Automated reel tension control systems and processes

Abstract

The present application pertains to an automated control system for controlling and adjusting reel tension on a coiled tubing unit. The system may comprise real time data received from one or more sensors, input by an operator, or calculated.

1 . An automated reel tension control system for a coiled tubing reel comprising:
 one or more sensors configured to monitor one or more parameters of tubing size, tubing wall thickness, tubing grade, reel geometry, well position, and tubing movement direction, and transmit real time data to a processor;   an actuator for controlling reel tension;   a processor operably connected to the actuator, wherein the processor is configured to calculate a proper reel tension based on the transmitted real time data and transmit a signal to the actuator to adjust tension on the reel; and   an operator input operably connected to the processor.   
     
     
         2 . The system of  claim 1  wherein the actuator adjusts reel tension using a hydraulic, an electric, or a pneumatic pressure. 
     
     
         3 . The system of  claim 1  wherein the actuator comprises an electroproportional valve. 
     
     
         4 . The system of  claim 1  wherein the processor further employs a reel core diameter, reel drive components, or both to calculate the proper reel tension. 
     
     
         5 . The system of  claim 1  wherein the operator input comprises a touch screen. 
     
     
         6 . The system of  claim 1  wherein the operator input comprises a keyboard and monitor. 
     
     
         7 . The system of  claim 1  wherein tubing size, tubing wall thickness, tubing grade, and reel geometry are operator inputs. 
     
     
         8 . The system of  claim 1  wherein well position is employed to calculate the number of coiled tubing wraps on the coiled tubing reel. 
     
     
         9 . A process for controlling reel tension on a coiled tubing reel comprising:
 transmitting data comprising tubing size, tubing wall thickness, tubing grade, reel geometry, well position, and tubing movement direction to a processor;   calculating a proper reel tension for a coiled tubing reel with the processor based on the transmitted data;   transmitting a signal comprising the calculated proper reel tension to an actuator configured to control reel tension; and   adjusting reel tension with the actuator to the calculated proper reel tension using the transmitted signal.   
     
     
         10 . The process of  claim 9  wherein the actuator is configured to adjust reel tension using a hydraulic, an electric, or a pneumatic pressure. 
     
     
         11 . The process of  claim 9  wherein the actuator comprises an electroproportional valve. 
     
     
         12 . The process of  claim 9  wherein the processor further employs a reel core diameter, reel drive components, or both to calculate the proper reel tension. 
     
     
         13 . The process of  claim 9  wherein tubing size, tubing wall thickness, tubing grade, and reel geometry are operator inputs. 
     
     
         14 . The process of  claim 9  wherein well position is employed to calculate the number of coiled tubing wraps on the coiled tubing reel.