Optical Threaded Connection Monitoring for Tubular Make-Up Control
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Solution Overview
Problem
Existing methods for making-up and breaking-out threaded connections in tubular strings for subterranean wells are prone to human error and inefficiencies, leading to improper connections that can result in fluid leakage or unthreading.
Innovation Solution
The use of optical monitoring through cameras and image processors to detect optical flow vector fields during the threading process, allowing for real-time control of the connection make-up or break-out operations to ensure proper alignment and torque application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual methods are used for making-up and breaking-out threaded connections, then operational flexibility is maintained, but human error increases and connection reliability decreases
Solution Approach 1:
The patent replaces manual mechanical operations with an optical monitoring system that uses cameras and image processing to detect and verify threaded connection status. The system captures images of the threading process, processes them to detect thread engagement, and provides feedback to ensure proper make-up and break-out operations, eliminating human error while maintaining operational control.
Solution Approach 2:
The patent implements a feedback mechanism where the optical monitoring system continuously captures images during the threading process, analyzes thread engagement in real-time, and provides feedback to the operating personnel or automated system. This feedback loop ensures that connections are properly made-up and broken-out, improving reliability through continuous verification.
2Measurement precision
If optical monitoring systems are implemented to detect thread engagement, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement devices with an optical system using cameras and image processing algorithms. The system captures images of the threaded connection and uses computational methods to detect thread engagement, achieving high measurement precision while avoiding the mechanical complexity of traditional dial indicators or mechanical gauges.
Solution Approach 2:
The patent creates optical copies (images) of the threaded connection during the make-up and break-out processes. By capturing and analyzing these visual copies, the system can precisely measure thread engagement without physically contacting the threads, thereby improving measurement precision while keeping the monitoring system non-intrusive and relatively simple.
3Manufacturing precision
If real-time optical monitoring is used during threading operations, then manufacturing precision improves, but loss of time increases due to image processing
Solution Approach 1:
The patent performs preliminary actions by capturing multiple images during the threading process and pre-processing them for analysis. The system is set up to continuously monitor and prepare image data for rapid analysis, so that when thread engagement detection is needed, the processing can be performed on already-prepared data, reducing the time penalty for precision monitoring.
Solution Approach 2:
The patent maintains continuous image capture and processing during the entire threading operation, rather than taking intermittent measurements. This continuous monitoring ensures that no critical thread engagement moment is missed, improving manufacturing precision while the continuous nature of the process minimizes downtime compared to stop-and-check manual methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces human error and improves the efficiency of threaded connection processes by ensuring proper engagement and disengagement of tubular components, thereby preventing leakage and facilitating seamless well operations.
Implementation Method 1
positioning a first camera at a first location, the first camera thereby simultaneously observing at least threaded first and second tubulars
Implementation Method 2
the image processor detecting optical flow vector fields from the image data, the optical flow vector fields representing first and second displacements of the respective first and second tubulars during the threading
Data Source
Figure 1
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Figure 2B
AI summary
The present disclosure related to a method of making-up or breaking-out tubular string components, which can include positioning a first camera at a first location, the first camera thereby simultaneously observing at least threaded first and second tubulars; threading the first and second tubulars with each other; outputting image data from the first camera to an image processor; the image processor detecting optical flow vector fields from the image data, the optical flow vector fields representing first and second displacements of the respective first and second tubulars during the threading; and controlling the threading in response to the image processor detecting the optical flow vector fields.