Tubular Makeup Interlock for Drilling Top Drive
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Solution Overview
Problem
The existing top drive systems for drilling with casing face inefficiencies in connecting and disconnecting tubulars due to threaded connections, which are time-consuming and prone to thread damage, and lack an effective interlock system to prevent inadvertent release of tubular strings during assembly or disassembly.
Innovation Solution
An interlock system that ensures at least one tubular holding device is engaged before another disengages, using a load compensator and sensors to control the operations of the top drive and spider, allowing them to open or close based on the load, thereby preventing inadvertent release and ensuring proper engagement during tubular handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded connection is used to connect casing to top drive, then connection can be made, but the process is time consuming and increases likelihood of thread damage
Solution Approach 1:
The patent extracts the threading operation from the connection process by using a threaded adapter that remains permanently attached to the top drive quill. This eliminates the need to thread and unthread connections repeatedly, as only the casing needs to be connected/disconnected from the adapter body, not from threads. This significantly reduces connection time while maintaining reliable threaded connection where needed.
Solution Approach 2:
The threaded adapter is pre-threaded onto the top drive quill before casing operations begin. This preliminary action ensures that the threading work is done once rather than repeatedly during each casing connection/disconnection cycle, reducing overall operation time while maintaining secure connection.
2Ease of operation
If operator manually controls top drive and spider with levers, then operation flexibility is maintained, but inadvertent release of casing string can occur
Solution Approach 1:
The patent implements an interlock system that provides feedback between the top drive and spider control mechanisms. The system monitors the state of both devices and automatically prevents operations that would result in simultaneous disengagement, thereby preventing inadvertent release while maintaining operator control and flexibility through the lever interface.
Solution Approach 2:
The interlock system acts as an intermediary between the operator's lever controls and the actual top drive/spider operations. It mediates the control signals to ensure that commands are executed only when safe conditions are met, preventing direct manual override that could lead to simultaneous disengagement while preserving operator intent and control.
3Reliability
If threading process is used for casing connection, then connection is achieved, but thread damage risk increases leading to potential downtime
Solution Approach 1:
The patent extracts the threading operation from the routine connection process by using a permanently attached threaded adapter on the top drive. This eliminates repeated threading cycles that cause thread wear and damage, thereby maintaining connection stability while preventing the thread damage that leads to downtime and preserving operational continuity.
Data Source
AI summary
Apparatus and methods used to prevent an operator from inadvertently dropping a string into a wellbore during assembling and disassembling of tubulars. In one instance, an interlock system is used to control the operations of a gripping apparatus connected to the top drive and a spider such that at least one of the top drive or the spider retains the tubular. The interlock system allows the spider to open when the gripping apparatus is supporting a load of the tubular or is in position to support a load of the tubular.