Patent Grant
9404322
1. Field of the Invention
Embodiments of the invention relate to an electronic control system for controlling the operation of one or more tubular handling tools. Embodiments of the invention relate to an electronic interlock for a tubular handling system for performing tubular handling operations.
2. Description of the Related Art
It is known in the drilling industry to use a top drive system on a drilling rig for rotating a tubular or tubular string for making up or breaking out tubular connections while drilling a well and for installing the casing after the well is drilled. Top drive systems are equipped with a motor to provide torque for rotating the tubulars, and may be equipped with a tubular gripping tool to facilitate the handling of the tubulars. During a tubular makeup/breakout operation, the top drive works in tandem with a spider provided at the rig floor. While handling a string of tubulars suspended from a drilling rig, either the top drive, an elevator attached to the top drive, or the spider must be engaged with the tubular string to prevent the string from falling into the well.
Typically, an operator located on the platform controls the top drive, elevator, and the spider with manually operated levers that control fluid power to the slips that cause the top drive/elevator and spider to retain the tubular string. At any given time, the operator can inadvertently drop the tubular string by moving the wrong lever. Conventional interlocking systems based around hydraulic or pneumatic circuits have been developed and used with elevator/spider systems to address this problem.
There is a need for a more sophisticated interlock system for use with one or more tubular handling tools to prevent inadvertent release of a tubular or tubular string.
In one embodiment, an electronic control system comprises a first tubular handling tool; a sensor coupled to the first tubular handling tool; and a controller in communication with the sensor. The controller is configured to control actuation of the first tubular handling tool in response to an electronic signal received from the sensor. The electronic signal corresponds to an operational characteristic of the first tubular handling tool. The first tubular handling tool includes at least one of an elevator and a spider. The sensor includes at least one of a strain gauge, a load cell, a torque sub, a pressure transducer, and a potentiometer. The operational characteristic includes at least one of a load that is supported by the first tubular handing tool, a pressure that is supplied to the first tubular handling tool, and a position of the first tubular handling tool. The controller includes at least one of a programmable logic controller and an electronic processing unit. The system further comprises an electronic manifold coupled to the first tubular handling tool for directing the electronic signal from the sensor to the controller. The system further comprises an electronically controlled valve that is actuatable by the controller to prevent or allow pressurized fluid to or from the first tubular handling tool. The system further comprises a second tubular handling tool, and a second sensor that is in communication with the controller, wherein the controller is configured to prevent or allow actuation of the second tubular handling tool in response to an electronic signal received from the second sensor that corresponds to an operational characteristic of the second tubular handling tool. The system further comprises a second electronically controlled valve that is actuatable by the controller to prevent or allow pressurized fluid to or from the second tubular handling tool. The system further comprises a remote control in communication with the controller that is configured to receive data from the controller corresponding to the operational characteristic of the first tubular handling tool.
In one embodiment, an electronic control system comprises a first tubular handling tool; a second tubular handling tool; and an electronic interlock system operable to control actuation of the first and second tubular handling tools. The electronic interlock system includes a first sensor coupled to the first tubular handling tool, a second sensor coupled to the second tubular handling tool, and a controller in communication with the first and second sensors. The sensors are configured to send an electronic signal to the controller that corresponds to an operational characteristic of the tubular handling tools. The controller is configured to actuate a valve to prevent or allow pressurized fluid to or from the tubular handling tools in response to the operational characteristics. The operational characteristics include at least one of a load that is supported by the tubular handing tools, a pressure that is supplied to the tubular handling tools, and a position of the tubular handling tools. The sensors include at least one of a strain gauge, a load cell, a torque sub, a pressure transducer, and a potentiometer. The first tubular handling tool is an elevator and the second tubular handling tool is a spider.
In one embodiment, a method of controlling a tubular handling tool comprises measuring an operational characteristic of the tubular handling tool; communicating the operational characteristic to a controller in the form of an electronic signal; and using the controller to control actuation of the tubular handling tool in response to the measured operational characteristic. The method further comprises sending an electronic signal to a valve to actuate the valve and thereby supply or release fluid pressure to the tubular handling tool. The method further comprises actuating the tubular handling tool by actuating an electronically controlled valve with the controller.
In one embodiment, a tubular handling system comprises a tubular handling tool having a sensor configured to measure an operational characteristic of the tubular handling tool; an electronic control system in communication with the sensor; and a rig winch system in communication with the electronic control system, wherein the rig winch system is operable to raise or lower the tubular handing tool in response to the operational characteristic measured by the sensor and communicated to the electronic control system.
In one embodiment, a tubular handling system comprises an actuation assembly; a gripping tool coupled to the actuation assembly such that the actuation assembly is operable to actuate the gripping tool; a first sensor coupled to the actuation assembly; and an identification device. The first sensor is operable to communicate with the identification device and transmit a signal to an electronic control system corresponding to information regarding the gripping tool. The electronic control system is operable to actuate the actuation assembly to actuate the gripping tool in response to the information.
In one embodiment, a tubular handling system comprises a tubular handling tool having a sensor configured to measure a position of a bail assembly of the tubular handling tool; and an electronic control system in communication with the sensor, wherein the electronic control system is operable to actuate the bail assembly in response to a position measurement that is sent to the electronic control system from the sensor.
In one embodiment, a method of controlling a tubular handling system comprises measuring an operational position of at least one of a gripping assembly, a compensation assembly, and a bail assembly of a tubular handling tool; communicating the operational position to an electronic control system in the form of an electronic signal; and controlling the actuation of at least one of the gripping assembly, the compensation assembly, and the bail assembly using the electronic control system in response to the operational position.
In one embodiment, an electronic control system comprises a first tubular handling tool; a second tubular handling tool; a sensor coupled to the first tubular handling tool; and a controller in communication with the sensor, wherein the controller is configured to control actuation of the second tubular handling tool in response to an electronic signal received from the sensor that corresponds to an operational characteristic of the first tubular handling tool.
So that the manner in which the above recited features of the invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
The electronic control system 10 includes a controller 40, such as a programmable logic controller or other electronic processing unit, having a processing unit, a memory, a mass storage device, an input/output control, a power supply, and/or a display unit, that is in communication with one or more sensors 27, 28, 29 attached to the first tubular handling tool 20. The sensors 27, 28, 29 may send one or more electronic signals via wired or wireless communication to the controller 40, the signals corresponding to measured operational characteristics of the first tubular handling tool 20. Similarly, one or more sensors 37, 38, 39 attached to the second tubular handling tool 30 may send electronic signals via wired or wireless communication to the controller 40 regarding the operation of the second tubular handling tool 30. The controller 40 is configured to prevent or allow opening and closing of the tubular handling tools 20, 30 depending on their operational status as measured by the sensors. In particular, the controller 40 is configured to analyze, process, and/or compare the signals received from the sensors to each other and/or to one or more pre-programmed conditions to determine whether to enable actuation of or actuate the first and second tubular handling tools 20, 30. An operator 5 may initiate actuation of the tubular handing tools 20, 30 via the controller 40. The operator 5 may be a person, another controller, or an electronic signal that is sent to the controller 40 from another device, such as a computer. The controller 40 may override, ignore, or follow the operator's command if certain pre-programmed conditions are or are not met, and/or if the controller 40 is receiving signals from the sensors that are or are not in accordance with certain pre-determined conditions with respect to the operational status of the tubular handling tools 20, 30. The controller 40 may be operable to provide an indication that operator's command was overridden, ignored, or followed. The indication may be in the form of an auditory or visual alarm, or an electronic signal, such as a message on a display screen. The electronic control system 10 may thus function as an electronic interlock system between the tubular handling tools 20, 30 as further described herein.
The electronic control system 10 may include first and second valves 45, 47, such as solenoid valves, for directing the supply and release of fluid pressure to and from the tubular handling tools 20, 30. A fluid pressure source 60, such as a hydraulic power unit or an air supply, may be coupled to the valves 45, 47 by a fluid line 41 to supply pressurized fluid to the tubular handling tools 20, 30. Another fluid line 43 may be provided to release fluid pressure from the tools via valves 45, 47. Fluid line 43 also may be coupled to the fluid pressure source 60 to return the fluid to the source and/or to release the fluid pressure from the fluid line 43 into the atmosphere. The controller 40 may send an electronic signal to the valves 45, 47 to actuate the valves into open and closed positions. Optionally, the controller 40 may send an electronic signal to the fluid pressure source 60 to control operation of the supply and return of pressurized fluid to the tubular handling tools 20, 30.
The first valve 45 is configured to selectively direct fluid from the fluid line 41 to one of the fluid lines 42, 44 to supply pressurized fluid to one of chambers 25, 26 of the piston/cylinder assembly 21, to thereby actuate the gripping assembly 22 of the first tubular handling tool 20 to grip or release tubular 15a. Simultaneously, pressurized fluid is released from the other one of chambers 25, 26 of the piston/cylinder assembly 21 through the other one of the fluid lines 42, 44 and is directed to the fluid line 43 via the first valve 45 to release or exhaust the pressurized fluid. An electronic signal is sent from the controller 40 to the first valve 45 to actuate the first valve 45 to connect fluid line 41 with one of fluid lines 42, 44 (and thus connect fluid line 43 with the other one of fluid lines 42, 44) depending on whether the tubular handling tool 20 is to be opened or closed, to release or grip the tubular 15a. In addition, the controller 40 may send an electronic signal to actuate the first valve 45 to prevent any fluid communication between fluid lines 41, 43 and fluid lines 42, 44. The second valve 47 is operable in the same manner as the first valve 45, with respect to the second tubular handling tool 30. The controller 40 may open or close one or more of the tubular handling tools 20, 30. The operator 5 communicates with the controller 40 to operate the tubular handling tools 20, 30, but the controller 40 electronically controls or determines whether to actuate the tubular handling tools 20, 30 in response to signals received from the sensors and/or one or more pre-programmed conditions. The controller 40 may also control at which time to actuate the tubular handling tools 20, 30.
To determine whether to open or close, or prevent opening or closing, of either of the tubular handling tools 20, 30, the controller 40 receives one or more electronic signals from the sensors 27, 28, 29 and 37, 38, 39, corresponding to the operational status of the tubular handling tools 20, 30. The controller 40 may analyze, process, and/or compare the signals received from the sensors to each other and/or to one or more pre-programmed conditions to determine whether to enable actuation of or actuate the tubular handling tools 20, 30. The controller 40 may continuously monitor the sensors and the signals received from the sensors to track the operational status of the tubular handling tools 20, 30 throughout a tubular handling procedure. Based on the operational status of the tubular handling tools 20, 30 as computed by the controller 40, the controller 40 may automatically and/or upon initiation by the operator 5 control actuation of the tubular handling tools 20, 30 to prevent inadvertent mishandling of a tubular or tubular string.
In one embodiment, the sensors 27, 37 may send a signal corresponding to the load being borne by the tubular handling tools 20, 30 or the gripping assemblies 22, 32, thereby indicating whether the tools are supporting at least a portion of the weight of a tubular or tubular sting. The measured load may correspond to the weight of the tubular or tubular string. In one embodiment, the sensors 27, 37 may include strain gauges, compression and tension load cells, a torque sub, and/or other similar load measuring devices. In one embodiment, the sensor 27 may include a torque sub connected between the tubular handling tool 20 and the top drive system that is used to rotate the tool 20. An example of a torque sub that may be used with the embodiments described herein is illustrated in
In one embodiment, the sensors 28, 38 may send a signal corresponding to the clamping pressure of the piston/cylinder assemblies 21, 31, thereby indicating whether the gripping assemblies 22, 32 are being forced into a closed (gripping) position. In one embodiment, the sensors 28, 38 may measure the pressure in either of the chambers 25, 26 and 35, 36 of the piston/cylinder assemblies 21, 31. A high pressure measurement in one chamber and a lower pressure measurement in the opposite chamber may indicate the position of the gripping assemblies 22, 32. In one embodiment, the sensors 28, 38 may include pressure transducers or pressure switches.
In one embodiment, the sensors 29, 39 may send a signal corresponding to the position of the gripping assemblies 22, 32, thereby indicating whether the tubular handling tools 20, 30 are in an open (release) position or are in a closed (gripping) position. In one embodiment, the sensors 29, 39 may measure the stroke of the piston/cylinder assemblies 21, 31, and/or the stroke of the gripping assemblies 22, 32 to indicate whether the tools 20, 30 are in the open or closed position. In one embodiment, the sensors 29, 39 may measure position, displacement, and/or proximity. In one embodiment, the sensors 29, 39 may include one or more linear transducers, such as potentiometric, ultrasonic, magnetic, inductive, laser, optical, and/or (absolute/incremental) encoder-type sensors. Other similar sensing devices, such as proximity sensors, may be used to measure the stroke, position, displacement, and/or proximity of the piston/cylinder assemblies and/or the gripping assemblies to indicate whether the handling tools 20, 30, 80 are in the open or closed position.
In one embodiment, a first sensor may be used to measure the position of the gripping assembly 22, 32 of the tubular handling tool 20, 30 to determine whether the gripping assembly 22, 32 is away from or in contact with a tubular or tubular string. A second sensor may be used to measure the gripping force or pressure being applied to the tubular or tubular string by the gripping assembly 22, 32. A third sensor may be used to measure the weight being borne by the tubular handling tool 20, 30. The combination of the first, second, and third sensor measurements may provide a confirmation that the tubular handling tool 20, 30 is gripping and supporting the tubular or tubular string. The first, second, and third sensors may be any one of the sensors described herein.
In one embodiment, the controller 40 may be in communication with a sensor 51 from a hook load measuring system 50. The measuring system 50 may be attached to a crane, pulley, and/or drawworks system that raises and lowers the tubular handling tool 20. The sensor 51 may send a signal to the controller 40 that indicates the load or weight supported by the tubular handling tool 20, to determine whether the tool is supporting a tubular or tubular string.
In one embodiment, other electronic signals corresponding to the weight measurement of a tubular or tubular string may be generated by other external or third party rig systems, such as a top drive system, a power tong system, or other tubular handling devices, and communicated to the controller 40 to control operation of the tubular handling tools 20, 30. In one embodiment, other electronic signals corresponding to the open and/or closed positions of the tubular handling tools 20, 30 may be generated by other external or third party rig systems and communicated to the controller 40 to control operation of the tools 20, 30. In one embodiment, one or more control lines may be attached to the tubular string while the string is being run into the well. The controller 40 may be in communication with a control line guide assembly of the tubular handling tools 20, 30, or other tubular running device, for protecting the one or more control lines from damage by the gripping assemblies of the tools 20, 30. An example of a control line guide assembly is illustrated in
In response to one or more of the electronic signals received from the various sensors and/or the operational command by the operator 5, the controller 40 may thus function as an electronic interlock to prevent opening or closing of either of the tubular handling tools 20, 30 and thereby prevent inadvertent dropping or mishandling of tubulars. In one embodiment, the controller 40 may prevent opening (e.g. release of pressure and/or pressurization) of either piston/cylinder assemblies 21, 31 if it is receiving a signal that either of the tubular handling tools 20, 30 are in a closed position, are supporting a load that corresponds to the weight of a tubular, are actuated into the closed position, and/or are otherwise gripping and supporting a tubular or tubular string, while the other tool is not supporting the same. In one embodiment, the controller 40 will only allow the first tubular handling tool 20 to open or release when the tubular or tubular string weight is supported by the second tubular handling tool 30. In one embodiment, the controller 40 will only allow the second tubular handling tool 30 to open or release when the tubular or tubular string weight is supported by the first tubular handling tool 20.
In one embodiment, the controller 40 may be configured to prevent or allow actuation of the tubular handling tools 20, 30 only when it receives an electronic signal corresponding to a particular operational state of either tool 20, 30 from at least one of the sensors, at least two of the sensors, or each one of the sensors on either tool 20, 30. In one embodiment, the controller 40 may be configured to prioritize the signals received from each sensor to determine whether to prevent or allow actuation of the tubular handling tools 20, 30. In one embodiment, the controller 40 may be configured to prioritize the data received from one or more of the sensors. Alternatively, the controller 40 may be configured to give equal priority to the data from two or more of the sensors. The prioritization or equal prioritization may be from the sensors of one or both tools 20, 30. For example, if both tools 20, 30 are closed around the tubular string, and it is desired to open the spider, priority may be give to the data from the sensors associated with the elevator which measure string weight. In one embodiment, the electronic control system 10 may include a manual override feature to manually override the controller 40 at any time during a tubular handling operation to allow the operator 5 to directly actuate the tubular handling tools 20, 30 into an open or closed position.
In one embodiment, the controller 40 may be configured to prevent or allow actuation of the tubular handling tools 20, 30 when it receives a signal that corresponds to a measurement within a pre-determined operational range. The controller 40 may be pre-programmed with acceptable sensor data ranges according to the equipment being used and the tubulars being handled. In one embodiment, a signal corresponding to a load and/or pressure measurement may be within a pre-determined load and/or pressure range for the controller 40 to prevent or allow actuation of the tubular handling tools 20, 30. In one embodiment, a signal corresponding to a position of the piston/cylinder assembly may be within a pre-determined range of distance for the controller 40 to prevent or allow actuation of the tubular handling tools 20, 30. In one embodiment, the controller 40 may be pre-programmed with acceptable positions or ranges of positions of the gripping (slip) assembly. Upon receiving a signal corresponding to the position of the gripping assembly from the sensors, the controller 40 may compare the measured position to the pre-programmed acceptable positions to determine whether to prevent or allow actuation of the tools 20, 30. In one embodiment, the controller 40 may be pre-programmed with acceptable values or ranges of values for comparison with the data received from the sensors.
In one embodiment, the electronic control system 10 may be configured as an electronic interlock system for only one of the tubular handling tools 20, 30. The system 10 may include the first or second tubular handling tool 20, 30, the controller 40, and at least one sensor (e.g. sensors 27, 28, 29, 37, 38, 39). The controller 40 may actuate either valve 45, 47 (depending on the tool being controlled) to prevent or allow actuation of the tool based upon the signal received from the sensor. In one embodiment, the electronic control system 10 may be configured as an electronic interlock system for only one of the tubular handling tools 20, 30 but may receive measured data from sensors on both tubular handling tools 20, 30. In one embodiment, one of the tubular handling tools 20, 30 may be manually operated, while the other tool is interlocked by the controller 40. The operational status of one of the tools 20, 30 may be manually input into the controller 40, while the status of the other tool is measured by the sensors.
In one embodiment, a method of operation of the electronic control system 10 may begin with the first tubular handling tool 20 supporting a first tubular, a corresponding load measurement of which is sent to the controller 40 via one or more sensors described above. The first tubular handling tool 20 may be used to lower the first tubular into the second tubular handling tool 30. The operator 5 may communicate to the controller 40 to actuate the second tubular handling tool 30, and thereafter actuate the first tubular handling tool 20 to transfer the first tubular from the first to the second tubular handling tool 30. The controller 40 may actuate the second tubular handling tool 30 to grip the first tubular, while preventing release of the first tubular by the first tubular handling tool 20. The first tubular handling tool 20 may then be lowered until the measured load indicates that the weight of the first tubular is being supported by the second tubular handing tool 30 and/or is not being supported by the first tubular handling tool 20. The controller 40 may then actuate the first valve 45 to allow actuation of the first tubular handling tool 20 into an open position to release the first tubular. The controller 40 may also prevent actuation of the second tubular handling tool 30 because the controller 40 is receiving signals corresponding to the weight of the first tubular being supported by the tool 30. The first tubular handling tool 20 may then engage a second tubular and support it above the first tubular, which is held by the second tubular handling tool 30. The load measurement of the second tubular is sent to the controller 40 to prevent inadvertent opening of the first tubular handling tool 20. The first and second tubulars may be joined by rotation of at least one of the tubulars via a top drive, a power tong assembly, and/or the tubular handling tools 20, 30. After the tubulars are joined to form a tubular string, the first tubular handling tool 20 may be raised to lift the tubular string. When the measured weight of the tubular string is signaled to the controller 40 as being supported by the first tubular handling tool 20 and/or upon the command of the operator 5, the controller 40 may then actuate the second valve 47 to allow actuation of the second tubular handling tool 20 into an open position to release the tubular string. The first tubular handling tool 20 may then lower the tubular string through the second tubular handling tool 30, and the controller 40 may allow actuation of the second tubular handling tool 30 to grip the tubular string, while preventing inadvertent release of the tubular string by the first tubular handling tool 20. The first tubular handing tool 20 may then release the tubular string as stated above, and move to engage a third tubular. This process may be repeated to make up the tubular string, and may be reversed to break out the tubular string.
In one embodiment, one or more sensors may be attached to the piston/cylinder assembly of the first tubular handling tool 120. The sensors are in communication with an electronic manifold 124, such as a junction box, that is also attached to the first tubular handling tool 120. The electronic manifold 124 sends electronic signals received from the sensors to a controller 142 (also illustrated in
The controller 142 is supported in a housing 141 that may be positioned on the rig floor 163 adjacent to the tubular handling tools 120, 130 or at any other convenient location. As stated above, the controller 142 receives electronic signals from the sensors attached to the tools 120, 130. The controller 142 is programmed to process the data received from the electronic signals and determine whether to prevent or allow actuation of the tubular handling tools 120, 130 during a tubular handling operation. In this manner, the controller 142 can automatically prevent inadvertent opening and/or closing of either tubular handling tool 120, 130.
An operator remote control 170 may be provided so that an operator may communicate with the controller 142 via a wired or wireless connection, radio frequency for example. The operator remote control 170 may be configured to retrieve and display the data sent to the controller 142 by the sensors. The operator remote control 170 may also be configured to program the controller 142 with one or more tubular handling operation parameters so that the controller 142 can automatically control the tubular handling tools 120, 130 as necessary during the tubular handling operations.
A driller remote control 180 may also be provided so that an operator or driller may communicate with the controller 142 via a wired or wireless connection, radio frequency for example. The driller remote control 180 may be configured to retrieve and display the data sent to the controller 142 by the sensors. The driller remote control 180 may be used to confirm and track the positions and operations of the tubular handing tools 120, 130 so that the operator or driller may operate the top drive, rig winch, and other components on the rig to conduct the tubular handling operations.
A logging system 150 may be provided to communicate with the controller 142 via a wired or wireless connection. The logging system 150 may be configured to retrieve, analyze, compare, display, and store the data sent to the controller 142 by the sensors. The logging system 150 may log the actions of the tubular handing tools 120, 130 for each tubular handling operation. In one embodiment, the logging system 150 may be integrated with the controller 142. In one embodiment, the logging system 150 and/or the controller 142 may be configured to record data for the make up and break out of each tubular connection. The recorded data can be used for post-job evaluation and system diagnostic purposes.
The electronic manifold 124 may be powered by a power source 143 that is disposed within the housing 141 of the control assembly 140. The power source 143 may also provide power to the other components of the assembly, including the controller 142, the module 148, a network switch 144, and a receiver 149. The components of the electronic manifold 124 and the control system 140 may be intrinsically safe and/or stored in explosion/flame proof housings to prevent sparks or any type of energy release that can cause an ignition.
One or more sensors 138 may be attached to the second tubular handling tool 130, and may also communicate with the module 148 via wired or wireless communication to send electronic signals to the controller 142. The sensors 138 may be arranged to measure the load in the second tubular handling tool 130, and/or the position of a gripping assembly and a piston/cylinder assembly of the second tubular handling tool 130. The sensors 138 and the second tubular handling tool 130 may be the same type of sensors (e.g. 37, 38, 39) and tools (e.g. 30) as discussed above.
An operator may initiate operation of either tubular handling tool 120, 130 via the controller 142 during a tubular handling operation. However, based on the measurements received from the sensors 127, 128, 138, the controller 142 is programmed to determine whether to actuate the first and second tubular handling tools 120, 130, such as by preventing or allowing the supply/return of pressurized fluid to and from the first and second tubular handling tools 120, 130. In particular, the controller 142 may send an electronic signal to a first valve 145, via a valve drive 122 of the electronic manifold 124, to thereby open or close the first valve 145. In one embodiment, the first valve 145 may include a valve block and one or more solenoid valves arranged to open and close fluid communication to various components of the tool 120, such as the piston/cylinder assembly. The first valve 145 may open or close one or more fluid lines connected to the first tubular handling tool 120 to thereby actuate the tool to grip or release a tubular. Depending on the position of the valve 145, pressurized fluid may be supplied to and/or returned from the first tubular handling tool 120 to actuate it into an open or closed position. Similarly, the controller 142 may send an electronic signal to a second valve 147, via module 148, to thereby open or close the second valve 147. In one embodiment, the second valve 147 may include a valve block and one or more solenoid valves arranged to open and close fluid communication to various components of the tool 130, such as the piston/cylinder assembly. The second valve 147 may open and/or close one or more fluid lines connected to the second tubular handling tool 130 to thereby actuate the tool to grip or release a tubular. Depending on the position of the valve 147, pressurized fluid may be supplied to and/or returned from the second tubular handling tool 130 to actuate it into an open and closed position. The controller 142 operates as an electronic interlock to prevent the inadvertent opening and closing of either tubular handling tool 120, 130 based on the measured operational characteristics of the tools by the sensors.
Pressurized fluid may be supplied to the tubular handling tools 120, 130 from a fluid pressure source, such as fluid pressure source 160 shown in
The operator remote control 170 and the driller's remote control 180 may each be provided to allow the operator to communicate with the control assembly 140, and allow the control assembly 140 to communicate with the operator, via wired or wireless communication 171. The remote controls 170, 180 may be configured to retrieve and display the information sent to the controller 142 by the sensors. In one embodiment, the operator remote control 170 may also be configured to send data to and program the controller 142 with one or more tubular handling operation parameters so that the controller 142 can automatically control operation of the tubular handling tools 120, 130. In one embodiment, a driller may use the driller's remote control 180 to confirm and track the positions and operations of the tubular handing tools 120, 130 so that the driller may operate the top drive, rig winch, and other components on the rig to conduct the tubular handling operations. The remote controls 170, 180 may communicate with the control assembly 140 using the network switch 144, the receiver 149, and/or other communication methods known in the art.
For example, an operator may send a signal to the controller 142 with the remote control 170 to open the main valve 165 to actuate the first and/or second tubular handling tools 120, 130. However, based on the measured signals received from the sensors 127, 128, 138, the controller 142 may be programmed to prevent or allow the flow of pressurized fluid to and/or from the tubular handling tools 120, 130 via the first and second valves 145, 147 to prevent mishandling or dropping of a tubular or tubular string. If the operator initiates opening of the first tubular handing tool 120 manually or remotely, via the operator remote control 170 for example, and the controller 142 is receiving signals from the sensors 127, 128, 138 that the first tubular handling tool 120 is supporting a weight corresponding to the tubular or tubular string, and that the second tubular handling tool 130 is not supporting any load or is in an open position, then the controller 142 would actuate or maintain the first valve 145 to prevent supply or return of fluid with the first tubular handling tool 120. The driller may use the driller's remote control 180 to confirm whether the tubular handling tools 120, 130 are in an open or closed position prior to initiating another action, such as rotating, raising, and/or lowering the first tubular handling tool 120.
Optionally, one or more logging systems 150 may be provided to communicate with the control system 140 via wired or wireless communication 172 to retrieve, analyze, compare, display, and store the information sent to the controller 142 by the sensors. The logging systems 150 may log the actions of the tubular handing tools 120, 130 for each tubular handling operation, such as the loads supported by the tools, the operational status of the tools, the torque applied to the tools and the tubulars, etc. The actions are measured by one or more sensors connected to the tools 120, 130 or connected to other rig components that can be used to measure the various operational characteristics. Each of the sensors may be in communication with the control system 140.
In one embodiment, the control system 140 may be configured to communicate with a top drive system that is used to support (e.g. secure, rotate, raise, lower) the first tubular handling tool 120. Information relating to the operational status of the tubular handling tools 120, 130 may be communicated between the control system 140 and the top drive system via wired or wireless communication 173. The controller 142 may use electronic signals received from the top drive system that correspond to the load supported by the top drive system, the rotational state (speed and/or torque) of the top drive system, and/or the height of the top drive system relative to the tools 120, 130 and the rig floor, to prevent or allow opening and/or closing of the tools 120, 130 to prevent inadvertent mishandling of a tubular or tubular string. In one embodiment, the controller 142 may be used to control the top drive system, such as by preventing, allowing, or initiating operation of the top drive system. In one embodiment, the remote controls 170, 180 may be used to control the top drive system via the control system 140.
The tubular handling system 1000 may be adapted for interchangeable and/or modular use, as shown in
In operation, the modular aspect of the tubular handling system 1000 allows for quick and easy accommodation of any size tubular without the need for removing the tubular handling system 1000 and/or the drive mechanism. Thus, the external modular gripping tool 1080, shown in
In one embodiment, one or more sensors, such as sensors 27, 28, 29, 98, 99A-B, 128, 150, etc., are attached to the piston/cylinder assemblies 1035 of the compensation assembly 1030 to measure the position and/or operating pressure of the assemblies. The sensors may be in communication with an electronic control system, such as electronic control systems 10, 100, via the electronic manifold 1124, such as electronic manifold 124 (each described above) that is coupled to the tubular handling system 1000. The sensors may send a signal corresponding to the position or amount of stroke of the piston/cylinder assemblies 1035. The load measuring device 1015 may also be in communication with the electronic control system via the electronic manifold 1124, and may send a signal corresponding to a load generated in the drive shaft 1010 during a tubular handling operation. Based on the position or amount of stroke of the piston/cylinder assemblies 1035 and/or the load in the drive shaft 1010, the electronic control system may actuate an electronically controlled valve (such as valves 45, 47, 49 described above with respect to
In one embodiment, the tubular handling system 1000 may be used to connect a tubular to a tubular string that is being supported by another tubular handling tool, such as a spider. The load measuring device 1015 may send a signal to the electronic control system to indicate that the tubular handling system 1000 is supporting the weight of the system 1000 only and is not supporting the weight of a tubular. Based on the load information, the electronic control system may allow actuation of the piston/cylinder assemblies 1035 to a fully extended position. The sensors on the piston/cylinder assemblies 1035 may send a signal to the electronic control system to indicate that the assemblies 1035 are in the fully extended position. The bail assembly 1040 may be used to grip a tubular, which may then be lifted to a position above the tubular string. The tubular may be set on the tubular string, and the tubular handling system 1000 may be lowered until the upper end of the tubular engages the gripping tool of the tubular handling system 1000.
The tubular handling system 1000 may be lowered further until the piston/cylinder assemblies 1035 are driven in to a retracted position, such as to a mid-stroke position of the piston/cylinder assemblies 1035. The sensors on the piston/cylinder assemblies 1035 may send a signal to the electronic control system to indicate that the assemblies 1035 are in the retracted position. Based on the piston/cylinder assembly 1035 position, the electronic control system may allow actuation of the gripping assembly 1040 and/or the top drive to grip and rotate the tubular to make the connection to the tubular string. The piston/cylinder assemblies 1035 may extend automatically to allow the gripping tool to move relative to the tubular handling system 1000 and/or the top drive to compensate for the thread makeup between the tubular and the tubular string. The sensors on the piston/cylinder assemblies 1035 may be used to monitor the position of the assemblies 1035 to ensure that they do not reach the fully extended position prior to completion of the tubular connection. The load measuring device 1015 may also be used to monitor the load in the tubular handling system 1000 during the tubular makeup operation to indicate any unexpected change in the load that may potentially harm the tubular connection and/or the tubular handling system 1000 and top drive.
In one embodiment, one or more sensors, such as sensors 27, 28, 29, 98, 99A-B, 128, 1050, etc. may be attached to piston/cylinder assemblies 1045 of the bail assembly 1040. The sensors may be in communication with the electronic control system, such as systems 10, 100, to communicate the (angular) position of bails 1047 relative to the tubular handling system 1000. In one embodiment, the fully retracted position of the piston/cylinder assemblies 1045 as measured by the sensors may indicate that the bails 1047 are substantially parallel to the longitudinal axis of the tubular handling system 1000. In one embodiment, the partially or fully extended position of the piston/cylinder assemblies 1045 as measured by the sensors may indicate that the bails 1047 are positioned at an angle relative to the longitudinal axis of the tubular handling system 1000. In one embodiment, one or more sensors may be used to measure an angular position of the bails 1047 relative to a specific reference axis, such as the horizontal axis, the vertical axis, and/or the longitudinal axis of the tubular handling system 1000 or one or more components of the tubular handling system 1000. One or more sensors, such as a laser/position sensor, may also be attached to the tubular handling system 1000 to measure the distance or height of the tubular handling system 1000 relative to another tubular handling system, such as a spider, and/or the rig floor. Based on the position of the bails 1047 and the location of the tubular handling system 1000 as measured by the sensors, the electronic control system is configured to actuate an electronically controlled valve (such as valves 45, 47, 49 described above with respect to
The sensors 1260 are also in communication with the electronic control system, such as systems 10, 100, via the electronic manifold 1124. One or more sensors 1270, such as sensors 27, 28, 29, 98, 99A-B, 128, 1050, etc. are attached to the piston/cylinder assemblies 1025 of the tubular handling system 1000. The sensors 1260, 1270 communicate with the electronic control system 10, 100 via the electronic manifold 1124 to send information regarding the specific gripping tool 1200A-C being used and the position or amount of stroke the piston/cylinder assemblies 1025 should be operated to properly engage and disengage a specific tubular size. Based on the information from the sensors 1260, 1270, the electronic control system 10, 100 is configured to actuate an electronically controlled valve (such as valves 45, 47, 49 described above with respect to
Fluid may be supplied to the valve assemblies of the hydraulic manifold 1060 by fluid (hydraulic and/or pneumatic) source 160 via a fluid manifold 161, which also supplies fluid to tubular handling system 130. Control lines 1565, 1570, 1575, 1580, 1585 may be provided to direct fluid to the tubular handling system 130 during use with the tubular handling system 1000. In particular, control lines 1565, 1570, 1575 may be used to supply pneumatic and/or hydraulic fluid to actuate the tubular handling system 130 into an open and closed position. Control lines 1580, 1585 may be used to communicate a pneumatic and/or hydraulic pressure signal corresponding to the position of the tubular handling system 130 to indicate whether the system 130 is clamping or engaging a tubular. One or more sensors 1555, 1560, such as pressure sensors or switches, may be operable to measure the pneumatic and/or hydraulic pressure signals and communicate the pressure measurements to the electronic control system 100. The electronic control system 100 may open and close one or more electronically controlled valves 1550 to thereby actuate the tubular handling system 130. Valve 1540 may be provided to manually override the interlock function of the electronic control system 100 by closing fluid communication to the hydraulic manifold 1060 and opening fluid communication directly to one or more of the tubular handling system 1000 components. Valve 1545 may be provided to control (open and close) fluid supply from the fluid source 160 to both tubular handling systems 130, 1000.
An operator 5 may use the electronic control system 100 to operate the tubular handling systems 130, 1000. During operation, the electronic control system 100 receives electronic signals corresponding to pressure measurements from the various sensors, which indicate one or more operational characteristics of the tubular handling system 130, 1000 components. Based on the operational characteristic of either tubular handling system 130, 1000, the electronic control system 100 is programmed to function as an electronic interlock by automatically preventing or allowing actuation of the tubular handling systems 130, 1000 to prevent inadvertent handling of a tubular or tubular string.
While the foregoing is directed to embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
This application claims the benefit of U.S. Provisional Application No. 61/424,575, filed Dec. 17, 2010, and U.S. Provisional Application No. 61/516,609, filed Apr. 5, 2011, each application of which is herein incorporated by reference in its entirety.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4545017 | Richardson | Oct 1985 | A |
| 4604724 | Shaginian et al. | Aug 1986 | A |
| 4676312 | Mosing et al. | Jun 1987 | A |
| 4800968 | Shaw et al. | Jan 1989 | A |
| 4875530 | Frink et al. | Oct 1989 | A |
| 5736938 | Ruthroff | Apr 1998 | A |
| 5791410 | Castille et al. | Aug 1998 | A |
| 5909768 | Castille et al. | Jun 1999 | A |
| 6626238 | Hooper | Sep 2003 | B2 |
| 6742596 | Haugen | Jun 2004 | B2 |
| 6845825 | Bischel et al. | Jan 2005 | B2 |
| 6968895 | Mosing et al. | Nov 2005 | B2 |
| 7073598 | Haugen | Jul 2006 | B2 |
| 7182133 | Webre et al. | Feb 2007 | B2 |
| 7322406 | Wiggins et al. | Jan 2008 | B2 |
| 7874352 | Odell, II et al. | Jan 2011 | B2 |
| 8051909 | Angelle et al. | Nov 2011 | B2 |
| 8733454 | Bouligny et al. | May 2014 | B2 |
| 20050247483 | Koch et al. | Nov 2005 | A1 |
| 20050269104 | Folk et al. | Dec 2005 | A1 |
| 20060011350 | Wiggins et al. | Jan 2006 | A1 |
| 20060108113 | Scott et al. | May 2006 | A1 |
| 20060191690 | Severin et al. | Aug 2006 | A1 |
| 20070017682 | Abrahamsen et al. | Jan 2007 | A1 |
| 20070124220 | Griggs et al. | May 2007 | A1 |
| 20070131416 | Odell, II et al. | Jun 2007 | A1 |
| 20080149326 | Angelle et al. | Jun 2008 | A1 |
| 20080173480 | Annaiyappa et al. | Jul 2008 | A1 |
| 20080264648 | Pietras et al. | Oct 2008 | A1 |
| 20090151934 | Heidecke et al. | Jun 2009 | A1 |
| 20090272542 | Begnaud et al. | Nov 2009 | A1 |
| 20090274545 | Liess et al. | Nov 2009 | A1 |
| 20100193198 | Murray et al. | Aug 2010 | A1 |
| 20100270033 | Angelle et al. | Oct 2010 | A1 |
| 20110017474 | Pietras et al. | Jan 2011 | A1 |
| 20110226486 | Haugen | Sep 2011 | A1 |
| Number | Date | Country |
|---|---|---|
| 1426550 | Jun 2004 | EP |
| 1 808 568 | Jul 2007 | EP |
| 9831914 | Jul 1998 | WO |
| 0052297 | Sep 2000 | WO |
| 0052297 | Sep 2000 | WO |
| 0236927 | May 2002 | WO |
| 2004090279 | Oct 2004 | WO |
| 2004090279 | Oct 2004 | WO |
| 2005121493 | Dec 2005 | WO |
| 2005121493 | Dec 2005 | WO |
| Entry |
|---|
| Extended European Search Report for Application No. 11157091.7-1605 / 2322756 dated Apr. 9, 2014. |
| Extended European Search Report for Application No. 11157094.1-1605 / 2322755 dated Apr. 9, 2014. |
| PCT Search Report and Written Opinion for International Application No. PCT/US2011/065218 dated Jun. 24, 2013. |
| EPO Examination Report dated Apr. 20, 2015, for European Patent Application No. 11805345.3. |
| EPO Examination Report dated Jan. 28, 2016, for EPO Patent Application No. 11805345.3. |
| Canadian Office Action dated Feb. 1, 2016, for Canadian Patent Application No. 2,819,155. |
| Number | Date | Country | |
|---|---|---|---|
| 20120152530 A1 | Jun 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| 61424575 | Dec 2010 | US | |
| 61516609 | Apr 2011 | US |
