Autonomous Threaded Connection Makeup With Corrected Torque Evaluation
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Solution Overview
Problem
Existing methods for making up and evaluating tubular connections in oil or gas wells are inefficient and prone to false failure diagnoses due to manual control and reliance on heuristic measurements.
Innovation Solution
An autonomous method and system for making up and evaluating threaded connections using a tong assembly with a controller that measures torque, turns, and other parameters, corrects for mechanical and dynamic effects, and evaluates the connection based on corrected data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control of tong assembly is used during makeup, then operator flexibility is maintained, but over torque occurs and reliability deteriorates
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 parameters. This substitution eliminates human error in torque control while maintaining operational flexibility through programmable parameters, directly resolving the contradiction between operator flexibility and connection reliability.
Solution Approach 2:
The patent implements a closed-loop feedback system where torque and rotational speed are continuously measured during makeup, and the controller adjusts parameters based on real-time feedback to achieve target torque accurately. This feedback mechanism prevents over torque while maintaining operational adaptability, resolving the reliability issue without sacrificing ease of operation.
2Reliability
If closed-loop control of torque or rotational speed is used, then target torque is achieved, but makeup time increases and productivity decreases
Solution Approach 1:
The patent employs dynamic control strategies that adapt the rotational speed profile during makeup based on real-time torque measurements. The system uses different speed phases (acceleration, constant speed, deceleration) optimized for each stage of connection engagement, achieving target torque reliably while minimizing total makeup time, thus resolving the contradiction between reliability and productivity.
Solution Approach 2:
The patent changes operational parameters (rotational speed, torque thresholds) dynamically during the makeup process based on measured conditions. By adjusting parameters in real-time rather than using fixed slow speeds, the system achieves reliable target torque while maintaining higher productivity, resolving the contradiction between these two factors.
3Device complexity
If predetermined time rotation at constant speed is used, then makeup process is simplified, but false failure diagnosis occurs and measurement precision deteriorates
Solution Approach 1:
The patent replaces simplified time-based control with automated measurement and control systems that continuously monitor torque and rotational parameters. This substitution maintains procedural simplicity through automation while dramatically improving measurement precision by capturing actual physical parameters rather than relying on predetermined time values, resolving the contradiction between device complexity and measurement precision.
Solution Approach 2:
The system performs self-evaluation by automatically measuring torque and turns during makeup and comparing results against acceptance criteria. This self-service capability eliminates false failure diagnoses by using precise automated measurements rather than simplified predetermined parameters, improving measurement precision while maintaining operational simplicity through automation.
4Productivity
If initial evaluation based on torque and turns measurements is used, then evaluation process is quick, but false failure diagnosis occurs and reliability deteriorates
Solution Approach 1:
The patent implements comprehensive feedback measurement of multiple parameters (torque, rotational speed, turns) throughout the makeup process, not just final values. This continuous feedback enables accurate evaluation of the entire connection process, eliminating false failure diagnoses while maintaining quick automated evaluation, thus resolving the contradiction between productivity and reliability in the evaluation process.
Solution Approach 2:
The patent replaces manual evaluation with automated analysis of measured parameters using a controller that applies acceptance criteria algorithms. This substitution maintains rapid evaluation speed while improving reliability by eliminating human judgment errors and using precise automated measurements, resolving the contradiction between evaluation speed and diagnostic accuracy.
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A
AI summary
Tubular makeup system (200) and method for making up threaded connections. A threaded connection may be made up automatically by controlling the rotation speed of a tong assembly (202) 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.