# US 11,441,413 B2 · Apparatus and method for monitoring a power swivel system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,441,413 B2 - Document ID: US11441413B2 - Status: Granted - Kind: B2 - Application number: 16/504,307 - Filed: 2019-07-07 - Published: 2021-01-07 - Granted: 2022-09-13 - Earliest claimed: 2019-07-07 - Applicants: Barry J. Nield; George A. Nield - Inventors: Barry J. Nield; George A. Nield - Web page: https://patentgrep.com/patent/US11441413B2 ## CPC - E21B 44/04: in response to the torque of the drive {; Measuring drilling torque (E21B44/06 takes precedence; measuring stresses in a well bore pipe E21B47/007)} - G05B 19/042: using digital processors (G05B19/05 takes precedence) - B25B 23/145: specially adapted for fluid operated wrenches or screwdrivers - E21B 3/022: {Top drives} - E21B 19/166: {Arrangements of torque limiters or torque indicators} - G05B 23/0235: {based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold} - G05D 16/00: Control of fluid pressure - G05D 16/2066: {using controlling means acting on the pressure source} - G08B 21/182: {Level alarms, e.g. alarms responsive to variables exceeding a threshold} - H04Q 9/00: Arrangements in telecontrol or telemetry systems for selectively calling a substation from a main station, in which substation desired apparatus is selected for applying a control signal thereto or for obtaining measured values therefrom - E21B 49/003: {by analysing drilling variables or conditions (E21B49/005 takes precedence; systems specially adapted for monitoring a plurality of drilling variables or conditions E21B44/00)} - H04Q 2209/823: where the data is sent when the measured values exceed a threshold, e.g. sending an alarm - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) - B25B: TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING, OR HOLDING - G05D: SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES - G08B: SIGNALLING SYSTEMS, e.g. PERSONAL CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS - H04Q: SELECTING (switches, relays, selectors H01H; wireless communication networks H04W) ## Abstract An apparatus for monitoring a power swivel system includes a smart box comprising a processing device electrically associated with a memory, communication technology and least one of a local display device or a remote display device where the communication technology. The smart box is associated with a power swivel system comprising a power swivel unit in fluid communication with a hydraulic pump system driven by a motor. The hydraulic pump system is configured to pump a hydraulic fluid through the power swivel unit to activate rotating elements. A plurality of sensors are connected to the processing device and various components of the power swivel system including the rotating elements to monitor such elements and minimize the possibility of an over speed and/or over torque condition. Data providing a status of the power swivel system components is transmitted to a remote device and presented to a user via a GUI. ## Claims ### Claim 1 An apparatus for monitoring a power swivel system, said apparatus comprising: a smart box comprising a processing device electrically associated with a memory, and least one of a local display device or a remote display device and communication technology configured to communicate with a remote device wherein said smart box is associated with a power swivel system comprising a power swivel unit in fluid communication with a hydraulic pump system driven by a motor controlled by an electronic control module (ECM) wherein said ECM is electrically associated with said processing device and wherein said hydraulic pump system is configured to pump a hydraulic fluid through said power swivel unit to activate rotating elements; a plurality of sensors for generating power swivel system data wherein each sensor is electrically associated with said processing device and wherein said plurality of sensors include: a rotation sensor associated with said power swivel unit and configured for generating rotation data for said rotating elements; a torque sensor associated with said power swivel system and configured for generating torque data for said rotating elements; a location sensor configured to generate location data for said power swivel system; and wherein said processing device is configured to format said power swivel system data and at least one of store said power swivel data and transfer at least part of said power swivel system data to said remote device for display on a user interface. ### Claim 2 (depends on 1) The apparatus for monitoring a power swivel system as in claim 1, wherein a plurality of automatic commands for controlling said power swivel system are stored in said memory and wherein said hydraulic pump system comprises one of a non-variable volume hydraulic pump or a variable volume hydraulic pump connected to a controller electrically associated with said processing device. ### Claim 3 (depends on 2) The apparatus for monitoring a power swivel system as in claim 2, wherein at least one rotation data threshold value defining at least one rotation limitation is stored in said memory and wherein said smart box compares said rotation data with said at least one rotation data threshold value and transmits a Speed Alert warning to at least one of a local device or said remote device when said rotation data exceeds a rotation data threshold value and wherein said smart box is configured to execute at least one of said plurality of automatic commands after a predefined delay period unless an override signal is received during said predefined delay period. ### Claim 4 (depends on 2) The apparatus for monitoring a power swivel system as in claim 2, wherein at least one torque threshold value defining at least one torque limitation is stored in said memory and wherein said smart box compares said torque data with said at least one torque data threshold value and transmits an Over Torque Alert warning to at least one of a local device or said remote device when said torque data exceeds a torque data threshold value and wherein said smart box is configured to execute at least one of said plurality of automatic commands after a predefined delay period unless an override signal is received during said predefined delay period. ### Claim 5 (depends on 2) The apparatus for monitoring a power swivel system as in claim 2, wherein said plurality of sensors further comprises a hydraulic pressure sensor configured to generate hydraulic fluid pressure data related to said hydraulic pump system and a temperature sensor associated with said hydraulic fluid configured to generate hydraulic fluid temperature data. ### Claim 6 (depends on 5) The apparatus for monitoring a power swivel system as in claim 5, wherein at least one pressure threshold value defining at least one pressure limitation is stored in said memory and wherein said smart box compares said hydraulic fluid pressure data to said at least one pressure threshold value and generates and transmits a Pressure Alert warning to at least one of a local device and said remote device when said hydraulic fluid pressure data exceeds a pressure threshold value and wherein said smartbox is furthered configured to execute at least one of said plurality of automatic commands after a predefined delay period when said Pressure Alert warning is generated unless an override signal is received during said predefined delay period. ### Claim 7 (depends on 5) The apparatus for monitoring a power swivel system as in claim 5, wherein at least one hydraulic fluid temperature threshold value defining at least one temperature limitation is stored in said memory wherein said smart box is configured to generate and transmit a Temperature Alert warning to one of a local device or said remote device when said hydraulic temperature data exceeds a hydraulic fluid temperature threshold value and wherein said smart box is furthered configured to execute at least one of said plurality of automatic commands after a predefined delay period when said Temperature Alert warning is generated unless an override signal is received during said predefined delay period. ### Claim 8 (depends on 1) The apparatus for monitoring a power swivel system as in claim 1, wherein a first temperature sensor is associated with a fluid input defined by said power swivel unit and a second temperature sensor is associated with a fluid output defined by said power swivel unit and wherein said processing device is configured to monitor the fluid temperature delta between said fluid input and said fluid output and generate a Swivel Temperature Alert warning when said temperature delta exceeds a temperature delta threshold value. ### Claim 9 (depends on 8) The apparatus for monitoring a power swivel system as in claim 8, further comprising an ambient temperature sensor electrically associated with said processing device wherein said processing device is configured to store ambient temperature data comprising a maximum ambient temperature, a minimum ambient temperature and a normal ambient temperature for the location of said power swivel system and use said stored ambient temperate data and real time temperature data to determine when to generate said Swivel Temperature Alert warning. ### Claim 10 (depends on 1) The apparatus for monitoring a power swivel system as in claim 1, wherein said remote device defines at least one of a smart phone, a tablet computer or a remote server. ### Claim 11 An apparatus for monitoring a power swivel system, said apparatus comprising: a smart box means associated with a power swivel system comprising a power swivel unit in hydraulic fluid communication with a hydraulic pump system being driven by a motor associated with an electronic control module (ECM), said smart box means configured for collecting, formatting, storing and transmitting power swivel system data and warnings to a remote device; a plurality of sensors for generating power swivel system data wherein each sensor is electrically associated with said processing device and wherein said plurality of sensors include: a. a rotation sensor associated with rotating elements defined by said power swivel unit wherein said rotation sensor is configured for generating rotation data for said rotating elements; b. a torque sensor associated with said power swivel system wherein said torque sensor is configured for generating torque data for said rotating elements; c. a hydraulic pressure sensor associated with said hydraulic pump system wherein said hydraulic pressure sensor is configured to generate hydraulic fluid pressure data for said hydraulic pump system; d. a temperature sensor associated with said hydraulic fluid wherein said temperature sensor is configured for generating hydraulic fluid temperature data; and e. a location sensor associated with said power swivel system wherein said location sensor is configured to generate location data for said power swivel system; and wherein one of said remote device or said smart box means is configured to evaluate said power swivel system data to determine when to generate power swivel system warnings. ### Claim 12 (depends on 11) The apparatus for monitoring a power swivel system as in claim 11, wherein said smart box means is configured to cause a user interface to be displayed on a local display device or a remote display device and wherein said user interface comprises at least part of said power swivel system data. ### Claim 13 (depends on 12) The apparatus for monitoring a power swivel system as in claim 12, wherein a plurality of automatic commands are stored in said memory and wherein said hydraulic pump system comprises one of a variable volume hydraulic pump connected to a controller electrically associated with said processing device or a non-variable volume hydraulic pump. ### Claim 14 (depends on 13) The apparatus for monitoring a power swivel system as in claim 13, wherein at least one rotation data threshold value defining at least one rotation limitation is stored in said memory and wherein said smart box means compares said rotation data with said at least one rotation data threshold value and transmits a Speed Alert warning when said rotation data exceeds a rotation data threshold value and wherein said smart box means is configured to execute at least one of said plurality of automatic commands after a predefined delay period when a Speed Alert warning is generated unless an override signal is received during said predefined delay period. ### Claim 15 (depends on 13) The apparatus for monitoring a power swivel system as in claim 13, wherein at least one pressure threshold value defining at least one pressure limitation is stored in said memory and wherein said smart box means compares said hydraulic fluid pressure data to said at least one pressure threshold value and generates and transmits a Pressure Alert warning to at least one of a local device and said remote device when said hydraulic fluid pressure data exceeds a pressure threshold value and wherein said smart box means is furthered configured to execute at least one of said plurality of automatic commands after a predefined delay period when said Pressure Alert warning is generated unless an override signal is received during said predefined delay period. ### Claim 16 (depends on 13) The apparatus for monitoring a power swivel system as in claim 13, wherein at least one hydraulic fluid temperature threshold value defining at least one temperature limitation is stored in said memory wherein said smart box means is configured to generate and transmit a Temperature Alert warning to one of a local device or said remote device when said hydraulic temperature data exceeds a hydraulic fluid temperature threshold value and wherein said smart box is furthered configured to execute at least one of said plurality of automatic commands after a predefined delay period when said Temperature Alert warning is generated unless an override signal is received during said predefined delay period. ### Claim 17 A method for monitoring the components of a power swivel system comprising a power swivel unit in hydraulic fluid communication with a hydraulic pump system being driven by a motor associated with an electronic control module (ECM), said method comprising: associating a smart box with a power swivel system wherein said smart box comprises a processing device electrically associated with a memory, a display device and communication technology; associating a rotation sensor with said processing device and rotating elements defined by said power swivel unit wherein said rotation sensor is configured for generating rotation data for said rotating elements; associating a hydraulic pressure sensor with said processing device and said hydraulic pump system wherein said hydraulic pressure sensor is configured to generate hydraulic fluid pressure data for said hydraulic pump system; associating a location sensor with said processing device and said power swivel system wherein said location sensor is configured to generate location data for said power swivel system; configuring said processing device for at least one of collecting, formatting, storing or transmitting power swivel system data comprising said rotation data, said hydraulic fluid pressure data and said location data; storing threshold data in said memory; configuring said processing device to use said communication technology to transfer at least part of said power swivel system data and at least part of said threshold data to a remote device; configuring one of said processing device or said remote device to cause said display device or a remote device to generate and display a user interface wherein said user interface presents processed or unprocessed power swivel system data and threshold data; and configuring one of said processing device or said remote device to evaluate said power swivel system data using said threshold data to determine when a warning should be generated. ### Claim 18 (depends on 17) The method for monitoring the components of a power swivel system as in claim 17, further comprising the step of configuring one of said processing device or said remote device to generate an automatic command pending warning, define a predefined wait time and wait said predefined wait time and then executing said automatic command if no override signal has been received. ### Claim 19 (depends on 18) The method for monitoring the components of a power swivel system as in claim 18, associating a temperature sensor with said smartbox and said hydraulic fluid wherein said temperature sensor is configured for generating hydraulic fluid temperature data and wherein said power swivel system data includes said hydraulic fluid temperature data. ### Claim 20 (depends on 19) The method for monitoring the components of a power swivel system as in claim 19, wherein said hydraulic pump system comprises a variable volume hydraulic pump connected to a controller and wherein said controller is associated with said processing device.