Wireline Head Tension Control Using Closed-Loop Speed Feedback
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Solution Overview
Problem
Operators in wireline systems for oil and gas operations face challenges in maintaining head tension within a set range, leading to inefficiencies and potential mistakes due to the need to manually adjust winch or tractor speed and monitor multiple parameters, especially in horizontal well sections.
Innovation Solution
A head tension control system that automates the regulation of head tension by determining errors based on speed differences and target tensions, adjusting winch or tractor operations to maintain optimal cable tension through defined operating zones, utilizing a head tension control system with a computing device and processor to execute instructions for automated control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation of winch and tractor is used to convey tool string, then operator can control the system, but operator becomes overwhelmed and makes mistakes due to multiple parameters to monitor
Solution Approach 1:
The system enables self-service automation where the control system automatically monitors head tension, compares it to target values, and adjusts winch or tractor speed without continuous operator intervention. The automated control system serves itself by making real-time adjustments based on sensor feedback, reducing operator workload while maintaining reliable head tension control.
Solution Approach 2:
The system implements closed-loop feedback control by continuously measuring head tension with sensors, comparing the measured tension to target tension values, and automatically adjusting winch or tractor speed based on the error signal. This feedback mechanism ensures reliable head tension control while eliminating the need for operators to manually monitor multiple parameters.
2Productivity
If automated head tension control is implemented, then operational efficiency improves, but system complexity increases
Solution Approach 1:
The patent merges the head tension control function with the existing winch or tractor control systems. The automated control system integrates multiple functions (tension sensing, error calculation, speed adjustment) into a unified control architecture that leverages existing components, thereby improving operational efficiency without proportionally increasing system complexity.
Solution Approach 2:
The control system is designed with multi-functionality, serving both as a monitoring system and an automatic control system. The same control architecture handles both manual and automated operation modes, and can adapt to different well conditions and tool string configurations, improving productivity while keeping the system versatile rather than overly complex.
Data Source
AI summary
A head wireline tension control system may determine a head tension based on a speed of the tool driving equipment and a cable speed of the cable as a function of an operation of the winch. A head tension regulation error may be determined based on a comparison of the head tension and a target head tension, and the head tension control system may operate the winch or the tool driving equipment according to an operating zone that includes the head tension regulation error. The operating zone may be defined by a first range of values for a difference between the speed of the tool driving equipment and the cable speed, and a first range of values for a difference between the head tension and the target head tension.