Compensated Top Drive Links for Thread-Safe Tubular Makeup
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Solution Overview
Problem
In oil and gas well construction, existing methods for making up tubular connections often damage threads, leading to improper connections and leaks, as they fail to control the axial movement and torque applied during the connection process.
Innovation Solution
A top drive unit with a drive stem, carrier, and compensation cylinders that axially move and rotate the tubular to connect it to a tubular string, reducing the load on the threads by compensating for axial movement during makeup or breakout, using a makeup tool or elevator assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to make up tubular connections, then the connection process can be completed, but thread damage occurs leading to improper connections and leaks
Solution Approach 1:
The system performs preliminary actions by pre-positioning the tubular and controlling axial movement before the actual threading operation begins. The controlled axial movement mechanism is activated in advance to maintain proper thread engagement throughout the connection process, preventing thread damage before it can occur.
Solution Approach 2:
The invention changes the parameter of axial movement control during the connection process. By dynamically adjusting and controlling the axial movement rate to match the thread engagement rate, the system maintains optimal parameters throughout the makeup process, preventing thread damage while ensuring reliable connections.
2Productivity
If torque is applied to overcome the weight of the second tubular during connection, then the tubular can be connected to the string, but thread damage occurs
Solution Approach 1:
The system applies preliminary support forces to counterbalance the tubular weight before full torque application. By pre-positioning and supporting the tubular weight, the system reduces the sudden torque shock that would otherwise damage threads during the connection process.
Solution Approach 2:
The invention changes the torque application parameter by controlling it to increase gradually as thread engagement progresses. The system adjusts torque parameters dynamically, applying higher forces only after initial thread engagement is established, preventing thread damage while maintaining connection productivity.
3Ease of operation
If the drilling rig operator manually controls the lowering rate of the second tubular, then the connection can be made, but thread damage may occur due to improper rate control
Solution Approach 1:
The system incorporates feedback mechanisms that monitor thread engagement progress and automatically adjust the axial lowering rate accordingly. This feedback loop ensures the lowering rate precisely matches the thread engagement rate, eliminating the imprecision of manual control while maintaining ease of operation through automated control systems.
Solution Approach 2:
The connection system performs self-service by automatically controlling its own axial movement rate based on thread engagement feedback. The system serves itself by detecting thread engagement progress and autonomously adjusting the lowering rate, eliminating the need for manual operator intervention and ensuring precise thread engagement.
Data Source
AI summary
A top drive unit including a top drive housing, a drive stem disposed in the top drive housing, a carrier configured to axially move the drive stem relative to the top drive housing, and a drive mechanism for rotating the drive stem.