Coiled Tubing Injector Chain Control for Load-Based Tension Adjustment
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Solution Overview
Problem
Current systems lack the ability to consistently manage chain systems on coiled tubing injectors during in-hole and out-hole operations, leading to frequent adjustments of tension and traction pressures, which can cause wear and failure of consumable parts, and divert operator attention from wellbore safety.
Innovation Solution
A system that utilizes real-time data from sensors to monitor load feedback, controls hydraulic, electric, or pneumatic pressure to adjust tension and traction systems, and maintains preset safe operating limits, reducing manual adjustments and improving chain management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustments of tension and traction pressures are made frequently, then the chain system can be adapted to varying load conditions, but wear and failure of consumable parts increases and operator attention is diverted from wellbore safety
Solution Approach 1:
The system employs sensors to automatically detect load conditions and adjusts tension and traction pressures without manual intervention. The chain system serves itself by maintaining optimal parameters through automated control, eliminating the need for frequent manual adjustments and reducing wear on consumable parts while keeping operator attention focused on wellbore safety
Solution Approach 2:
Sensors continuously monitor load conditions and provide real-time feedback to the control system. This feedback loop enables automatic adjustment of tension and traction pressures to match varying operational demands, achieving adaptability without manual intervention and preventing excessive wear through precise, condition-based control
2Duration of action of stationary object
If higher tensile strength tubing is used, then tubing life is extended and deeper wells can be completed, but operating equipment such as coiled tubing injectors suffers detrimental impact
Solution Approach 1:
The system dynamically adjusts tension and traction pressure parameters based on real-time load feedback from sensors. By optimizing these parameters for the specific tensile strength of the tubing being used, the system prevents excessive forces from damaging the injector equipment while still enabling the use of higher tensile strength tubing for extended life and deeper well applications
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
Enhances the lifecycle of coiled tubing by minimizing wear on components, preventing chain bunching, and freeing operators to focus on wellbore safety, thereby reducing maintenance downtime and costs.
Implementation Method 1
Real time data received from sensors monitoring load feedback on the injector drive system
Implementation Method 2
The amount of hydraulic, electric, or pneumatic pressure allocated to the chain system
Implementation Method 3
The amount of hydraulic, electric, or pneumatic pressure allocated to the chain system
Data Source
AI summary
The present application pertains to a method and system for coiled tubing injector chain management on a coiled tubing unit. Advances in tubing technology combined with lack of operator training have been detrimental to injector longevity. Optimizing chain and equipment life requires operating parameter control. This method utilizes feedback from loads on the injector chassis to adjust chain traction and tension to optimal levels to extend equipment life.