Drawworks Interlock System for Drill Rig Tong Position Sensing
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Solution Overview
Problem
Drill rig operations pose a hazardous environment due to the repetitive and forceful nature of adding and removing drill string segments, risking equipment damage and personnel injury, particularly when the drawworks is activated with a tong connected to the drill string.
Innovation Solution
An interlock system between the drawworks and tongs that senses the position of the tongs and generates an interlock signal to disable the drawworks operation if the tong is not in its storage area, preventing accidental activation and ensuring safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the drawworks is activated while a tong is connected to the drill string, then the drilling operation can proceed, but equipment damage and personnel injury may occur
Solution Approach 1:
A position sensing system acts as an intermediary between the tong and the drawworks control system. The sensor detects tong position and transmits this information to the control system, which then决定是否 to enable drawworks operation. This intermediary mechanism prevents direct harmful interaction while maintaining operational capability.
Solution Approach 2:
The system implements feedback by continuously monitoring tong position through sensors and using this information to control drawworks operation. The control system receives real-time position data and adjusts the enable/disable state accordingly, creating a closed-loop safety mechanism that prevents equipment damage while allowing continuous drilling when safe.
2Reliability
If a position sensing system and interlock control are added to prevent drawworks activation with tong connected, then safety is improved, but device complexity increases
Solution Approach 1:
The safety function is extracted as a separate, independent control system rather than being integrated into the existing drawworks control. The position sensing and interlock logic are implemented as distinct components that monitor and control the enable/disable state, simplifying the overall system architecture while improving reliability through functional separation.
Data Source
AI summary
An interlock between a drawworks and a tong includes a sensor for sensing a position of the tong. An interlock signal is generated by the sensor for sensing the position of the tong that is reflective of the position of the tong. 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 tong to add or remove segments to the drill string. The method further includes sensing a position of the tong, generating an interlock signal that reflects the position of the tong, and disabling the drawworks if the interlock signal meets a predetermined criterion.