Wireless Sensor Unit for Tubular Presence Detection
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Solution Overview
Problem
In the oil and gas industry, there is a risk of catastrophic incidents due to the inability to accurately confirm the presence or absence of tubulars in fingerboard latch assemblies, leading to potential pipe falls and safety hazards.
Innovation Solution
A sensor unit is mounted on the latch bracket or latch of fingerboard latch assemblies, equipped with sensors and a processor to detect the presence, position, and orientation of tubulars, using wireless communication to ensure safe operation and prevent pipe drops by interlocking latches until the tubular is securely positioned.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection is used to confirm tubular presence in slots, then the system remains simple and cost-effective, but the ability to accurately detect tubular presence is insufficient leading to safety hazards
Solution Approach 1:
The patent replaces visual inspection (mechanical/optical system) with electronic sensors including electromagnetic sensors, acoustic sensors, and imaging sensors to detect tubular presence. This substitution enables automated, accurate detection without relying on human visual confirmation, thereby improving measurement precision while the modular sensor design keeps device complexity manageable.
Solution Approach 2:
The patent introduces sensor units as intermediary devices mounted on latch assemblies that detect tubular presence and transmit signals to the control system. This intermediary layer provides reliable detection data between the tubular and the control system, enabling accurate presence confirmation without direct human visual inspection.
2Reliability
If latches are allowed to be opened without verification, then the operation is fast and efficient, but the risk of pipe falls and catastrophic incidents increases
Solution Approach 1:
The patent implements a feedback mechanism where sensors continuously monitor tubular presence and transmit signals to the control system. The control system receives real-time feedback about tubular location and uses this information to control latch operation, preventing latch opening when tubulars are present in slots, thereby ensuring safety without significantly complicating the operation.
Solution Approach 2:
The patent performs preliminary detection of tubular presence before allowing latch opening. The sensor unit detects and confirms tubular location in advance, and the control system uses this information to prevent latch operation when unsafe conditions exist, thereby ensuring safety before the actual latch opening action occurs.
3Productivity
If sensor units are mounted on each latch assembly, then real-time tubular monitoring is achieved, but the device complexity and cost increase
Solution Approach 1:
The patent designs sensor units with multi-functionality, where each sensor unit can perform multiple detection functions (electromagnetic detection, acoustic detection, imaging) and the control system can manage multiple sensors through a unified interface. This universality reduces the need for separate specialized devices for each function, thereby improving productivity while managing device complexity.
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 sensor unit effectively monitors tubulars, preventing accidental pipe drops and ensuring secure storage by providing real-time feedback for controlled handling and operation of latch assemblies, enhancing safety and operational efficiency.
Implementation Method 1
one of ultrasonic, acoustic, electromagnetic, magnetic, radio-frequency, microwave, ultra-wideband, optical, infrared, imaging or inductive sensing
Implementation Method 2
one of ultrasonic, acoustic, electromagnetic, magnetic, radio-frequency, microwave, ultra-wideband, optical, infrared, imaging or inductive sensing
Implementation Method 3
one of ultrasonic, acoustic, electromagnetic, magnetic, radio-frequency, microwave, ultra-wideband, optical, infrared, imaging or inductive sensing
Data Source
AI summary
A sensor unit for a fingerboard latch assembly that comprises a latch bracket and a latch rotatably supported on the latch bracket is mountable on the latch. The sensor unit comprises a sensor configured to sense an adjacent tubular, and a processor that processes the output of the sensor to provide a tubular monitor signal representing the presence or absence of an adjacent tubular A wireless communication unit wirelessly communicates the tubular monitor signal. This allows a wireless sensor unit to be provided that is suitable for operation in remote locations and can verify the presence or absence of tubular to ensure it is securely stored in a fingerboard.