Hydrocarbon Tool Control Panels With Flexible I/O and Calibration
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Solution Overview
Problem
Existing control systems for hydrocarbon recovery tools lack sufficient input/output capabilities, flexibility in adapting to newer tool models, and fail to integrate with existing systems, and calibration of tool sensors, leading to inefficiencies and increased costs.
Innovation Solution
A system and method for automated control systems for hydrocarbon recovery tools, including a first tool with a control device having an explosion-proof housing and a processor, and a bi-directional communication system between local and remote controllers, enabling efficient and flexible operation of tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dedicated remote control panels are used for each drilling tool, then each tool can be controlled with specific parameters, but the system lacks sufficient input/output capabilities and flexibility for newer tool models
Solution Approach 1:
The patent implements a universal control system where a single remote control panel can manage multiple different drilling tools through standardized communication protocols and configurable software. The system uses a common controller architecture that can be programmed to work with various tool types (tongs, elevators, positioning devices) without requiring dedicated hardware for each tool, thereby providing both versatility and adequate I/O capabilities.
Solution Approach 2:
The control system employs dynamic reconfiguration capabilities where the controller can be programmatically adjusted to accommodate different tool models and parameters. The system allows for software-based parameter customization and can dynamically adapt its I/O configuration based on the specific tool being controlled, enabling flexibility for newer tool models while maintaining systematic control.
2Measurement precision
If separate calibration is performed for tool sensors and control system inputs, then each component can be calibrated independently, but the process becomes costly and inefficient
Solution Approach 1:
The patent integrates the calibration process into a unified system-level procedure rather than performing separate calibrations for tool sensors and control system inputs. The controller coordinates the calibration of multiple components simultaneously through integrated test routines and cross-referenced measurement protocols, maintaining calibration accuracy while significantly improving efficiency and reducing costs.
Solution Approach 2:
The control system implements feedback mechanisms during calibration where the controller continuously monitors and adjusts sensor readings against known reference values. The system uses closed-loop calibration procedures where measurement data from tools is fed back to the controller, which automatically adjusts calibration parameters to achieve precise alignment between sensor outputs and control system inputs, ensuring measurement precision throughout the integrated system.
3Stability of the object's composition
If existing control systems are used for new tool models, then backward compatibility is maintained, but the systems lack sufficient electronic, hydraulic, pneumatic, data, and signal connections
Solution Approach 1:
The control system is divided into modular segments where the core controller maintains backward compatibility through standardized interfaces, while additional I/O modules and expansion cards can be added to provide the specific electronic, hydraulic, pneumatic, data, and signal connections required by newer tool models. This segmented architecture allows the system to maintain stability for existing tools while adapting to new connection requirements.
Solution Approach 2:
The control system employs dynamic I/O configuration where the controller can be programmatically reconfigured to provide different connection types and protocols based on the specific tool model being controlled. The system dynamically activates or deactivates specific I/O channels and communication protocols to match the requirements of either legacy or modern tools, maintaining backward compatibility while providing adaptability for newer connection standards.
Data Source
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AI summary
Methods and systems for controlling a set of tools for hydrocarbon recovery are presented. One example system generally includes a remote controller (206), a first tool (202a), and a first control device (204) mounted on the first tool. The remote controller is communicatively coupled to the first control device. The first control device is generally configured to receive a command to operate the first tool from the remote controller. Based on the command, the first control device generates one or more instructions executable by the first control device. The first control device executes the one or more instructions to operate the first tool.