METHODS AND SYSTEMS FOR INDUSTRIAL INTERNET OF THINGS DATA COLLECTION FOR EQUIPMENT ANALYSIS IN AN UPSTREAM OIL AND GAS ENVIRONMENT

Abstract

In embodiments of the present invention improved capabilities are described for a monitoring system for data collection in an industrial drilling environment comprising a data collector communicatively coupled to a plurality of input channels, wherein a subset of the plurality of input channels are communicatively coupled to sensors measuring operational parameters from an industrial drilling component; a data storage structured to store a plurality of collector routes and collected data that correspond to the plurality of input channels, wherein the plurality of collector routes each comprise a different data collection routine; a data acquisition circuit structured to interpret a plurality of detection values from the collected data, each of the plurality of detection values corresponding to at least one of the plurality of input channels; a data analysis circuit structured to analyze the collected data from the plurality of input channels to detect an anomalous condition associated with the industrial drilling component; and a data response circuit structured to switch one of the data collection routines from a first data collection routine to a second collection routine based on the detection of the anomalous condition.

Claims

1. A monitoring system for data collection in an industrial drilling environment, the system comprising: a data collector communicatively coupled to a plurality of input channels, wherein a subset of the plurality of input channels are communicatively coupled to sensors measuring operational parameters from an industrial drilling component; a data storage structured to store a plurality of collector routes and collected data that correspond to the plurality of input channels, wherein the plurality of collector routes each comprise a different data collection routine; a data acquisition circuit structured to interpret a plurality of detection values from the collected data, each of the plurality of detection values corresponding to at least one of the plurality of input channels; a data analysis circuit structured to analyze the collected data from the plurality of input channels to detect an anomalous condition associated with the industrial drilling component; and a data response circuit structured to switch one of the data collection routines from a first data collection routine to a second collection routine based on the detection of the anomalous condition.

2. The system of claim 1, wherein the anomalous condition is a pre-failure mode condition for the industrial drilling component.

3. The system of claim 1, wherein the second collection routine comprises data collector input channels coupled to sensors measuring additional operational parameters from the industrial drilling component relative to the first data collection routine.

4. The system of claim 1, wherein one of the plurality of input channels is connected to a tri-axial sensor connected to multiple input channels for monitoring different positions associated with the industrial drilling component.

5. The system of claim 1, wherein one of the plurality of input channels provides for a gap-free digital waveform from which the data analysis circuit detects the anomalous condition.

6. The system of claim 1, wherein the data analysis circuit is further structured to analyze at least two of the plurality of input channels, to determine a relative phase value between the at least two of the plurality of input channels, and to detect the anomalous condition in response to the relative phase difference.

7. The system of claim 1, wherein the industrial drilling component comprises a rotating component, and wherein the data analysis circuit is further structured to perform band-pass tracking associated with the rotating component to detect the anomalous condition.

8. The system of claim 1, wherein the data collector includes at least one delta-sigma analog-to-digital converter that is configured to increase input oversampling rates.

9. The system of claim 1, wherein the industrial drilling component comprises a rotating component, the system further comprising a frequency evaluation circuit structured to detect a signal on one of the plurality of input channels at frequencies higher than a frequency at which the rotating component rotates.

10. The system of claim 1, wherein the data analysis circuit is further structured to utilize a neural network model to detect the anomalous condition.

11. The system of claim 10, wherein the neural network model is a probabilistic neural network that predicts a fault condition for the industrial drilling component.

12. The system of claim 10, wherein the neural network model is a time delay neural network trained on data collected over time from the plurality of input channels.

13. The system of claim 10, wherein the neural network model is a convolutional neural network which provides a recommended route change for the data collector based on the data collected from the plurality of input channels, and wherein the data response circuit is further structured to adjust one of the collector routes in response to the recommended route change.

14. A computer-implemented method for monitoring an industrial drilling environment, the method comprising: collecting data from a plurality of input channels, wherein a subset of the plurality of input channels are communicatively coupled to sensors measuring operational parameters from an industrial drilling component; accessing a plurality of collector routes on a data storage, and storing the collected data on the data storage, wherein the plurality of collector routes each comprise a different data collection routine; interpreting a plurality of detection values from the collected data, each of the plurality of detection values corresponding to at least one of the plurality of input channels; analyzing the collected data to detect an anomalous condition associated with the industrial drilling component; and switching from a first data collection routine to a second collection routine based on the detection of the anomalous condition.

15. The method of claim 14, wherein the anomalous condition is a pre-failure mode condition for the industrial drilling component, and wherein the switching increases data monitoring of the industrial drilling component.

16. The method of claim 14, wherein detecting the anomalous condition comprises determining a relative phase difference between the detection values interpreted from two of the plurality of input channels.

17. The method of claim 14, wherein the industrial drilling component comprises a rotating component, and wherein detecting the anomalous condition comprises performing a frequency analysis at a selected multiple of a rotational speed of the rotating component.

18. A monitoring apparatus for data collection in an industrial drilling environment, the apparatus comprising: a data collector component communicatively coupled to a plurality of input channels, wherein a subset of the plurality of input channels are communicatively coupled to sensors measuring operational parameters from an industrial drilling component; a data storage component structured to store a plurality of collector routes and collected data that correspond to the plurality of input channels, wherein the plurality of collector routes each comprise a different data collection routine; a data acquisition component structured to interpret a plurality of detection values from the collected data, each of the plurality of detection values corresponding to at least one of the plurality of input channels; a data analysis component structured to analyze the collected data from the plurality of input channels to detect an anomalous condition associated with one of the plurality of industrial drilling components; and a data response circuit structured to adjust at least one of the data collection routines based on the detection of the anomalous condition.

19. The apparatus of claim 18, wherein the data response circuit is further structured to adjust the at least one of the data collection routines by changing at least one of: the collected data such that different sensors are utilized to monitor the industrial drilling component; and sensor configuration values such that operational parameters of the sensors monitoring the industrial drilling component are changed.

20. The apparatus of claim 18, wherein the anomalous condition comprises a reduced operating capability of the industrial drilling component, and wherein the data response circuit is further structured to provide a drilling process adjustment to reduce a work load of the industrial drilling component.