LOCAL ELECTRIC POWER GENERATION FOR TONG CONTROL SYSTEM
A method and apparatus for tong power and control. A tong includes a tong control system; and a local electric power generation system, wherein the tong control system is powered by the local electric power generation system. A method includes supplying hydraulic power to a motor on a tong; driving an electric generator on the tong with the motor; and supplying electric power to a tong control system on the tong. A method includes installing a tong control system on a tong; and installing a local electric power generation system on the tong, wherein the tong control system is powered by the local electric power generation system.
Field of the Invention
Embodiments of the present invention generally relate to systems and methods for local control and/or electric power generation for a tong.
Description of the Related Art
Tongs are devices used on oil and gas rigs for gripping and/or rotating tubular members, such as casing, drill pipe, drill collars, and coiled tubing (herein referred to collectively as tubulars and/or tubular strings). Tongs may be used to make-up or break-out threaded joints between tubulars. Tongs typically resemble large wrenches, and may sometime be referred to as power tongs, torque wrenches, spinning wrenches, and/or iron roughnecks. Tongs typically use hydraulic power to provide sufficiently high torque to make-up or break-out threaded joints between tubulars. Equipment utilized with/on tongs may also need some electric power, for example actuators and/or sensors. Supplying the electric power to such equipment commonly requires the routing of the electric wires through several junction boxes, cables, and/or connectors. Such routing can be expensive and hazardous due to the circumstances in explosive atmosphere. Such routing can also require manual mating/de-mating of connectors, which presents additional risks, costs, and reliability concerns. In some instances, adequate connectors may not be available or certified for the particular operational conditions.
Historically, tongs have been either manually operated or controlled remotely by an operator in the driller's cabin. Onboard tong control has heretofore not been achievable due to control system size, power, and safety requirements.
Onboard control of a tong—facilitated by local electric power generation—may provide improved handling, greater reliability, and increased safety and efficiency.
SUMMARY OF THE INVENTIONEmbodiments of the present invention generally relate to systems and methods for local control and/or electric power generation for a tong, wherein the tong control system is powered by the local electric power generation system.
In an embodiment a tong includes a tong control system; and a local electric power generation system.
In an embodiment, a method includes supplying hydraulic power to a motor on a tong; driving an electric generator on the tong with the motor; and supplying electric power to a tong control system on the tong.
In an embodiment, a method includes installing a tong control system on a tong; and installing a local electric power generation system on the tong, wherein the tong control system is powered by the local electric power generation system.
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
Embodiments of the present invention generally relate to systems and methods for local control and/or electric power generation for a tong.
In some embodiments, a tong control system may be small (e.g., less than about 2 ft in any dimension; for example 16″×16″×6″), so that it can be placed on the tong. In some embodiments, data communication between the local tong control system and remote logging/monitoring equipment may be wireless. In some embodiments, electric power generation may occur locally on the tong by branching off a portion of an existing hydraulic supply line. Consequently, existing tongs may be beneficially retrofitted. Some embodiments may provide beneficial reduction in electrical connectors, supply boxes, and/or cables that could be damaged, cause accident or injury, contamination, and/or corrosion issues. There may be beneficially only a few required components (e.g., a hydraulic motor, a volume control valve, an alternator, and a belt or drive shaft to connect both). In some embodiments, a battery system may power the tong control system during the absence of hydraulic power in the event of an emergency shut-down.
A tong control system may monitor and actuate several parts of the tong. For example, the tong control system may monitor and actuate components of the tong to provide varying torque and/or angular displacement. Disconnection of a tubular joint may require both a high-torque/low-angular displacement “break” action to disengage the contact shoulders, and a low-torque/high-angular displacement “spin” action to screw-out the threads. Connection of a tubular joint may occur in the reverse sequence. In the make/break action, torque may be high (e.g., 10,000-100,000 ft-lb), having a small (e.g., 0.12-0.24 revolutions) angular displacement. In the spin action, torque may be low (e.g., 1,000-3,000 ft-lb), having a large (e.g., 3-5 revolutions) angular displacement.
As another example, the tong control system may monitor and actuate components of the tong to provide varying clamping and rotation actions. Upper and lower jaws of the tong may turn relative to each other to break a connection between upper and lower tool joints. The upper jaw may then be released while the lower jaw remains clamped onto the lower tool joint. A spinning wrench, commonly separate from the torque wrench and mounted higher up on the carriage, may engage the stem of the upper joint of drill pipe to spin the upper joint until it is disconnected from the lower joint. Upper and lower jaws of the tong may turn relative to each other to make-up two joints of pipe. The lower jaw may grip the lower tool joint while the upper pipe is brought into position. The spinning wrench may engage the upper joint to spin it into the lower joint. The torque wrench may clamp the pipe and tighten the connection.
In some embodiments, tong control system 160 may be configured to control how the tong 100 handles tubulars, grips tubulars, turns tubulars, and/or manages hydraulic power for handling, gripping, and/or turning tubulars. In some embodiments, tong control system 160 may be configured to receive input (e.g., from sensors) regarding how the tong 100 interacts with tubulars. In some embodiments, tong control system 160 may be configured to process and/or store data (e.g., pipe size, thread size, thread count, etc.) regarding how the tong 100 interacts with tubulars. In some embodiments, tong control system 160 may be configured to generate and/or send control signals (e.g., to actuators) to control how the tong 100 interacts with tubulars. Tong control system 160 may include a torque sensor (e.g., a load cell) and/or a turns counter. In some embodiments, tong control system 160 may also include a clock (e.g., a timer). Tong control system 160 may be configured to receive input from a torque sensor and/or a turns counter. In some embodiments, tong control system 160 may be configured to also receive input from a clock. Tong control system 160 may include data storage and/or data processors. Tong control system 160 may be configured to store and/or process tong control data. Tong control system 160 may include a tubular gripping actuator, a tubular turning actuator, and/or a hydraulic power control actuator (e.g., a dump valve). In some embodiments, tong control system 160 may also include a jaw positioning actuator. Tong control system 160 may be configured to send control signals to a tubular gripping actuator, a tubular turning actuator, and/or a hydraulic power control actuator. In some embodiments, tong control system 160 may be configured to also send control signals to a jaw positioning actuator.
In some embodiments, and at times during operations, the hydraulic coupler 170 may supply hydraulic power to the motor 130. In some embodiments, and at times during operations, the electric generator 140 may supply electric power to the battery system 150, the tong control system 160, and/or the electrical equipment 165.
At times during operations, hydraulic power from the hydraulic coupler 170 may be reduced or stopped. Consequently, it is expected that motor 130 may not run continuously and/or consistently. Likewise, it is expected that electric generator 140 may not run continuously and/or at a consistent output rate. In some embodiments, when electric generator 140 is not running, or is running at a low output rate, the battery system 150 may supply electric power to the tong control system 160 and/or the electrical equipment 165. In some embodiments, and at times during operations, the electric generator 140 and the battery system 150 may jointly supply electric power to the tong control system 160 and/or the electrical equipment 165.
As a normal part of operations, tong 100 may be disconnected from rig 200, for example to be stored between jobs. Battery system 150 may remained charged, even while hydraulic lines 180 are disconnected from motor 130. At times, information that has been logged by and/or stored in tong control system 160 may be accessed and/or downloaded while tong 100 is disconnected from rig 200. Battery system 150 may provide electrical power to tong control system 160 and/or wireless communication equipment 190 to facilitate accessing and/or downloading data while tong 100 is disconnected from rig 200. Likewise, data, software, firmware updates, etc., may be uploaded to control system 160 while tong 100 is disconnected from rig 200. Battery system 150 may provide electrical power to tong control system 160 and/or wireless communication equipment 190 to facilitate uploading data and/or software while tong 100 is disconnected from rig 200.
Conventional tongs may be retrofitted with one or more embodiments of local tong control systems and/or local electric power generation.
In an embodiment a tong includes a tong control system; and a local electric power generation system, wherein the tong control system is powered by the local electric power generation system.
In one or more embodiments disclosed herein, the tong control system includes: a torque sensor; a turns counter; a tubular gripping actuator; and a tubular turning actuator.
In one or more embodiments disclosed herein, the tong control system further includes a clock.
In one or more embodiments disclosed herein, the tong control system further includes a jaw positioning actuator.
In one or more embodiments disclosed herein, the tong control system further includes data storage and a data processor.
In one or more embodiments disclosed herein, the tong control system further includes a hydraulic power control actuator.
In one or more embodiments disclosed herein, the tong control system is configured to: receive input from: a torque sensor and a turns counter; and send control signals to: a tubular gripping actuator, and a tubular turning actuator.
In one or more embodiments disclosed herein, the tong control system is further configured to receive input from a clock.
In one or more embodiments disclosed herein, the tong control system is further configured to send control signals to a jaw positioning actuator.
In one or more embodiments disclosed herein, the tong control system is further configured to store tong control data and process tong control data.
In one or more embodiments disclosed herein, the tong control system is further configured to send control signals to a hydraulic power control actuator.
In one or more embodiments disclosed herein, the local electric power generation system includes a motor; and an electric generator.
In one or more embodiments disclosed herein, the motor directly drives the electric generator.
In one or more embodiments disclosed herein, the motor is dedicated to drive only the electric generator.
In one or more embodiments disclosed herein, the local electric power generation system further comprises a battery system.
In one or more embodiments disclosed herein, the battery system comprises a charge controller.
In one or more embodiments disclosed herein, the motor is a hydraulic motor.
In one or more embodiments disclosed herein, the tong also includes a frame, wherein the local electric power generation system is disposed on the frame.
In one or more embodiments disclosed herein, the tong also includes electrical equipment, wherein the local electric power generation system powers the electrical equipment.
In one or more embodiments disclosed herein, the electrical equipment is located on a stationary portion of the tong.
In one or more embodiments disclosed herein, the tong also includes a hydraulic coupler; and a plurality of jaws, wherein power for the plurality of jaws comes through the hydraulic coupler.
In one or more embodiments disclosed herein, the local electric power generation system comprises a hydraulic motor; and power for the hydraulic motor comes through the hydraulic coupler.
In one or more embodiments disclosed herein, the tong also includes a volume control valve between the hydraulic coupler and the hydraulic motor.
In one or more embodiments disclosed herein, the tong control system comprises wireless communication equipment.
In an embodiment, a method includes supplying hydraulic power to a motor on a tong; driving an electric generator on the tong with the motor; and supplying electric power to a tong control system on the tong.
In one or more embodiments disclosed herein, the method also includes supplying electric power to a battery system on the tong.
In one or more embodiments disclosed herein, the electric power is supplied to the tong control system by at least one of the electric generator and the battery system.
In one or more embodiments disclosed herein, the method also includes stopping the driving the electric generator with the motor; and while the driving is stopped, continuing to supply electric power to the tong control system.
In one or more embodiments disclosed herein, the electric power is supplied to the tong control system by the battery system while the driving is stopped.
In one or more embodiments disclosed herein, the method also includes recording operational status information while the driving is stopped.
In one or more embodiments disclosed herein, the method also includes supplying electric power to a battery system on the tong; then disconnecting the hydraulic power supply from the motor and the electric power from the tong control system, leaving the battery system charged; then supplying electric power to the tong control system with the battery system.
In one or more embodiments disclosed herein, the method also includes, while the hydraulic power supply is disconnected from the motor, at least one of: running a startup routine for the tong control system; accessing data from the tong control system; downloading data from the tong control system; uploading data to the tong control system; and uploading software to the tong control system.
In an embodiment, a method includes installing a tong control system on a tong; and installing a local electric power generation system on the tong, wherein the tong control system is powered by the local electric power generation system.
In one or more embodiments disclosed herein, the tong is located on a rig floor, the method further comprising disconnecting from the tong and removing from the rig floor at least one of programmable logic controllers, input/output systems, joint-analyzed makeup systems, junction boxes, cables, connectors, and electrical couplings.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
Claims
1. A tong comprising:
- a tong control system; and
- a local electric power generation system, wherein the tong control system is powered by the local electric power generation system.
2. The tong of claim 1, wherein the tong control system comprises:
- a torque sensor;
- a turns counter;
- a tubular gripping actuator; and
- a tubular turning actuator.
3. The tong of claim 2, wherein the tong control system further comprises a clock.
4. The tong of claim 2, wherein the tong control system further comprises a jaw positioning actuator.
5. The tong of claim 2, wherein the tong control system further comprises data storage and a data processor.
6. The tong of claim 2, wherein the tong control system further comprises a hydraulic power control actuator.
7. The tong of claim 1, wherein the local electric power generation system comprises:
- a motor; and
- an electric generator.
8. The tong of claim 7, wherein the motor directly drives the electric generator.
9. The tong of claim 7, wherein the motor is dedicated to drive only the electric generator.
10. The tong of claim 7, wherein the local electric power generation system further comprises a battery system.
11. The tong of claim 1, further comprising a frame, wherein the local electric power generation system is disposed on the frame.
12. The tong of claim 1, further comprising electrical equipment, wherein the local electric power generation system powers the electrical equipment, and the electrical equipment is located on a stationary portion of the tong.
13. The tong of claim 1, further comprising:
- a hydraulic coupler; and
- a plurality of jaws, wherein: power for the plurality of jaws comes through the hydraulic coupler; the local electric power generation system comprises a hydraulic motor; and power for the hydraulic motor comes through the hydraulic coupler.
14. The tong of claim 13, further comprising a volume control valve between the hydraulic coupler and the hydraulic motor.
15. The tong of claim 1, wherein the tong control system comprises wireless communication equipment.
16. A method comprising:
- supplying hydraulic power to a motor on a tong;
- driving an electric generator on the tong with the motor; and
- supplying electric power to a tong control system on the tong.
17. The method of claim 16, further comprising supplying electric power to a battery system on the tong.
18. The method of claim 17, wherein the electric power is supplied to the tong control system by at least one of the electric generator and the battery system.
19. The method of claim 17, further comprising:
- stopping the driving the electric generator with the motor; and
- while the driving is stopped, continuing to supply electric power to the tong control system.
20. The method of claim 19, wherein the electric power is supplied to the tong control system by the battery system while the driving is stopped.
21. The method of claim 19, further comprising recording operational status information while the driving is stopped.
22. The method of claim 16, further comprising:
- supplying electric power to a battery system on the tong;
- then disconnecting the hydraulic power supply from the motor and the electric power from the tong control system, leaving the battery system charged;
- then supplying electric power to the tong control system with the battery system.
23. A method comprising:
- installing a tong control system on a tong; and
- installing a local electric power generation system on the tong, wherein the tong control system is powered by the local electric power generation system.
24. The method of claim 23, wherein the tong is located on a rig floor, the method further comprising disconnecting from the tong and removing from the rig floor at least one of programmable logic controllers, input/output systems, joint-analyzed makeup systems, junction boxes, cables, connectors, and electrical couplings.
Type: Application
Filed: May 26, 2017
Publication Date: Nov 29, 2018
Inventors: Frank WERN (Hannover), Federico AMEZAGA (Cypress, TX)
Application Number: 15/607,049