Automated Tubular Thread Inspection and Remediation After Failed Make-Up
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Solution Overview
Problem
Existing methods for making-up threaded connections in tubular strings in well operations are prone to human error and require manual inspection and remediation, which can lead to inefficiencies and safety risks.
Innovation Solution
An automated system with sensors and remediation tools is employed to inspect and remediate threaded connections in real-time, using devices like terahertz scanners, cameras, and mechanical probes, with machine learning for evaluation, to ensure proper connection make-up and reduce human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection and remediation methods are used for threaded connections, then device complexity is reduced, but reliability and productivity deteriorate due to human error and inefficiency
Solution Approach 1:
The system enables self-inspection and self-remediation of threaded connections through automated sensors and actuators. The inspection device detects connection quality parameters, and the system automatically adjusts make-up parameters or triggers remediation actions without human intervention, allowing the system to service itself and improve reliability while maintaining manageable complexity
Solution Approach 2:
Manual mechanical inspection and adjustment processes are replaced with automated sensing systems (acoustic, mechanical, optical sensors) and computer-controlled actuation. This substitution eliminates human error in inspection while using electronic control systems that, although more complex, provide superior precision and consistency in connection make-up
2Productivity
If manual inspection and remediation are performed, then device complexity is lower, but productivity and time efficiency worsen due to manual operation speeds
Solution Approach 1:
The inspection and remediation processes occur continuously during tubular string deployment rather than as discrete manual operations. Sensors continuously monitor connection parameters, and the control system continuously adjusts make-up operations or triggers remediation, eliminating idle time and maintaining continuous productive action throughout the deployment process
Solution Approach 2:
The system incorporates real-time feedback loops where sensors monitor connection quality parameters (acoustic signals, mechanical forces, positional data) and the control system immediately processes this information to adjust make-up parameters or initiate remediation. This closed-loop feedback enables rapid correction of issues and optimizes productivity by preventing defective connections from progressing
3Manufacturing precision
If real-time automated inspection is implemented, then connection quality improves, but the complexity of the making-up process increases
Solution Approach 1:
The inspection system is segmented into multiple specialized sensors (acoustic sensors for thread engagement detection, mechanical sensors for force measurement, optical sensors for positional tracking) rather than using a single complex inspection device. This segmentation allows each sensor to focus on specific parameters, improving measurement precision while keeping individual sensor complexities manageable
Solution Approach 2:
The inspection device is designed as a multi-functional integrated system that performs multiple inspection functions (acoustic analysis, mechanical measurement, optical verification) and multiple remediation functions (parameter adjustment, connection re-making, quality verification) through a single unified platform. This universality improves connection precision by combining multiple inspection methods while avoiding the complexity of separate dedicated devices for each function
Data Source
AI summary
A method can include, after a failed make-up of a threaded connection between tubulars, performing an inspection of a threaded end of one of the tubulars using at least one sensor, thereby generating inspection data, evaluating the inspection data, thereby determining whether the threaded end passes the inspection, and preparing the threaded end for make-up after the evaluating. A system can include at least one sensor to inspect a threaded end of a tubular, a remediation tool to prepare the threaded end for make-up, an actuator to displace the remediation tool relative to the threaded end, and a control system to receive inspection data from the sensor, evaluate the inspection data, and control actuation of the actuator.