Tubular Connection Evaluation Using Torque-Turn Shoulder Detection
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Solution Overview
Problem
Conventional methods for evaluating connections between tubulars in wellbore construction lack automation, relying on operator decisions and not effectively detecting issues like torque spikes, drops, and shoulder positions, which can lead to unreliable connections.
Innovation Solution
A method and system using a programmable logic controller to measure torque and turns during tubular makeup, analyzing these parameters to detect discontinuities, torque spikes, torque drops, and shoulder positions, and autonomously accepting or rejecting connections based on the evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional manual evaluation methods are used for tubular connections, then operator experience and judgment can be applied, but the process lacks automation and consistency leading to potential human error and unreliable connections
Solution Approach 1:
The patent replaces manual operator evaluation with an automated system that uses sensors to measure torque, turns, and time parameters during tubular connection makeup. The mechanical evaluation process is substituted with electronic sensing and computational analysis, eliminating human error while improving consistency and reliability of connection acceptance decisions
Solution Approach 2:
The system implements real-time feedback by continuously monitoring torque, turns, and time parameters during the connection process. The measured data is fed back to the control system which compares it against acceptance criteria and automatically makes accept/reject decisions, creating a closed-loop control system that ensures reliable connections through objective measurement rather than subjective judgment
2Measurement precision
If detailed measurement and analysis of torque, turns, and time parameters are implemented, then connection quality can be precisely evaluated, but the system complexity increases
Solution Approach 1:
The patent employs a multi-functional programmable logic controller that performs multiple tasks: acquiring sensor data, processing measurements, evaluating connection parameters, and controlling the makeup process. By consolidating these functions into a single controller, the system achieves high measurement precision without proportionally increasing overall system complexity
Solution Approach 2:
The patent introduces a programmable logic controller as an intermediary between the physical measurement sensors and the decision-making process. This intermediary component standardizes the complex measurements of torque, turns, and time into simplified acceptance/rejection decisions, managing system complexity while maintaining precise measurement capabilities
3Reliability
If autonomous acceptance or rejection decisions are made based on measured parameters, then human error is reduced, but the requirement for sophisticated real-time analysis increases
Solution Approach 1:
The patent establishes acceptance criteria and evaluation algorithms before the connection process begins. The system pre-configures the thresholds and logic for evaluating torque, turns, and time parameters, so that during the actual makeup process, the system only needs to compare real-time measurements against these pre-established criteria, simplifying real-time analysis while ensuring reliable autonomous decisions
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A
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 torque applied to the connection, and measuring turns of the first tubular. The method further includes using a programmable logic controller for: finding at least one candidate for a shoulder position; detecting the shoulder position based on analyses of the said candidate; wherein finding the at least one candidate comprises: overlaying a first line from a measured final torque value of the torque-turns curve to a point along the orque-turns curve; overlaying a second line from a measured starting torque value on the torque-turns curve to a point; and measuring an angle between the first line and the second line.