Electronic Threading Control for Tubular Connections
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Solution Overview
Problem
Drilling operators face challenges in accurately controlling the rate of assembly of tubular connections during make-up and break-out, leading to potential stalling or damage due to inadequate torque and speed management, which increases intervention and reduces efficiency.
Innovation Solution
A system with a drive assembly controller that manages vertical and rotational movements of tubulars, transitioning through modes like stabbing, threading, torquing, and tripping, using user-defined values and a PID controller to maintain optimal axial force and torque, reducing human intervention and errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual control of tubular assembly rate is used, then operator flexibility is maintained, but assembly precision deteriorates due to inability to maintain optimal torque and speed
Solution Approach 1:
The patent replaces manual mechanical control with an electronic control system that uses sensors to detect torque and speed, and a controller to automatically adjust drive parameters. This substitution enables precise maintenance of assembly rates within optimal parameters while reducing operator intervention.
Solution Approach 2:
The patent implements feedback control by using sensors to continuously monitor torque and speed during tubular assembly, comparing actual values against target parameters, and automatically adjusting the drive assembly to maintain optimal assembly rates throughout the threading process.
2Productivity
If automated threading control is implemented, then assembly rate control improves, but device complexity increases
Solution Approach 1:
The patent designs a multi-functional control system that handles multiple aspects of tubular assembly including torque monitoring, speed control, mode transitions (stabbing, threading, torquing, tripping), and safety functions within a single integrated system, reducing overall complexity compared to separate control mechanisms.
Solution Approach 2:
The control system automatically monitors and adjusts assembly parameters without continuous operator intervention. The system self-regulates torque and speed within optimal ranges, transitions between operational modes autonomously, and maintains assembly rates within specified parameters through automated feedback control.
3Productivity
If human intervention is reduced, then operational efficiency improves, but system reliability may worsen due to automation errors
Solution Approach 1:
The patent uses sensors to continuously monitor torque and speed, providing real-time feedback to the controller. This feedback mechanism enables the system to detect deviations from optimal parameters and automatically correct them, maintaining high reliability through continuous closed-loop control rather than relying solely on pre-programmed parameters.
Solution Approach 2:
The patent replaces manual mechanical control with an electronic control system that uses sensors to detect torque and speed, and a controller to automatically adjust drive parameters. This substitution enables precise maintenance of assembly rates within optimal parameters while reducing operator intervention.
Data Source
AI summary
A system to control a threading operation includes a first tubular and a second tubular, wherein the first tubular and the second tubular include corresponding thread profiles. The system further includes a drive assembly configured to rotate the second tubular with respect to the first tubular, wherein vertical and rotation movements of the drive assembly are controllable through a drive assembly controller, and wherein the drive assembly controller is configured to operate in a threading mode when the second tubular is threaded with the first tubular.