Intelligent Drill Pipe Torque Control System
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Solution Overview
Problem
Downhole tools in oil and gas well drilling operations face damage due to wear and over-torquing during make-up and break-down processes, leading to inefficiencies and potential failures.
Innovation Solution
A torque control system utilizing processors, fluid pressure sensors, and torque sensors to automatically control torque applied to downhole assets by adjusting fluid pressure, monitoring health in real-time, and optimizing torque profiles based on asset dimensions and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual torque application is used during make-up of tool strings, then operational simplicity is maintained, but downhole tools may be over-torqued causing damage to threaded connections
Solution Approach 1:
The system incorporates torque sensors that provide real-time feedback on the torque being applied to downhole tools. This feedback loop allows the control system to monitor and adjust the torque application, preventing over-torquing while maintaining automated operation. The feedback mechanism directly addresses the reliability concern by ensuring torque remains within safe limits.
Solution Approach 2:
The patent replaces manual mechanical torque application with an automated hydraulic torque application system controlled by a computer. This substitution eliminates human error in torque estimation and application, providing consistent and controlled torque levels that prevent connection damage while maintaining ease of operation through automation.
2Reliability
If higher torque is applied to ensure secure connections, then connection reliability improves, but wear and damage to downhole tools increases
Solution Approach 1:
The system dynamically adjusts the torque parameter based on real-time measurements from torque sensors and feedback from the control system. By precisely controlling torque to match the specific requirements of each connection rather than applying excessive torque, the system ensures secure connections while minimizing wear and damage to tool surfaces.
Solution Approach 2:
Real-time torque measurement and feedback allow the system to apply only the necessary torque for secure connections. The feedback mechanism prevents excessive torque application that would cause wear and pitting, while still achieving the required connection security through precise torque control.
3Manufacturing precision
If automated torque control systems are implemented, then torque precision and tool protection improve, but system complexity increases
Solution Approach 1:
The automated system uses torque sensors and computer control to provide real-time feedback and adjustment of torque application. This feedback mechanism achieves precise torque control while managing system complexity through automated monitoring and adjustment, reducing the need for manual intervention and calibration.
Solution Approach 2:
The control system automatically monitors torque application, compares it to target values, and adjusts hydraulic pressure accordingly without external intervention. This self-service capability maintains torque precision while reducing operational complexity by eliminating the need for continuous manual monitoring and adjustment.
Data Source
AI summary
Tools and method for automatically controlling torque when making-up and/or breaking-down threaded connections between downhole assets such as drill pipe, drill collars, and BAH components. An iron roughneck may be controlled by, for instance, automatically monitoring and adjusting the fluid pressure of cylinders that ultimately provide the torque to the downhole assets. The torque may further be automatically controlled by automatically identifying the downhole assets and selecting a corresponding torque profile or target torque. Clamping force may also be controlled, and is optionally proportional to the target torque.