Dynamic Hookload Limit Control for Well Service Rig Safety
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Solution Overview
Problem
Well service rigs face challenges in managing fluctuating hookloads during tubing removal and insertion operations, which can lead to rig damage and worker injury due to inadequate load control and changing weight limits.
Innovation Solution
A method for controlling hookloads on well service rigs using a computer system that calculates and adjusts hookload limits based on real-time data, comparing accepted load values to predetermined limits, and determining average hookloads and rig weights to prevent overpull and ensure safe operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single fixed hookload limit is used during tubing operations, then the rig is protected during certain portions of the run, but its effectiveness is reduced as the ratio of hookload limit to total hookload changes during POH or RIH activities
Solution Approach 1:
The patent implements dynamic hookload limits that automatically adjust based on real-time operational conditions. The system calculates total hookload during POH/RIH activities and dynamically modifies the applicable limit threshold, transitioning from a fixed static limit to a dynamic adaptive limit that maintains appropriate protection levels throughout the entire operation cycle.
Solution Approach 2:
The system changes the parameter of the hookload limit from a constant value to a variable value that depends on operational phase. During RIH, the limit adjusts as tubing is added to the string; during POH, the limit adjusts as tubing is removed. This parameter transformation allows the limit to remain effective across varying load conditions.
2Reliability
If real-time hookload monitoring and automatic limit adjustment is implemented, then rig protection and worker safety are improved, but system complexity increases
Solution Approach 1:
The system is designed to automatically monitor hookload, calculate total load, determine appropriate limits, and enforce restrictions without requiring continuous operator intervention. The computer system performs self-service functions by autonomously processing sensor data, applying calculation algorithms, and controlling rig operations based on predefined safety parameters.
Solution Approach 2:
The patent implements continuous feedback loops where sensor data on hookload is constantly monitored, compared against dynamic limits, and used to automatically adjust system behavior. The feedback mechanism provides real-time information flow from the physical system (hookload) to the control system, enabling automatic safety responses.
3Device complexity
If manual monitoring and operator intervention is used for hookload control, then system simplicity is maintained, but response time is insufficient to prevent rig damage or injury
Solution Approach 1:
The patent replaces manual mechanical monitoring and operator-based decision-making with an automated computer-controlled system. Electronic sensors, processors, and control algorithms substitute for human operators, enabling instantaneous detection and response to overload conditions without the delays inherent in manual observation and reaction.
Data Source
AI summary
A method and system for automatically setting adjusting and monitoring load-based limits is capable of monitoring the hookload, rig weight and combined measured weight and compare those parameters to limits. If any of the hookload, rig weight or measured weight should increase to a level beyond its limit, the system is able to adjust the operation of the well service rig to limit damage to the equipment and danger to the operators and service personnel. The system is also capable of adjusting each of the limits as the weight of the rig and actual hookload change over time while conducting an activity to maintain the respective limits in the most beneficial range.