Top drive automatic lubrication pre-maintenance method and system

Abstract

The invention discloses a top drive automatic lubrication pre-maintenance method and system, and belongs to the field of oil drilling and production industrial products.The maintenance method comprises the steps that at least one operation parameter of a top drive bearing piece is collected to obtain a measured value of the operation parameter of the top drive bearing piece; comparing the collected measured value of each operating parameter with the set value of the operating parameter, and generating a maintenance instruction based on the comparison result of each operating parameter; and the injection amount of the top drive bearing part lubricant is adjusted based on the maintenance instruction. The multiple operation parameters of the top drive bearing part are collected, the operation state of the top drive bearing part is known based on the comparison result of the collected values and the preset values of the multiple operation parameters, then the maintenance scheme conforming to the operation state of the top drive bearing part is generated, and the rationality of the additive amount of a lubricating agent is guaranteed.

Description

Technical Field

[0001] The invention belongs to the field of oil drilling and production industry, and in particular relates to a top drive automatic lubrication pre-maintenance method and system. Background Art

[0002] A top drive (TDR) is a type of drilling rig installed inside a derrick and suspended by a traveling block. In oil drilling and production, the TDR primarily provides reliable and controllable rotary power for drilling operations. As a large piece of oil machinery, its main load-bearing components can carry hundreds of tons. Dynamic and static friction between the components can cause heating and wear of the components. To ensure normal, efficient, and smooth operation, lubricant must be applied between the friction pairs of the TDR. Lubricant fills uneven surfaces and maintains a thick lubricant film, separating the contacting surfaces of the friction pairs, reducing friction and wear. It also cools the components and acts as a seal. The proper amount of lubricant is crucial to the operation of the TDR. Too little lubricant can accelerate equipment wear and aging, gradually reducing the remaining lifespan and potentially leading to component damage, total TDR shutdown, and other serious accidents. Excessive lubricant addition generates significant stirring heat, which raises the lubricant temperature, creating significant waste and undesirable consequences.

[0003] Due to the differences in the working methods and conditions of various parts of the equipment, there are strict requirements for the refueling cycle, amount of oil added each time, and method of refueling at each lubrication point. The lubrication method and lubricant dosage of traditional top drives are mostly based on on-site experience and preventive maintenance of parts, and the amount of lubricant added cannot be accurately grasped. Summary of the Invention

[0004] The object of the present invention is to provide a top drive automatic lubrication pre-maintenance method and system to solve the problem of adding lubricant during the operation of the existing top drive, that is, the problem of top drive maintenance in the actual process, as mentioned in the background art.

[0005] To achieve the above object, the present invention provides the following technical solution: a top drive automatic lubrication pre-maintenance method, comprising the following steps:

[0006] collecting at least one operating parameter of the top drive bearing component to obtain a measured value of the operating parameter of the top drive bearing component;

[0007] comparing the collected measured value of each operating parameter with the set value of the operating parameter, and generating a maintenance instruction based on the comparison result of each operating parameter;

[0008] The injection amount of top drive bearing lubricant is adjusted based on the maintenance instructions.

[0009] Preferably, the operating parameters include analog data and / or digital data.

[0010] Preferably, the comparison of the collected measurement value and the set value of the operating parameter includes comparing whether the digital quantities are the same and / or comparing the numerical values of the analog quantities.

[0011] Preferably, the maintenance instruction includes an instruction to increase or decrease the lubricant injection amount based on a standard value of the lubricant injection amount.

[0012] Preferably, the lubricant injection amount standard value is configured to change with changes in operating parameter measurement values and ambient temperature.

[0013] Preferably, the collection period of the operating parameters is adjusted based on operating conditions, and the operating conditions include at least one of the operating state of the top drive equipment, load, bottom hole drilling conditions and ambient temperature.

[0014] On the other hand, the present application discloses a drive lubrication maintenance system, comprising:

[0015] a collection module configured to collect at least one operating parameter of the top drive bearing component to obtain a measured value of the operating parameter of the drive component;

[0016] a control module having set values of operating parameters stored therein, the control module being configured to receive the measurement data output by the acquisition module and to issue a maintenance instruction based on a comparison result between the measurement data and the set values;

[0017] An execution module is configured to adjust an injection amount of lubricant of the top drive bearing component based on the maintenance instruction.

[0018] Preferably, the acquisition module includes a plurality of sensor devices and / or proximity switches, the sensor devices are configured to acquire analog data, and the proximity switches are configured to acquire digital data.

[0019] Preferably, the comparison of the collected measurement value and the set value of the operating parameter includes comparing whether the digital quantities are the same and / or comparing the numerical values of the analog quantities.

[0020] Preferably, the execution module includes multiple lubrication circuits, a single lubrication circuit is connected to the top drive bearing, and the amount of lubricant injected into the top drive bearing is adjusted by adjusting the flow in the lubrication circuit.

[0021] Preferably, each of the lubrication circuits is equipped with an independent oil pump.

[0022] Preferably, the control module is connected to the acquisition module and the execution module via an optical fiber, a cable or a power line carrier.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] The present application collects multiple operating parameters of the top drive bearing component, and understands the operating status of the top drive bearing component based on the comparison results of the collected values ​​of the multiple operating parameters and the preset values, and then generates a maintenance plan that conforms to the operating status of the top drive bearing component to ensure the rationality of the lubricant addition amount. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A flow chart for maintenance methods;

[0026] Figure 2 Indicates the maintenance system Figure 1 ;

[0027] Figure 3 It is a schematic diagram of the maintenance system;

[0028] Figure 4 Indicates the maintenance system Figure 2 ;

[0029] Figure 5-11 Schematic diagram of the locations of lubrication points on different top drive bearing components. DETAILED DESCRIPTION

[0030] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0031] A top drive automatic lubrication and pre-maintenance system, comprising:

[0032] a collection module configured to collect at least one operating parameter of the top drive bearing component to obtain a measured value of the operating parameter of the drive component;

[0033] a control module having set values of operating parameters stored therein, the control module being configured to receive the measurement data output by the acquisition module and to issue a maintenance instruction based on a comparison result between the measurement data and the set values;

[0034] An execution module is configured to adjust an injection amount of lubricant of the top drive bearing component based on the maintenance instruction.

[0035] In some examples, the acquisition module includes a plurality of sensor devices and / or proximity switches, wherein the sensor devices are configured to acquire analog data, and the proximity switches are configured to acquire digital data.

[0036] In some examples, the comparing the collected measurement value with the set value of the operating parameter includes comparing whether the digital quantities are the same and / or comparing the numerical values of the analog quantities.

[0037] In some examples, the execution module includes multiple lubrication circuits, a single lubrication circuit is connected to the top drive bearing, and the amount of lubricant injected into the top drive bearing is adjusted by adjusting the flow in the lubrication circuit.

[0038] In some examples, each of the lubrication circuits is equipped with an independent oil pump.

[0039] In some examples, the control module is connected to the acquisition module and the execution module via an optical fiber, a cable, or a power carrier.

[0040] The addition of lubricants (such as lubricating oil or grease) plays a vital role in the operation of the top drive. During the long-term operation of the top drive, if the amount of lubricant is less than the actual need, it will accelerate the wear and aging of the equipment, and the remaining life will gradually decrease, which may easily lead to serious accidents such as damage to parts and overall shutdown of the top drive. Excessive addition of lubricating oil will generate a large amount of stirring heat, causing the temperature of the lubricating oil to rise, which is harmful rather than beneficial and will also bring huge waste. Therefore, it is very important to reasonably adjust the amount of lubricant for different bearing parts of the top drive according to the different moving parts, working methods, status and ambient temperature.

[0041] Based on the limitations of the existing top drive lubricant addition method, this application discloses a top drive automatic lubrication pre-maintenance system (hereinafter referred to as the maintenance system), referring to Figure 2 The main body is composed of an acquisition module, a control module and an execution module. The acquisition module collects the operating parameter (such as speed and pressure) data of each component in the top drive (for example, such as the motor and the reducer) and transmits it to the control module. The control module generates maintenance instructions based on the operating parameter data to control the action of the execution module, and then adjusts the amount of lubricant (grease) added to each component in the top drive (hereinafter referred to as the top drive bearing). Therefore, the top drive bearing can be adaptively maintained based on the actual operating conditions of the top drive bearing to adapt to bearings with different fatigue levels. It can significantly reduce manual maintenance time, improve system safety, increase lubrication effect, reduce lubricant usage, and effectively improve the automation, intelligence, and green environmental protection of top drive equipment.

[0042] Specifically, the acquisition module is configured to acquire at least one operating parameter of the top drive bearing component. In some embodiments, the operating parameter includes analog data and / or digital data. Correspondingly, the acquisition module includes multiple sensor devices for acquiring analog data of the top drive bearing component. Exemplarily, the acquisition module includes a vibration sensor, a temperature sensor, and a strain sensor to realize the acquisition of vibration data, temperature data, and strain data of the driving component. At the same time, the acquisition module also includes a contactor and a proximity switch to monitor the switching and closing states of the top drive bearing component, that is, to obtain digital data of the driving component. In some embodiments, for different top drive bearing components, the operating parameters acquired can be adaptively selected based on their own characteristics. For example, for the rotation characteristics of the rotating shaft component during operation, torque parameter data can be collected in a targeted manner to improve the targeted maintenance and maintenance efficiency.

[0043] In some embodiments, the collection period of the collection module can be set to a fixed value based on past experience, for example, set to 24 hours, or it can be adjusted based on the operating conditions, that is, its collection period can be adjusted based on changes in the operating conditions. For example, the operating conditions include at least one of the operating status, load, bottom hole drilling conditions and ambient temperature of the top drive equipment. In some examples, the maintenance system can shorten the collection period during the operation of the top drive equipment, that is, increase the collection frequency of the operating parameters, and increase the collection period during the idle period of the top drive equipment, that is, reduce the collection frequency of the operating parameters. In other examples, the maintenance system shortens the collection period in high or low temperature environments, and increases the collection period in normal temperature environments.

[0044] Back to Figure 2 , continue to explain the composition of the maintenance system, refer to Figure 4 The control module includes a comparison unit and a storage unit, wherein the storage unit stores set values of operating parameters, such as temperature set values, pressure set values, fatigue set values, and switch state set values. The set values corresponding to analog data are analog quantities, and the set values corresponding to digital quantities are digital quantities. The set values of the operating parameters can be set based on past experience, such as the data marked on the nameplate of the top drive bearing component, or can also be set based on past maintenance experience. In some embodiments, for the same operating parameter, different top drive bearing components have different operating parameter set values. For example, for operating temperature data, different top drive bearing components have different optimal operating temperatures. Correspondingly, the temperature set values in different components are also different, so as to achieve an optimal solution for the lubrication scheme of each drive component.

[0045] Continuing to explain the control module, the above-mentioned comparison unit is configured to compare the operating parameters (hereinafter referred to as measured values) transmitted by the acquisition module with the operating parameters stored in the storage unit (i.e., set values), and generate maintenance instructions based on the comparison results to control the actions of the execution module, thereby increasing or decreasing the amount of lubricant (lubricating oil or grease) added to the top drive bearing, that is, increasing or decreasing the injection amount of lubricant based on the standard value. In some embodiments, the standard value of the lubricant injection amount can be dynamically adjusted based on the operating status and ambient temperature of the top drive equipment, that is, the standard value of the lubricant injection amount can be adjusted based on the measured values of the operating parameters and the ambient temperature, and the adjustment can be based on the lubrication experience of the top drive equipment under different previous operating conditions (i.e., different operating parameters and ambient temperatures), for example, comparing the lubrication effects of different lubricant injection amounts under different operating conditions. In some embodiments, the comparison of the above-mentioned measured values and set values includes comparison of analog data and comparison of digital data, wherein the comparison of digital data is performed. It mainly depends on whether the measured value and the set value are the same to realize the control of the execution module. For example, 0 and 1 represent the open and closed states of the top drive bearing respectively. When the set value is 0, the measured value is the same as the set value, which indicates that the top drive bearing is in the closed state. Correspondingly, lubricant can be added to the top drive bearing according to the standard injection amount or no lubricant is added. When the measured value is different from the set value, it indicates that the top drive bearing is in the open state. Correspondingly, the injection amount of lubricant can be increased on the basis of the standard injection amount or lubricant can be added to the top drive bearing according to the standard injection amount. At the same time, the injection amount of lubricant is controlled based on the difference between the measured value and the set value through comparison of the analog quantity. At this time, the amount of lubricant added depends on the positive and negative of the difference, that is, the comparison of the measured value and the set value. For example, when the temperature measurement value is greater than the set value, the injection amount of lubricant is correspondingly increased compared with the standard value. On the other hand, the amount of lubricant added depends on the absolute value of the difference, that is, the increase or decrease of the lubricant compared with the standard value is controlled by the absolute value of the difference.

[0046] Furthermore, for a single top drive bearing component, the effects of the comparison results of multiple operating parameters on the generation of maintenance instructions are independent of each other, that is, the maintenance based on a single operating parameter constitutes a maintenance loop alone, and at the same time, the maintenance loops with different operating parameters share the same execution module, which can uniformly manage the preset values of the operating parameters in each loop. By establishing an automatic lubrication pre-maintenance system for top drive bearing components based on the multi-level single-loop closed-loop negative feedback idea, it is expected to achieve the combination of the actual working conditions and ambient temperature of the top drive, meet the lubrication threshold adjustment of bearing components with different fatigue levels, adjust the lubrication threshold of the automatic lubrication system, and dynamically regulate the lubricant dosage of key components. Figure 3At this time, the maintenance system is composed of multiple independent maintenance loops. Furthermore, the baseline amount of lubricant corresponding to the above-mentioned different operating parameters is different. For example, the collection of temperature and vibration operating parameters is used as an example for explanation, wherein the standard value of lubricant injection corresponding to the temperature parameter is B1, and the standard value of lubricant injection corresponding to the vibration parameter is B2. Based on the comparison result of the temperature parameter, the final amount of lubricant added increases by A1 compared to its baseline value B1. Then, the control instruction generated based on the temperature parameter comparison result is a lubricant addition amount of B1+A1. Based on the comparison result of the vibration parameter, the final amount of lubricant added increases by A2 compared to its baseline value B2. Then, the control instruction generated based on the vibration parameter comparison result is a lubricant addition amount of B2+A2.

[0047] Continuing to explain the above maintenance system, the above execution module body is composed of multiple lubrication pipelines, one end of the multiple lubrication circuits is connected to the lubricant storage device (such as a box), and the other end is connected to different top drive bearings, and the top drive components are provided with corresponding lubrication points, refer to Figure 5-Figure 11 , which is a schematic diagram of the lubrication point locations of different drive top components. Figure 5 The lubrication points of the middle back-up tongs are set at the back-up tongs pin, guide ring and straightening ring. Figure 6 The lubrication points of the main motor are located at the upper and lower positions on the side of the main motor. Figure 7 The lubrication point of the middle upper bearing cover is set on the side of the upper bearing cover. Figure 8 The lubrication point of the middle coupling is set on the side of its motor bracket. Figure 9 The lubrication point of the middle tilt cylinder pin is set on the outside of the tilt cylinder pin. Figure 10 The lubrication point of the middle flush tube packing assembly is set on the side of the sealing box. Figure 11 The lubrication points of the middle rotating head are set at the lifting eye, rotating gear and oil nozzle position in front of the suspension body. The lubricant is transported to the lubrication point positions of different top drive bearing components through different pipelines. The control module can control the flow rate of lubricant in different pipelines based on the maintenance instructions received to achieve control of the lubricant injection amount of different top drive bearing components. In some examples, a single lubrication pipeline is equipped with an independent oil pump, and the lubricant flow in the lubrication pipeline is controlled by controlling the operation of the oil pump. In other examples, all lubrication pipelines are connected to the same oil pump. At this time, the opening and closing control of the lubrication pipeline is achieved by controlling the opening and closing of the valve body in the single lubrication pipeline, thereby achieving the flow control of the lubricant in the lubrication pipeline.

[0048] In some embodiments, the above-mentioned control module and acquisition module, as well as the control module and execution module are connected through optical fiber, cable or power line carrier, so as to realize signal transmission between the control module and the acquisition module and the execution module, that is, to realize signal transmission in the maintenance system. Based on the explosion-proof, sand-proof and anti-interference capabilities of optical fiber, cable or power line carrier, the real-time communication and signal transmission stability of the maintenance system located above the oil drilling head can be guaranteed.

[0049] On the other hand, the present application discloses a top drive automatic lubrication pre-maintenance method, referring to Figure 1 , mainly includes the following steps:

[0050] S100: collecting at least one operating parameter of a top drive bearing component to obtain a measured value of the operating parameter of the drive component;

[0051] S200: comparing the collected measured value of each operating parameter with the set value of the operating parameter, and generating a maintenance instruction based on the comparison result of each operating parameter;

[0052] S300: Adjusting the injection amount of lubricant of the top drive bearing component based on the maintenance instruction.

[0053] In some embodiments, the above-mentioned operating parameters include analog data and / or digital data. Correspondingly, the comparison between the collected measurement values and the set values of the operating parameters includes a comparison of whether the digital quantities are the same and / or a comparison of the numerical values of the analog quantities. At the same time, the comparison of each operating parameter is independent of each other, that is, the maintenance instructions generated based on each operating parameter will not affect the maintenance instructions generated by other operating parameters. At this time, the maintenance of a single operating parameter constitutes a maintenance loop separately, which can uniformly manage the preset values of the operating parameters in each loop. By establishing an automatic lubrication pre-maintenance system for top drive bearings based on the multi-level single-loop closed-loop negative feedback idea, it is expected to achieve the combination of the actual working conditions and ambient temperature of the top drive, meet the lubrication threshold adjustment of bearings with different fatigue levels, adjust the lubrication threshold of the automatic lubrication system, and dynamically regulate the lubricant usage of key components.

[0054] In some embodiments, the collection period of the above-mentioned operating parameters can be set to a fixed value based on past experience, or can be adjusted based on the operating conditions. For example, the above-mentioned operating conditions include the operating status and / or ambient temperature of the top drive equipment. In some examples, the above-mentioned maintenance system can shorten the collection period during the operation of the top drive equipment, that is, increase the collection frequency of the operating parameters, and increase the collection period during the idle period of the top drive equipment, that is, reduce the collection frequency of the operating parameters. In other examples, the above-mentioned maintenance system shortens the collection period in high temperature or low temperature environments, and increases the collection period in normal temperature environments.

[0055] In the description of the present invention, the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, a feature specified as "first" or "second" may explicitly or implicitly include at least one of such features. In the description of the present invention, "plurality" means at least two, for example, two, three, etc., unless otherwise specifically defined.

[0056] In the description of the present invention, the reference terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In the present invention, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine different embodiments or examples described in the present invention and features of different embodiments or examples without contradiction.

[0057] Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein; and these modifications or replacements 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. A top drive automatic lubrication pre-maintenance method, characterized by: The steps include: collecting at least one operating parameter of the top drive bearing component to obtain a measured value of the operating parameter of the top drive bearing component; comparing the collected measured value of each operating parameter with the set value of the operating parameter, and generating a maintenance instruction based on the comparison result of each operating parameter; The injection amount of top drive bearing lubricant is adjusted based on the maintenance instructions.

2. A top drive automatic lubrication pre-maintenance method according to claim 1, characterized in that: The operating parameters include analog data and / or digital data.

3. A top drive automatic lubrication pre-maintenance method according to claim 2, characterized in that: The comparison of the collected measurement value and the set value of the operating parameter includes comparing whether the digital quantities are the same and / or comparing the numerical values of the analog quantities.

4. The top drive automatic lubrication pre-maintenance method according to claim 1, characterized in that: The maintenance instruction includes an instruction to increase or decrease the lubricant injection amount based on a lubricant injection amount standard value.

5. The top drive automatic lubrication pre-maintenance method according to claim 1, characterized in that: The lubricant injection amount standard value is configured to change with changes in operating parameter measurement values and ambient temperature.

6. The top drive automatic lubrication and pre-maintenance method according to claim 1, characterized in that: The collection period of the operating parameters is adjusted based on operating conditions, wherein the operating conditions include at least one of an operating state of the top drive equipment, a load, a bottom hole drilling condition, and an ambient temperature.

7. A top drive automatic lubrication and pre-maintenance system, characterized by: include: a collection module configured to collect at least one operating parameter of the top drive bearing component to obtain a measured value of the operating parameter of the drive component; a control module having set values of operating parameters stored therein, the control module being configured to receive the measurement data output by the acquisition module and to issue a maintenance instruction based on a comparison result between the measurement data and the set values; An execution module is configured to adjust an injection amount of lubricant of the top drive bearing component based on the maintenance instruction.

8. The top drive automatic lubrication and pre-maintenance system according to claim 7, characterized in that: The acquisition module includes a plurality of sensor devices and / or proximity switches. The sensor devices are configured to acquire analog data, and the proximity switches are configured to acquire digital data.

9. The top drive automatic lubrication and pre-maintenance system according to claim 8, characterized in that: The comparison of the collected measurement value and the set value of the operating parameter includes comparing whether the digital quantities are the same and / or comparing the numerical values of the analog quantities.

10. The top drive automatic lubrication and pre-maintenance system according to claim 7, characterized in that: The execution module includes multiple lubrication circuits, a single lubrication circuit is connected to the top drive bearing, and the amount of lubricant injected into the top drive bearing is adjusted by adjusting the flow in the lubrication circuit.

11. The top drive automatic lubrication and pre-maintenance system according to claim 10, characterized in that: Each of the lubrication circuits is equipped with an independent oil pump.

12. The top drive automatic lubrication and pre-maintenance system according to claim 7, characterized in that: The control module is connected to the acquisition module and the execution module via optical fiber, cable or power carrier.

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