Power Swivel Monitoring for Remote Torque and Overspeed Alerts
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Solution Overview
Problem
Current monitoring systems for power swivel systems in drilling rigs are inadequate for remote and local monitoring and control, leading to increased downtime and repair costs due to limited capabilities and lack of comprehensive data collection and analysis.
Innovation Solution
A smart box system integrated with sensors and communication technology that collects, formats, and transmits data from power swivel systems to remote devices, including rotation, torque, hydraulic pressure, and location data, enabling real-time monitoring and control through a user interface, and issuing warnings based on threshold values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a basic local monitoring system is used for power swivel systems, then the system structure remains simple, but the monitoring capability and reliability are insufficient
Solution Approach 1:
The monitoring system is divided into independent modular components: multiple sensors (rotation sensor, torque sensor, hydraulic pressure sensor, temperature sensor) that each monitor specific parameters, a processing device that collects and analyzes data from all sensors, and a communication module that transmits data remotely. This segmentation allows the system to achieve comprehensive monitoring capability while maintaining manageable complexity through modular design.
Solution Approach 2:
The processing device serves multiple functions: it collects data from various sensors, processes and analyzes the data, stores information in memory, transmits data remotely via communication technology, and provides local display. This multi-functionality consolidates what could be multiple separate systems into a single integrated unit, improving reliability without proportionally increasing complexity.
2Measurement precision
If comprehensive sensors and data collection systems are installed, then monitoring precision and data quality improve, but device complexity and cost increase
Solution Approach 1:
Multiple sensors monitoring different parameters (rotation, torque, hydraulic pressure, temperature) are integrated with a single processing device that consolidates data collection, processing, and communication functions. This merging approach achieves comprehensive high-precision monitoring of all critical parameters while avoiding the complexity of multiple independent monitoring systems.
Solution Approach 2:
The processing device acts as an intermediary between the various sensors and the remote monitoring system. It collects precise measurements from all sensors, processes the data, and transmits it remotely, thereby enabling high measurement precision without requiring direct complex connections between all sensors and remote systems.
3Reliability
If real-time remote monitoring is implemented, then operational reliability and response time improve, but system complexity and communication requirements increase
Solution Approach 1:
The system implements real-time feedback by continuously monitoring parameters through sensors, processing the data, and transmitting it remotely for immediate analysis. The processed information provides feedback on system status, enabling timely operational decisions and maintaining reliability through continuous monitoring and responsive communication.
Solution Approach 2:
The system replaces complex mechanical monitoring and communication infrastructure with electronic sensors and digital communication technology. This substitution achieves real-time remote monitoring capability with simpler, more reliable electronic systems compared to traditional mechanical or manual monitoring approaches.
4Productivity
If the system is designed for unattended operation, then operational efficiency improves, but the ability to detect and respond to failures decreases
Solution Approach 1:
The monitoring system enables unattended operation by automatically collecting data from sensors, processing information, and transmitting status updates remotely without requiring constant human presence. The system serves itself by autonomously monitoring its own operational parameters and communicating status, thereby maintaining both productivity and reliability.
Solution Approach 2:
The system performs preliminary monitoring and data collection continuously, preparing information about system status before failures occur. By continuously gathering and transmitting data on parameters like temperature, pressure, and torque, the system enables early detection of potential issues, allowing preventive action before actual failures occur, thus maintaining reliability during unattended operation.
Data Source
AI summary
An apparatus for monitoring a power swivel system includes a smart box comprising a processing device electrically associated with a memory, communication technology and least one of a local display device or a remote display device where the communication technology. The smart box is associated with a power swivel system comprising a power swivel unit in fluid communication with a hydraulic pump system driven by a motor. The hydraulic pump system is configured to pump a hydraulic fluid through the power swivel unit to activate rotating elements. A plurality of sensors are connected to the processing device and various components of the power swivel system including the rotating elements to monitor such elements and minimize the possibility of an over speed and/or over torque condition. Data providing a status of the power swivel system components is transmitted to a remote device and presented to a user via a GUI.