U.S. patent application number 12/757146 was filed with the patent office on 2011-10-13 for assembly, system, and method for cable tension measurement.
Invention is credited to Dominique Aubry, Stephane Breard, Lucas Teurlay.
Application Number | 20110251803 12/757146 |
Document ID | / |
Family ID | 44761542 |
Filed Date | 2011-10-13 |
United States Patent
Application |
20110251803 |
Kind Code |
A1 |
Teurlay; Lucas ; et
al. |
October 13, 2011 |
ASSEMBLY, SYSTEM, AND METHOD FOR CABLE TENSION MEASUREMENT
Abstract
A tension measurement assembly, for measuring and monitoring a
tension force in a cable being deployed from a spooling device on
which the cable is spooled, comprises at least one force sensor
disposed adjacent the spooling device for sensing a force applied
to the spooling device and generating a force signal representing
the sensed force, and a processor responsive to the force signal
for calculating and monitoring a tension force present in the
cable. A cable sensor engages the deployed cable for sensing a
spooling/unspooling rate and a length of the cable moving past the
cable sensor in a pre-determined time period and generating a
spooling signal representing the sensed rate and length to the
processor for use in the calculating and monitoring of the tension
force.
Inventors: |
Teurlay; Lucas; (Amiens,
FR) ; Breard; Stephane; (Oust-Marest, FR) ;
Aubry; Dominique; (Hallencourt, FR) |
Family ID: |
44761542 |
Appl. No.: |
12/757146 |
Filed: |
April 9, 2010 |
Current U.S.
Class: |
702/43 |
Current CPC
Class: |
G01L 5/103 20130101;
G01L 5/04 20130101 |
Class at
Publication: |
702/43 |
International
Class: |
G01L 5/04 20060101
G01L005/04 |
Claims
1. A tension measurement assembly for measuring and monitoring a
tension force in a cable being deployed from a spooling device on
which the cable is spooled, comprising: at least one force sensor
disposed adjacent the spooling device for sensing a force applied
to the spooling device and generating a force signal representing
the sensed force; and a processor responsive to the force signal
for calculating and monitoring a tension force present in the
cable.
2. The assembly according to claim 1, wherein said at least one
force sensor is a multi-axis force sensor.
3. The assembly according to claim 1, wherein said at least one
force sensor comprises a multi-axis transducer for measuring forces
along a pre-determined coordinate system.
4. The assembly according to claim 1, further comprising a chassis
for supporting the spooling device, wherein said at least one force
sensor is disposed adjacent said chassis.
5. The assembly according to claim 1, further comprising a cable
sensor disposed to engage the cable and measure a
spooling/unspooling characteristic of the cable.
6. The assembly according to claim 5, wherein said cable sensor
comprises a measuring wheel to engage the cable and an encoder to
measure a rotation of the measuring wheel due to a movement of the
cable.
7. The assembly according to claim 5, wherein the
spooling/unspooling characteristic of the cable comprises at least
one of a spooling/unspooling rate and a length of the cable moving
past said cable sensor in a pre-determined time period.
8. A system for measuring and monitoring a tension force in a
cable, comprising: a spooling device for deploying and retrieving
the cable spooled thereon, wherein said spooling device includes a
support member; a force sensor disposed adjacent the support member
of said spooling device for sensing a force on said support member
and generating a force signal representing the sensed force; a
cable sensor disposed to measure spooling/unspooling
characteristics of the cable and generate a spooling signal
representing the measured spooling/unspooling characteristics; and
a processor for computing and monitoring the tension force in the
cable in response to the force signal and the spooling signal.
9. The system according to claim 8, wherein said force sensor
comprises a multi-axis force sensor.
10. The system according to claim 8, wherein said force sensor
comprises a multi-axis transducer for measuring forces along a
pre-determined coordinate system.
11. The system according to claim 8, wherein said spooling device
comprises a drum having the cable spooled thereon and said support
member comprises a shaft rotatably supporting said drum.
12. The system according to claim 8, further comprising a chassis
for engaging said support member of said spooling device, wherein
said force sensor is disposed adjacent said chassis to measure a
force between said support member and said chassis.
13. The system according to claim 12, further comprising a bearing
mounted to said chassis for receiving said support member, wherein
said bearing allows said support member to rotate.
14. The system according to claim 8, further comprising a cable
sensor disposed to engage the cable and measure a
spooling/unspooling characteristic of the cable.
15. The system according to claim 14, wherein said cable sensor
comprises a measuring wheel to engage the cable and an encoder to
measure a rotation of said measuring wheel due to a movement of the
cable.
16. The system according to claim 14, wherein the
spooling/unspooling characteristic of the cable is at least one of
a spooling/unspooling rate and a length of the cable moving past
said cable sensor in a pre-determined time period.
17. A method for measuring and monitoring a tension force in a
spoolable device, comprising: providing a spooling device for
deploying and retrieving the spoolable device; directing the
spoolable device from the spooling device to and from a downstream
point; providing at least one force sensor disposed adjacent the
spooling device for sensing a force applied to the spooling device
and generating a force signal representing the sensed force;
providing a spoolable device sensor disposed to measure
spooling/unspooling characteristics of the spoolable device and
generate a spooling signal representing the measured
spooling/unspooling characteristics; and calculating the tension
force in the spoolable device based on the force signal from the at
least one force sensor and the spooling signal from the spoolable
device sensor.
18. The method according to claim 17, wherein the at least one
force sensor is a multi-axis force sensor.
19. The method according to claim 17, wherein the
spooling/unspooling characteristic of the spoolable device is at
least one of a spooling/unspooling rate and a length of the
spoolable device moving past the spoolable device sensor in a
pre-determined time period.
20. The method according to claim 17, further comprising a step of
calculating a drum weight, wherein the step of calculating the
tension force in the spoolable device is based on the force signal
from the force sensor, the spooling signal from the spoolable
device sensor, and the drum weight.
21. The method according to claim 17, wherein the spoolable device
comprises a wireline cable.
Description
BACKGROUND OF THE INVENTION
[0001] The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
[0002] The present invention generally relates to wellsite surface
equipment such as wireline surface equipment and the like. In
particular, the invention is directed to an assembly, a system, and
a method for measuring a tension in a cable.
[0003] During a typical wireline operation a tool string is moved
up and down in a well using a winch. Specifically, the tool string
is attached to a cable, whereby the cable is spooled/unspooled on a
drum. In this context, it is critical to monitor a tension in the
cable to prevent operational pitfalls such as cable breaks (e.g.
tool string stuck into the well), cable slacking (e.g. not enough
cable tension), and the like.
[0004] Currently, cable tension is measured using a Cable Mounted
Tension Device (CMTD), wherein the cable is trapped between three
wheels and a shaft is deformed proportionally to the cable tension.
For monitoring a tension in the cable, the shaft deformation is
sensed by a strain gauge.
[0005] In certain instances, a conventional strain gauge has shown
some reliability issues and the wheels of the CMTD can damage the
winch cable (under high tension the CMTD could even break the
cable).
[0006] More accurate assemblies, systems, and methods are needed
for measuring the tension of a cable, without the use of a CMTD. It
also remains desirable to provide improvements in wellsite surface
equipment in efficiency, flexibility, reliability, and
maintainability.
SUMMARY OF THE INVENTION
[0007] An embodiment of a tension measurement assembly for
measuring and monitoring a tension force in a cable being deployed
from a spooling device on which the cable is spooled, includes at
least one force sensor disposed adjacent the spooling device for
sensing a force applied to the spooling device and generating a
force signal representing the sensed force, and a processor
responsive to the force signal for calculating and monitoring a
tension force present in the cable.
[0008] In an embodiment, a system for measuring and monitoring a
tension force in a cable, includes: a spooling device for deploying
and retrieving the cable spooled thereon, wherein said spooling
device includes a support member; a force sensor disposed adjacent
the support member of said spooling device for sensing a force on
the support and generating a force signal representing the sensed
force; a cable sensor disposed to measure spooling/unspooling
characteristics of the cable and generate a spooling signal
representing the measured spooling/unspooling characteristics; and
a processor for computing and monitoring the tension force in the
cable in response to the force signal and the spooling signal.
[0009] The invention also includes methods for measuring a tension
of a cable.
[0010] In an embodiment, a method includes the steps of: providing
a spooling device for deploying and retrieving the cable; directing
the cable from the spooling device to a downstream point; providing
a force sensor disposed adjacent the spooling device for sensing a
force applied to the spooling device and generating a force signal
representing the sensed force; providing a cable sensor disposed to
measure spooling/unspooling characteristics of the cable and
generate a spooling signal representing the measured
spooling/unspooling characteristics; and calculating the tension
force in the cable based on the force signal from the force sensor
and the spooling signal from the cable sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other features and advantages of the present
invention will be better understood by reference to the following
detailed description when considered in conjunction with the
accompanying drawings wherein:
[0012] FIG. 1 is a schematic representation of a tension
measurement system and assembly according to an embodiment of the
present invention; and
[0013] FIG. 2 is a schematic block diagram of the tension
measurement system and assembly of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring now to FIGS. 1-2, there is shown an embodiment of
a tension measurement system, indicated generally at 10. As shown,
the tension measurement system 10 includes a spooling device 12 for
spooling a cable 14, a plurality of force sensors 16, 18 positioned
to measure forces acting on the spooling device 12, a cable sensor
20, and a processor 22 in communication with the force sensors 16,
18 and the cable sensor 20. Those skilled in the art will
appreciate that the cable 14 may comprise a wireline electrical or
electro-optical cable, a slickline cable, a length of coiled
tubing, or a similar suitable spoolable device that is operable to
be spooled onto the spooling device 12.
[0015] As shown in FIG. 1, the spooling device 12 includes a drum
24 having a shaft 26 (i.e. support member) disposed therethrough,
wherein a portion of the shaft 26 extends from opposites sides of
the drum 24. A pair of bearings 28 are disposed on a chassis 30
(e.g. cradle) and positioned to receive the portion of the shaft 26
extending from opposite sides of the drum 24. It is understood that
the bearings 28 are mounted to the chassis 30 to provide support to
the drum 24, while allowing the drum 24 to rotate for spooling and
unspooling the cable 14. It is further understood that other
support members may be used to engage the chassis 30 to support the
drum 24, while allowing the drum 24 to rotate.
[0016] The force sensors 16, 18 are multi-axis force sensors. As a
non-limiting example, each of the force sensors 16, 18 includes a
plurality of independent strain gauges to measure force vectors
along three pre-defined axes (i.e. pre-defined coordinate system),
as well as measure the moments about each force vector. As a
further non-limiting example, each of the force sensors 16, 18
includes a transducer for measuring and outputting forces along all
three Cartesian coordinates (x, y and z). It is understood that the
coordinate system of the force sensors 16, 18 can be configured in
any orientation relative to the spooling device 12. It is further
understood that any sensors can be used to measure forces acting on
the spooling device 12 and output a force signal representing the
measured forces such as a multi-axis force/torque transducer and a
multi-axis load cell, known in the art.
[0017] In the embodiment shown, the force sensors 16, 18 are
disposed adjacent the shaft 26, wherein each of the force sensors
16, 18 is adjacent an associated one of the bearings 28 in order to
monitor the forces between the shaft 26 and the bearings 28 along
at least one axis. In certain embodiments, at least one of the
force sensors 16, 18 is integrated with the shaft 26. In certain
embodiments, at least one of the force sensors 16, 18 is integrated
with at least one of the bearings 28. It is understood that in
context to the force sensors 16, 18, the phrase "disposed adjacent"
can be defined as: nearby; abutting; integrated with; or a
functional equivalent of the same. It is further understood that
any number of the force sensors 16, 18 can be used to measure
forces applied to the spooling device 12.
[0018] The cable sensor 20 is positioned to measure
spooling/unspooling characteristics of the cable 14 or spoolable
device such as spooling/unspooling rate of the cable 14 and a
length of the cable 14 moving past the cable sensor 20 over a pre-
determined time period, for example. It is understood that the
cable sensor 20 can be adapted to measure any number of
characteristics of the cable 14.
[0019] As a non-limiting example, the cable sensor 20 is a depth
wheel adapted to engage the cable 14 to measure at least a length
of the cable 14 passing thereby and a spooling/unspooling rate of
the cable 14. As a further non-limiting example, the cable sensor
20 includes a plurality of measuring wheels 32 to engage the cable
14. Each of the measuring wheels 32 is mounted to an encoder
assembly 34 such that a rotation of the measuring wheel 32 is
monitored by an associated one of the encoder assemblies 34, as
appreciated by one skilled in the art of encoders. A spooling
signal (i.e. pulse output) is generated by the encoder assembly 34
in response to a rotation of an associated one of the measuring
wheels 32. The spooling signal represents the spooling/unspooling
characteristics of the cable 14 and can be analyzed to determine at
least a length of the cable 14 passing through the cable sensor 20
and a spooling/unspooling rate of the cable 14. It is understood
that any suitable sensor can be used to measure characteristics of
the cable 14.
[0020] The processor 22 is in data communication with the force
sensors 16, 18 and the cable sensor 20 to receive data signals
(e.g. force signal and spooling signal) therefrom and analyze the
signals based upon a pre-determined algorithm, mathematical
process, or equation, for example. As shown in FIG. 2, the
processor 22 analyzes and evaluates a received data based upon an
instruction set 36. The instruction set 36, which may be embodied
within any computer readable medium, includes processor executable
instructions for configuring the processor 22 to perform a variety
of tasks and calculations. It is understood that the instruction
set 36 may include at least one of an algorithm, a mathematical
process, and an equation for calculating a tension of the cable 14.
It is further understood that the processor 22 may execute a
variety of functions such as controlling various settings of the
force sensors 16, 18 and the cable sensor 20, for example.
[0021] As a non-limiting example, the processor 22 includes a
storage device 38. The storage device 38 may be a single storage
device or may be multiple storage devices. Furthermore, the storage
device 38 may be a solid state storage system, a magnetic storage
system, an optical storage system or any other suitable storage
system or device. It is understood that the storage device 38 is
adapted to store the instruction set 36. In certain embodiments,
data relating to the cable 14 or spoolable device (e.g. known,
pre-determined, or measured) is stored in the storage device 38
such as a mass per unit length (i.e. weight per unit length), an
overall length of the cable 14, and a history of previous
measurements and calculations. Other data and information may be
stored in the storage device 38 such as the parameters calculated
by the processor 22 and a database of physical characteristics
(e.g. mass per unit length) for various types of cable, for
example. It is further understood that certain known parameters may
be stored in the storage device 38 to be retrieved by the processor
22.
[0022] As a further non-limiting example, the processor 22 includes
a programmable device or component 40. In certain embodiments, the
programmable device includes a human-machine interface (not shown).
It is understood that the programmable device or component 40 may
be in communication with any other component of the tension
measurement system 10 such as the force sensors 16, 18 and the
cable sensor 20, for example. In certain embodiments, the
programmable component 40 is adapted to manage and control
processing functions of the processor 22. Specifically, the
programmable component 40 is adapted to control the analysis of the
data signals received by the processor 22. It is understood that
the programmable component 40 may be adapted to store data and
information in the storage device 38, and retrieve data and
information from the storage device 38.
[0023] In certain embodiments, the processor 22 is in data
communication with a controller or control system 42 to provide a
centralized management of the system 10. As a non-limiting example,
the processor 22 communicates with the control system 42 via a
Controller Area Network (CAN) Bus. However, other networks,
architectures, and protocols can be used. The processor 22 can also
be in data communication with other equipment 44 for sending and
receiving data and control signals therebetween.
[0024] In use, the system 10 is initialized when no cable tension
is applied to the drum 24, thereby allowing the force sensors 16,
18 to identify the drum weight having no initial component forces
due to a tension in the cable 14. The drum weight is defined as a
weight of the drum 24 having a predetermined length of the cable 14
spooled thereon. The initial drum weight vector (including
magnitude and direction relative to the coordinate system of the
force sensors 16, 18) is stored on the storage device 38 and relied
upon by the processor 22 to subsequently calculate a tension in the
cable 14, as described herein below.
[0025] Once the initial drum weight vector is stored, the cable 14
is deployed and retrieved by the spooling device 12. As the cable
14 is routed past the cable sensor 20, the force sensors 16, 18
measure the forces along a pre-determined coordinate system, while
the cable sensor 20 measures the spooling/unspooling
characteristics of the cable 14. The processor 22 receives the
force signals from the force sensors 16, 18 and the spooling signal
from the cable sensor 20. The processor 22 analyzes the received
signals to compute a tension in the cable 14.
[0026] It is understood that during operation, a length of the
cable 14 that is spooled on the drum 24 is continuously changing.
For example, when the cable 14 is deployed from the drum 24, a
force acting on the shaft 26 of the spooling device 12 due to a
weight of a spooled portion of the cable 14 is reduced. Conversely,
when the cable 14 is retrieved and spooled onto the drum 24, a
force acting on the shaft 26 of the spooling device 12 due to a
weight of a spooled portion of the cable 14 is increased. As such,
a portion of the forces measured by the force sensors 16, 18 is due
to the weight of the drum 24 along with an instantaneous weight of
the spooled portion of the cable 14. A remaining portion of the
forces measured by the force sensor 16, 18 is directly proportional
to a tension in the cable.
[0027] In certain embodiments, the processor 22 computes the
instantaneous weight of the spooled portion of the cable 14 by
analyzing of the initial weight of the drum 24 and a length of the
cable 14 spooled thereon and a weight of a portion of the cable 14
that has been unspooled from the drum 24 since the initial weight
was measured. It is understood that the instantaneous drum weight
is equal to the initial drum weight less the weight of the portion
of the cable 14 that has been unspooled since the initial drum
weight was measured. It is further understood that, in situation
where the cable 14 is being spooled onto the drum 24 after the
initial weight was measured, the weight of a length of the cable 14
being spooled is additive to the initial drum weight.
[0028] As a non-limiting example, a length of the cable 14 that has
been unspooled from the drum 24 since the initial drum weight was
measured can be retrieved from the spooling signal generated by the
cable sensor 20. The length of the cable 14 that has been unspooled
since the initial drum weight was measured is multiplied by an
associated weight per unit length (retrieved from the storage
device 38) to compute a weight of a portion of the cable 14 that
has been unspooled since the initial weight was measured.
Accordingly, the initial drum weight minus the unspooled cable
weight is equal to the weight of the drum along with the weight of
a spooled portion of the cable 14. By zeroing the portion of the
forces representing the weight of the drum 24 and the spooled
portion of the cable 14, the remaining portion of the forces
measured by the force sensors 16, 18 are analyzed using formulas
known in mechanics to determine a tension in the cable 14.
[0029] As a non-limiting example, the forces measured by the force
sensors 16, 18 along each of the axes can be summed to generate a
single force vector along a path of travel of the cable 14. As a
further example, the cable 14 is shown being deployed directly
along a Z-axis of the coordinate system of the force sensors 16,
18. As such, the forces measured by the force sensors 16, 18 along
the Y-axis are representative of a weight of the drum 24 and the
spooled portion of the cable 14, while the cumulative forces
measured by the force sensors 16, 18 along the Z-axis are
representative of the tension in the cable 14. However, it is
understood that the tension in the cable 14 can be computed in any
path or direction relative to the coordinate system of the force
sensors 16, 18 using components of the measured forces along the
pre-defined axes, as would be appreciated by one skilled in
classical mechanics. It is further understood that other equations,
formulas, and algorithms can be used to calculate a tension in the
cable 14. It is further understood that the cable 14 or spoolable
device may be directed from the tension measurement system 10 to a
wellbore penetrating a subterranean formation in order to perform
operations within the wellbore such as, but not limited to, data
logging operations, sampling operations, wellbore treatment
operations such as, but not limited to, fracturing operations, acid
treatment operations, perforating operations, completion
operations, seismic operations, and the like.
[0030] The preceding description has been presented with reference
to presently preferred embodiments of the invention. Persons
skilled in the art and technology to which this invention pertains
will appreciate that alterations and changes in the described
structures and methods of operation can be practiced without
meaningfully departing from the principle, and scope of this
invention. Accordingly, the foregoing description should not be
read as pertaining only to the precise structures described and
shown in the accompanying drawings, but rather should be read as
consistent with and as support for the following claims, which are
to have their fullest and fairest scope.
* * * * *