Automated Pipe Diameter Measurement Using Laser Sensors
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Solution Overview
Problem
Existing methods for measuring the outer diameter of drill pipes in wellbore operations are inefficient and prone to errors due to variations in pipe shape, affecting drilling operations and tool performance.
Innovation Solution
A system comprising a frame with a movable carriage and guide sensors, including rotary and ultrasonic sensors, that measures the outer diameter of pipes by rotating them and using lasers to emit beams on opposite sides, allowing for precise alignment and data processing to determine the pipe's diameter and parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hand held micrometers or contact measurement methods are used to measure outer diameter, then measurement can be performed, but measurement precision deteriorates due to variations in pipe shape and human error
Solution Approach 1:
The patent replaces manual mechanical measurement tools (hand held micrometers) with an automated optical measurement system using lasers and sensors. The system uses non-contact optical measurement to eliminate human error and mechanical contact issues, achieving consistent and precise outer diameter measurements across the entire pipe length through automated data collection and processing.
Solution Approach 2:
The patent transitions from point-based manual measurement to continuous multi-dimensional measurement by using multiple sensors positioned at different locations around the pipe circumference. The system captures measurements across the entire length of the pipe simultaneously, creating a comprehensive three-dimensional profile of the pipe geometry that reveals shape variations invisible to traditional methods.
2Loss of information
If multiple measurement points are taken along the pipe length, then measurement completeness improves, but measurement time and complexity increase
Solution Approach 1:
The patent implements continuous measurement along the entire pipe length by mounting multiple sensors on a carriage that travels the full length of the pipe. Instead of taking discrete measurements at separate locations, the system continuously collects data as the carriage moves, eliminating gaps in measurement coverage and providing complete full-body measurement of the pipe in a single pass.
Solution Approach 2:
The measurement system is divided into multiple independent sensor units positioned at different locations around the pipe circumference. Each sensor independently measures the outer diameter at its specific location, and all measurements are integrated by the control system to create a complete profile of the entire pipe, allowing parallel data collection that reduces total measurement time.
Data Source
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AI summary
A system and method for measuring a pipe is provided. The system includes a frame rotatably receiving the pipe, a carriage movably positionable along the frame, a guide floatingly positionable about the carriage, at least one sensor for measuring a position of the pipe, and a measurement unit operatively linked to the sensor for collecting measurements therefrom. The guide has a mouth that receivingly engages the pipe and axially aligns therewith. The pipe is measured with the sensor(s) while moving at least one of the pipe, the carriage and the guide.