Apparatus for automated oilfield torque wrench set-up to make-up and break-out tubular strings
First Claim
1. A torque wrench apparatus configured to manipulate tubulars, the torque wrench apparatus comprising:
- a memory store including a plurality of records, each record storing a plurality of tubular type specific parameters comprising at least one of a spin-in time value and a spin-out time value, the spin-in time value specifying an amount of time to couple tubulars, the spin-out time value specifying an amount of time to uncouple tubulars;
at least one sensor configured to monitor at least one process step of a tubular make-up process step or a tubular break-out process step, the at least one sensor reporting a sensor value that indicates completion of the process step;
a timer configured to measure elapsed time from the beginning of the at least one process step until an occurrence of at least one step completion confirmatory event, the timer reporting a timer value; and
a counter configured to be incremented each time the at least one process step fails to complete within the spin-in time value or the spin-out time value, the counter reporting a counter value;
a comparator configured to compare values, the comparator reporting a comparator value; and
a controller configured to;
look-up at least one of the plurality of records to retrieve at least one of the spin-in time value and the spin-out time value;
cause the comparator to compare;
the reported timer value, to the spin-in time value or the spin-out time value to detect whether the at least one process step fails to complete within the spin-in time value or the spin-out time value; and
receive the counter value from the counter when the at least one process step fails to complete within the spin-in time value or the spin-out time value.
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Accused Products
Abstract
Automated make-up and break-up methods and apparatus for rotary oil well drilling are presented. The apparatus includes a drilling database storing tubular type records, a torque wrench having a spinner, and a controller. During make-up, the controller retrieves one or more tubular type records stored in the drilling database in order to configure the torque wrench and/or the spinner to connect an additional tubular section to a tubular string or to disconnect a connection between tubulars in accordance with tubular type parameters. Sensors are employed on various drill rig components and reported sensor values are monitored. Timers are started concurrent with the initiation of various make-up and break-out steps. Exceptions are thrown when sensor values are out-of-range or when steps take too long to complete. Advantages are derived from speeding-up drill rig operations.
137 Citations
18 Claims
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1. A torque wrench apparatus configured to manipulate tubulars, the torque wrench apparatus comprising:
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a memory store including a plurality of records, each record storing a plurality of tubular type specific parameters comprising at least one of a spin-in time value and a spin-out time value, the spin-in time value specifying an amount of time to couple tubulars, the spin-out time value specifying an amount of time to uncouple tubulars; at least one sensor configured to monitor at least one process step of a tubular make-up process step or a tubular break-out process step, the at least one sensor reporting a sensor value that indicates completion of the process step; a timer configured to measure elapsed time from the beginning of the at least one process step until an occurrence of at least one step completion confirmatory event, the timer reporting a timer value; and a counter configured to be incremented each time the at least one process step fails to complete within the spin-in time value or the spin-out time value, the counter reporting a counter value; a comparator configured to compare values, the comparator reporting a comparator value; and a controller configured to; look-up at least one of the plurality of records to retrieve at least one of the spin-in time value and the spin-out time value; cause the comparator to compare;
the reported timer value, to the spin-in time value or the spin-out time value to detect whether the at least one process step fails to complete within the spin-in time value or the spin-out time value; andreceive the counter value from the counter when the at least one process step fails to complete within the spin-in time value or the spin-out time value. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A torque wrench apparatus configured to manipulate tubulars, the torque wrench apparatus comprising:
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a) a memory store including a plurality of records, each record storing a plurality of tubular type specific parameters comprising at least one of a spin-in time value and a spin-out time value, the spin-in time value specifying an amount of time to couple tubulars, the spin-out time value specifying an amount of time to uncouple tubulars; b) at least one sensor configured to monitor at least one process step of a tubular make-up process step or a tubular break-out process step, the at least one sensor reporting a sensor value; c) a timer configured to measure elapsed time from the beginning of the at least one process step until the occurrence of at least one step completion confirmatory event, the timer reporting a timer value; d) a counter configured to be incremented each time the at least one process step fails to complete within the spin-in time value or the spin-out time value, the counter reporting a counter value; e) a comparator configured to compare values, the comparator reporting a comparator value; and f) a controller configured to; i) look-up at least one of the plurality of records to retrieve at least one of the spin-in time value and the spin-out time value; ii) cause the comparator to compare; the reported timer value against at least one of the spin-in time value and the spin-out time value to detect whether the at least one process step fails to complete within the spin-in time value or the spin-out time value; iii) detect the occurrence of the at least one step completion confirmatory event based on at least one of;
the reported sensor value, the reported timer value, the reported counter value, the reported comparator value, the result of the comparison, and at least one of the spin-in time value and the spin-out time value;iv) raise an exception triggered by the detection of the occurrence of the at least one step completion confirmatory event; and v) address the exception by performing at least one of the following; repeat the at least one process step once;
repeat the at least one process step for a predetermined number of times while incrementing a counter each time;
repeat the at least on process step for a predetermined amount of time measured by the timer; and
skip the at least one process step, restart, shutdown a subsystem, and prompt for human intervention.
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Specification