Well Service Rig Block Speed Governing System
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Solution Overview
Problem
During well service operations, there is a risk of equipment damage and safety hazards due to excessive speed of equipment removal, particularly when only a small amount of tubing or rods remain in the well, as it reduces elasticity and reaction time, and can lead to misleading inspection data if logging equipment is pulled too quickly.
Innovation Solution
A system and method for governing the speed of a block on a well service rig based on the task being performed, limiting the maximum allowable speed and disabling the lock-up system when the hookload is light, using sensors and a speed evaluation computer to manage engine throttle and prevent excessive speed, ensuring safe and controlled operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the block speed is increased to complete the job more quickly, then productivity is improved, but the risk of equipment damage and safety hazards increases
Solution Approach 1:
The system dynamically changes the block speed parameter based on the amount of tubing remaining in the well. When less than 1000 feet of tubing remains, the maximum block speed is reduced from 2000 feet per minute to 100 feet per minute. This parameter adjustment resolves the contradiction by allowing high speed during safe conditions while preventing damage during critical low-tubing conditions.
2Loss of time
If the block speed is increased to reduce operation time, then loss of time is reduced, but the reliability of the operation deteriorates
Solution Approach 1:
The block speed limit is made dynamic rather than fixed. The system automatically adjusts the maximum allowable block speed based on real-time conditions (tubing remaining in well). This dynamic approach allows the system to maintain high productivity when safe while ensuring reliability when the well is nearly empty, resolving the contradiction between speed and safety.
3Use of energy by moving object
If the lock-up system is engaged to improve transmission efficiency, then use of energy is improved, but the risk of dangerous conditions increases when hookload is light
Solution Approach 1:
The system changes the transmission lock-up parameter based on hookload conditions. When the hookload is light (less than 1000 feet of tubing remaining), the lock-up system is prevented from engaging. This parameter change resolves the contradiction by allowing efficient energy use during normal operations while preventing dangerous conditions during light-load operations.
Data Source
AI summary
A task input is received at a well service rig. The maximum allowable speed is determined for the task. Current block speed inputs are received. The throttle position for the engine controlling the block is evaluated to determine if the block is to be sped up or slowed down. When the throttle position indicates the operator is attempting to speed up the block, the current block speed is compared to the maximum allowable speed and the engine is only allowed to speed up the block up to the maximum allowable speed, at which point the operators control of block speed is limited to reducing block speed. Each task can have multiple maximum allowable speeds, which can vary based on specified conditions. When the hookload is light or the remaining equipment in the well is small, the lock-up feature for the transmission can be disengaged in addition to the block speed governing feature.