Tubular Joint Imaging for Automated Tong Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual alignment of tong assemblies with tubulars in oil and gas well construction is time-consuming, expensive, and prone to human errors, necessitating an automated alignment solution.
Innovation Solution
A system utilizing two lasers to project markers on tubulars, a camera to capture two-dimensional images, and a controller to determine the vertical position of tubular joints, enabling automated alignment of tong assemblies with tubulars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual alignment of tong assembly with tubulars is performed by human operators, then the operation can be completed with simple equipment, but the process is time-consuming and prone to human errors
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical-mechanical system. A camera captures images of the tubulars, and a controller processes these images to automatically determine joint positions and control the tong assembly's movement, eliminating manual visual inspection and physical positioning.
Solution Approach 2:
The system enables the tong assembly to automatically locate and align with tubular joints through self-contained imaging and control capabilities. The camera and controller work together to provide autonomous positioning without requiring external human operators to manually measure or estimate joint locations.
2Productivity
If automated alignment system with imaging and control is implemented, then efficiency and reliability are improved, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it processes images from the camera, determines the positions of tubular joints through image analysis, calculates the required tong assembly movement, and controls the tong's actuators. This multi-functionality reduces the need for separate dedicated components for each task.
Solution Approach 2:
The camera acts as an intermediary between the physical tubulars and the control system. It captures optical information about the tubular joints and converts it into image data that the controller can process, serving as a bridge between the physical alignment task and the digital control system.
3Reliability
If manual operation is used, then equipment cost is lower, but operational cost and susceptibility to errors increase
Solution Approach 1:
The system uses feedback from the camera's continuous or periodic imaging to monitor the tong assembly's position relative to the tubulars. The controller processes this visual feedback and adjusts the tong's movement in real-time to achieve precise alignment with the joints, ensuring reliable operation.
Solution Approach 2:
The patent substitutes manual mechanical positioning with an automated system that uses optical sensing and computer control. The controller receives image data, processes it to determine joint locations, and automatically controls the tong assembly's mechanical movement, replacing human operators' visual and manual functions.
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
Automated alignment improves efficiency, reduces costs, and enhances reliability by accurately positioning tong assemblies for tubular makeup and breakout operations.
Implementation Method 1
a camera to capture two-dimensional images of the tubular structure
Implementation Method 2
two lasers to project markers on tubulars
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
Embodiments of the present disclosure relate to apparatus and methods for locating a tubular joint using two dimensional images. A tubular feature may be located by capturing a first two dimensional image of a tubular, capturing a second two dimensional image of the tubular including a reference, identifying a tubular joint or stick-up of the tubular from the first or second two dimensional image, and determining a vertical position of the tubular joint or stick-up of the tubular using the reference.