Rig systems self diagnostics

Abstract

Systems and methods for calculating a standardized Health Index for a plurality of different components are shown and described. There is a vast number of different components used on an oil rig and each one may have a different definition of new, worn, damaged, or depleted. The system includes a measurement component that takes a measurement of the different components, and a health modeling component which calculates the standardized Health Index. Monitoring the Health Indices provides a rig operator information from which decisions on equipment use can be made.

1 . A system for deriving a numerical Health Index for one or more components, the system comprising:
 a first drilling rig component having a first feature which decays when the first component is operated;   a second drilling rig component having a second feature which decays when the second component is operated, wherein the second component is different from the first component;   a measurement component operably coupled to the component and configured to measure the decay of the first feature or the second feature; and   a health modeling component configured to receive a measurement from the measurement component, wherein the measurement represents the decay of the first measurable feature or the second measurable feature or both, the health modeling component being configured to compute a first Health Index corresponding to the first component and a second Health Index corresponding to the second component.   
     
     
         2 . The system of  claim 1  wherein the measurement component is configured to measure the decay of at least one of the first feature or the second feature using at least one of a direct measurement or an indirect measurement. 
     
     
         3 . The system of  claim 1  wherein the measurement component is configured to execute one or more self-diagnostic routine sequences. 
     
     
         4 . The system of  claim 3  wherein the self-diagnostic routine sequences comprise part of a normal operation for at least one of the first and second components. 
     
     
         5 . The system of  claim 1  wherein the first and second drilling rig components comprise drilling equipment, sensors, suspension systems, mud logging equipment, transportation systems, or a combination thereof. 
     
     
         6 . The system of  claim 1  wherein the first and second drilling rig components comprise communications components or transportation equipment or a combination thereof. 
     
     
         7 . The system of  claim 1 , further comprising a data storage component configured to receive and store information pertaining to the first and second Health Indices. 
     
     
         8 . The system of  claim 1  wherein the first or second drilling rig component comprises a mud pump, a top drive, a hydraulic power unit, a draw works, a pipe handler, a walking system, a mast raising system, a power generator, a motor, a cooling unit, a lubrication system, a shaker, a degasser, a communication system, or a rig control system. 
     
     
         9 . The system of  claim 1 , further comprising an alarm component configured to issue an alarm if one or more of the Health Indices reaches a predetermined threshold. 
     
     
         10 . The system of  claim 1  wherein the first drilling rig component comprises an aggregation of multiple subcomponents. 
     
     
         11 . A method of monitoring a health of one or more components, the method comprising:
 taking a first measurement of a feature of a first drilling rig component;   taking a second measurement of a feature of a second drilling rig component, wherein the first and second drilling rig components are different;   calculating a first Health Index and a second Health Index from the first and second measurements, respectively, wherein the first and second Health Indices are on a comparable scale; and   monitoring at least one of the first and second Health Indices relative to a predetermined Health Index threshold.   
     
     
         12 . The method of  claim 11  wherein the predetermined Health Index threshold is a first predetermined Health Index threshold, the method further comprising monitoring the at least one of the first and second Health Indices relative to a second predetermined Health Index threshold different from the first predetermined Health Index threshold. 
     
     
         13 . The method of  claim 12  wherein the first predetermined Health Index threshold has a first associated suggested action and the second predetermined Health Index threshold has a second associated suggested action different from the first associated suggested action. 
     
     
         14 . The method of  claim 12  wherein the first associated suggested action is recommended maintenance and the second associated suggested action is mandatory shut down. 
     
     
         15 . The method of  claim 11 , further comprising performing maintenance on at least one of the first and second drilling rig components and recalculating at least one of the first and second Health Indices after performing the maintenance. 
     
     
         16 . The method of  claim 15 , further comprising comparing at least one of the first and second Health Indices after the maintenance to itself before the maintenance and calculating a numerical score representing an effect of the maintenance generally corresponding to a difference between the at least one of first and second Health Indices before and after the maintenance. 
     
     
         17 . The method of  claim 11 , further comprising altering an operation of at least one of the first and second drilling rig components sufficiently to change a Health Index for at least one of the first and second components. 
     
     
         18 . The method of  claim 17  wherein altering the operation of the at least one of the first and second drilling rig components comprises causing the first and second Health Indices to reach the first predetermined threshold substantially the same time. 
     
     
         19 . The method of  claim 17  wherein altering the operation of the at least one of the first and second drilling rig components comprises causing the first and second Health Indices not to reach the first predetermined threshold at substantially the same time. 
     
     
         20 . A method for predicting a health of a component of an oil rig, the method comprising:
 classifying the drilling rig component and calculating a Health Index for the component, wherein the Health Index includes an initial Health index value;   identifying conditions for operation of the drilling rig component;   accessing a database of Health Index information pertaining to drilling rig components similarly classified;   identifying a time at which the Health Index for the drilling rig component will reach a predetermined threshold according to the Health Index information and the initial Health Index value.   
     
     
         21 . The method of  claim 17 , further comprising identifying one or more operations to be carried out by the drilling rig component, wherein the database of Health Index information includes information pertaining to similar operations. 
     
     
         22 . The method of  claim 18 , further comprising calculating a plot of expected Health Index progression according to the database of Health Index information. 
     
     
         23 . The method of  claim 17  further comprising comparing the Health Index to an expected Health Index and calculating a difference between the Health Index and the expected Health Index. 
     
     
         24 . The method of  claim 19  wherein calculating the plot of expected Health Index progression comprises plotting the expected Health Index for each operation in order of operation. 
     
     
         25 . The method of  claim 19 , further comprising identifying a period of time for which Health Index information is not available. 
     
     
         26 . The method of  claim 22 , further comprising calculating a beginning Health Index value and an ending Health Index value for the period of time, wherein a difference between the beginning Health Index value and the ending Health Index value quantifies a Health Index deterioration for the period of time.