Top Drive Sensor Integration for Accurate Hook Load Measurement
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Solution Overview
Problem
Current drilling rig measurement systems face challenges such as non-linearities, reduced resolution, and noise due to indirect measurements of parameters like hook load, which are not corrected for friction in sheaves, limiting the accuracy of drilling parameters like weight on bit (WOB) and rate of penetration (ROP).
Innovation Solution
A top-drive system with a sheave, frame, and integrated sensors and controller that directly measure physical parameters of drilling operations, transmitting data to a rig control system for accurate calculation and control of drilling parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If indirect measurement of hook load is used via dead-line sensor, then the measurement system is simple to implement, but measurement precision deteriorates due to friction in sheaves and non-linearities
Solution Approach 1:
A load cell is introduced as an intermediary device between the sheave and the dead-line to directly measure the hook load. This load cell acts as a mediator that captures the force information at the point of interest without being affected by friction in the sheaves or non-linearities in the drilling line, thereby improving measurement precision while maintaining system simplicity
Solution Approach 2:
The indirect mechanical measurement method (using dead-line tension through sheaves) is replaced with a direct force sensing approach using a load cell. This substitution eliminates the need to account for friction and non-linearities in the mechanical system, providing more accurate hook load measurements
2Device complexity
If sensors are distributed on the drilling rig with indirect measurements, then device complexity is reduced, but measurement precision deteriorates due to noise and reduced resolution
Solution Approach 1:
Load cells are positioned as intermediaries at critical points (between sheave and dead-line, between travelling block and hook) to directly capture force information. This intermediary approach provides high-resolution direct measurements without the noise and non-linearities associated with indirect sensing methods
Solution Approach 2:
The force measurements are taken at the source (at the hook and travelling block) before the forces propagate through the mechanical system where friction and non-linearities would degrade the signal. This preliminary measurement approach preserves measurement precision
3Device complexity
If weight of travelling block, hook and top drive is included in hook load measurement, then the measurement system is simpler, but measurement precision deteriorates due to limited resolution
Solution Approach 1:
The weight of the travelling block, hook, and top drive is extracted and separated from the hook load measurement. By placing load cells at strategic locations, the system directly measures only the drill string weight, excluding the equipment weights. This extraction improves measurement resolution by eliminating the need to measure small differences against large equipment weights
Data Source
AI summary
A top-drive system and a drilling rig. The top-drive system includes a sheave configured to receive a drilling line, a frame coupled with the sheave and configured to transmit a weight of a tubular string suspended therefrom to the sheave, a controller, and a sensor in communication with the controller. The sensor is configured to directly measure one or more physical parameters of a drilling operation and provide data representing the one or more physical parameters to the controller.