Tubular String Make-Up Using Image-Based Thread Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for making-up threaded connections in tubular strings for subterranean wells are prone to human error and inefficiencies, leading to potential leakage and unthreading issues.
Innovation Solution
Utilizing image processing with cameras and controllers to monitor and control the threading process, ensuring proper alignment and torque application through automated detection of marks on tubulars, thereby reducing human error and improving connection quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated image processing is implemented to monitor and control threading, then manufacturing precision and reliability improve, but device complexity increases
Solution Approach 1:
The patent replaces manual visual inspection and mechanical alignment methods with an automated optical imaging system. Cameras capture images of alignment marks on tubulars, and image processing algorithms automatically determine threading status, eliminating the need for human operators to visually assess connection quality.
Solution Approach 2:
The system creates optical copies (images) of the physical alignment marks on the tubulars. These digital replicas are then processed to extract positioning information, allowing the system to analyze thread alignment without physically measuring the actual threads themselves.
2Reliability
If manual monitoring of threading is performed, then device complexity remains low, but reliability and precision deteriorate due to human error
Solution Approach 1:
The system continuously captures images during the threading process and provides real-time feedback on alignment mark positions. The controller monitors the threading progression and can detect when proper alignment is achieved or when errors occur, enabling corrective action before the connection is finalized.
Solution Approach 2:
The system performs self-monitoring and self-assessment of the threading quality. The image processing algorithm automatically evaluates whether the alignment marks indicate proper threading, eliminating dependence on human judgment and reducing variability in quality assessment.
3Productivity
If traditional threading methods are used, then ease of operation is maintained, but productivity and precision improve through automation
Solution Approach 1:
Alignment marks are pre-marked on the tubulars during manufacturing, preparing them for automated detection. The imaging system is pre-configured with knowledge of where these marks should appear, enabling rapid automated assessment without requiring complex real-time calculations.
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
The method ensures properly made-up connections with reduced human intervention, enhancing efficiency and reliability in tubular string assembly.
Implementation Method 1
inputting image data to an image processor, the image data being output from at least one camera
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A method of making-up tubular string components can include inputting to an image processor image data output from at least one camera (28), the image processor in response detecting positions of a tubular (14) and a mark (30) on another tubular (20), threading the tubulars with each other while inputting position data from the image processor to a controller, and the controller terminating the threading in response to the position of the mark relative to the position of the first tubular being within a predetermined range. Another method of making-up tubular string components can include, in response to inputting image data to an image processor, the image processor detecting longitudinal positions of two tubulars, threading the tubulars with each other, and a controller terminating the threading in response to the longitudinal position of one tubular relative to the longitudinal position of the other tubular being within a predetermined range.