Intelligent Powerslip Interlock for Verified Tubular Weight Transfer

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Solution Overview

Problem

Current powerslip systems in the petroleum industry face issues with human error, miscommunication, and safety hazards during tubular handling, leading to incidents of casing slipping and dropping, which existing interlock systems fail to adequately prevent.

Innovation Solution

An intelligent powerslip system interfaced with a powerlock system, utilizing a programmable logic controller (PLC) to monitor sensors for weight transfer, pressure, and temperature, ensuring full engagement and safe disengagement of the grappling device, and incorporating a failsafe mechanism to prevent accidental release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing interlock systems are used with powerslip, then basic engagement detection is possible, but human error and miscommunication still occur leading to casing slips and drops

Engineering Contradiction:

Improveengagement verification reliabilityVSAvoidcasing slip and drop incidents

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system implements automated feedback loops where sensors continuously monitor engagement status, weight transfer, and system state. The PLC receives real-time data from multiple sensors and automatically adjusts system state or alerts operators, eliminating reliance on manual verification and communication between drillers and FMS operators. This closed-loop feedback system ensures engagement is genuinely confirmed before allowing tool release.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The intelligent powerslip system performs self-verification of engagement conditions through integrated sensors and automated logic. Instead of requiring external manual checks by multiple personnel, the system autonomously monitors its own state, confirms weight transfer, verifies engagement parameters, and controls the interlock function based on predetermined safety criteria, reducing human intervention points where errors can occur.

Inventive Principle:

Principle #25Self-service

2Ease of operation

If manual monitoring and communication between driller and FMS operator is used, then system operation is possible, but miscommunication and human error lead to safety incidents

Engineering Contradiction:

Improvesystem operation simplicityVSAvoidoperation safety

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system replaces manual mechanical monitoring and human-to-human communication with an automated electronic control system. The PLC-based intelligent powerslip system uses electronic sensors, signal processing, and automated logic to monitor engagement conditions and control the interlock function, substituting the mechanical/manual process with an electronic automation system that eliminates miscommunication and human error while maintaining operational simplicity through automated decision-making.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If existing interlock systems are used, then basic safety function is provided, but full weight transfer confirmation and engagement verification are not ensured

Engineering Contradiction:

Improvesafety function reliabilityVSAvoidweight transfer and engagement detection accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The system segments the safety verification process into multiple independent sensor measurements rather than relying on a single detection method. Multiple sensors monitor different parameters (engagement status, weight transfer, piston position, line pressure) independently, and the PLC integrates these segmented measurements to make a comprehensive determination of safe operating conditions, ensuring both full weight transfer confirmation and proper engagement verification before allowing tool release.

Inventive Principle:

Principle #1Segmentation

4Reliability

If automated sensor monitoring and PLC control are implemented, then human error is eliminated and safety is improved, but system complexity increases

Engineering Contradiction:

Improveerror eliminationVSAvoidsystem structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The PLC-based control system serves multiple functions simultaneously: it monitors engagement status, tracks weight transfer, verifies sensor readings, controls the interlock logic, and manages system diagnostics. By making the PLC a universal control unit that performs all these functions through a single integrated system rather than separate dedicated devices for each function, the patent reduces overall system complexity while maintaining high reliability and comprehensive safety verification.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20230074177A1Intelligent powerslip and power lock system for running and retrieving tubulars from a wellbore

Publication Date: 2023.03.09 SAUDI ARABIAN OIL CO

AI summary

Systems and methods include a computer-implemented method for the operation of an intelligent powerslip including interfacing with a powerlock system. Measurements from multiple sensors are monitored using an interface between a powerlock and a powerslip of a well. The measurements measure weights, pressures, and temperatures corresponding to use of the powerslip and a grappling device during operation of the well. The measurements from the multiple sensors are compared to pre-determined tolerances to verify that an appropriate engagement exists between the tubular, powerlock and the powerslip. In response to verifying the appropriate engagement and logic, either one of the grappling device or the powerslip can be released depending on the ongoing operation.