Tongs Speed Control for Consistent Sucker Rod Torque

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Solution Overview

Problem

Conventional tongs systems face challenges in consistently achieving proper tightening of sucker rods and tubulars due to varying specifications and uncontrollable factors, leading to inefficiencies in the make-up process and inaccurate torque measurements.

Innovation Solution

A system and method that utilize a computer processor to control the speed of tongs during the make-up process by adjusting the speed based on target settings and monitoring actual speed data, while also employing a load cell to accurately measure and control torque applied during the make-up and breakout processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional tongs systems are used without speed control, then the make-up process can proceed quickly, but the tightening consistency and torque accuracy deteriorate due to varying speeds affecting thread engagement quality

Engineering Contradiction:

Improvetightening consistencyVSAvoidmake-up process speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system dynamically adjusts the tongs speed during the make-up process based on real-time feedback from encoders and torque sensors. The speed is not fixed but varies according to the threading stage and load conditions, optimizing both precision and efficiency throughout the operation cycle

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system incorporates feedback mechanisms using encoders to monitor rod position and speed, and torque sensors to measure applied torque. This feedback is continuously processed by a microprocessor to adjust hydraulic valve positioning and pump delivery, ensuring consistent tightening quality while maintaining optimal speed

Inventive Principle:

Principle #23Feedback

2Measurement precision

If tongs speed varies during make-up, then the process can adapt to different thread conditions, but torque measurement accuracy deteriorates due to speed-related measurement errors

Engineering Contradiction:

Improvetorque measurement accuracyVSAvoidtongs make-up speed

Core Design Contradiction:

Measurement precisionVSSpeed

Solution Approach 1:

The system uses feedback from torque sensors and encoders to continuously monitor both torque and speed. The microprocessor processes this feedback to compensate for speed variations in torque measurements, ensuring accurate readings regardless of the current make-up speed

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system changes operational parameters dynamically, adjusting hydraulic pump delivery and valve positioning based on real-time speed and torque measurements. This allows the system to optimize torque application accuracy across varying speed conditions by modifying hydraulic flow characteristics

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If hydraulic pump delivery is not controlled, then the system is simpler to operate, but speed consistency and torque control precision deteriorate

Engineering Contradiction:

Improvespeed consistencyVSAvoidsystem operation complexity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The system performs self-adjustment through automated feedback control. The microprocessor continuously monitors speed and torque via encoders and sensors, then automatically adjusts hydraulic valve positioning and pump delivery without requiring manual intervention, maintaining speed consistency while simplifying operator tasks

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces manual mechanical control with automated electronic-hydraulic control. A microprocessor-based control system substitutes for manual operation, using electronic signals to control hydraulic valves and pumps, thereby achieving precise speed and torque control while reducing operational complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9027416B2Method and system for controlling tongs make-up speed and evaluating and controlling torque at the tongs

Publication Date: 2015.05.12 KEY ENERGY SERVICES INC

AI summary

Make-up speed for a tongs drive system is monitored and controlled to maintain the speed within a limited target range either throughout the make-up process or during the final portion of the make-up process, thereby improving make-up consistency and allowing for improved evaluation or torque during the make-up process. An encoder generates speed and position data during the make-up process. The speed data is compared to a target speed, which is based on rod and/or tongs characteristics. If the speed does not match the target speed or is not within a range of the target speed, a signal is transmitted to the tongs drive to adjust the speed accordingly. Furthermore, position data from the encoder, or other position sensors, provide position data for the rod during the make-up process to limit or vary the speed control parameters during different portions of the make-up process.