The invention relates to both a method and an apparatus to reduce the slot width in slotted tubular members, such as tubular liners.
Slotted tubular members, known as slotted tubular liners or slotted metal pipes, are used in the oil industry, and in other industries, as screens to limit the amount of sand entering a well. The equipment which is used to cut these slots circumferentially around the tubular members is capable of forming slots having a width of about 0.015″ (thou=thousandths of an inch) or 0.381 mm. Slot widths less than 15 thou (0.381 mm) are needed in most industries in order to exclude sand. While equipment may be capable of cutting narrower slots, normally seaming equipment is used. Seaming equipment applies pressure to the tubular member in the vicinity of the slot to both narrow the slot width at the exterior surface of the tubular member, and to form a slot profile known as a “keystone slot.” Canadian Patent 2,183,032 issued Jul. 17, 2001 to I.S.I. Canada Inc. describes one method of reducing slot width in such tubular liners. Pressure is applied with a seaming roller to the exterior surface of a slotted pipe along the longitudinal peripheral edges of the slot until the metal pipe is deformed to close the slot to a desired width. Another scheme for reducing slot width is described in Canadian Patent No. 2,324,730 issued on Aug. 12, 2003 and reissued on Mar. 16, 2004, to Regent Technologies Ltd. This patent describes a method wherein the seaming roller traverses the slot in a helical sweep pattern in order to reduce the slot width. The apparatus described to accomplish this includes a rotating forming head equipped with three hydraulic actuators which apply a load to three forming rollers.
The above described methods for reducing slot width in tubular members have short comings which are addressed by the present invention. While Canadian Patent No. 2,324,730, issued to Regent Technologies Inc., recognizes an improved approach compared to I.S.I Canadian Patent No. 2,183,032, in traversing the slot in order to reduce slot width, the apparatus disclosed to accomplish this is limited to a rotating forming head with rigid hydraulic actuator control. Canadian Patent No. 2,324,730, fails to address certain problems recognized by the inventors of this patent application as follows:
The apparatus and method of the present invention address these short comings of the prior art and achieve improved tolerance and width control in narrow slots in slotted tubular liners.
In a broad aspect, the present invention provides a method of reducing the width of a plurality of slots (preferably longitudinal slots) or other openings spaced circumferentially around a slotted tubular member, comprising:
providing at least one seaming roller positioned to contact the outer surface of the slotted tubular member for transverse movement relative to the longitudinal axis of the slotted tubular member, preferably across the plurality of slots;
detecting an initial width of each of the plurality of slots to generate a detection signal proportional to the detected initial width;
comparing the detected initial width of the slots to a set value indicative of a desired end slot width to generate a correction signal proportional to the difference;
applying a downward force onto the slotted tubular member with the at least one seaming roller, and;
varying the force applied by the at least one seaming roller to the plurality of slots along the slotted tubular member in response to the correction signal.
In another broad aspect, the present invention provides an apparatus for reducing the width of a plurality of longitudinal slots or other openings spaced circumferentially around a slotted tubular member comprising:
a seaming roller positioned to contact the outer surface of the slotted tubular member for transverse movement across the plurality of slots, and adapted to apply a force onto the slotted tubular member so as to reduce the slot width;
first detecting means or a first detector adjacent the seaming roller for detecting all initial width of the plurality of slots and generating a detection signal proportional to the detected initial width;
comparing means or a comparator connected to the first detecting means or the first detector for comparing the detected initial width to a set value indicative of a desired end slot width and to generating a correction signal proportional to the difference;
varying means or an adjustor connected to the seaming roller and the comparing means or the comparator, for varying or adjusting the force applied by the seaming roller to the plurality of slots in response to the correction signal.
In yet another broad aspect, the present invention provides a method of reducing the width of a plurality of longitudinal slots or other openings spaced circumferentially around a slotted tubular member, comprising:
providing at least one seaming roller positioned to contact the outer surface of the slotted tubular member for transverse movement across the plurality of slots;
applying a downward force onto the slotted tubular member with the at least one seaming roller; and
maintaining the force applied by the at least one seaming roller as the seaming roller moves across each of the plurality of slots with an accumulator.
In another broad aspect, the present invention provides a method of reducing the width of a plurality of longitudinal slots or other openings spaced circumferentially around a slotted tubular member, comprising:
providing at least one seaming roller positioned to contact the outer surface of the slotted tubular member for transverse movement across the plurality of slots;
applying a downward force onto the slotted tubular member with the at least one seaming roller; and
longitudinally feeding and axially rotating the slotted tubular member through the at least one seaming roller.
In another broad aspect, the present invention provides a slotted tubular liner comprising: a metal slotted tubular member formed with a plurality of longitudinal slots ≦3.175 mm in width spaced circumferentially around the member, each slot having been cut and then transversely seamed to have a profile with a width tolerance, that throughout the length of the slot profile, varies no more than +/−0.0127 mm, and preferably varies no more than +/−0.00762 nun from a desired end slot width.
In another broad aspect, the present invention provides a method of forming a slotted tubular member having a plurality of longitudinal slots comprising:
providing at least one seaming roller positioned to contact the outer surface of the slotted tubular member for transverse movement across the plurality of slots;
detecting a width of each of the plurality of slots to generate a detection signal proportional to the detected width;
comparing the detected width of the slots to a set value indicative of a desired end slot width to generate a correction signal proportional to the difference;
applying a downward force onto the slotted tubular member with the at least one seaming roller; and
varying the force applied by the at least one seaming roller to the plurality of slots along the slotted tubular member in response to the correction signal so that each opening has a profile with a width tolerance, that throughout the length of the slot profile, varies no more than +/−0.0381 mm from a desired end slot width, preferably varies no more than +/−0.0127 mm from a desired end slot width, and most preferably varies no more than +/−0.00762 mm from a desired end slot width.
In another broad aspect, the present invention provides an apparatus for reducing the width of a plurality of longitudinal slots or other openings spaced circumferentially around a slotted tubular member comprising:
a seaming roller positioned to contact the outer surface of the slotted tubular member for transverse movement across the plurality of slots, and adapted to apply a force onto the slotted tubular member so as to reduce the slot width;
first detecting means or a first detector adjacent the seaming roller for detecting a width of the plurality of slots and generating a detection signal proportional to the detected width;
comparing means or a comparator connected to the detecting means or the first detector for comparing the detected width to a set value indicative of a desired end slot width and to generating a correction signal proportional to the difference;
varying means or adjustor connected to the seaming roller and the comparing means or comparator, for varying or adjusting the force applied by the seaming roller to the plurality of slots in response to the correction signal.
In yet another broad aspect, the present invention provides a method of reducing the width of a plurality of longitudinal slots or other openings spaced circumferentially around a slotted tubular member, comprising:
providing at least one seaming roller positioned to contact the outer surface of the slotted tubular member for transverse movement across the plurality of slots;
detecting a width of each of the plurality of slots to generate a detection signal proportional to the detected width;
comparing the detected width of the slots to a set value indicative of a desired end slot width to generate a correction signal proportional to the difference;
applying a downward force onto the slotted tubular member with the at least one seaming roller; and
varying the force applied by the at least one seaming roller to the plurality of slots along the slotted tubular member in response to the correction signal.
The invention in a preferred embodiment includes an apparatus and method for maintaining the force applied by the at least one seaming roller to the plurality of slots as the seaming roller moves across each slot. This is readily accomplished with gas compressed hydraulic accumulators on the seaming roller.
The invention in a preferred embodiment includes the slotted tubular member being made of metal having a plurality of longitudinal slots cut circumferentially around the member.
Other preferred embodiments of the apparatus and method of the invention include one or more of the following features:
detecting the final width of each of the plurality of slots, generating a final width signal proportional to the detected final width, and comparing the final width signal to the set value indicative of a desired end slot width;
moving the at least one seaming roller longitudinally along the length of the slotted tubular member;
optically detecting the width of the plurality of slots with a digital camera;
laser detecting the width of the plurality of slots with a laser and a laser detector.
As used herein and in the claims, the terms and phrases set out below have the meanings which follow.
“Width tolerance” is a measure of the difference between a set value indicative of a desired end slot width and the final width of a slot after the seaming process. For example, if a slotted tubular member has a set value indicative of a desired end slot width of 0.15 mm, and the desired width tolerance is +/−0.02 mm, then the final width of a slot after the seaming process should be in the range of 0.13–0.17 mm (or should not vary in width along the length of the slot by more than 0.02 mm). A final slot width within this range yields a slot width that is within a +/−0.02 mm width tolerance from the desired end slot width.
By “desired end slot width” is meant a slot width which is a set standard. For example, a standard set by the operator to achieve appropriate quality control or industry standard. This desired end slot width is generally less than 3.175 mm for oil and gas purposes but preferably is in the range of 0.0127 mm–3.175 mm.
By “longitudinal slot” is meant a slot cut generally along the longitudinal axis of the tubular member but includes slots formed at an angle less than 60° from the longitudinal axis.
“Roughness Average (Ra)” is a measure of the surface roughness of a slotted tubular member. The higher the Ra value for a given slotted tubular member, the greater the number of protuberances or peaks and valleys present on the outer surface of the tubular member. The Ra value is the arithmetic average of the absolute value of the measured profile height deviations taken within the sampling length and measured from the graphical centerline; it is a determination of the average linear deviation of the measured surface from the nominal surface. Roughness average is typically expressed in micrometers (μm).
“Ground Finished” describes a slotted tubular member or pipe that has been subjected to grinding in order to reduce the surface roughness of the outer surface. Typical Ra values for ground finished pipes are in the range of 1.6–0.10 μm.
The apparatus of the present invention as seen in
The head stock assembly is best illustrated in
As shown in
As shown in
As shown in
As shown in
Alternative methods to drive the head stock assembly along the base may be used. For example ball screw and nut embodiments or threaded screw and nut embodiments wherein a nut is attached to the base of the head stock housing 10 and longitudinal movement is effected by a screw. As another alternative, a timing belt or chain may be used to drive the quill from the motor. As another alternative method, a hydraulic cylinder attached to the base of the head stock housing 10 can be used to push or pull the head stock housing longitudinally along the length of the slotted tubular member.
The clamp roller assembly is best illustrated in
The clamp roller assembly 6 includes two upper floating rollers 52 and two lower rigid rollers 54. The floating rollers 52 are housed in a floating roller holder 56 that allows vertical movement of said upper rollers 52 by means of floating roller hydraulic cylinder 58.
The floating roller holder 56 is equipped with four floating roller linear bearing carriages 60, which are attached to two floating roller linear bearing guideways 62 bolted to the roller stand 64. This allows the floating roller holder 56 to be held in place and guided while being activated by the floating roller hydraulic cylinder 58. The floating roller hydraulic cylinder 58 is mounted by bolts 66 to the roller stand 64. The hydraulic cylinder rod end 68, which is threaded, is attached to the floating roller holder 56.
The lower rigid rollers 54 are housed in a rigid roller holder 70 which allows vertical movement of the lower rigid rollers 54 by means of a Temposonics® controlled rigid roller hydraulic cylinder 72 (Temposonics® is a trade mark of MTS® Systems Corporation, Minnesota, U.S.A. for magnetostrictive linear position sensors).
The rigid roller holder 70 is equipped with four rigid roller linear bearing carriages 74, which are attached to two rigid roller linear bearing guideways 76 bolted to the roller stand 64. This allows the rigid roller holder 70 to be held in place and guided while being activated by a Temposonics® controlled rigid roller hydraulic cylinder 72. The Temposonics® controlled rigid roller hydraulic cylinder 72 is mounted by bolts 78 to the roller stand 64. The hydraulic cylinder rod end 80, which is threaded, is attached to the rigid roller holder 70.
In a preferred embodiment, roller stand 64 is mounted on base 34 by four roller stand linear bearing carriages 82, which are attached to two roller stand linear bearing guideways 84 fixed to the base 34. This allows longitudinal movement of the roller stand 64 relative to the base 34. Alternatively the roller stand can be fixed to the base by bolts without the intervening structure of roller stand linear bearing carriages or roller stand linear bearing guideways.
The clamp roller assembly 6 supports and centers the slotted tubular member thus allowing the seaming rollers to act with equal force on the slotted tubular member in order to bring the slots to plastic deformation. A minimal amount of pressure, depending on the yield strength of the slotted tubular member, acting on the piston area of the cylinders 58 and 72 is enough to give slot openings with a width tolerance of plus or minus 0.0005″ (0.0127 mm) during plastic deformation, depending on the initial physical characteristics of the slotted tubular member 4.
As depicted schematically in
The floating roller holder hydraulic cylinder 58 has a dual purpose. Firstly, it clamps the tubular member 4 with the upper rollers 52. Secondly, it stabilizes the tubular member 4 with minimum force to minimize harmonic vibrations. As depicted schematically in
As shown schematically in
The seaming roller assembly 8 is best illustrated in
With reference to
The tubular member is formed with a plurality of slots or openings of any shape. Typically, a plurality of slots are formed oriented longitudinally (i.e., along the longitudinal axis of the tubular member). However, the slots can be formed at virtually any angle, including perpendicular to the longitudinal axis fo the pipe. Slots may be oriented in a number of patterns such as single (inline, staggered, or spiral) and multiple (inline, staggered or spiral). The staggered pattern places each adjacent row of slots off center to the row previously cut. The inline pattern places each adjacent row of slots even with the row previously cut. The spiral pattern arranges the slots circumferentially in a helical pattern along the longitudinal axis of the tubular member. Typically the plurality of longitudinal slots of a slotted tubular member 4 are cut to have equal lengths, but unequal lengths can be accommodated by the present invention. The slots may also be cut at an angle to the longitudinal axis of the pipe. Generally a metal slotted tubular member is formed with a plurality of longitudinal slots cut circumferentially around the member that range from 0.203 mm to 6.350 mm in width but may deviate from this range depending on the application for the slots. Typically the slots are cut less than 3.175 mm in width for oil and gas purposes.
The plurality of slots or openings of the slotted tubular member 4 are seamed so that the profile of a given slot 9 has a width that is generally consistent throughout the length of the slot profile. The actual variance in the width tolerance of the final slot profile from a desired end slot width is dependent on the initial characteristics of the slotted tubular member 4. Such initial characteristics may include the surface finish of the slotted tubular member 4 or any slot preparations performed on the tubular member prior to subjecting the slotted tubular member 4, to the seaming roller assembly 8.
Seaming of the slot width is dependent on contact between the seaming rollers 98 and the periphery edges of a given slot 9. The rougher the outer surface of a slotted tubular member 4, the rougher the periphery edges of a given slot 9. As the roughness increases the number of peaks and valleys on the peripheral edge of a slot increases and, as such, the surface area of the slotted tubular member in contact with the seaming rollers 98 decreases. This decrease in contact surface between the seaming rollers 98 and the peripheral edges of the slot 9, reduces the ability of the seaming rollers to plastically deform the slot. For example, a surface finish with an roughness average of 6.3 μm (250 μin.) or greater, generally results in a slot 9 having a profile with a width tolerance that throughout the length of the slot profile, varies no more than about +/−0.0381 mm from the desired end slot width. A surface finish with a roughness average of 1.6 μm (63 μin.) or smaller, generally results in a slot 9 having a profile with a width tolerance that throughout the length of the slot profile, varies no more than about +/−0.0127 mm from the desired end-slot width. In some circumstances a surface finish with a roughness average of 1.6 μm or smaller, or slotted tubular members that have been ground finished (roughness average of 1.6–0.10 μm), can result in a slot 9 having a profile with a width tolerance that throughout the length of the slot profile, varies no more than about +/−0.00762 mm from the desired end slot width. Width tolerances as low as +/−0.00762 mm from the desired end slot width, are generally possible when slot preparations have been performed on the slotted tubular member 4 prior to subjecting the member to the seaming roller assembly 8. Such slot preparations on the slotted tubular member 4 may include cleaning the slots with a wire brush or solvents or polishing, lapping or superfinishing the slotted tubular member 4.
In an alternate embodiment, the seaming rollers 98 can be operated by pneumatic cylinders (not shown) in place of seaming roller hydraulic cylinders 100 and seaming roller accumulator 106.
The electronic control over seaming the tubular member 4 includes a laser detection assembly 120 and the PLC.
As shown in
Alternatives to laser detection may be used. For example an optic system in place of the laser detection assembly of the preferred embodiment may be employed. In an alternative embodiment, as shown in
In a preferred embodiment the final width of each of the plurality of slots is measured to ensure quality control. The laser detection assembly 120 as shown in
In a preferred embodiment the width of each of the plurality of slots is continually measured and detected, relayed to the PLC, compared to a set value indicative of a desired end slot width, and varied through varying the force applied by the seaming roller to a given slot 9 to ensure that each opening has a profile with a width that is generally consistent. In a preferred embodiment an opening with a profile that is generally consistent has a width tolerance that varies no more than +/−0.0127 mm from the desired end slot width throughout the length of the slot profile, depending on the initial characteristics of the slotted tubular member 4.
To demonstrate the calculation of reduced slot width using the laser detection apparatus the following non-limiting sample calculation is provided. A section of the slotted tubular member 4 is positioned beneath the laser detection apparatus 120, in which the rotational speed of the section of the slotted tubular member 4 is 60 rpm, the data acquisition sampling speed is 100 kHz and the assumed diameter of the section of the slotted tubular member is 7″ (17.7800 cm). Based on these input variables the circumference of the pipe is calculated to be approximately 21.9911″ (55.8574 cm) which in turn provides a calculated inches/sample of 0.000219911″/sample (0.0006 cm/sample) as follows:
21.9911″/100000 samples=0.000219911″/sample (0.0006 cm/sample).
The width of the slot 9 is measured at 50.25 samples wide (slot width determined by measurement of pulse width), resulting in a calculated width of the slot 9 of:
Therefore the detected width of the measured slot 9 is 0.01105″ (0.0281 cm) subject to application of a calibration factor, which eliminates any slight inaccuracies introduced in the slot measurement process.
As shown in
In a preferred embodiment the laser may be a StockerYale Lasiris™ MFL-670-5-1-65 with 5 mW line generator producing a 13 μm×1 mm line at 670 nm and the detectors may be a Edmund Optics silicon detector 54-034 with 16.4 mm2 active area, operation in unbiased (photovoltaic) mode with the voltage measured across a 100 k ohm resistor. In measuring the input from the detectors a National Instruments PCI-6070E data acquisition card may be used which has a 1.25 MS/s maximum sampling speed with 12-bit accuracy. An analog voltage proportional to the amount of reflected laser radiation is produced. The laser and the detector assembly are kept at a constant distance (focal length) from the section of the slotted tubular member 4 being measured to ensure accuracy and reduce errors in the final measurement of slot width. Alternatives to these lasers, detectors and data cards may be used and are well known in the art.
On detection by the laser detection assembly, an analog signal proportional to the reflected signal is produced and then fed to a Programmable Logic Control (PLC) device. The PLC controls the mechanical motion of the seaming rollers 98 through two Head stock drive motors (quill drive motor 20 and rack drive motor 36 as shown in
Signals sent to the clamp roller assembly 6 serve to manipulate the Temposonics® controlled rigid roller hydraulic cylinder 72 such that the pressure applied to this cylinder locates the rigid rollers 54 so as to center and support the slotted tubular member for entry into the seaming roller assembly 8. The exact positioning of the tubular member 4 is important to ensure that equal forces are applied to the tubular member 4 during the seaming process. Signals sent to the seaming roller assembly 8 from the PLC serve to manipulate the seaming roller hydraulic cylinders 100 that in turn vary the force applied by the seaming rollers onto the slotted tubular member 4.
As schematically outlined in
On initiation, the PLC sends signals to the multiple assemblies 2, 6, 8 to perform three functions: a signal is related to the Head stock drive motors (rack drive motor 36 and quill drive motor 20) to correlate the speed of the motors with the dimensions inputted for the tubular member; a signal is sent to the Temposonics® controlled rigid roller hydraulic cylinder to position the rigid rollers 72 so as to center and support the given tubular member; and a signal is sent to proportional amplifier 116 to set the initial starting pressure to be applied to the seaming roller hydraulic cylinders 100 that correlates with the dimensions of the given tubular member. The PLC continuously performs a self check of the rotational speed and head stock assembly motion using encoders built into the rack drive motor 36 and quill drive motor 20. The encoders are pulse generators that send a signal back to the PLC to the degree of 1024 pulses/revolution.
For the process control the PLC receives an analog signal from the laser system indicating the width of the slot 9. The PLC then processes this information to decipher the appropriate amount of analog output signal and the reaction time to send to the hydraulic proportional pressure control valve 114, through the proportional amplifier 116. The proportional amplifier 116 exerts the seaming force into the slotted tubular member 4. This process is performed at each seaming roller assembly 204.
When the PLC device senses a row of slots on the slotted tubular member via a measurement system (i.e., laser detection assembly or digital camera in alternate embodiment), a measuring process starts that relates the width of a slot 9 to a voltage value. For example, as shown schematically in
The hydraulic pressure at each seaming roller hydraulic cylinder, the actual chuck rotation 18, the head stock assembly 2 motion longitudinally as along the linear bearing guideway 32, the slot width at each seaming roller 98 and the output hydraulic pressure signal can all be monitored at the operator console on the touch screen (not shown).
When the measurement system (ex., laser detection assembly in preferred embodiment) senses the end of the row of slots on the tubular member, the PLC decreases the hydraulic pressure to the seaming rollers 98 by sending a signal to the proportional amplifier. If the end of a tubular member is detected by the measurement system, then a stop signal is sent from the PLC to the Head stock drive motors (the quill drive motor 20 and the rack drive motor 36) and the hydraulic power unit. If another region of slots is detected by the measurement system then the measurement process begins again to compare and adjust the width of the slot 9 being measured against the desired slot width entered.
All publications mentioned in this specification are indicative of the level of skill in the art of the invention. All publications are herein incorporated by reference to the same extent as if each publication was specifically and individually indicated to be incorporated by reference. The terms and expressions used are, unless otherwise defined herein, used as terms of description and not limitation. There is no intention, in using such terms and expressions, of excluding equivalents of the features illustrated and described it being recognized that the scope of the invention is defined and limited by the claims which follow.
This application claims benefit of U.S. Provisional Application No. 60/463,917 filed Apr. 17, 2003, which is incorporated herein to the extent not inconsistent herewith.
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