Torque Transfer Control Tool for Drilling Rig Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Top-drive-equipped drilling rigs face challenges in precisely controlling torque transfer during the assembly of casing and production tubing strings, which is critical for preventing damage and ensuring leakage integrity, as existing systems lack the necessary rapid response and precision for these applications.
Innovation Solution
A torque transfer control tool featuring a rotary-stroking piston actuated by a mandrel, which uses fluid chambers and flow control means to limit torque transfer between torsional drive system components, ensuring that the torque applied does not exceed pre-set pressures, thereby preventing damage and ensuring precise control during make-up operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If top drive is used for make-up of tubing string connections, then drilling operations can be performed with casing running, but torque control precision deteriorates due to large size and slow response of top drive
Solution Approach 1:
A torque transfer control tool is introduced as an intermediary device between the top drive and the tubing string connection. This tool includes a mandrel, piston, and fluid chamber system that mediates the torque transfer, providing precise control while the top drive maintains its primary drilling functions.
Solution Approach 2:
The torque control function is segmented from the top drive system into a separate, dedicated torque transfer control tool. This segmentation allows the top drive to maintain its large size and drilling capabilities while the separate tool provides specialized precise torque control for tubing make-up operations.
2Reliability
If make-up torque is increased to ensure proper engagement of torque shoulders and metal-to-metal seals, then connection integrity improves, but risk of over-torque damage increases
Solution Approach 1:
The torque transfer control tool incorporates a feedback mechanism where fluid pressure in the closed hydraulic circuit provides real-time information about torque transfer. The piston position and fluid pressure feedback allow the system to maintain torque within the optimal range, ensuring proper engagement without exceeding damage thresholds.
Solution Approach 2:
A closed hydraulic circuit with fluid chamber and piston is used to control torque transfer. The hydraulic system provides smooth, controlled torque application and can rapidly respond to torque conditions, enabling precise control between the minimum torque needed for proper engagement and the maximum torque before damage occurs.
3Productivity
If top drive torque control system is designed for drill pipe connections, then drilling operations are efficient, but response speed and precision deteriorate for casing and production tubing connections
Solution Approach 1:
The torque transfer control tool acts as an intermediary that provides rapid torque control response specifically for tubing make-up operations, while the top drive continues to handle drilling operations efficiently. The intermediary tool's hydraulic system responds much faster than the top drive's mechanical torque control system.
Solution Approach 2:
The hydraulic piston system provides dynamic torque control with rapid response capability. The fluid-based system can quickly adjust torque levels in response to connection conditions, whereas the top drive's mechanical system has inherent inertia and slower response time.
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 tool effectively manages torque loads during the assembly of tubing strings, providing precise control and preventing over-torque damage, thus ensuring the integrity of connections and structural capacity in drilling and completion operations.
Implementation Method 1
a fluid chamber in the region of the housing bore not occupied by the mandrel; a primary piston sealingly movable axially within the fluid chamber
Implementation Method 2
fluid communication means for enabling fluid communication out of the at least one fluid chamber at a selected pressure
Data Source
AI summary
A torque transfer control tool has a rotary-stroking piston that is axially movable within a fluid chamber in response to rotation of mandrel having an upper end co-rotatably coupled to a first torsional drive system component and a lower end coaxially disposed and rotatable within the bore of a cylindrical housing. A lower end of the housing is co-rotatably coupled to a second torsional drive system component. Mandrel rotation in a first rotational direction moves the piston downward to pressurize a fluid in a lower fluid chamber below the piston. Fluid flow control means associated with the piston allows fluid flow out of the lower fluid chamber to prevent the fluid pressure therein from exceeding a first pre-set pressure, thus limiting the magnitude of the torque transferred to the second torsional drive system component in the first rotational direction via the tool housing.