Patent Description:
Various types of tubular components can be threaded together to form tubular strings for use in a well. Tubulars used in wells can include protective wellbore linings (such as, casing, liner, etc.), production or injection conduits (such as, production tubing, injection tubing, screens, etc.), drill pipe and drill collars, and associated components (such as tubular couplings).

It is typically important for threaded connections between tubulars to be properly made-up. For example, when a threaded connection is properly made-up, the threaded connection may prevent leakage of fluid into or out of the tubular string, or may resist unthreading of the connection.

It will, therefore, be readily appreciated that improvements are continually needed in the art of making-up threaded connections in tubular strings. The present disclosure provides such improvements to the art.

<CIT> discloses a pipe "spinning-up" method. The method involves seating a nipple end on one pipe in a clutch end of another pipe, which is prevented from rotating; screwing-in the nipple end of the first pipe into another one with increasing torque; aligning a mark formed on the first pipe with a mark created on the clutch end of the other, fixed, pipe by rotation of the nipple end of the first pipe; and "screwing-up" the nipple pipe end. Screwing-up the nipple pipe end is carried out due to resilient deformation of threads to obtain a predetermined interference in threaded connection, and bringing into register a nipple pipe end mark with an additional mark formed at the clutch end of the fixed pipe and spaced apart from the first mark, so that the clutch pipe end is located at a level of the mark formed the nipple pipe end.

<CIT> discloses a control system for making-up threaded connections between tubulars. The control system monitors and controls torque and rotational speed that a top drive applies to the tubulars to protect the threads of the tubulars from damage during the make-up process. During a thread matching phase, a controller sets the direction of rotation of the rotatable tubular in a direction opposite of the threading direction. When the rotatable tubular has been rotated by a predetermined amount (one and one half revolutions), the controller terminates the thread matching phase and sets the direction of rotation of the rotatable tubular in the threading direction.

<CIT> discloses an optical imaging and assessment system for tong cassette positioning devices. The system may include one or more cameras and one or more controllers. The system may detect the upper edge of a box and a lower edge of a pin/thread or any other mark on the pipe to measure make-up loss during a stab-in process.

Representatively illustrated in <FIG> is a system <NUM> for use with a subterranean well, and an associated method, which can embody principles of this disclosure. However, it should be clearly understood that the system <NUM> and method are merely one example of an application of the principles of this disclosure in practice, and a wide variety of other examples are possible. Therefore, the scope of this disclosure is not limited at all to the details of the system <NUM> and method described herein and/or depicted in the drawings.

In the <FIG> example, a tubular string <NUM> is being assembled and deployed into a well. The tubular string <NUM> in this example is a production or injection tubing string, but in other examples the tubular string could be a casing, liner, drill pipe, completion, stimulation, testing or other type of tubular string. The scope of this disclosure is not limited to use of any particular type of tubular string, or to any particular tubular components connected in a tubular string.

As depicted in <FIG>, a tubular <NUM> is suspended near its upper end by means of a rotary table <NUM>, which may comprise a pipe handling spider and/or safety slips to grip the tubular <NUM> and support a weight of the tubular string <NUM>. In this manner, the upper end of the tubular <NUM> extends upwardly through a rig floor <NUM> in preparation for connecting another tubular <NUM> to the tubular string <NUM>.

In this example, a tubular coupling <NUM> is made-up to the upper end of the tubular <NUM> prior to the tubular <NUM> being connected in the tubular string <NUM>. The coupling <NUM> is internally threaded in each of its opposite ends.

In conventional well operations, it is common for a threaded together tubular and coupling to be referred to as a "joint" and for threaded together joints to be referred to as a "stand" of tubing, casing, liner, pipe, etc. However, in some examples, a separate coupling may not be used; instead one end (typically an upper "box" end of a joint) is internally threaded and the other end (typically a lower "pin" end of the joint) is externally threaded, so that successive joints can be threaded directly to each other.

Thus, the scope of this disclosure can encompass the use of a separate coupling with a tubular, or the use of a tubular without a separate coupling (in which case the coupling can be considered to be integrally formed with, and a part of, the tubular). In the <FIG> example, the coupling <NUM> can also be considered to be a tubular, since it is a tubular component connected in the tubular string <NUM>.

To make-up a threaded connection between the tubular <NUM> and the coupling <NUM>, a set of tongs or rotary and backup clamps <NUM>, <NUM> are used. The rotary clamp <NUM> in the <FIG> example is used to grip, rotate and apply torque to the upper tubular <NUM> as it is threaded into the coupling <NUM>.

The backup clamp <NUM> in the <FIG> example is used to grip and secure the lower tubular <NUM> against rotation, and to react the torque applied by the rotary clamp <NUM>. The rotary clamp <NUM> and the backup clamp <NUM> may be separate devices, or they may be components of a rig apparatus known to those skilled in the art as an "iron roughneck.

In one example, the rotary clamp <NUM> and backup clamp <NUM> may be components of a tong system, such as the VERO(TM) tong system marketed by Weatherford International, Inc. of Houston, Texas USA. In this example, the rotary clamp <NUM> may be a mechanism of the tong system that rotates and applies torque to the upper tubular <NUM>, and the backup clamp <NUM> may be a backup mechanism of the tong system that reacts the applied torque and prevents rotation of the lower tubular <NUM>. Thus, the term "rotary clamp" as used herein indicates the rotation and torque application mechanism, and the term "backup clamp" as used herein indicates the torque reacting mechanism.

Note that it is not necessary for the tubulars <NUM>, <NUM> (and coupling <NUM>, if used) to be vertical in the tubular make-up operation. The tubulars <NUM>, <NUM> could instead be horizontal or otherwise oriented. Additional systems in which the principles of this disclosure may be incorporated include the CAM(TM), COMCAM(TM) and TORKWRENCH(TM) bucking systems marketed by Weatherford International, Inc.

In other examples, a top drive (not shown) may be used to rotate and apply torque to the upper tubular <NUM>. Thus, it will be appreciated that the scope of this disclosure is not limited to use of any particular equipment to grip, rotate, apply torque to, or react torque applied to, any tubular in a threaded connection make-up operation.

After the upper tubular <NUM> is properly made-up to the lower tubular <NUM> or coupling <NUM>, the tubular string <NUM> can be lowered further into the well, and the make-up operation can be repeated to connect another stand to the upper end of the tubular string. In this manner, the tubular string <NUM> is progressively deployed into the well by connecting successive stands to the upper end of the tubular string. In some examples, an individual tubular component may be added to the tubular string <NUM>, instead of a stand.

In the <FIG> method, the threaded connection make-up process can be controlled, so that a properly made-up connection is obtained, and this control can be automatic, so that human error is avoided. As described more fully below, at least one camera <NUM> is used in certain examples to facilitate this automatic control of the threaded connection make-up process.

As used herein, the term "camera" is used to indicate a device capable of obtaining images of an observed structure. Each image can comprise an array or matrix of pixels, with each pixel having a combination of optical characteristics. Examples of cameras include digital video cameras, time of flight sensors and optical matrix sensors. Preferably, a camera does not contact a structure observed by the camera.

Referring additionally now to <FIG>, a first example of the method of making-up tubular string components is representatively illustrated. For convenience, various examples of the method are described below as they may be used with the system <NUM> of <FIG>, but the methods may be used with other systems in keeping with the principles of this disclosure.

As depicted in <FIG>, the threaded connection make-up process has been initiated. The tubular <NUM> is positioned above and axially aligned with the coupling <NUM>, with the rotary clamp <NUM> appropriately positioned to grip an outer surface of the tubular <NUM>. The backup clamp <NUM> (see <FIG>) can grip an outer surface of the tubular <NUM> to react torque applied during the threaded connection make-up process.

A mark <NUM> is provided on the outer surface of the tubular <NUM> for use as an indicator of when a proper threaded connection has been achieved. In this example, the mark <NUM> is in the shape of a triangle having a base facing toward the lower end of the tubular <NUM>. The threaded connection is properly made-up when the upper end of the coupling <NUM> is axially or longitudinally aligned with the base of the triangle mark <NUM>, or at least within a predetermined distance range of the base of the triangle mark. In other examples, different shapes (such as, circles, lines, rectangles, etc.), alignments (such as, centered, adjacent, etc.) or positions of marks may be used to indicate a properly made-up threaded connection.

As depicted in <FIG>, multiple cameras <NUM> (only two of which are visible in the drawing) are positioned about the tubular <NUM> and coupling <NUM>. In this example, the cameras <NUM> may be distributed circumferentially about the tubular <NUM> and coupling <NUM>, so that the mark <NUM> can be observed by the cameras in all azimuthal positions of the mark, including when the tubular <NUM> is rotated by the rotary clamp <NUM> to make-up the threaded connection. Any number of cameras <NUM> may be used.

While the tubular <NUM> is rotated by the rotary clamp <NUM>, the cameras <NUM> can observe the mark <NUM>, including its longitudinal position relative to the upper end of the coupling <NUM>. The cameras <NUM> are connected to an image processor <NUM> (described more fully below, see <FIG>), and the image processor is capable of identifying or recognizing images of the coupling <NUM> and mark <NUM> in image data output by the cameras.

Once the images of the coupling <NUM> and mark <NUM> are identified by the image processor, the longitudinal distance between the positions of the coupling and mark can be conveniently determined. A controller <NUM> (described more fully below, see <FIG>) receives position data from the image processor and terminates the rotation of the tubular <NUM> by the rotary clamp <NUM> when the threaded connection has been properly made-up.

Referring additionally now to <FIG>, the threaded connection is representatively illustrated after the tubular <NUM> has been properly threaded into the coupling <NUM>. Note that the upper end of the coupling <NUM> is now longitudinally aligned with the base of the triangle mark <NUM> (or at least within a predetermined distance range of the base of the triangle mark).

In the <FIG> example, the cameras <NUM> are able to rotate with the tubular <NUM> as it is threaded into the coupling <NUM>, instead of being in fixed positions about the tubular <NUM> and coupling <NUM>. On the right-hand side of <FIG>, one of the cameras <NUM> is attached to a rotor <NUM> of the rotary clamp <NUM>.

The rotor <NUM> is rotated by a motor (not shown) of the rotary clamp <NUM>. Jaws <NUM> carried in the rotor <NUM> grip the outer surface of the tubular <NUM>, thereby transmitting torque from the rotor to the tubular as the tubular is threaded into the coupling <NUM>. If a top drive is instead used to rotate the tubular <NUM>, then the rotor <NUM> could be a component of the top drive mechanism that rotates with the tubular. The scope of this disclosure is not limited to use of any particular component to mount a camera so that the camera rotates with the tubular <NUM> while the threaded connection is made-up.

On the left-hand side of <FIG>, one of the cameras <NUM> is attached to an aerial vehicle <NUM> (such as a drone). The controller mentioned above and described more fully below may be used to control a flight path of the aerial vehicle <NUM>, so that the camera <NUM> can continuously observe the mark <NUM> and the coupling <NUM> while the tubular <NUM> is threaded into the coupling. Thus, the camera <NUM> supported by the aerial vehicle <NUM> will rotate with the tubular <NUM>, and will observe the mark <NUM>, as the threaded connection is made-up.

Because each of the two cameras <NUM> in the <FIG> example can rotate with the tubular <NUM> and continuously observe the mark <NUM> and the coupling <NUM> while the threaded connection is made-up, it is not necessary for multiple cameras to be used. However, multiple cameras <NUM> can be used if desired, for example, to provide redundancy or for other purposes.

As described above, the controller <NUM> can terminate the threading of the tubular <NUM> into the coupling <NUM> when the position of the mark <NUM> (such as a longitudinal position of the base of the mark) relative to the position of the coupling <NUM> (such as a longitudinal position of an upper end of the coupling) is within a predetermined range. In some examples, additional conditions may need to be satisfied for the threaded connection to be considered acceptable. Thus, the scope of this disclosure is not limited to use of only the relative positions of the mark <NUM> and the coupling <NUM> to indicate a proper or acceptable threaded connection.

For example, a minimum torque or range of torque values may need to be applied to the threaded connection in order for the threaded connection to be accepted or approved for use in the well. A sensor (such as a torque sensor of the rotary clamp <NUM>, a top drive, a bucking unit or an "iron roughneck") may be used to monitor the torque applied during the threaded connection make-up process.

In the <FIG> example, the method includes the steps of:.

The controller <NUM> may terminate the threading step in response to a longitudinal distance between the positions of the coupling <NUM> and the mark <NUM> being within the predetermined range, for example, in response to the base of the mark <NUM> being longitudinally aligned with the upper end of the coupling <NUM> or within a predetermined longitudinal distance of the upper end of the coupling.

The threading step may include rotating the tubular <NUM> relative to the coupling <NUM>. The camera <NUM> may rotate with the tubular <NUM> during the threading step.

The method may include connecting the camera <NUM> to a rotor <NUM> used to rotate the tubular <NUM>, so that the camera <NUM> rotates with the rotor <NUM>. The method may include connecting the camera <NUM> to an aerial vehicle <NUM>. A flight path of the aerial vehicle <NUM> may be controlled by the controller <NUM> in response to the position data output from the image processor <NUM>.

Referring additionally now to <FIG>, a second example of the method of making-up tubular string components is representatively illustrated. In this example, each of the tubular <NUM> and the coupling <NUM> is provided with the mark <NUM> in the form of a longitudinally extending line on its outer surface. The threaded connection is properly made-up when the marks <NUM> are azimuthally aligned (or within a predetermined range of such alignment) after the tubular <NUM> has shouldered up against the coupling <NUM>.

The cameras <NUM> observe the marks <NUM> as the tubular <NUM> is threaded into the coupling <NUM>. Image data from the cameras <NUM> is input to the image processor <NUM> in order to identify or recognize the azimuthal positions of the marks <NUM> while the tubular <NUM> is threaded into the coupling <NUM>.

A torque sensor (such as the torque sensor mentioned above for monitoring the torque applied during the threaded connection make-up process) may be connected to the controller <NUM> and used to determine when the tubular <NUM> has shouldered up against the coupling <NUM>. Thereafter, when it is determined that the azimuthal positions of the marks <NUM> are aligned (or within a predetermined range of such alignment), the controller <NUM> can terminate the rotation of the tubular <NUM> by the rotary clamp <NUM>.

As depicted in <FIG>, the tubular <NUM> is positioned above and axially aligned with the coupling <NUM> in preparation for initiating the threaded connection make-up process. The cameras <NUM> observe the marks <NUM>. Image data is output from the cameras <NUM> to the image processor <NUM>, which identifies or recognizes the marks <NUM> and the azimuthal positions of the marks.

As depicted in <FIG>, the tubular <NUM> is rotated by the rotary clamp <NUM> and is thereby threaded into the coupling <NUM> until at least two conditions are satisfied: <NUM>) the tubular <NUM> is shouldered up against the coupling <NUM>, and <NUM>) after shouldering up, the marks <NUM> are azimuthally aligned with each other (or within a predetermined range of such alignment). When these conditions are satisfied, the controller <NUM> terminates the rotation of the tubular <NUM> by the rotary clamp <NUM>.

Note that the cameras <NUM> illustrated in <FIG> are in fixed positions relative to the tubular <NUM> and the coupling <NUM>, and the cameras illustrated in <FIG> are rotatable with the tubular <NUM> relative to the coupling. Any number, positions, displacement or arrangement of the cameras <NUM> may be used in the <FIG> example in keeping with the principles of this disclosure.

The position of the coupling <NUM> may include an azimuthal position of a mark <NUM> on the coupling <NUM>, and the position of the mark <NUM> on the tubular <NUM> may include an azimuthal position of the mark <NUM> on the tubular <NUM>.

The terminating step may include the controller <NUM> terminating the threading in response to the azimuthal position of the mark <NUM> on the tubular <NUM> relative to the azimuthal position of the mark <NUM> on the coupling <NUM> being within the predetermined range. The predetermined range may correspond to azimuthal alignment of the marks <NUM> on the coupling <NUM> and the tubular <NUM>.

The terminating step may include the controller <NUM> terminating the threading in response to the azimuthal position of the mark <NUM> on the tubular <NUM> relative to the azimuthal position of the mark <NUM> on the coupling <NUM> being within the predetermined range after the coupling <NUM> and the tubular <NUM> are shouldered up.

Referring additionally now to <FIG>, a third example of the method of making-up tubular string components is representatively illustrated. In this example, at least one camera <NUM> is used to observe the tubular <NUM> and the coupling <NUM>, in order to determine when a desired total thread loss TTL has been achieved as an indication of a proper threaded connection make-up.

Total thread loss TTL in this example is an axial length of the lower end of the tubular <NUM> (which includes the external threads on the tubular) received in the coupling <NUM> during the threaded connection make-up process. As the tubular <NUM> is threaded into the coupling <NUM>, the threaded lower end of the tubular <NUM> is gradually received into the upper end of the coupling. In this example, the total thread loss TTL corresponds to a longitudinal overlap of the first and second tubulars <NUM>, <NUM>.

As depicted in <FIG>, the tubular <NUM> is positioned above and axially aligned with the coupling <NUM>. The camera <NUM> observes the tubular <NUM> and the coupling <NUM>. Image data is output from the camera <NUM> to the image processor <NUM>, which identifies or recognizes the tubular <NUM> and the coupling <NUM>. Longitudinal positions of the lower end of the tubular <NUM> and the upper end of the coupling <NUM> are determined.

Alternatively, relative longitudinal positions, or a longitudinal distance between the positions of the lower end of the tubular <NUM> and the upper end of the coupling <NUM>, can be determined. As another alternative, the tubular <NUM> may be lowered until the longitudinal position of the lower end of the tubular <NUM> is the same as the longitudinal position of the upper end of the coupling <NUM>, so that a longitudinal distance the tubular <NUM> is received into the coupling can be computed from this reference point.

As depicted in <FIG>, the tubular <NUM> has been rotated by the rotary clamp <NUM>, so that the tubular <NUM> is threaded into the coupling <NUM>. The total thread loss TTL is now at a desired value, or within a predetermined range. The controller <NUM> terminates the rotation of the tubular <NUM> by the rotary clamp <NUM> when the desired total thread loss TTL is achieved, or when the TTL is within the predetermined range.

A sensor <NUM> (such as a position sensor, a proximity sensor, a displacement sensor, etc.) may be used to measure longitudinal displacement of the tubular <NUM> as it is threaded into the coupling <NUM>, in order to determine the TTL. For example, the longitudinal positions of the lower end of the tubular <NUM> and the upper end of the coupling <NUM> may be determined at the initiation of the threaded connection make-up process (see <FIG>), thereby allowing a calculation of the required downward longitudinal displacement of the tubular <NUM> required in order to achieve the desired TTL. When the tubular <NUM> has displaced the required longitudinal distance as it is threaded into the coupling <NUM> (see <FIG>), the controller <NUM> can terminate the threaded connection make-up process by ceasing rotation of the tubular <NUM> by the rotary clamp <NUM>.

The predetermined range may comprise a desired total thread loss TTL between the tubulars <NUM>, <NUM>.

During the threading step, the longitudinal position of the tubular <NUM> relative to the longitudinal position of the coupling <NUM> may include a total thread loss TTL corresponding to a longitudinal overlap of the coupling <NUM> and the tubular <NUM>.

The longitudinal position of the coupling <NUM> may comprise a longitudinal position of an end of the coupling <NUM>, and the longitudinal position of the tubular <NUM> may comprise a longitudinal position of an end of the tubular <NUM>.

The detecting step may include detecting when the longitudinal position of the end of the tubular <NUM> is the same as the longitudinal position of the end of the coupling <NUM>. After detecting when the longitudinal position of the end of the tubular <NUM> is the same as the longitudinal position of the end of the coupling <NUM>, the detecting step may include detecting a longitudinal displacement of the tubular <NUM> relative the coupling <NUM>. The terminating step may include terminating the threading in response to the longitudinal displacement of the tubular <NUM> relative to the coupling <NUM> being within the predetermined range.

Referring additionally now to <FIG>, a fourth example, not being part of the present invention, of the method of making-up tubular string components is representatively illustrated. In this example, at least one camera <NUM> is used to observe the tubular <NUM> and the coupling <NUM>, in order to determine when a desired number of rotations of the tubular <NUM> have been performed as an indication of a proper threaded connection make-up. The number of rotations are counted after a thread start on the tubular <NUM> is operatively aligned with a thread start on the coupling <NUM>.

The camera <NUM> may be used to observe only the tubular <NUM> in order to monitor rotation of the tubular <NUM>. Alternatively, the camera <NUM> may be used to observe both of the tubular <NUM> and the coupling <NUM>, for example, so that insertion of the tubular <NUM> into the coupling <NUM> can be detected or confirmed, and then rotation of the tubular <NUM> relative to the coupling can be monitored.

As depicted in <FIG>, the tubular <NUM> has been positioned above and axially aligned with the coupling <NUM>, and then the tubular <NUM> has been lowered until the threads <NUM> on an exterior of the tubular <NUM> contact the threads <NUM> on an interior of the coupling <NUM>. As mentioned above, the camera <NUM> can be used to confirm that this insertion of the tubular <NUM> into the coupling <NUM> has been accomplished.

At this point, the threads <NUM>, <NUM> are contacting each other, but are not yet operatively threaded together. Confirmation that this contact between the threads <NUM>, <NUM> has been achieved can be obtained by monitoring a load cell measurement (such as a hook weight measurement or a top drive load cell measurement), which should show a decrease in supported load when the threads <NUM>, <NUM> contact each other. This contact between the threads <NUM>, <NUM> should occur after the insertion of the tubular <NUM> into the coupling <NUM> is confirmed as discussed above.

After the contact between the threads <NUM>, <NUM> is confirmed, the tubular <NUM> is rotated by the rotary clamp <NUM> in a rotary direction that is opposite to a rotary direction that will later be used to thread the tubular <NUM> into the coupling <NUM>. For example, if the threads <NUM>, <NUM> on the tubular <NUM> and coupling <NUM> are right-hand threads, so that the tubular <NUM> will later be threaded into the coupling by rotating the tubular <NUM> in a clockwise direction as viewed from above, then the tubular <NUM> will initially be rotated in an opposite (counter-clockwise) direction. If the threads <NUM>, <NUM> on the tubular <NUM> and coupling <NUM> are left-hand threads, then the tubular <NUM> will initially be rotated in a clockwise direction. For convenience of description, it is assumed hereafter that the threads <NUM>, <NUM> are right-hand threads, so that the tubular <NUM> is initially rotated in a counter-clockwise direction after the threads contact each other.

As the tubular <NUM> is rotated in the counter-clockwise direction, a thread start on the tubular <NUM> will eventually be azimuthally aligned with a thread start on the coupling <NUM>. This azimuthal alignment will permit some axially downward displacement of the tubular <NUM>, so that the threads <NUM>, <NUM> are appropriately positioned for threading the tubular <NUM> into the coupling <NUM>.

When the thread starts become azimuthally aligned and the tubular <NUM> displaces downward somewhat, the threads <NUM>, <NUM> will again come into contact with each other, which will produce a detectable vibration. This vibration can be measured using a sensor <NUM> (such as, an acoustic sensor, an accelerometer, etc.). Alternatively, a displacement or position sensor (such as the sensor <NUM>, see <FIG>) may be used to measure the downward displacement of the tubular <NUM>. The downward displacement and vibration should occur after the tubular <NUM> is rotated in the counter-clockwise direction in this example.

After the downward displacement and/or vibration is detected, the tubular <NUM> is rotated in an opposite rotary direction (clockwise in this example) by the rotary clamp <NUM>, in order to thread the tubular <NUM> into the coupling <NUM> as depicted in <FIG>. The camera <NUM> can be used to observe the rotation of the tubular <NUM>, so that a number of turns or rotations of the tubular can be measured. When it is determined that a desired number of turns or rotations have been achieved, the controller will terminate the rotation of the tubular <NUM> by the rotary clamp <NUM>.

Alternatively, the tubular <NUM> may be rotated in the clockwise direction until a desired TTL is achieved, as described above for the <FIG> example. As another alternative, the tubular <NUM> may be rotated in the clockwise direction until the tubular <NUM> shoulders up against the coupling <NUM> and a desired torque is applied to the threaded connection. For example, the shouldering-up can be indicated by a substantial increase in applied torque rate upon contact of the lower end of the tubular <NUM> with an annular shoulder <NUM> in the coupling <NUM>.

Referring additionally now to <FIG>, the threads <NUM>, <NUM> on the tubular <NUM> and coupling <NUM> are representatively illustrated in configurations corresponding to the threaded connection make-up process described above for the <FIG> example. For convenience of illustration and description, only the threads <NUM>, <NUM> are depicted in <FIG>. The external threads <NUM> on the tubular <NUM> are shown in solid lines, and the internal threads on the coupling <NUM> are shown in dashed lines.

As depicted in <FIG>, the threads <NUM>, <NUM> are in contact with each other, as described above with regard to <FIG>. Note that a thread start 40a of the threads <NUM> is not azimuthally aligned with a thread start 42a of the threads <NUM>. At least a portion of a weight of the tubular <NUM> is supported by the contact between the threads <NUM>, <NUM> in an area azimuthally between the thread starts 40a, 42a.

As depicted in <FIG>, the tubular <NUM> has been rotated in the counter-clockwise direction until the thread starts 40a, 42a are azimuthally aligned. At this point, the weight of the tubular <NUM> is no longer supported by the contact between the threads <NUM>, <NUM>.

As depicted in <FIG>, the tubular <NUM> has displaced downward somewhat, until at least a portion of the weight of the tubular <NUM> is again supported by contact between the threads <NUM>, <NUM>. This downward displacement and/or vibration produced by the displacement and then contact between the threads <NUM>, <NUM> can be measured by the sensor <NUM> and/or <NUM> as described above.

The threads <NUM>, <NUM> are now operatively aligned for threading the tubular <NUM> into the coupling <NUM>. The tubular <NUM> can now be rotated in the clockwise direction by the rotary clamp <NUM> as described above in order to make-up the threaded connection.

In the <FIG> example, the method can include the steps of:.

The method may include inputting image data to an image processor <NUM> (see <FIG>), the image data being output from at least one camera <NUM>; and in response to the inputting step, the image processor <NUM> detecting the rotating of the tubular <NUM> relative to the coupling <NUM> in the second direction.

The method may include inputting rotation data from the image processor <NUM> to a controller <NUM> (see <FIG>), the rotation data being indicative of a total rotation of the tubular <NUM> relative to the coupling <NUM> in the second direction; and the controller <NUM> terminating the threading in response to the total rotation of the tubular <NUM> relative to the coupling <NUM> in the second direction being within a predetermined range.

The method may include a sensor <NUM> detecting the vibration produced when the thread start 40a on the tubular <NUM> is azimuthally aligned with the thread start 42a on the coupling <NUM>.

The method may include a sensor <NUM> detecting the longitudinal displacement produced when the thread start 40a on the tubular <NUM> is azimuthally aligned with the thread start 42a on the coupling <NUM>.

Referring additionally now to <FIG>, a schematic view of an example of a make-up control system <NUM> that may be used with the system <NUM> of <FIG> and the method examples of <FIG> is representatively illustrated. The make-up control system <NUM> may be used with other systems and methods in keeping with the principles of this disclosure.

The make-up control system <NUM> includes a controller <NUM> for controlling operation of various components of the system <NUM>. In this example, the controller <NUM> is connected to the rotary clamp <NUM> for controlling rotation of the tubular <NUM>. In examples described above, the controller <NUM> can terminate or cease the rotation of the tubular <NUM> by the rotary clamp <NUM> when a proper threaded connection has been achieved, for example, to avoid over-torquing the threaded connection, to avoid human error, to achieve a greater level of efficiency, etc. The scope of this disclosure is not limited to any particular purpose or benefit obtained by use of the controller <NUM> in the system <NUM>.

The controller <NUM> can include various components designed to facilitate the operation of the system <NUM>. For example, the controller <NUM> may include volatile and non-volatile memory (such as RAM, ROM, EPROM, a hard drive or solid state drive, etc.), a database and instructions stored in the memory, data ports, input devices (such as a keyboard, keypad, touch screen, mouse, etc.), output devices (such as a monitor, a printer, etc.), communication devices (such as a satellite link, a fiber optic connection, a WiFi or Bluetooth transceiver, etc.), a computer processor, a programmable logic controller (PLC) or any other component or combination of components. The scope of this disclosure is not limited to any particular configuration, structure or capability of the controller <NUM>.

As depicted in <FIG>, at least one camera <NUM> is connected to an image processor <NUM>. The image processor <NUM> receives image data from the camera <NUM> and, based on the image data, identifies or recognizes tubular string components (such as the tubular <NUM> and/or coupling <NUM>) as represented in the image data. In addition, the image processor <NUM> may be able to identify or recognize movements of the tubular string components as represented in the image data.

The image processor <NUM> can include various components and capabilities designed to facilitate the identification or recognition of the tubular string components and their movements. For example, the image processor <NUM> may include neural or neuronal networks, fuzzy logic, artificial intelligence or other programmed capabilities that may be trained to identify or recognize particular tubular string components. The image processor <NUM> may include or comprise elements known to those skilled in the art as an image processing engine, an image processing unit or an image signal processor. Techniques such as optical flow techniques may be used to identify, recognize and quantify movements (such as longitudinal displacements and/or rotations) of the tubular string components. The scope of this disclosure is not limited to any particular configuration, structure or capability of the image processor <NUM>.

The controller <NUM> may also receive outputs from various sensors of the system <NUM>, such as the position or displacement sensor <NUM>, the vibration sensor <NUM>, a sensor that measures torque applied to the threaded connection, a sensor that measures hook weight, a load cell, etc. Any type or combination of sensors may provide outputs to the controller <NUM> in keeping with the principles of this disclosure.

The controller <NUM> may be in communication with the aerial vehicle <NUM>, for example, via a wireless connection in the <FIG> & <FIG> examples. In this manner, a flight path of the aerial vehicle <NUM> may be controlled by the controller <NUM> in response to the position data output from the image processor <NUM>, so that the camera <NUM> supported by the aerial vehicle rotates with the tubular <NUM> as it is threaded into the coupling <NUM>.

It may now be fully appreciated that the above disclosure provides significant advancements to the art of making-up threaded connections in tubular strings. In various examples described above, methods are provided which produce properly made-up threaded connections in a manner that reduces or eliminates human error and improves efficiency of the threaded connection make-up process.

More specifically, the above disclosure provides to the art a method of making-up tubular string components for use in a subterranean well. In one example, the method includes the steps of: inputting image data to an image processor <NUM>, the image data being output from at least one camera <NUM>; in response to the inputting, the image processor <NUM> detecting positions of a threaded first tubular (such as the coupling <NUM> or tubular <NUM>) and a mark <NUM> on a threaded second tubular <NUM>; threading the first and second tubulars <NUM>, <NUM> with each other; during the threading, inputting position data from the image processor <NUM> to a controller <NUM>, the position data being indicative of the position of the mark <NUM> relative to the position of the first tubular <NUM>; and the controller <NUM> terminating the threading in response to the position of the mark <NUM> relative to the position of the first tubular <NUM> being within a predetermined range.

The controller <NUM> may terminate the threading in response to a longitudinal distance between the positions of the first tubular <NUM> and the mark <NUM> being within the predetermined range.

The threading may include rotating the second tubular <NUM> relative to the first tubular <NUM>.

The camera <NUM> may rotate with the second tubular <NUM> during the threading.

The method may include connecting the camera <NUM> to a rotor <NUM> used to rotate the second tubular <NUM>, so that the camera <NUM> rotates with the rotor <NUM>.

The method may include connecting the camera <NUM> to an aerial vehicle <NUM>. A flight path of the aerial vehicle <NUM> may be controlled by the controller <NUM> in response to the position data output from the image processor <NUM>.

The position of the first tubular <NUM> may include an azimuthal position of a mark <NUM> on the first tubular <NUM>, and the position of the mark <NUM> on the second tubular <NUM> may include an azimuthal position of the mark <NUM> on the second tubular <NUM>.

The terminating step may include the controller <NUM> terminating the threading in response to the azimuthal position of the mark <NUM> on the second tubular <NUM> relative to the azimuthal position of the mark <NUM> on the first tubular <NUM> being within the predetermined range.

The predetermined range may correspond to azimuthal alignment of the marks <NUM> on the first and second tubulars <NUM>, <NUM>.

The terminating step may include the controller <NUM> terminating the threading in response to the azimuthal position of the mark <NUM> on the second tubular <NUM> relative to the azimuthal position of the mark <NUM> on the first tubular <NUM> being within the predetermined range after the first and second tubulars <NUM>, <NUM> are shouldered up.

The "at least one" camera <NUM> may comprise multiple cameras <NUM> distributed circumferentially about the first and second tubulars <NUM>, <NUM>.

Another method of making-up tubular string components for use in a subterranean well is provided to the art by the above disclosure. In this example, the method includes:
inputting image data to an image processor <NUM>, the image data being output from at least one camera <NUM>; in response to the inputting, the image processor <NUM> detecting longitudinal positions of a threaded first tubular (such as the coupling <NUM> and/or the tubular <NUM>) and a threaded second tubular <NUM>; threading the first and second tubulars <NUM>, <NUM> with each other; inputting position data from the image processor <NUM> to a controller <NUM>, the position data being indicative of the longitudinal position of the second tubular <NUM> relative to the longitudinal position of the first tubular <NUM>; and the controller <NUM> terminating the threading in response to the longitudinal position of the second tubular <NUM> relative to the longitudinal position of the first tubular <NUM> being within a predetermined range.

During the threading step, the longitudinal position of the second tubular <NUM> relative to the longitudinal position of the first tubular <NUM> may include a total thread loss TTL corresponding to a longitudinal overlap of the first and second tubulars <NUM>, <NUM>.

The predetermined range may comprise a desired total thread loss TTL between the first and second tubulars <NUM>, <NUM>.

The longitudinal position of the first tubular <NUM> may comprise a longitudinal position of an end of the first tubular <NUM>, and the longitudinal position of the second tubular <NUM> may comprise a longitudinal position of an end of the second tubular <NUM>.

The detecting step may include detecting when the longitudinal position of the end of the second tubular <NUM> is the same as the longitudinal position of the end of the first tubular <NUM>. After detecting when the longitudinal position of the end of the second tubular <NUM> is the same as the longitudinal position of the end of the first tubular <NUM>, the detecting step may include detecting a longitudinal displacement of the second tubular <NUM> relative the first tubular <NUM>. The terminating step may include terminating the threading in response to the longitudinal displacement of the second tubular <NUM> relative to the first tubular <NUM> being within the predetermined range.

Another method of making-up tubular string components for use in a subterranean well is described above. In this example, not being part of the present invention, the method can include supporting a threaded first tubular (such as the coupling <NUM> and/or the tubular <NUM>) relative to a rig floor <NUM>; engaging a threaded second tubular <NUM> with the first tubular <NUM>; rotating the second tubular <NUM> relative to the first tubular <NUM> in a first direction, thereby producing at least one of a detectable vibration and a longitudinal displacement, when a thread start 40a on the second tubular <NUM> is azimuthally aligned with a thread start 42a on the first tubular <NUM>; and then rotating the second tubular <NUM> relative to the first tubular <NUM> in a second direction opposite to the first direction, thereby threading together the first and second tubulars <NUM>, <NUM>.

The method may include inputting image data to an image processor <NUM>, the image data being output from at least one camera <NUM>; and in response to the inputting step, the image processor <NUM> detecting the rotating of the second tubular <NUM> relative to the first tubular <NUM> in the second direction.

The method may include inputting rotation data from the image processor <NUM> to a controller <NUM>, the rotation data being indicative of a total rotation of the second tubular <NUM> relative to the first tubular <NUM> in the second direction; and the controller <NUM> terminating the threading in response to the total rotation of the second tubular <NUM> relative to the first tubular <NUM> in the second direction being within a predetermined range.

The method may include a sensor <NUM> detecting the vibration, or a sensor <NUM> detecting the longitudinal displacement, produced when the thread start 40a on the second tubular <NUM> is azimuthally aligned with the thread start 42a on the first tubular <NUM>.

Although various examples have been described above, with each example having certain features, it should be understood that it is not necessary for a particular feature of one example to be used exclusively with that example. Instead, any of the features described above and/or depicted in the drawings can be combined with any of the examples, in addition to or in substitution for any of the other features of those examples. One example's features are not mutually exclusive to another example's features. Instead, the scope of this disclosure encompasses any combination of any of the features.

Although each example described above includes a certain combination of features, it should be understood that it is not necessary for all features of an example to be used. Instead, any of the features described above can be used, without any other particular feature or features also being used.

It should be understood that the various embodiments described herein may be utilized in various orientations and configurations, without departing from the principles of this disclosure. The embodiments are described merely as examples of useful applications of the principles of the disclosure, which is not limited to any specific details of these embodiments.

In the above description of the representative examples, directional terms (such as "above," "below," "upper," "lower," "upward," "downward," etc.) are used for convenience in referring to the accompanying drawings. However, it should be clearly understood that the scope of this disclosure is not limited to any particular directions described herein.

The terms "including," "includes," "comprising," "comprises," and similar terms are used in a non-limiting sense in this specification. For example, if a system, method, apparatus, device, etc., is described as "including" a certain feature or element, the system, method, apparatus, device, etc., can include that feature or element, and can also include other features or elements. Similarly, the term "comprises" is considered to mean "comprises, but is not limited to.

Claim 1:
A method of making-up tubular string components for use in a subterranean well, the method comprising:
inputting image data to an image processor (<NUM>), the image data being output from at least one camera (<NUM>);
in response to the inputting, the image processor (<NUM>) detecting positions of a threaded first tubular (<NUM>) and a mark (<NUM>) on a threaded second tubular (<NUM>);
threading the first and second tubulars (<NUM>, <NUM>) with each other;
during the threading, inputting position data from the image processor (<NUM>) to a controller (<NUM>), the position data being indicative of the position of the mark (<NUM>) relative to the position of the first tubular (<NUM>); and
the controller (<NUM>) terminating the threading in response to the position of the mark (<NUM>) relative to the position of the first tubular (<NUM>) being within a predetermined range.