Real Time Torque System Strain Gauge Measurement
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Solution Overview
Problem
Current torque measurement methods in oilfield applications are inaccurate due to the lack of national standards, reliance on indirect reference measurements, and parasitic torque losses, leading to significant errors exceeding 10% tolerance in tubular connections.
Innovation Solution
A real-time torque system (RTTS) that directly measures applied torque using calibrated load cells and strain gauges, capable of in-situ measurement regardless of orientation, with a calibration process that establishes granular torque maps and provides continuous reference through wireless communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If indirect reference measurements are used to measure torque, then the measurement system can be implemented without national torque standards, but the measurement precision deteriorates with errors exceeding 10% tolerance
Solution Approach 1:
The patent replaces indirect mechanical reference measurements with direct electrical measurements using strain gauges and load cells. Instead of using mechanical moment arms and tape measures, the system uses electrical signals from strain-sensitive elements bonded directly to the torque reaction arm, eliminating the need for manual measurements and calculations that introduced errors.
Solution Approach 2:
The patent introduces strain gauges and load cells as intermediary elements that directly sense torque forces. These sensors act as mediators between the mechanical torque application and the measurement system, providing accurate electrical signals that represent the actual torque applied to tubular connections without requiring indirect mechanical calculations.
2Ease of manufacture
If load cells are calibrated by application of force with no involvement of torque, then the calibration process is simplified, but the reliability of torque measurement deteriorates
Solution Approach 1:
The patent applies preliminary calibration actions by bonding strain gauges to the torque reaction arm before field use and establishing calibration factors that account for the specific mechanical configuration. This preliminary setup ensures that subsequent measurements automatically incorporate the correct torque relationships without requiring recalibration for each measurement.
Solution Approach 2:
The patent replaces mechanical force calibration with electrical calibration methods. Instead of physically applying known forces to calibrate load cells, the system uses electrical signals from strain gauges that are calibrated through electrical means, maintaining reliability while simplifying the calibration process.
3Ease of operation
If moment arm is measured with a tape measure, then the installation process is simplified, but the measurement precision deteriorates due to arm length errors and angle errors
Solution Approach 1:
The patent replaces manual tape measure measurements with direct electrical sensing. Strain gauges are bonded directly to the torque reaction arm at precise locations, eliminating the need for manual measurement of arm length and angle. The electrical signals from the strain gauges directly represent the torque forces without requiring geometric calculations.
Solution Approach 2:
The strain gauges perform self-measurement of the torque forces acting on the reaction arm. The sensors automatically detect and report the forces without requiring external measurement tools or manual calculations, eliminating human error in measurement and calculation.
4Ease of manufacture
If torque reaction of tong body is measured, then the measurement system can be implemented with existing equipment, but parasitic torque losses cause significant errors
Solution Approach 1:
The patent extracts the measurement function from the tong body structure and places it directly on the torque reaction arm that connects to the tubular connections. By separating the measurement function from the tong mechanics, the system directly measures the torque applied to the connections without being affected by parasitic losses in the tong mechanism.
Solution Approach 2:
The patent introduces a dedicated torque reaction arm with strain gauges as an intermediary measurement element. This separate measurement system directly senses the torque forces without being part of the torque transmission path that suffers from parasitic losses, providing accurate measurements of the actual torque applied to connections.
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 RTTS achieves precise torque measurement with minimal downtime, reducing errors to within 10% tolerance and ensuring consistent measurements over time, thereby improving the accuracy of torque application in oilfield operations.
Implementation Method 1
A real time torque system (RTTS) that directly measures applied torque using calibrated load cells and strain gauges
Implementation Method 2
A real time torque system (RTTS) that directly measures applied torque using calibrated load cells and strain gauges
Data Source
AI summary
Apparatus and methods for measuring in-situ applied torque in tubular operations. A torque cylinder has a first end and a second end. A torque rod is at least partially contained in the torque cylinder and is coupled to the first end of the torque cylinder. The torque rod extends longitudinally outward from the second end of the torque cylinder. A strain gauge is connected to the torque rod at a predetermined distance from the first end of the torque cylinder. The strain gauge is configured to measure in-situ the applied torque between two tubular drill string segments each coupled to a respective one of the torque cylinder and the torque rod.