Hardbanding Removal Apparatus with Dynamic Grinding Depth Control
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Solution Overview
Problem
Existing hardbanding removal systems face challenges with uneven erosion, improper application, tubular eccentricity, and 'pipe walk' during grinding, leading to incomplete or damaging removal of hardbanding, requiring manual correction and increasing time and cost.
Innovation Solution
A hardbanding removal apparatus with a grinding wheel assembly, idler wheel system, and shock absorber, which adjusts depth and compensates for tubular eccentricity and movement, allowing precise and uniform removal by tracing contours and preventing lateral movement during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed-depth grinding system is used to remove hardbanding, then the grinding depth is consistent, but uneven hardbanding deposits result in under-grinding of high spots or over-grinding of low spots
Solution Approach 1:
The grinding wheel assembly is made dynamically adjustable through the linkage system and shock absorber, allowing the grinding depth to be varied in real-time based on the actual hardbanding thickness and tubular surface conditions, rather than using a fixed grinding depth setting
Solution Approach 2:
The idler wheel assembly provides continuous feedback about the tubular surface position and hardbanding thickness, which is transmitted through the linkage system to automatically adjust the grinding wheel depth, ensuring consistent hardbanding removal without manual intervention
2Adaptability or versatility
If the drill pipe is rotated during grinding to address eccentricity, then all surfaces can be accessed, but the distance between the pipe surface and grinding wheel changes, causing uneven removal
Solution Approach 1:
The support arm and linkage system allow the grinding wheel assembly to dynamically adjust its position and orientation during pipe rotation, maintaining optimal contact pressure and grinding depth despite changes in the distance between the pipe surface and grinding wheel
Solution Approach 2:
The shock absorber acts as a counterbalancing mechanism that compensates for the varying gravitational and centrifugal forces experienced during pipe rotation, maintaining consistent grinding pressure and preventing uneven removal caused by eccentricity
3Manufacturing precision
If manual correction is performed to fix under or over grinding, then accuracy can be improved, but time and cost increase
Solution Approach 1:
The grinding system is designed to be self-correcting through the automatic depth adjustment mechanism, where the idler wheel and linkage system continuously monitor and adjust the grinding depth to prevent under or over-grinding from occurring in the first place, eliminating the need for manual correction
Solution Approach 2:
The continuous feedback loop between the idler wheel, linkage system, and grinding wheel assembly ensures that any deviations from the desired grinding depth are automatically detected and corrected in real-time, preventing the need for post-processing manual corrections
4Productivity
If grinding pressure is applied to remove hardbanding, then removal efficiency increases, but pipe walk occurs reducing accuracy
Solution Approach 1:
The shock absorber provides a counterbalancing force that opposes the grinding pressure, preventing pipe walk by maintaining a stable equilibrium between the downward grinding force and the upward compensating force from the shock absorber
Solution Approach 2:
The linkage system and shock absorber create a dynamically balanced system that allows high grinding pressure to be applied for efficient hardbanding removal while automatically compensating for any pipe movement or walk through real-time position adjustments
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
Enables accurate and efficient removal of hardbanding without under or over grinding, reducing rework and improving consistency, while maintaining precision and accuracy even with eccentric or curved tubulars.
Implementation Method 1
a shock absorber slidably engaging a second end of the piston rod and coupled to the support arm
Implementation Method 2
The friction between the idler wheel and tubular surface prevents lateral movement
Data Source
AI summary
The disclosure relates to a hardbanding removal apparatus and method for use with oilfield tubulars and downhole tools. The apparatus includes a tiltable frame with support arm, a grinding wheel coupled to the support arm, and an idler wheel assembly to supply mechanical feedback to the grinding wheel through the support arm. The mechanical feedback allows the grinding wheel to remove hardbanding accurately and uniformly on tubulars that are eccentric, curved, or have eccentric hardbanding. The tiltable frame enables grinding of tapered sections of the tubular without reorienting the tubular. The method includes removing hardbanding using the apparatus.