Automated Tubular Dimension Measurement via Sensor Arrays
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Solution Overview
Problem
Conventional drilling operations face inefficiencies and inaccuracies in measuring tubular components due to time-consuming manual processes and the use of expensive, imprecise devices, leading to difficulties in constructing appropriately sized drill strings and increased operational costs.
Innovation Solution
A drilling system equipped with a horizontal tubular handling and transfer assembly featuring sensor arrays and processing circuitry to determine tubular component dimensions, including length and diameter, by receiving data feedback from multiple sensor arrays and calculating dimensions based on velocity and sensor data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement and data entry processes are used for tubular components, then operational flexibility is maintained, but measurement time increases and measurement precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical measurement processes with an automated optical measurement system. Multiple sensor arrays (including laser scanners and cameras) automatically capture tubular component dimensions, eliminating the need for manual measurement tools and data entry. The system processes measurements through computer vision algorithms and generates digital models automatically, resolving the contradiction by substituting mechanical/manual operations with automated optical-electronic systems that achieve both high precision and speed.
Solution Approach 2:
The measurement system performs self-service by automatically capturing, processing, and analyzing tubular component dimensions without human intervention. The sensor arrays autonomously detect features, the processing circuitry automatically calculates dimensions, and the system generates reports independently. This self-service capability eliminates time loss associated with manual operations while maintaining or improving measurement precision through consistent automated procedures.
2Measurement precision
If conventional measurement devices are used for tubular components, then device simplicity is maintained, but measurement precision and comprehensiveness deteriorate
Solution Approach 1:
The patent divides the measurement system into multiple specialized sensor arrays positioned at different locations and orientations. Each sensor array (laser scanners, cameras, proximity sensors) focuses on specific measurement tasks such as outer diameter, inner diameter, length, or surface features. This segmentation allows the system to achieve comprehensive and precise measurements of all tubular dimensions while managing complexity through modular, distributed sensing rather than a single complex device.
Solution Approach 2:
The system transitions from conventional single-point or linear measurement approaches to multi-dimensional spatial measurement. By positioning sensor arrays in three-dimensional space around the tubular component and using optical fields, the system captures comprehensive dimensional data from multiple angles simultaneously. This dimensional approach enables precise measurement of complex tubular geometries including tool joints, threads, and surface features that conventional devices cannot measure comprehensively.
3Productivity
If automated sensor arrays are deployed to measure tubular dimensions, then measurement precision and productivity are improved, but device complexity increases
Solution Approach 1:
The patent designs the measurement system with universal, multi-functional sensor arrays that can measure various tubular component types and dimensions using the same hardware platform. The sensor arrays are configured to handle different tubular sizes, geometries, and features through software configuration rather than requiring separate specialized devices for each measurement type. This universality improves productivity by enabling rapid measurement of diverse tubular components while managing device complexity through standardized, reconfigurable sensing modules.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system enhances accuracy and precision in measuring tubular dimensions, reducing operational costs and improving drill string construction and deconstruction processes.
Implementation Method 1
measure tubular dimensions via interferometer arrays disposed on an assembly station and/or a catwalk machine
Data Source
AI summary
A drilling system includes a horizontal tubular handling and transfer assembly configured to receive a tubular component, a first sensor array disposed at a first axial location on the horizontal tubular handling and transfer assembly, and a second sensor array disposed at a second axial location on the horizontal tubular handling and transfer assembly. The drilling system also includes processing circuitry configured to determine a length dimension of the tubular component based on first data feedback from the first sensor array, second data feedback from the second sensor array, or both. The processing circuitry is also configured to determine a diameter dimension of the tubular component based on the first data feedback, the second data feedback, or both.