Automated Tool Identification in Modular Top Drive Systems
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Solution Overview
Problem
The current tool exchange process during well operations, such as drilling, casing, and cementing, is time-consuming and hazardous due to the need for manual identification of tools by personnel working at heights, highlighting the need for an automated tool identification system in modular top drive systems.
Innovation Solution
A modular top drive system equipped with active and passive identification devices, including RFID tags and barcode labels, that connect to a central control unit for automatic tool recognition and management, enabling automated tool exchange by reading identification information from tools and storing operational parameters and history.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tool identification is used during tool exchange, then personnel can identify tools, but the process becomes time-consuming and hazardous due to working at heights
Solution Approach 1:
The patent replaces manual visual identification and mechanical tool handling with an automated identification system using RFID tags and readers. The system automatically detects tool identities through electromagnetic fields without requiring personnel to physically inspect tools or work at heights, thereby reducing both time and safety risks.
Solution Approach 2:
The patent introduces RFID tags as intermediary elements attached to tools and RFID readers mounted on the top drive. These intermediaries enable automatic communication of tool identity information between the tool and control system, eliminating the need for manual identification while ensuring accurate tool recognition during exchange operations.
2Reliability
If manual tool identification is used, then personnel can verify tool correctness, but safety risks increase due to working at heights
Solution Approach 1:
The patent replaces manual verification processes with an automated RFID identification system. The reader automatically reads tool identifiers and the control system verifies correctness without requiring personnel to physically handle or visually inspect tools while positioned at heights, thereby eliminating safety risks associated with manual verification.
Solution Approach 2:
The system enables self-verification where the RFID reader automatically reads and verifies tool identity information without human intervention. The control system compares the read identifier against the required tool type, providing automatic verification that ensures correctness while keeping personnel safely away from hazardous areas.
3Productivity
If automated tool exchange is implemented, then efficiency improves, but system complexity increases due to identification devices and control systems
Solution Approach 1:
The patent employs universal RFID tags that can be attached to various tool types (drilling tools, casing tools, cementing tools) and a multi-functional top drive system with integrated RFID readers. This universal approach allows a single identification system architecture to handle diverse tool types, improving efficiency while managing complexity through standardization rather than requiring separate systems for each tool type.
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 facilitates safe and efficient automated tool exchange by ensuring correct tool identification and management, reducing human error and improving operational safety and efficiency in well construction processes.
Implementation Method 1
an active identification device including identification information
Data Source
Figure 1
Figure 2A~2D
Figure 2B~2E
AI summary
A modular top drive system for construction of a wellbore includes an identification reader for automatically identifying tools during operation for rig up and tool exchange. The identification reader may be disposed in one of a tool storage unit, a tool change unit or a top drive unit. Drilling tools, cementing tools and casing tools with one or more identification devices may be used with the modular top drive system. The one or more identification devices may be radio frequency identification devices, barcodes, text tags, micro-controllers, or combinations thereof.