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. When a threaded connection is properly broken-out, the tubulars may be usable in subsequent well operations, such as (but not necessarily) drilling operations.

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

<CIT>) discloses an image based system for drilling operations. An imaging device is configured to detect a location of an end of a tubular or a feature of the tubular. A processor receives an input from the imaging device and is configured to calculate a distance between the end of the tubular and another element, a diameter of the tubular, or movement of the tubular.

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; the scope of protection is limited only by the appended claims.

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 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 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 make-up or break-out operations. 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 (see <FIG>) 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 or break-out 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> can be 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>, an example of the method of making-up tubular string components is representatively illustrated. For convenience, this example of the method is described below as it may be used with the system <NUM> of <FIG>, but the method may be used with other systems in keeping with the principles of this disclosure.

In the <FIG> example, the camera <NUM> observes and obtains images of at least the tubulars <NUM>, <NUM>, the coupling <NUM> and a rotor <NUM> of the rotary clamp <NUM> while the tubular <NUM> is threaded into the coupling. Jaws <NUM> carried in the rotor <NUM> grip the tubular <NUM> in order to apply torque to the tubular <NUM> as it is threaded into the coupling <NUM>. Jaws <NUM> of the backup clamp <NUM> grip the tubular <NUM> in order to react the torque applied by the rotary clamp <NUM>.

Image data is output from the camera <NUM>. As described more fully below, the image data is input to an image processor <NUM> (see <FIG>). The image processor <NUM> detects displacements of the various structures observed by the camera <NUM> using optical flow techniques. These optical flow techniques include grouping optical vector fields representing movements of the various components observed by the camera <NUM>. As used herein, the term "displacement" is used to indicate longitudinal or rotational movement, or a combination of longitudinal and rotational movements (e.g., helical displacement).

The movements of the components observed by the camera <NUM> can then be compared to determine when a proper threaded connection has been achieved, or if a proper threaded connection can be achieved. A controller <NUM> (see <FIG>) controls the connection make-up process based on these determinations. For example, the controller <NUM> may control operation of the rotary clamp <NUM> so that a predetermined number of turns of the tubular <NUM> are accomplished, or so that a total thread loss (e.g., a longitudinal overlap between threaded-together components) is achieved.

In the <FIG> example, the camera <NUM> can observe components (such as the tubular <NUM> and the rotor <NUM>) that displace during the connection make-up process, as well as components (such as the tubular <NUM> and coupling <NUM>) that should remain stationary during the connection make-up process. In this manner, slippage between the rotor <NUM> and the tubular <NUM> can be detected if there is a difference between rotational displacements of the rotor and the tubular <NUM>. Similarly, slippage between the jaws <NUM> of the backup clamp <NUM> and the tubular <NUM> can be detected if there is rotation of the tubular <NUM> and the coupling <NUM> during the connection make-up process.

Longitudinal displacement of the tubular <NUM> into the coupling <NUM> can be detected, so that the connection make-up process can be terminated by the controller <NUM> when the total thread loss is within a predetermined range. Similarly, a number of turns of the tubular <NUM> as it is threaded into the coupling <NUM> can be detected, so that the connection make-up process can be terminated by the controller <NUM> when the number of turns is within a predetermined range.

Detection of the displacements of the components as discussed above are facilitated by the use of the camera <NUM> to observe multiple components during the connection make-up process. A single camera <NUM> may observe one, two, three, four, or any other number of components. However, it is not necessary that only a single camera be used to observe all of the components for which it is desired to determine displacements.

Referring additionally now to <FIG>, another example of the method is representatively illustrated. In this example, multiple cameras <NUM> are used to observe components of the system <NUM> during the tubular connection make-up process.

Each one of the cameras <NUM> may observe a single component or multiple components. As depicted in <FIG>, an upper camera <NUM> observes the rotor <NUM> and the tubular <NUM>. A middle camera <NUM> observes the tubulars <NUM>, <NUM> and the coupling <NUM>. A lower camera <NUM> observes the tubular <NUM> and the backup clamp <NUM>.

Image data from the multiple cameras <NUM> can be combined by the image processor <NUM>, so that the movements of all of the components can be determined using the optical flow techniques discussed more fully below. Based on these detected movements, the controller <NUM> can control the connection make-up process.

Referring additionally now to <FIG>, another example of the method is representatively illustrated. In this example, a top drive <NUM> is used to rotate and apply torque to the tubular <NUM>. The backup clamp <NUM> reacts the torque applied by the top drive <NUM>.

The camera <NUM> can observe any, or any combination of, the tubular <NUM>, the coupling <NUM>, the tubular <NUM> and the backup clamp <NUM>. Multiple cameras <NUM> may be used if desired.

The rotor <NUM> of the top drive <NUM> is used to rotate and apply torque to the tubular <NUM>. The camera <NUM>, or another camera, can observe the rotor <NUM> and the tubular <NUM> during the tubular connection make-up process.

Referring additionally now to <FIG>, various components of the system <NUM> are representatively illustrated as observed by the camera <NUM> in the example of <FIG>. Optical vector fields representing detected movements of the components are superimposed on the illustrated components. The vector fields result from the optical flow techniques discussed above.

Rotation of the tubular <NUM> by the rotor <NUM> of the rotary clamp <NUM> is represented by an arrow <NUM> in <FIG>. Note that a group of vectors 30a indicate this rotation of the rotor <NUM> and can be detected by the image processor <NUM> with appropriate instruction, programming and/or training.

Another group of vectors 20a indicate a similar rotation of the tubular <NUM>. The vectors 20a also indicate longitudinal displacement of the tubular <NUM> as it is threaded into the coupling <NUM>. The rotation and longitudinal displacement of the tubular <NUM>, as indicated by the vectors 20a can be detected by the image processor <NUM> with appropriate instruction, programming and/or training.

Although in a normal connection make-up process the tubular <NUM> and the coupling <NUM> should not rotate, rotation of these components is depicted in <FIG> for convenience in describing a condition that may cause the controller <NUM> to terminate the connection make-up process. In this example, a group of vectors 22a indicate rotation of the coupling <NUM>, and a group of vectors 14a indicate rotation of the tubular <NUM>. These groups of vectors 14a, 22a can be detected by the image processor <NUM> with appropriate instruction, programming and/or training.

The controller <NUM> may terminate the connection make-up process (e.g., by ceasing the rotation of the rotor <NUM>) if any of the following conditions is indicated by the optical vector fields:.

In a tubular connection break-out operation, the controller <NUM> may terminate the connection break-out process (e.g., by ceasing the rotation of the rotor <NUM>) if the rotor <NUM> rotates at a faster rate than the tubular <NUM>, the coupling <NUM> rotates relative to the tubular <NUM>, or if the tubular <NUM> rotates.

Referring additionally now to <FIG>, the groups of the optical vectors 14a, 20a, 22a, 30a are representatively illustrated apart from the components of the system <NUM>. In this view, the manner in which the image processor <NUM> can detect optical vector fields in the image data output by the camera <NUM> can be more readily visualized.

As mentioned above, optical flow techniques are used to detect the optical vectors 14a, 20a, 22a, 30a represented in the image data. For example, prior to the connection make-up process, the camera <NUM> may observe the environment of the rig floor <NUM> (see <FIG>) as a background reference to produce a reference image. Then, at a start of the connection make-up process, the camera <NUM> begins observing the various components involved (such as the tubulars <NUM>, <NUM>, the coupling <NUM> and the rotor <NUM>).

While the tubular <NUM> is threaded into the coupling <NUM>, the image processor <NUM> detects the optical vectors 14a, 20a, 22a, 30a in real time by comparing later (or current) image data to earlier (or past) image data. Based on appropriate instruction, programming and/or training, the image processor <NUM> is able to group the vectors 14a, 20a, 22a, 30a into respective vector fields 14b, 20b, 22b, 30b.

For example, an operator could input to a control system <NUM> (see <FIG>) a known diameter and length of the coupling <NUM>, and the image processor <NUM> can use this information to identify a group of vectors 22a corresponding to this diameter and length as being a vector field 22b representing displacement of the coupling. Similarly, reduced diameter components are typically expected to be positioned on opposite sides of the coupling <NUM>, so the image processor <NUM> can use this information to identify a group of vectors 14a, 20a corresponding to this reduced diameter as being vector fields 14b, 20b representing displacements of the respective tubulars <NUM>, <NUM>. In a similar manner, the rotor <NUM> is typically expected to be positioned above the connection and to have a larger diameter than the tubular <NUM>, so the image processor <NUM> can use this information to identify a group of vectors 30a corresponding to this diameter and position as being a vector field 30b representing displacement of the rotor.

The above are merely examples of possible ways in which the image processor <NUM> can be instructed, programmed or trained to detect the various components and displacements of the components represented in the image data output by the camera <NUM>. Other techniques known to those skilled in the optical image processing art may be utilized in keeping with the principles of this disclosure. Neural or neuronal networks, fuzzy logic and other artificial intelligence techniques or programmed capabilities may be particularly useful in detecting the various components and displacements of the components represented in the image data output by the camera <NUM>.

Referring additionally now to <FIG>, the control system <NUM> is representatively illustrated in schematic form. The control system <NUM> may be used with the system <NUM> example of <FIG> and the method examples of <FIG>, or the control system may be used with other systems and methods.

The control system <NUM> includes the 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> or top drive <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.), or the controller can terminate rotation of the tubular <NUM> when a proper threaded connection cannot be achieved (for example, due to slippage between the jaws <NUM> and the tubular <NUM> or slippage between the jaws <NUM> and the tubular <NUM>), or the controller can terminate rotation of the tubular <NUM> when a properly unthreaded or broken-out connection cannot be achieved (for example, due to slippage between the jaws <NUM> and the tubular <NUM>, slippage between the jaws <NUM> and the tubular <NUM> or unthreading of the coupling <NUM> from the tubular <NUM>). The scope of this disclosure is not limited to any particular purpose or benefit obtained by use of the controller <NUM> in the control 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 the 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 tubulars <NUM>, <NUM>, coupling <NUM> and/or rotor <NUM> or <NUM>) as represented in the image data. In addition, the image processor <NUM> identifies or recognizes movements of the 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 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. Optical flow techniques can be used to identify, recognize and quantify movements (such as longitudinal displacements and/or rotations) of the components. The scope of this disclosure is not limited to any particular configuration, structure or capability of the image processor <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 can include the steps of: threading first and second tubulars <NUM>, <NUM> with each other while a first camera <NUM> obtains images of the first and second tubulars <NUM>, <NUM>; outputting image data from the first camera <NUM> to an image processor <NUM>; the image processor <NUM> detecting optical flow vector fields from the image data, the optical flow vector fields representing first and second displacements of the respective first and second tubulars <NUM>, <NUM> during the threading; and controlling the threading in response to a difference between the first and second displacements.

The threading step may comprise threading together the first and second tubulars <NUM>, <NUM>, for example, to make-up a threaded connection. Alternatively, the threading step may comprise unthreading the first and second tubulars <NUM>, <NUM> from each other, for example, to break-out the threaded connection.

The first camera <NUM> may obtain images of a threaded third tubular <NUM> during the threading step. The second and third tubulars <NUM>, <NUM> may be threaded together prior to the threading step.

The first camera <NUM> may obtain images of a rotor <NUM> of a rotary clamp <NUM> or a rotor <NUM> of a top drive <NUM> during the threading step.

The controlling step may include controlling the threading in response to a difference between the first displacement of the first tubular <NUM> and a third displacement of the rotor <NUM> or <NUM>. The first and third displacements may comprise rotations of the respective first tubular <NUM> and the rotor <NUM> or <NUM>.

The controlling step may include controlling the threading in response to the second displacement of the second tubular <NUM> being greater than zero. The second displacement may comprise a rotation of the second tubular <NUM>.

The controlling step may include controlling the threading in response to the first displacement of the first tubular <NUM> being within a predetermined range. The first displacement may comprise a longitudinal displacement of the first tubular <NUM>.

The controlling step may include controlling the threading in response to the first displacement of the first tubular <NUM> being within a predetermined range. The first displacement may comprise a rotation of the first tubular <NUM>.

The controlling step may include controlling the threading in response to the optical flow vector fields representing a predetermined difference between the first and second displacements.

The method may include a second camera <NUM> obtaining images of a threaded third tubular <NUM> and at least one of the first and second tubulars <NUM>, <NUM> during the threading. The optical flow vector fields may represent a third displacement of the third tubular <NUM> and at least one of the first and second displacements during the threading step.

The method may include a second camera <NUM> obtaining images of a rotor <NUM>, <NUM> of a rotary clamp <NUM> or a top drive <NUM> and at least one of the first and second tubulars <NUM>, <NUM>. The optical flow vector fields may represent a third displacement of the rotor <NUM>, <NUM> and at least one of the first and second displacements during the threading step.

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 can include: positioning a first camera <NUM> at a first location, the first camera <NUM> thereby simultaneously observing at least threaded first and second tubulars <NUM>, <NUM>; threading the first and second tubulars <NUM>, <NUM> with each other; outputting image data from the first camera <NUM> to an image processor <NUM>; the image processor <NUM> detecting optical flow vector fields from the image data, the optical flow vector fields representing first and second displacements of the respective first and second tubulars <NUM>, <NUM> during the threading; and controlling the threading in response to the image processor <NUM> detecting the optical flow vector fields.

The positioning step may include positioning the first camera <NUM> at the first location, the first camera <NUM> thereby simultaneously observing at least the first and second tubulars <NUM>, <NUM> and a threaded third tubular <NUM>. The second and third tubulars <NUM>, <NUM> may be threaded together prior to the threading step.

The positioning step may include positioning the first camera <NUM> at the first location, the first camera <NUM> thereby simultaneously observing at least the first and second tubulars <NUM>, <NUM> and a rotor <NUM> of a rotary clamp <NUM>, or a rotor <NUM> of a top drive <NUM>.

The controlling step may include controlling the threading in response to a difference between the first displacement of the first tubular <NUM> and a third displacement of the rotor <NUM>, <NUM>. The first and third displacements may comprise rotations of the respective first tubular <NUM> and the rotor <NUM>, <NUM>.

The method may include positioning a second camera <NUM> at a second location, the second camera <NUM> thereby simultaneously observing a threaded third tubular <NUM> and at least one of the first and second tubulars <NUM>, <NUM>. The optical flow vector fields may represent a third displacement of the third tubular <NUM> and at least one of the first and second displacements during the threading.

The method may include positioning a second camera <NUM> at a second location, the second camera <NUM> thereby simultaneously observing a rotor <NUM> or <NUM> of a rotary clamp <NUM> or a top drive <NUM>, and at least one of the first and second tubulars <NUM>, <NUM>. The optical flow vector fields representing a third displacement of the rotor <NUM> and at least one of the first and second displacements during the threading.

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 or breaking-out tubular string components for use in a subterranean well, the method comprising:
threading first and second tubulars (<NUM>, <NUM>) with each other while a first camera (<NUM>) obtains images of the first and second tubulars (<NUM>, <NUM>);
outputting image data from the first camera (<NUM>) to an image processor (<NUM>);
the image processor (<NUM>) detecting optical flow vector fields from the image data, the optical flow vector fields representing first and second displacements of the respective first and second tubulars (<NUM>, <NUM>) during the threading; and
controlling the threading in response to a difference between the first and second displacements.