Compact Sensor Sub Layout for Top-Drive Drilling Monitoring
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Solution Overview
Problem
Existing sensor subs for oil and gas well drilling and completion operations face challenges in fitting within the limited space of top-drive systems, requiring costly extensions of torque arrestors and high power consumption, which leads to frequent stoppages and compatibility issues with all top-drive models.
Innovation Solution
A compact sensor sub system that measures drilling and completion parameters using sensors for torque, pressure, acceleration, and temperature, with low-power integrated circuits and RF transmitters, allowing data transmission to a remote receiver hub for processing, and a battery holder design for safe battery replacement in hazardous environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor sub is installed in the top drive system, then drilling and completion parameters can be measured, but the limited space requires extending the torque arrestor length which increases cost and installation difficulty
Solution Approach 1:
The sensor sub is nested within the existing torque arrestor structure by positioning it in the space between the quill and the pipe handler, eliminating the need for external extensions. The sensor sub integrates into the confined internal space of the top drive system.
Solution Approach 2:
Instead of extending the torque arrestor in the axial direction (length), the solution repositions the sensor sub within the radial and vertical dimensions of the existing structure, utilizing the three-dimensional space between existing components without increasing overall length.
2Measurement precision
If traditional sensor subs are used, then drilling parameters can be monitored, but high power consumption leads to frequent battery changes and stoppages
Solution Approach 1:
The low-power integrated circuits transmit data periodically rather than continuously, reducing power consumption while maintaining effective monitoring. The RF transmitter sends measurements at intervals, allowing the battery to last through multiple drilling operations without frequent changes.
3Adaptability or versatility
If the torque arrestor is extended to accommodate the sensor sub, then the sensor sub can be installed, but installation becomes more difficult and cost increases
Solution Approach 1:
The sensor sub is designed with a universal mounting approach that fits within the standard top drive configuration without requiring model-specific modifications. The same installation procedure works across different top drive models as long as the quill-to-pipe-handler space is available.
4Adaptability or versatility
If a compact sensor sub design is used, then compatibility with existing top-drive systems is improved, but space constraints require more careful positioning
Solution Approach 1:
The sensor sub positions different sensing elements at specific locations within the compact structure to optimize measurement of different parameters. Torque sensors are positioned to measure rotational force, acceleration sensors are oriented to detect vertical and lateral movements, ensuring each sensor operates in its optimal measurement zone.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient measurement and real-time monitoring of drilling and completion operations without extending torque arrestors, reducing power consumption and improving compatibility with existing top-drive systems, while allowing extended battery life and safe battery replacement.
Implementation Method 1
The new method is to determine the number of rotations using inertial measurements
Implementation Method 2
Primary forces to be monitored include torque applied by the top drive
Implementation Method 3
downward weight on the drilling bit
Implementation Method 4
rotational speed
Implementation Method 5
fluid pressure
Implementation Method 6
Secondary forces are generated by the interaction of the pipe string and drilling bit with the surrounding formations that can be measured using acceleration sensors
Data Source
AI summary
A system for measuring drilling and completion operational parameters in a tubular handling system is provided. The system includes a sensor sub connected below a top drive of the tubular handling system; one or more sensors within the sensor sub, for measuring, in the form of electrical signals, operational parameters; one or more low-power integrated circuits within the sensor sub, for receiving electrical signals from the sensors and digitizing the signals; two or more radio frequency (RF) transmitters located in the sensor sub, for transmitting the digitized signals; one or more commercially available lithium batteries within the sensor sub and remote receiver hub located remote from the tubular handling system and including a remote antenna for receiving the digitized signals from the two or more RF transmitters; one or more processing units for processing received digitized signals into engineering units for each of the operational parameters; and an input/output data connection for communicating operational parameters to an operator.