Tong Positioning Control Attachment for Legacy Hydraulic Compatibility
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Solution Overview
Problem
Oilfield operators face the challenge of using new tong assemblies with existing positioning devices, as the positioning devices are often heavy, expensive, and require complex hydraulic control systems, making it costly to upgrade both systems simultaneously.
Innovation Solution
A control attachment is developed that can be attached to preexisting positioning devices, incorporating a shutoff valve, control valve block, and control device to actuate both the positioning device and the tong assembly, allowing for movement along x, y, and z axes, as well as thread makeup and breakout operations.
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 connection is improved, but the cost increases and the positioning device becomes obsolete
Solution Approach 1:
A control attachment is introduced as an intermediary component between the existing positioning device and the new tong assembly. This control attachment includes a control valve assembly with first and second valves that interface with the positioning device's hydraulic system, and a compensation valve block with a third valve that interfaces with the tong assembly's hydraulic system, enabling compatibility without replacing the entire positioning device
2Reliability
If both the positioning device and tong assembly are upgraded simultaneously, then the system performance is improved, but the cost becomes prohibitive
Solution Approach 1:
The upgrade is segmented into two parts: the existing positioning device is retained, and only a relatively inexpensive control attachment is added. This segmentation allows the system to achieve improved performance by upgrading only the necessary control components rather than replacing entire systems
Solution Approach 2:
The control attachment serves as a cost-effective intermediary solution that bridges the gap between old positioning devices and new tong assemblies, avoiding the need for expensive simultaneous upgrades of both systems
3Adaptability or versatility
If a complex hydraulic control system is used to operate both the positioning device and tong assembly, then the functionality is complete, but the system complexity increases
Solution Approach 1:
The control attachment merges the control functions for both the positioning device and tong assembly into a single integrated unit. The control valve assembly and compensation valve block are combined with a common hydraulic supply connection, allowing one hydraulic system to control both devices through coordinated valve operation
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, simplifying the hydraulic control system and reducing costs by allowing a single positioning device to operate with multiple tong assemblies, improving operational efficiency and flexibility.
Implementation Method 1
Tong assemblies and positioning devices are often both hydraulically actuated
Implementation Method 2
a hydraulic supply in communication with the control attachment and configured to provide hydraulic fluid to the control attachment
Data Source
AI summary
A tong positioning system includes a positioning device configured to move a tong assembly. The positioning device includes a first actuator, a second actuator, and a control attachment attachable to the positioning device. The control attachment includes a shutoff valve fluidly coupled to a hydraulic supply, a control valve block, and a control device. 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.