Automated anti-collision systems (ACS) for drilling rig pipe handling operations. PLC-controlled monitoring of racking arm position with visual and audible warnings and action to prevent collisions between racking arms and travelling blocks.
Access Basket, in proximity to Travelling Block
Dual Derrick, Travelling Blocks with Top Drives
Mast Rig
Travelling Block, Moving Well Equipment
Travelling Block with a Top Drive
Iron Roughneck on a Drillfloor
TBM ACS – Driller’s Indication Panel
Derrick, with a Travelling Block and a Top Drive
System Overview
RCP’s racking arm anti-collision system monitors the position and movement of upper and lower racking arms during pipe handling operations. The PLC-controlled system uses intrinsically safe proximity sensors positioned to detect targets fitted onto the racking arms, providing real-time collision hazard warnings to the Derrickman and Driller.
The system monitors up to three dynamic functions of the Upper Racking Arm (URA): trolley travel, gripper arm slew, and arm telescope. Lower Racking Arm (LRA) monitoring is available using the same sensor and target methodology. Higher accuracy solutions are available, tracking angles and travel distances via encoders.
The system is designed to operate within the full drillfloor equipment environment. In addition to racking arm monitoring, the system can be configured to account for the operational envelopes of other drillfloor and pipe handling equipment — including iron roughnecks, stabmasters, access baskets, hydraulic catwalks, and drillfloor manipulator arms — ensuring collision hazard assessment reflects the complete working environment.
When proximity sensors detect that racking arm position creates potential for collision with travelling blocks or other tracked equipment, the system provides both visual and audible warnings through lamp stations and beacons, and acts to stop hydraulic or pneumatic control of the racking system. The failsafe sensor design ensures that if targets are no longer sensed, or if sensor or cable faults occur, the system automatically reverts to an alarm state until the hazard is cleared or the fault is rectified.
System Operation
Position Monitoring
- PLC-controlled monitoring system
- Intrinsically safe proximity sensors positioned to monitor targets fitted onto racking arms
- Monitors up to 3 dynamic URA functions: trolley travel, gripper arm slew, arm telescope
- Lower Racking Arm (LRA) monitoring capability
- Wireless technology for link tilt angle monitoring and status indication
- High feature sensing option with encoder/inclinometer-based solutions.
Warning & Alarm Functions
- Warning lamp station with green (safe) and red (hazard) indication for Derrickman and Driller
- Audible beacon sounds when racking arm enters potentially hazardous position
- Pushbutton alarm accept to silence audible alarm
- Red hazard lamp remains illuminated until racking arm returns to recognized safe position
- Failsafe operation: system reverts to alarm state if any sensor fails or cable breaks
Integration Capability
- Integrates with TBM (Traveling Block Monitor) systems for comprehensive collision avoidance
- Compatible with new generation TBM systems
- Combined link tilt monitoring and TBM integration provides complete anti-collision capability
Collision Prevention Applications
RCP anti-collision systems (ACS) provide collision warning and avoidance solutions for multiple drill floor equipment collision points:
- Upper, intermediate, and lower racking arms
- Monkey board
- Dolly retract mechanisms
- Access basket
- Drill floor manipulator arm
- Iron roughneck
- Case stabbing board
- Raised back system
- Stabmaster
- Catwalk
- Travelling blocks
System Benefits
RCP collision warning systems are proven effective in the prevention of drill floor collisions, reducing the time and costs associated with collision incident investigations and operational downtime. The automated safety management approach provides continuous monitoring, warning and prevention of hazardous conditions during pipe handling operations.
Applications
- Offshore drilling rig pipe handling operations
- Land-based drilling rig racking systems
- Automated pipe handling systems requiring collision avoidance
- Drilling operations with upper and lower racking arm configurations
- Drill floor equipment with multiple collision hazard points
