CA-3115300-C - UNIVERSAL RIG CONTROLLER INTERFACE

Abstract

A rig control interface includes a plurality of interface systems. Each of the interface systems is configured to manipulate a rig control based on a signal received from an automated rig control system. The interface systems includes a mechanical control interface. The mechanical control interface includes an actuator configured to mechanically move a control handle from a first position to a second position responsive to the signal.

Inventors

• Christian Younes
• Michael Mayerich

Assignees

• NATIONAL OILWELL VARCO, L.P.

Dates

Publication Date

20260505

Application Date

20191118

Priority Date

20181119

Claims (20)

1. CLAIMS What is claimed is: 1.
2. 2. A universal rig control interface, comprising: a plurality of interface systems, each of the plurality of interface systems configured to manipulate a rig tool based on a signal received from an automated rig control system, the plurality of interface systems comprising: a mechanical control interface, comprising: an actuator configured to mechanically move a control handle from a first position to a second position responsive to the signal; and a coupler comprising: an engaging structure comprising: a first plate and a second plate configured to exert pressure on a front side and a back side of the control handle, wherein the control handle is a knob mounted on an operator control panel; and a splined shaft extending from the first plate, the splined shaft configured to be rotated by the actuator. The universal rig control interface of claim 1, wherein the coupler is configured to transfer force from the actuator to the control handle.
3. 3. The universal rig control interface of claim 2, wherein the coupler is configured to allow manual manipulation of the control handle.
4. 4.
5. 5. The universal rig control interface of claim 1, wherein the actuator is a stepper motor. The universal rig control interface of claim 1, wherein the mechanical control interface further comprises a sensor configured to measure a position of the control handle.
6. 6. The universal rig control interface of claim 1, wherein the mechanical control interface further comprises a flexible shaft coupled to the actuator and configured to transfer force from the actuator to the control handle. 14
7. 7. The universal rig control interface of claim 1, wherein the mechanical control interface further comprises a hydraulic system coupled to the actuator and configured to transfer force from the actuator to the control handle.
8. 8. The universal rig control interface of claim 1, wherein the actuator is mounted on the control handle.
9. 9. The universal rig control interface of claim 1, further comprising an electrical analog control interface comprising a relay configured to: while contacts of the relay are in a first position: electrically connect the automated rig control system to a tool controller; route a first analog control signal from the automated rig control system to the tool controller; and electrically isolate a legacy rig control system from the tool controller; and while contacts of the relay are in a second position: electrically isolate the automated rig control system from the tool controller; electrically connect the legacy rig control system to the tool controller; and route a second analog control signal from the legacy rig control system to the tool controller.
10. 10. The universal rig control interface of claim 1, further comprising a pneumatic control interface, comprising: a pneumatic valve configured to: route a first pneumatic signal from the automated rig control system to a tool controller while the pneumatic valve is in a first position; and route a second pneumatic signal from a legacy rig control system to the tool controller while the pneumatic valve is in a second position.
11. 11. The universal rig control interface of claim 1, further comprising a digital control interface comprising a digital control bus master configured to enable communication between the automated rig control system and a tool controller via a digital control bus.
12. 12. A method for controlling a rig, comprising: measuring, by an automated rig control system, a rig control parameter; 15 determining, by the automated rig control system, based on the measured rig control parameter, a change to a value of the rig control parameter; activating, by the automated rig control system, a motor responsive to the determining; applying rotation of the motor to mechanically move a control handle of the rig via a coupler that engages the control handle, wherein the coupler comprises: an engaging structure comprising: a first plate and a second plate configured to exert pressure on a front side and a back side of the control handle, wherein the control handle is a knob mounted on an operator control panel; and a splined shaft extending from the first plate, the splined shaft configured to be rotated by the motor; and measuring, by a sensor coupled to the control handle, a position of the control handle.
13. 13.
14. 14.
15. 15.
16. 16.
17. 17. The method of claim 12, further comprising transferring force to the control handle via the coupler that engages the control handle. The method of claim 13, further comprising: disengaging the coupler from the motor; and manually moving the control handle. The method of claim 12, further comprising transferring force from the motor to the control handle via a flexible shaft. The method of claim 12, further comprising transferring force from the motor to the control handle via hydraulic fluid. The method of claim 12, further comprising setting contacts of a relay to a first position that electrically connects the automated rig control system to a tool controller, and electrically isolates a legacy rig control system from the tool controller; routing, with the contacts in the first position, a first analog control signal, via the relay, from the automated rig control system to the tool controller; 16 setting the contacts of the relay to a second position that electrically isolates the automated rig control system from the tool controller, and electrically connects the legacy rig control system to the tool controller; and routing, with the contacts in the second position, a second analog control signal, via the relay, from the legacy rig control system to the tool controller.
18. 18.
19. 19. The method of claim 12, further comprising: setting a pneumatic valve to route a first pneumatic signal from the automated rig control system to a tool controller; providing the first pneumatic signal to the tool controller via the pneumatic valve; setting the pneumatic valve to route a second pneumatic signal from a legacy rig control to the tool controller; and providing the second pneumatic signal to the tool controller via the pneumatic valve. The method of claim 12, further comprising providing communication between the automated rig control system and a tool controller via a digital control interface and a digital control bus.
20. 20. A method for automating control of a rig, comprising: mounting a coupler on a mechanical control handle of the rig; wherein: movement of the mechanical control handle changes a signal that controls a tool of the rig; the mechanical control handle is a knob mounted on an operator control panel; and the coupler comprises: an engaging structure comprising: a first plate and a second plate configured to exert pressure on a front side and a back side of the knob; and a splined shaft extending from the first plate; connecting an electric motor to the coupler, the motor configured to rotate the splined shaft; connecting an automated rig control system to the electric motor; monitoring, by the automated rig control system, a sensor that measures a value of a parameter of the tool; 17 generating, by the automated rig control system, a control signal to change the value of the parameter of the tool; activating the electric motor responsive to the signal; and moving, by the electric motor, the mechanical control handle to change the value of the parameter of the tool.

Description

WO 2020/106610 PCT/0S2019/061969 UNIVERSAL RIG CONTROLLER INTERFACE BACKGROUND [0001] Rigs, such as drilling rigs or production rigs, used in exploration and production of oil and gas, apply a variety of tools and rig systerns to irnplement the operations performed by the rig For example, a drilling rig includes a dravv works to raise and loYver a drill string, a top drive or rotary table to rotate the drill string, pumps to circulate drilling fluid in the bore hole, and various other tools. TI1.e rig includes controls that an operator uses to manipulate the tools. SUMMARY [0002] A rig control interface includes a plurality of interface systems. Each of the interface systems is configured to manipulate a rig control based on a signal received from an automated rig control system The interface systems includes a mechanical control interface. The mechanical control interface includes an actuator configured to mechanically move a control handle from a first position to a second position responsive to the signal. [0003] A method for controlling a rig includes measuring, by an automated rig control system, a rig control parameter. Based on the measured rig control parameter, the automated rig control system, determines to change the value of the rig control parameter. A motor is activated, by the automated rig control system, responsive to the determining. Rotation of the motor is applied to mechanically move a control handle of the rig. A position of the control handle is measured by a sensor coupled to the control handle. [0004] A method for automating control of a rig includes mounting a coupler on a mechanical control handle of a rig. Movement of the mechanical control handle changes a signal that controls a tool of the rig. An electric motor is connected to the coupler. An automated rig control system is electrically connected to the electric motor. A sensor that measures a value of a parameter of the tool is monitor by the automated rig control system A control signal to change the value of the parameter of the tool is generated by the automated rig control system The electric motor is activated responsive to the signal. The control handle is moved by the electric motor to change the value of the parameter of the tool. BRIEF DESCRIPTION OF THE DRAWINGS [0005] For a detailed description of various examples, reference will now be made to the accompanying drawings in which: [0006] Figure 1 shows an example rig that includes a universal rig interface in accordance with the present disclosure; 1 WO 2020/106610 PCT/0S2019/061969 [0007] Figure 2 shows a block diagram for an example of rig systems including a universal rig interface in accordance with the present disclosure; [0008] Figure 3 shows a block diagram for an example of a universal rig interface in accordance with the present disclosure; [0009] Figures 4-6 show block diagrams for example mechanical rig control interfaces in accordance with the present disclosure; [001 0] Figure 7 shows a block diagram for an example analog control interface m accordance with the present disclosure; [0011] Figure 8 shows a block diagram for an example pneumatic control interface m accordance with the present disclosure; [0012] Figure 9 shows a block diagram for an example digital control interface in accordance with the present disclosure; [0013] Figure 10 shows a flow diagram for an example method for controlling a rig in accordance with the present disclosure; [0014] Figure 11 shows a flow diagram for an example method for automated manipulation of a mechanical control handle for controlling a rig in accordance with the present disclosure; [0015] Figure 12 shows a flow diagram for an example method for controlling a rig using an analog signal in accordance with the present disclosure; [0016] Figure 13 shows a flow diagram for an example method for controlling a rig using a pneumatic analog signal in accordance with the present disclosure; [0017] Figure 14 shows a flow diagram for an example method for controlling a rig using a digital control bus in accordance with the present disclosure; and [0018] Figure 15 shows a flow diagram for an example method for automating control of a rig using a universal rig interface in accordance with the present disclosure. DETAILED DESCRIPTION [0019] Certain terms have been used throughout this description and claims to refer to particular system components. As one skilled in the art will appreciate, different parties may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. In this disclosure and claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to .... "Also, the term "couple" or "couples" is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection