US 4,583,170 AGrant

Portable Oilfield Fluid Management System and Method

Issue Date:1986-04-15

•26 Claims

•14 Drawing Sheets

Abstract

A portable oilfield fluid management system and method provides display information concerning fluid status and includes a plurality of local sensing units which can be selectively attached in any order to a plurality of different storage tanks having different sizes, shapes and capacities located in different oilfields. A plurality of cable segments each of equal predetermined length are used to interconnect the attached local sensing units to each other in a serial connection and a central touch activated monitor located away from the local sensing units is interconnected to the first attached local sensing unit by means of an elongated cable. Because the local storage units which function to measure the level of fluid in the storage tanks can be attached to the storage tanks in any order, the central touch-activated monitor autoconfigures the local sensing units by assigning binary addresses to each attached local sensing unit. The first attached local sensing unit when it receives its binary address from the central touch activated monitor, stores that binary address in its random access memory and interconnects an upstream data transmission path to enable the central monitor to assign the next binary address to the next attached local sensing unit. This process is repeated for each attached and interconnected local sensing unit until all local sensing units have a binary address. The system autoconfigures the local sensing units for each different oilfield location.

Metadata

Assignee

Cypher Systems, Inc.

Inventors

John A. Carlin
William G. Mesch
Joseph R. Skovrinski
J. Bart Henthorn
David G. Feldman
Steven A. Beard

Application Information

Application Number:US 5588413

Filing Date:1983-12-06

Priority Date:1983-11-22

Art Unit:236

Classifications

IPC:

G06F 1520G06F 305

Field of Search:

364340166400;420;422;505-506;509-510606;609;618;623;825.36;870.16250;261;280;351;373

Patent Drawings (14 sheets)

Description

Field of the Invention

The present invention relates to an improved oilfield fluid management system and method for monitoring the levels of different fluids in varying sized and shaped storage tanks and, in particular, to a highly portable system that can autoconfigure itself to different numbers and sizes of fluid tanks wherein the tanks contain the different fluids necessary for treating oil and gas bearing formations.

Description of the Prior Art

One technique to enhance recovery in an oil and gas bearing formation through fluid treatment is to "fracture" the formation through the injection of fluids under known hydraulic techniques.

In a series of articles by Viphal Pai and Sam Garbis appearing in four issues of the Oil & Gas Journal (July 25, 1983; Aug. 8, 1983; Aug. 22, 1983; and Sept. 5, 1983) and entitled "MHF Treatment Design", the current design techniques for implementing massive hydraulic fracturing (MHF) is set forth for the stimulation of low permeability hydrocarbon reservoirs.

In designing an MHF system for a particular oilfield, great care must be taken in not only designing the overall injection procedure but also in operating the system to anticipate and avoid problems that can be encountered. For example, and as set forth in Table 5 of the Pai and Garbis articles, the following suggested pumping schedule, in part, is set forth for the injection of frac fluids into a wellhead:

a. Pump 100,000 gal gelled 2% K+Cl water prepad; at the rate allowed.

b. Pump 80,000 gal 50 lb X-linked 2% K+Cl water at 20 bbl/min.

c. Pump 80,000 gal 50 lb X-linked 2% K+Cl water with 0.5 ppg 20-40 sand.

d. Pump 80,000 gal 40 lb X-linked 2% K+Cl water with 1 ppg 20-40 sand.

e. Pump 40,000 gal 30 lbs X-linked 2% K+Cl water with 2 ppg 20-40 sand.

f. Pump 20,000 gal 30 lb X-linked 2% K+Cl water with 3 ppg 20-40 sand.

g. Pump 20,000 gal 30 lb X-linked 2% K+Cl water with 4 ppg 20-40 sand.

h. Pump 40,000 gal 30 lb X-linked 2% K+Cl water with 6 ppg 20-40 sand.

Such a formulation requires large quantities of frac fluid and proppant such as sand. In a typical operation up to three different fluids such as crude oil condensate from the formation, gelled water, and acid are stored in large storage tanks. As witnessed in the above table, these fluids are combined in different proportions at different stages of the frac operation. Furthermore, the frac design for each different oilfield location can involve different numbers of tanks, different sizes of tanks, and different configurations of tanks as well as totally different quantities, types and proportions of fluids.

Typically large fluid and proppant volumes are pumped over a three to forty-eight hour time interval into the wellhead and it is of paramount importance, as recognized in the Pai and Garbis articles, to monitor fluid rates at all times. Small variations in fluid rates can become significant when such rates are not monitored over extended periods of time. The aforesaid authors recommend that three methods be used simultaneously to monitor fluid rates. The first is to use conventionally available turbine-type flow meters, the second is to count pump strokes which when correllated with the pump displacement capacity and efficiency of the pump provides information as to flow rate, and the third approach, one emphasized by the authors, is to physically measure the change in the level of the fluid in the various frac tanks over a given length of time.

To accomplish the latter test, persons (termed gaugers) are assigned to measure the level of fluids in the tanks and this is essentially a full-time responsibility. The tanks are spaced relatively close to each other and the gaugers jump from the top of one tank to the top of an adjacent tank, open the hatch on each tank and with a measuring stick determine the level of the fluid present in the tank. The gaugers then ratio the measured levels to a control truck and, after conversion of the measured level (based upon a chart) to barrels, the operators (termed treaters) in the control truck have up-to-the-minute readings for each tank. The treaters ascertain, in part, whether the flow from the tanks is uniform or whether one tank is flowing faster than the others.

It is important that the level of the fluid in any one of the tanks does not drop below a predetermined low value in order to prevent the introduction of "air" into the system which can result in an extremely dangerous condition. When air is introduced into the pumping system from the tanks, the conventionally used pumps can be thrown out of balance thereby causing possible severe damage to the pumps sometimes with such force as to cause the pump truck to bounce off the ground. In that event, any personnel in the vicinity could be hurt. Another problem caused by the introduction of air is the creation of an air hammer effect in the plumbing which may result in severe vibration in the lines. Such air hammers have been known to cause lines to blow, thereby ending the frac operation and risking the destruction of the well itself.

The present invention provides a highly portable system and method for monitoring the level of fluid in the frac tanks, and, in doing so, improves upon the teachings set forth in "Oilfield Lease Management and Security System and Method Therefor" Ser. No. 472,651 filed on Mar. 7, 1983, now U.S. Pat. No. 4,551,719 and in "Storage Tank Level Monitoring Apparatus and Method Therefor", U.S. Pat. No. 4,487,065 issued on Dec. 11, 1984 to Carlin et al. which are commonly assigned with this application. In the aforesaid applications, a novel oilfield lease management and security system and method therefore was set forth which utilized a plurality of transducers connected to oilfield storage tanks, a communication access panel for allowing authorized users to interface with the system, and a monitoring system for monitoring the levels of the fluid in each of the oilfield storage tanks as fluid is added to and taken from the tanks. In the event of unauthorized taking of fluid from the oilfield storage tanks, an alarm is sounded. The oilfield lease management and security system has been improved upon and modified, as hereinafter set forth, to provide a system for continuously monitoring the levels of fluid stored in the various "frac" tanks, to provide a system that is adaptable to any configuration or any size of frac tanks, to provide a system which is highly portable and one which can be moved from oilfield location to oilfield location and be quickly assembled and disassembled. Because of this portability, the system has the capability to autoconfigure itself to the specific structural arrangement of each different location.

SUMMARY OF THE INVENTION

The present invention sets forth an improved oilfield fluid management system which is highly portable and which can be moved from one oilfield location to another. The oilfield fluid management system, in the preferred environment, can be assembled and disassembled in a matter of hours and is capable of measuring the levels of a plurality of different fluids stored in a plurality of different storage tanks located at each different oilfield. The fluid management system of the present invention is adaptable to storage tanks having the same or different sizes, shapes and capacities.

The present invention includes a plurality of local sensing units which can be selectively attached in any order to an exterior surface on the storage tanks. Attached to each local sensing unit is a level sensing device which can be unwrapped and inserted through a hatch on the tank and selectively attached to the interior of the tank for measuring the level of the fluid. In the preferred embodiment, an ultrasonic sensor is used to measure the levels. Each local sensing unit is highly portable and can be quickly attached and detached from the tank. The sensor is designed to wrap around the underlying pedestals of the handle of the local sensing unit.

A plurality of cable segments each of equal predetermined length are used to interconnect the attached local sensing units to each other in a serial connection. The cable segments are unreeled from a reel carriage for installation and each cable segment is attached to each other on the reel by means of opposing male and female connectors. When the system is disassembled, the cable segments are reattached to each other and reeled back onto the reel carriage.

A central touch-activated monitor is located away from the local sensing units and is interconnected by means of a cable connected therewith which cable is also reeled and unreeled from the carriage reel. When the system is installed and interconnected, the central monitor is capable of autoconfiguration wherein the central monitor assigns a binary address to each attached local sensing unit. This autoconfiguration process eliminates the necessity of having internal identity codes permanently assigned in each local sensing unit and the necessity of placing these local sensing units in a particular order on the tanks. Hence, once the central monitor autoconfigures the system, the central monitor knows which local sensing unit is connected to which tank.

The autoconfiguration process includes a double handshake process wherein the first interconnected local sensing unit receives the first binary address from the central monitor. The first local sensing unit stores that binary address in its random access memory and retransmits the first binary address back to the central monitor with an acknowledgement signal. The central monitor receives the retransmitted first binary address and compares it to the address sent and if proper, resends the first binary address back to the first local sensing unit. The local sensing unit receives the redelivered first binary address, compares it to the address stored in its random access mamory, and if correct, connects a path to the next interconnected local sensing unit by enabling an upstream transmitter so that the central monitor can now communicate with the next serially interconnected local sensing unit. This process is repeated for each interconnected local sensing unit.

DESCRIPTION OF THE DRAWING

FIG. 1 shows a prior art illustration, in partial perspective, of an MHF oilfield frac system;

FIG. 2 is an illustration of the present invention being installed, in a modular fashion, to the MHF oilfield system of FIG. 1;

FIG. 3 is a side and partial perspective view of the local sensing unit (LSU) of the present invention;

FIG. 4 is the bottom view of the lower cover of the local sensing unit (LSU) of FIG. 3;

FIG. 5 is the top planar view of the upper cover of the local sensing unit (LSU) of FIG. 3;

FIG. 6 is a perspective view of the sensor of the present invention;

FIG. 7 is a perspective view of the carrying case for the local sensing units (LSUs) of the present invention;

FIG. 8 is the carrying case for the touch activated monitor (TAM) of the present invention;

FIG. 9 is a block diagram of the monitoring system of the present invention;

FIG. 10 is a block diagram of the autoconfigure process of the present invention;

FIG. 11 sets forth the start processing sequence of the present invention;

FIG. 12 sets forth the autoconfigure sequence of the present invention;

FIG. 13 sets forth the start touch sequence of the present invention;

FIG. 14 sets forth the start setup sequence of the present invention;

FIG. 15 sets forth the key function sequence of the present invention;

FIG. 16 is a graphical illustration of the bar display of the present invention;

FIG. 17 is a graphical illustration of the groups display of the present invention;

FIG. 18 is a graphical illustration of the individual display of the present invention;

FIG. 19 sets forth the start LSU sequence of the present invention;

FIG. 20 is a block diagram representation of the circuitry contained in the TAM of the present invention;

FIG. 21 is a circuit diagram of the components contained in the LSU of the present invention;

FIG. 22 is a circuit diagram of the personality board of the present invention;

FIG. 23 is a circuit diagram of the CPU board of the present invention; and

FIG. 24 is the circuit diagram of Card 6 of FIG. 20.

DESCRIPTION OF THE PREFERRED EMBODIMENT

1. Prior Art

In FIG. 1, is shown in simplified illustration and based upon FIG. 9 in the aforesaid Pai and Garbis articles a prior art MHF operation located in an oilfield. The frac system comprises a plurality of frac tanks 12, 14 and 16 in a first bank 10 of tanks and a second plurality of frac tanks 22, 24, and 26 oriented in a second bank 20 of tanks. In a typical installation, a total of ten to twenty frac tanks are utilized which contain the fluid necessary to treat the oil and gas bearing formation. These tanks can range fron eight feet to twelve feet in height and are of varying lengths, configurations and capacities. For purposes of illustration, each of the tanks 12, 14, and 16 in bank 10 of tanks are different sizes and configurations. And, hence, each are of different capacities. The tanks 22, 24 and 26 in back 20 of tanks, also for purposes of illustration, are of uniform shape and size.

The tanks 10 are interconnected over plumbing 30 to a first blender 40 and tanks 20 are interconnected over plumbing 50 to a second blender 60. Blender 40 receives sand proppant from silo 70 over plumbing 72 and blender 60 receives sand proppant from silo 80 over plumbing 82. The sand proppant could be silica jell or beads or, in high pressure formations, bauxite. The blenders 40 and 60 function to mix the fluids from the tanks 10 and 20, respectively, in proper proportion and to blend in a predetermined amount of sand from the sand silos 70 and 80. The combined slurry from the blenders 40 and 60 are then delivered over plumbing 84 and 86, respectively, to pumps 90 and 100. The pumps 90 and 100 inject the slurry into the well head 110 over plumbing 112 and 114.

Conventionally, signals such as signals on lines 120 interconnected with the pumps 90 and 100 are delivered into a control truck 130 so that treater personnel located in the control truck, typically parked on the opposite side of the well head 110, can view the equipment and monitor the operation of the equipment. It is to be expressly understood that the signals appearing on lines 120 which, for example, deliver signals as to the pump stroke count is representative of but one of many signals from other monitors that are delivered into the control truck 130 from the equipment shown in FIG. 1. Other typical signals which may be delivered into the control truck 130 are the well head, casing, and line pressures 122 at the well head, readings 129 from nuclear densiometers 128 in the flow lines, and signals 124 from flow meter 126. The structural arrangement discussed above is known to those skilled in the art. All of the equipment shown is portable and can be moved from oilfield location to oilfield location.

The present invention, in part, pertains to the added equipment shown in dotted lines in FIG. 1. This equipment includes a plurality of local sensing units (LSUs) 140 connected in series by means of cable segments 230 of predetermined equal lengths which are further interconnected over cable 150 to a central touch activated monitor (TAM) 160 located in the control truck 130. The system of the present invention through its autoconfiguring capability is retrofitable to any number of any sized tanks 10 or 20 and can be quickly disassembled into a highly portable carrying system for secure transportation to the next well head location.

For example, the treatment for a typical well head operation may be finished in several days time after which all of the portable equipment in FIG. 1 is disassembled and moved to another oilfield location or is split up and moved to other locations. The equipment of the present invention, therefore, must be highly portable, easy to install and disassemble, highly reliable and only take a short time such as an hour or less to install and disassemble. Under the teachings of the present invention, the attachment of the LSUs 140 to the tanks 10 and 20 can be in any order since the TAM 60 will automatically configure the mounted LSUs to any tank setup. This is important since the system of the present invention can be used in a large number of different oilfield environments.

The system of the present invention also eliminates the necessity of having manual readings taken by the gaugers as to the physical level of the fluid in each of the storage tanks. It further improves the quality control during a job by eliminating the possible human error whenever the levels in a tank are physically measured. Clearly the provision of continuous monitoring of the level in each tank permits immediate detection of any dangerously low fluid levels and, hence, the risk of introducing air. The elimination of manpower for this function is significant in view of recent cutbacks in the oil and gas industry. For example, when ten tanks are used two to three gaugers may be necessary and three to four gaugers may be required to read twenty tanks. In addition, the method and system of the present invention is safer than that present when personnel move from the top of one tank to another to take physical readings during the job. Hence, lower insurance premium rates may be possible through implementation of the present invention.

2. Monitoring System of the Present Invention

In FIG. 2, the monitoring system of the present invention is set forth to include one of a plurality of local sensing units (LSUs) 140 removably attachable to a fluid tank 210, an ultrasonic sensor 220 mounted to the interior of tank 210 and connected to the LSU 140 by means of a sensor cable 222, a plurality of interconnecting cable segments 230 of equal predetermined length 232, a main interconnecting elongated cable 150, and a touch activated central monitor (TAM) 160 which is located in the control truck 130.

In operation, the frac tanks 10 and 20 as shown in FIG. 1 and with one as specifically represented in FIG. 2 as tank 210 are transported to the oilfield site and are typically laid side-by-side. Under the teachings of the present invention, each LSU 140 is self-contained in a shock resistant plastic case and is magnetically mounted to the outside of tank 210 as shown in FIG. 2. Connected to each LSU 140 is an ultrasonic detector 220 and a cable 222. The ultrasonic detector 220 is inserted through the hatch 240 of the tank and is positioned on the upper inside surface of the tank 210 so that ultrasonic waves 224 are directed downwardly to the surface of the fluid contained within tank 210. Cable segments 230 of equal predetermined length 232 (such as twenty feet) are unreeled from a moveable reel carrier 250 which is pushed along the ground 274 and in front of the tanks 10 and 20. One or more segments 230 may be necessary to connect adjacent LSUs 140. As will be discussed, the LSUs 140 are serially electrically connected. Each cable segment 230 has a conventional male connector 260 on one end and a conventional female connector 262 on the other end which can be quickly engaged to form cable lengths in multiples of the predetermined length of 232 or which can be reeled back onto the reel carrier 250 when disassembled for transportation to the next oilfield location.

Hence, as can be observed in FIGS. 1 and 2, the number of tanks 10 and 20 in a given location can vary and the present invention being portable and modular can quickly adapt to any configuration in a given oilfield location as set forth above.

In a typical installation, the installer climbs ladder 212 which is located on the front of tank 210 and places a single LSU 140 on the top of tank 210. The installer then opens the hatch 240 and inserts the ultrasonic detector 220 which is magnetically mounted to the upper surface on the inside of the tank 210. The installer then removes cable segments 230 from the reel 250 and attaches a segment on either side of the LSU 140 to the corresponding male and female connectors as shown in FIG. 2. The installer continues for each adjacent tank until all of the tanks 10 and 20 are serially interconnected as shown in FIG. 1. The first LSU 140 is connected to one end of cable 150 and cable 150 is typically 100 to 200 feet in length which is connected to the TAM 160. TAM 160 provides monitoring output information as well as receives operator input information such as the strapping table information for each tank and the current level of fluid in the tank. Hence, the installer or user of the system will input information concerning the capacity and configuration of each tank 210 (strapping information) and the current level of the fluid. The nature and format of this input information will be discussed later. Once inputted, however, TAM 160 will autoconfigure each of the LSUs 140 independent of the order of being installed in a manner also to be subsequently explained. In the preferred embodiment up to twenty LSUs can be interconnected to the TAM 160 in this fashion. It is to be understood that the teachings of the present invention can be utilized in situations having more than twenty LSUs.

3. Local Sensing Unit (LSU) of the Present Invention

In FIGS. 3-5, the container for the local sensing unit (LSU) 140 is set forth. Each LSU is protected by a rectangular modular container 300 which is comprised of an upper cover 310 and a lower cover 320 all of which is made of molded plastic or the like. The engagement of the upper cover 310 with the lower cover 320 is watertight. Disposed on the upper cover 310 is a handle 330 mounted on two attached supports or pedestals 340. The handle 330 is preferably a flat elongated metal plate coated with protective plastic or paint.

Disposed on the lower cover 320 are two opposing electrical connectors 350 and 360. Connector 360 is a male connector and connector 350 is a female connector. Each connector 350 and 360 is receptive of the appropriate mating end of cable segment 230. On the underside of the lower cover 320 is affixed a flat circular magnet 370 for holding the container to the tank. Finally, attached to the side of the bottom cover 320 by means of cable 222 is an ultrasonic detector 220 having a magnet 224 affixed on the upper surface and an ultrasonic detector 226 affixed on the lower opposing surface.

In operation, the installer grasps the handle 330 and places the container 300 on the top of tank 210 by means of magnet 370 which holds it firmly in place. The installer then unwraps cable 222 from around pedestals 340 and places the ultrasonic detector 220 on the underside of the upper surface of tank 210 as previously discussed. When the LSUs 140 are not in use or in transit, the installer removes the container 300 from the side of the tank 210, wraps cord 222 around the pedestals 340 between said handle 330 and said cover top 310 and affixes the ultrasonic detector 220 to the underside of the handle 330 by means of magnet 224 as shown by the dotted lines in FIG. 3. The pedestals are of sufficient height to permit the detector 220 to slide under the handle 330 and above the upper cover 310. In this fashion, each LSU 140 can be transported and stored with the sensor 220 and the cord 222 also neatly stored or tucked under the handle or whenever the level is not attached to the tank.

The details of the bottom cover 320 are shown in FIG. 4 whereas the details of the upper cover 310 are shown in FIG. 5. As shown in FIGS. 3-5, slots 500 are formed around the periphery of the top and bottom covers 310 and 320 and centered in each slot of the bottom cover 320 is a formed hole 510 which is receptive of cap screws or the like to firmly engage the upper cover 310 to the lower cover 320 in a conventional fashion.

In addition, a raised ledge 520 is formed on the top cover 310 directly underneath the handle 330. The raised ledge 520 has a formed slot opening 530 which is slightly larger than the diameter of the transducer 220 and which is receptive of the transducer 220 when the transducer 220 is stored underneath the handle as shown by the dotted lines in FIG. 3.

In the preferred embodiment, cable 222 is four to six feet long, and the container is approximately six and one-half inches wide by eight inches long by four inches deep. Finally, on the top and bottom covers 310 and 320 are formed protruding lips 540 which extend longitudinally outwardly from the container 300 a sufficient distance to protect the male and female connectors 350 and 360 from damage when being transported, stored or dropped.

On the interior of each container 140 is held the LSU package of electronics mounted in a shock absorbing environment. The electronics used in the LSUs 140 and in the TAM 160 are similar to those utilized in the aforesaid mentioned Oilfield Lease Management and Security Systems and Method Therefore, Ser. No. 472,651, filed Mar. 7, 1983 now U.S. Pat. No. 4,551,719 (hereinafter specifically referred to as "Oilfield Lease reference"). The one important modification is found in the removal of the permanent identity code found in each LSU. Under the teachings of the present invention, the LSUs do not contain a permanent identity code since the system, because of its high portability and adaptability to different frac operations in different oilfields autoconfigures itself to the LSUs independent of which LSU is installed on which tank. It is to be further noted that for measuring the level of "frac" fluids, the temperature of the environment within the tank need not be measured but can optionally be performed.

FIG. 6 shows the details of the ultrasonic detector 220 to include a main housing portion 600, a circular magnet 610 epoxied onto the top of the housing 600 and a cover 620 for retaining the ultrasonic detector, not shown, on the interior of the housing 600. One end of cable 222 is attached to the transducer through a weatherproof grommet 633. An electrical connector 632 is further provided on the end of cable 222 so that the ultrasonic transducer 220 can quickly connect and be disconnected from the LSU 140 by means of a mating electrical coupler 630 located in the upper cover of the housing as shown in FIGS. 3 through 5. The sensor, as shown in FIG. 6, is fixed to the magnet, however, it is to be expressly understood that the mounting between the magnet 610 and the housing 600 could swivel as disclosed in the aforesaid Oilfield Lease reference.

In FIGS. 7 and 8 are set forth the shipping containers which are used to transport and store the LSUs 140 and the TAM 160. The shipping container 700 shown in FIG. 7 has divider-like compartments 710 made from plastic, foam or the like for holding up to ten LSU's in a cushioned and shock absorbing environment. In a typical installation, two cases 700 would be utilized to contain up to twenty LSU's 140. The containers 700 are of conventional construction having high impact resistance plastic exteriors, partitions 710 and an elongated handle 720. A similar type of container 800 is shown in FIG. 8 for carrying the TAM 160 in a shock absorbing environment. Container 800 has a front cover 810 for closing over the front of TAM 160 and a rear cover 820 for closing over the rear of TAM 160. A handle 830 is further provided for carrying the container 800 as well as supporting the TAM 160 as shown in FIG. 8.

For transportation to a new oilfield, the LSUs 140 can be quickly removed from each tank, the sensor cable 222 wrapped around pedestals 340, and the detector 220 stored under the handle 330. The LSUs 140 are then placed in individual compartments 710 in container 700 and the lid 730 closed. Likewise, the TAM 160 can be disconnected from power and cable 150 and lids 820 and 810 closed and the TAM 160 is ready for transportation. Cable segments 230 are connected to each other and are reeled onto the reel carriages 250 (more than one may be required) as well as the elongated cable 150. It can be observed that the system of the present invention is highly portable and can be quickly installed and disassembled at a given oilfield location. Furthermore, because of the modular arrangement of the present invention, the system through its numerous components can adapt to different treatment configurations.

4. System Autoconfiguration

In FIGS. 9 and 10, the autoconfiguration process of the present invention is set forth. As discussed, the modular LSUs 140 which are stored in the shipping container at 700 of FIG. 7 can be taken out by the installer and installed in any order on the tanks 10 and 20. It is important, therefore, that no permanently assigned identity code be resident in each LSU 140.

Under the method and process of the present invention, once the LSUs 140 are installed and interconnected to the TAM 160, the TAM 160 enters the autoconfigure mode of operation as shown in FIGS. 9 and 10. TAM 160 sends the first binary address over cable 150 to the first interconnected LSU 140. This LSU becomes power activated (awakened) according to the teachings of the Oilfield Lease reference and receives the first binary address. The first interconnected LSU thereupon stores the first binary address in its random access memory (RAM) 1000 and then transmits an acknowledgement signal (ACK) plus the first binary address back to the TAM 160 over cable 150. TAM 160 receives back the transmitted acknowledgement signal from the first interconnected LSU as well as the first binary address. TAM 160 then compares the received first binary address with the first binary address originally delivered and, if the same, redelivers the first binary address back to the first interconnected LSU which in turn again receives it and if it compares to the address stored in the RAM 1000, the LSU connects a hardware upstream transmission path to the path interconnected LSU. This hardware upstream path will be discussed subsequently but involves the enabling of an upstream transmitter as shown in FIG. 10. In the event of an address mismatch at the TAM, the TAM will form a bad address and deliver it to the first interconnected LSU who will receive it, store it in RAM 1000, mark itself as bad, and then connect the upstream data transmission path as before. TAM 160 then increments the address to the second binary address and sends the second binary address through the connected upstream path of the first interconnected LSU to the next interconnected LSU and repeats the process discussed above for adjacent and interconnected LSU.

The above represents a "double hand shake arrangement" in that the binary address to a given LSU is delivered to the LSU in its resident RAM, stored by the LSU, retransmitted back to the TAM, received and checked by the TAM and again redelivered to the LSU, the LSU receives the redelivered binary address and checks it with the address stored. It is to be expressly understood that this is a preferred approach and that variations of the above could be made.

In this fashion and independent of the order that the LSUs 140 are placed on tanks 10 and 20 by the installer, TAM 160 will always autoconfigure the first interconnected LSU 140 to a first binary address, the second interconnected LSU 140 to the second binary address and so forth until all LSUs receive an identity code in numerical sequence. After autoconfiguration has taken place, TAM 160 can then directly address each LSU based upon its unique identity address stored in its resident RAM 1000.

Therefore, it can be observed that the monitoring system of the present invention can rapidly autoconfigure itself to a predetermined address sequence independent of the order of the installation of the LSUs.

Under the autoconfiguration process of the present invention, and as witnessed in FIGS. 9 and 10, the present invention can be adapted to an environment wherein the transducers 220 can either be any conventional sensor or controller S/C for measuring controlling parameters on oilfield equipment or other types of equipment. For example, and with reference back to FIGS. 1 and 2, the modular LSUs 140 can be attached to other sensing or controlling equipment 220 in the oilfield such as for example to the flow meter 126, the nuclear densiometers 128, and wellhead, casing, and line pressure sensors 122.

5. System Operation

In FIGS. 11-14, the operational process of the present invention is set forth. In FIG. 2, the TAM 160 is started by activation of switch 161 and as shown in FIG. 11 enters into a first operational step wherein the TAM 160 becomes powered and is configured to be operational. The TAM is initialized by software termed STFRAC (start frac) which is disclosed later.

Once configured, the TAM 160 receives its input and output data through its touch screen 270 as shown in FIG. 2 which has a plurality of defined regions 272 capable of receiving input data by means of the user's touch on the screen. The touch screen and the associated circuitry is conventionally available as Model 1780A from:

John Fluke Manufacturing Co., Inc., P.O. Box C9090, Everett, Wash. 98206

When the system is up, series of communications occurs between the user and the TAM, the more important ones of which are set forth in the following. In order to receive the time and data, TAM 160 prompts the user as follows:

Enter the Current Time & Date

The touch screen 270 then displays a numeric keyboard and the user enters the time and date into the system. The system then inquires:

Have all LSUs been installed and connected to the TAM?

If so, the system then enters the autoconfigure mode as shown in FIG. 12 and is termed the CONTNK (configure tank) software routine set forth later. The first step, and as previously discussed in the Oilfield Lease Reference is to deliver power to each LSU 140 and each LSU becomes "awakened." With all interconnected LSUs functional, the system is now ready to autoconfigure as priorly discussed in FIGS. 9 and 10. The first binary address, in hexidecimal, which is sent is 01 and this is sent to the first interconnected LSU 140. If the first interconnected LSU 140 responds back to the TAM 160, the TAM sends hexidecimal address 01 once again. The TAM then increments the address to the next address 02 for delivery to the next interconnected LSU.

In the event that the response back from the LSU is bad, the TAM 160 marks that LSU address as inoperative or bad and proceeds to send the incremented address to the next interconnected LSU. When all LSUs 140 are interconnected TAM 160 by means of the touch screen 270 displays the number of LSUs that it has autoconfigured and asks the user the following question:

These are the tanks found during Auto-configure. (displays tanks) Are these correct?

If the answer is correct, the operator presses "yes" and the autoconfiguration sequence ends. If the answer is not correct, the operator presses "no", something is wrong and the TAM powers down the LSUs and puts them in a "sleep" mode and prompts the user to replace the last interconnected LSU. In other words, if only seven LSUs were autoconfigured out of ten that have been physically installed, then LSU 8 is inoperative, the system will interconnect the first seven LSUs and think it is done. However, the user knows that the eighth LSU is inoperative and with the system powered down, can go out in the field and replace the eighth LSU. In addition, if the user presses one of the tank keys on the touch screen 270 corresponding to the identity of the tank, the system will remove that LSU by storing in its memory to ignore the address for that LSU.

In this fashion, and as discussed in FIGS. 9 and 10, the system autoconfigures itself and recognizes inoperative LSUs, LSUs sending back bad addresses, and provides for the option of ignoring interconnected LSUs at the users option. Of course, the identity of each LSU corresponds to the identity of the storage tank.

Returning now to FIG. 11, the TAM 160 will now ascertain the present level of fluid in each tank by asking:

Enter High Gauge (Present Tank Level)

And the user will input this information based on a manually measured reading. The TAM will now, as for example, inquire:

Is the tank about 9 feet?

The TAM takes the present tank level reading and adds it to the height of the tank above the fluid (which it has just measured) and makes this inquiry as a double check and to which the user responds with an affirmative.

TAM 160 now prompts the user for the strapping table information and the user by means of the displayed keyboard inputs the strapping table for each tank. The software responsible for this is TKUTIL (tank utility) and TABLES as will be presented later. The prompt, for example, would be:

Enter the Barrels at 0 Feet, 6 Inches

And the response would be:

bbls 20.8

This interchange would occur at, preferably, one to six inch intervals for the height of the tank. For example, if a particular tank 210 has an LSU 140 having address 02, then that tank's strapping table, at six inch intervals, having been entered would be displayed by the TAM as follows:

If corrections are required, the TAM 160 will direct the user to:

Make the ARROW point to the Number to Correct

And then corrections can be reentered.

In the event that other tanks have a strapping table identical to the tank just entered (as in the case of tanks 20 in FIG. 1), TAM 160 will inquire:

Select tanks with IDENTICAL Strapping Tables

This simply serves time and the possibility of error when tanks are of identical size and shape.

It is to be noted that each tank in the bank of tanks 10 and 20 of FIG. 1 normally has the strapping table affixed to the side of the tank in one inch increments. In the example, barrels at six inch increments are entered in as shown above although it is to be expressly understood that data based upon the one inch intervals or any other convenient interval could also be entered into TAM 160 under the teachings of the present invention.

After the entry of the strapping table information for all tanks, the TAM 160 prompts the user for the type of fluid and the low limit trip point for each tank. The software for handling this is termed BLDPG (build page) and is presented later. In the preferred embodiment, each tank can be assigned to one of three different types of fluids. The TAM will first inquire:

Enter Alarm Trip Level for ALL Tanks

And the user will respond with the low limit drop point which, for example, in a nine foot tank could be three feet. TAM 160 will then inquire:

Each Tank can belong to one of three GROUPS. Each GROUP is shown with a different type of BAR. The BARS look like: (Examples shown)

Touch when You are ready to Select the Tank Groups

The TAM 160 will then display:

Select the Tanks in Group #1.

The user then selects the tanks in Group 1 and TAM 160 will then sequence through the remaining two groups. After receiving all of the user information pertaining to the time, date, strapping table, groups, and predetermined limits, the system enters the run system mode.

In FIG. 13, in the "start touch" operational process, which is the higher priority task of the system, the system continues to loop until the user presses any active key on the screen 270. The software for this routine is identified as STTUCH (Start Touch) and is presented later. In the event that a key is pressed on the screen, the system passes the number to a display driver and enters the "start setup" operational process.

In FIG. 14, the operational process for the start setup step which is the lowest priority task of the system is shown wherein TAM 160 ascertains if a setup of the touch screen 270 is required and if so sets it up and ends the routine. If not, it ascertains whether or not a key has been pressed and if so, decodes which key has been pressed and performs the function corresponding to that key. These keys and funtions are set forth in FIG. 15. If no key has been pressed, the system inquires as to whether or not there is new LSU information and if so updates this LSU information and displays the data. The software for the start setup is termed STFLUK and is presented later.

In FIG. 15, the operational sequences for the key functions are set forth and the associated software is contained within STFLK. Upon entering this sequence, the appearance of the start and maintenance keys on the touch screen 270 indicates that the frac job is ready but not yet started. If the start key has not been activated the system determines whether the maintenance key (MNTC) has been pushed, if not the sequence ends. If so, the system inquires of the user if it would like to reconfigure the tanks. If the response is affirmative, then autoconfiguration of the tanks will occur as previously discussed. If negative, the system asks if the user wants to change the alarm trip points. If the user does, he enters the new alarm trip points and if not the sequence ends. The display for the TAM would then show:

The example above only shows data for tank 1 and this data would include the current level of fluid (i.e., 10'7") and the amount in storage (i.e., 468 barrels). The rate of flow and the barrels delivered out of the tank (since pumping has not started) is zero. Comparable data for each tank is shown on the screen.

If the start switch has been activated, the job is started. Starting the frac job consists of displaying new action keys and "locking" the current volume in each tank as its respective "maximum volume" which is later used to calculate volume delivered. If the job has been started, the sequence analyzes each of the keys in turn to see which has been activated. If the QUIT key has been activated, the touch screen displays a question such as "are you sure you want to quit." If so, the TAM 160 is reset. The reset software is termed FRSTRT (frac start) and is presented later. It is important to note that the double check as to whether or not the QUIT key has been activated is necessary to prevent an accidental hitting of the QUIT key since, upon resetting, all the prior information relating to the setting of the groups and the limits is all erased. However, the strapping table for each tank is retained.

The setup Display routine of FIG. 14 displays the "BARS" graph display showing all of the tanks and their current levels when the job is first started and any time the "BARS" key is pressed. In FIG. 16, the touch screen 270 is shown displaying the bars for all of the individual tanks which in this case is twenty tanks. The bar graph also conveniently shows the nature of the liquid in each of the tanks by a system of dots, solid, and bars. The relative percent full is shown on a vertical scale and, therefore, irregardless of a tank's capacity all bars will be of equal height when filled (i.e., 100% full). This bar display also shows the minutes until empty for each of the tanks which is an important parameter for the treater to follow. Although, not shown, in FIGS. 16 through 18, the following information is also displayed:

TIME: 14:43:39

ELAPSED: 00:07:54

START: 14:35:45

This indicates the start time, the current time, and the elapsed time since the start of the job.

The keys 272 are reconfigured for each different display in the following fashion. For example, if the GROUPS key is activated in FIG. 16, then the display, as shown in FIG. 17, will be presented showing the following keys 272:

BARS

INDV

ALARM

MODE

(MNTC)

QUIT

The maintenance key MNTC is normally not shown and hence is shown in dotted lines. It is only shown when the MODE key is pressed. Each tank, as mentioned, can be assigned to one of three groups and the display summarizes this information for each group. The type of liquid content is then set forth. This display also shows the total group flow rate, the total group pumped volume and the number of tanks in each group. It is to be understood that the total volume pumped for all three groups could be displayed if desired on the three displays of FIGS. 16 through 19.

When the individual key (INDV) is activated, the fluid height in each tank is numerically displayed as well as, the barrels pumped out, the barrels remaining, and the flow rate in barrels per minute. A representative display showing this information is shown in FIG. 18. For example and as shown in FIG. 18, Tank 1, for example, has a fluid level of 7' 6", 348 barrels remaining in the tank (I:), 120 barrels delivered out of the tank (0:), and a flow rate of 10 barrels per minute.

An alarm occurs when the level of fluid in a tank actually drops below the predetermined low point value. It is to be expressly understood that each tank can have a different predetermined level which will activate the alarm. When the level drops below the set value, an internal audible alarm is activated as well as a visual indication will start flashing on and off. In FIG. 16, the visual indication is the flashing of the lower portion of the bar display for that tank; in FIG. 17, it is the group number that flashes; and in FIG. 18, it is the tank number that flashes. Hence, when the alarm key is enabled, the audible alarm is silenced.

Returning back to FIG. 15 when the mode key is activated, the system determines whether or not it is running. If it is not, it erases the maintenance (MNTC) key and starts reading the LSUs. If it is running, it stops reading the LSUs 140 and displays the maintenance key.

Whenever the system is STOPPED by use of the MODE key, the maintenance key is visible and active. It is important to note that power is always supplied to the LSUs except during LSU maintenance/reconfiguration. In the maintenance mode, as discussed as LSU can be replaced, the system reconfigured, and new trip levels added. Hence, in the maintenance mode, power to all the LSUs is turned off so that the installer can go to the particular defective LSU and repair or replace it. Once repaired, the system is brought back up and continues to run.

In FIG. 19, the final sequencing operation of the system termed STNODE (start node) software relates to the reading of each LSU 140. This sequence is middle in priority and an entry point occurs every time a one-half second, in the preferred embodiment, timer times out. It will then read the next LSU and convert that reading to an actual level and volume value and pass that reading to the display driver sequence in the start setup routine of FIG. 14. When done, the timer will restart itself.

The above represents the preferred operation of the system especially as it autoconfigures itself, obtains information from the user, and sequences on a step-by-step basis. It is to be expressly understood that variations could be made to the system operation as presented and still be under the teachings of the present invention.

6. System Hardware

The circuit diagram for the hardware resident in the TAM 160 is detailed in FIG. 20 and includes a regulated power supply 2000, a touch screen 270, a card cage 2010, and indicators 2012 and 2014.

The AC line power supply is connected to AC line power over lines 2020. A visual indicator 2012 is provided to show when power is on. Lines 2020 are further connected to touch screen 270 providing AC power to that device. The power supply 2000 is connected over to the card cage power supply over lines 2024. The regulated output provides control and power to the card cage 2010 which contains its own power supply. Powwer is also delivered over lines 2026 to the LSU bus 150 and to a loop power visual indicator 2014. The two power supplies are conventionally available from:

Card Cage Power Supply: Power General Corporation, 152 Well Drive, Canton, Mass. 02021, Part No. 127-CM

LSU Power Supply 2000: Power Mate Corporation, 514 S. River Street, Hackensack, N.J. 07601, Part No. ES24H

The touch screen as previously mentioned is available from John Fluke Manufacturing Co. Inc. and is connected over bus 2030 to card #3 in the card cage 2010. The card cage 2010 contains five commercially available electronic cards, these cards are all conventionally available from National Semiconductor Corporation, 2900 Semiconductor Drive, Santa Clara, Calif. 95051.

Card 1:

Power Supply Card No. CIM-610, (Power supply and regulation for computer cards in cage 2010)

Card 2:

Serial I/O Card, Part No. CIM-201, (Wired as DTE (Date Terminal Equipment) for communications to LSUs)

Card 3:

Serial I/O Card, Part No. CIM-201, (Wired as DCE (Data Communication Equipment) for communication with TAM display)

Card 4:

CPU Card, Part No. CIM-802A, (800 CPU modified for offboard ROM)

Card 5:

Memory Card, Part No. CMX-300, Citadel Computer Corporation, 2 Paul's Way, Amherst, N.H. 03031, (Gives machine instruction PROM and data RAM for TAM operation)

The circuitry contained on Card 6 is detailed in FIG. 24 and contains an RS 422 to RS 232 communications converters. The conversion is necessary to provide sufficient strength to the signals for transmission over lines 150. The RS 232 to TTL receiver 2400 is connected over pin J2-2 via ribbon cable to the corresponding pin of Card 2 which is the serial I/O communications and Circuit 2400 is commercially available from National Semiconductor Corporation as Model No. DS 1489. Receiver 2400 interconnects with transmitter 2410 over lines 2420 whcih is a TTL to RS 422 transmitter commercially available as Model No. DS 26LS31. The output of transmitter 2410 is delivered to the first interconnected LSU over cable 150. Likewise, the signals from the first interconnected LSU are delivered over cable 150 into a RS 422 to TTL receiver (Model No. DS26LS32) 2430 which, in turn, is connected to a TTL to RS 232 transmitter (Model No. DS 1488) 2440 over line 2450. The transmitters 2410 and 2440 and the receivers 2400 and 2430 are conventionally connected to power and ground.

The above six cards plug into a National Semiconductor Corporation card rack Part No. CIM-602 CIMBUS card carrier and interconnection board as per National Semiconductor Corporations defined CIMBUS standard. The backplane wiring is fixed per this standard.

In essence, TAM 160 from an operations viewpoint is similar to the operation of the monitoring system 50 of the aforesaid Oilfield Lease reference.

The circuit diagrams for the hardware resident in the LSU 140 is set forth in FIGS. 21 through 23 and as shown in FIG. 21 includes a personality circuit 2100, a CPU circuit 2110, buffers 2120, a regulator 2130, a receiving transceiver 2140 and a sending transceiver 2150.

The cable 230 carries power on lines 2026, a receiving bus on lines 2160, and a sending bus 2170. Power on lines 2026 is delivered to regulator 2130 which is a UPC 7805H and is conventionally available from:

NEC, 252 Humbolt Court, Sunnyvale, CA 94086

The regulator 2130 always supplies power to the CPU circuit 2110.

The personality circuit 2100 functions to communicate over cable 222 with the ultrasonic sensor 220 and receives tank level (and, optionally, tank temperature) measurements as priorly discussed.

The CPU circuit 2110 contains the internal RAM 1000 which stores the identity address for each LSU 140 based on the aforesaid autoconfigure mode of operation and functions to provide internal control over bus 2124 to the personality circuit 2100 and is in communication with the transmitters 2140 and 2150, over buses 2160 and 2170 and with the TAM 160.

The buffers 2120 function to buffer data between the buses 2160 and 2170 and the CPU circuit 2110 and are conventionally available from National Semiconductor Corporation as Part No. SN74 LS373.

The transmitters 2140 and 2150 are also conventionally available from National Semiconductor Corporation as Part Nos. SN26 LS33A-Receiver, and DS3487-Driver.

In FIG. 22, the personality circuit 2100 is shown to include a controlled regulator 2200 which receives power from the loop over lines 2026, a ranging module 2210 which receives regulated power over lines 2202, and an optional quad temp module 2220 which also receives power over lines 2202. The regulator is conventional and is capable of operating from a voltage range of 8 to 24 volts DC appearing on lines 2026 to output a regulated 5 VDC only upon an enable signal appearing on controls 2124 from the CPU circuit 2110. Hence, when not enabled the ranging module 2210 and the optional quad temp module 2220 are not powered (i.e., "asleep"). However, when enabled the regulator 2200 delivers power over lines 2202 to these circuits (i.e., "awakened"). As explained in the earlier filed Oilfield Lease reference, such an arrangement saves on power consumption.

The ranging module 2210 and the quad temperature module 2220 function as those taught in the Oilfield Lease reference and disclosed in FIGS. 15 and 16 thereof. The ranging module 2210 includes a sensor control 2250, a timer 2252, and a one MegaHertz clock 2254. In the preferred embodiment, the sensor control 2250 is an ultrasonic control circuit made by Texas Insrument Co., PO Box 5012, Dallas, Tex. 75222 as Model T1-Board SN28827 and the timer 2252 is available as D8253 from National Semiconductor. The ranging module functions as follows. A signal is delivered over control lines 2124 from the CPU circuit 2110 to cause the sensor control 2250 to activate the sensor 220 to emit an ultrasonic pulse. The sensor 220 is available from the POLAROID Corporation, 784 Memorial Drive, Cambridge, Mass. 02139. When an echo is received by the sensor 220, the time between emission and receipt is measured through the cooperation of clock 2254 and timer 2252. An interrupt signal is delivered back to the CPU circuit over control lines 2124 and the CPU circuit determines the level of fluid based upon elapsed time.

The quad temperature module 2220 is optional but includes an analog to digital converter 2260, a current to voltage converter 2262, and an analog multiplexer 2264. The quad temperature circuit 2220 interconnects with four temperature probes T1, T2, T3, and T4. These temperature probes are conventional and are available through National Semiconductor Corporation as Model No. AD590. Each temperature sensor increases the current through it one microamp per one degree centigrade rise in temperature. The analog multiplexer which is conventionally available as Part No. MC14016B and is available from MOTOROLA Semiconductor, PO Box 20912, Phoenix, Ariz. 85036 selects which one of the four temperature probes are to be measured and that selection is made based upon digital signals appearing on the control line 2124 from the CPU circuit. The analog multiplexer 2264 functions to provide a twelve volt signal to each of the temperature probes T1-T4. Based upon the temperature of the probe, a current is delivered back over lines 222 to the current to voltage converter which converts the current to a voltage signal for delivery to the analog to digital converter 2260 over lines 2266 for delivery back to the CPU circuit 2110.

FIG. 23 discloses the details of the CPU board 2110 and includes a microprocessor 2300, two latch circuits 2310 and 2320, a decode chip 2330 and a Read Only Memory 2340 all of which receive regulated power from regulator 2130 over lines 2132. The microprocessor 2300 is interconnected over serial communication lines 2122 to buffers 2120. The Data Bus accesses latch 2310 which is connected to ROM 2340 over bus 2360. The ROM 2340 is also connected to both the address and data busses. The latch 2310 is under control of the microprocessor chip 2300 and serves to address the ROM 2340. The decode circuit 2330 is connected to the address bus and under control of signals on lines 2342 decodes certain address into control signals on lines 2344 which are retained in a latch circuit for delivery to the personality circuit 2100 over lines 2124 and to the transmitter 2150 over lines 2134. The microprocessor is conventionally available as:

Model Nos. 80C31 or 8031, Intel Corporation, 3065 Bowers Avenue, Santa Clara, Calif. 95051

The latch circuits 2310 and 2320 are available from National Semiconductor Corporation as Model No. SN74 LS374. The ROM 2340 is also available from National Semiconductor Corporation as Model No. 27C16. Finally, the decode circuit 2330 is available from National Semiconductor Company as SN74LS138.

The connection of the upstream data path discussed in reference to FIG. 10 occurs as follows. When the microprocessor receives the redelivered binary address back from the TAM 160, it compares the redelivered address to the address stored in RAM 1000 which is resident in the microprocessor 2300. If the redelivered address is identical to the stored address, then a control signal is issued on lines 2134 to the sending transmitter 2140. This control signal enables the sending transmitter 2140 to operate thereby establishing the upstream data transmission path.

It is to be expressly understood that the above sets forth a preferred hardware embodiment and that changes could be made thereto without departing from the scope and coverage of the present invention.

7. System Software

Attached to the appendix of this application is the source code programming for the programming contained in the central touch activated monitor TAM 160. The source code presented is based on the "C" source standard programming language found, as for example, in the book entitled "The C Programming Language" by Kernighan and Ritchie of Bell Telephone Laboratories and published by Prentice Hall (1978). This programming is found in Card 5, the memory card of the TAM and is contained in a programmable read only memory (PROM). The assembler for this source code can be any commercially available 8080/Z80 assembler such as that available from Microsoft, 10700 Northup Way, Belleview, Wash. 98004. The following modules are contained in alphabetical order in the appendix.

The build page module (BLDPG) contains the global definitions for the offsets into the various group structures according to C source and provides the utility routines for assigning tanks 10 and 20 to one of three groups (i.e., types of fluids).

The block move module (BLKMOV) is a utility program designed to move blocks of data within the memory in Card 5 of the TAM.

The interface software (CAMXLB) provides the necessary software interface between the C source code and the AMX operating system. In the preferred embodiment, the AMX operating system is conventionally available from Kadak Products Ltd., 206-1847 West Broadway Avenue, Vancouver, British Columbia VSJ 1Y5.

The configure tank routine (CONTNK) provides the utility routine that performs the aforesaid autoconfiguration of the various local sensing units.

The input/output routines interfacing the TAM display to the system is provided by the FLUKEIO routine. The utility routine for outputting and formatting data and information for the TAM display is set forth in the FLUTIL module. The utility routine for communication by the TAM with the LSUs is set forth through the NODEIO module which utilizes the terminal handler through the aforesaid AMX software.

The STFLUK module is the main source module which implements the major functions in the "start setup" flow chart.

The STFRAC module is the main source module which performs initialization of the TAM system including the strapping tables and the like.

The STNODE module is the main module that performs polling of the local sensing units, converts new data into systems and into useful information.

The STTUCH module is the main software module that peforms the "start touch" key input scanning as previously discussed.

The TKUTIL module is a utility routine to manipulate tank setup data such as strapping tables.

The FRSTRT module is the main software module executable at the time of system reset and, therefore, initializes system hardware to the proper state.

The FRACTH module is the software module for the TAM display and for the local sensing unit communications interface routines which operates the interface IO drivers.

The TABLES module is a software module necessary for the data area for storage of tank and local sensing unit tables.

Finally, the UTIL 32 module is the software interface routine from the "C" source programs to the AMX 32 bit math package.

The program listings contained in the appendix to this application are protected by Federal Copyright Law.

The program listings for the operation of the Processor 2110 in the local sensing unit, in Intel Corporation machine code (IS1SII MCS-51), is set forth in the Appendix and follows the UTIL 32 software priorly discussed. Eighteen input modules are provided with a link map setting forth how they are linked together. The operation of this software has been priorly discussed.

While the present invention has been described with reference to a preferred embodiment, it is to be expressly understood that modifications could be made thereto which would still be covered by the following claims. In particular, the preferred embodiment made reference to a system adaptable to a frac or well treatment arrangement. It is to be expressly understood that the teachings of the present invention could be adapted to environments requiring a portable system for the continuous monitoring of fluids in tanks. Furthermore, the system can be adapted to include recording capabilities at the TAM so that a permanent record can be made of the well treatment. This record can serve as proof as to the types and quantities of fluids that were delivered downhole and could further be used as the simulation data for training purposes. ##SPC1## ##SPC2## ##SPC3## ##SPC4## ##SPC5## ##SPC6## ##SPC7## ##SPC8## ##SPC9## ##SPC10## ##SPC11## ##SPC12## ##SPC13## ##SPC14## ##SPC15## ##SPC16## ##SPC17## ##SPC18## ##SPC19## ##SPC20## ##SPC21## ##SPC22##

Claims

We claim:

1. A portable oilfield fluid management system movable from one oilfield location to another for measuring the levels of a plurality of different fluids stored in a plurality of storage tanks located at each oilfield location, said storage tanks being either of the same or different sizes, shapes, and capacities, each of said storage tanks having means for gaining access to the interior of the tank and having a strapping table showing volume at different heights within the tank, said system including a plurality of local sensing units and a central monitor with an input device and a display, said central monitor being capable of being interconnected with each of said local sensing units, each of said local sensing units being further connected by means of a sensor cable through said access means to a level sensor attached to an upper inside surface of said storage tank, each said local sensing unit with its connected level sensor being capable of measuring the level of fluid in said storage tank, said system comprising: means containing each of said local sensing units for attaching each said local sensing unit to an exterior surface of one of said storage tanks in any order of attachment, a plurality of cable segment means for interconnecting electrically each attached local sensing unit to the adjacent local sensing unit so that all local sensing units are connected in series, means connected to said central monitor for electrically connecting said central monitor to the first interconnected local sensing unit, said central monitor being capable of autoconfiguring said attached and interconnected local sensing units in each different oilfield by delivering a first address over said connecting means to said first interconnected local sensing unit, said first local sensing unit being capable of storing said first address as its identity code, said first local sensing unit being further capable of connecting an upstream path in response to said storing so that the adjacent and interconnected local sensing unit is capable of receiving the next address from said central monitor, each of said interconnected local sensing units receiving a unique address from said central monitor and once received connecting an upstream path as aforesaid for said first interconnected local sensing unit, and means in said central monitor for manually receiving tank information from a user for each said tank, said tank information at least including said strapping table volume information for each said tank and the identity of the fluid in each said tank, said central monitor in response to said received information being capable of continually determining for display in said display the current level of fluid in each of said tanks, the identity of the fluid in each of said tanks, and the flow rate of fluid flowing out of each said tank through communication with each of said local sensing units over said connecting means and said interconnecting cable segment means.

2. The system of claim 1 in which said central monitor is further capable of issuing an alarm signal when the level of fluid in any one of said tanks drops below a predetermined level.

3. The system of claim 1 in which said attaching means comprises: a substantially rectangular modular container for holding each said local sensor unit, said modular container having connectors on opposing elongated ends for connecting to said cable segment means, supports attached on the top of said container, an elongated handle mounted on top of said supports, said supports being of sufficient height to allow said sensor cable to be wrapped about said supports to allow said level sensor to be stored under said handle when said level sensor is not attached to said tank, and means on the bottom of said container for holding said container to said tank.

4. The system of claim 1 in which each of said cable segment means are of equal predetermined length.

5. A portable oilfield fluid management system moveable from one oilfield location to another for measuring the levels of a plurality of different fluids stored in a plurality of storage tanks located at each oilfield location, said storage tanks being either of the same or different sizes, shapes, and capacities, each of said storage tanks having means for gaining access to the interior of the tank and having a strapping table showing volume at different heights within the tank, said system including a plurality of local sensing units and a central monitor capable of being interconnected with each of said local sensing units, each of said local sensing units being further connected by means of a sensor cable through said access means to a level sensor attached to an upper inside surface of said storage tank, each said local sensing unit with its connected level sensor being capable of measuring the level of fluid in said storage tank said improved system comprising: means containing each of said local sensing units for attaching each said local sensing unit in any order to a exterior surface of said storage tanks, means for interconnecting electrically each attached local sensing unit to the adjacent local sensing unit so that all local sensing units are connected in series, and means connected to said central monitor for electrically connecting said central monitor to the first interconnected local sensing unit, said central monitor being capable of autoconfiguring said attached and interconnected local sensing units in each different oilfield by delivering a first binary address over said connecting means to said first interconnected local sensing unit, said first local sensing unit being capable of storing said first binary address as its identity code, said first local sensing unit being further capable of transmitting over said connecting means said first binary address back to said central monitor, said central monitor being further capable of receiving said transmitted first binary address from said first interconnected local sensing unit, said central monitor being capable of comparing said received first binary address to said delivered first binary address and when said comparison is the same said central monitor (a) redelivering said first binary address back to said first local sensing unit and (b) incrementing said first binary address to the next binary address, said first local sensing unit being further capable of receiving the redelivered first binary address from said central monitor and comparing it to said stored first binary address and when said comparison is the same said first local sensing unit connecting an upstream path so that said adjacent local sensing unit is capable of receiving said next incremented binary address from said central monitor, each of said interconnected local sensing units receiving its unique binary address from said central monitor in the same sequence as did said first interconnected local sensing unit.

6. The system of claim 5 further comprising: means in said central monitor for manually receiving the following information from a user: (a) said volume levels from said strapping table, (b) the identity of the fluids in each of said tanks, (c) a predetermined minimum level of fluid for each tank and (d) the current level of said fluid in each of said tanks, said central monitor in response to said received information being capable of monitoring for display the current level of fluid in each of said tanks, the identity of the fluid in each of said tanks, and the flow rate of fluid flowing out of each said tank through communication with each of said local sensing units, said central monitor being further capable of issuing an alarm signal when the level of fluid in any of said tanks drops below a predetermined level.

7. The system of claim 5 in which said attaching means comprises: a substantially rectangular modular container for holding each said local sensor unit, said modular container having connectors on opposing elongated ends for connecting to said cable segment means, supports attached on the top of said container, an elongated handle mounted on top of said supports, said supports being of sufficient height to allow said sensor cable to be wrapped about said supports to allow said level sensor to be stored under said handle when said level sensor is not attached to said tank, and means on the bottom of said container for holding said container to said tank.

8. A portable oilfield fluid management system moveable from one oilfield location to another system moveable from one oilfield location to another for measuring the levels of a plurality of different fluids stored in a plurality of storage tanks located at each oilfield location, said storage tanks being either of the same or different sizes, shapes, and capacities, each of said storage tanks having means for gaining access to the interior of the tank and having a strapping table showing volume at different heights within the tank, said system including a plurality of local sensing units and a central monitor capable of being interconnected with each of said local sensing units, each of said local sensing units being further connected by means of a sensor cable through said access means to a level sensor attached to an upper inside surface of said storage tank, each said local sensing unit with its connected level sensor being capable of measuring the level of fluid in said storage tank said system comprising: means containing each of said local sensing units for attaching each said local sensing unit to an exterior surface of said storage tanks in any order of attachment, a plurality of cable segment means for interconnecting electrically each attached local sensing unit to the adjacent local sensing unit so that all local sensing units are connected in series, each of said cable segments being of predetermined equal length, means connected to said central monitor for electrically connecting said central monitor to the first interconnected local sensing unit, said central monitor being capable of autoconfiguring said attached and interconnected local sensing units in each different oilfield by delivering a first binary address over said connecting means to said first interconnected local sensing unit, said first local sensing unit being capable of storing said first binary address as its identity code, said first local sensing unit being further capable of transmitting over said connecting means (a) an acknowledgement signal and (b) said first binary address back to said central monitor, said central monitor being further capable of receiving (a) said transmitted first binary address and (b) said acknowledgement signal from said first interconnected local sensing unit, said central monitor being capable of comparing said received first binary address to said delivered first binary address and when said comparison is the same said central monitor being capable of (a) redelivering said first binary address back to said first local sensing unit and (b) incrementing said first binary address to the next binary address and when said comparison is not the same said central monitor designating said first interconnected local sensing unit as defective, said first local sensing unit being further capable of receiving said redelivered first binary address from said central monitor and comparing it to said stored first binary address and when said comparison is the same said first local sensing unit connecting an upstream transmitter path so that said adjacent local sensing unit is capable of receiving said next incremented binary address from said central monitor, each of said interconnected local sensing units receiving its unique binary address from said central monitor in the same sequence as aforesaid for said first interconnected local sensing unit, and means in said central monitor for manually receiving the following information from a user: (a) said volume levels from said strapping table, (b) the identity of the fluids in each of said tanks, (c) a predetermined minimum level of fluid for each tank and (d) the current level of said fluid in each of said tanks, said central monitor in response to said received information being capable of continually determining for display the current level of fluid in each of said tanks, the identity of the fluid in each of said tanks, and the flow rate of fluid flowing out of each said tank through communication with each of said local sensing units, said central monitor being further capable of issuing an alarm signal when the level of fluid in any of said tanks drops below a predetermined level.

9. The system of claim 8 in which said attaching means comprises: a substantially rectangular modular container for holding each said local sensor unit, said modular container having (1) connectors on opposing elongated ends for connecting to said cable segment means and (2) outwardly protruding lips on either side of said connectors to protect said connectors from damage, supports attached on the top of said container, an elongated handle mounted on top of said supports, said supports being of sufficient height to allow said sensor cable to be wrapped about said supports to allow said level sensor to be stored under said handle when said level sensor is not attached to said tank, and means on the bottom of said container for holding said container to said tank.

10. A portable oilfield fluid management system for measuring in different oilfields the levels of different fluids stored in a plurality of different and the same sized tanks, the type of fluids and the configuration and number of tanks capable of varying from oilfield to oilfield, said system having a central monitor for displaying fluid information for each of said tanks, said portable oilfield fluid management system comprising: a plurality of local sensing unit means removably attachable in any order to said tanks, one of said local sensing unit means being attached to one of said second plurality of tanks for measuring the level of fluid stored in the aforesaid tank, at least one container for transporting said plurality of local sensing unit means when said local sensing unit means are removed from said tanks, a plurality of cable segment means having connectors on opposing ends for releasably and electrically interconnecting each attached local sensing unit means to the adjacent local sensing unit attached to the next tank, an elongated cable means for releasably interconnecting said central monitor to the first interconnected local sensing unit means, at least one moveable reel means for reeling said cable segment means when said cable segment means are disconnected from said plurality of local sensing unit means, said cable segment means being further releasably interconnected with each other's connectors, said at least one moveable reel means being further capable of reeling said elongated cable when released from said central monitor and said first interconnected local sensing unit means, said central monitor being capable of autoconfiguring said attached local sensing unit means in each oilfield location by delivering a unique identity address to each attached local sensing unit means over said interconnected elongated cable and said interconnected cable segment means, each said local sensing unit means being capable of storing its unique address delivered by said central monitor, and means in said central monitor for determining for display the current level of fluid in each of said tanks, the identity of fluid in each of said tanks, and the flow rate of fluid flowing out of each said tank, said central monitor being further capabe of issuing an alarm signal when the level of fluid in any of said tanks below a predetermined level.

11. A portable oilfield fluid management system for measuring in different oilfields the levels of different fluids stored in a plurality of different and the same sized tanks, the type of fluids and the configuration and number of tanks capable of varying from oilfield to oilfield, said system having a central monitor for displaying fluid information for each of said tanks, said portable oilfield fluid management system further comprising: a plurality of local sensing unit means removably attachable in any order to said tanks, one of said local sensing unit means being attached to one of said second plurality of tanks for measuring the level of fluid stored in the aforesaid tank, at least one container for transporting said plurality of local sensing unit means when said local sensing unit means are removed from said tanks, a plurality of cable segment means having connectors on opposing ends for releasably and electrically interconnecting each attached local sensing unit means to the next adjacent local sensing unit attached to the next tank, each of said cable segments means being of equal predetermined length, an elongated cable for releasably interconnecting said central monitor to the first interconnected local sensing unit means, at least one moveable reel means for reeling said cable segment means when said cable segment means are disconnected from said plurality of local sensing unit means, said cable segment means being further releasably interconnected with each other's connectors, said at least one moveable reel means being further capable of reeling said elongated cable when released from said central monitor and said first interconnected local sensing unit means, said central monitor being capable of autoconfiguring said attached local sensing unit means in each oilfield location by delivering a unique identity address to each attached local sensing unit means over said interconnected elongated cable and said cable segment means, each said local sensing unit means being capable of storing its unique address delivered by said central monitor, and means in said central monitor for manually receiving at least the following information from a user in said oilfield: (a) volume level data for each said tank, (b) the identity of the fluids in each of said tanks, (c) a predetermined minimum level of fluid for each tank and (d) the current level of said fluid in each of said tanks, said central monitor in response to said received information being capable of continually determining for display the current level of fluid in each of said tanks, the identity of the fluid in each of said tanks, and the flow rate of fluid flowing out of each said tank through communication with each of said local sensing units, said central monitor being further capable of issuing an alarm signal when the level of fluid in any of said tanks drops below its said predetermined level.

12. A portable oilfield treatment fluid management system for measuring in different oilfields the levels of a first plurality of different treatment fluids stored in a second plurality of different and the same sized tanks, the type of fluids and the configuration and number of tanks capable of varying from oilfield to oilfield, said system having a central monitor for displaying fluid information for each of said tanks, said portable oilfield treatment fluid management system comprising: a plurality of local sensing unit means removably attachable in any order to said tanks, one of said local sensing unit means being attached to one of said second plurality of tanks for measuring the level of fluid stored in the aforesaid tank, each of said local sensing unit means having a male and a female electrical connector, each said local sensing unit means further comprising: (a) a fluid level sensor connected to each said local sensing unit means for determining said level, and (b) a sensor cable connected at one end to said fluid level sensor and at the opposing end to said local sensing unit means, at least one container for transporting said plurality of local sensing unit means when said local sensing unit means are removed from said tanks, a plurality of cable segment means having male and female connectors on opposing ends for releasably and electrically interconnecting the male and female connectors of each attached local sensing unit means to said male and female connectors on the adjacent local sensing unit attached to the next tank, each of said cable segments means being of equal predetermined length, an elongated cable for releasably interconnecting said central monitor to the first interconnected local sensing unit means, at least one moveable reel means for reeling said cable segment means when said cable segment means are disconnected from said plurality of local sensing unit means, said cable segment means being further releasably interconnected with each other's male and female connectors, said at least one moveable reel means being further capable of reeling said elongated cable when released from said central monitor and said first interconnected local sensing unit means, means connected to said central monitor for electrically connecting said central monitor to the first interconnected local sensing unit, said central monitor being capable of autoconfiguring said attached and interconnected local sensing units in each different oilfield by delivering a first binary address over said connecting means to said first interconnected local sensing unit, said first local sensing unit being capable of storing said first binary address as its identity code, said first local sensing unit being further capable of connecting an upstream path in response to said storing so that said adjacent and interconnected local sensing unit is capable of receiving said next incremented binary address from said central monitor, each of said interconnected local sensing units receiving its unique binary address from said central monitor connecting an upstream path as aforesaid for said first interconnected local sensing unit, and means in said central monitor for manually receiving tank information form a user said tank information at least including volume information for each said tank and the identity of the fluid in each said tank, said central monitor in response to said received tank information being capable of continually determining for display the current level of fluid in each of said tanks, the identity of the fluid in each of said tanks, and the flow rate of fluid flowing out of each said tank.

13. The system of claim 12 wherein said central monitor is further capable of issuing an alarm signal when the level of fluid in any of said tanks drops below a predetermined level.

14. The system of claim 12 in which each said local sensing means further comprises: a substantially rectangular modular container for holding each said local sensor unit, said modular container having male and female connectors on opposing elongated ends for connecting to said cable segment means, supports attached on the top of said container, an elongated handle mounted on top of said supports, said supports being of sufficient height to allow said sensor cable to be wrapped about said supports to allow said level sensor to be stored under said handle when said fluid level sensor is not attached to said tank, and means on the bottom of said container for holding said container to said tank.

15. A portable oilfield management system for measuring parameters for pieces of equipment in different oilfields, said system having a central monitor for displaying information concerning said parameters, said portable oilfield management system further comprising: a plurality of local sensing unit means removably attachable in any order of attachment to said pieces of equipment, one of said local sensing unit means being attached to one of said pieces of equipment for measuring said parameter, at least one container for transporting said plurality of local sensing unit means when said local sensing unit means are removed from said equipment, a plurality of cable segment means having male and female connectors on opposing ends for releasable and electrically interconnecting the male and female connectors of each attached local sensing unit means to the male and female connectors on the adjacent local sensing unit attached to the next piece of equipment, each of said cable segments being of equal predetermined length, an elongated cable means for releasably connecting said central monitor to the first interconnected local sensing unit means, at least one moveable reel means for reeling said cable segment means when said cable segment means are disconnected from said plurality of local sensing unit means, said cable segment means being further releasably interconnected with each other's connectors, said at least one moveable reel means being further capable of reeling said elongated cable when released from said central monitor and said first interconnected local sensing unit means, said central monitor being capable of autoconfiguring said attached local sensing unit means in each oilfield location by delivering a unique identity address to each attached local sensing unit means over said interconnected elongated cable and said cable segment means, each said local sensing unit means being capable of storing its unique address delivered by said central monitor, and means in said central monitor for determining for display said information, through communication with each of said local sensing units over said interconnecting cable means and over said connecting elongated cable means, said central monitor being further capable of issuing an alarm signal when the parameter for any piece of said equipment exceeds a ppredetermined level.

16. An oilfield fluid management method for a portable system adaptable for use in one oilfield location and then to another, said method being capable of determining the levels of a plurality of different fluids stored in a plurality of storage tanks located at each oilfield location, said storage tanks being either of the same or different sizes, shapes, and capacities, each of said storage tanks having a strapping table showing volume at different heights within the tank, said system including a plurality of local sensing units and a central monitor with an input device and a display, said central monitor being capable of being interconnected with each of said local sensing units, each of said local sensing units being capable of measuring the level of fluid in a tank, said method comprising the steps of: attaching in any order each local sensing unit to one of the storage tanks so that the levels of fluid can be monitored in said tanks, interconnecting each attached local sensing unit to each adjacent attached local sensing unit with one or a plurality of equal predetermined lengths of cable, connecting the first interconnected local sensing unit to the central monitor with an elongated cable, manually keying into said input device of the central monitor input information in order to initialize said portable system, said input information at least including the volume information from said strapping table, the identity of fluids in each of said tanks, and a predetermined minimum level of fluid for each tank, periodically measuring the level of fluid in each of said tanks through selective addressing of the stored address in each interconnected local sensing unit, delivering signals conveying the measured level of fluid in each said tank from the attached local sensing unit to the central monitor in response to said measurement, and determining for display in said display the current level of fluid in each of said tanks and the flow rate of fluid out of each said tank in response to said delivered signals and the identity of fluid in each of said tanks in response to said input information.

17. The method of claim 16 further comprising the step of: autoconfiguring each attached local sensing unit with a unique address by performing the steps of: (a) delivering a first address from said central monitor to said first interconnected local sensing unit, over said elongated cable, (b) storing said delivered first address in said first interconnected local sensing unit in response to said delivery from said central monitor, (c) transmitting said stored first address from said first interconnected local sensing unit back to said central monitor in response to said storage of said first address by said first interconnected local sensing unit, (d) comparing said delivered first address with said transmitted first address in said central monitor in response to said transmitted first address from said first interconnected local sensing unit, (e) redelivering said compared first address from said central monitor to said first interconnected local sensing unit in response to said comparison being the same address by said central monitor, (f) comparing said redelivered first address with said stored address in said local sensing unit and when the same enabling an upstream data path to connect said central monitor with the next interconnected local sensing unit, (g) incrementing the first address in response to said comparison being the same addresses in aforesaid step (f) by said central monitor, (h) repeating steps (a) through (g) for all adjacent interconnected local sensing units.

18. The method of claim 16 further comprising the steps of: displaying a graph having a vertical bar showing the fluid on a relative percent full scale contained in each tank in response to a user request, and indicating on each vertical bar displayed the type of fluid stored in the tank represented by the bar.

19. The method of claim 17 further comprising the steps of: continually determining in said central monitor the minutes until empty for each attached tank, and displaying in said display of said control monitor the minutes until empty for each tank in response to a user request.

20. The method of claim 16 further comprising the steps of: continually determining in said central monitor the total barrels pumped for each type of fluid and the number of tanks containing each type of fluid, and displaying in said display of said central monitor the total barrels pumped for each type of fluid and the number of tanks containing each type of fluid in response to a user request.

21. The method of claim 16 further comprising the steps of: continually determining in said central monitor the total barrels pumped out of each tank, the total barrels remaining in each tank, the flow rate in each tank and the level of fluid in each tank, and displaying in said display of said central monitor for each tank the total barrels pumped out, the total barrel remaining, the flow rate, and the level of fluid in response to a user request.

22. An oilfield fluid management method for a portable system adaptable for use in one oilfield location and then to another, said method being capable of determining the levels of a plurality of different fluids stored in a plurality of storage tanks located at each oilfield location, said storage tanks being either of the same or different sizes, shapes, and capacities, each of said storage tanks having a strapping table showing volume at different heights within the tank, said system including a plurality of local sensing units and a central monitor with an input device and a display, said central monitor being capable of being interconnected with each of said local sensing units, each of said local sensing units being capable of measuring the level of fluid in a tank, said method comprising the steps of: attaching in any order each local sensing unit to one of the storage tanks so that the levels of fluid can be monitored in said tanks, interconnecting each attached local sensing unit to each adjacent attached local sensing unit with one or a plurality of equal predetermined lengths of cable, connecting the first interconnected local sensing unit to the central monitor with an elongated cable, assigning each attached local sensing unit a unique address, delivering the aforesaid unique address from the central monitor to each attached local sensing unit over the elongated cable and said predetermined lengths of cable, manually keying into said input device of the central monitor input information in order to initialize said portable system, said input information at least including the volume information from said strapping table, the identity of fluids in each of said tanks, and a predetermined minimum level of fluid for each tank, periodically measuring the level of fluid in each of said tanks through selective addressing of the stored address in each interconnected local sensing unit, delivering signals conveying the measured level of fluid in each said tank from the attached local sensing unit to the central monitor in response to said measurement, and determining for display in said display the current level of fluid in each of said tanks and the flow rate of fluid out of each said tank in response to said delivered signals and the identity of fluid in each of said tanks in response to said input information.

23. The method of claim 22 further comprising the steps of: displaying a graph having a vertical bar showing the fluid on a relative percent full scale contained in each tank in response to a user request, and indicating on each vertical bar displayed the type of fluid stored in the tank represented by the bar.

24. The method of claim 23 further comprising the steps of: continually determining in said central monitor the minutes until empty for each attached tank, and displaying in said display of said central monitor the minutes until empty for each tank in response to a user request.

25. The method of claim 22 further comprising the steps of: continually determining in said central monitor the total barrels pumped for each type of fluid and the number of tanks containing each type of fluid, and displaying in said display of said central monitor the total barrels pumped for each type of fluid and the number of tanks containing each type of fluid in response to a user request.

26. The method of claim 22 further comprising the steps of: continually determining in said central monitor the total barrels pumped out of each tank, the total barrels remaining in each tank, the flow rat4rate in each tank and the level of fluid in each tank, and displaying in said display of said central monitor for each tank the total barrels pumped out, the total barrel remaining, the flow rate, and the level of fluid in response to a user request.

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Abstract

Description