Drawworks Interlock for Drill Rig Segment Hoist Safety
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Solution Overview
Problem
Drill rig operations pose a hazardous environment due to the repetitive and coordinated efforts required for adding and removing segments from the drill string, which can lead to equipment damage and personnel injury, especially when the segment hoist is connected to the drill string during lowering operations.
Innovation Solution
An interlock system is implemented between the drawworks and the segment hoist, utilizing sensors to monitor the position of the segment hoist and generate an interlock signal that disables the drawworks operation when predetermined criteria are met, preventing accidental engagement and ensuring safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the drawworks operates to lower the drill string while the segment hoist is connected to a segment, then the drill string can be lowered efficiently, but the segment hoist may be seriously damaged and operators may be injured
Solution Approach 1:
The system uses position sensors to continuously monitor the segment hoist position and provides feedback signals to the drawworks control system. When the sensor detects that the segment hoist is in a vulnerable position (extended or partially retracted), it generates an interlock signal that prevents drawworks operation, thereby avoiding equipment damage and injury while maintaining efficient operation when safe
Solution Approach 2:
The patent introduces an intermediary interlock control system that mediates between the drawworks and segment hoist operations. This intermediary system processes position information from sensors and controls the drawworks enable/disable state, acting as a safety buffer that prevents direct harmful interaction between the two systems
2Adaptability or versatility
If manual coordination is used between multiple operators for segment operations, then flexibility in handling various scenarios is maintained, but the risk of human error and accidents increases
Solution Approach 1:
The system enables self-service safety monitoring where position sensors automatically detect the segment hoist position and the interlock control system automatically enables or disables drawworks operation based on detected conditions. This eliminates the need for manual coordination between operators, reducing human error while maintaining operational flexibility through automated decision-making
3Ease of operation
If the segment hoist is positioned for segment handling, then segment connection operations can be performed, but the drawworks must be prevented from operating to avoid damage
Solution Approach 1:
The patent replaces complex mechanical interlocking mechanisms with an electrical/electronic sensing and control system. Position sensors detect the segment hoist position and send electrical signals to the interlock control system, which then controls drawworks operation through electrical signals. This substitution reduces mechanical complexity while improving reliability and ease of operation
Data Source
AI summary
An interlock between a drawworks and a segment hoist includes a sensor for sensing a position of the segment hoist. An interlock signal is generated by the sensor for sensing the position of the segment hoist and is reflective of the position of the segment hoist. A lock operably connected to the drawworks receives the interlock signal and disables operation of the drawworks if the interlock signal meets a predetermined criterion. A method for operating a drill rig includes operating a drawworks to raise and lower a drill string and operating a segment hoist. The method further includes sensing a position of the segment hoist, generating an interlock signal that reflects the position of the segment hoist, and disabling the drawworks if the interlock signal meets a predetermined criterion.