Well Service Rig Load Control via Real-Time Hookload Monitoring
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Solution Overview
Problem
During well service operations, there is a risk of rig damage and worker injury due to sudden increases in load when removing tubing or rods from a well, as operators may not quickly recognize snagging or sticking issues, leading to excessive hookload beyond safe limits, especially when only a small amount of tubing remains.
Innovation Solution
A method and apparatus that monitor rig load data to determine average loads, set upper load limits, reduce hoist speed when necessary, and prevent lifting if the stand is not fully disengaged from the remaining tubing, using sensors and computer systems to manage the well service rig operations and prevent overloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the operator lifts the stand of tubing quickly to improve productivity, then the removal speed increases, but the risk of sudden load increase and rig damage increases
Solution Approach 1:
The system continuously monitors hookload during tubing removal and provides real-time feedback to the control system. When the load approaches or exceeds the predetermined limit, the system automatically responds by reducing hoist speed or stopping the lifting operation, preventing dangerous overload conditions while allowing normal high-speed operation
Solution Approach 2:
The hoist speed is dynamically adjusted based on real-time load conditions. The control system varies the lifting speed according to the current hookload, maintaining high speed when safe and automatically reducing speed when approaching load limits, rather than using a fixed speed throughout the operation
2Productivity
If the operator works quickly to remove tubing stands, then the operation efficiency improves, but the reaction time to detect snagging or sticking issues decreases
Solution Approach 1:
The automated load monitoring system provides continuous feedback on hookload conditions, immediately detecting snagging or sticking issues through load changes. This eliminates the need for operator interpretation and provides instant detection, maintaining high operation speed while ensuring immediate response to problems
Solution Approach 2:
The system replaces the operator's manual monitoring and decision-making with an automated electronic load monitoring and control system. Sensors and control algorithms continuously analyze load data and automatically adjust hoist operation, removing human reaction time limitations
3Productivity
If the operator lifts the stand before full disengagement to save time, then the operation speed increases, but the risk of violent load increase and injury increases
Solution Approach 1:
The system performs preliminary monitoring of the disengagement process by continuously tracking hookload during the critical period when the stand is being separated from the tubing. The predetermined load limit is set to trigger before dangerous conditions develop, providing advance warning and automatic intervention
Solution Approach 2:
Real-time load feedback during the disengagement process allows the control system to detect the separation event and respond automatically. When the load changes indicate that disengagement is complete or approaching, the system adjusts hoist operation to prevent lifting before full separation, eliminating the need for operator judgment
4Reliability
If automated load monitoring and control systems are implemented to improve safety, then rig damage and injury risk decrease, but the system complexity increases
Solution Approach 1:
The control system is designed to monitor and control itself through automated feedback loops. The system automatically compares measured load against predetermined limits and self-adjusts hoist speed without requiring external intervention or complex operator procedures, simplifying the overall system architecture
Solution Approach 2:
The load monitoring system serves multiple functions: it monitors hookload continuously, detects snagging conditions, determines disengagement completion, prevents overload, and controls hoist speed. This multi-functionality consolidates what would otherwise require separate systems into a single integrated solution
Data Source
AI summary
The present invention is directed to methods for controlling the operations of a well service rig at a well site by evaluating load sensor data obtained from sensors on or associated with the well service rig. A rig load data chart can be reviewed and an average rig load can be determined for each pull of tubing or rods from a well. The average rig load can be used to calculate and set a rig overload level. If the rig load sensor reads a rig load at or above the rig overload level, the clutch for the hoist can be disengaged and the brake applied to prevent the load from either damaging the rig or breaking off the tubing or rods in the well. In addition, the rig load can be evaluated to determine when the limit the block speed when pulling rods or tubing.