Tubular Makeup Controller Using Torque Feedback
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Solution Overview
Problem
Current methods for achieving target torque during tubular makeup in oil or gas well construction are inefficient, often leading to over-torque due to manual control or require lengthy closed-loop control processes.
Innovation Solution
A closed-loop controller system that measures torque between tubulars and adjusts rotational speed using a set point calculated from measured torque values, employing a sigmoidal function to smoothly reduce speed to zero at the target torque, preventing over-torque and optimizing the makeup process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual control with dump valve is used to stop rotation at target torque, then the makeup process can be completed, but over-torque occurs when rotational speed is too high at final stage
Solution Approach 1:
The system continuously measures torque during makeup and feeds this information back to the controller, which automatically adjusts rotational speed based on real-time torque values. This closed-loop feedback mechanism prevents over-torque by reducing speed when torque approaches the target value, eliminating the need for manual operator intervention and dump valve operation.
Solution Approach 2:
The system dynamically adjusts rotational speed during the makeup process based on measured torque values. Rather than maintaining constant speed, the controller modifies speed in real-time according to the torque curve, allowing high speed during low-torque phases and automatically reducing speed as torque approaches the target, thereby preventing over-torque while maintaining productivity.
2Manufacturing precision
If closed-loop control of torque or rotational speed is used to achieve target torque, then over-torque is prevented, but the makeup process takes a long time
Solution Approach 1:
The system employs periodic measurement of torque during rotation and uses this information to modulate rotational speed in a controlled manner. By measuring torque at regular intervals and adjusting speed periodically rather than continuously, the system achieves precise torque control while minimizing the time penalty associated with constant speed reduction.
Solution Approach 2:
The system changes the rotational speed parameter dynamically based on measured torque values. Rather than maintaining a constant low speed throughout, the controller allows high rotational speed when torque is low and only reduces speed when torque approaches the target value, thereby minimizing the time loss while maintaining precise torque control.
3Device complexity
If rotation is performed for predetermined time at constant speed, then the process is simple, but torque control precision depends on heuristically measured values
Solution Approach 1:
The system replaces the mechanical/heuristic approach of predetermined time and constant speed with an automated control system that uses torque measurement and electronic control. The controller substitutes manual heuristics with algorithm-based decision-making, automatically adjusting speed based on real-time torque feedback, thereby achieving precise torque control without increasing operational complexity.
Data Source
AI summary
The present disclosure generally relates to a method for making up a tubular joint. The method includes rotating a first tubular relative to a second tubular to engage the first and second tubulars while measuring a torque between the first and second tubulars, calculating a set point of a relative rotational speed between the first and second tubulars using the measured torque, and using the calculated set point with a closed-loop controller to control the relative rotational speed between the first and second tubulars.