Bop control systems and related methods

Abstract

Some embodiments of the present BOP control systems include a system controller configured to actuate a first BOP function by communicating one or more commands to one or more nodes of a functional pathway selected from one or more available functional pathways associated with the first BOP function, each node comprising an actuatable component configured to actuate in response to a command received from the system controller, each node having one or more sensors configured to capture a first data set corresponding to actuation of the component and a processor configured to analyze the first data set to determine a useful life remaining of the component and/or compare the first data set to a second data set corresponding to a simulation of actuation of the component.

1 . A blowout preventer (BOP) control system comprising:
 a system controller configured to actuate a first BOP function by communicating one or more commands to one or more nodes of a functional pathway selected from at least two functional pathways associated with the first BOP function;   each node comprising an actuatable component configured to actuate in response to a command received from the system controller, each node having:
 one or more sensors configured to capture a first data set corresponding to actuation of the component; and 
 a processor configured to:
 analyze the first data set to determine a useful life remaining of the component; and 
 communicate the useful life remaining of the component to the system controller; 
 
   where the system controller is configured to:
 assign a risk level to each of the at least two functional pathways based, at least in part, on the useful life remaining of at least one of the one or more nodes of the functional pathway; and 
 identify at least one of the at least two functional pathways for actuating the first BOP function based, at least in part, on the risk levels of each of the at least two functional pathways. 
   
     
     
         2 . The control system of  claim 1 , where the risk level of at least one of the at least two functional pathways is assigned, based, at least in part, upon one or more of the following:
 a number of functional pathways for actuating the first BOP function;   a number of BOP functions for accomplishing a same outcome as the first BOP function; and   a time elapsed since the previous actuation of the one or more actuatable components of the one or more nodes of the functional pathway.   
     
     
         3 . The control system of  claim 1 , where the system controller is configured to communicate the useful life remaining of the component of each node to a user. 
     
     
         4 . The control system of  claim 1  or  3 , where the processor of each node is configured to communicate a fault to the system controller if the useful life remaining of the component is below a threshold. 
     
     
         5 . The control system of any of  claims 1 - 4 , where the processor of each node is configured to:
 analyze the first data set to identify an abnormal actuation of the component; and   communicate a fault to the system controller if an abnormal actuation of the component is identified.   
     
     
         6 . The control system of any of  claims 1 - 5 , where the processor of each node is configured to:
 compare the first data set to a second data set corresponding to a simulation of actuation of the component; and   communicate a fault to the system controller if differences between the first data set and the second data set exceed a threshold.   
     
     
         7 . The control system of  claim 6 , where at least one node comprises a memory configured to store at least a portion of the second data set. 
     
     
         8 . A blowout preventer (BOP) control system comprising:
 a system controller configured to actuate a first BOP function by communicating one or more commands to one or more nodes of a functional pathway selected from one or more functional pathways associated with the first BOP function;   each node comprising an actuatable component configured to actuate in response to a command received from the system controller, each node having:
 one or more sensors configured to capture at least two sensed values during actuation of the component; and 
 a processor configured to:
 receive the at least two sensed valves from at least one of the one or more nodes; 
 obtain an expected value of a model based on at least one of the at least two sensed values; 
 compare the expected value to the other of the at least two sensed values to obtain a difference between the two values; and 
 communicate to the system controller one or more of the following:
 (i) a fault if the difference between the two values exceeds a threshold; 
 (ii) a useful life remaining of the actuatable component based at least on the difference between the two values; 
 (iii) a risk level based at least on the difference between the two values; or 
 (iv) the difference between the two values. 
 
 
   
     
     
         9 . The control system of  claim 8 , where at least one node comprises a memory configured to store at least a portion of the sensed values. 
     
     
         10 . The control system of  claim 8  or  9 , where the system controller is configured to communicate the useful life remaining of the component of each node to a user. 
     
     
         11 . The control system of  claims 8  to  10 , where the processor of each node is configured to communicate a fault to the system controller if the useful life remaining of the component is below a threshold. 
     
     
         12 . A blowout preventer (BOP) control system comprising:
 a system controller configured to actuate a first BOP function by communicating one or more commands to one or more nodes of a functional pathway selected from one or more available functional pathways associated with the first BOP function;   each node comprising an actuatable component configured to actuate in response to a command received from the system controller, each node having:
 one or more sensors configured to capture a first data set during an actuation of the component; and 
 a processor configured to:
 adjust one or more coefficients of a model such that the adjusted model approximates one or more values from the first data set; and 
 communicate to the system controller data based at least on at least one of the one or more coefficients of the adjusted model. 
 
   
     
     
         13 . The control system of  claim 12 , where the processor is configure to compare the one or more coefficients of the adjusted model to the model to obtain a difference between corresponding coefficients; and communicate to the system controller one or more of the following:
 (i) a fault to the system controller if the difference between one or more corresponding coefficients exceeds a threshold;   (ii) a failure risk level to the system controller based at least on the difference between one or more corresponding coefficients; or   (iii) the difference between one or more corresponding coefficients.   
     
     
         14 . The control system of  claim 12 , where at least one node comprises a memory configured to store at least a portion of the first data set. 
     
     
         15 . The control system any of  claims 12  to  13 , where the processor of each node is configured to:
 analyze the coefficients of the adjusted model to determine a useful life remaining of the actuatable component; and 
 communicate the useful life remaining to the system controller. 
 
     
     
         16 . The control system of  claim 15 , where the system controller is configured to communicate the useful life remaining of the component of each node to a user. 
     
     
         17 . The control system of  claim 15  or  16 , where the processor of each node is configured to communicate a fault to the system controller if the useful life remaining of the component is below a threshold. 
     
     
         18 . The control system of any of  claims 7  to 16 , where the system controller is configured to remove a first functional pathway from the one or more functional pathways if one or more nodes of the first functional pathway communicates a fault or a risk level exceeding a threshold to the system controller. 
     
     
         19 . The control system of  claim 18 , where the system controller is configured to remove a second functional pathway from one or more functional pathways associated with a second BOP function if the second functional pathway includes one or more of the one or more nodes of the first functional pathway that communicates a fault or a risk level exceeding a threshold to the system controller. 
     
     
         20 . The control system of any of  claims 1 - 19 , where the system controller is configured to select a second BOP function if one or more nodes of the first functional pathway associated with the first BOP function communicates a fault or a risk level exceeding a threshold to the system controller. 
     
     
         21 . The control system of any of  claims 7 - 20 , where:
 the one or more functional pathways comprises a first functional pathway and a second functional pathway; and   the system controller is configured to actuate the first BOP function by communicating one or more commands to one or more nodes of the second functional pathway if one or more nodes of the first functional pathway communicates a fault or a risk level exceeding a threshold to the system controller.   
     
     
         22 . The control system of any of  claims 1 - 21 , where the system controller is configured to scan the BOP control system for available functional pathways for actuating the first BOP function. 
     
     
         23 . The control system of any of  claims 1 - 22 , where the system controller is configured to communicate to a user a number of available functional pathways for actuating the first BOP function. 
     
     
         24 . The control system of any of  claims 1 - 23 , comprising a memory in communication with each node of a functional pathway. 
     
     
         25 . The control system of any of  claims 1 - 24 , where at least one node comprises a memory configured to store at least a portion of the first data set. 
     
     
         26 . The control system of any of  claims 1 - 25 , where at least one node comprises a virtual sensor. 
     
     
         27 . The control system of any of  claims 1 - 26 , where at least one node is configured to communicate with the system controller wirelessly. 
     
     
         28 . The control system of any of  claims 1 - 27 , where at least one node is configured to communicate with the system controller through a wired connection. 
     
     
         29 . The control system of any of  claims 1 - 28 , where at least one node is configured to communicate with at least one controller outside of the BOP control system. 
     
     
         30 . The control system of any of  claims 1 - 29 , where the component of at least one node comprises a hydraulic manifold including one or more actuatable valves. 
     
     
         31 . The control system of any of  claims 1 - 30 , where the component of at least one node comprises a hydraulic pump. 
     
     
         32 . The control system of  claim 31 , where the hydraulic pump is battery-powered. 
     
     
         33 . The control system of any of  claims 1 - 32 , where the first data set includes data indicative of a number actuation cycles of the component. 
     
     
         34 . The control system of any of  claims 1 - 33 , where the first data set includes data indicative of a response time of the component. 
     
     
         35 . The control system of any of  claims 1 - 34 , where the system controller comprises two or more system controllers. 
     
     
         36 . A method for actuating a first blowout preventer (BOP) function, the method comprising:
 selecting a first functional pathway from two or more available functional pathways associated with the first BOP function;   communicating one or more commands to an actuatable component of each of one or more nodes of the first functional pathway to actuate the component, where actuation of the component of each of the one or more nodes of the first functional pathway actuates the first BOP function; and   receiving, from at least one of the one or more nodes of the first functional pathway, information associated with actuation of the component.   
     
     
         37 . The method of  claim 36 , where the received information includes a useful life remaining of the component. 
     
     
         38 . The method of  claim 37 , where the received information indicates a fault if the useful life remaining of the component is below a threshold. 
     
     
         39 . The method of any of  claims 36 - 38 , where the received information includes an identification of abnormal actuation of the component. 
     
     
         40 . The method of  claim 39 , where the received information indicates a fault if an abnormal actuation of the component is identified. 
     
     
         41 . The method of any of  claims 36 - 40 , where the received information includes differences between a first data set corresponding to actuation of the component and a second data set corresponding to a simulation of actuation of the component. 
     
     
         42 . The method of  claim 41 , where the received information indicates a fault if differences between the first data set and the second data set exceed a threshold. 
     
     
         43 . The method of any of  claims 36 - 42 , comprising selecting a second functional pathway from the two or more available functional pathways associated with the first BOP function if the received information indicates a fault. 
     
     
         44 . The method of any of  claims 36 - 43 , comprising removing the first functional pathway from the two or more available functional pathways if the received information indicates a fault. 
     
     
         45 . The method of any of  claims 36 - 44 , comprising removing a second functional pathway from two or more available functional pathways associated with a second BOP function if the received information indicates a fault of a node common to the first functional pathway and the second functional pathway. 
     
     
         46 . The method of any of  claims 36 - 45 , comprising selecting a second BOP function if the received information indicates a fault. 
     
     
         47 . The method of any of  claims 36 - 46 , comprising assigning a risk level to the first BOP function. 
     
     
         48 . The method of  claim 47 , where the risk level is assigned based, at least in part, on a number of available functional pathways for actuating the first BOP function. 
     
     
         49 . The method of  claim 47  or  48 , where the risk level is assigned based, at least in part, on a harm associated with a failure to actuate the first BOP function. 
     
     
         50 . The method of any of  claims 47 - 49 , where the risk level is assigned based, at least in part, on a type of a fault indicated by the received information. 
     
     
         51 . The method of any of  claims 36 - 50 , comprising scanning a BOP control network for available functional pathways for actuating the first BOP function. 
     
     
         52 . The method of any of  claims 36 - 51 , comprising communicating to a user a number of available functional pathways for actuating the first BOP function. 
     
     
         53 . The method of any of  claims 36 - 52 , comprising storing the received information in a memory.