Drill Rig Interlock System for Safe Relocation
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Solution Overview
Problem
Drill rigs face safety hazards due to the risk of personnel injury and equipment damage during relocation and operation, particularly due to the large size and weight of components, which can lead to catastrophic failures if not properly assembled and levelled.
Innovation Solution
Incorporating an interlock system that uses sensors to monitor parameters such as the horizontal angle of the drill rig, locked condition of the derrick, fluid pressure, and operating limits, generating an interlock signal to disable the travelling block controller or drawworks if predetermined criteria are met, ensuring safe and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the drill rig is made mobile for convenient relocation, then portability is improved, but safety risks increase due to additional dangers during relocation and assembly
Solution Approach 1:
The system performs preliminary checks of critical parameters (derrick verticality, platform levelness, component assembly status) before allowing drill rig operation. Sensors detect these parameters in advance and the control system prevents operation until all safety criteria are met, thereby eliminating safety risks associated with mobile relocation and assembly
Solution Approach 2:
The system continuously monitors critical parameters through sensors and provides feedback to the control system. The control system compares sensor readings against safety thresholds and automatically disables operation when parameters fall outside acceptable ranges, creating a closed-loop safety mechanism that addresses the increased risks of mobile operation
2Reliability
If additional procedures are implemented to address safety dangers during relocation, then safety is improved, but operational complexity increases
Solution Approach 1:
The system performs self-verification of safety parameters through automated sensors and control logic. Instead of requiring manual checking and documentation of multiple safety procedures, the system autonomously monitors derrick verticality, platform levelness, and component assembly status, and automatically determines whether safe operation is permitted, thereby improving safety while reducing procedural complexity
3Reliability
If the derrick and large components are properly re-assembled after relocation, then operational safety is improved, but the assembly process becomes more time-consuming
Solution Approach 1:
The system incorporates sensors that verify derrick assembly completeness and verticality alignment before permitting operation. This preliminary verification ensures proper assembly is achieved while providing clear feedback on assembly status, allowing operators to efficiently complete assembly without unnecessary delays while maintaining safety standards
Data Source
AI summary
A drill rig includes a drawworks having a drum operably connected to a drive system and a brake. A drill string extends from the drum of the drawworks, along a derrick, to a block and tackle arrangement holding a travelling block so that operation of the drawworks causes the drum to release or retract the drill string. A travelling block controller controls the operation of the drawworks. An interlock sensor senses a sensed parameter, and the sensed parameter is at least one of a drill rig parameter, a drawworks parameter, or a travelling block controller parameter. An interlock signal generated by the interlock sensor is reflective of the sensed parameter. An interlock operably connected to the travelling block controller receives the interlock signal and disables operation of at least one of the travelling block controller or the drawworks if the interlock signal meets a predetermined criteria.