Automated Roughneck Torque Control for Thread Protection

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Solution Overview

Problem

The existing methods for making up and breaking out threadedly connected tubular members in oil and gas well drilling operations are inefficient and prone to costly disconnections, with manual tools requiring high torque that can damage threads and lead to unintended separation downhole.

Innovation Solution

An automated roughneck system comprising a backup tong and a makeup tong with gripper and spinner assemblies, driven by motors, which allows for controlled and precise engagement and disengagement of tubular members, reducing the risk of thread damage and ensuring secure connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical tongs or iron roughnecks are used to apply high-torque to ensure complete engagement of threaded connections, then connection reliability is improved, but thread damage and material yielding may occur

Engineering Contradiction:

Improveconnection reliabilityVSAvoidthread damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system dynamically adjusts torque parameters during the making-up process, transitioning from high torque for initial engagement to controlled lower torque for final tightening, preventing thread damage while ensuring reliable connections

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Torque sensors and control systems monitor the making-up process in real-time, providing feedback to adjust applied torque and prevent excessive force that could cause thread yielding or damage

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If automated systems with multiple components are used to precisely control torque and movement, then connection precision is improved, but device complexity increases

Engineering Contradiction:

Improveconnection precisionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The automated roughneck is divided into modular functional components (gripper assembly, spinner assembly, drive assembly, control system) that can be independently manufactured, maintained, and replaced, managing complexity through modularity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system integrates multiple functions (gripping, rotating, torque application, sensing, and control) into a single automated platform that can handle various tubular sizes and connection types, reducing overall system complexity through consolidation

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9657539B2Automated roughneck

Publication Date: 2017.05.23 NABORS SERVICES

AI summary

An automated roughneck may include a backup tong and a makeup tong. The makeup tong and backup tong may be selectively movable relative to one another. The makeup tong and backup tong may include spinner and gripper assemblies respectively adapted to make up and break out threaded connections. The automated roughneck may be configurable to be removable from the drill string in a lateral direction.