Automated Oil and Gas Equipment Certification System
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Solution Overview
Problem
Existing methods for testing and certifying oil and gas well equipment, particularly 'frac iron,' are laborious, prone to human error, and inefficient, leading to inconsistent results and operational downtime, with manual recording and lack of real-time data access.
Innovation Solution
A system comprising a central management server, testing apparatus, and database that automates testing operations, generates and stores data in real-time, and dynamically produces certificates based on predefined test specifications, ensuring consistent and efficient certification processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual testing and certification methods are used, then flexibility in performing tests is maintained, but productivity is reduced and loss of time increases due to lengthy one to three week certification processes
Solution Approach 1:
The patent replaces manual mechanical testing processes with an automated computer-controlled system. The testing apparatus is controlled by a computer that automatically executes test sequences, collects data, and generates certification reports, eliminating the need for manual operation and significantly reducing certification time from weeks to hours or minutes.
Solution Approach 2:
The automated testing system performs self-service by automatically executing test protocols, recording results, and generating certification documents without requiring continuous human intervention. The system manages its own operation through pre-programmed test sequences and automatic data processing capabilities.
2Measurement precision
If manual recording of test results is used, then simplicity of the system is maintained, but measurement precision deteriorates due to human error and recording variances
Solution Approach 1:
The patent replaces manual recording processes with automated electronic data capture and processing. Sensors and detectors connected to the computer system automatically record test results, eliminating human error in data collection, storage, and analysis, thereby significantly improving measurement precision and consistency.
3Reliability
If frequent inspections every 90 days are performed, then reliability of equipment is improved, but loss of time increases due to operational downtime
Solution Approach 1:
The automated testing system enables continuous or near-continuous operation by rapidly performing inspections and generating certifications without requiring extended equipment downtime. The system can quickly process multiple pieces of equipment in sequence, minimizing the interruption to normal operations while maintaining frequent inspection schedules for reliability.
Solution Approach 2:
The patent accelerates the inspection process by using automated test sequences that rapidly execute through multiple test procedures. The system skips the lengthy manual steps by automatically transitioning between test phases, collecting data, and generating reports in a condensed timeframe, thus reducing operational downtime while maintaining comprehensive inspection coverage.
4Productivity
If manual testing procedures are used, then ease of operation is maintained, but productivity deteriorates due to laborious one to three week certification processes
Solution Approach 1:
The patent replaces manual testing operations with an automated computer-controlled system that executes test sequences, processes data, and generates certifications automatically. This substitution dramatically increases certification throughput from one to three weeks to hours or minutes, while the system maintains ease of operation through user-friendly interfaces and pre-programmed test protocols that require minimal operator input.
Data Source
AI summary
Embodiments of machines, systems, computer-implemented methods, and computer program products certify oil and gas well equipment. Embodiments identify a selected well equipment device, a device test specification, and testing sequences to be performed by a corresponding testing apparatus. Embodiments select a testing sequence responsive to the selected device. Embodiments control the testing apparatus for the selected testing sequence so that the corresponding testing apparatus performs the sequence responsive to the device test specification. Embodiments generate testing data for the selected testing sequence and link the testing data for the selected testing sequence to the device identifier for the device so that a certificate can be generated. Embodiments generate a certificate for the selected device responsive to the testing sequences having been performed upon the selected device and link the certificate for the selected device to the device identifier so that the certificate can be readily recalled.