Power catwalk pipe column posture detection device and detection method

Abstract

This invention discloses a power catwalk string attitude detection device, including a driller's terminal, a power catwalk controller, a power catwalk controlled unit, an edge computing box, and a digital camera. The invention also discloses a power catwalk string attitude detection method. The power catwalk controller sends a command to the edge computing box to detect the string attitude. Upon receiving the command, the edge computing box immediately sends a signal to the digital camera to capture a video image, driving the digital camera to capture video. The edge computing box acquires the video image from the digital camera and identifies the string attitude. Based on the string attitude detection result, the power catwalk controller decides whether to continue executing subsequent catwalk actions. This device solves the problem that the power catwalk cannot automatically sense whether the string attitude is safe after rolling into the string, avoiding the increased operational risk of directly raising the catwalk due to an unsafe string attitude. It can reduce the driller's workload while improving the operating efficiency and safety of the power catwalk.

Description

Technical Field

[0001] This invention belongs to the technical field of oil drilling and production testing equipment, specifically relating to a power catenary string attitude detection device and a power catenary string attitude detection method. Background Technology

[0002] In recent years, with the continuous deepening of cost reduction and efficiency improvement reforms in drilling companies, automated equipment has been widely promoted in oil fields. Among them, the power catwalk, as an important automated tool for tubing transport, has created good benefits for users due to its high efficiency and labor saving.

[0003] Hydraulically driven catwalks are commonly used. When delivering the tubing string, two tilting mechanisms simultaneously lift and lower the string into the drill string, then the string is raised to the drilling platform by a hydraulic winch or cylinder. However, during the tubing string tilting process, mechanical jamming or pipeline blockage can cause asynchronous movements of the tilting mechanisms, leading to tubing string tilting. If the catwalk is raised directly while the tubing string is tilted, there is a risk of the tubing string slipping. Currently, the driller usually needs to manually observe the catwalk after the tubing string has been rolled in, and only raises it when it is safe to do so. However, with the continuous improvement of drilling rigs in efficiency, safety, and intelligence, rigs relying heavily on manual intervention are clearly no longer suitable for modern needs. Therefore, a more efficient method is urgently needed to automatically identify the tubing string posture on the power catwalk, incorporating the identification results into automatic control to reduce driller distraction and further improve the intelligence level of the power catwalk. Summary of the Invention

[0004] The purpose of this invention is to provide a power catwalk column attitude detection device, which solves the problem that the power catwalk cannot sense whether the column attitude is safe after rolling into the column.

[0005] Another objective of this invention is to provide a method for detecting the attitude of a powered catwalk column.

[0006] The technical solution adopted in this invention is a power catwalk string attitude detection device, including a driller's terminal, a power catwalk controller, a power catwalk controlled unit, an edge computing box, and a digital camera. The power catwalk controller and the edge computing box are connected by a communication line; the driller's terminal and the power catwalk controller are connected by a communication line; the edge computing box and the digital camera are connected by a communication line; and the power catwalk controller and the power catwalk controlled unit are connected by a signal control line.

[0007] Another technical solution adopted in this invention is a method for detecting the attitude of a powered catenary support column, which is implemented according to the following steps:

[0008] Step 1: The power catwalk controller sends an instruction to the edge computing box to detect the posture of the pipe string. After receiving this instruction, the edge computing box immediately sends a signal to the digital camera to drive the digital camera to capture video images.

[0009] Step 2: The edge computing box obtains video images from the digital camera and uses digital image processing technology to identify the posture of the pipe string.

[0010] Step 3: The power catwalk controller makes a decision on whether to continue to execute the subsequent actions of the catwalk based on the detection result of the pipe string posture.

[0011] The features of this invention also include that

[0012] In Step 2, specifically:

[0013] Step 2.1: The edge computing box performs image segmentation on each frame of the collected video images in the HSV color space, and performs morphological operations on the segmented images for image smoothing to obtain processed images.

[0014] Step 2.2: Obtain the contour area of the ROI region, and screen out the contour groups that meet the requirements according to the contour area and aspect ratio features of the ROI region.

[0015] In Step 2.1, the process of image segmentation is as follows: Set the lower limits of the thresholds of hue h, saturation s, and value v to [h1, s1, v1], and the upper limits to [h2, s2, v2]. Extract the ROI region in the video image that satisfies h>h1&h<h2 and s>s1&s<s2 and v>v1&v<v2.

[0016] In Step 2.2, specifically:

[0017] Set the lower limit of the contour area threshold to area1, the upper limit to area2, set the lower limit of the threshold of the aspect ratio r of the minimum contour bounding rectangle to r1, and the upper limit to r2; perform contour search on the segmented image to screen out all contours with a contour area area that satisfies area>area1&area<area2, and then secondarily screen out the contour groups that satisfy r>r1&r<r2 from these contours; define a counter and then traverse each element in the contour group. Each time an element is traversed, the counter is incremented by 1 until all elements are traversed and ended, so as to obtain the length of the contour group.

[0018] When the length of the contour group is 0, the situation of the pipe string posture is that there is no pipe string in the catwalk, then the pipe string posture is safe; if the length of the contour group is greater than 0, continue to find the rotation angle θ of each contour. Set the lower limit of the rotation angle threshold of the safe posture to θ1, and the upper limit to θ2. If θ>θ1&θ<θ2, then the pipe string posture is in a safe state, otherwise it is in an unsafe state.

[0019] In step 3, specifically: if the result of the pipe string attitude detection is unsafe, the catwalk controller stops the subsequent actions of the catwalk and sends an alarm to the driller's terminal indicating that there is an unsafe attitude of the pipe string in the catwalk; otherwise, the subsequent actions of the catwalk continue to be executed.

[0020] The beneficial effects of this invention are that the power catwalk string attitude detection device and method of this invention, by using hardware devices such as the driller's terminal, power catwalk controller, edge computing box, and digital camera, build a power catwalk string attitude recognition system. After the string rolls in, the system captures video frames and uses image recognition algorithms to segment and extract the string outline from the string image in the catwalk. Based on the outline attributes and features, the azimuth angle of the string is calculated, and then the value of the azimuth angle is used to determine whether the string attitude is in a safe state. This device solves the problem that the power catwalk cannot sense whether the string attitude is safe after it rolls in, and avoids directly raising the catwalk due to an unsafe string attitude, which increases the operational risk. This device and detection method can reduce the driller's labor intensity while improving the operating efficiency and safety of the power catwalk. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the dynamic catwalk column attitude detection device of the present invention;

[0022] Figure 2 This is a flowchart of the dynamic catwalk column attitude detection method of the present invention;

[0023] Figure 3 This is a schematic diagram of the detection results of Embodiment 1 of the present invention;

[0024] Figure 4 This is a schematic diagram of the detection results in Embodiment 2 of the present invention.

[0025] In the diagram, 1. Driller's terminal, 2. Power catwalk controller, 3. Power catwalk controlled unit, 4. Edge computing box, 5. Digital camera. Detailed Implementation

[0026] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0027] Example 1

[0028] Reference Figure 1 The power catwalk string attitude detection device of the present invention includes a driller's terminal 1, a power catwalk controller 2, a power catwalk controlled unit 3, an edge computing box 4, and a digital camera 5. The power catwalk controller 2 and the edge computing box 4 are connected by a communication line; the driller's terminal 1 and the power catwalk controller 2 are connected by a communication line; the edge computing box 4 and the digital camera 5 are connected by a communication line; and the power catwalk controller 2 and the power catwalk controlled unit 3 are connected by a signal control line.

[0029] The driller's terminal 1 is used for the driller to operate the power catwalk. It can be a wireless remote control box or a control terminal such as the driller's room control panel, and it can display alarm information.

[0030] The power catwalk controller 2 is installed inside the power catwalk control box and contains the power catwalk control program. It receives control commands from the driller's terminal 1, sends image capture commands to the edge computing box 4, acquires the pipe string attitude from the edge computing box 4, and sends control signals to the power catwalk controlled unit 3. The power catwalk controller 2 is a Siemens 1500 PLC.

[0031] The controlled unit 3 of the power catwalk can be an electronic control component such as a solenoid valve or a frequency converter, used to drive the mechanical mechanism of the power catwalk, such as the pulley or the drill string.

[0032] The edge computing box 4 is equipped with image processing software and a column attitude detection algorithm. It sends a photo signal to the digital camera 5 to acquire digital images, and then performs feature extraction and analysis on the digital images to form the column attitude detection results.

[0033] Edge computing box 4 uses the IVP02D edge box from Incode Technology.

[0034] Digital camera 5 is a network camera used to acquire video images of the catwalk. It is usually installed on the drilling platform or derrick area and can cover the entire catwalk area.

[0035] Example 2

[0036] The working principle of the dynamic catwalk column attitude detection device of the present invention is as follows:

[0037] A digital camera 5 is used to capture video images of the power catwalk, and the video images are stored in the edge computing box 4. The edge computing box 4 completes the drill pipe attitude detection through the built-in pipe attitude detection program and sends the detection result to the power catwalk controller 2. The power catwalk controller 2 uses this signal as the program's running condition to control the operation of the power catwalk.

[0038] Example 3

[0039] The method for detecting the attitude of a powered catenary support column of the present invention is implemented according to the following steps:

[0040] Step 1: The power cat path controller 2 sends a command to the edge computing box 4 to detect the posture of the column. After receiving the command, the edge computing box 4 immediately sends a signal to the digital camera 5 to capture video images, driving the digital camera to capture video.

[0041] Step 2: Edge computing box 4 acquires video images from digital camera 5 and uses digital image processing technology to identify the posture of the tube column; specifically:

[0042] Step 2.1, the edge computing box 4 performs image segmentation on each frame of the collected video image in the HSV color space, sets the lower limits of the thresholds of hue h, saturation s, and value v to [h1, s1, v1], and the upper limits to [h2, s2, v2], and extracts the ROI region in the image that satisfies h>h1&h<h2 and s>s1&s<s2 and v>v1&v<v2; the segmented image is smoothed through morphological operations to obtain the processed image;

[0043] Step 2.2, obtain the contour area of the ROI region, and screen out the contour groups that meet the requirements according to the contour area of the ROI region and the aspect ratio feature;

[0044] Set the lower limit of the contour area threshold to area1, the upper limit to area2, set the lower limit of the threshold of the aspect ratio r of the minimum contour bounding rectangle to r1, and the upper limit to r2; perform contour search on the segmented image to screen out all contours whose contour area (area) satisfies area>area1&area<area2, and then secondarily screen out the contour groups that satisfy r>r1&r<r2 among these contours;

[0045] By defining a counter and then traversing each element in the contour group, the counter is incremented by 1 for each traversed element until all elements are traversed and ended, so as to obtain the length of the contour group;

[0046] When the length of the contour group is 0, the pipe string attitude situation is that there is no pipe string in the catwalk, then the pipe string attitude is safe; if the length of the contour group is greater than 0, continue to find the rotation angle (θ) of each contour, set the lower limit of the rotation angle threshold of the safe attitude to θ1, and the upper limit to θ2. If θ>θ1&θ<θ2, the pipe string attitude is in a safe state, otherwise it is in an unsafe state;

[0047] Step 3, the power catwalk controller 2 makes a decision on whether to continue to execute the subsequent actions of the catwalk according to the pipe string attitude detection result;

[0048] In this step, if it is judged that the pipe string attitude detection result is unsafe, the catwalk controller stops the subsequent actions of the catwalk and sends an alarm of unsafe pipe string attitude in the catwalk to the driller terminal, otherwise continues to execute the subsequent actions of the catwalk.

[0049] Embodiment 4

[0050] The power catwalk pipe string attitude detection method proposed in this embodiment includes the following specific steps:

[0051] Set the basic conditions as: all mechanisms of the power catwalk operate normally, the communication of the pipe string attitude detection device is normal, and the location of the catwalk is at the horizontal position of the site.

[0052] Step 1: When the power catwalk controller receives the signal from the driller's terminal indicating that the tubing has rolled into the casing, it immediately sends a request signal for casing attitude detection to the edge computing box. After receiving the casing attitude detection signal from the catwalk controller, the edge computing box immediately drives the digital camera to capture video.

[0053] Step 2: After acquiring video images from the digital camera, the edge computing box uses digital image processing technology to identify the posture of the tube column.

[0054] After the edge computing box reads each frame of the video image, it maps the image from the RGB space to the HSV color space. Within the HSV space, it segments image regions that meet the requirements for hue, saturation, and value. Then, after morphological smoothing, it filters out contour groups that meet the requirements for area and aspect ratio. If the length of a contour group is 0, it indicates that no pipes exist within the catwalk. The result is illustrated below. Figure 3 As shown.

[0055] Step 3: The cat path controller makes the decision to roll into the tubing.

[0056] Example 5

[0057] The dynamic catwalk column attitude detection method proposed in this embodiment includes the following specific steps:

[0058] The basic conditions are: all mechanisms of the power catwalk are functioning normally, the column attitude detection device is communicating normally, and the catwalk is located in a horizontal position on the site.

[0059] Step 1: After the rolling into the column process is completed, the catwalk controller sends a command to the edge computing box to detect the column attitude.

[0060] Step 2: The edge computing box acquires video images from the digital camera and uses digital image processing technology to identify the posture of the tubing.

[0061] After the edge computing box reads each frame of the video image, it maps the image from the RGB space to the HSV color space. In the HSV space, it segments the image region that meets the requirements for hue, saturation, and value. Then, after morphological smoothing, it filters out contour groups that meet the requirements for area and aspect ratio. The length of the contour group is set to 1. The rotation angle of this contour is then checked. If the rotation angle is 2.2°, which is not within the required range, the column attitude detection is considered unsafe. The result is illustrated below. Figure 4 As shown.

[0062] Step 3: The catwalk controller makes a decision to stop executing subsequent actions of the catwalk and sends an alarm about an unsafe pipe posture to the driller's terminal.

[0063] Example 6

[0064] The dynamic catwalk column attitude detection method proposed in this embodiment includes the following specific steps:

[0065] First, the powered catwalk controller 2 detects a trigger condition requiring a check of the column's posture (e.g., before each operation or movement of the column), and then sends a command to the edge computing box 4 to detect the column's posture. Upon receiving the command, the edge computing box 4 immediately sends a signal to the digital camera 5 to capture a video image. The digital camera 5 begins capturing video within the powered catwalk, covering the entire area where columns might be present, at a frame rate of 10 frames per second for a duration of 0.5 seconds to ensure that the complete state of the columns is captured.

[0066] Next, edge computing box 4 acquires video images captured by digital camera 5. During image recognition processing, for image segmentation, the thresholds are set as follows: lower threshold h1 = 0, upper threshold h2 = 30 for hue h; lower threshold s1 = 20, upper threshold s2 = 180 for saturation s; and lower threshold v1 = 50, upper threshold v2 = 120 for value v. With these settings, the image is segmented in the HSV color space, extracting ROI regions that satisfy a specific color range, which likely contain the cylindrical image portion. The segmented image is then smoothed using morphological opening operations (erosion followed by dilation) to remove noise and small interfering contours, resulting in the processed image.

[0067] In the ROI region contour area and aspect ratio feature filtering stage, the contour area threshold is set to a lower limit of area1 = 2000 pixels and an upper limit of area2 = 5000 pixels. The minimum contour bounding rectangle aspect ratio threshold is set to a lower limit of r1 = 15 and an upper limit of r2 = 17. Contour search is performed on the segmented image to filter out all contours whose area satisfies area > 2000 & area < 5000. Among these contours, contour groups that satisfy r > 15 & r < 17 are further filtered out. The length of the contour group is calculated by iterating through each element in the contour group using a defined counter.

[0068] Assuming that the calculated profile length is 0 in this inspection, this indicates that no suitable tubing string was detected within the catwalk. According to the inspection logic, the tubing string posture is safe. Based on this inspection result, the power catwalk controller 2 determines that subsequent tubing string loading or transfer actions can continue. The entire power catwalk system operates according to the normal procedure, smoothly transporting the new tubing string to the designated position, ready for the next drilling operation connection operation.

[0069] The safety attitude rotation angle threshold is set with a lower limit θ1 = -0.5° and an upper limit θ2 = 0.5°. If, in a certain detection, the length of the profile group is greater than 0, and the rotation angle of the profile is found to be <-0.5° or θ>0.5°, the pipe string attitude is determined to be unsafe. The power catwalk controller 2 immediately stops the subsequent actions of the catwalk and sends an alarm message to the driller's terminal indicating an unsafe pipe string attitude within the catwalk. After receiving the alarm, the driller's terminal operator can promptly check the pipe string situation within the catwalk, adjust the pipe string position or attitude, and restart the power catwalk system operation procedure only after ensuring operational safety. If the rotation angle of a found profile is θ = 0.2°, the pipe string attitude is considered safe, and the power catwalk controller 2 continues to execute subsequent actions; if the rotation angle of a profile exceeds this range θ = -2°, the pipe string attitude is determined to be unsafe. The power catwalk controller 2 immediately stops the subsequent actions of the catwalk and sends an alarm message to the driller's terminal indicating that there is an unsafe position of the tubing in the catwalk. After receiving the alarm, the driller's terminal operator can promptly check the condition of the tubing in the catwalk, adjust the position or position of the tubing, and restart the power catwalk system only after ensuring the safety of the operation.

[0070] As can be seen from the above embodiments, the power catwalk string attitude detection method can effectively detect the string attitude and make reasonable decisions based on the detection results, thus ensuring the safety and reliability of the power catwalk system in oil drilling operations.

Claims

1. A power catwalk column attitude detection device, characterized in that, It includes a driller's terminal (1), a power catwalk controller (2), a power catwalk controlled unit (3), an edge computing box (4), and a digital camera (5). The power catwalk controller (2) and the edge computing box (4) are connected by a communication line; the driller's terminal (1) and the power catwalk controller (2) are connected by a communication line; the edge computing box (4) and the digital camera (5) are connected by a communication line; the power catwalk controller (2) and the power catwalk controlled unit (3) are connected by a signal control line.

2. The dynamic catwalk column attitude detection device as described in claim 1, characterized in that, The driller's terminal (1) is used for the driller to operate the power catwalk; the power catwalk controller (2) is used to receive the control command from the driller's terminal (1), send a photographing instruction to the edge computing box (4), obtain the pipe string attitude from the edge computing box (4), and send a control signal to the power catwalk controlled unit (3).

3. A method for detecting the attitude of a powered catenary tube column, characterized in that, It is specifically implemented according to the following steps: Step 1: The power catwalk controller (2) sends an instruction to detect the pipe string attitude to the edge computing box (4). After receiving this instruction, the edge computing box (4) immediately sends a signal to drive the digital camera to capture a video image to the digital camera (5). Step 2: The edge computing box (4) obtains the video image from the digital camera (5) and uses digital image processing technology to identify the pipe string attitude situation. Step 3: The power catwalk controller (2) makes a decision on whether to continue to execute the subsequent actions of the catwalk according to the pipe string attitude detection result.

4. The method for detecting the attitude of a powered catenary support column as described in claim 3, characterized in that, Specifically: In step 2, specifically: Step 2.1: The edge computing box (4) performs image segmentation on each frame of the collected video image in the HSV color space, and performs morphological operations on the segmented image for image smoothing to obtain a processed image. Step 2.2: Obtain the contour area of the ROI region, and screen out the contour groups that meet the requirements according to the contour area and aspect ratio characteristics of the ROI region.

5. The method for detecting the attitude of a powered catenary support column as described in claim 4, characterized in that, In step 2.1, the process of image segmentation is: set the lower limit of the thresholds of hue h, saturation s, and value v to [h1, s1, v1], and the upper limit to [h2, s2, v2], and extract the ROI region in the video image that satisfies h>h1&h<h2 and s>s1&s<s2 and v>v1&v<v2.

6. The method for detecting the attitude of a powered catenary support column as described in claim 5, characterized in that, In step 2.2, specifically: Set the lower limit of the contour area threshold to area1, the upper limit to area2, set the lower limit of the threshold of the aspect ratio r of the minimum contour bounding rectangle to r1, and the upper limit to r2; perform contour search on the segmented image to screen out all contours with a contour area area that satisfies area>area1&area<area2, and then secondarily screen out the contour groups that satisfy r>r1&r<r2 from these contours; define a counter and then traverse each element in the contour group, and the counter is incremented by 1 for each traversed element until all elements are traversed and ended, so as to obtain the length of the contour group.

7. The method for detecting the attitude of a powered catenary support column as described in claim 6, characterized in that, When the length of the contour group is 0, the column posture is that there is no column in the catwalk, so the column posture is safe. If the length of the contour group is greater than 0, continue to find the rotation angle θ of each contour, set the lower limit of the rotation angle threshold for safe posture to θ1 and the upper limit to θ2. If θ>θ1&θ<θ2, the column posture is safe; otherwise, it is unsafe.

8. The method for detecting the attitude of a powered catenary support column as described in claim 7, characterized in that, In step 3, specifically: if the result of the pipe string attitude detection is unsafe, the catwalk controller stops the subsequent actions of the catwalk and sends an alarm to the driller's terminal that there is an unsafe attitude of the pipe string in the catwalk; otherwise, the subsequent actions of the catwalk continue to be executed.

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