Explosion-Proof Torque Actuator for Drilling Rigs
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Solution Overview
Problem
Existing actuators for managing wellbore pressure in Managed Pressure Drilling face challenges such as difficulty in tracking pressure changes, safety issues in explosive environments, and a large footprint, which are not effectively addressed by current control systems and hydraulic power units.
Innovation Solution
An integrated electrical actuator with a servo motor, torque sensor assembly, encoder, and onboard controls housed in a sealed explosion-proof enclosure, capable of autonomously controlling rotational equipment in response to pressure and torque changes, with a small footprint suitable for explosive environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic power unit is used to supply pressurized hydraulic fluid to actuators, then the actuator can operate without electrical power sources in explosive environments, but the system creates a large footprint and has safety issues including hydraulic leaks
Solution Approach 1:
The patent combines the electrical motor, drive, power supply, and control components into a single integrated actuator unit, eliminating the need for separate hydraulic power units and reducing the overall footprint on the drilling rig while maintaining safety through intrinsic safety design
Solution Approach 2:
The patent replaces the hydraulic power system with an electrically driven actuator system that uses intrinsically safe electrical components, substituting mechanical hydraulic connections with electrical connections that can be sealed and protected
2Ease of operation
If separate electrical motors and drives are used in an actuator, then the actuator can provide precise control, but the separate enclosures create numerous failure points and increase the risk of sparks and explosions
Solution Approach 1:
The patent integrates the motor, drive, power supply, and control components into a single unified actuator housing, reducing the number of separate enclosures and connections from multiple to one, thereby minimizing failure points and reducing spark risks
3Reliability
If multiple separate enclosures are used for electrical components, then each component can be protected, but the combined footprint and number of failure points increase
Solution Approach 1:
The patent consolidates multiple protected enclosures into a single integrated housing that contains all electrical components, maintaining protection while reducing the total footprint from multiple separate units to one unified structure
4Reliability
If a sealed explosion-proof enclosure is used for the actuator, then the actuator can operate safely in explosive environments, but the internal heat load may overheat the components
Solution Approach 1:
The patent uses intrinsically safe electrical components that generate minimal heat and cannot cause explosions under normal operating conditions, allowing the use of sealed enclosures without overheating issues
Solution Approach 2:
The patent changes the operational parameters of the electrical components to operate at intrinsically safe levels of energy and heat generation, allowing sealed enclosures to be used without thermal management issues
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
The actuator provides precise and rapid control of choke and valve positions, reducing the risk of sparks and explosions while minimizing space requirements, enabling efficient operation in harsh environments with reduced heat loads and failure points.
Implementation Method 1
a torque sensor assembly mounted in the housing and configured to sense torque from rotation of the servo motor output shaft
Implementation Method 2
a position encoder in communication with the motor controller
Implementation Method 3
a housing having a plurality of components coupled therein, the housing being sealable from external liquids and gases
Data Source
AI summary
The present disclosure provides an actuator and related method of use that can change and control positions of chokes, valves, and other rotational equipment in response to changes in either pressure, torque, or a combination thereof. The actuator with associated integrated components including a servo motor, motor controller, torque sensor assembly, encoder, holding brake, and onboard controls can be encased in a sealed explosion proof rated enclosure for deployment on a drilling rig or other explosive environments with a small footprint suitable for space limited locations. Pressure applied over a known area, such as a choke plug, is converted to torque and can be repeated regardless of flow rate, temperature, fluid type, or density. The torque sensing ability advantageously can quickly respond to fluid changes and make large steps to different set points with accuracy. The onboard controls can control the actuator autonomously without constant communication with a remote controller.