Tong Assembly Distance Monitoring for Collision Avoidance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for making up and breaking out threaded connections in oil and gas well drilling lack effective monitoring of the distance between tongs, leading to potential collisions and damage due to insufficient accounting for makeup loss, which can result in operational inefficiencies and equipment damage.
Innovation Solution
A system that includes a sensor and controller to measure and compare the distance between a power tong and a backup tong, using threshold values to control the rotation and axial movement of the tongs, ensuring safe and efficient connection and disconnection by stopping or restarting operations based on predetermined distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the power tong moves towards the backup tong to account for makeup loss during threading, then the threaded connection is properly made up, but the tongs may collide if the distance is insufficient
Solution Approach 1:
The system performs preliminary measurement of the distance between power tong and backup tong before the tong movement begins. This allows the control system to pre-calculate the available travel distance and adjust the makeup loss compensation accordingly, preventing collision while ensuring proper thread engagement.
Solution Approach 2:
The system continuously monitors the distance between power tong and backup tong during the makeup operation using sensors. This real-time feedback allows the control system to dynamically adjust the power tong movement, stopping before collision occurs while ensuring sufficient movement to properly make up the threaded connection.
2Reliability
If the power tong moves away from the backup tong during breakout, then the threaded connection is broken out, but the power tong may cease movement and damage the connection if the distance is insufficient
Solution Approach 1:
Before the breakout operation begins, the system measures the distance between the power tong and the upper limit stop. This preliminary measurement allows the control system to determine the available travel distance and ensure sufficient movement for complete thread disengagement, preventing premature stopping and connection damage.
Solution Approach 2:
During the breakout operation, the system continuously monitors the distance between power tong and backup tong. This real-time feedback enables the control system to track the power tong movement and ensure it travels far enough to completely break out the connection without exceeding the upper limit stop.
3Device complexity
If manual monitoring of tong distance is used, then the system is simple, but the makeup loss cannot be accurately accounted for leading to collisions
Solution Approach 1:
The system replaces manual visual monitoring with automated sensors that continuously measure the distance between power tong and backup tong. This substitution of mechanical/manual measurement with electronic sensing provides accurate, real-time distance data without adding significant complexity to the overall system.
Solution Approach 2:
The distance measurement system serves multiple functions: it monitors tong position during both makeup and breakout operations, prevents collisions in both directions, and provides data for calculating appropriate makeup loss compensation. This multi-functionality justifies the added measurement capability.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of connecting or disconnecting a first tubular to a second tubular includes engaging the first tubular with a power tong; engaging the second tubular with a backup tong; and rotating the first tubular relative to the second tubular. The method also includes, while rotating, monitoring a distance between the backup tong and the power tong and comparing the distance to a first threshold value; and stopping rotation of the first tubular when the distance equals to the first threshold value. According to one embodiment, a tong assembly includes a power tong, a backup tong, a sensor configured to measure a distance between the power tong and the backup tong, and a controller configured to compare the distance to a threshold value.