Threaded Tubular Makeup Monitoring for Autonomous Connection Acceptance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for evaluating connections between tubulars in wellbore construction lack automation, requiring human intervention to assess the quality of connections, which can lead to inefficiencies and potential failures.
Innovation Solution
A method and system utilizing a programmable logic controller (PLC) to measure torque, turns, and time during tubular makeup, evaluating for discontinuities, torque spikes, torque drops, and shoulder position detection to autonomously accept or reject connections, incorporating a power drive, torque cell, and turns counter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manual evaluation methods are used for tubular connections, then human operators can make decisions based on experience, but the process is time-consuming and prone to human error
Solution Approach 1:
The patent replaces manual visual inspection and experience-based judgment with an automated electronic system that uses sensors, processors, and algorithms to evaluate connection parameters such as torque, turns, and load. This substitution of mechanical/manual evaluation with electronic automation resolves the contradiction by providing both high reliability through consistent objective criteria and speed through automated processing.
Solution Approach 2:
The system enables autonomous self-evaluation of connections by automatically collecting data from sensors, analyzing connection parameters against predetermined criteria, and making accept/reject decisions without human intervention. This self-service capability eliminates human error while maintaining rapid evaluation throughput.
2Productivity
If automated evaluation systems are implemented, then evaluation speed and consistency improve, but system complexity increases
Solution Approach 1:
The patent integrates multiple evaluation functions (torque measurement, turns counting, load monitoring, criterion comparison, and decision-making) into a single multi-functional automated system. This universal system handles all aspects of connection evaluation, improving productivity while managing complexity through functional integration rather than separate dedicated devices for each measurement.
Solution Approach 2:
The system uses intermediate sensors and transducers to convert physical connection parameters (torque, turns, load) into electrical signals that can be processed electronically. These intermediary devices bridge the mechanical connection process and the electronic evaluation system, enabling automated high-speed evaluation without requiring direct complex mechanical-electrical integration.
3Measurement precision
If multiple connection parameters are monitored simultaneously, then detection accuracy improves, but measurement system complexity increases
Solution Approach 1:
The patent combines multiple measurement functions (torque sensing, turns counting, load monitoring) into an integrated measurement system that collects and processes multiple parameters simultaneously. By merging these measurement capabilities into a unified system with centralized processing, the patent achieves high measurement precision across all parameters while avoiding the complexity of entirely separate measurement systems.
Data Source
AI summary
A method of connecting a first threaded tubular to a second threaded tubular includes engaging the threads of the tubulars and rotating the first tubular relative to the second tubular to makeup a threaded connection. The method further includes, during makeup of the threaded connection: measuring time, measuring torque applied to the connection, and measuring turns of the first tubular. The method further includes using a programmable logic controller for: evaluating at least one of the measured turns, measured torque, and measured time for at least one of a discontinuity, a torque spike, and a torque drop and accepting or rejecting the connection based on the evaluation.