Tubular Connection Control via Turn Estimation
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Solution Overview
Problem
Existing tubular connection systems in the resource recovery and fluid sequestration industries face challenges in achieving precise and efficient threaded connections, often resulting in delays and costs due to improper connections and variable torque application.
Innovation Solution
A method and system that utilize a tubular connection system with a control system to measure rotational position, speed, and torque, estimate the number of turns remaining to reach a target torque, and control rotational speed through a speed controller to ensure precise connections, reducing reliance on human operators and improving consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual tubular connection methods are used, then operators have flexibility in operation, but connection precision and torque consistency deteriorate resulting in improper connections and delays
Solution Approach 1:
The patent replaces manual mechanical operation with an automated控制系统 that integrates sensors, processors, and actuators. The system automatically controls tubular rotation, torque application, and connection timing based on real-time data from torque sensors and rotational position sensors, eliminating manual judgment and improving connection precision while managing complexity through integrated control architecture.
Solution Approach 2:
The patent implements closed-loop feedback control where torque sensors and rotational position sensors continuously monitor connection parameters, and the控制系统 adjusts rotational speed and torque in real-time based on measured values. This feedback mechanism ensures consistent torque application and precise connection control, directly addressing the precision issue while using standard control system components.
2Reliability
If automated control systems are implemented to improve connection precision, then connection consistency improves, but system complexity and initial costs increase
Solution Approach 1:
The patent enables the connection system to automatically monitor and adjust its own operation through integrated sensors and control logic. The system self-regulates torque application and rotational speed based on real-time feedback from torque sensors and rotational position sensors, reducing the need for external intervention and improving reliability while keeping the control architecture self-contained and manageable.
Solution Approach 2:
The控制系统 is designed to perform multiple functions: monitoring torque, tracking rotational position, controlling rotational speed, determining connection completion, and providing operational feedback. This multi-functional integration improves reliability comprehensively while avoiding the need for separate dedicated systems for each function, thereby managing overall system complexity.
3Productivity
If rotational speed is maintained at high levels throughout connection, then productivity increases, but torque precision and connection quality deteriorate
Solution Approach 1:
The patent implements dynamic rotational speed control where the rotational speed varies during the connection process. The控制系统 maintains higher speeds during initial engagement and alignment phases to improve productivity, then automatically reduces speed as the connection approaches completion to ensure precise torque application. This dynamic adjustment optimizes both speed and precision at different connection stages.
Solution Approach 2:
The system performs preliminary high-speed rotation for tubular alignment and engagement, then transitions to controlled lower-speed operation for precision torque application. This preliminary action approach allows the system to maximize productivity during non-critical phases while ensuring precision during the critical final tightening stages, effectively resolving the speed-precision trade-off.
4Measurement precision
If multiple sensors and control mechanisms are added to improve connection precision, then measurement accuracy improves, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent combines torque sensing and rotational position measurement into an integrated control system that processes both parameters simultaneously. The控制系统 merges data from torque sensors and rotational position sensors to comprehensively monitor connection status, improving measurement precision through multi-parameter monitoring while reducing overall complexity by using a unified control architecture rather than separate independent systems.
Data Source
AI summary
A method of connecting tubular components includes positioning a first tubular component at a surface location and a second tubular component at least partially disposed in a borehole to initiate a threaded connection, and rotating the first tubular component relative to the second tubular component by a tubular connection system, and during the rotating, measuring at least one of a rotational position of the first tubular component and/or a component of the tubular connection system, relative to the second tubular component, and a rotational speed of the first tubular component and/or the component of the tubular connection system. The method further includes measuring a torque, estimating a number of turns remaining to reach a target torque on the first tubular component, and controlling a rotational speed of the first tubular component based on the estimated number of turns remaining to connect the first tubular component to the second tubular component.