Active monitoring of alignment of rig component

Abstract

A tool for use in subterranean operations can include a top drive and an alignment sensor coupled to the top drive. The alignment sensor can measure an alignment condition of a first rig component relative to an alignment position. A system for wellbore operations can include the tool and generate an alarm signal upon misalignment of rig components prior to damage of the equipment.

What is claimed is: 
     
         1 . A tool for use in subterranean operations, comprising:
 a top drive; and   an alignment sensor coupled to the top drive;   wherein the alignment sensor is configured to measure an alignment condition of a first rig component relative to an alignment position.   
     
     
         2 . The tool of  claim 1 , wherein the alignment position includes a first axis, a second axis, or both and the first and second axis are orthogonal compared to each other. 
     
     
         3 . The tool of  claim 1 , wherein measuring an alignment condition includes measuring an angle of departure from the alignment position. 
     
     
         4 . The tool of  claim 3 , wherein the alignment condition includes a normal alignment when the angle of departure from the alignment position is no greater than 5°, no greater than 1°, no greater than 0.5°, or no greater than 0.1°. 
     
     
         5 . The tool of  claim 3 , wherein the alignment condition includes a misalignment when the angle of departure from the alignment position is at least 0.1°, at least 0.5°, at least 1°, or at least 5°. 
     
     
         6 . The tool of  claim 3 , wherein the angle of departure includes a pitch angle, a roll angle, or a combination thereof. 
     
     
         7 . The tool of  claim 3 , wherein the angle of departure is measured at an interval sensitivity of at least 0.1°, at least 0.01°, or at least 0.001°. 
     
     
         8 . The tool of  claim 1 , wherein the top drive is coupled to a mast and the alignment sensor is further configured to detect drifting of the top drive as it moves through the mast. 
     
     
         9 . The tool of  claim 1 , wherein the alignment sensor includes an inclinometer. 
     
     
         10 . The tool of  claim 9 , wherein the inclinometer includes a microelectromechanical system (MEMS) or a nanoelectomechanical system (NEMS). 
     
     
         11 . The tool of  claim 9 , wherein the inclinometer includes a dual axis inclinometer configured to measure pitch and roll inclination. 
     
     
         12 . The tool of  claim 1 , wherein the alignment sensor is adapted to be monitored in a rig control system. 
     
     
         13 . The tool of  claim 1 , wherein the alignment sensor is coupled to a fixed position on the top drive. 
     
     
         14 . The tool of  claim 13 , wherein the alignment sensor is adhered to the top drive. 
     
     
         15 . The tool of  claim 1 , wherein the alignment sensor is integrated into a remote panel on the top drive. 
     
     
         16 . The tool of  claim 1 , wherein the alignment condition is configured to be transmitted to a computing system. 
     
     
         17 . The tool of  claim 16 , wherein the computing system is configured to display the alignment condition on a human-machine interface and display the alignment condition using models of adjustable sections of a mast, the top drive, a top drive support structure, or an entire rig. 
     
     
         18 . The tool of  claim 16 , wherein the computing system is configured to adjust the rig component based on the alignment condition, display realignment instructions based on the alignment condition, or both. 
     
     
         19 . A system for use in subterranean operations comprising:
 a top drive;   an alignment sensor coupled to the top drive, the alignment sensor configured to measure and transmit an alignment condition of a first rig component relative to an alignment position; and   a computing system in communication with the alignment sensor, the computing system configured to receive the alignment condition from the alignment sensor and determine adjustments to the rig component based on the alignment condition.   
     
     
         20 . A method of operating a system for subterranean operations comprising:
 providing a drill rig and establishing a first alignment position, wherein the drill rig includes a top drive and an alignment sensor coupled to the top drive;   acquiring an alignment condition of a first rig component relative to an alignment position; and   adjusting the first rig component to change the alignment condition the first rig component relative to the alignment position.