Pipe Handler Position Detection for Drill Rig Safety
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Solution Overview
Problem
Current drill pipe handling systems in deep drilling operations rely heavily on manual control, which can lead to unsafe conditions, particularly when elevator brackets are left pivoted, risking contact with the drilling rig's mast and potentially causing damage or injury.
Innovation Solution
A pipe handler system with integrated position detection and monitoring capabilities for elevator brackets, allowing for the forwarding of position information to ensure safe vertical and rotational movements, using hydraulic and electrical signal transmission to prevent undesirable contact with the mast.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control is used for elevator bracket positioning, then operational flexibility is maintained, but safety risks increase due to human error in monitoring bracket positions
Solution Approach 1:
The patent implements automatic feedback systems that continuously monitor elevator bracket positions and provide real-time information to the control system. Position sensors detect bracket locations and feed this data back to the control unit, which automatically responds by commanding the bracket to return to its initial position if a dangerous situation is detected, thereby eliminating the need for constant manual monitoring while maintaining safety.
Solution Approach 2:
The control system is designed to autonomously manage elevator bracket positioning without requiring continuous human intervention. When the system detects that a bracket has moved to a dangerous position or failed to return to its initial position, it automatically activates the actuator to correct the position, enabling the system to serve itself and maintain safety independently.
2Reliability
If automatic position monitoring is implemented for elevator brackets, then safety is improved by preventing contact with the mast, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent integrates position monitoring functionality into the existing control system of the drilling rig, allowing the same control unit to perform both traditional drilling operations and safety monitoring of elevator brackets. This multi-functionality approach avoids the need for separate dedicated monitoring hardware, thereby improving safety while minimizing the increase in overall system complexity.
Solution Approach 2:
The system employs an intermediary control unit that acts as a mediator between the elevator bracket actuator and the main drilling system. This intermediary receives position information from sensors, processes safety conditions, and communicates with the actuator to command bracket position corrections, thereby simplifying the architecture by centralizing control logic rather than distributing complex monitoring across multiple independent systems.
3Productivity
If the top drive is lowered when elevator brackets are pivoted, then operational efficiency is maintained, but the risk of contact with the mast increases causing potential damage or injury
Solution Approach 1:
The system performs preliminary checks of elevator bracket positions before allowing the top drive to be lowered. Position sensors detect whether brackets are in safe positions, and the control system preemptively commands the actuator to return brackets to their initial retracted positions if they are detected to be pivoted, thereby preventing dangerous contact conditions before they can occur and maintaining both safety and operational flow.
Solution Approach 2:
The control system applies preliminary anti-action by automatically counteracting the dangerous positioning of elevator brackets before the top drive lowering operation proceeds. When brackets are detected in extended or pivoted positions that could cause contact with the mast, the system immediately activates the actuator to retract the brackets to safe positions, preventing the harmful effect from manifesting while allowing the drilling operation to continue efficiently.
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 automatic and manual control processes to safely avoid dangerous conditions by determining whether vertical or rotational movements are possible, reducing the risk of damage or injury and enhancing operational safety.
Implementation Method 1
The first measuring cylinder (40) is actuated by the tilt arm (34)
Implementation Method 2
which are hydraulically connected in two channels
Implementation Method 3
the position information is passed on... to a second measuring cylinder (42)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a handling device for drill pipes (18) and to a so-called top drive (16) gripping said handling device, a so-called pipe handler, having means for detecting a position of elevator equipment (30) gripped by the handling device/pipe handler and for forwarding the associated positional information. The positional information is forwarded from the pipe handler to, for example, the top drive (16) and is converted into an electrical signal for detecting and avoiding possibly critical situations as a result of a position/deflection of the elevator equipment (30).