Injection head assembly, injection head system and coiled tubing unit

Abstract

This invention relates to the field of coiled tubing operation technology, providing an injection head assembly, an injection head system, and a coiled tubing installation machine. The injection head assembly includes: an injection head assembly comprising: multiple injection heads connected in series; multiple weight / lightness sensors, each corresponding to one of the injection heads, for monitoring the weight / lightness of the injection heads; and a controller connected to the multiple weight / lightness sensors for receiving the weight / lightness readings from the multiple injection heads and adjusting at least one of the driving force, clamping force, and chain tension of the multiple injection heads based on the comparison results of the weight / lightness readings. This invention not only connects multiple injection heads in series, increasing the lifting force range of the injection heads through capacity expansion, but also improves the safety performance of the equipment through synchronous control and automatic load distribution control of the multiple injection heads.

Description

Technical Field

[0001] This invention relates to the field of coiled tubing operation technology, and more particularly to an injection head assembly, an injection head system, and a coiled tubing operation machine. Background Technology

[0002] Coiled tubing workover rigs, with their versatility, flexibility, and stability, have garnered significant attention in recent years. The injection head assembly is the core component of the coiled tubing system. Its main function is to clamp the tubing and overcome the upward pressure and friction on the tubing string from downhole, allowing the coiled tubing to be lowered into the well, held stationary, or pulled out, while controlling the injection and retrieval speeds. Existing injection head assemblies typically utilize a reversible hydraulic motor powered by a chain drive, which moves the clamping blocks up and down to hold the coiled tubing. Two sets of tensioning hydraulic cylinders push the floating clamping blocks to achieve chain tension; clamping hydraulic cylinders then clamp the floating clamping blocks, which in turn clamp the tubing using tubing clamping blocks mounted on the chain. The chain-driven clamping blocks then facilitate the tubing's raising and lowering operations.

[0003] Currently, coiled tubing injection heads are categorized into models such as 200K, 140K, 100K, and 80K based on their lifting capacity. Statistical analysis of the current domestic injection head model range leads to the following conclusions: 140K and 100K injection heads are the most prevalent, with these two models being the most common. Although research and development of injection heads exceeding 140K has occurred both domestically and internationally, practical applications are limited. Large-diameter injection heads are significantly affected by their external dimensions, greatly influencing transport dimensions and main unit capacity configuration. Therefore, for some ultra-deep wells, especially those exceeding 7000m, existing injection heads cannot meet the lifting capacity requirements, necessitating complete equipment replacement based on well site needs, which is cumbersome and economical. Therefore, improving and expanding the lifting capacity of injection heads is one of the urgent problems to be solved. Summary of the Invention

[0004] This invention provides an injection head assembly, an injection head system, and a coiled tubing installation machine to solve the defects of existing coiled tubing installation equipment where the injection head cannot meet the lifting force requirements, requiring the replacement of the entire machine, resulting in cumbersome operation and poor economy. This invention expands the lifting force range of the injection head by connecting multiple injection heads in series.

[0005] This invention provides an injection head assembly, comprising:

[0006] Multiple injection heads, connected in series;

[0007] Multiple finger weight and finger lightness sensors are provided, one-to-one, on the injection head to monitor the finger weight and finger lightness of the injection head.

[0008] The controller is connected to multiple finger weight / lightness sensors to receive the finger weight / lightness of the multiple injection heads, and adjusts at least one of the driving force, clamping force, and chain tension of the multiple injection heads based on the comparison results of the finger weight / lightness of the multiple injection heads.

[0009] According to an injection head assembly provided by the present invention, the plurality of injection heads include:

[0010] First injection head;

[0011] A second injection head is connected in series with the first injection head;

[0012] The plurality of said finger weight / finger light sensors include:

[0013] The first finger weight and lightness sensor is disposed on the first injection head and is used to monitor the finger weight and lightness of the first injection head.

[0014] The second finger-weight / finger-light sensor, disposed on the second injection head, is used to monitor the finger-weight / finger-lightness of the second injection head; wherein...

[0015] The first and second finger weight sensors are respectively connected to the controller.

[0016] According to an injection head assembly provided by the present invention, it further includes: a fixing device, one end of which is fixed to one end of one of the injection heads, and the other end of which is adapted to be fixedly connected to one end of an adjacent injection head.

[0017] An injection head assembly according to the present invention further includes: a connector disposed between two adjacent injection heads, the connector having a through hole adapted for continuous tubing to pass through.

[0018] According to an injection head assembly provided by the present invention, it further includes: a limiting sleeve, wherein the connector is connected to the injection head through the limiting sleeve, the limiting sleeve forming a limiting hole, the limiting hole being adapted for insertion and connection of the connector.

[0019] According to an injection head assembly provided by the present invention, the connector includes:

[0020] First mounting base;

[0021] A first sleeve, fixed to the mounting base, is adapted to be inserted into one end of the adjacent injection head;

[0022] A second sleeve is fixed to the mounting base and located on the opposite side of the first sleeve. The second sleeve is adapted to be inserted into one end of the adjacent injection head.

[0023] According to an injection head assembly provided by the present invention, the limiting sleeve includes:

[0024] A second mounting base, the second mounting base being adapted to engage with the first mounting base;

[0025] A third sleeve is fixed to the second mounting base, and the second sleeve is adapted to be inserted into the third sleeve and into one end of the adjacent injection head.

[0026] An injection head assembly according to the present invention further includes: a connecting flange, wherein the connector is connected to an adjacent injection head via the connecting flange.

[0027] The present invention also provides an injection head system, comprising:

[0028] The injection head assembly in this embodiment of the invention;

[0029] A driving force balancing subsystem, which is electrically connected to the controller, is used to adjust the driving force of the corresponding injection head;

[0030] A clamping force balancing subsystem, which is electrically connected to the controller, is used to adjust the clamping force of the injection head on the continuous tubing.

[0031] The tension balancing subsystem is electrically connected to the controller and is used to adjust the chain tension of the corresponding injection head.

[0032] The present invention also provides a continuous tubing installation machine, including: the injection head assembly or injection head system in the embodiments of the present invention.

[0033] This invention provides an injection head assembly that connects multiple injection heads in series. By expanding the capacity of the injection heads, the lifting force range of the injection heads is increased. A finger-weight sensor monitors the finger-weight of the injection heads. The controller adjusts at least one of three indicators—driving force, clamping force, and chain tension—of different injection heads by comparing the finger-weight data. This achieves closed-loop feedback for at least one of the three indicators of the injection heads, enabling synchronous control of multiple injection heads and automatic load distribution control, thus improving the safety performance of the equipment.

[0034] Furthermore, the injection head system provided by the present invention controls the driving force balancing subsystem, the clamping force balancing subsystem, and the tension force balancing subsystem through a controller. A closed-loop feedback is formed in the driving force balancing subsystem to achieve a final balance between the two injection heads in terms of weight distribution; a closed-loop feedback is formed in the clamping force balancing subsystem to achieve a final balance in the clamping pressure of each injection head; and a closed-loop feedback is formed in the tension force balancing subsystem to achieve a final balance in the tension pressure of the chain of each injection head.

[0035] Furthermore, the present invention also provides a coiled tubing workover machine, which includes the injection head assembly or injection head system of the embodiments of the present invention, and therefore has the same advantages as described above. Attached Figure Description

[0036] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0037] Figure 1 This is a three-dimensional structural schematic diagram of the injection head assembly provided by the present invention;

[0038] Figure 2 This is a front view of the injection head assembly provided by the present invention;

[0039] Figure 3 This is a left view of the injection head assembly provided by the present invention;

[0040] Figure 4 This is a schematic diagram of the connector provided by the present invention;

[0041] Figure 5 This is a schematic diagram of the structure of the limiting sleeve provided by the present invention;

[0042] Figure 6 This is a schematic diagram of the injection head system provided by the present invention;

[0043] Figure label:

[0044] 1: First injection head; 2: Bolt; 3: Connecting flange; 4: Connector; 5: Limiting sleeve; 6: Second injection head; 7: Blowout preventer; 8: First heavy / light sensor; 9: Second heavy / light sensor; 10: Hydraulic motor; 11: Chain;

[0045] 41: First mounting base; 42: First sleeve; 43: Second sleeve;

[0046] 51: Second mounting base; 52: Third sleeve;

[0047] 100: Controller; 200: Drive force balancing subsystem; 300: Clamping force balancing subsystem; 400: Tension force balancing subsystem. Detailed Implementation

[0048] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0049] The following is combined with Figures 1 to 5 This invention describes an injection head assembly. The injection head assembly includes: a plurality of injection heads, a plurality of finger weight / lightness sensors, and a controller 100.

[0050] The system comprises multiple injection heads connected in series; multiple finger weight / finger lightness sensors are respectively installed on the injection heads to monitor the finger weight / finger lightness of the injection heads; the controller 100 is connected to the signals of the multiple finger weight / finger lightness sensors to receive the finger weight / finger lightness of the multiple injection heads, and adjusts at least one of the driving force, clamping force and tension force of the chain 11 of the multiple injection heads based on the comparison results of the finger weight / finger lightness of the multiple injection heads.

[0051] Specifically, multiple injection heads connected in series are added by adding at least one injection head in series to the existing single injection head. The specifications of the injection heads connected in series can be the same as or different from the original injection heads. Each injection head in series has an independent drive device, chain 11, clamping block, and hydraulic cylinder, etc. It can be understood that the drive device is generally a hydraulic motor 10, which provides power for the movement of the injection head and drives it to move through the chain 11. The clamping block, driven by the hydraulic cylinder, clamps the continuous hydraulic cylinder, thereby fixing the continuous oil pipe or driving the continuous oil pipe to rise or fall.

[0052] Each injection head is equipped with a corresponding finger weight sensor, which monitors the finger weight data of the corresponding injection head and transmits the data to the controller 100. The controller 100 receives finger weight data from multiple injection heads and adjusts at least one of the three indicators—driving force, clamping force, and chain tension—of different injection heads by comparing the finger weight data. This achieves closed-loop feedback for at least one of the three indicators of the injection head. Taking the finger weight indicator as an example, if the design or theoretical finger weight specifications of injection head A and injection head B are 45t and 22.5t respectively, while the monitored actual finger weights are 80t and 30t respectively, the driving force of the injection head can be adjusted accordingly to maintain the actual finger weight ratio of injection head A to injection head B at 2:1, thus balancing the finger weights of the two injection heads.

[0053] The operation of coiled tubing using this embodiment has at least the following beneficial effects:

[0054] 1. By setting multiple injection heads, the coiled tubing can be lowered into the well, held in place, or pulled out of the well, thus solving the problem of insufficient lifting force and cumbersome replacement and operation caused by using only one injection head in the existing technology. A new concept of injection head expansion is proposed by increasing the capacity of the injection head, i.e., setting multiple injection heads, which improves the lifting force range of the injection head compared to the traditional injection head structure.

[0055] 2. The weight and lightness data of the injection head are monitored by the weight and lightness sensor, and the controller 100 uses the weight and lightness data to form a closed loop feedback on at least one of the indicators of the driving force, clamping force and tension force of the corresponding injection head and the chain 11, so as to realize the synchronous control of multiple injection heads and automatic load distribution control, thereby improving the safety performance of the equipment.

[0056] This invention provides an injection head assembly that connects multiple injection heads in series. By expanding the capacity of the injection heads, the lifting force range of the injection heads is increased. A finger-weight sensor monitors the finger-weight of the injection heads. The controller 100 adjusts at least one of three indicators—driving force, clamping force, and chain tension—of different injection heads by comparing the finger-weight data. This achieves closed-loop feedback for at least one of the three indicators of the injection heads, enabling synchronous control of multiple injection heads and automatic load distribution control, thus improving the safety performance of the equipment.

[0057] In one embodiment of the present invention, the plurality of injection heads includes: a first injection head 1 and a second injection head 6; the plurality of finger weight / lightness sensors includes: a first finger weight / lightness sensor 8 and a second finger weight / lightness sensor 9. The second injection head 6 is connected in series with the first injection head 1. The first finger weight / lightness sensor 8 is disposed on the first injection head 1 and is used to monitor the finger weight / lightness of the first injection head 1; the second finger weight / lightness sensor 9 is disposed on the second injection head 6 and is used to monitor the finger weight / lightness of the second injection head 6. The first finger weight / lightness sensor 8 and the second finger weight / lightness sensor 9 are respectively connected to the controller 100 via signals. In this embodiment, the two injection heads are specifically described in series, so two finger weight / lightness sensors are also correspondingly provided, such as... Figures 1 to 3As shown, the first injection head 1 and the second injection head 6 are fixed in series from top to bottom. A first finger weight sensor 8 monitors the finger weight of the first injection head 1, and a second finger weight sensor 9 monitors the finger weight of the second injection head 6. The first and second finger weight sensors 8 and 9 are respectively connected to the controller 100, transmitting the monitored finger weight data to the controller 100. In this embodiment, the first injection head 1 can be a standard injection head, and the second injection head 6 can be an expanded-capacity injection head. It should be understood that two or more injection heads can also be connected in series, with the number of finger weight sensors matching the number of injection heads, and each sensor is configured to monitor the finger weight of its corresponding injection head. This embodiment is not limited to the number of injection heads and finger weight sensors, but the number of injection heads and finger weight sensors should be consistent.

[0058] In one embodiment of the invention, the injection head assembly further includes a fixing device, one end of which is fixed to one end of one of the injection heads, and the other end of which is adapted to be fixedly connected to one end of an adjacent injection head. In this embodiment, two adjacent injection heads are fixedly connected by the fixing device, and the injection heads are connected in series to form a whole. Figure 1 As shown, the fixing device uses bolt 2 and nut. It can be understood that the fixing device can also use a locking pin instead of bolt 2 and nut.

[0059] In one embodiment of the present invention, the injection head assembly further includes a connector 4 disposed between two adjacent injection heads. The connector 4 has a through hole suitable for the passage of a continuous tubing. In this embodiment, the connector 4 is disposed between two adjacent injection heads, and the connector 4 has at least a through hole for the passage of a continuous tubing. The main function of the connector 4 is to protect the continuous tubing when it passes through the series-connected injection heads, preventing bending and buckling of the continuous tubing during injection, thereby avoiding damage to the continuous tubing.

[0060] In one embodiment of the present invention, such as Figure 4As shown, connector 4 includes: a first mounting base 41, a first sleeve 42, and a second sleeve 43. The first sleeve 42 is fixed to the mounting base and is adapted to be inserted into one end of an adjacent injection head. The second sleeve 43 is fixed to the mounting base and located on the opposite side of the first sleeve 42, and is also adapted to be inserted into one end of an adjacent injection head. In this embodiment, connector 4 consists of three parts: the first mounting base 41, the first sleeve 42, and the second sleeve 43. The first sleeve 42 and the second sleeve 43 are integrally formed with the first mounting base 41 and are located on the upper and lower surfaces of the first mounting base 41, respectively. The first sleeve 42 is inserted into the upper injection head adjacent to it, and the second sleeve 43 is inserted into the lower injection head adjacent to it, thereby installing connector 4 between two adjacent injection heads. It is understandable that the through hole formed in the connector 4 is through the first sleeve 42, the first mounting base 41 and the second sleeve 43, and the continuous oil tube can pass through the first injection head 1, the first sleeve 42, the second sleeve 43 and the second injection head 6 in sequence.

[0061] In one embodiment of the present invention, the injection head assembly further includes a limiting sleeve 5, through which the connector 4 is connected to the injection head. The limiting sleeve 5 forms a limiting hole suitable for insertion and connection of the connector 4. In this embodiment, the main function of the limiting sleeve 5 is to limit the injection head, ensuring alignment of the upper and lower injection heads. Specifically, the second sleeve 43 of the connector 4 is inserted into the limiting hole of the limiting sleeve 5, and then the limiting sleeve 5 is inserted into the injection head, thereby achieving alignment of two adjacent injection heads.

[0062] In one embodiment of the present invention, such as Figure 5 As shown, the limiting sleeve 5 includes a second mounting base 51 and a third sleeve 52. The second mounting base 51 is adapted to engage with the first mounting base 41; the third sleeve 52 is fixed to the second mounting base 51, and the second sleeve 43 is adapted to be inserted into the third sleeve 52 and into one end of the adjacent injection head. It can be understood that the limiting hole on the limiting sleeve 5 penetrates both the second mounting base 51 and the third sleeve 52. When the second sleeve 43 is inserted into the third sleeve 52, the first mounting base 41 abuts against the second mounting base 51 accordingly. Specifically, the third sleeve 52 and the second mounting base 51 are an integral structure. The third sleeve 52 is fixed to the lower surface of the second mounting base 51, and the third sleeve 52 can be inserted into the adjacent lower injection head, thereby achieving alignment with the injection head above it via the connector 4.

[0063] In one embodiment of the invention, the injection head assembly further includes a connecting flange 3, and a connector 4 is connected to an adjacent injection head via the connecting flange 3. In this embodiment, the connector 4 is fixed between two adjacent injection heads via the connecting flange 3, the connecting flange 3 having mounting holes, and is fixed between the two adjacent injection heads by fasteners. The connector 4 is fixed to the connecting flange 3 to be fixed between the two injection heads.

[0064] In one embodiment of the invention, the injection head assembly further includes a blowout preventer 7. Taking a first injection head 1 and a second injection head 6 connected in series as an example, the blowout preventer 7 is disposed at the bottom of the second injection head 6.

[0065] like Figure 6 As shown, the present invention also provides an injection head system. This injection head system includes: an injection head assembly as described in the above embodiments of the present invention, a driving force balancing subsystem 200, a clamping force balancing subsystem 300, and a tension force balancing subsystem 400.

[0066] Among them, the driving force balancing subsystem 200 is electrically connected to the controller 100 and is used to adjust the driving force of the corresponding injection head; the clamping force balancing subsystem 300 is electrically connected to the controller 100 and is used to adjust the clamping force of the corresponding injection head on the continuous tubing; the tension force balancing subsystem 400 is electrically connected to the controller 100 and is used to adjust the tension of the chain 11 of the corresponding injection head.

[0067] Specifically, if the injection head is driven by a hydraulic motor 10, the driving force balancing subsystem 200 adjusts the pressure and flow rate of the hydraulic oil input to the injection head to balance the driving force of multiple injection heads, ensuring the synchronous operation of the chains 11 of multiple injection heads and achieving a preliminary balance of the weight of multiple injection heads.

[0068] By monitoring the finger-weight and finger-lightness data of the injection head using a finger-weight and finger-lightness sensor, the controller 100 controls at least one of the driving force balancing subsystem 200, clamping force balancing subsystem 300, and tension force balancing subsystem 400 to adjust at least one of the driving force, clamping force, and chain 11 tension of the injection head, thereby achieving finger-weight and finger-lightness balance of the injection head. Preferably, in this embodiment, the controller 100 compares the finger-weight and finger-lightness data of different injection heads and controls the driving force balancing subsystem 200, clamping force balancing subsystem 300, and tension force balancing subsystem 400 respectively. A closed-loop feedback is formed with the driving force balancing subsystem 200 to achieve final balance of finger-weight and finger-lightness between the two injection heads; a closed-loop feedback is formed with the clamping force balancing subsystem 300 to achieve final balance of clamping pressure for each injection head; and a closed-loop feedback is formed with the tension force balancing subsystem 400 to achieve final balance of chain 11 tension for each injection head.

[0069] It is understood that the aforementioned drive force balancing subsystem 200, clamping force balancing subsystem 300 and tension force balancing subsystem 400 are all electronic control systems. The drive force balancing subsystem 200 can control the hydraulic flow of the hydraulic motor 10 through a solenoid valve. The clamping force balancing subsystem 300 can adjust the clamping force of the clamping block by controlling the contraction of the hydraulic cylinder. The tension force balancing subsystem 400 can adjust the tension of the chain 11 by using a tensioner installed on the chain 11.

[0070] The present invention provides an injection head system that controls the driving force balancing subsystem 200, clamping force balancing subsystem 300, and tension force balancing subsystem 400 through a controller 100. The driving force balancing subsystem 200 forms a closed-loop feedback to achieve a final balance between the two injection heads; the clamping force balancing subsystem 300 forms a closed-loop feedback to achieve a final balance between the clamping pressures of each injection head; and the tension force balancing subsystem 400 forms a closed-loop feedback to achieve a final balance between the tension pressures of the chains 11 of each injection head.

[0071] The present invention also provides a coiled tubing installation machine. This coiled tubing installation machine includes: the injection head assembly or injection head system described in the above embodiments of the present invention.

[0072] The present invention also provides a coiled tubing installation machine, which includes the injection head assembly or injection head system in the embodiments of the present invention, and therefore has the same advantages as described above.

[0073] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An injection head assembly, characterized in that, include: Multiple injection heads, connected in series; Multiple finger weight and finger lightness sensors are provided, one-to-one, on the injection head to monitor the finger weight and finger lightness of the injection head. The controller is connected to multiple finger weight and finger lightness sensors respectively, and is used to receive the finger weight and finger lightness of multiple injection heads, and adjust at least one of the driving force, clamping force and chain tension of multiple injection heads based on the comparison result of the finger weight and finger lightness of multiple injection heads. A connector is provided between two adjacent injection heads, and the connector has a through hole adapted for the passage of a continuous tubing. A limiting sleeve is provided, through which the connector is connected to the injection head. The limiting sleeve forms a limiting hole, which is suitable for the connector to be inserted and connected. The connector includes: First mounting base; A first sleeve, fixed to the mounting base, is adapted to be inserted into one end of the adjacent injection head; The second sleeve is fixed to the mounting base and located on the opposite side of the first sleeve. The second sleeve is adapted to be inserted into one end of the adjacent injection head. The limiting sleeve includes: A second mounting base, the second mounting base being adapted to engage with the first mounting base; A third sleeve is fixed to the second mounting base, and the second sleeve is adapted to be inserted into the third sleeve and into one end of the adjacent injection head.

2. The injection head assembly according to claim 1, characterized in that, The plurality of injection heads include: First injection head; A second injection head is connected in series with the first injection head; The plurality of said finger weight / finger light sensors include: The first finger weight and lightness sensor is disposed on the first injection head and is used to monitor the finger weight and lightness of the first injection head. The second finger-weight / finger-light sensor, disposed on the second injection head, is used to monitor the finger-weight / finger-lightness of the second injection head; wherein... The first and second finger weight sensors are respectively connected to the controller.

3. The injection head assembly according to claim 1, characterized in that, Also includes: A fixing device, one end of which is fixed to one end of one of the injection heads, and the other end of which is adapted to be fixedly connected to one end of an adjacent injection head.

4. The injection head assembly according to claim 1, characterized in that, Also includes: A connecting flange is provided, through which the connector is connected to the adjacent injection head.

5. An injection head system, characterized in that, include: The injection head assembly according to any one of claims 1 to 4; A driving force balancing subsystem, which is electrically connected to the controller, is used to adjust the driving force of the corresponding injection head; A clamping force balancing subsystem, which is electrically connected to the controller, is used to adjust the clamping force of the injection head on the continuous tubing. The tension balancing subsystem is electrically connected to the controller and is used to adjust the chain tension of the corresponding injection head.

6. A coiled tubing installation machine, characterized in that, include: The injection head assembly according to any one of claims 1 to 4 or the injection head system according to claim 5.

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