Autonomous Threaded Connection Makeup With Torque-Corrected Evaluation
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Solution Overview
Problem
Current methods for making up and evaluating threaded connections in oil or gas well construction are inefficient due to manual control, leading to potential over-torque and false failure diagnoses, which can result in lengthy closed-loop control processes and require human intervention for final evaluation.
Innovation Solution
An autonomous method and system using a tong assembly with a controller to measure and correct torque and turns parameters, accounting for mechanical and dynamic properties, to automatically make and evaluate threaded connections, ensuring accurate acceptance or rejection based on evaluated measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control of tong assembly is used during makeup, then ease of operation is improved, but manufacturing precision deteriorates due to potential over-torque
Solution Approach 1:
The patent replaces manual mechanical control with an automated控制系统 that uses sensors to measure torque and rotational speed, and a controller to automatically adjust the tong assembly's operation. This substitution eliminates human error in torque control while maintaining ease of operation through automation.
Solution Approach 2:
The patent implements a feedback mechanism where torque and rotational speed are continuously measured during the makeup process, and the controller uses this feedback information to automatically adjust the tong assembly's operation to achieve precise target torque without over-torque conditions.
2Manufacturing precision
If closed-loop control of torque or rotational speed is used, then manufacturing precision is improved, but productivity deteriorates due to long makeup time
Solution Approach 1:
The patent dynamically adjusts the rotational speed of the tong assembly during the makeup process based on real-time torque measurements. The system starts at higher speeds for initial engagement and then automatically reduces speed as target torque approaches, optimizing both speed and precision throughout the process.
Solution Approach 2:
The patent uses periodic measurement and adjustment cycles where torque is measured at intervals during makeup, and the controller makes incremental adjustments to rotational speed. This periodic control approach maintains precision while avoiding the continuous slow operation that reduces productivity.
3Productivity
If predetermined time rotation at constant speed is used, then productivity is improved, but manufacturing precision deteriorates due to heuristic timing
Solution Approach 1:
The patent replaces heuristic timing methods with real-time torque measurement and automated control. Instead of rotating for a predetermined time at constant speed, the system continuously measures torque and automatically adjusts rotational speed to achieve precise target torque, eliminating the imprecision of heuristic approaches.
Solution Approach 2:
The system performs self-adjustment based on real-time feedback from torque sensors. The controller automatically modifies the tong assembly's operation to achieve target torque without requiring external intervention or predetermined timing parameters, enabling both high speed and precision.
4Productivity
If initial evaluation based on torque and turns measurements is used, then productivity is improved, but reliability deteriorates due to false failure diagnosis
Solution Approach 1:
The patent implements comprehensive feedback from multiple sensors measuring torque, rotational speed, and turns throughout the makeup process. This multi-parameter feedback enables more reliable evaluation by providing complete process data for analysis, reducing false failure diagnoses while maintaining automated evaluation speed.
Solution Approach 2:
The patent replaces human operator evaluation with automated analysis of measured parameters. The controller systematically evaluates torque and turns data against predetermined criteria, eliminating human error and subjectivity in failure diagnosis while maintaining rapid automated evaluation.
Data Source
AI summary
Embodiments of the present disclosure relate to apparatus and methods for making up and evaluating tubular threaded connections. A tong assembly may be used for making up threaded connections. A threaded connection may be made up automatically by controlling the rotation speed of the tong assembly according to measurements of torque, turns, and/or time. After a threaded connection is made up, measurements of time, torque, and/or turns may be corrected based on operating parameters. The corrected measurements may be evaluated for indications of failure, such as discontinuity, torque spikes, and torque drops. The threaded connection is then accepted or rejected based on the evaluation.