Electronic Tong Torque Control via PLC and Pressure Transducer
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Solution Overview
Problem
Existing line pull tong systems rely on manual monitoring and disengagement of torque, which can be inaccurate and inefficient in applying and recording the precise make-up torque required for tubing joints in well servicing and drilling operations.
Innovation Solution
A torque monitoring and limiting apparatus that integrates with existing line pull tong systems, using a pressure transducer and solenoid valve controlled by a Programmable Logic Controller (PLC) to automatically disengage the winch when the preselected torque is reached, while recording the applied torque for each joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual monitoring and disengagement of torque is used, then the system is simple to operate, but the accuracy and consistency of torque application deteriorates
Solution Approach 1:
The patent replaces the manual mechanical monitoring system with an automated electronic control system. A torque sensor electronically measures the torque applied to the tubing joint, and a PLC (Programmable Logic Controller) automatically processes this data and controls the winch disengagement, eliminating manual monitoring while improving measurement accuracy and consistency.
Solution Approach 2:
The system enables self-service automation where the torque monitoring and control system operates autonomously. The electronic torque sensor continuously monitors torque application, and the PLC automatically disengages the winch when the predetermined torque threshold is reached, without requiring manual intervention or judgment.
2Manufacturing precision
If automated torque control is implemented, then torque application accuracy improves, but the ease of operation deteriorates
Solution Approach 1:
The system implements closed-loop feedback control where the torque sensor continuously monitors the actual torque being applied and feeds this information back to the PLC. The PLC compares the measured torque against the predetermined target torque and automatically adjusts the winch operation accordingly, ensuring precise torque application while maintaining simple operation through automated decision-making.
Solution Approach 2:
The PLC acts as an intermediary between the torque sensor and the winch control system. It receives torque data from the sensor, processes the information according to predetermined criteria, and automatically controls the winch disengagement, thereby achieving precise torque application without requiring the operator to manually interpret torque readings or make disengagement decisions.
3Productivity
If manual torque monitoring is used, then the device complexity is low, but the productivity and efficiency deteriorates
Solution Approach 1:
The system performs preliminary action by pre-programming the target torque values and control parameters into the PLC before operation. This allows the automated system to immediately begin precise torque application without requiring manual setup or adjustment during operation, thereby increasing productivity while the complexity is confined to the initial programming stage.
Solution Approach 2:
The electronic torque monitoring system enables continuous automated monitoring and control throughout the entire torque application process. The torque sensor continuously measures torque, and the PLC continuously processes this data and controls the winch, eliminating interruptions or delays associated with manual monitoring and enhancing overall productivity.
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
This solution ensures accurate and consistent application of make-up torque, reducing human error and increasing efficiency by automating the torque control and recording process, allowing for precise monitoring and documentation of torque values for each joint.
Implementation Method 1
a pressure transducer and solenoid valve controlled by a Programmable Logic Controller (PLC) to automatically disengage the winch
Implementation Method 2
a pressure transducer and solenoid valve controlled by a Programmable Logic Controller (PLC)
Data Source
AI summary
Disclosed is an apparatus for attachment to a line pull tong tubing joint make-up system on an oil rig, having tongs attached to two sections of pipe with one tong connected to a line pull apparatus, having a fluid-operated clutch connected to pressurized fluid source and the other tong connected to a piston-cylinder assembly. The apparatus has: a pressure transducer connected to the piston-cylinder assembly to sense the internal pressure in the piston-cylinder assembly and generate an output signal; a valve operable in response to a valve control signal, the valve located in the connection between the clutch and the pressurized fluid source movable between a first position, permitting fluid flow from the fluid source to the clutch and a second position interrupting flow between the fluid source and the clutch; and a controller operably connected to the valve and transducer, programmed to provide a valve control signal to move the valve between the first and second positions in response to the output signal from the pressure transducer, whereby the line pull apparatus is engaged and disengaged. The controller has a display, memory and clock.