Pipe Tally Vision System Tool Joint Detection
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Solution Overview
Problem
Current wellbore operations face challenges in accurately managing tubular strings due to difficulties in observing diameter changes and tool joint alignment, leading to potential damage to seals and incomplete sealing or shearing, and manual logging of tubular specifications is laborious and ineffective.
Innovation Solution
A pipe tally system is implemented, comprising sensors and a controller that measure and generate a database of tubular string parameters, including diameter and length, to provide real-time observations and ensure accurate alignment and operation of BOP and RCD systems, reducing wear on seals and ensuring reliable sealing and shearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual logging of tubular specifications is used, then the process is simple to implement, but it is laborious and not always effective in accurately determining tool joint positions
Solution Approach 1:
The patent replaces manual mechanical logging processes with an automated optical sensing system. Sensors capture images of the tubular string, and image processing algorithms automatically identify tool joint positions and log specifications, eliminating manual labor while improving accuracy and efficiency simultaneously
Solution Approach 2:
The system creates visual copies (images) of the tubular string components and uses image processing to extract measurement data. By copying the visual information and analyzing it computationally, the system achieves both high measurement precision for tool joint positions and high productivity through automated data extraction
2Reliability
If the BOP and RCD are positioned beneath the drill floor, then the wellbore can be sealed and controlled, but the operator may have difficulty directly observing the tubular string to determine the relative location between tool joints and the BOP or RCD
Solution Approach 1:
The patent introduces an intermediary optical sensing system that captures images of the tubular string as it passes through the BOP and RCD. This intermediary system translates the otherwise unobservable positions into visible image data, allowing operators to determine tool joint locations relative to the BOP and RCD without compromising the sealing and control functions
Solution Approach 2:
The system replaces direct visual observation with automated optical sensing and image processing. Sensors positioned to capture images of the tubular string enable automated detection of tool joint positions, substituting the need for direct visual inspection while maintaining reliable sealing and control operations
3Productivity
If a tubular string passes through the RCD with tool joints, then the wellbore operation can proceed, but the seal within the RCD is at risk for damage if a change in diameter of the tubular string occurs too quickly
Solution Approach 1:
The patent implements preliminary detection of tool joint positions using optical sensors and image processing before the tubular string reaches the RCD seal. This advance knowledge allows the system to prepare for upcoming diameter changes, enabling preventive actions to be taken to protect the seal from damage while maintaining operational continuity
Solution Approach 2:
The system continuously monitors the position of tool joints relative to the RCD and provides real-time feedback. This feedback mechanism enables dynamic adjustment of operations to anticipate and mitigate potential seal damage from rapid diameter changes, balancing productivity with seal protection
Data Source
AI summary
A pipe tally vision system may be positioned on a drilling rig. A drill string may be positioned within a wellbore using the drilling rig. The drill string may be observed with the pipe tally system during a wellbore operation. A pipe tally database may be generated by the pipe tally system based on the observations of the drill string made by the pipe tally system and observations may be made as the drill string is moved into or out of the wellbore.