Top Drive Control System Simultaneous Torque Rocking
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Solution Overview
Problem
Current control systems for top drives in drilling rigs lack the ability to automatically rock the drill string using both right and left hand torque simultaneously while monitoring speed, and they do not offer remote control operation for orienting, drilling, making-up, or breaking out drill pipe safely and efficiently.
Innovation Solution
A control system that integrates data storage and processors to manage hydraulic pumps, prime movers, and remote control operations, enabling simultaneous right and left hand torque application, speed monitoring, and remote control of drilling, orienting, making-up, and breaking out drill pipe operations, with features like torque control, speed monitoring, and safety features like low hydraulic oil and temperature warnings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a control system is designed to automatically rock the drill string using both right hand torque and left hand torque simultaneously while monitoring speed, then the automation capability and operational safety are improved, but the device complexity and control system architecture become more complex
Solution Approach 1:
The control system is divided into separate functional modules: a torque controller that manages right and left hand torque independently, a speed monitor that tracks drill string rotation, and a coordinator that integrates their operations. This segmentation allows complex automated rocking control to be achieved through manageable, independent components working in unison.
Solution Approach 2:
The control architecture implements a hierarchical structure where the torque controller and speed monitor operate as subordinate subsystems within the broader automated control framework. The torque controller manages immediate torque application while the speed monitor provides real-time feedback, both nested within the overall automated rocking control system that coordinates their simultaneous operation.
2Reliability
If remote control operation is implemented for orienting, drilling, making-up, and breaking out drill pipe, then operational safety is improved by allowing operation from a zone of safety, but the communication system complexity and potential signal delays increase
Solution Approach 1:
A communication interface acts as an intermediary between the remote control system and the top drive actuators. This intermediary layer processes control signals, manages data transmission, and coordinates operations between the remote operator and the drilling equipment, enabling safe remote operation while managing communication complexity through a dedicated mediation layer.
Solution Approach 2:
The system implements real-time feedback loops where sensors on the drill string and top drive continuously monitor operational parameters and transmit data back to the remote control system. This feedback mechanism allows the remote operator to observe drilling conditions and adjust controls accordingly, maintaining operational safety through continuous monitoring and responsive control despite the physical distance.
3Measurement precision
If simultaneous torque application and speed monitoring are implemented, then the precision of drill string control is improved, but the measurement and control requirements become more stringent
Solution Approach 1:
Traditional mechanical torque measurement devices are replaced with electronic sensors and transducers that convert mechanical parameters into electrical signals for digital processing. This substitution enables more precise simultaneous measurement of torque and speed, as electronic systems can capture multiple parameters concurrently with higher accuracy and resolve the measurement difficulties through non-contact, electronic detection methods.
Data Source
AI summary
A top drive control system with a remote control having a processor and data storage connected to a torque pin sensor, a speed sensor, a remote control, which enables a user to actuate automatic remote rocking, drilling, orienting and making-up of a drill string using the top drive and provides simultaneous right hand and left hand torque applied to the drill string while simultaneously controlling speed of turning of the drill string. The top drive control system includes computer instructions for automated orienting of drill pipe, automated drilling with drill pipe and automated making-up of drill pipe into a drill string.