Tubular String Threading with Image-Based Make-Up Control

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Solution Overview

Problem

Current methods for making up threaded connections in tubular strings for subterranean wells are prone to human error and inefficiency, leading to potential leaks and unthreading issues.

Innovation Solution

The implementation of an image processing system using cameras and an image processor to automatically control the threading process by detecting alignment marks and torque conditions, ensuring proper connection through real-time feedback and termination of the threading process when predetermined criteria are met.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual methods are used to make up threaded connections, then operational flexibility is maintained, but human error increases and reliability decreases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical operations with an automated system that uses image processing and computer vision to monitor and control the threading process. Cameras capture images of alignment marks, and a computer automatically processes these images to determine when proper threading is achieved, eliminating human error while maintaining operational control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables the threading process to self-regulate by automatically detecting alignment marks and determining when the connection is properly made up. The computer processes images and automatically controls the threading operation, allowing the system to service itself without continuous human intervention, thereby improving reliability.

Inventive Principle:

Principle #25Self-service

2Productivity

If automated image processing is implemented, then productivity and precision are improved, but device complexity increases

Engineering Contradiction:

Improvethreading efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces manual visual inspection and decision-making with an automated image processing system. Cameras capture images of alignment marks, and a computer automatically processes these images to determine threading status, significantly improving productivity while the automation handles the complexity of real-time image analysis.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements real-time feedback by continuously capturing images during the threading process, processing these images through computer vision algorithms, and automatically adjusting or terminating the threading operation based on detected alignment mark positions. This closed-loop feedback mechanism improves productivity by eliminating delays associated with manual inspection.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If real-time image monitoring is used, then manufacturing precision is improved, but use of energy and device complexity increase

Engineering Contradiction:

Improvealignment precisionVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent uses optical image capture and digital processing instead of manual measurement tools to achieve precise alignment detection. The system captures images of alignment marks and uses computer vision algorithms to determine threading status with high precision, consuming minimal energy compared to continuous mechanical measurement systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The image monitoring system operates periodically rather than continuously, capturing images at key moments during the threading process when alignment marks become visible. This periodic operation achieves high manufacturing precision while minimizing energy consumption by keeping cameras and processing systems inactive during non-critical phases.

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS11773662B2Tubular string make-up methods utilizing image processing

Publication Date: 2023.10.03 WEATHERFORD TECHNOLOGY HOLDINGS LLC

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, the image processor in response detecting positions of a tubular and a mark on another tubular, 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.