Eddy Current Probe for Power Tong Positioning
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Solution Overview
Problem
Existing power tong positioning systems face accuracy issues due to anomalies in the pipe surface, such as corrosion and hard banding, which can affect the detection of the connection seam, leading to suboptimal positioning of the power tong and backup unit during drilling operations.
Innovation Solution
A magnetic eddy current detection system with a differential winding probe is used to generate a pipe profile, distinguishing the connection seam from non-target attributes by filtering out surface features like corrosion and hard banding, and optionally employing RFID tags or markers for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a magnetic eddy current detection system is used to sense the location of the connection seam, then the positioning of the power tong unit can be achieved remotely, but the accuracy of detection is affected by surface anomalies such as corrosion, hard banding, and other pipe surface features
Solution Approach 1:
The detection system divides the pipe surface into multiple measurement zones by using an array of eddy current sensors that scan along the pipe length. The system segments the detection process into discrete measurement points, allowing it to identify and filter out localized surface anomalies (such as corrosion or hard banding) from the actual connection seam signal through pattern recognition and comparison across adjacent sensor zones.
Solution Approach 2:
The patent introduces signal processing algorithms and reference profile databases as intermediary layers between the raw eddy current signals and the final positioning output. These intermediaries compare detected signals against known connection seam patterns, filtering out false signals from surface anomalies while enhancing the detection of genuine connection features, thereby improving measurement accuracy without sacrificing remote operation capability.
2Adaptability or versatility
If the power tong unit is positioned by human operators, then flexibility and adaptability are maintained, but safety risks increase and integration with automated drilling systems is limited
Solution Approach 1:
The system enables self-positioning of the power tong unit by automatically detecting the connection seam location through eddy current sensing and calculating the optimal positioning point. The system serves itself by autonomously determining where the power tong should be placed relative to the connection, eliminating the need for human operators to physically position the equipment while maintaining the adaptability to handle various connection types through programmable detection parameters.
3Device complexity
If conventional eddy current detection is used without differential winding, then the system complexity is lower, but the accuracy in distinguishing connection seam from surface anomalies is reduced
Solution Approach 1:
The differential winding configuration applies local quality by creating two distinct sensing zones within the probe: one oriented to detect connection seam features and another to detect surface anomalies. Each winding section has optimized sensitivity characteristics for specific types of features, allowing the system to distinguish between connection seams and surface defects like corrosion or hard banding by comparing the differential signals from each zone.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances the accuracy of power tong positioning by differentiating target and non-target attributes, ensuring proper alignment and operation of the power tong and backup unit, even in the presence of surface anomalies, thereby improving drilling efficiency and safety.
Implementation Method 1
A magnetic eddy current detection system with a differential winding probe is used to generate a pipe profile
Implementation Method 2
A magnetic eddy current generating system, with an eddy current detector or probe, which preferably utilizes a differential winding
Data Source
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AI summary
A power tong positioner has one or more eddy current probes mounted in association with a power tong/backup unit. An electric current runs through the probe, and with the probe positioned close to a tubular connection, movement of the probe along the length of the connection, with the electric field encompassing surface features on the tubular, will cause a change in the electrical impedance (conductivity) which enable identification of the connection seam or other defined attributes (the "target" attributes). The power tong/backup unit can be positioned accordingly. A portfolio of profiles of non-connection seam surface features of different tubular connections maybe generated, stored in a database, and accessed by the system, which enables identifying the connection seam/face with greater accuracy. Other attributes of the invention include storing profile information on RFID tags, and storing and accessing tubular information from a cloud server or other form of remote database.