Digital greasing intelligent tool
A method and a system to perform a wellhead maintenance process are disclosed. The wellhead maintenance process includes digitizing data records of wellhead valve greasing operations, automatic well and wellhead valve data recognition and verification, automatic generation of greasing operation volume recommendations, and generating advanced greasing operation analytics. A portable microcontroller device is used for geolocating and timestamping the digital maintenance records of the wellhead valve greasing operation to improve operation efficiency and automation as well as compliance audit verification.
1 . A method for performing a greasing operation at a wellsite of a hydrocarbon field, comprising:
initiating, using a data logger and control panel device, a valve greasing operation at a wellsite of a plurality of wellsites of a field, wherein said initializing comprises:
obtaining an operator identifier of a greasing operator,
a wellhead identifier of a wellhead at the wellsite,
a grease gun identifier of a grease gun used by the greasing operator, and
a valve identifier of a valve of the wellhead;
communicatively connecting, by the greasing operator and via a greasing adapter, the grease gun and the valve, wherein the greasing adapter comprises a pressure sensor and a flow meter;
connecting, by the greasing operator, the data logger and control panel device to the pressure sensor and the flow meter:
retrieving, from a grease gun database and based on the grease gun identifier of the grease gun, a known grease volume per stroke of the grease gun;
injecting, by the operator using the grease gun, grease into the valve for lubrication;
collecting, during said injecting and by the data logger and control panel device, sensor data from a pressure sensor and a flow meter;
generating, based on the collected sensor data and by the data logger and control panel device, an indication of grease acceptance,
wherein generating the indication comprises:
evaluating a measure of grease acceptance based on the collected sensor data, and
comparing the measured grease acceptance with manufacturer specified grease volume; and
stopping, in response to the indication of grease acceptance, the injection by the operator of the grease into the valve.
2 . The method of claim 1 ,
wherein obtaining the operator identifier of the greasing operator comprises scanning, using a radio frequency identification (RFID) reader of the data logger and control panel device, a first RFID tag of the greasing operator,
wherein obtaining the wellhead identifier of the wellhead at the wellsite comprises:
obtaining, using a global positioning system (GPS) receiver of the data logger and control panel device, a GPS location of the wellsite; and
retrieving, from a wellsite GPS location database and based on the GPS location of the wellsite, the wellhead identifier,
wherein obtaining the grease gun identifier of the grease gun used by the greasing operator comprises scanning, using the RFID reader of the data logger and control panel device, a second RFID tag of the grease gun, and
wherein obtaining the valve identifier of the valve of the wellhead comprises scanning, using the RFID reader of the data logger and control panel device, a third RFID tag of the valve.
3 . The method of claim 2 , further comprising:
connecting, by the greasing operator and via a greasing adapter, the grease gun and the valve, wherein the greasing adapter comprises the pressure sensor and the flow meter;
connecting, by the greasing operator, the data logger and control panel device to the pressure sensor and the flow meter; and
retrieving, from a grease gun database and based on the grease gun identifier of the grease gun, a known grease volume per stroke of the grease gun.
4 . The method of claim 3 , further comprising:
analyzing, during said injecting, the sensor data to detect a plurality of pressure spikes with respect to time;
tallying, during said injecting, the plurality of pressure spikes to generate a stroke count with respect to time; and
calculating, by multiplying the stroke count and the known grease volume per stroke of the grease gun, a total pumped grease volume with respect to time.
5 . The method of claim 4 , further comprising:
retrieving, from a valve database and based on the valve identifier of the valve, a manufacturer specified lubrication grease amount, and
wherein generating the indication of grease acceptance is based at least on comparing the calculated total pumped grease volume with respect to time and the manufacturer specified lubrication grease amount.
6 . The method of claim 4 , further comprising:
compiling, in response to stopping said injection, job data of the valve greasing operation the wellsite, wherein the job data comprises the operator identifier of the greasing operator, the wellhead identifier of the wellhead, the grease gun identifier of the grease gun, the valve identifier of the valve, the sensor data and the stroke count with respect to time; and
uploading the job data to a job database, wherein the job database comprises historical job data of a plurality of valve greasing operations performed at the plurality of wellsites.
7 . The method of claim 6 , further comprising:
generating, by at least combining the job database and cumulative records of valve repair and replacement throughout the field, a training data set;
training, based on the training data set, a machine learning algorithm for the greasing operation of the field; and
generating, using the machine learning algorithm, a maintenance notice to facilitate the greasing operation of the field,
wherein the maintenance notice comprises one or more of a greasing due date, a problem status of a particular valve, and an operator performance measure.
8 . A data logger and control panel device for performing greasing operations on a valve at a wellsite of a hydrocarbon field, comprising:
a radio frequency identification (RFID) reader configured to:
scan a plurality of RFID tags of a greasing operator performing a greasing operation at the wellsite to generate an operator identifier;
scan a second RFID tag of a grease gun used by the greasing operator to generate a grease gun identifier; and
scan a third RFID tag of a valve of a wellhead at the wellsite to generate a valve identifier,
wherein the grease gun is connected to the valve via a greasing adapter;
a global positioning system (GPS) receiver configured to obtain a GPS location of the wellsite;
a pressure sensor connector for connecting to a pressure sensor of the greasing adapter;
a flow meter connector for connecting to a flow meter of the greasing adapter,
wherein the pressure sensor connector and the flow meter connector are communicatively connected to the data logger and control panel device;
a computer core module configured to:
collect, during injection of grease from the grease gun into the valve for lubrication, sensor data from the pressure sensor and the flow meter; and
generate, based on the collected sensor data, an indication of grease acceptance; and
a display configured to display the indication of grease acceptance,
wherein said injection of grease into the valve for lubrication is stopped in response to the indication of grease acceptance.
9 . The data logger and control panel device of claim 8 , the computer core module further configured to:
retrieve, from a wellsite GPS location database and based on the GPS location of the wellsite, a wellhead identifier; and
retrieve, from a grease gun database and based on the grease gun identifier of the grease gun, a known grease volume per stroke of the grease gun.
10 . The data logger and control panel device of claim 9 , the computer core module further configured to:
analyze, during said injecting, the sensor data to detect a plurality of pressure spikes with respect to time;
tally, during said injecting, the plurality of pressure spikes to generate a stroke count with respect to time; and
calculate, by multiplying the stroke count and the known grease volume per stroke of the grease gun, a total pumped grease volume with respect to time.
11 . The data logger and control panel device of claim 10 , the computer core module further configured to:
retrieve, from a valve database and based on the valve identifier of the valve, a manufacturer specified lubrication grease amount,
wherein generating the indication of grease acceptance is based at least on comparing the calculated total pumped grease volume with respect to time and the manufacturer specified lubrication grease amount.
12 . The data logger and control panel device of claim 11 , the computer core module further configured to:
compile, in response to stopping said injection, job data of the valve greasing operation the wellsite, wherein the job data comprises the operator identifier of the greasing operator, the wellhead identifier of the wellhead, the grease gun identifier of the grease gun, the valve identifier of the valve, the sensor data and the stroke count with respect to time; and
upload the job data to a job database, wherein the job database comprises historical job data of a plurality of valve greasing operations performed at the plurality of wellsites.
13 . The data logger and control panel device of claim 12 ,
wherein a training data set is generated, by at least combining the job database and cumulative records of valve repair and replacement throughout the field,
wherein a machine learning algorithm for the greasing operation of the field is trained based on the training data set,
wherein a maintenance notice is generated using the machine learning algorithm to facilitate the greasing operation of the field, and
wherein the maintenance notice comprises one or more of a greasing due date, a problem status of a particular valve, and an operator performance measure.
14 . A digital greasing intelligent tool (DGIT) for performing a greasing operation at a wellsite of a field, comprising:
a data logger and control panel device, comprising:
a radio frequency identification (RFID) reader configured to:
scan a first RFID tag of a greasing operator performing a greasing operation at the wellsite to generate an operator identifier;
scan a second RFID tag of a grease gun used by the greasing operator to generate a grease gun identifier;
scan a third RFID tag of a valve of a wellhead at the wellsite to generate a valve identifier;
a global positioning system (GPS) receiver configured to obtain a GPS location of the wellsite;
a pressure sensor connector for connecting to a pressure sensor of a greasing adapter;
a flow meter connector for connecting to a flow meter of the greasing adapter,
wherein the pressure sensor connector and the flow meter connector are communicatively connected to the data logger and control panel device;
a computer core module configured to:
collect, during injecting grease from the grease gun into the valve for lubrication, sensor data from the pressure sensor and the flow meter; and
generate, based on the collected sensor data, an indication of grease acceptance; and
a display configured to display the indication of grease acceptance; and
a greasing adapter adapted to connect the grease gun and the valve, the greasing adapter comprising the pressure sensor and the flow meter,
wherein said injecting grease into the valve for lubrication is stopped in response to the indication of grease acceptance.
15 . The DGIT of claim 14 , the computer core module further configured to:
retrieve, from a wellsite GPS location database and based on the GPS location of the wellsite, a wellhead identifier; and
retrieve, from a grease gun database and based on the grease gun identifier of the grease gun, a known grease volume per stroke of the grease gun.
16 . The DGIT of claim 15 , the computer core module further configured to:
analyze, during said injecting, the sensor data to detect a plurality of pressure spikes with respect to time;
tally, during said injecting, the plurality of pressure spikes to generate a stroke count with respect to time; and
calculate, by multiplying the stroke count and the known grease volume per stroke of the grease gun, a total pumped grease volume with respect to time.
17 . The DGIT of claim 16 , the computer core module further configured to:
retrieve, from a grease gun database and based on the grease gun identifier of the grease gun, a known grease volume per stroke of the grease gun,
retrieve, from a valve database and based on the valve identifier of the valve, a manufacturer specified lubrication grease amount,
wherein generating the indication of grease acceptance is based at least on comparing the calculated total pumped grease volume with respect to time and the manufacturer specified lubrication grease amount.
18 . The DGIT of claim 16 , the computer core module further configured to:
compile, in response to stopping said injection, job data of the valve greasing operation the wellsite, wherein the job data comprises the operator identifier of the greasing operator, the wellhead identifier of the wellhead, the grease gun identifier of the grease gun, the valve identifier of the valve, the sensor data and the stroke count with respect to time.
19 . The DGIT of claim 18 , the computer core module further configured to upload job data to a job database, wherein the job database comprises historical job data of a plurality of valve greasing operations performed at a plurality of wellsites.
20 . The DGIT of claim 19 ,
wherein a training data set is generated, by at least combining the job database and cumulative records of valve repair and replacement throughout the field,
wherein a machine learning algorithm for the greasing operation of the field is trained based on the training data set,
wherein a maintenance notice is generated using the machine learning algorithm to facilitate the greasing operation of the field, and
wherein the maintenance notice comprises one or more of a greasing due date, a problem status of a particular valve, and an operator performance measure.