed above. Thus, they provide little value to operators other than reporting a major event (for example, a catastrophic component failure).
    [005] Given these deficiencies, monitoring instruments for subsea equipment are often considered unreliable and unused. With no ability to monitor subsea equipment during operation, acceptable safety levels are achieved by building excessively robust subsea equipment and implementing conservative maintenance schedules - both of which add considerable cost to subsea operations.
    [006] Thus, there is a need in the art for improved subsea equipment monitoring systems that can provide more detailed monitoring of equipment during operation. In addition, there is a need for such systems to have built-in redundancy and the ability to be maintained separately from subsea equipment in order to avoid unnecessary maintenance in the event of a monitoring system failure. DESCRIPTION OF THE INVENTION
    [007] The present invention addresses these needs by providing systems and methods for monitoring subsea equipment using a plurality of sensors and a digital data processor to analyze data collected by the sensors. For example, a system can include a plurality of acoustic sensors and the signals detected by the sensors can be used to determine any of a variety of equipment characteristics (for example, the speed of rotation of a drill, the presence of internal leaks or the presence of worn seals or bearings, etc.). The systems described in this document generally include a plurality of acoustic sensor arrangements both mounted on and positioned remotely from the subsea equipment being monitored. The use of multiple arrays (each containing multiple acoustic sensors) positioned close to, and remotely, from the equipment being monitored may allow the digital data processor to isolate particular areas of the equipment being monitored, or to locate a source of a detected acoustic signal. In addition, the acoustic monitoring systems described in this document can identify particular acoustic signals associated with a physical event, for example, the formation of a leak, etc., and tracking trends over time to identify operational abnormalities. Finally, the increased amount of acoustic data collected by the plurality of sensors provides a greater amount of detail than the known monitoring instruments. This can allow, for example, monitoring of individual seals, bearings or other components to determine when replacement is required before catastrophic component failure.
    [008] In one embodiment, a system for monitoring subsea equipment includes a plurality of acoustic sensor arrangements that each include at least two acoustic sensors, in which at least one first acoustic sensor arrangement is mounted on an external surface of subsea equipment being monitored and at least a second acoustic sensor array is positioned remotely from subsea equipment. The system also includes a digital data processor in communication with the plurality of acoustic sensor arrays, and the digital data processor can be configured to process data from selected sensors from the plurality of acoustic sensor arrays both to focus, so selective, in a portion of the subsea equipment and determine a point of origin of an acoustic signal. These skills can allow a subsea equipment monitoring system to, for example, detect irregular noise, locate the source of the noise on or in the equipment being monitored, and listen selectively to that portion of the equipment. All of this is possible even though the system may not include an acoustic sensor in the immediate area of the portion being examined.
    [009] The enhanced monitoring capabilities of the systems described in this document can be combined with traditional equipment monitoring systems to confirm expected operation of subsea equipment. For example, in one embodiment, a method for monitoring underwater drilling includes detecting acoustic signals generated by a drill using a plurality of acoustic sensor arrangements that each include at least two acoustic sensors, at least one of which is first acoustic sensor array is mounted on an external surface of a subsea prevention set (BOP) surrounding the drill and at least one second acoustic sensor array is positioned remotely from the BOP. The method also includes determining a drill characteristic and operation within the BOP based on the acoustic signals detected using a digital data processor that communicates with the plurality of acoustic sensor arrangements. Additionally, the method includes detecting the drill's operating characteristic at a location above a sea surface, as well as alerting a user through a user interface coupled to the digital data processor if a difference between the characteristic value of the drill inside the BOP and the characteristic value of the borer above the sea surface is greater than a predetermined amount. For example, if the operating characteristic being measured is the rotation speed of a drill, a difference between speeds measured on the surface and under the sea can indicate the formation of tension (wind-up) in the drill.
    [0010] The systems described in this document can only identify acoustic signals associated with physical events and conclude that a particular event occurred based on the detection of a single signal. In one embodiment, for example, a method for detecting leaks in subsea equipment may include detecting acoustic signals generated by subsea equipment using a plurality of acoustic sensor arrangements that each include at least two acoustic sensors, in which at least at least one first acoustic sensor array is mounted on an external surface of the subsea equipment and at least one second acoustic sensor array is positioned remotely from the subsea equipment. The method may additionally include developing a baseline of acoustic signals produced during normal operation of subsea equipment with the use of a digital data processor coupled to the plurality of acoustic sensor arrangements, as well as alerting a user via a coupled user interface to the digital data processor if a detected acoustic signal differs from the baseline by at least a predetermined amount.
    [0011] A person skilled in the art will verify additional advantages and variations of the systems described in this document in relation to the state of the art. Such variations are considered to be within the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS
    [0012] The realizations of the invention described above will be understood more fully from the detailed description below obtained in conjunction with the accompanying drawings, in which: Figure 1 is an illustration of an implementation of an underwater equipment monitoring system; Figure 2 is an illustration of an alternative embodiment of an underwater equipment monitoring system; Figure 3 is a schematic diagram of yet another embodiment of an underwater equipment monitoring system; and Figure 4 is a flowchart illustrating a sensor data flow through a digital data processor. DESCRIPTION OF ACCOMPLISHMENTS OF THE INVENTION
    [0013] Certain achievements will now be described to provide a general understanding of the principles of the systems and methods revealed in this document. One or more examples of these achievements are illustrated in the accompanying drawings. Those skilled in the art will understand that the systems and methods specifically described in this document and illustrated in the accompanying drawings are non-limiting embodiments and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one realization can be combined with the features of other realizations. Such modifications and variations are intended to be included within the scope of the present invention.
    [0014] The present invention relates, in general, to systems and methods for monitoring subsea equipment that employ a plurality of non-intrusive sensors to provide a detailed view of the equipment during operation. The systems and methods described in this document can be used to determine a variety of characteristics of the equipment being monitored, including operating characteristics (for example, the speed of rotating machinery, etc.), equipment failures (for example, internal leaks and external, cracks, etc.), and operational abnormalities (for example, vibrations, erratic flow, pressure transients, gas kick, etc.). The systems and methods described in this document can also be used to identify vibrational or acoustic changes associated with normal wear and tear so that preventive maintenance can be performed when really necessary and before catastrophic failure of any component.
    [0015] The systems and methods disclosed in this document can be applied widely in any subsea machinery or equipment, but are described in this document in connection with use in an oil well blowout preventer (BOP). A BOP is a piece of safety equipment used in underwater oil and / or gas drilling to prevent uncontrolled flow from a well (ie, a blowout). The BOP includes a vertical “stack” that sits on top of a wellhead on the seabed. The stack includes a series of hydraulically actuated shears that are intended to seal a wellhead by force in the event of a blowout. The systems described in this document can be used to monitor any one of a number of different specific BOP configurations and / or architectures known in the art.
    [0016] Figure 1 illustrates a typical underwater drilling operation to extract natural gas and / or oil from a deep reservoir 102. In particular, a drill 104 is driven through a well head 106 at the bottom of the sea 108 from of a probe 110 floating on the sea surface 112. Drill 104 extends from the probe to the wellhead 106 through a riser tube 114 that can be used to capture oil and / or gas in the depths (check that the Figure 1 is not shown to scale, as drill 104 and riser 114 can extend for thousands of meters to reach the depth of the ocean at the well site). Finally, a BOP 116 is shown in its typical location at the top of wellhead 106.
    [0017] Also shown in Figure 1 is a realization of an underwater equipment monitoring system used to monitor BOP 116. As shown in the Figure, the system includes a first array of acoustic sensor 118 mounted on an external surface of BOP 116, a second acoustic sensor array 120 positioned remotely from BOP 116, and a digital data processor 122 in communication with the plurality of acoustic sensor arrays 118, 120. Each acoustic sensor array includes a plurality of individual acoustic sensors grouped together , for example, arrangements 118, 120 in Figure 1 each include three individual acoustic sensors.
    [0018] The data collected by the arrangements 118, 120 can be communicated through strings 121, 123 to the digital data processor 122 for subsequent signal processing and analysis. The digital data processor 122 can provide operators with several important monitoring capabilities, including (1) beam formation, that is, selective focus on a desired portion of the BOP 116 (even if no individual sensors are located in the desired portion), (2) source location, that is, the identification of a point of origin of a detected noise, (3) event identification, that is, the association of a particular acoustic signal with a physical event, and (4) identification of trend, that is, the acoustic signal identification changes over time.
    [0019] The ability to provide robust monitoring through signal processing and analysis is made possible by the architecture of the acoustic sensor arrangements in relation to the equipment being monitored (for example, the BOP 116). In particular, the system includes at least one acoustic sensor arrangement (the same having at least two individual acoustic sensors) mounted on the equipment (either in direct contact with the equipment or immediately adjacent to it) and at least one acoustic sensor arrangement positioned remotely from the equipment. This grouping of a plurality of acoustic sensors both close and remotely, the equipment allows the acoustic signals to be detected in a variety of positions and distances from the equipment being monitored. In addition, the grouping and positioning of sensors in relation to the equipment being monitored can provide better detection of certain frequencies that may not be detected otherwise. All collected data can be processed in parallel by the digital data processor 122 to, for example, triangulate the source of a detected noise, isolate only those noises that originate from a particular location, etc.
    [0020] Figure 2 illustrates an alternative realization of an underwater equipment monitoring system arranged on a BOP 202. The system includes a first array of acoustic sensor 204 mounted on an external surface of the BOP 202, as well as a second sensor array acoustic 206 positioned remotely from the BOP. In this embodiment, a digital data processor 208 is positioned at the site of the equipment being monitored, instead of a surface drilling rig, as shown in Figure 1. The digital data processor 208 can be mounted on an external surface of the BOP 202 as shown, or can be mounted on the seabed or another piece of equipment in a location close to the BOP. In addition, a third acoustic sensor array 210 is shown coupled to digital data processor 208. The third acoustic sensor array 210, as well as any other acoustic sensor arrangements that may be included, can add to the data collected by the first and second acoustic sensor arrangements 204, 206.
    [0021] Each of the sensor arrangements 204, 206, 210, can include at least two individual acoustic sensors. For example, in the embodiment shown in Figure 1, the acoustic sensor arrangements 118, 120 each include three individual acoustic sensors, while the arrangements 204, 206, 210 each include five individual sensors. The particular number of sensors used in an array can be determined based on available space, as well as requirements for power, communication bandwidth, etc. In addition, any of a variety of known acoustic sensors (eg hydrophones, etc.) can be used in arrangements 204, 206, 210. For example, in some embodiments, piezoelectric ultrasonic acoustic sensors can be used in acoustic sensor arrangements .
    [0022] The individual sensors in an array can be arranged in a variety of configurations relative to each other. For example, individual sensors in an array can be rigidly attached to each other in a number of shapes (for example, arranged in a straight line as shown in Figure 2), or they can be coupled together in one mode that allows relative movement (for example, connecting them with a flexible wire or rope). In addition, a distance between the individual sensors in an array can be uniform or varied, and can vary between different arrays in certain embodiments.
    [0023] In addition, each of the individual sensors in an array can be housed together or individually. In some embodiments, housing the sensors individually can provide an additional advantage that entering water into a housing will not cause a failure of all sensors in the arrangement. Separate sensor housings can therefore provide redundancy for the array and can allow the monitoring system to continue to operate even if several individual sensors fail over time.
    [0024] Acoustic sensor arrangements, such as arrangement 204, can be mounted on the BOP 202 in a variety of ways known in the art. For example, in some embodiments the arrangement 204 can be mounted on the BOP 202 using screws or magnets. In such an embodiment, arrangement 204 can act as a vibration sensor as well, given its rigid fixation on BOP 202. In other embodiments, however, arrangement 204 can be mounted on BOP 202 with a small amount of gap between individual sensors of the arrangement and the BOP. Positioning array 204 so immediately adjacent to BOP 202 in this way will have little effect on its ability to detect noise, given the water transmission properties. Finally, in still other embodiments, a subset of the individual sensors in a sensor array can be rigidly mounted on the BOP, and a subset of the individual sensors can be mounted on the BOP in a position immediately adjacent to it. All of these configurations can be varied through a number of arrays (or individual sensors within an array) to provide enhanced acoustic detection capability.
    [0025] Other acoustic sensor arrangements, such as arrangement 206, can be positioned remotely from BOP 202. In the illustrated embodiment, the acoustic sensor arrangement 206 is freely suspended at a distance from BOP 202, but is coupled to the digital data processor 208 by a string 212. As noted above, the acoustic sensor array 206 can have a variety of configurations, including any number of individual acoustic sensors arranged in a variety of geometries (for example, straight line, circle, sphere, etc.). In addition, arrangement 206 can be suspended in any desired orientation (for example, vertical, horizontal, diagonal, etc.) in relation to BOP 202 of the seabed. For example, in addition to the rope 212 that couples arrangement 206 to the digital data processor 208, ropes, additional cables or other ropes can be used to anchor arrangement 206 to the seabed, the BOP 202, or other equipment at a location and desired orientation.
    [0026] Any arrangement of acoustic sensor arranged to monitor subsea equipment can be in coupling of communications with the digital data processor performing signal processing and analysis. As noted above, the digital data processor (or processors) can be positioned on the seabed close to the equipment being monitored (for example, as shown in Figure 2), or on the surface in a drilling rig or other machinery above the level water (for example, as shown in Figure 1). The coupling between the acoustic sensor arrangements and the digital data processor can be accomplished in a variety of ways, including the use of cable strings (for example, string 212) that house power delivery and communication wires. Exemplary wires may include traditional copper (or other conductive metal) wiring, or fiber optic cabling. In some embodiments, a rope hose filled with oil can be used to provide a barrier against water intrusion and equalize pressure on the wires, thereby preventing irregular compression of copper wires and / or optical fiber within the rope.
    [0027] In other embodiments, however, wireless communications can be used to reduce the number of wires extending around BOP 202 or other equipment being monitored. Wireless communication methods suitable for use in an underwater environment may include short-range or acoustic radio communications. In embodiments in which wireless communications are employed, each acoustic sensor array may also include a battery attached to it to supply power to the individual acoustic sensors and any required wireless transmitters.
    [0028] In some embodiments, the particular form of coupling of communications employed can influence the position of the digital data processor. For example, if copper wiring or short-range wireless communications are employed, bandwidth and / or transmission distance limitations may require that the digital data processor be located on the seabed, as shown in Figure 2. If the fiber optic cabling is employed, however, large amounts of raw data can be transmitted quickly to a digital data processor positioned on the ocean surface, as shown in Figure 1. In still other embodiments, a repeater positioned on the seabed can be used, for example, to collect short-range wireless signals and communicate data with the surface through a single fiber-optic connection (similar to the only connection 213 that couples the digital data processor 208 to a surface drilling probe).
    [0029] In certain embodiments, a subsea equipment monitoring system may also include one or more individual acoustic sensors mounted on the equipment being monitored. For example, Figure 2 shows a number of individual acoustic sensors 214 mounted on BOP 202 at various locations. These individual acoustic sensors can be identical to the individual acoustic sensors used in each of the acoustic sensor arrangements 204, 206, 210, and can be mounted on BOP 202 in the same way as the first acoustic sensor arrangement 204. Individual sensors 214 can be positioned close to individual components of the BOP 202, such as a valve, bearing, seal, etc., and can provide localized detection of noise and / or vibration that originates from the component. This data can be combined with data captured from the acoustic sensor arrays to provide a better location of noise source (for example, allowing discrimination between two seals located close to each other, etc.). In addition, it is also possible that one or more individual acoustic sensors can be positioned remotely from the equipment being monitored to provide additional input to the digital data processor.
    [0030] In still other embodiments, other types of sensors can be integrated into an underwater equipment monitoring system along with the plurality of acoustic sensor arrangements and any additional individual acoustic sensor. Figure 3 illustrates an embodiment of an underwater equipment monitoring system 300 that includes a digital data processor 302 as well as a first acoustic sensor array 304, a second acoustic sensor array 306, and an individual acoustic sensor 308. The system additionally includes a camera 310. The camera 310 can be mounted on the seabed next to BOP 202, for example, or it can be arranged in a remotely operated vehicle (ROV) positioned next to BOP 202. In addition, any other type of sensor can be used in combination with the 300 system, for example, pressure and temperature sensors, sensors positioned on a surface drill rig, etc.
    [0031] Regardless of their particular type or position, data captured by additional sensors can be incorporated into signal processing and analysis conducted by the 302 digital data processor. For example, in one embodiment, data gathered by the monitoring system's acoustic sensors subsea equipment can be used to confirm or verify the quality of data gathered by an additional sensor, such as camera 310. Camera 310 can indicate, for example, that BOP 202 or other equipment is vibrating, when, in fact, it may be a faulty camera mount that is creating vibration. Data gathered from the acoustic sensor arrays mounted on, and positioned remotely from the BOP can be used to confirm or refute the camera's vibration indication on the equipment.
    [0032] The digital data processor 302 can have a number of different configurations. For example, the 302 digital data processor may be an advanced computing device configured for placement on the seabed near (or over) BOP, or it may be one more traditional computing device arranged on a surface drill rig or a ship. The digital data processor 302 can be a single computing device, or it can include a number of different networked digital data processors together. In addition, the digital data processor 302 can be coupled to a digital data store 314 so that analysis, historical trends, and other data can be accessed and updated as needed. Exemplary digital data stores include individual solid state or other types of digital storage media, digital network storage repositories, etc. The digital data processor 302 can also be coupled to a user interface device 316 to allow interaction with one or more operators. For example, in some embodiments, a digital data processor 302 can be attached to a display screen, status panel, keyboard, mouse, etc. to allow user interaction with the 302 digital data processor. Other exemplary user interface devices may include warning lights, speakers, etc.
    [0033] The digital data processor 302 uses multivariate signal processing to analyze data collected by all acoustic sensor arrangements, individual acoustic sensors and other types of sensors to isolate signals of interest. Regarding the acoustic sensor data, the digital data processor 302 can create multi-resolution sensor groups by combining acoustic data from subsets of the plurality of sensors in various ways. For example, in one embodiment, a generic set of N acoustic sensors dispersed across a plurality of acoustic sensor arrangements and distributed in three-dimensional space, the set can be divided into K subsets of at least four sensors, where K is defined by binomial coefficient (N, 4). In addition, each subset can be selected so that it reaches three-dimensional space, and all sensors can be synchronized over time.
    [0034] The resulting subsets can be processed in parallel to achieve a system with multi-resolution properties. That is, a small sensor array (that is, a short distance between individual sensors) may suffer from poor resolution at low frequencies and instability in distance estimation. Conversely, small sensor arrays may be better suited for high frequency detection because of spatial overlap. Large sensor arrays (ie, a long distance between individual sensors) can behave in reverse, exhibiting improved spatial resolution at low frequencies and improved performance in distance estimation. Importantly, the overall performance of the system will overcome the difficulties of individual sensor arrangements by combining them in various ways, resulting in a multi-resolution system.
    [0035] As mentioned above, two primary capabilities provided by the signal processing of the digital data processor 302 are beam formation and source localization. In beam formation, the system selectively focuses on a portion of the equipment being monitored to isolate noise that originates from that portion. This is accomplished in the digital data processor 302 by introducing appropriate phase delays for raw digitized sensor signals before summing in order to focus on a point in three-dimensional space, while at the same time ignoring contributions from other sources of interference in other locations in three-dimensional space. However, beam formation theory, in general, reaches far beyond this basic concept and more favorable methods such as adaptive beam formation can also be introduced. An adaptive feat trainer is a dynamic system that automatically adapts to arrival signals in order to maximize or minimize a desired parameter. The location of the source is essentially the reverse of beam formation, in which the point of origin of a detected noise is determined. This is done in the digital data processor 302 by estimating the phase delays of acoustic arrival sensor signals and mapping them over geographic coordinates.
    [0036] The digital data processor can also determine operating characteristics of the equipment being monitored, and compare those operating characteristics with one or more operating characteristics measured at a different location, for example, above the water surface. Referring to Figure 1, for example, digital data processor 122 can be configured to determine the rotation speed of drill 104 disposed within BOP 116 with the use of acoustic signals detected from the plurality of acoustic sensor arrangements 118 , 120. The digital data processor 122 can also be configured to determine the rotation speed of drill 104 at a location above a sea surface, for example, with the use of rotation sensor 124 mounted on drilling rig 110. The speed of rotation above the water surface can then be compared to the speed of rotation in the BOP. A significant difference in these values can indicate what voltage is forming on the probe axis. If the difference between the top side and subsurface measurements is significantly large (for example, exceeding a predetermined value), an operator can be alerted or other action can be taken (for example, drill stop, choke valve adjustment, etc.). Of course, the speed of rotation of a drill bit that passes through a BOP is only one example of an operating characteristic that can be determined by the subsea monitoring system, and any of a variety of other characteristics can also be determined and compared to measurements obtained at different locations in the drilling operation.
    [0037] As noted above, in addition to selectively focusing on portions of equipment being monitored or determining operating characteristics of subsea equipment, the digital data processor can also identify physical events based on their unique acoustic signals and track acoustic trends over time to check for deviations from a baseline profile. For example, and as shown in Figure 4, data 402 for all acoustic sensors from the plurality of sensor arrays, individual sensors and any other sensor coupled to the system, can be routed in parallel to a 401 event processing system and a system 403 trend processing.
    [0038] The 401 event system can be configured to analyze sudden events of limited duration, for example, closing and opening of BOP cutting drawers. A 404 event validator can process the data to eliminate or confirm the presence of an event based on a predetermined set of rules. For example, a typical rule may require spatial stationarity, that is, that the noise source originates from a stationary location, in order to qualify as an event (for example, if acoustic signals are indicating that a particular seal has failed, the signals continue to originate from the location of the failed seal). To determine spatial stationarity, the digital data processor can use its source source and selective focus capabilities. For example, spatial stationarity can be measured by calculating the source of the event multiple times over a period of time. The standard deviation of these measurements can indicate whether the source of the event is moving or not.
    [0039] After determining that an event has occurred (or is occurring), a 406 event preprocessor can process and format the event's acoustic signals. In some embodiments, the event's acoustic signals can be processed into an event signature that includes a temporal distribution and a spatial distribution of the event's acoustic signals. The temporal distribution can be, for example, a sparse representation such as a time-scale / time-frequency / honey-time representation (for example, using the Short Time Fourier Transform and / or Wave) that describes the event resources in an acoustic sense. The spatial distribution can, for example, be estimated with the use of array processing including the cross spectral matrix, complex analytical cross correlations, phase transform and delay mapping for angle and delay mapping for distance. In some embodiments, the Karhunen-Loève Transform can be applied to both distributions to reduce dimensionality and provide easier classification and / or grouping of similar events.
    [0040] An event comparator 408 can identify or classify the detected acoustic signals, or their computed signatures, using a 410 event library that includes a listing of physical events and the acoustic signals of the same known associates or signatures . If the detected event matches one of those already stored in event library 410, event comparator 408 can update the status of system 412 by reporting the occurrence of the event and recommending or initiating a response action. This can be done, for example, using the 316 user interface device shown in Figure 3. If, on the other hand, the detected acoustic signals or computed signature do not match any of the events stored in event library 410, the signals detected acoustics and / or their computed signature can be stored in the event library 410 for later classification and association with a physical event. The event comparator 408 can be deployed using machine learning theory and classification, including discriminant analysis (DA) techniques or pattern matching algorithms, such as the dynamic programming algorithm (DP), or, for example , using a K-nearest neighbors approach.
    [0041] In parallel with the 401 event detection and classification system, the digital data processor can also run a 403 trend system based on the data collected by the acoustic sensor arrays. The 403 trend system can run continuously regardless of any special events found in the collected data. The trend system can include a 414 trend preprocessor that forms a baseline of acoustic signals - or data calculated from them produced during normal operation of subsea equipment. The trend preprocessor can calculate a number of trends from the input data given a prescribed realization. For example, computed trends can include full frequency spectra, energy in certain frequency bands, positions of signal sources, level of spatial stationarity, etc. The baseline of acoustic signals, as well as any other computed data or trends, can be stored in a historical trend library 416. A 418 trend comparator can compare the detected acoustic signals (or computed trend data from them) with baseline acoustic signals (or trend data computed from them) to determine whether the monitored equipment is operating in a normal state or not. If a difference between the detected values and the baseline values exceeds a predetermined amount, the status of the 412 system can be updated to alert an operator.
    [0042] The combination of trend monitoring and event detection may allow the subsea equipment monitoring systems described in this document to detect a number of subsea equipment operating abnormalities. Examples include the detection of internal and external leaks, erratic flow, gas kick (vibrations induced by flow from the annular space or drilling column), and erratic pressure transients, among others. Of particular note is that the systems described in this document can detect the presence of worn seals or bearings before catastrophic failure of these components. That is, the acoustic signals emitted by a seal may change over time (for example, deviating from a baseline beep) as the seal wears out and the subsea equipment monitoring system described in this document can detect that change. State-of-the-art acoustic monitoring systems do not have the capacity to provide the level of detail necessary to detect this change. The ability to detect individual seal wear can allow operators to plan preventive maintenance more intelligently based on actual wear and tear in subsea equipment rather than a set of maintenance schedules. Such a modification has the potential and will increase both the safety and efficiency of subsea drilling operations or other activities.
    [0043] The subsea equipment monitoring systems described in this document also provide an ability to detect crack formation in subsea equipment at a very early stage. In particular, the development of cracks, for example, in the housing of a piece of equipment, can create sudden transient acoustic signals. State of the art acoustic monitoring systems do not have the ability to detect these transient signals that indicate the initial stages of crack formation. It is found that the inability of state of the art systems to detect these transient signals can stem either from a total inability to detect the signal (ie, inaccurate acoustic detection), or an inability to determine that the transient represents a deviation from the normal operation of the equipment (ie no trend monitoring).
    [0044] The detection of crack formation and seal wear are just two examples of improvements over state of the art underwater monitoring systems. Other advantages of the systems and methods described in this document include the use of externally mounted non-intrusive arrangements of acoustic sensors. The use of non-intrusive arrangements allows the monitoring system to be maintained separately from subsea equipment, which avoids the need to stop a drilling operation or raise subsea equipment to repair the monitoring system. In addition, the use of arrangements that have two or more individual acoustic sensors can provide redundancy to the system in the event that one or more sensors fail, again allowing service of a monitoring system to be carried out in the most convenient and efficient time for the operator. Additionally, the use of non-intrusive acoustic sensor arrangements allows for easy retrofitting of subsea equipment so that the monitoring system does not require the purchase and installation of new subsea equipment.
    [0045] The increased visibility of subsea equipment during operation allows operators to increase safety, treat failures better and increase efficiency by optimizing equipment downtime for preventive maintenance. As noted above, the achievements revealed in this document have focused on monitoring a BOP, but the subsea monitoring systems described in this document can be used with almost any subsea operation that produces unique acoustic signals. Specific examples of BOP include monitoring the placement of a BOP in a wellhead during initial well construction, the operation of cutting drawers to seal the well, confirmation that the well flow has been interrupted after cutting drawer activation, characterization flow within the BOP, etc. In addition, the systems described in this document can be used in any of a variety of other subsea equipment, including solenoid valves, pumps, compressors, etc.
    [0046] The advantages of the systems described in this document derive from the use of a plurality of acoustic sensor arrangements, in which at least one first arrangement is mounted on the equipment being monitored and at least a second arrangement is positioned remotely from the equipment being monitored. A digital data processor, when coupled with this array of acoustic sensor arrays, can selectively analyze signals from the set of acoustic sensor arrays to provide the powerful monitoring capabilities described above.
    [0047] All documents and publications cited in this document are incorporated into this document for reference in their entirety. One skilled in the art will see additional advantages and features of the invention based on the achievements described above. Thus, the invention should not be limited by what has been particularly shown and described, except as indicated by the appended claims.
    权利要求:
    Claims (15)
    [0001]
    1. SYSTEM FOR MONITORING SUBMARINE EQUIPMENT, characterized by comprising: a plurality of acoustic sensor arrangements (118, 120, 204, 206, 210) that each include at least two acoustic sensors, in which at least one first sensor arrangement acoustic (118, 204) is mounted on an external surface (202) of subsea equipment being monitored and at least a second acoustic sensor array (120, 206) is positioned remotely from subsea equipment; and a digital data processor (122, 208) in communication with the plurality of acoustic sensor arrangements (118, 120, 204, 206, 210), the digital data processor (122, 208) being configured to process data from sensors selected from the plurality of acoustic sensor arrangements (118, 120, 204, 206, 210) both to selectively focus on a portion of subsea equipment and to determine a point of origin for an acoustic signal , in which the second acoustic sensor array (120, 206) is suspended in any orientation at a distance from the subsea equipment and coupled to the digital data processor (122, 208) by a rope (123, 212).
    [0002]
    2. SYSTEM, according to claim 1, characterized by the digital data processor (122, 208) being located below the sea surface, and the plurality of acoustic sensor arrangements (118, 120, 204, 206, 210) includes at least at least one third acoustic sensor array (210) positioned adjacent to the digital data processor (122, 208).
    [0003]
    SYSTEM, according to any one of claims 1 to 2, characterized in that it additionally comprises at least one individual acoustic sensor (118, 120, 204, 206, 210) mounted on the external surface (202) of the subsea equipment.
    [0004]
    4. SYSTEM, according to any one of claims 1 to 3, characterized in that the first acoustic sensor arrangement (118, 204) mounted on the subsea equipment is any one screwed and magnetically coupled to the subsea equipment.
    [0005]
    5. SYSTEM, according to any one of claims 1 to 4, characterized by the second arrangement of acoustic sensor (120, 206) positioned remotely from the subsea equipment to be connected to any one of the digital data processor (122, 208 ) and submarine equipment through a flexible rope (123, 212).
    [0006]
    6. SYSTEM, according to claim 5, characterized by the flexible cord (123, 212) including an internal lumen that houses one or more wires to supply energy to the second acoustic sensor array (120, 206) and communication between the array and the digital data processor (122, 208).
    [0007]
    A system according to any one of claims 1 to 6, characterized in that it further comprises an image capture device (310).
    [0008]
    8. SYSTEM, according to any one of claims 1 to 7, characterized in that the subsea equipment is a set of oil well preventers (116, 202).
    [0009]
    9. SYSTEM, according to any one of claims 1 to 8, characterized in that each of the plurality of acoustic sensor arrangements (118, 120, 204, 206, 210) is powered by batteries and configured to communicate with the data processor (122, 208) wirelessly.
    [0010]
    10. SYSTEM, according to any one of claims 1 to 9, characterized in that the digital data processor (122, 208) is additionally configured to identify an event based on a comparison of a detected acoustic signal with a library of acoustic signals associated with one or more known events.
    [0011]
    11. METHOD FOR MONITORING SUBMARINE DRILLING, characterized by comprising the steps of: detecting acoustic signals generated by a drill (104) using a plurality of acoustic sensor arrangements (118, 120, 204, 206, 210) that include, each one, at least two acoustic sensors, in which at least a first acoustic sensor array (118, 204) is mounted on an external surface (202) of a set of submarine preventers (116, 202) surrounding the drill (104) and at least a second acoustic sensor array (120, 206) is positioned remotely from the set of preventers (116, 202); determine an operational characteristic of the drill (104) within the set of preventers (116, 202) based on the acoustic signals detected using a digital data processor (122, 208) that communicates with the plurality of acoustic sensor arrangements (118, 120, 204, 206, 210); detecting the operational characteristic of the borer (104) at a location above a sea surface; and alert a user through a user interface coupled to the digital data processor (122, 208) if the difference between the characteristic value of the drill (104) within the set of preventers (116, 202) and the characteristic value of the drill ( 104) above the sea surface is greater than a predetermined amount.
    [0012]
    12. METHOD, according to claim 11, characterized in that the characteristic is the rotation speed of the drill (104).
    [0013]
    13. METHOD FOR DETECTING LEAKS IN SUBMARINE EQUIPMENT, characterized by understanding the steps: detecting acoustic signals generated by subsea equipment using a plurality of acoustic sensor arrangements (118, 120, 204, 206, 210) that each include , at least two acoustic sensors, in which at least a first acoustic sensor array (118, 204) is mounted on an external surface of the subsea equipment (202) and at least a second acoustic sensor array (120, 206) is positioned remotely from subsea equipment; develop a baseline of acoustic signals produced during normal operation of subsea equipment with the use of a digital data processor (122, 208) coupled to the plurality of acoustic sensor arrangements (118, 120, 204, 206, 210), in that the second acoustic sensor array (120, 206) is suspended in any orientation at a distance from the subsea equipment and coupled to the digital data processor (122, 208) by a rope (123, 212); and alerting a user through a user interface coupled to the digital data processor (122, 208) if a detected acoustic signal differs from the baseline by at least a predetermined amount.
    [0014]
    METHOD, according to claim 13, characterized in that it additionally determines a point of origin of the detected acoustic signal that differs from the baseline signature by at least the predetermined quantity.
    [0015]
    15. METHOD, according to any one of claims 13 to 14, characterized in that it additionally seeks a digital data storage containing a library of events and associated acoustic signals for an acoustic signal that corresponds to the detected acoustic signal; if a match is found, alert a user of the event associated with the detected acoustic signal; if the match is not found, store the acoustic signal detected in the digital data store for future association with an event.
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    同族专利:
    公开号 | 公开日
    BR102014031037A2|2016-08-09|
    EP2891761A3|2016-03-30|
    US9798030B2|2017-10-24|
    US20150177403A1|2015-06-25|
    US20170293043A1|2017-10-12|
    US10451760B2|2019-10-22|
    EP2891761B1|2019-02-20|
    EP2891761A2|2015-07-08|
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    法律状态:
    2016-08-09| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|
    2018-11-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-04-07| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-11-03| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-12-22| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/12/2014, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US14/139,860|US9798030B2|2013-12-23|2013-12-23|Subsea equipment acoustic monitoring system|
    US14/139,860|2013-12-23|
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