U.S. patent application number 14/793927 was filed with the patent office on 2016-01-14 for multi-stage pressure control dump valve assembly for torque control operations.
The applicant listed for this patent is PREMIERE, INC.. Invention is credited to KRIS HENDERSON, LEE J. MATHERNE, JR..
Application Number | 20160010406 14/793927 |
Document ID | / |
Family ID | 55064805 |
Filed Date | 2016-01-14 |
United States Patent
Application |
20160010406 |
Kind Code |
A1 |
HENDERSON; KRIS ; et
al. |
January 14, 2016 |
MULTI-STAGE PRESSURE CONTROL DUMP VALVE ASSEMBLY FOR TORQUE CONTROL
OPERATIONS
Abstract
A "dump" or bypass system for use with fluid-powered tongs
utilized to apply torque forces to threaded connections during pipe
installation operations. A computer having a data processor
monitors and analyzes rotations of, and torque forces applied to,
pipe sections being assembled. A pilot-operated relief valve
actuates a bypass dump valve. The bypass system operates in
"real-time", quickly and efficiently dumping fluid supplying a
power tong--and stopping the application of torque forces on a pipe
section--once a predetermined measured torque value is
achieved.
Inventors: |
HENDERSON; KRIS; (HOUSTON,
TX) ; MATHERNE, JR.; LEE J.; (Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PREMIERE, INC. |
Houston |
TX |
US |
|
|
Family ID: |
55064805 |
Appl. No.: |
14/793927 |
Filed: |
July 8, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62022001 |
Jul 8, 2014 |
|
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|
Current U.S.
Class: |
81/470 |
Current CPC
Class: |
E21B 19/164 20130101;
E21B 19/166 20130101 |
International
Class: |
E21B 19/16 20060101
E21B019/16 |
Claims
1. A fluid pressure bypass assembly for controlling the application
of torque to a threaded pipe connection comprising: a) a tong unit
adapted to impart torque to said threaded connection; b) a supply
conduit adapted to supply hydraulic fluid to an inlet of said tong
unit; c) an outlet conduit adapted to receive hydraulic fluid from
an outlet of said tong unit; d) a bypass conduit extending between
said supply conduit and said outlet conduit; e) a pilot controlled
hydraulic valve disposed along said bypass conduit, wherein said
pilot controlled hydraulic valve is adapted to shift between a
first closed position and a second open position in response to a
pneumatic pilot signal; f) a torque sensor adapted to measure
torque applied to said threaded connection by said tong unit; and
g) a computer having a data processor, wherein said computer
receives data from said torque sensor and shifts said pilot
controlled hydraulic valve from said first position to said second
position to bypass said tong unit when said torque sensor measures
a preselected torque value.
2. The fluid pressure bypass assembly of claim 1, wherein said
torque sensor comprises a load cell.
3. The fluid pressure bypass assembly of claim 1, further
comprising a rotary encoder adapted to measure speed, direction
and/or rotation of said threaded connection, and wherein said
computer receives measured data from said rotary encoder.
4. A fluid pressure bypass assembly for controlling the application
of torque to a threaded pipe connection comprising: a) a tong unit
adapted to impart torque to said threaded connection; b) a supply
conduit adapted to supply hydraulic fluid to an inlet of said tong
unit; c) an outlet conduit adapted to receive hydraulic fluid from
an outlet of said tong unit; d) a bypass conduit extending between
said supply conduit and said outlet conduit; e) a pilot controlled
hydraulic valve disposed along said bypass conduit, wherein said
pilot controlled hydraulic valve is adapted to shift between a
first closed position and a second open position in response to a
pneumatic pilot signal; f) an air compressor adapted to provide a
pneumatic pilot signal to said pilot controlled hydraulic valve; g)
a torque sensor adapted to measure torque applied to said threaded
connection by said tong unit; and h) a computer having a data
processor, wherein said computer receives data from said torque
sensor and interrupts said pneumatic pilot signal to said pilot
controlled hydraulic valve, thereby shifting said pilot controlled
hydraulic valve from said first position to said second position
and bypassing said tong unit, when said torque sensor measures a
preselected torque value.
5. The fluid pressure bypass assembly of claim 4, wherein said
torque sensor comprises a load cell.
6. The fluid pressure bypass assembly of claim 4, further
comprising a rotary encoder adapted to measure speed, direction
and/or rotation of said threaded connection, and wherein said
computer receives measured data from said rotary encoder.
7. The fluid pressure bypass assembly of claim 4, further
comprising: a) a pneumatic supply conduit connecting said air
compressor to said pilot controlled hydraulic valve; and b) a
pneumatic control valve disposed along said pneumatic supply
conduit, wherein said pneumatic control valve is adapted to shift
between a first open position and a second closed position.
8. The fluid pressure bypass assembly of claim 7, wherein said
pneumatic control valve is adapted to shift between said first open
position and said second closed position in response to an
electronic signal from said computer.
9. The fluid pressure bypass assembly of claim 8, wherein said
pneumatic control valve comprises a solenoid operated valve.
Description
BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains to a method and apparatus for
controlling torque forces during pipe string assembly operations in
various industrial applications such as, for example, in the oil
and gas industry. More particularly, the present invention pertains
to a dump valve system for use in torque control systems utilized
during make-up of threaded collar and pipe connections.
[0003] 2. Brief Description of the Prior Art
[0004] During well drilling and completion operations, pipe (such
as, for example, drill pipe, casing or tubular workstring) can be
installed into a well bore in a number of separate sections of
substantially equal length, commonly referred to as "joints." The
joints, which generally include threaded connections at each end,
are typically joined end-to-end at the earth's surface (frequently
from a drilling rig) in order to form a substantially continuous
"string" of pipe that reaches downward into a well bore.
[0005] As part of the pipe installation process, additional
sections of pipe are added to the upper end of the pipe string at
the earth's surface (typically at a drilling rig or other similar
facility) in order to increase the overall length of the pipe
string and its penetration depth in a well bore. The addition of
pipe sections at the earth's surface is repeated until a desired
length of pipe is inserted into the well bore.
[0006] The process of installing a string of pipe in a well is
typically commenced by lowering a first section of pipe into a
wellbore at a drilling rig floor, and suspending said section of
pipe in place using a set of "lower slips." In this position, the
uppermost end of said first section of pipe is generally situated a
few feet above the rig floor. Thereafter, a second section of pipe
is lifted within a drilling rig derrick and suspended vertically
within said derrick; the second section of pipe is then positioned
in linear alignment above the first section of pipe suspended there
below.
[0007] After said pipe sections are axially aligned with each
other, the lower end of said hanging second pipe section is then
lowered or "stabbed" into the upper end of said first pipe section.
Thereafter, torque is applied to the second pipe section using a
power tong or other device, in order to make up (that is, screw
together) mating threaded connections of said first and second pipe
sections. In most cases, said power tong is powered using hydraulic
or other fluid.
[0008] After said threaded connection members are joined and said
pipe sections are attached in mating relationship, said lower slips
can be disengaged. The attached pipe sections (suspended from a
rig's traveling block or top drive unit) can be lowered further
into the well. After said attached pipe sections are lowered to a
desired position, said lower slips can be reengaged in order to
safely suspend such pipe within the well bore. The process can then
be repeated until a desired length of pipe is run into the
well.
[0009] During such pipe make-up/connection and installation
operations, it is critically important to control torque forces
applied to said pipe sections. If such applied torque is too high,
the mating threaded connection members can become damaged such as,
for example, by over torque-ing or thread galling. If such applied
torque is too low, the mating threaded connection members may not
fully engage with one another, thereby affecting the pressure
integrity and/or axial load supporting capacity of the threaded
connection. As a result, torque control systems are frequently
employed to ensure proper application of torque during such pipe
make-up operations.
[0010] Conventional torque control systems used during pipe
installation operations generally comprise a rotational sensor
(frequently mounted to a power tong) to measure pipe rotation
during connection make-up, a load cell or other torque measurement
sensor to measure the amount of applied torque on the connection,
and a computer that logs and compares such measured torque to the
accumulated turns. The computer then uses this information to
predict the torque rise as the threaded connection is made up. When
the computer determines that such optimum connection torque has
been reached, the computer sends a signal to said power tong
assembly to cease the application of torque on the pipe.
[0011] Specifically, said computer can send a "dump" signal to a
valve that is connected to an input conduit supplying pressurized
power fluid to said tong, as well as an outlet conduit extending
from said tong into a reservoir or storage tank, thereby forming a
bridge between said conduits and a fluid bypass to said tong. When
said valve receives a "dump" actuation signal from said computer,
said valve opens, thereby allowing pressurized fluid (that was
previously driving the tong) to bypass the tong and be diverted via
said output conduit to said tank. When said "dump" process is
triggered, the tong ceases applying torque forces to the pipe.
[0012] Typically, such conventional fluid dump valves are operated
using an electronic (or partially electronic) system. In most
cases, the computer sends an electronic signal to a solenoid. The
solenoid is actuated which, in turn, shifts said valve. As
discussed above, when said valve is shifted in response to a "dump"
signal from the computer, fluid flow from the inlet or supply line
of the tong is diverted to the outlet or tank line, thereby
bypassing said tong.
[0013] Due to the mechanics of the solenoid and valve, such dumping
action typically includes a built-in time delay; frequently, this
delay can be in a range between 50 ms and 100 ms. In some cases,
specialized computer software includes a "look ahead" feature that
attempts to anticipate when optimal torque levels will be reached.
However, when mating threaded connection members are cross
threaded, or when a galling problem is encountered, torque forces
can rise very rapidly. Thus, even with such a "look ahead" system,
a dump signal may not be sent fast enough to stop thread damage
from occurring.
[0014] Thus, there is a need for a quick, reliable and effective
system for controlling torque applied to threaded connections
during the pipe installation process. The system should permit the
dumping of pressurized power fluid supplying a power tong or other
torque application device to occur, without significant delay, when
predetermined measured values are obtained.
SUMMARY OF INVENTION
[0015] In a preferred embodiment, the present invention comprises a
"dump" system for use with hydraulically powered tongs utilized to
apply torque to threaded connections during pipe installation
operations. The dump system of the present invention is controlled
by a computer having a data processor that can monitor and analyze
rotations and torque of each pipe section that is being assembled
within a pipe string. Specifically, the dump system of the present
invention quickly and efficiently dumps hydraulic energy that is
feeding a power tong once a predetermined optimum torque for a
threaded connection is achieved.
[0016] In a preferred embodiment, the present invention comprises a
pilot-operated relief valve that uses the same hydraulic fluid
power that is powering a hydraulic tong as a power source to shift
a bypass dump valve. The dump system of the present invention can
operate in "real-time" with little or no delay time observed with
conventional dump systems. For example, the dump system of the
present invention can actuate in as little as (2) milliseconds,
thereby allowing a cross-threading incident to be stopped before
any damage occurs to the threads.
[0017] Additionally, in a preferred embodiment, the dump system of
the present invention permits maximum operating pressure to be set
at a significantly lower level than conventional dump systems. Such
lower pressure beneficially allows for the maximum system pressure
to be set at or below a maximum torque capability of a threaded
connection, therefore providing a redundant safety factor in an
event of a computer failure or other unanticipated problem during
pipe connection operations.
[0018] Although the torque control dump system of the present
invention is used primarily in connection with rig-based pipe
installation operations (that is, in the field), it is to be
observed that said torque control dump system can also be used with
bucking units or other pipe connection operations performed in
shops, facilities or other locations.
BRIEF DESCRIPTION OF DRAWINGS
[0019] The foregoing summary, as well as any detailed description
of the preferred embodiment, is better understood when read in
conjunction with the drawings and figures contained herein. For the
purpose of illustrating the invention, the drawings and figures
show certain preferred embodiments. It is understood, however, that
the invention is not limited to the specific methods and devices
disclosed in such drawings or figures.
[0020] FIG. 1 depicts a schematic illustration of a preferred
embodiment of the dump valve bypass assembly of the present
invention incorporated within a tubular assembly system.
[0021] FIG. 2 depicts a schematic illustration of a preferred
embodiment of a multi stage dump valve assembly of the present
invention.
[0022] FIG. 3 depicts a schematic illustration of a preferred
embodiment of a dump valve remote control assembly of the present
invention.
[0023] FIG. 4 depicts a schematic illustration of a preferred
embodiment of the dump valve assembly of the present invention
during make-up of a threaded pipe connection.
[0024] FIG. 5 depicts a schematic illustration of said dump valve
assembly of the present invention when a dump signal is sent from a
torque-turn computer to actuate said dump valve assembly.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0025] FIG. 1 depicts a schematic illustration of a preferred
embodiment of the dump valve bypass assembly of the present
invention incorporated within a tubular assembly system used, for
example, during the installation of tubular goods in a well.
Numbered elements depicted in FIG. 1 comprise the following: [0026]
100--multi-stage dump valve assembly [0027] 200--dump valve remote
control assembly [0028] 300--a computer having a data processor for
controlling and monitoring applied torque forces and pipe turns
[0029] 301--rotary encoder/sensor (measures speed, direction and
rotation of pipe) [0030] 301a--rotary encoder signal line [0031]
302--load cell/sensor (measures torque forces applied to pipe by
tong) [0032] 302a--load cell signal line [0033] 401--hydraulic pump
(fluid pressure source) [0034] 402--hydraulic fluid reservoir
[0035] 501--manually operated directional control valve mounted on
or near tong (manually controls speed and direction of power tong
motor) [0036] 502--power tong hydraulic motor--supplies power to
tong unit needed to "make-up" or screw together mating threaded
pipe connections
[0037] Still referring to FIG. 1, a fluid power source 401 is in
fluid communication with motor 502 used to drive a torque imparting
device, such as a set of conventional power tongs, used to assemble
mating threaded connection members of pipe sections. Although other
fluid types and component configurations can be employed without
departing from the scope of the present invention, in a preferred
embodiment such power fluid comprises hydraulic fluid.
[0038] In such configuration, motor 502 is hydraulically powered,
and fluid power source 401 comprises a hydraulic pump. Hydraulic
fluid is supplied from said fluid power source (pump) 401 through
fluid supply line or conduit 109 and manually operated control
valve 501, to tong hydraulic motor 502. Hydraulic fluid leaves said
tong hydraulic motor 502 via hydraulic outlet line or conduit 110,
through manually operated control valve 501 to hydraulic fluid
reservoir 402. Although not depicted in FIG. 1, it is to be
observed that hydraulic fluid returned to hydraulic fluid reservoir
402 can be filtered and/or otherwise conditioned and returned to
fluid power source (pump) 401 as part of a closed-loop hydraulic
fluid system.
[0039] Load cell 302 serves as a sensor to measure torque forces
applied by tong motor 502 (via a set of power tongs) to a pipe
section having a threaded connection member, which is being
threadably connected to another mating pipe section. Data measured
by load cell 302 is transmitted via load cell signal line 302a,
which typically comprises a data conducting wire, to a computer 300
having a data processor. Similarly, rotary encoder member 301
serves as a sensor to measure speed, direction and/or rotation of
said section of pipe being threadably connected to another mating
pipe section. Data measured by rotary encoder member 301 is
transmitted via rotary encoder signal line 301a, which is typically
a data conducting wire, to said computer 300.
[0040] Computer 300 is operationally connected to dump valve remote
control assembly 200 which, in turn, is operationally connected to
multi-stage dump valve assembly 100 of the present invention as
more fully described below. Said multi-stage dump valve assembly
100 is in selective fluid communication with hydraulic supply
conduit 109 and hydraulic outlet conduit 110.
[0041] FIG. 2 depicts a schematic illustration of said multi-stage
dump valve assembly 100 of the present invention. As depicted in
FIG. 2, said multi-stage dump valve assembly 100 includes, without
limitation, a piloted main relief valve, a pneumatic three way
valve, a full pressure pneumatic dump signal, a power tong, and a
hydraulic power unit. Numbered elements depicted in FIG. 2 comprise
the following: [0042] 101--piloted relief valve assembly [0043]
101a--hydraulic pilot control line [0044] 101b--hydraulic pilot
sensing line [0045] 101c--hydraulic bridge/bypass (pressure) line
[0046] 101d--hydraulic bridge/bypass (return) line [0047]
102--pneumatic piloted, pilot relief valve assembly [0048]
102a--pilot relief inlet from main relief valve [0049] 102b--pilot
relief return [0050] 102c--air pilot inlet, controlled air supply
[0051] 102d--junction [0052] 103--pneumatic three way valve
(normally open) [0053] 103a--three way valve regulated air inlet
[0054] 103b--three way valve regulated air outlet (to 102c air
pilot) [0055] 103c--three way valve exhaust port [0056] 103d--three
way valve air pilot, full pressure unregulated pilot signal inlet
[0057] 104--full pressure pneumatic dump signal conduit [0058]
105--reduced pressure regulated pilot air signal (used to set
hydraulic system pressure on pilot valve 102) [0059] 106--hydraulic
pressure sample line for remote gauge [0060] 107--power tong
conduit, tank/reservoir side [0061] 108--power tong conduit, supply
side [0062] 109--hydraulic supply conduit from hydraulic power
source [0063] 110--hydraulic outlet conduit to reservoir
[0064] FIG. 3 depicts a schematic illustration of a preferred
embodiment of the dump valve control assembly 200 of the present
invention. Numbered elements depicted in FIG. 3 comprise the
following: [0065] 200--dump valve control assembly [0066]
201--solenoid operated three way air valve (used to send dump
signal to three stage dump valve) [0067] 201a--electrically
operated solenoid [0068] 201b--electric dump signal from torque
control computer 300 [0069] 202--precision air regulator (used to
set pressure on valve 102) [0070] 203--main
filter/regulator/lubricator (ensures rig air coming in as at proper
cleanliness and pressure) [0071] 203a--rig air inlet to system
[0072] 203b--pneumatic conduit to solenoid operated three way air
valve 201 [0073] 203c--pneumatic conduit to precision air regulator
202 [0074] 104--full pressure pneumatic dump signal conduit [0075]
204--hydraulic pressure gauge (reads output hydraulic pressure from
sampling line 106) [0076] 105--reduced pressure regulated pilot air
signal (used to set hydraulic system pressure on pilot valve
102)
[0077] FIG. 4 depicts a schematic illustration of a preferred
embodiment of the dump valve assembly of the present invention
during assembly of a threaded pipe connection, while FIG. 5 depicts
a schematic illustration of said dump valve assembly when a dump
signal is sent from a torque-turn computer to actuate said dump
valve assembly.
[0078] Referring to FIG. 1, rig air blower 600 generates pneumatic
air pressure which is sent to dump valve control assembly 200.
Referring to FIG. 3, said pneumatic air pressure passes through
inlet 203a into main filter/regulator/lubricator 203, which ensures
that rig air entering the pneumatic control system meets desired
cleanliness and pressure requirements.
[0079] Said pneumatic air pressure exiting
filter/regulator/lubricator 203 is split via conduits 203b and
203c; pneumatic air pressure in conduit 203b is sent to solenoid
operated three way air valve 201 having electrically operated
solenoid 201a, while pneumatic air pressure in conduit 203c is sent
to precision air regulator 202. Electrical conducting line 201b
provides an electric dump signal from torque control computer 300
to electrically operated solenoid 201a of three way air valve 201.
Hydraulic pressure gauge 204 reads output hydraulic pressure from
sensing line 106.
[0080] Referring to FIG. 2, a hydraulic relief valve 101 is set
with a pneumatic operated pilot relief valve 102; actuation of
pneumatic pilot relief valve controls operation of hydraulic relief
valve 101. Pneumatic pressure provided via conduit 105 (from
precision air regulator 202) is a regulated pressure signal that
regulates the hydraulic pressure based on a desired ratio
(typically approximately 50:1) that allows for a low pressure
pneumatic signal to convert into a high pressure hydraulic pressure
signal. (As a result of this ratio, a relatively small amount of
pneumatic pressure can offset a much greater amount of hydraulic
pressure). In order to provide for a dumping action that can be
applied at a predetermined torque measurement, the pneumatic signal
line 105 is broken by an air piloted three way valve 103.
[0081] During normal operation, a pneumatic pressure signal from
conduit 105 passes through valve 103 at inlet port 103a to outlet
port 103b, and is connected to pilot relief valve 102 at pilot
valve inlet 102c. Load cell sensor 302 measures torque forces
applied by tong motor 502 (via a set of power tongs) to a pipe
section having a threaded connection member, which is being
threadably connected to another mating pipe section.
[0082] Data measured by load cell 302 is transmitted via load cell
signal line 302a to a computer 300 having a data processor.
Similarly, rotary encoder member 301 serves as a sensor to measure
speed, direction and/or rotation of said section of pipe being
threadably connected to another mating pipe section, while data
measured by rotary encoder member 301 is transmitted via rotary
encoder signal line 301a to said computer 300.
[0083] When a predetermined torque measurement (as sensed by load
cell 302) has been achieved, an electronic signal is sent from
computer 300 via line 201b to electrically operated solenoid 201a.
Said electrically operated solenoid 201a actuates valve 201. When
this occurs, a pneumatic dump signal is sent via dump signal
conduit 104 to full pressure unregulated pilot signal inlet 103d of
pneumatic three way valve 103. Once said dump signal is applied to
valve 103, said three-way valve 103 shifts, thereby connecting
valve air outlet 103b to exhaust port 103c, which is vented to
atmosphere.
[0084] With said valve 103 shifted, regulated air pilot signal via
line 105 is blocked. As such, regulated pneumatic pressure from
line 105 that was holding pneumatic pressure on air pilot inlet
102c of pilot relief valve assembly 102 is vented, and pneumatic
pressure from line 105 is no longer held on air pilot inlet 102c.
Without such pilot air held on pilot relief valve assembly 102,
said relief valve assembly 102 shifts. When this occurs, pneumatic
pressure on piloted relief valve assembly 101 is bled off, thereby
causing said piloted relief valve 101 to open.
[0085] With said piloted relief valve assembly 101 open, hydraulic
fluid in hydraulic supply conduit 109 (from hydraulic power source
401) flows through hydraulic bridge or bypass (supply) conduit
101c, open relief valve 101, and hydraulic bridge or bypass
(return) conduit 101d. Said hydraulic fluid exits said conduit 101d
via return line 110. In this manner, supply hydraulic fluid used to
power tong motor 502 (which imparts torque forces to a threaded
connection of a pipe section) can be quickly and efficiently dumped
or bypassed around said motor 502 in order to cease the application
of torque to said threaded connection.
[0086] In a preferred embodiment, utilizing the same hydraulic
energy that is also used to operate the power tong (and which is
already present in the system) in order to shift the bypass/relief
valve once pneumatic pilot pressure 105 is vented from pilot valve
102c insures a fast-acting relief valve actuation that quickly
opens the bypass/relief valve and removes the hydraulic energy
(supply) from the power tong during thread assembly operations.
Conventional dump valves use components that must be energized in
order to supply the force necessary to shift a bypass or "dump"
valve. The present invention utilizes hydraulic energy that is
already present in the system. The same hydraulic pressure used to
power the tong (which is already present in the system) also
supplies the energy to open the bypass valve; unlike conventional
dump systems, no additional energy must be added to actuate the
bypass valve.
[0087] Additionally, valve 103 can be located in close physical
proximity to valves 102 and 101 (typically at a distance of 12
inches or less), thereby reducing travel time for pneumatic signal
pressure. This distance factor, together with the fact that a
regulated low pressure pneumatic (air) signal travels faster than a
hydraulic fluid, further ensures a very quick actuation of bypass
valve 101. Moreover, the use of a desired ratio (typically
approximately 50:1) of hydraulic pressure to pneumatic pressure
ensures that a relatively small change in pneumatic pressure
results in a much greater impact on hydraulic pressure (or the
ability to offset much higher hydraulic pressures with relief valve
101).
[0088] The above-described invention has a number of particular
features that should preferably be employed in combination,
although each is useful separately without departure from the scope
of the invention. While the preferred embodiment of the present
invention is shown and described herein, it will be understood that
the invention may be embodied otherwise than herein specifically
illustrated or described, and that certain changes in form and
arrangement of parts and the specific manner of practicing the
invention may be made within the underlying idea or principles of
the invention.
* * * * *