Patent Description:
Construction of oil or gas wells usually requires making long tubular strings that make up casing, risers, drill pipe or other tubing. Due to the length of these strings, sections or stands of tubulars are progressively added to or removed from the tubular strings as they are lowered or raised from a drilling platform.

The tubular strings are formed by connecting a plurality of tubulars by fluid-tight threaded joints. Each fluid-tight threaded joint is formed by making up two tubulars with a threaded connection at a target torque.

A tong assembly is commonly used to make up or break out joints in the tubular strings. Typically, a tong assembly may be manually controlled by an operator during makeup. A dump valve is usually used to stop the rotation when at a target torque. Depending on parameters of the tubulars, this manual control may lead to over torque, for example, when the rotational speed of the tong assembly is too high at a final stage of joint make up. Another approach to achieve the target torque is using a closed-loop control of torque or rotational speed during makeup. However, depending on the set speed, the closed-loop control method takes a long time to makeup each joint. Another approach to achieve the target torque is to rotate the tong assembly for a predetermined time at a constant speed. The predetermined time is obtained from heuristically measured values, which are results of particular parameters, such as the reactions time of the tong assembly to a specific type of tubulars and the speed of the tong assembly.

After a threaded connection is made up, the threaded connection is typically evaluated before carrying any loads. The initial evaluation may be used based on torque measurements and/or turn measurements made during makeup. However, the initial evaluation based on the measurements usually results in false failure diagnosis and a human operator has to perform further examination to reach a final decision. <CIT> and <CIT> describe methods of calculating and applying torques during make up of tubular connections.

Therefore, there is a need for improved methods for making up and evaluating tubular connections.

Embodiments of the present disclosure relate to apparatus and methods for autonomous making up and evaluation of threaded connections. In one aspect, a method of making up a tubular joint is provided in accordance with claim <NUM> and a tubular makeup system in accordance with claim <NUM>.

Also described is a method of making up a tubular joint. The method includes rotating a first tubular relative to a second tubular at a first speed to make a threaded connection between the first and second tubulars using a tong assembly while measuring one or more parameters, wherein the one or more parameters includes at least one of torque applied to the threaded connection, turns of the first tubular, or combination thereof, correcting measurements of the one or more parameters to remove effects due to mechanical properties and dynamic behavior of the tong assembly, evaluating corrected measurements of the one or more parameters, and accepting or rejecting the threaded connection based on the evaluation.

Further described is a tubular makeup system. The system includes a tong assembly comprising a power tong for clamping to a first tubular and rotating the first tubular, and a backup tong for clamping to a second tubular and holding the second tubular stationary, and a controller including instructions, which when executed, perform operations comprising making up a threaded connection using the tong assembly while measuring one or more parameters, wherein the one or more parameters include at least one of torque applied to the threaded connection, turns of the first tubular, or combination thereof, correcting measurements of the one or more parameters to remove effects due to mechanical properties and dynamic behavior of the tong assembly, and evaluating the threaded connection using corrected measurements of the one or more parameters.

Also described is a method of making up a tubular joint. The method includes rotating a first tubular relative to a second tubular at a first speed to make a threaded connection between the first and second tubulars using a tong assembly while measuring one or more parameters, wherein the one or more parameters includes at least one of torque applied to the threaded connection, turns of the first tubular, or combination thereof, recording one or more operating parameters of the tong assembly, evaluating the one or more operating parameters and measurements of the one or more parameters for a marker, and accepting or rejecting the threaded connection based on the evaluation.

Embodiments of the present disclosure relate to apparatus and methods for making up and evaluating tubular threaded connections. A tong assembly may be used for making up threaded connections. A threaded connection may be made up automatically by controlling the rotation speed of the tong assembly according to measurements of torque, turns, and/or time. After a threaded connection is made up, measurements of time, torque, and/or turns may be corrected based on operating parameters, such as rotation speed. The corrected measurements may be evaluated for compliance with torque and/or turns requirements and indications of failure, such as discontinuity, torque spikes, torque drops, etc. The threaded connection is then accepted or rejected based on the evaluation.

<FIG> illustrates a connection <NUM> between premium grade tubulars <NUM>, <NUM>. The tubulars <NUM>, <NUM> may be any oil industry tubular good, such as production tubing, casing, liner, or drill pipe. The connection <NUM> may include a first tubular <NUM> joined to a second tubular <NUM> through a tubular coupling <NUM>. Each of the tubulars <NUM>, <NUM> and the coupling <NUM> may be made from a metal or alloy, such as plain carbon steel, low alloy steel, high strength low alloy steel, stainless steel, or a nickel based alloy. The end of each tubular <NUM>, <NUM> may have a tapered externally-threaded surface <NUM> (aka a pin) which co-operates with a correspondingly tapered internally-threaded surface (aka box) <NUM> on the coupling <NUM>. Each tubular <NUM>, <NUM> may be provided with a torque shoulder <NUM> which co-operates with a corresponding torque shoulder <NUM> on the coupling <NUM>. At a terminal end of each tubular <NUM>, <NUM>, there may be defined an annular sealing area <NUM> which is engageable with a co-operating annular sealing area <NUM> defined between the tapered portions <NUM>, <NUM> of the coupling <NUM>. Alternatively, the sealing areas <NUM>,<NUM> may be located at other positions in the connection <NUM> than adjacent the shoulders <NUM>,<NUM>.

During makeup, the box <NUM> is engaged with the pin <NUM> and then screwed onto the pin by relative rotation therewith. During continued rotation, the annular sealing areas <NUM>, <NUM> contact one another, as shown in <FIG>. This initial contact is referred to as the "seal position". As the coupling <NUM> is further rotated, the co-operating tapered torque shoulders <NUM>, <NUM> contact and bear against one another at a machine detectable stage referred to as a "shoulder position", as shown in <FIG>. The increasing pressure interface between the tapered torque shoulders <NUM>, <NUM> cause the seals <NUM>, <NUM> to be forced into a tighter metal-to-metal sealing engagement with each other causing deformation of the seals <NUM> and eventually forming a fluid-tight seal.

<FIG> illustrates an ideal torque-turns curve <NUM> for the tubular connection. <FIG> illustrates an ideal torque gradient-turns curve 50a for the tubular connection. During makeup of the tubulars <NUM>, <NUM>, torque and turns measurements may be recorded and the curves <NUM>, 50a displayed for evaluation by a technician. Shortly after the coupling <NUM> engages the tubular <NUM> and torque is applied, the measured torque increases linearly as illustrated by curve portion <NUM>. As a result, corresponding curve portion 52a of the differential curve 50a is flat at some positive value.

During continued rotation, the annular sealing areas <NUM>, <NUM> contact one another causing a slight change (specifically, an increase) in the torque rate, as illustrated by point <NUM>. Thus, point <NUM> corresponds to the seal position shown in <FIG> and is plotted as the first step 54a of the differential curve 50a. The torque rate then again stabilizes resulting in the linear curve portion <NUM> and the plateau 56a. In practice, the seal condition (point <NUM>) may be too slight to be detectable. However, in a properly behaved makeup, a discernable/detectable change in the torque rate occurs when the shoulder position is achieved (corresponding to <FIG>), as represented by point <NUM> and step 58a. The torque rate then again increases linearly as illustrated by curve portion <NUM> and the plateau 60a until makeup of the connection is terminated at final torque <NUM>.

<FIG> is a schematic perspective view of a tubular makeup and evaluation system <NUM>. The tubular makeup and evaluation system <NUM> may include a tong assembly <NUM> and a controller <NUM> for controlling the tong assembly <NUM> during a makeup process and for evaluating threaded connections.

The tong assembly <NUM> may include a power tong <NUM> and a backup tong <NUM>. During operation, the tong assembly <NUM> may be placed on a drilling rig coaxially with a central axis <NUM> of a workstring <NUM>. The tong assembly <NUM> may be disposed above a spider <NUM> on the drilling rig to add a tubular <NUM> to the workstring <NUM> or to remove the tubular <NUM> from the workstring <NUM> while the workstring <NUM> rests in the spider <NUM>.

During operation, the power tong <NUM> receives and clamps to a first tubular, such as the tubular <NUM>, while the backup tong <NUM> receives and clamps to a second tubular, such as a tubular <NUM> on top of the work string <NUM>. The tubular <NUM> may include a coupling <NUM> that is pre-made on the tubular <NUM>. The backup tong <NUM> clamps to the tubular <NUM> below the coupling <NUM>. The power tong <NUM> rotates the first tubular while the backup tong <NUM> holds the second tubular stationary causing relative rotation between the first tubular and second tubular, thus, making up a threaded connection between the first and second tubulars or breaking out the threaded connection between the first and second tubulars.

The power tong <NUM> and the backup tong <NUM> may be coupled together by a frame <NUM>. The power tong <NUM> may include a side door <NUM> which may open to receive or release a tubular and close to clamp the tubular in the power tong <NUM>. Similarly, the backup tong <NUM> may include a side door <NUM> which may open to receive or release a tubular and close to clamp the tubular in the backup tong <NUM>.

One or more actuators <NUM> may be used to drive gripping pads in the power tong <NUM> to clamp a tubular during operation. One or more actuators <NUM> may be used to drive gripping pads in the backup tong <NUM> to clamp a tubular and hold the tubular stationary during operation. The actuators <NUM>, <NUM> may be hydraulic actuators, mechanical actuators, or other suitable actuators. The actuators <NUM>, <NUM> are connected to the controller <NUM> and may receive commands from the controller <NUM> to clamp a tubular, release a tubular, or adjust clamping force exerted against a tubular. The controller <NUM> may be connected to other actuators, such as the actuators <NUM>, <NUM>, through a drive unit, such as a hydraulic power unit when the actuators are hydraulic actuators.

The power tong <NUM> may include a drive unit <NUM> configured to drive a motor assembly <NUM>. The motor assembly <NUM> is configured to rotate the tubular clamped in the power tong <NUM>. The drive unit <NUM> may be a hydraulic drive circuit configured to drive a hydraulic motor. The motor assembly <NUM> may include a drive motor and a gear assembly. The motor assembly <NUM> may include a hydraulic motor assembly or an electric motor assembly. The motor assembly <NUM> and the drive unit <NUM> are connected to the controller <NUM>. The motor assembly <NUM> may receive commands from the controller <NUM> to rotate forward, backward, and at a target speed.

The tong assembly <NUM> may include a turns counter <NUM>. The turns counter <NUM> may be connected to the controller <NUM> to monitor the rotation of the power tong <NUM>. The turns counter <NUM> may be an internal turns counter such as a decoder connected to a drive shaft inside a gear box of the power tong <NUM>. The turns counter <NUM> is connected to the controller <NUM> and can be used to measure turns of the tubular clamped in the power tong <NUM> during operation.

The tong assembly <NUM> may include a turns sensor <NUM> mounted on the power tong <NUM>. The turns sensor <NUM> is configured to measure turns of the tubular clamped in the power tong <NUM>. Measurements of the turns sensor <NUM> may be used to generate commands for rotational speed in a closed loop control during an automated makeup process according to the present disclosure. Measurements of the turns sensor <NUM> may also be used to evaluate the threaded connection during an automated evaluation process according to the present disclosure. The turns sensor <NUM> may be any sensor capable of measuring rotation. The turns sensor <NUM> may be contactless turns counter. For example, the turns sensor <NUM> may be an optical camera based sensor or a laser based sensor. Alternatively, the turns sensor <NUM> may be configured to contact a surface to be measured for rotation. For example, the turns sensor <NUM> may be a friction wheel sensor. The turns sensor <NUM> is connected to the controller <NUM> to send measurements to the controller <NUM>.

The tong assembly <NUM> may include a turns sensor <NUM> mounted on the backup tong <NUM> configured to measure rotation of the tubular clamped in the backup tong <NUM>. The turns sensor <NUM> may be positioned to measure relative rotation of the tubular <NUM> or the coupling <NUM> relative to the backup tong <NUM>. Measurements of the turns sensor <NUM> may be used to detect backup slippage and/or coupling rotation during an automated makeup process according to the present disclosure. Measurements of the turns sensor <NUM> may also be used to evaluate the threaded connection during an automated evaluation process according to the present disclosure. The turns sensor <NUM> may be any sensor capable of measuring rotation. The turns sensor <NUM> may be contactless turns counter. For example, the turns sensor <NUM> may be an optical camera based sensor or a laser based sensor. Alternatively, the turns sensor <NUM> may be configured to contact a surface to be measured for rotation. For example, the turns sensor <NUM> may be a friction wheel sensor.

The tong assembly <NUM> may include one or more load cells <NUM> positioned to measure the torque applied to the tubulars of the threaded connection being made up or broken out by the tong assembly <NUM>. The load cell <NUM> may be disposed in a torque load path between the power tong <NUM> and the backup tong <NUM>. Alternatively, the load cell <NUM> may be positioned to measure a displacement of the tong assembly <NUM>. The measured displacement may be used to calculate the torque between the tubulars in the tong assembly <NUM>. Measurements of the load cell <NUM> may be used to generate rotation command to the power tong <NUM> during an automated makeup process according to the present disclosure. Measurements of load cell <NUM> may also be used to evaluate the threaded connection during an automated evaluation process according to the present disclosure.

The controller <NUM> is connected to the tong assembly <NUM> and may include hardware and software for performing automated makeup operations and automated evaluation operations. The controller <NUM> may include various hardware, such as processors, programmable logic controllers (PLCs), one or more computers, and one or more mobile devices. Hardware of the controller <NUM> may be positioned together or at separate locations. For example, the controller <NUM> may include a PLC that is positioned in-situ with the tong assembly <NUM> for performing an automated makeup process, a computer that is positioned remotely for performing an automated evaluation process, and one or more mobile devices that are located at remote locations. Communications between the controller <NUM> and the tong assembly <NUM> may include wired and wireless communication.

<FIG> is a block diagram illustrating the tubular makeup system 200e. <FIG> schematically illustrates the controller <NUM>. <FIG> also demonstrates connections between the controller <NUM> and the tong assembly <NUM> to achieve a combined automated makeup process and automated evaluation process.

As discussed above, the controller <NUM> includes a combination of hardware components and software programs configured to perform an automated makeup process and automated evaluation process. Even though the controller <NUM> is shown as one block in <FIG>, hardware and software components in the controller <NUM> may be integrated together or distributed in multiple locations.

The controller <NUM> includes an automated makeup module <NUM> and an automated evaluation module <NUM>. The controller <NUM> may also include one or more input devices <NUM>, one or more output devices <NUM>, and a storage device <NUM>.

The input device <NUM> may include keyboards, mice, push buttons, microphones, joysticks, or other user interface components. The input device <NUM> is configured to receive tubular information, system configuration, commands from human operators, or other information related to the automated makeup process and the automated evaluation process according to the present disclosure. Predetermined values, such as an optimum torque value, a dump torque value, and a minimum and maximum torque value, may be input through the input device <NUM> prior to making a threaded connection.

The output devices <NUM> may include monitors, printers, speakers, or other user interface components. The output device <NUM> may be used to provide operating details to human operators. For example, during an automated makeup process, a technician may observe the operating details on an output device, such as a video monitor. A technician may observe the various predefined values which have been input for a particular connection. Further, the technician may observe graphical information such as the torque rate curve <NUM> and the torque rate differential curve 50a.

The storage device <NUM> may be a hard drive or solid state drive that is connected to hardware components of the controller <NUM>. Alternatively, the storage device <NUM> may be located in the cloud for recording makeup data, tubular information, and other data related to an operation. The stored data may then be used to generate a post makeup report.

Information related to the automated makeup process may be used in the automated evaluation process to correct measurement data, remove false failure information, therefore, improve efficiency of the entire process. <FIG> schematically illustrates connections among the tong assembly <NUM>, the automated makeup module <NUM> and the automated evaluation module <NUM>.

The automated makeup module <NUM> sends out commands to the motor assembly <NUM> to control the rotation direction and speed of the power tong <NUM> via connection <NUM>. A first branch 316a of the connection <NUM> goes to the motor assembly <NUM> to control the power tong <NUM> during operation. A second branch 316b of the connection <NUM> goes to the automated evaluation module <NUM>, wherein data related to motor operation is recorded and used for evaluation of the connection being made.

The automated makeup module <NUM> sends out commands to the actuators <NUM>, <NUM> to clamping and clamping forces in the backup tong <NUM> and the power tong <NUM> via connections <NUM>, <NUM> respectively. A first branch 318a, 322a of the connection <NUM>, <NUM> goes to the actuators <NUM>, <NUM> to control clamping and release of tubulars in the tong assembly <NUM> during operation. A second branch 318b, 322b of the connection <NUM>, <NUM> goes to the automated evaluation module <NUM>, wherein data related to clamping operation is recorded and used for evaluation of the connection being made.

Similarly, other operations commands from the automated makeup module <NUM> may also be connected to both the actuators and the automated evaluation module <NUM> for use in evaluation. Operation parameters generated in the automated makeup module <NUM> but not sent out to any actuators, such as a determination of backup tong slippage, non-engagement between the tubulars, may be sent to the automated evaluation module <NUM> via connection <NUM>.

Measurements of the load cell <NUM> may be sent to the automated makeup module <NUM> and the automated evaluation module <NUM> through connection <NUM>-324a and <NUM>-324b respectively. During operation, the measurements of the load cell <NUM> may be sent to the automated makeup module <NUM> and the automated evaluation module <NUM> in synchronization or at different frequency and/or for different time periods according to the process design. Measurements of the load cell <NUM> may be used to determine torque applied to the threaded connection and used for controlling the makeup process and as basis for evaluating the threaded connection.

Measurements of the turns counter <NUM> may be sent to the automated makeup module <NUM> and the automated evaluation module <NUM> through connection <NUM>-326a and <NUM>-326b respectively. During operation, the measurements of the turns counter <NUM> may be sent to the automated makeup module <NUM> and the automated evaluation module <NUM> in synchronization or at different frequency and/or for different time periods according to the process design. Measurements of the turns counter <NUM> may be used to determine turns made by the motor to the threaded connection and used for controlling the makeup process and as basis for evaluating the threaded connection.

Measurements of the turns sensor <NUM> may be sent to the automated makeup module <NUM> and the automated evaluation module <NUM> through connection <NUM>-330a and <NUM>-330b respectively. During operation, the measurements of the turns sensor <NUM> may be sent to the automated makeup module <NUM> and the automated evaluation module <NUM> in synchronization or at different frequency and/or for different time periods according to the process design. Measurements of the turns sensor <NUM> may be used to determine turns made to the tubular clamped by the power tong <NUM> and used for controlling the makeup process and as basis for evaluating the threaded connection.

Measurements of the turns sensor <NUM> may be sent to the automated makeup module <NUM> and the automated evaluation module <NUM> through connection <NUM>-328a and <NUM>-328b respectively. During operation, the measurements of the turns sensor <NUM> may be sent to the automated makeup module <NUM> and the automated evaluation module <NUM> in synchronization or at different frequency and/or for different time periods according to the process design. Measurements of the turns sensor <NUM> may be used to determine backup tong slippage or coupling rotation and used for controlling the makeup process and as basis for evaluating the threaded connection.

The connections <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may be wired connections, wireless connections, or virtual connections achieved by data sharing according to the function of the connection.

The automated makeup module <NUM> configured to enable automated makeup or breakout process. The automated makeup module <NUM> may include a programmable logic controller (PLC) that is connected to actuators and sensors in the tong assembly <NUM>. The automated makeup module <NUM> may include a control program, which when operated, generates commands to control rotational speed of the power tong <NUM> according to the measured torque applied between the tubulars in the tong assembly <NUM> or other operating conditions.

The makeup module <NUM> may include an operating sequence program <NUM> and a PID controller program <NUM>. When operated, the operating sequence program <NUM> generates commands to the tong assembly <NUM> to perform an automated makeup process or automated breakout process. For example, the operating sequence program <NUM> sends commands to the tong assembly <NUM> to perform a plurality of steps for making up or breaking out a threaded connection. The PID controller program <NUM> is configured to control the tong assembly <NUM> at a certain stage of a makeup process to perform an automatic speed reduction operation to stop rotation when a threaded connection is made. The PID controller program <NUM> may be activated by the operating sequence program <NUM> when a trigger condition occurs. The trigger condition may include a measured torque between the tubulars reaches a predetermined value, rotation of the tubular has been performed for a predetermined time duration, or a predetermined turns is rotated between the first and second tubulars. Examples of the PID controller program <NUM> may be found in <CIT> (entitled "apparatus and method for connecting tubulars") and <CIT> (entitled "apparatus and method for connecting tubulars"), which are incorporated herein by references.

During operation, the automated makeup module <NUM> monitors various sensors in the tong assembly <NUM>, generates commands based on the sensor measurements, and sends out command signals to various components in the tong assembly <NUM> to complete the operation.

The automated evaluation module <NUM> is configured to automatically evaluate a threaded connection based on process parameters and sensor measurements made during makeup. After a threaded connection is made using the automated makeup module <NUM>, the threaded connection can be evaluated by the automated evaluation module <NUM> for a decision whether the threaded connection is acceptable or should be rejected and remake.

The automated evaluation module <NUM> may include a measurement corrector <NUM>, a torque-turn generator <NUM>, and a connection evaluator <NUM>. The measurement correction block <NUM> is configured to correlate measurements with recorded operating data to reduce false failure diagnosis by the connection evaluator <NUM>. The torque-turn generator <NUM> is configured to generate torque-turn curves and/or other correlations between the measured data. The torque-turn curves may be used by the connection evaluator <NUM> to detect markers that indicate an unacceptable threaded connection.

The connection evaluator <NUM> includes various algorithms used to process measured data and identify markers of an unacceptable threaded connection. For example, the connection evaluator <NUM> may include a discontinuity detector, a lack of connection detector, a spike detector, a data filter, a final torque value calculator, a dump detector, a torque drop detector, a shoulder detector, and an overlay processor. For example, the connection evaluator <NUM> evaluates the measured turns, measured torque, and/or measured time for a discontinuity, a torque spike, and/or a torque drop, and rejects the threaded connection if one or more discontinuity, torque spike, and/or torque drop is identified. Examples of the connection evaluator <NUM> may be found in <CIT> (entitled "autonomous connection evaluation and automated shoulder detection for tubular make") and <CIT> (entitled "Method and system for evaluating tubular makeup.

One or a combination of measurements made during makeup, such as time, torque, and/or turns measurements, may be corrected by the measurement corrector <NUM> before being used to evaluate the threaded connection by the connection evaluator <NUM>. The measurement corrector <NUM> may correlate the torque measurements, turn measurements, and time measurements with operating information received from the automated makeup module <NUM>.

The measurement corrector <NUM> may include a coupling rotation correction. When making up a threaded connection between a first tubular, such as tubular <NUM>, with a second tubular having a coupling, such as the tubular <NUM> and the coupling <NUM>, rotation of the coupling <NUM> relative to the backup tong <NUM> affects the measurements of the turns counter attached to the first tubular, such as the turns counter <NUM> or the turns counter <NUM>. When the coupling <NUM> turns, which may be caused by backup tong slippage or rotation between the coupling <NUM> and the tubular <NUM>, turns of the tubular <NUM> measured by the turns counter <NUM> or turns counter <NUM> does not reflect the actual turns occurred in the threaded connection being evaluated, that is the threaded connection between the tubular <NUM> and the coupling <NUM>.

The measurement corrector <NUM> may include correcting turns measurement of the tubular rotated by the power tong <NUM> with measurement of coupling turns. For example, when turns measurement from the turns counter <NUM> or <NUM> is used to evaluate the threaded connection, the turns measurement is first corrected using turns measurement by the turns counter <NUM> or <NUM>, which measure turns of the coupling <NUM> or the second tubular <NUM>. Measurements of turns counter <NUM> may be subtracted from the turns measurements of the turns counter <NUM> or <NUM>. The coupling rotation correction removes potential false characterization of yielding through the torque-turn graph.

The measurement corrector <NUM> may include a structure dynamic correction. Dynamic behavior of the tong assembly <NUM> has a significant influence on torque-turn curves that are used in evaluating a threaded connection made by the tong assembly and is likely to create patterns in the torque-turn curve that appear unacceptable. For example inertia of the tong assembly during reducing speed on the power tong will create a changing torque signature the same as yielding. The measurement corrector <NUM> may correlate recorded operating parameters, such as deaccelerating commands received from the connection <NUM>-316b, with the torque measurements to identify and remove torque spikes caused by tong dynamics during decelerating. Similarly, other actions, such as acceleration and dumping, may be correlated to remove false failure patterns in the torque-turn curve or other graphs used for evaluation.

The measurement corrector <NUM> may include a displacement correction. Flexible deformation of the tong structure occurs during operations, such as when the tong assembly carries the load of torque and/or weight, when the tong clamps at the tubular, and when the clamping force is changed. For example, an increased clamping force will drive protrusions on the gripping pads deeper into the tubular being clamped resulting in additional turns of the tong assembly while the tubulars clamped in the tong assembly stay stationary. The flexible deformation sometime results in additional turns measured in the turns sensors coupled to the tong assembly, such as the turns counter <NUM>. The additional turns captured by the internal turns counters, such as the turns counter <NUM>, do not reflect the actual turns of the tubulars. Turns measurement, such as measurements from the turns counter <NUM>, may be corrected according to commands of clamping, such as commands received from the automated makeup module <NUM> via connections <NUM>-318b and <NUM>-322b.

Correlating the operating information from the automated makeup module <NUM> with the automated evaluation module <NUM> makes it possible to correlate false failure patterns in the torque-turn graphs according to the mechanisms that caused the false failure patterns. The measurement corrector <NUM> may identify and remove false failure patterns that result from incorrect turns data like that described in the coupling rotation correction and the displacement correction. The measurement corrector <NUM> may also identify and remove false failure patterns that result from erroneous torque-turn data or noise like that described in the structure dynamic correction. In general, the measurement corrector <NUM> may account for false failure patterns caused by various tong operating parameters so that evaluation of the threaded connection is predominantly based on actual change in torque and turns of the threaded connection, thus increasing accuracy.

By correlating operating parameters with measurements, the automated evaluation module <NUM> according to the present disclosure increases accuracy of the automated evaluation. Automated evaluation based on measurements only has a higher reject rate than evaluation by human operators. Connections that are acceptable by a human operator are sometime rejected because false failure patterns that result from dynamic behaviors and mechanical properties of the tong assembly as well as incorrect turns data. Automated evaluation according to the present disclosure improves traceability of decisions by a human and allows for more detailed evaluation without sacrificing measurement resolution by applying filters. Instead of reducing sensitivity of the evaluation using filters, the automated evaluation methods according to the present disclosure removes known issues from the evaluation, therefore allowing a higher resolution on the data.

<FIG> is a flow chart of a method <NUM> for making up and evaluating a tubular connection evaluator. The method <NUM> may be performed by the tubular makeup and evaluation system <NUM> described above.

In operation <NUM>, a first threaded tubular, such as the tubular <NUM>, and a second threaded tubular, such as the tubular <NUM> and coupling <NUM>, are engaged using a tong assembly, such as the tong assembly <NUM>. The engagement of the threaded tubulars may be in the condition as shown in <FIG>.

In operation <NUM>, a threaded connection is made automatically by rotating the first threaded tubular relative to the second tubular using the tong assembly. The threaded connection may be made by operating the automated makeup module <NUM> described above to control the tong assembly <NUM>. Operating information, such as instructions to the tong assembly, may be recorded during operation. The operating information may include clamping commands, change to rotational speed, and rotation speed and direction. At least one time, torque applied to the threaded connection, and turns of the first tubular may be measured in operation <NUM>. The measurements are used to achieve automatic control during makeup and to evaluate quality of the threaded connection being made.

Relative rotation of the tubulars may be stopped when a threaded connection has reached a target torque, a target time or a target turns. Making the threaded connection may include starting an automatic speed reduction operation to reduce rotating speed to zero upon detection of a trigger condition. The trigger condition may be one of: a measured torque between the first and second tubulars reaches a predetermined value, rotation of the first tubular has been performed for a pre-determined time duration, and a predetermined turns is rotated between the first and second tubulars.

In operation <NUM>, measurements used for evaluating the threaded connection are corrected by correlating with recorded operation information. Operation <NUM> may be performed by operating the measurement corrector <NUM> in the automated evaluation module <NUM>. The measurement correction may include correcting measured turns according to coupling rotation. The measurement correction may include correction measured torque according the tong dynamic behaviors, such as deceleration of the tong assembly. Measurement correction may include correcting measured turns according to flexible deformation occurred during clamping and loading.

In operation <NUM>, the threaded connection is evaluated using the corrected measurements. Operation <NUM> may be performed by operating the connection evaluator <NUM> in the automated evaluation module <NUM>. Evaluation may include evaluating at least one of corrected measured turns, corrected measured torque, and measured time for a discontinuity, a torque spike or a torque drop.

In operation <NUM>, the threaded connection is either rejected or accepted according the evaluation in operation <NUM>.

A method of making up a tubular joint is described. The method includes rotating a first tubular relative to a second tubular at a first speed to make a threaded connection between the first and second tubulars using a tong assembly while measuring one or more parameters, wherein the one or more parameters includes at least one of torque applied to the threaded connection, turns of the first tubular, or combination thereof, correcting measurements of the one or more parameters to remove effects due to mechanical properties and dynamic behavior of the tong assembly, evaluating corrected measurements of the one or more parameters, and accepting or rejecting the threaded connection based on the evaluation.

Evaluating corrected measurements of the one or more parameters may comprise evaluating corrected measurements of turns or corrected measurements of torque for a discontinuity, a spike, and a drop.

During rotating, the first tubular may be clamped by a power tong in the tong assembly and the second tubular is clamped by a backup tong of the power tong.

The method may further include measuring the turns of the second tubular using a turns sensor attached to the backup tong, and wherein correcting measurements of the one or more parameters comprises: correcting measurements of turns of the first tubular according to turns of the second tubular.

Correcting measurements of the one or more parameters may comprise: correcting measurements of torque according to a rotational speed change of the tong assembly.

The method may further include correcting measurement of torque made during deceleration of the tong assembly.

Correcting measurements of the one or more parameters may comprise: correcting measurements of turns of the first tubular according to clamping commands or change of clamping force.

The method may further include reducing measurements of turns when clamping force is increased.

A tubular makeup system is described. The system includes a tong assembly comprising a power tong for clamping to a first tubular and rotate the first tubular, and a backup tong for clamping to a second tubular and hold the second tubular stationary, and a controller including instructions, which when executed, perform operations comprising making up a threaded connection using the tong assembly while measuring one or more parameters, wherein the one or more parameters include at least one of torque applied to the threaded connection, turns of the first tubular, or combination thereof, correcting measurements of the one or more parameters to remove effects due to mechanical properties and dynamic behavior of the tong assembly, and evaluating the threaded connection using corrected measurements of the one or more parameters.

The instructions may further comprise recording one or more operating parameters while making up the threaded connection, and correcting measurements of the one or more parameters to remove effects according to the one or more recorded operating parameters.

The system may further include a turns counter positioned to measure turns of the second tubular relative to the backup tong, wherein the instructions further comprise correcting measurements of turns of the first tubular according to measured turns of the second tubular.

Correcting measurements of the one or more parameters to remove effects may comprise correcting measurements of torque made during deceleration of the tong assembly.

The controller may comprise a programmable logic controller including programs for automatically making the threaded connection, and a computer having programs for correcting measurements of torque and evaluating the threaded connection.

A method of making up a tubular joint is described. The method includes rotating a first tubular relative to a second tubular at a first speed to make a threaded connection between the first and second tubulars using a tong assembly while measuring one or more parameters, wherein the one or more parameters includes at least one of torque applied to the threaded connection, turns of the first tubular, or combination thereof, recording one or more operating parameters of the tong assembly, evaluating the one or more operating parameters and measurements of the one or more parameters for a marker, and accepting or rejecting the threaded connection based on the evaluation.

Recording one or more operating parameters may comprise recording commands sent to the tong assembly.

Evaluating the one or more operating parameters may comprise: evaluating the one or more operating parameters for a deceleration command to the tong assembly and correcting measurements of torque made during deceleration.

The method may further include measuring turns of the second tubular, and correcting measured turns of the first tubular according to measured turns of the second tubular.

Rotating the first tubular relative to the second tubular may comprise starting an automatic speed reduction operation to reduce rotating speed to zero upon detection of a trigger condition based on measurements of the one or more parameters.

The marker may include at least one of a discontinuity, a torque spike, and a torque drop in a torque-turn curve.

Evaluating the one or more operating parameters may comprise evaluating the one or more operating parameters for dynamic behavior and mechanical properties of the tong assembly, and removing effects caused by dynamic behavior and mechanical properties of the tong assembly from the torque-turn curve.

Other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope of the invention is determined by the claims that follow.

In some embodiments, the marker includes at least one of a discontinuity, a torque spike, and a torque drop in a torque-turn curve.

In some embodiments, evaluating the one or more operating parameters comprises evaluating the one or more operating parameters for dynamic behavior and mechanical properties of the tong assembly, and removing effects caused by dynamic behavior and mechanical properties of the tong assembly from the torque-turn curve.

Claim 1:
A method of making up a tubular joint, comprising:
rotating a first tubular (<NUM>) relative to a second tubular (<NUM>) to make a threaded connection between the first and second tubulars using a tong assembly (<NUM>) while measuring torque applied to the threaded connection and while measuring turns of the first tubular (<NUM>) relative to the second tubular (<NUM>);
correcting measurements of the torque during rotation of the tong assembly as required to compensate for dynamic behavior and mechanical properties of the tong assembly (<NUM>);
correcting measurements of the turns during rotation of the tong assembly as required to compensate for incorrect turns data;
evaluating the corrected measurements of the torque and the corrected measurements of the turns; and
determining whether the threaded connection is acceptable based on the evaluation of the corrected measurements.