Gear Assembly Torque Control for Casing Running Tools
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Solution Overview
Problem
Current top drive systems face challenges during makeup and break out operations in wellbores, including connection failures and misalignment, which can lead to over-torqueing and damage due to the inability to adjust torque and speed effectively.
Innovation Solution
A top drive assembly with a gear assembly that allows for the transmission of torque and change in rotational speed and direction between the top drive and the casing running tool, utilizing a computer-implemented system to control the gear assembly and sensors for real-time alignment and torque management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gear assembly is added to change torque and rotational speed, then connection reliability is improved, but device complexity increases
Solution Approach 1:
A gear assembly is introduced as an intermediary mechanism between the top drive and casing running tool. The gear assembly includes a first gear set for torque transmission and a second gear set for rotational speed control, allowing independent adjustment of torque and speed parameters to prevent over-torqueing and misalignment during makeup and break out operations.
2Manufacturing precision
If automatic control system with sensors is implemented for real-time alignment and torque management, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
A computer-implemented control system with sensors is integrated to provide real-time feedback on the alignment and torque parameters. The system monitors the angular position of the casing running tool and automatically adjusts the gear assembly to maintain precise alignment with the wellbore and control torque within safe limits, eliminating the need for manual operation and improving consistency.
3Productivity
If gear assembly with multiple gear shafts is used to adjust rotational speed, then productivity is improved, but device complexity increases
Solution Approach 1:
The gear assembly is designed with multiple gear shafts (first gear shaft, second gear shaft, third gear shaft) that can be dynamically engaged or disengaged based on operational requirements. This allows the system to switch between different rotational speed ratios during makeup and break out operations, optimizing productivity while maintaining the ability to control torque and speed independently.
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 prevents over-torqueing and misalignment by automatically adjusting torque and speed, reducing the risk of connection damage and ensuring precise alignment with the wellbore, thereby enhancing the reliability and efficiency of tubular operations.
Implementation Method 1
The gear assembly engages the top drive and the casing running tool to transmit torque from the top drive to the casing running tool. The gear assembly reverses a direction of torque between the top drive and the casing running tool or changes a rotational speed between the top drive and the casing running tool.
Implementation Method 2
the top drive and the casing running tool each include an external helix, and the gear assembly includes one or more gear shafts configured to engage the external helixes and transmit torque from the top drive to the casing running tool
Implementation Method 3
the sensor system includes a micro-electromechanical system (MEMS) gyroscope. The angle of the casing running tool includes an angle of a central longitudinal axis of the casing running tool
Implementation Method 4
a system including one or more computers in one or more locations. The system transmits instructions to a controller coupled to an actuator configured to move, in response to instructions from the controller, at least one of i) the gear assembly to change speed or direction of rotation of the casing running tool
Data Source
AI summary
A top drive assembly includes a top drive, a casing running tool, and a gear assembly. The top drive is coupled to a rig. The casing running tool is fluidly coupled to and driven by the top drive. The gear assembly engages the top drive and the casing running tool to transmit torque from the top drive to the casing running tool. The gear assembly reverses a direction of torque between the top drive and the casing running tool or changes a rotational speed between the top drive and the casing running tool.