A coiled tubing tension monitoring device and coiled tubing tension monitoring control system

Abstract

This invention relates to a continuous tube tension monitoring device and a continuous tube tension monitoring and control system. The continuous tube tension monitoring device includes a guide, an injection head, and a roller, wherein the roller provides continuous tube to the injection head. The lower end of the guide is connected to the upper end of the injection head via a pin. An inclined support rod is also connected to the injection head, and the upper end of the guide is connected to the free end of the support rod via a pin-type pressure sensor. This invention utilizes a pin-type sensor to measure the force on the guide, and can calculate the continuous tube tension based on the guide's structural dimensions, enabling real-time acquisition and display of the continuous tube tension value. Furthermore, this invention uses a pin-type sensor, requiring only the replacement of the pin on the injection head, making it suitable for both new injection head designs and upgrades of existing equipment.

Description

Technical Field

[0001] This invention relates to the field of coiled tubing technology applications in oil and gas field development, specifically to a coiled tubing tension monitoring device and a coiled tubing tension monitoring and control system. Background Technology

[0002] Coiled tubing technology has been widely applied in all stages of oil and gas development, including drilling, completion, testing, production, and repair, demonstrating its versatility. Coiled tubing technology is one of the fastest-growing sectors in the global oil and gas field services industry, and China is the fastest-growing region for its application. CNPC's own coiled tubing equipment has increased from 32 units to 116 units, and its annual tubing consumption has increased from 347 tons to 7,646 tons, leading the development of coiled tubing technology in China. Since 2010, the number of well operations has increased from 360 to 5,206, and is projected to reach 15,000 well operations per year by 2025, indicating a promising future. my country has an estimated 10 billion tons of undeveloped reserves. Overcoming technological bottlenecks in energy development across deep-sea, offshore, non-offshore, old, and new (geothermal, hot dry rock, hydrate) resources, and developing efficient oil and gas development equipment are crucial for future development. Upgrading coiled tubing technology and innovating equipment are important components of this.

[0003] Coiled tubing tension control is extremely critical in coiled tubing operations. Under actual operating conditions, coiled tubing failures manifest in various forms, including bending, fatigue, pitting, tension overload, and mechanical damage. Failure investigations show that tension overload and mechanical damage account for a significant proportion of coiled tubing failures, and tension greatly impacts coiled tubing lifespan. Furthermore, during coiled tubing winding, excessive tension can cause tearing or excessive mutual compression leading to surface damage, and may also cause the injection head to tilt, resulting in operational accidents. Insufficient tension, on the other hand, can cause coiled tubing to float on the drum, reducing the drum's coiling capacity and leading to repeated coiling. Therefore, to avoid potential accidents during operation and minimize coiled tubing damage and failure due to tension overload, it is necessary to monitor, alarm, and control the coiled tubing tension during operation. This has significant practical implications for the automation, scientific, and efficient operation of coiled tubing equipment.

[0004] The tension setting of coiled tubing is influenced by numerous factors, including the coiled tubing diameter, stiffness, winding diameter, the angle between the roller and the injection head, winding speed, and the state of the tubing during lifting and lowering. Currently, research on automatic monitoring and control of coiled tubing tension is limited. Tension cannot be directly monitored; both domestically and internationally, the appropriateness of the tension is mainly determined by observing the coiled tubing morphology between the roller and the injection head, with tension control primarily achieved through manual adjustment of the roller pressure. However, this method requires highly experienced operators and is only qualitative control, failing to achieve precise control of coiled tubing tension, which can lead to floating tubing and excessive tension shortening its lifespan. The use of a pin-type sensor to measure tension and achieve automatic tension control is a first in China.

[0005] During coiled tubing field operations, coiled tubing tension adjustment between the injection head and the drum is an essential part of coiled tubing tripping. Currently, well depths and horizontal sections in domestic oilfields are increasing, leading to longer coiled tubing tripping times. Complex drilling and milling processes require frequent tripping and tension adjustments, resulting in long working hours and high intensity for operators. Currently, coiled tubing tension adjustment relies primarily on manual observation, heavily depending on operator experience. However, differences in experience and mental state can affect the results, inevitably leading to tension adjustment errors, causing tubing to float or excessive tension that shortens coiled tubing life. Summary of the Invention

[0006] In order to solve one or more technical problems existing in the prior art, the present invention provides a continuous tube tension monitoring device and a continuous tube tension monitoring and control system.

[0007] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: a continuous tube tension monitoring device, comprising a guide, an injection head and a roller, wherein the roller is used to provide a continuous tube for the injection head; the lower end of the guide is connected to the upper end of the injection head by a pin; the injection head is also connected to an inclined support rod, and the upper end of the guide is connected to the free end of the support rod by a pin-type pressure sensor.

[0008] The beneficial effects of this invention are as follows: During the continuous tube lifting and lowering process, the continuous tube is wound into or out of the drum. It is necessary to control the tension value of the continuous tube between the injection head and the drum to ensure that the continuous tube is tightly wound. Currently, conventional continuous tube operating machines mainly rely on personnel to observe the aerial shape of the continuous tube, which depends on the experience of the personnel. The continuous tube tension monitoring device of this invention uses a pin-type sensor to measure the force on the guide, and can calculate the tension of the continuous tube by combining the structural dimensions of the guide, and collect and display the tension value of the continuous tube in real time. In addition, this invention uses a pin-type sensor, which only requires replacing the pin on the injection head, making it suitable for the design of new injection heads as well as for the upgrading and transformation of old equipment.

[0009] Based on the above technical solution, the present invention can be further improved as follows.

[0010] A continuous tube tension monitoring and control system includes the aforementioned continuous tube tension monitoring device, and further includes a control module and an electro-hydraulic drive module. The electro-hydraulic drive module is connected to the drum and drives the drum to run by outputting torque.

[0011] The control module obtains the support force F1 by acquiring the support force signal of the injection head on the guide and the continuous tube on it from the pin-type pressure sensor; the control module calculates the actual tension value of the continuous tube between the roller and the injection head based on the support force F1, and controls the output torque of the electro-hydraulic drive module based on the actual tension value.

[0012] The beneficial effects of this invention are as follows: The continuous tube tension monitoring and control system of this invention, by placing the pin sensor at the support of the injection head against the guide, can directly calculate the actual tension value of the continuous tube without changing the structure of the injection head, thus avoiding the problem of structural incompatibility during upgrades and modifications. Furthermore, the electro-hydraulic drive module enables real-time tension adjustment, reducing the risk of tube floating due to improper tension adjustment, reducing the workload of operators, and lowering operating costs.

[0013] Furthermore, the control module calculates the actual tension value of the continuous tube between the roller and the injection head based on the support force F1, compares the actual tension value with the target tension value, and controls the output torque of the electro-hydraulic drive module based on the comparison result.

[0014] The beneficial effects of adopting the above-mentioned further scheme are: the tension of the continuous tube can be monitored and automatically controlled in real time by comparing the actual tension value with the target tension value, which can avoid tube floating, reduce the intensity of operation, and improve the efficiency of continuous tube raising and lowering and conventional processes.

[0015] Furthermore, the control module controls the output torque of the electro-hydraulic drive module based on the comparison results, including:

[0016] When the difference between the actual tension value and the target tension value exceeds the error range but is within the safe range, the output torque of the electro-hydraulic drive module is changed.

[0017] When the actual tension value exceeds the safe range, the control module controls the electro-hydraulic drive module to brake urgently. Alternatively, the control module is also connected to the alarm module, and while controlling the electro-hydraulic drive module to brake urgently, the control module also controls the alarm module to sound an alarm.

[0018] The beneficial effects of adopting the above-mentioned further solutions are: the control module can timely assess whether the actual tension value is appropriate, avoid the continuous tube from floating and reducing its lifespan, effectively reduce the ineffective lifting and lowering time of the continuous tube, reduce fatigue wear of the continuous tube, reduce the labor intensity of the workers, and improve the utilization efficiency of the continuous tube.

[0019] Furthermore, when the injection head cooperates with the roller to perform the tube lifting operation, the target tension value is a first target tension value, which is not less than the sum of the rebound force and winding force of the continuous tube on the roller;

[0020] When the injection head cooperates with the roller to perform the tube lowering operation, the target tension value is the second target tension value, which is not less than the rebound force of the continuous tube on the roller.

[0021] The beneficial effects of adopting the above-mentioned further scheme are as follows: Since the tension of the continuous tube must be greater than the sum of the spring force and winding force of the continuous tube on the drum during the tube-lifting operation, the first target tension value can be set to be no less than the sum of the spring force and winding force of the continuous tube. During the tube-lowering operation, the tension of the continuous tube only needs to overcome the spring force of the continuous tube; therefore, the second target tension value can be set to be no less than the spring force of the continuous tube on the drum.

[0022] Furthermore, the pin-type pressure sensor converts the collected support force signal of the injection head on the guide into a current signal, and transmits it to the control module through an isolated safety barrier;

[0023] The control module converts the current signal into a supporting force F1 through proportional conversion, and obtains the actual tension value of the continuous tube on the guide by analyzing the force on the pin at the hinge between the injection head and the guide.

[0024] Furthermore, the control module calculates the actual tension value of the continuous tube between the roller and the injection head based on the supporting force F1, including: point A where the pin is located, point B where the pin-type pressure sensor is located, and point C at the end of the guide. Treating the guide and the continuous tube as a whole, during operation, it is subjected to four forces: the tension exerted by the roller on the continuous tube at point C, which is also the actual tension value F of the continuous tube between the injection head and the roller; the supporting force F1 of the support rod on the injection head on the guide at point B; the supporting force F0 of the injection head on the guide at point A; and the supporting force F2 of the injection head on the continuous tube, where F2 is 0. The distance from point C to point A is L1, and the distance from point B to point A is L2. A torque balance analysis is performed at point A, where the torque is 0. According to the torque balance formula: F = L2F1cosβ / L1cosα, where F1 can be obtained from the pin-type pressure sensor, and α, β, L2, and L1 can all be measured.

[0025] Furthermore, it also includes a display module, which is connected to the control module and obtains a real-time tension change curve based on the actual tension value; when the actual tension value exceeds the safe range, the display module displays an alarm in real time.

[0026] The beneficial effects of adopting the above-mentioned further solution are: the real-time tension change curve can be displayed through the display module, and alarms can also be displayed.

[0027] Furthermore, the electro-hydraulic drive module includes a hydraulic control pipeline and a hydraulic pump, a hydraulic motor, and a relief valve connected in sequence to the hydraulic control pipeline. The hydraulic motor is also connected to a pilot-operated relief valve and a two-way relief valve, and the pilot-operated relief valve is also connected to an electro-proportional pressure reducing valve.

[0028] The control module calculates the actual tension value of the continuous tube between the roller and the injection head based on the support force F1, and controls the current of the electro-proportional pressure reducing valve based on the actual tension value, thereby controlling the output torque of the hydraulic motor; the hydraulic motor is installed on the roller and drives the roller to rotate or provides pressure to the roller through the output torque.

[0029] Furthermore, the hydraulic pump is equipped with a pressure sensor for detecting hydraulic pressure, and the pressure sensor is connected to the control module; a filter is also provided on the hydraulic control pipeline upstream of the hydraulic pump.

[0030] The beneficial effect of adopting the above-mentioned further solution is that the pressure sensor can detect the hydraulic pressure of the hydraulic pump, and can issue an alarm when the hydraulic pressure of the hydraulic pump exceeds the maximum pressure value. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of the injection head and guide of the present invention;

[0032] Figure 2 This is a schematic diagram of the structure of the roller of the present invention;

[0033] Figure 3 This is a schematic diagram of the principle structure of the electro-hydraulic drive module of the present invention.

[0034] Figure 4 A torque analysis diagram for calculating the actual tension value of the coiled tube;

[0035] The attached diagram lists the components represented by each number as follows:

[0036] 1. Injection head; 11. Support rod; 2. Roller; 3. Pin-type pressure sensor; 4. Pin; 5. Guide; 6. Electro-hydraulic drive module; 61. Hydraulic pump; 62. Hydraulic motor; 63. Relief valve; 64. Pilot-operated relief valve; 65. Two-way relief valve; 66. Electro-proportional pressure reducing valve; 67. Filter; 68. Pressure sensor. Detailed Implementation

[0037] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0038] like Figure 1 and Figure 2As shown, this embodiment of a continuous tube tension monitoring device includes a guide 5, an injection head 1, and a roller 2. The roller 2 provides continuous tube to the injection head 1. The lower end of the guide 5 is connected to the upper end of the injection head 1 via a pin 4. An inclined support rod 11 is also connected to the injection head 1. The upper end of the guide 5 is connected to the free end of the support rod 11 via a pin-type pressure sensor 3. A pin-type pressure sensor is used to replace the connecting pin between the injection head support rod and the guide because during the continuous tube lifting and lowering process, the continuous tube is wound into or out of the roller. It is necessary to control the tension value of the continuous tube between the injection head and the roller to ensure tight winding. Currently, conventional continuous tube operating machines mainly rely on personnel to observe the aerial shape of the continuous tube, depending on their experience. The continuous tube tension monitoring device uses a pin-type sensor to measure the force on the guide, and can calculate the continuous tube tension based on the guide's structural dimensions, allowing for real-time acquisition and display of the continuous tube tension value. Furthermore, this embodiment uses a pin-type sensor, which only requires replacing the pin on the injection head, making it suitable for both new injection head designs and upgrades of existing equipment.

[0039] This embodiment also provides a continuous tube tension monitoring and control system, including the aforementioned continuous tube tension monitoring device, a control module, and an electro-hydraulic drive module 6. The electro-hydraulic drive module 6 is connected to the drum 2 and drives the drum 2 to run by outputting torque. The control module obtains the support force F1 by collecting the support force signal of the continuous tube on the guide 5 from the injection head 1 using the pin-type pressure sensor 3. The control module calculates the actual tension value of the continuous tube between the drum and the injection head based on the support force F1, and controls the output torque of the electro-hydraulic drive module 6 based on the actual tension value. This continuous tube tension monitoring and control system, by placing the pin-type sensor at the support point of the injection head support rod on the guide, can directly calculate the actual tension value of the continuous tube without changing the structure of the injection head, avoiding the problem of structural incompatibility during upgrades and modifications. Furthermore, the electro-hydraulic drive module can achieve real-time tension adjustment, reducing the risk of tube floating due to improper tension adjustment, reducing the workload of operators, and lowering operating costs. The control module can be a PLC controller, which uses a PID control electro-proportional pressure reducing valve to control the current and adjust the drum pressure.

[0040] A further embodiment of this solution involves the control module calculating the actual tension value of the continuous tube between the roller 2 and the injection head 1 based on the supporting force F1, comparing the actual tension value with the target tension value, and controlling the output torque of the electro-hydraulic drive module based on the comparison result. By comparing the actual tension value with the target tension value, the tension of the continuous tube can be monitored and automatically controlled in real time, avoiding tube floating, reducing operational intensity, and improving the efficiency of continuous tube raising and lowering as well as conventional processes.

[0041] Specifically, the control module controls the output torque of the electro-hydraulic drive module 6 based on the comparison results. This includes changing the output torque of the electro-hydraulic drive module 6 when the difference between the actual tension value and the target tension value exceeds the error range but is within the safety range; and controlling the electro-hydraulic drive module 6 to perform an emergency brake when the actual tension value exceeds the safety range. Alternatively, the control module is also connected to an alarm module, which simultaneously controls the alarm module to sound an alarm while controlling the emergency brake of the electro-hydraulic drive module 6. The control module can promptly assess whether the actual tension value is appropriate, avoiding coiled tubing floating and reduced lifespan. It effectively reduces the ineffective lifting and lowering time of coiled tubing operations, reduces coiled tubing fatigue wear, lowers the labor intensity of workers, and improves the efficiency of coiled tubing use.

[0042] Specifically, when the injection head 1 cooperates with the roller 2 to perform tube lifting operations, the target tension value is a first target tension value, which is not less than the sum of the rebound force and winding force of the continuous tube on the roller 2. When the injection head 1 cooperates with the roller 2 to perform tube lowering operations, the target tension value is a second target tension value, which is not less than the rebound force of the continuous tube on the roller 2. Since the continuous tube tension is greater than the sum of the rebound force and winding force of the continuous tube on the roller during tube lifting operations, the first target tension value can be set to be no less than the sum of the rebound force and winding force of the continuous tube. During tube lowering operations, the continuous tube tension only needs to overcome the rebound force of the continuous tube, therefore the second target tension value can be set to be no less than the rebound force of the continuous tube on the roller.

[0043] In one specific embodiment, the pin-type pressure sensor 3 converts the support force signal of the injection head 1 against the guide into a current signal, which is then transmitted to the control module via an isolated safety barrier. The control module converts the current signal into a support force F1 through proportional conversion and obtains the actual tension value of the continuous tube on the guide by analyzing the force on the pin at the hinge between the injection head and the guide. The safety barrier is installed in the electrical control cabinet, and its main function is to prevent the control module from burning out when the current of the pin-type pressure sensor abnormally increases, thus protecting the control module.

[0044] Furthermore, such as Figure 4As shown, the control module calculates the actual tension value of the continuous tube between the roller and the injection head based on the supporting force F1, including: point A where the pin is located, point B where the pin-type pressure sensor is located, and point C at the end of the guide. Treating the guide and the continuous tube as a whole, during operation, it is subjected to four forces: the tension exerted by the roller on the continuous tube at point C, which is also the actual tension value F of the continuous tube between the injection head and the roller; the supporting force F1 of the support rod on the injection head on the guide at point B; the supporting force F0 of the injection head on the guide at point A; and the supporting force F2 of the injection head on the continuous tube, where F2 is 0. The distance from point C to point A is L1, and the distance from point B to point A is L2. A torque balance analysis is performed at point A, and the torque at point A is 0. According to the torque balance formula: F = L2F1cosβ / L1cosα, where F1 can be obtained by the pin-type pressure sensor, and α, β, L2, and L1 can all be measured.

[0045] The continuous tube tension monitoring and control system of this embodiment also includes a display module, which is connected to the control module and obtains a real-time tension change curve based on the actual tension value. When the actual tension value exceeds the safe range, the display module displays an alarm in real time. The display module can display the real-time tension change curve and also display alarms.

[0046] like Figure 3 As shown, the electro-hydraulic drive module 6 in this embodiment includes a hydraulic control pipeline and a hydraulic pump 61, a hydraulic motor 62, and a relief valve 63 connected sequentially to the hydraulic control pipeline. The hydraulic motor 62 is also connected to a pilot-operated relief valve 64 and a two-way relief valve 65, respectively. The pilot-operated relief valve 64 is also connected to an electro-proportional pressure reducing valve 66. The control module calculates the actual tension value of the continuous pipe between the roller 2 and the injection head 1 based on the support force F1, and controls the current of the electro-proportional pressure reducing valve 66 based on the actual tension value, thereby controlling the output torque of the hydraulic motor 62. The hydraulic motor 62 is mounted on the roller 2 and drives the roller 2 to rotate or provides pressure to the roller 2 through its output torque. When the electro-hydraulic drive module 6 in this embodiment is working, the hydraulic pump 61 draws hydraulic oil from the oil tank and outputs high-pressure hydraulic oil. The pilot-operated relief valve, in conjunction with the electro-proportional pressure reducing valve, adjusts the roller pressure. The two-way relief valve can protect the motor inlet and outlet pipelines. The relief valve 63 can ensure the minimum pressure on the low-pressure side of the hydraulic motor 62. During pipe lowering, the injection head pulls the roller to release the pipe. The pilot-operated relief valve 64 and the electro-proportional pressure reducing valve 66 can adjust the pressure of the hydraulic motor 62 to provide back pressure and ensure the tension between the roller and the injection head. At this time, the hydraulic motor 62 is pulled in reverse and operates as a pump. The relief valve 63 maintains a certain pressure on the low-pressure side to prevent the motor from sucking in cavitation. During pipe lifting, the roller 2 plays the role of winding the continuous pipe and maintaining tension.

[0047] like Figure 3 As shown, the hydraulic pump 61 in this embodiment is equipped with a pressure sensor 68 for detecting hydraulic pressure, and the pressure sensor 68 is connected to the control module. A filter 67 is also provided on the hydraulic control pipeline upstream of the hydraulic pump 61. The filter mainly filters the hydraulic oil and protects the hydraulic pump. The pressure sensor can detect the hydraulic pressure of the hydraulic pump, and can issue an alarm when the hydraulic pressure exceeds the maximum pressure value.

[0048] The specific working process of the continuous tube tension monitoring and control system in this embodiment is as follows:

[0049] Step 1: Select a suitable model of continuous tube operating machine and replace the two connecting pins at the connection between the injection head and the guide with pin-type sensors, such as... Figure 1 As shown, the control module obtains the supporting force F1 by collecting the supporting force signal of the injection head 1 on the guide 5 and the continuous tube on it from the pin-type pressure sensor 3. The actual tension value F of the continuous tube between the injection head and the roller is calculated by the mechanical analysis of the injection head structure. The specific calculation process is described in the torque analysis above. The actual tension value (unit N) can be displayed through the monitoring interface, and the historical change curve can be viewed when needed.

[0050] Step 2: Set the target tension value and safety range value of the coiled tubing based on the coiled tubing diameter, steel grade, and the jacking tube;

[0051] More specifically, during the tube lifting process, the continuous tube tension must be greater than the sum of the springback force and winding force of the continuous tube on the roller; during the tube lowering process, the continuous tube tension only needs to overcome the springback force of the continuous tube on the roller. Different continuous tube diameters and steel grades correspond to different springback forces and winding forces. Based on theoretical calculations and field tests, the target tension value and safe range value of the continuous tube in the control module are set.

[0052] Step 3: Compare the current actual tension value with the target tension value, and use the electro-hydraulic drive module to control the pressure of the hydraulic motor on the drum so that the actual tension value of the continuous tube reaches the target tension value; when the actual tension value exceeds the safe range, an alarm is triggered and automatic emergency control is activated.

[0053] More specifically, the control module compares the actual tension value with the target tension value. If the difference is outside the set error range, the control module adjusts the current of the drum electro-proportional pressure regulating valve according to the difference control program. This changes the pressure difference across the drum motor, altering the output torque and causing a change in the actual tension value between the injection head and the drum. The actual tension value is compared with the target tension value again until the difference is within the error range, at which point adjustment stops, achieving closed-loop tension control. If the actual tension value becomes too high or too low due to various reasons, exceeding the safety range, the system alarms and automatically reduces speed and stops the machine. When the coiled tubing speed changes or the tubing tripping is switched, causing a change in the target tension value, the PLC controller controls the electro-proportional pressure reducing valve to change the actual tension value to reach the recalibrated target error range. When the coiled tubing is pulled out of the wellhead, completing the operation, the drum brakes, and the drum pressure is released to 0.

[0054] This embodiment of the coiled tube tension monitoring and control system, by placing pin sensors at the two supports of the injection head against the guide, can directly calculate the actual tension value of the coiled tube and display it in real time. Furthermore, it does not require changes to the injection head structure, avoiding structural incompatibility issues during upgrades. Simultaneously, the control module can achieve real-time adjustment of the actual tension value, automatically adjusting it to the target tension value. This realizes a closed-loop control system of "monitoring—analysis and judgment—automatic adjustment" during coiled tube raising and lowering, providing a foundation for intelligent coiled tube operations. It reduces the risk of tube floating due to improper tension adjustment, reduces operator workload, and lowers operating costs. The method provided in this embodiment is applicable to a series of injection heads, including 180, 270, 450, and 580, and can be used for new equipment design and upgrades of existing injection heads, demonstrating wide applicability. As can be seen, the control system provided in this embodiment can monitor the tension in real time and adjust the roller pressure to control the tension of the continuous tube based on information such as the continuous tube and rollers. This eliminates reliance on personnel, reduces the risks of continuous tube operations caused by human factors, and reduces the labor intensity of workers, providing technical support for the automation and unmanned operation of continuous tube equipment. In addition, during continuous tube operations, there are often a large number of continuous tubes of different specifications, and different models of rollers, injection heads, and guides. Different continuous tube tensions are required when starting or lowering the tube. This embodiment can automatically correct the control module model parameters according to the corresponding parameters, ensuring the compatibility and practicality of the automatic tension control system.

[0055] In the description of this invention, it should be understood that the terms "upper" and "lower" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0056] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0057] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0058] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0059] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0060] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A continuous tube tension monitoring and control system, characterized in that, The device includes a continuous tube tension monitoring device, a control module, and an electro-hydraulic drive module. The continuous tube tension monitoring device includes a guide, an injection head, and a roller. The roller is used to provide continuous tube to the injection head. The lower end of the guide is connected to the upper end of the injection head via a pin. An inclined support rod is also connected to the injection head. The upper end of the guide is connected to the free end of the support rod via a pin-type pressure sensor. The electro-hydraulic drive module is connected to the drum and drives the drum to run by outputting torque; The control module obtains the support force F1 based on the support force signal of the injection head on the guide and the continuous tube on it collected by the pin-type pressure sensor; The control module calculates the actual tension value of the continuous tube between the roller and the injection head based on the support force F1, and controls the output torque of the electro-hydraulic drive module based on the actual tension value. The control module calculates the actual tension value of the continuous tube between the roller and the injection head based on the supporting force F1, including: point A where the pin is located, point B where the pin-type pressure sensor is located, and point C at the end of the guide. Treating the guide and the continuous tube as a whole, during operation, it is subjected to four forces: the tension exerted by the roller on the continuous tube at point C, which is also the actual tension value F of the continuous tube between the injection head and the roller; the supporting force F1 of the support rod on the injection head on the guide at point B; the supporting force F0 of the injection head on the guide at point A; and the supporting force F2 of the injection head on the continuous tube, where F2 is 0. The distance from point C to point A is L1, and the distance from point B to point A is L2. A torque balance analysis is performed at point A, where the torque is 0. According to the torque balance formula: F = L2F1cosβ / L1cosα, where F1 can be obtained from the pin-type pressure sensor, and α, β, L2, and L1 are all measured.

2. The continuous tube tension monitoring and control system according to claim 1, characterized in that, The control module calculates the actual tension value of the continuous tube between the roller and the injection head based on the support force F1, compares the actual tension value with the target tension value, and controls the output torque of the electro-hydraulic drive module based on the comparison result.

3. The continuous tube tension monitoring and control system according to claim 2, characterized in that, The control module controls the output torque of the electro-hydraulic drive module based on the comparison results, including... When the difference between the actual tension value and the target tension value exceeds the error range but is within the safe range, the output torque of the electro-hydraulic drive module is changed. When the actual tension value exceeds the safe range, the control module controls the electro-hydraulic drive module to brake urgently. Alternatively, the control module is also connected to the alarm module, and while controlling the electro-hydraulic drive module to brake urgently, the control module also controls the alarm module to sound an alarm.

4. The continuous tube tension monitoring and control system according to claim 2, characterized in that, When the injection head cooperates with the roller to perform the tube lifting operation, the target tension value is a first target tension value, which is not less than the sum of the rebound force and winding force of the continuous tube on the roller; When the injection head cooperates with the roller to perform the tube lowering operation, the target tension value is the second target tension value, which is not less than the rebound force of the continuous tube on the roller.

5. The continuous tube tension monitoring and control system according to claim 1, characterized in that, The pin-type pressure sensor converts the support force signal of the injection head on the guide into a current signal, and transmits it to the control module through an isolated safety barrier; The control module converts the current signal into a supporting force F1 through proportional conversion, and obtains the actual tension value of the continuous tube on the guide by analyzing the force on the pin at the hinge between the injection head and the guide.

6. The continuous tube tension monitoring and control system according to claim 1, characterized in that, It also includes a display module, which is connected to the control module and obtains a real-time tension change curve based on the actual tension value; when the actual tension value exceeds the safe range, the display module displays an alarm in real time.

7. The continuous tube tension monitoring and control system according to claim 1, characterized in that, The electro-hydraulic drive module includes a hydraulic control pipeline and a hydraulic pump, a hydraulic motor, and a relief valve connected in sequence to the hydraulic control pipeline. The hydraulic motor is also connected to a pilot-operated relief valve and a two-way relief valve, and the pilot-operated relief valve is also connected to an electro-proportional pressure reducing valve. The control module calculates the actual tension value of the continuous tube between the roller and the injection head based on the support force F1, and controls the current of the electro-proportional pressure reducing valve based on the actual tension value, thereby controlling the output torque of the hydraulic motor; the hydraulic motor is installed on the roller and drives the roller to rotate or provides pressure to the roller through the output torque.

8. The continuous tube tension monitoring and control system according to claim 7, characterized in that, The hydraulic pump is equipped with a pressure sensor that detects hydraulic pressure, and the pressure sensor is connected to the control module; a filter is also provided on the hydraulic control pipeline upstream of the hydraulic pump.

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