Deadline Anchor Load Sensors for Drilling Hook Load Measurement
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Solution Overview
Problem
Existing systems for measuring hook load and weight on bit (WOB) in drilling operations are prone to errors due to frequent calibration needs, hydraulic system issues, and lack of verification markers, leading to inaccurate readings.
Innovation Solution
A deadline anchor system equipped with first and second sensors coupled to the deadline anchor at different locations, which detect forces proportional to the tension in the drilling line, allowing for accurate measurement and verification of hook load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hydraulic load cell system is used to measure hook load, then the system can provide continuous tension measurement, but the system requires frequent calibration and is prone to errors from hydraulic issues
Solution Approach 1:
The patent divides the measurement system into multiple independent sensor units distributed along the deadline anchor. Instead of relying on a single hydraulic load cell, multiple independent sensors (such as strain gauges or load cells) are installed at different locations, each providing independent measurement capability. This segmentation eliminates the single point of failure inherent in hydraulic systems and removes the need for frequent calibration of a centralized hydraulic system.
Solution Approach 2:
The patent replaces the hydraulic measurement system with a direct mechanical sensing system. Instead of using hydraulic fluid pressure to indicate load, the system uses solid-state sensors that directly measure force or strain. This substitution eliminates hydraulic fluid leaks, air bubbles, and the need for hydraulic calibration, while providing more reliable and maintenance-free operation.
2Reliability
If a single sensor system is used, then the device complexity is low, but there is no verification of measurement accuracy
Solution Approach 1:
The patent combines multiple sensors with the deadline anchor structure itself, integrating the sensing function into the existing mechanical component. The sensors are mounted directly on the anchor body or on the drilling line as it passes through the anchor, merging the measurement function with the structural element. This integration adds verification capability without requiring a completely separate complex measurement system.
Solution Approach 2:
The deadline anchor structure serves multiple functions: it acts as both the mechanical component that guides the drilling line and as the mounting structure for the sensors. The same structural element that provides mechanical support also provides the platform for measurement, eliminating the need for separate verification infrastructure and reducing overall system complexity.
3Ease of operation
If hydraulic fittings and hoses are used to connect the load cell to the gauge, then the system can transmit pressure signals, but the system is prone to leaks and requires purging
Solution Approach 1:
The patent replaces the hydraulic signal transmission system with an electrical or digital signaling system. Instead of using hydraulic fluid under pressure to transmit measurement data, the system uses electrical wires or digital communication protocols to convey sensor data to the display device. This substitution eliminates hydraulic fittings, hoses, and the associated maintenance requirements for purging and leak prevention.
Solution Approach 2:
The patent introduces an electrical or digital intermediary system between the sensors and the display device. Instead of direct hydraulic coupling, electronic signals serve as the intermediary medium to transmit measurement information. This intermediary approach provides more reliable signal transmission without the maintenance burden of hydraulic connections.
Data Source
AI summary
A deadline anchor can include a base structure coupled to a rig floor, a wheel rotatably coupled to the base structure, a first sensor coupled to the deadline anchor at a first location, where the first sensor detects a first force, and a second sensor coupled to the deadline anchor at a second location, where the second sensor detects a second force. A method can include coupling a first sensor to a deadline anchor at a first location, coupling a second sensor to the deadline anchor at a second location, applying a tension force to the deadline anchor, where the tension force is proportional to an actual hook load, detecting a first force, via the first sensor, in response to applying the tension force, and detecting a second force, via the second sensor, in response to applying the tension force.