IBOP Valve Position Monitoring With Wireless Encoder Crank Assemblies
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Solution Overview
Problem
IBOP valves in top drives have reduced lifespans due to actuator designs that fail to ensure full opening or closing, leading to costly and time-consuming replacements, and there is a need for improved condition monitoring to track degradation and anticipate failures.
Innovation Solution
A top drive system with a two-piece actuator sleeve assembly and wireless encoders on crank assemblies for precise monitoring of IBOP valve position, allowing for tracking of wear and damage over time, and a processing device to calculate and display position data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional actuator designs are used for IBOP valves, then the valve can be operated, but the valve cannot achieve full opening or closing positions reliably, leading to reduced valve lifespan
Solution Approach 1:
The patent implements wireless encoders on the crank assemblies that continuously monitor the IBOP valve position and provide feedback data to a processing device. This feedback mechanism enables real-time detection of position deviations and wear patterns, allowing for predictive maintenance before complete valve failure occurs, thereby extending valve lifespan while maintaining operational reliability.
Solution Approach 2:
The patent replaces traditional mechanical position indication methods with wireless encoder technology that converts mechanical crank rotation into digital position data. This substitution enables precise monitoring of valve position without adding mechanical complexity to the actuation system itself, resolving the contradiction between reliable operation and extended lifespan.
2Reliability
If IBOP valves are replaced frequently due to wear and failure, then operational reliability is maintained, but maintenance time and costs increase significantly
Solution Approach 1:
The patent enables preliminary detection of valve wear and position deviations through continuous monitoring by wireless encoders and processing devices. By identifying degradation trends before they lead to failure, the system allows for planned maintenance scheduling, avoiding unexpected valve failures and reducing overall maintenance time and costs.
Solution Approach 2:
The monitoring system enables the valve assembly to effectively monitor its own condition through the wireless encoders on the crank assemblies, providing self-diagnostic capabilities that eliminate the need for frequent manual inspections and proactive replacement, thereby reducing maintenance time while maintaining reliability.
3Reliability
If new IBOP valves are installed frequently, then system reliability is maintained, but operational costs and downtime increase
Solution Approach 1:
The wireless encoder monitoring system provides continuous feedback on valve position and operational status, enabling real-time assessment of valve health. This feedback allows operators to maintain high system reliability by detecting early signs of wear and scheduling replacements during planned maintenance windows, thereby avoiding unplanned downtime and maintaining operational efficiency.
Solution Approach 2:
By detecting valve degradation trends in advance through the monitoring system, the patent enables preliminary scheduling of valve replacements during non-critical periods. This preliminary action prevents unexpected failures that would cause production downtime, thereby maintaining both system reliability and operational efficiency.
Data Source
AI summary
A system includes a top drive including a handling ring assembly including a main body, a main shaft that traverses the main body of the handling ring assembly, an internal blowout preventer (IBOP) valve, wherein the main shaft engages the IBOP valve, a two-piece actuator sleeve assembly including a non-rotating portion and a rotating portion, at least one hydraulic cylinder connected to the main body of the handling ring assembly, wherein the at least one hydraulic cylinder actuates the two-piece actuator sleeve assembly, and left and right hand crank assemblies having left and right wireless encoders connected thereto, wherein the crank assemblies with the wireless encoders are attached to, and are configured to rotate with, the IBOP valve along with the rotating portion of the two-piece actuator sleeve assembly.