Riser Sensor Unit for Hazardous Subsea Engagement
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Solution Overview
Problem
The process of connecting riser sections in drilling equipment requires significant operator involvement, leading to risks of injury, fatigue, and potential human error due to repetitive motion and the need for precise alignment, which existing technologies have not adequately addressed.
Innovation Solution
A riser sensor unit with proximity sensors attached to the riser tool, connected to an intrinsic safety barrier, which generates and transmits signals to a control system for automated engagement with the riser coupling, reducing operator intervention and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated sensing is implemented, then operator safety is improved, but device complexity increases
Solution Approach 1:
The sensing system is divided into multiple independent sensors (first sensor, second sensor, third sensor) positioned at different locations on the riser tool. Each sensor independently monitors specific engagement parameters, allowing the system to achieve comprehensive safety monitoring through modular, distributed sensing elements rather than a single complex sensor system.
2Manufacturing precision
If precise engagement sensing is implemented, then manufacturing precision is improved, but measurement precision requirements increase
Solution Approach 1:
The system introduces an intrinsic safety barrier as an intermediary device between the sensors and the control system. This barrier provides galvanic isolation and signal conditioning, enabling precise measurement of engagement parameters while protecting the control system from electrical hazards in the hazardous zone. The barrier acts as a mediator that maintains measurement precision while ensuring safety.
3Productivity
If operator involvement is reduced, then productivity is improved, but ease of operation decreases
Solution Approach 1:
The system implements automatic feedback control where sensors continuously monitor engagement parameters (alignment, contact force, coupling position) and provide real-time feedback to the control system. The control system automatically adjusts the riser tool positioning and engagement process based on this feedback, eliminating the need for manual operator adjustments and enabling high-speed automated operation while maintaining ease of use.
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
The system enables automated and precise engagement of riser tool with the riser coupling, minimizing operator risk, reducing downtime, and ensuring consistent and safe operation in hazardous environments.
Implementation Method 1
a first sensor configured to generate a first signal upon detecting contact with the riser coupling
Implementation Method 2
an intrinsic safety barrier configured to transmit the first signal to a control system
Implementation Method 3
a power supply unit for converting alternating current to direct current
Data Source
AI summary
A riser sensor unit is used to sense engagement of a subsea riser tool with a riser coupling. The riser sensor unit includes a power supply configured to convert alternating current to direct current, an intrinsic safety barrier connected to the power supply, and a first sensor powered by the intrinsic safety barrier. The first sensor is attached to a sub of the subsea riser tool and is configured to generate a first signal upon detecting contact of a bottom surface of the sub with the riser coupling. The intrinsic safety barrier is configured to receive the first signal from the first sensor and transmit the first signal to a control system located remotely from the intrinsic safety barrier.