Retrofit Control Attachment for Hydraulic Tong Positioning
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Solution Overview
Problem
Tong assemblies and positioning devices used in oilfield operations are heavy, expensive, and require complex hydraulic control systems, making it impractical for operators to upgrade both simultaneously.
Innovation Solution
A control attachment is designed to be retrofitted onto existing positioning devices, incorporating a control valve assembly and compensation valve block to actuate tong assemblies, allowing control over new tong assemblies and positioning devices with a simplified hydraulic system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a new tong assembly with advanced technology is purchased, then the success rate of making up threaded connections is improved, but the overall system cost and complexity increases because the positioning device must also be upgraded
Solution Approach 1:
The control system is divided into separate functional modules: a control attachment with control valves for the positioning device, and a separate control system for the tong assembly. This segmentation allows independent upgrading of the tong assembly without requiring upgrades to the positioning device control system.
Solution Approach 2:
The control attachment is designed with universal compatibility to work with both old and new tong assemblies. The control valves can actuate different types of actuators (hydraulic, electric, pneumatic) and the system can support various tong assembly configurations, allowing one control attachment to serve multiple functions across different equipment generations.
2Productivity
If both the positioning device and tong assembly are upgraded to new technology, then operational performance is improved, but the cost increases significantly
Solution Approach 1:
The control attachment extracts only the essential control functions needed to operate the tong assembly from a complete control system. By taking out just the necessary control valves and hydraulic circuitry, the system achieves tong assembly control without requiring the full control system that would be needed for a completely new positioning device.
Solution Approach 2:
The control attachment serves as a cost-effective, temporary solution that allows existing positioning devices to operate new tong assemblies. Rather than investing in expensive permanent upgrades to the positioning device, operators can use the relatively inexpensive control attachment to achieve improved operational performance, and replace or upgrade the control attachment later when economically feasible.
3Adaptability or versatility
If a control attachment is attached to an existing positioning device, then compatibility with new tong assemblies is improved, but the device complexity increases
Solution Approach 1:
The control attachment is designed as a nested modular unit that attaches to the existing positioning device hydraulic system. The control attachment contains its own control valves and hydraulic circuitry nested within a compact housing, which interfaces with the parent positioning device hydraulic system. This nested structure allows the control attachment to be added without fundamentally restructuring the entire positioning device system.
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 the use of new tong assemblies with existing positioning devices, reducing the need for costly upgrades and simplifying hydraulic control, enhancing operational efficiency and flexibility.
Implementation Method 1
a control valve assembly configured to actuate the first and second actuators
Implementation Method 2
a compensation valve block fluidly coupled to the control valve assembly and fluidly coupled to the first actuator
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A tong positioning system (100) includes a positioning device configured to move a tong assembly (400). The positioning device includes a first actuator (330), a second actuator (500), and a control attachment (200) attachable to the positioning device (300). The control attachment includes a shutoff valve (208) fluidly coupled to a hydraulic supply, a control valve block (230), and a control device (210). The control valve block includes a hydraulic input fluidly coupled to the shutoff valve, a hydraulic output fluidly coupled to a hydraulic return, a first valve fluidly coupled to the first actuator, the first valve configured to actuate the first actuator, and a second valve fluidly coupled to the second actuator, the second valve configured to actuate the second actuator. The control device is configured to control the first valve and to control the second valve to actuate the first and second actuators to move the tong assembly.