Tubular Running Rotation Sensing for Reliable Thread Make-Up
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Solution Overview
Problem
Existing methods for making-up threaded connections in tubular strings in wells face challenges such as fluid leakage, unthreading, and inaccuracies in rotation and torque measurements due to sensor malfunctions or communication issues, leading to potential human error and suboptimal connection quality.
Innovation Solution
A system utilizing multiple rotation sensors with a data fusion module to produce fused rotation measurements, which are used to control the make-up process of threaded connections, ensuring accurate and reliable deployment of tubular strings by integrating a data fusion module to process data from various sensors, including optical and contact-based sensors, and a control system to manage tong assembly operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to measure rotation and torque, then measurement accuracy and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple sensors (rotation sensors, torque sensors, and other measurement devices) into an integrated measurement system. The sensors are merged with the tubular components and coupling devices, and their data is fused through a processing system to produce comprehensive measurement outputs, thereby achieving high measurement accuracy without proportionally increasing operational complexity
Solution Approach 2:
The measurement system is designed with multi-functional capabilities, where a single integrated system performs multiple functions including rotation measurement, torque measurement, position tracking, and real-time monitoring. This universal approach allows one system to replace what would traditionally require multiple separate specialized devices
2Reliability
If automated control systems are implemented to manage tong assembly operations, then connection quality and safety are improved, but operational complexity and initial cost increase
Solution Approach 1:
The automated control system continuously receives feedback from multiple sensors measuring rotation, torque, and connection status during the make-up process. This feedback loop allows the control system to adjust operations in real-time, ensuring proper connection quality and preventing failures, thereby improving reliability through intelligent control
Solution Approach 2:
The control system is designed to autonomously manage the tong assembly operations, automatically controlling the make-up process based on sensor inputs. The system performs self-regulation and decision-making without requiring constant human intervention, reducing operational complexity while maintaining high reliability
3Manufacturing precision
If real-time monitoring and data processing are implemented, then connection quality is improved, but energy consumption and processing requirements increase
Solution Approach 1:
The system performs preliminary data processing and analysis during the make-up operation itself, rather than requiring extensive post-processing. Real-time monitoring enables immediate detection and correction of connection issues, reducing the need for energy-intensive retrospective analysis while ensuring high connection precision
Data Source
AI summary
A method of running a tubular string into a well can include measuring a threaded connection parameter using a sensor, thereby producing sensor measurements, measuring the threaded connection parameter using another sensor, thereby producing sensor measurements, and performing data fusion on the sensor measurements, thereby producing fused sensor measurements. An apparatus for running a tubular string into a well can include a rotation sensor configured to measure rotation of a tubular and produce rotation measurements, another rotation sensor configured to measure the rotation of the tubular and produce rotation measurements, and a control system including a data fusion module configured to determine fused rotation measurements from the sensed rotation measurements.