Patent Grant
7370707
1. Field of the Invention
The present invention relates to methods and apparatus of handling tubulars in and around a wellbore. More particularly, the invention relates to methods and apparatus to facilitate the formation of tubular strings. More particularly still, the invention relates to apparatus and methods for remote controlling the tubular connection process. More particularly still, the invention relates to methods and apparatus for supporting a string of tubular riser for use between an offshore oil and gas platform and the ocean floor.
2. Description of the Related Art
Wells are drilled and produced using strings of tubular that are threaded together. For example, wellbore are formed by disposing a drill bit at the end of a drill string. Due to the torsional forces present when rotating a bit at the end of the string that may be thousands of feet long, the connection in drill string include a shoulder that can be torqued to a certain value. Other tubulars that line a borehole or serve as a fluid path for production fluids have a simpler threaded connection that only has to be fluid tight.
With the advent of offshore drilling, a riser is commonly used to isolate drill string or production tubing from the ocean water. Riser is relatively large diameter tubing that extends between an offshore rig floor and a wellhead at the ocean floor. Because the well is sometimes in hundreds of feet of water, riser can be hundreds of feet long and must bend and sway with the ocean current and in some cases, with the movement and drift of a platform at the surface. In addition to its relatively large diameter, riser typically has a large upset portion at one end where it is threadedly connected to another piece of riser to form a string.
Due to its function of providing isolation between possible hazardous material and the ocean, it is desirable not to damage, scratch, or mar the outer surface of riser with tongs or other gripping devices that are typically used to date on a rig floor to connect sequential pieces of tubular pipe. For example, tubular strings are made today at a well site with the use of an elevator that can grasp a piece of tubular, lift it above the well center, and lower it into a threaded portion of another tubular extending from the well. Once the tubulars are connected, the elevator then lowers the entire string to a position where it can be grasped by another gripping apparatus known as a spider.
At any time, either the spider or the elevator or both must be able to retain the string. The prior art elevators and spiders necessarily grasp the outer diameter of the tubulars in order to retain them axially. The spiders and elevators often use a die to enhance their ability to grip the tubulars. However, the die tends to damage, scratch, or mar the outer surface of the tubular body. While the collateral damage to the outside of the tubulars is of little concern with liner or casing, it is often unacceptable with riser.
There is a need therefore, for a method and apparatus for handing tubulars at a well that does not result in damage to the outer surface of the tubulars. There is also a need for remotely controlling the tubular handling or connection process. There is a further need for a method and apparatus that permits the formation of tubular strings without utilizing the outer surface of the tubulars for axial retention.
Aspects of the present invention provide a tubular handling system for handling wellbore tubulars. In one aspect, the present invention provides a tubular handling system adapted to retain a tubular without damaging the outer surface of the tubular. In another aspect, the present invention provides a method of connecting tubulars by remotely controlling the connection process, including joint compensation, alignment, make up, and interlock.
In one embodiment, the tubular handling system comprises a first support member adapted to support a tubular utilizing a first portion of an upset of the tubular and a second support member adapted to support the tubular utilizing a second portion of the upset. In another embodiment, at least one of the first support member and the second support member is remotely controllable. In yet another embodiment, the first and second support members are adapted to support the tubular at the same time. Preferably, the tubular comprises a riser.
In another aspect, the tubular handling system further comprises a joint compensator.
In another aspect still, the tubular handling system further comprises a rotary seal adapted to provide communication between the first support member and a controller. The rotary seal allows a fluid to be transmitted to the first support member during rotation of the tubular.
In another aspect still, the tubular handling system further comprises a rotary table for supporting the second support member. Preferably, the rotary table is adapted to absorb a force experienced by the second support member. In one embodiment, the rotary table comprises a polyurethane layer. In another embodiment, the rotary table comprises one or more piston and cylinder assemblies. In another aspect, the rotary table is remotely controllable between an open position and a closed position.
In another aspect still, the tubular handling system further comprises an interlock system for ensuring the tubular is retained by at least one of the first support member and the second support member.
In another aspect still, the tubular handling system further comprises a tubular guide member for positioning the tubular. In one embodiment, the tubular guide member comprises a conveying member and a gripping member, wherein the conveying member moves the gripping member into engagement with the tubular.
In another aspect still, the tubular handling system further comprises a tong assembly for connecting the tubular with a second tubular.
In another aspect still, the tubular handling system further comprises a tong positioning device. In one embodiment, the tong positioning device comprises a single extendable beam having variable length. In another embodiment, the tong positioning device comprises a movable frame. In yet another embodiment, the tong positioning device comprises a flexible chain provided with compression members and a flexible locking chain.
In another aspect, the present invention provides a method of handling a tubular comprising supporting the tubular along a first portion of an upset using a first support member and supporting the tubular along a second portion of the upset using a second support member. In one embodiment, the method further comprises remotely controlling at least one of the first support member and the second support member. In another aspect, the method includes providing a fluid to first support member during rotation of the tubular.
In another embodiment, the method is used to connect the tubular to a second tubular. To connect the tubulars, the method may further comprise compensating for movement of the tubular during the connection. In another aspect, the method further comprises providing a rotary seal to provide communication between the first support member and a controller. The method may also comprise aligning the tubular with the second tubular using a tubular guide member. The tubulars may be aligned by recalling a memorized position of a previously aligned tubular.
In another aspect, the tubulars are connected by rotating the tubular relative to the second tubular using a tong assembly. The tong for rotating the tubular may be translated into position to connect the tubulars. The method also includes remotely operating the tong assembly.
In another aspect, the method includes absorbing a load experienced by the second support member. In one embodiment, the load is absorbed by the rotary table. The method also includes disposing the second support member on a rotary table. In another embodiment, the method includes remotely opening or closing the rotary table.
In another aspect still, the method of handling the tubular includes ensuring at least one of the first support member or the second support member is retaining the tubular.
In another aspect, the present invention provides a joint compensation system for a wellbore tubular. The joint compensation system includes a joint compensator; an elevator for retaining the tubular, the elevator coupled to the joint compensator; and a rotary seal operatively coupled to the elevator to provide communication between the elevator and a controller. In one embodiment, communication between the elevator and the controller comprises sending a fluid signal or an electric signal. In another embodiment, the rotary seal maintains communication between the elevator and the controller during rotation of the elevator. In yet another embodiment, the elevator is a side door elevator. In yet another embodiment, the elevator comprises a fluid operated piston and cylinder assembly.
In another aspect, the present invention provides a load absorbing table for a tubular gripping member comprising a load absorbing member disposed on a flat support member. In one embodiment, the load absorbing member comprises a polyurethane layer. In another embodiment, the table is movable between an open position and a closed position. In yet another embodiment, the load absorbing member comprises one or more piston and cylinder assemblies. Preferably, the one or more piston and cylinder assemblies are fluid operated. In another embodiment, the table is flush mounted. In yet another embodiment, the table is remotely operable. In yet another embodiment, the table is adapted to compensate for rig movement, thereby maintaining the flat support member in a substantially horizontal position.
So that the manner in which the above recited features of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof 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.
Aspects of the present invention provide a tubular handling system 100 for making up or breaking out tubulars. In one aspect, the tubular handling system 100 is adapted retain a tubular without damaging the outer surface of the tubular body. In another aspect, at least part of the tubular handling process is remotely controllable.
For clarity purposes, the tubular handling system will be described with respect to the make up process. However, it is understood that the system may also be used to break out tubulars. Additionally, although the make up process is described for a riser, the process is equally applicable to other types of wellbore tubulars such as casing, drill pipe, and tubing.
The tubular handling system includes a variety of apparatus for making or breaking the tubular connection.
The riser string for connection with the riser section is held in the rig floor by a spider. In one embodiment, the elevator and the spider are adapted to retain the risers without applying a radial gripping force. The rig may also include a tong assembly for rotating the riser section relative to the riser strings to complete the make up. A stabbing guide may also be used to align the riser section to facilitate the connection process.
A. Joint Compensator Assembly
In one aspect, the joint compensator assembly 200 includes a rotary seal 260 disposed between the upper elevator 220 and the hook end of the lift member 240. Any suitable rotary seal known to a person of ordinary skill in the art may be used.
The rotary seal 260 provides a method for communication with the lower elevator 250. For example, control lines may attach to ports 267 formed in the outer body 265 of the rotary seal 260. Each of the outer ports 267 is communicable with a mating port 268 in the inner body 262. Particularly, the ports 267, 268 are adapted to allow fluid communication between the outer body 265 and the inner body 262 even though the inner body 262 is rotating relative to the outer body 265. Additional control lines are provided to interconnect the mating ports 268 exiting the inner body 262 to the lower elevator 250. In this manner, the addition of the rotary seal 260 to the joint compensator assembly 200 allows signal transmission to and from the lower elevator 250.
Control lines attached to the lower elevator 250 may be used to operate the lower elevator 250. As shown, the lower elevator 250 is a side door elevator. The lower elevator 250 includes two side doors 251, 252 hingedly attached to the body of the elevator 250. A latch 253 is used to keep the side doors 251, 252 closed. The side doors 251, 252 and the latch 253 may be operated by one or more cylinder assemblies (not shown). The cylinder assemblies are controlled by signals transmitted through the control lines. The cylinder assemblies may be actuated using any suitable manner known, including electrics, mechanics, or fluids such as hydraulics and, preferably, pneumatics. Pneumatic fluid sent through the rotary seal 260 and the control lines may sequentially release the latch 253 and open the side doors 251, 252 to receive a riser section. Specifically, the cylinder assemblies pivot the side doors 251, 252 outward to enable the riser to pass between the side doors 251, 252. In this manner, the rotary seal 260 allows the lower elevator 250 to be remotely controlled or operated.
B. Elevator and Spider Assembly
In another aspect, the lower elevator is used in combination with a spider to handle a riser 10. As shown in
In one embodiment, the elevator 50 and spider 70 combination is adapted to take advantage of the large upset member 20 of the riser 10 as illustrated in
Referring to
Referring to
As shown in
In another embodiment, the spider 70 may employ a spider bushing 90 to center the riser 10 within the bore 75 of the spider 70, as illustrated in
In operation, the elevator 50 is suspended by bails 245 above the spider 70 disposed on the rig floor. As shown in
Referring to
The elevator 50 may now retrieve and position a second riser for connection with the riser 10 in the spider 70. After the risers have been connected, the elevator 50 may raise the risers relative to the spider 70 to transfer the load back to the elevator 50. Then the spider 70 is opened sufficiently to allow the riser 10 to be lowered into the wellbore. Once the upset member 20 has passed through the spider 70, the spider 70 is closed around the riser body of the second riser. Thereafter, the upset member of the second riser is lowered into engagement with the spider 70. This cycle of handling risers may be repeated to add additional risers. Because the elevator 50 and the spider 70 do not retain the riser 10 by gripping the riser body 15, the present invention provides methods and apparatus for handling risers without damaging the outer surface of the riser body.
C. Shock Table
In another aspect, the tubular handling system 100 provides a rotary table 300 to support the spider 370 on the rig floor. Preferably, the rotary table 300 is adapted to absorb the shock experienced by the spider 370.
The base 320 is movably disposed on a shock table 330. Each side of the base 320 may include a base extension 335 that is connected to anchors 340 disposed at each end of the shock table 330. Preferably, a cylinder assembly 345 is used to connect the base extension 335 to the anchors 340. Actuation of the cylinder assemblies 345 moves the respective base portions 321, 322 to and from the well center, thereby allowing the riser to move axially in the wellbore. The shock table 330 includes a hole that is sufficiently sized to accommodate axial movement of the riser without opening or closing. In this respect, the base portions 321, 322 move along the shock table 330 during operation. Attached below the shock table 330 is a cushion plate 350 and a shock absorbing layer 355 disposed therebetween. In one embodiment, the shock absorbing layer 355 defines a polyurethane layer. The shock absorbing layer 355 provides additional shock absorbing capability to the shock table 330.
In another aspect, the shock table 330 may be flushed mounted. For example, the support plate 310 may be disposed directly on the shock table 330, and the compensating cylinder assemblies 315 disposed below shock table 330. In this respect, the operating height of the spider 370 is reduced, thereby allowing easier access to the spider 370.
In another aspect, the spider 370 may site directly on the polyurethane layer 355 and the cushion plate 350.
D. Interlock System
In another aspect, the tubular handling system 100 includes an interlock system to insure the riser is retained by at least the spider 370 or the elevator 250. A suitable interlock system is disclosed in U.S. patent application Ser. No. 10/625,840, filed on Jul. 23, 2003, which application is assigned to the same assignee of the present invention and is herein incorporated by reference in its entirety. In one embodiment, the elevator 250 includes an elevator latch sensor 280 (
The controller 390 includes a programmable central processing unit that is operable with a memory, a mass storage device, an input control unit, and a display unit. Additionally, the controller 390 includes well-known support circuits such as power supplies, clocks, cache, input/output circuits and the like. The controller 390 is capable of receiving data from sensors and other devices and capable of controlling devices connected to it.
One of the functions of the controller 390 is to prevent the opening of the spider 370 and the lower elevator 250 at the same time. Preferably, the spider 370 is locked in the closed position by a solenoid valve that is placed in the control line for the source of fluid power operating the remotely controllable pin 325. Similarly, the elevator 250 is locked in the closed position by another solenoid valve that controls the fluid source to the cylinder assemblies actuating the elevator latch 253. The solenoid valves are operated by the controller 390, which is programmed to keep the valves closed until certain conditions are met. Although electrically operated solenoid valves are preferred, the solenoid valves may be fluidly or pneumatically operated so long as they are controllable by the controller 390. Generally, the controller 390 is programmed to keep the spider 370 locked until the riser is successfully joined to the riser string and supported by the elevator 250.
At step 520, the riser section is moved to the well center for connection with the riser string. A tubular guide member is used to align riser section with the riser string. Next, at step, 530, a tong is moved into position to connect the riser section to the riser string. After the connection is completed, at step 540, the spider 370 disengages from the riser string. At step 550, the extended riser string is then lowered through the spider 370. Thereafter, at step 560, the spider 370 reengages the riser string. After engagement, at step 560, the spider piston sensor 380 transmits the sensor data 562 to the controller 390. After receiving the sensor data 562 indicating that the spider 370, the controller 390 allows the elevator 250 to disengage from the riser string and pick up another riser for connection with the riser string.
E. Tubular Guide Member
In another aspect, the tubular handling system 100 includes a tubular guide member 101 for guiding the riser section into alignment with the riser string, as shown in
A conveying member 120 interconnects the gripping member 150 to the rotor 110. In one embodiment, two support members 106, 107 extend upwardly from the rotor 110 and movably support the conveying member 120 on the base 105. Preferably, the conveying member 120 is coupled to the support members 106, 107 through a pivot pin 109 that allows the conveying member 120 to pivot from a position substantially perpendicular to the rig floor to a position substantially parallel to the rig floor. Referring to
The telescopic arm 120 includes a first portion 121 slidably disposed in a second portion 122. A third piston and cylinder assembly 133 is operatively coupled to the first and second portions 121, 122 to extend or retract the first portion 121 relative to the second portion 122. In this respect, the telescopic arm 120 and the rotor 110 allow the tubular guide member 101 to guide the riser into alignment with the riser in the spider 370 for connection therewith. Although a telescopic arm 120 is described herein, any suitable conveying member known to a person of ordinary skill in the art are equally applicable so long as it is capable of positioning the gripping member 150 at a desired position.
The gripping member 150, also known as the “head,” is operatively connected to the distal end of the telescopic arm 120. The gripping member 150 defines a housing 151 movably coupled to two gripping arms 154, 155. Referring to
It is understood that the piston and cylinder assemblies 131, 132, 133, 134, and 135 may include any suitable fluid operated piston and cylinder assembly known to a person of ordinary skill in the art. Exemplary piston and cylinder assemblies include a hydraulically operated piston and cylinder assembly and a pneumatically operated piston and cylinder assembly.
In another aspect, the gripping member 150 may be equipped with a spinner 170 to rotate the riser retained by the gripping member 150. As shown in
A valve assembly 190 is mounted on the base 105 to regulate fluid flow to actuate the appropriate piston and cylinder assemblies 131, 132, 133, 134, 135 and motor 175. The valve assembly 190 may be controlled from a remote console (not shown) located on the rig floor. The remote console may include a joystick which is spring biased to a central, or neutral, position. Manipulation of the joystick causes the valve assembly 190 to direct the flow of fluid to the appropriate piston and cylinder assemblies. The tubular guide member 101 may be designed to remain in the last operating position when the joystick is released.
In another aspect, the tubular guide member 101 may include one or more sensors to detect the position of the gripping member 150. An exemplary tubular guide member having such a sensor is disclosed in U.S. patent application Ser. No. 10/625,840, filed on Jul. 23, 2003, assigned to the same assignee of the present invention, which application is incorporated by reference herein in its entirety. In one embodiment, a linear transducer may be employed to provide a signal indicative of the respective extension of piston and cylinder assemblies 131, 133. The linear transducer may be any suitable liner transducer known to a person of ordinary skill in the art, for example, a linear transducer sold by Rota Engineering Limited of Bury, Manchester, England. The detected positions may be stored and recalled to facilitate the movement of the riser. Particularly, after the gripping member 150 has place the riser into alignment, the position of the gripping member 150 may be determined and stored. Thereafter, the stored position may be recalled to facilitate the placement of additional risers into alignment with the riser string.
F. Tong
In another aspect, a tong may be remotely operated to connect the risers. An exemplary tong is disclosed in U.S. patent application Ser. No. 10/794,792, filed on Mar. 5, 2004, which application is assigned to the same assignee as the present invention and is herein incorporated by reference in its entirety.
Each of the tongs 1101, 1102 are segmented into three segments such that the front two segments pivotally attach to the back segment and enable movement of the tongs 1101, 1102 between an open and a closed position. In the open position, the front sections pivot outward enabling the tubulars 1108, 1110 to pass between the front sections so that the handling tool 1104 can align the tubulars 1108, 1110 within the tongs 1101, 1102. The tongs 1101, 1102 move to the closed position as shown in
A torque bar assembly 1112 located adjacent a counterweight 1120 connects the power tong 1101 to the back up tong 1102. The torque bar assembly 1112 includes two arms 1114 extending downward from each end of a horizontal top bar or suspension 1116. A back end of the power tong 1101 connects to a horizontal shaft 1118 that extends between the arms 1114 below the suspension 1116. The shaft 1118 may fit within bearings (not shown) in the arms 1114 to permit pivoting of the power tong 1101 relative to the torque bar assembly 1112. Damping cylinders 1400 (shown in
The torque bar assembly 1112 keeps side forces out of the connection between the tubulars 1108, 1110 by eliminating or at least substantially eliminating shear and bending forces. As the power tong 1101 applies torque to the upper tubular 1110, reaction forces transfer to the torque bar assembly 1112 in the form of a pair of opposing forces transmitted to each arm 1114. The forces on the arms 1114 place the suspension 1116 in torsion while keeping side forces out of the connection. A load cell and compression link 1126 may be positioned between the clamp 1122 and back up tong 1102 in order to measure the torque between the power tong 1101 and back up tong 1102 during make up and break out operations.
The power tong gate lock 1200 includes an outer shroud 1204 mounted on a housing 1207 of the power tong 1101. The outer shroud 1204 supports a gear profiled bolt 1206 having a lifting member 1208 connected thereto. Rotation of a gear 1216 mated with the gear profiled bolt 1206 lowers and raises the gear profiled bolt 1206 between a power tong gate locked position and a power tong gate unlocked position. In the power tong gate locked position shown in
At the end of the lifting member 1208, a slotted lip 1210 receives a recessed profile 1212 at the top of a rotor bolt 1214. Due to the slotted lip 1210 fitting in the recessed profile 1212, the lifting member 1208 which raises and lowers with the gear profiled bolt 1206 acts to raise and lower the rotor bolt 1214 when the rotor bolt 1214 is aligned below the lifting member 1208. Similar to the housing of the power tong 1101, a rotor 1300 is gated so that the rotor 1300 opens and closes as the power tong 1101 moves between the open and closed positions. Thus, the rotor 1300 includes a rotor extension 1232 and a corresponding rotor grooved portion 1234 that each have an aperture therein for receiving the rotor bolt 1214 which prevents movement between the rotor extension 1232 and the corresponding rotor grooved portion 1234 while in the power tong gate locked position. As the rotor 1300 rotates during make up and break out operations, the recessed profile 1212 of the rotor bolt 1214 slides out of engagement with the slotted lip 1210 and may pass through the slotted lip 1210 with each revolution of the rotor 1300. The rotor bolt 1214 realigns with the lifting member 1208 when the rotor returns to a start position such that the rotor bolt 1214 may be raised to the power tong gate unlocked position. Only when the rotor 1300 is in the start position with segments of the rotor 1300 properly aligned may the power tong 1101 be moved to the open position.
The back up gate lock 1201 locks the gate on the back up tong 1102 in the closed position similar to the power tong gate lock 1200 for the power tong 1101. A single back up bolt 1218 operated by a gear 1220 moves between a back up gate locked position and a back up gate unlocked position. Since the back up tong 1102 does not have a front housing or a rotor that rotates, a back up jaw assembly may include a gated section therein with mating features such as the gate of the power tong 1101. Thus, the bolt 1218 in the back up gate locked position prevents movement between members in the gated section of the back up jaw assembly similar to the gear profiled bolt 1206 and rotor bolt 1214 used in the power tong gate lock 1200 on the power tong 1101.
Referring still to
The rotary gear 1302 may be tensioned prior to assembly such that the rotary gear 1302 is initially deformed. Thus, when the rotary gear 1302 is assembled in the power tong 1101 and when the tubular 1110 is gripped by the jaws 1306, the deformed rotary gear reworks to obtain a circular outer circumference.
Support rollers 1316 hold the rotary gear 1302 in order to axially position the rotor 1300 within the power tong 1101. Each of the pinions 1310 creates a force on the rotary gear 1302 that is perpendicular to the tangential. Due to the 1120° spacing of the pinions 1310, these forces are all directed to the center of the rotor 1300 and cancel one another, thereby centrally aligning the rotor 1300. Therefore, the rotor 1300 does not require radial guiding since the rotary gear 1302 centrally aligns itself when a load is placed on the pinions 1310 arranged at 120° around the rotary gear 1302.
The jaws 1306 and support members 1308 laterally support one another throughout a 360° closed circle such that corresponding torque from the rotor 1300 only transmits to the tubular 1110 in a tangential direction without resulting in any tilting of the jaws 1306. During make up and break out operations, a side face of one jaw 1306 having a close contact with a side face of an adjacent support member 1308 transmits force to the adjacent support member 1308 which is in close contact with another jaw 1306. The closed 360° arrangement effectively locks the jaws 1306 and support members 1308 in place and helps the jaws 1306 and support members 1308 to laterally support one another, thereby inhibiting tilting of the jaws 1306. Thus, load on the tubular 1110 equally distributes at contact points on either side of the jaw pads 1314. Adapters (not shown) for both the support members 1308 and jaws 1306 may be added in order to allow the power tong 1101 the ability to grip tubulars having different diameters.
The jaw assembly (not shown) in the back up tong 1102 may be identical to the rotor 1300. However, the jaw assembly in the back up tong 1102 does not rotate such that an outer ring surrounding jaws in the back up tong may not be geared with motors providing rotation.
The top view of the power tong 1101 in
As described above, the rotor locks 1202 physically block rotation of the rotor 1300 until a fluid pressure is applied to the rotor locks 1202 in order to place the rotor locks 1202 in the rotor unlocked position. Thus, the fluid pressure for placing the rotor locks 1202 in the rotor unlocked position is supplied from the tong assembly hydraulic circuit through a disengage locks line 1808 that may be controlled independently from the supply lines 1805, 1807 by a lock valve 1820. A portion of the fluid from the disengage locks line 1808 is supplied to a pilot port of the pilot valve 1802 in order to close the pilot valve 1802 only when both the rotor locks 1202 are in the rotor unlocked position. Once the pilot valve 1802 closes, fluid pressure from either of the supply lines 1805, 1807 can pressurize a corresponding one of the pilot port lines 1809, 1811 that are no longer open to the tank 1816, thereby permitting opening of a corresponding one of the check valves 1804, 1806. Thus, opening the drive valve 1818 supplies fluid selectively to one of the supply lines 1805, 1807, which are blocked from operating the drive motors 1111 until actuation of the rotor locks 1202 unlocks the interlock that provides the motor lockout. Once both the rotor locks 1202 actuate and the drive valve 1818 is opened to permit fluid flow to the appropriate supply line 1805, 1807, a pressurized fluid is simultaneously supplied to all of the motors 1111 through a corresponding one of the drive lines 1810, 1812 during make up or break out. Further, each motor 1111 produces the same torque and any mechanical parts for “locking” such torque are not necessary as all the motors 1111 simultaneously stop hydraulically due to the check valves 1804, 1806. A gear change 1814 may be used to adjust the suction volume of the motors 1111 in order to adjust the speed of the motors 1111. Additionally, a solenoid valve (not shown) can be activated such that the drive motors 1111 are also immediately stopped, and a pressure limiter 1822 may protect the interlock portion 1800.
In alternative embodiments, the pilot valve 1802 is closed by a signal other than the hydraulic signal from the disengage locks line 1808. For example, the pilot valve 1802 may be controlled to close by an electric signal supplied thereto or may be manually closed. Further, the hydraulic circuit shown for the interlock portion 1800 may be used in applications and methods other than tong assembly 1100 where there is a desire to block actuation of motors prior to receiving a signal from an interlock.
The tong assembly 1100 described herein may be used in a method of making up a tubular connection between a first tubular 1110 and a second tubular 1108. For clarity, the method is described using the reference characters of the figures described herein when possible. The method includes opening a power tong 1101 and back up tong 1102 of the tong assembly 1100 and positioning the tubulars 1108, 1110 therein. The method further includes, closing the tongs 1101, 1102 around the tubulars 1108, 1110, locking gate locks 1200, 1201 to maintain the tongs 1101, 1102 and a rotor 1300 in the closed position, actuating jaws 1306 of the tongs 1101, 1102 such that the power tong 1101 grips the first tubular 1110 and the back up tong 1102 grips the second tubular 1108, unlocking a rotor lock 1202 to permit rotation of the rotor 1300, and unlocking an interlock including a rotor motor lockout. Additional, the method includes rotating the rotor 1300 by distributing a drive force on the rotor 1300 such as by simultaneous rotation of at least three motors 1111, wherein rotating the rotor 1300 rotates the first tubular 1110 relative to the second tubular 1108 and forms the connection. The method may be used with connections in tubulars having diameters greater than fifteen inches such as risers.
In another aspect, the tong assembly may be suspended from a tong positioning device capable of translating the tong assembly toward the risers to thread the connection. An exemplary tong assembly is disclosed in U.S. Pat. No. 6,412,553 assigned to the same assignee as the present application and is herein incorporated by reference in its entirety. In one embodiment, the positioning device comprises a single extendable beam having a variable length. A mounting assembly is coupled to one end of the beam for attachment to the rig, and the tong is suspended from the free end of the beam. The positioning device includes a motive assembly such as a piston and cylinder assembly adapted to extend or retract the beam. Extending or retracting the beam moves the tong to and away from the risers. The piston and cylinder assemblies may be operated by hydraulics, pneumatics, electrics, mechanics, and combinations thereof. In the preferred embodiment, the piston and cylinder assembly is adapted for remote controlled operation as is known to a person of ordinary skill in the art. For example, the power source of the piston and cylinder assemblies may be controlled remotely.
In another aspect, the tong may be placed on a movable frame to transport the tong to and from the well center. Examples of such movable frames are disclosed in U.S. patent application Ser. No. 10/074,947, filed on Feb. 12, 2002, and U.S. patent application Ser. No. 10/432,059, filed on May 15, 2003 and published as U.S. Publication No. 2004/0035573, which applications are herein incorporated by reference in their entirety. In one embodiment, actuation of the movable frame is remotely controlled.
Another suitable positioning device comprises a flexible chain provided with compression members and a flexible locking chain. The chains are brought into operative engagement to form a rigid member when a hydraulic motor is rotated counter-clockwise. The proximal end of the device is attached to the rig, while the distal end is suspended by a cable connected to the rig. A tong suspended from the distal end of the device may be advanced or withdrawn towards the riser by rotating the motor counter-clockwise or clockwise to extend or dismantle the rigid member. In the preferred embodiment, the hydraulic motor is adapted for remote controlled operation as is known to a person of ordinary skill in the art. Examples of such tong positioning devices are disclosed in U.S. Pat. Nos. 6,322,472; 5,667,026; and 5,368,113, which patents are assigned to the same assignee of the present invention and are herein incorporated by reference in their entirety.
Referring back to
At step 520, the riser section is moved to the well center for connection with the riser string. A tubular guide member 101 is used to align riser section with the riser string. Specifically, the gripping member 120 is extended toward the riser section and closed around the riser section. Preferably, movement of the gripping member 120 is remotely controlled and performed by recalling a previous position of the gripping member 120. The tubular guide member 101 positions the riser section in alignment with the riser string for connection therewith.
Next, at step, 530, a tong assembly 1100 is moved into position to connect the riser section to the riser string. In one embodiment, a single extendable beam type tong positioning device is actuated to translate the tong toward the risers. The piston and cylinder assembly of the beam is remotely controlled to move the tong. Once in position, the backup tong is actuated to engage the riser string and the power tong is actuated to engage the riser section. Thereafter, torque is supplied to the power tong to rotate the riser section relative to the riser string to make up the connection. As the threads are advanced, the joint compensator compensates for the axial movement of the riser section toward the riser string. Also, the rotary seal allows the lower elevator 250 to maintain communication with the remote controller during rotation of the riser section.
After the connection is completed, at step 540, the spider 370 disengages from the riser string. The lower elevator 250 is raised to transfer the weight of the extended riser string to the upper elevator 220. Thereafter, the spider is opened to allow passage of the riser string. In one embodiment, the shock table 300 is opened by first releasing the remotely controllable pin 325, and then actuating the cylinder assembly 345 to pull apart the two base portions 321, 322. At step 550, the extended riser string is then lowered through the spider 370. Thereafter, at step 560, the spider 370 reengages the riser string. After engagement, at step 560, the spider piston sensor 380 transmits the sensor data 562 to the controller 390. After receiving the sensor data 562 indicating that the spider 370, the controller 390 allows the elevator 250 to disengage from the riser string and pick up another riser for connection with the riser string. In this manner, the tubular handling assembly may be used to extend the riser string to the desired length. Although only some of the steps in the process is described as being remotely controlled, it must be noted that manipulation of the components of the tubular handling assembly throughout the entire process may be controlled remotely or automated. For example, all of the piston and cylinder assemblies in each of the components may be adapted for remote control capability. Moreover, the controls may be position in the same small area for easy access to the operator.
In another aspect, a fill up tool may be used with the tubular handling system. In one embodiment, two joint compensators are used to compensate for the thread action. Specifically, the upper end of one of the joint compensators is attached to one side of the upper elevator, and the lower end is coupled to a swivel via a cable. Additionally, cables extending below the swivel connect the lower elevator to the swivel. Before a tubular section is connected to the tubular string retained by the spider, the weight of the tubular section retained by the lower elevator is supported by the joint compensators. After the tubulars are connected, the upper elevator is lowered toward the rig floor to retain the tubulars, thereby supporting the weight of the connected tubulars. In one embodiment, the lower elevator may be a single joint elevator and the upper elevator may be a side door elevator.
A suitable fill up tool is disclosed in U.S. patent application Ser. No. 6,460,620, which application is assigned to the same assignee of the present invention and is herein incorporated by reference in its entirety. In one embodiment, the fill up tool is a mudsaver valve having an elongated tubular main body supporting a tubular mandrel-like mudsaver closure member therein for movement between valve open and closed positions. A coil spring is disposed in the main body member and is engageable with the mudsaver closure member to bias the mudsaver closure member in a valve closed position. The mudsaver closure member includes an axial passage formed therein and ports opening from the axial passage to the exterior of the mudsaver closure member. The mudsaver closure member is engageable with an annular resilient packoff element and is pressure biased to move to an open position wherein the ports pass through the annular packoff element to allow fluid to flow through the valve. A flowback valve is integrated with the mudsaver valve and comprises an annular resistant duckbill type closure member mounted in a second body member attached to the main body member and responsive to pressure fluid in a casing in which the mudsaver valve is disposed to equalize fluid pressure between the interior of the casing or similar conduit and a supply conduit connected to the mudsaver valve.
While the foregoing is directed to the preferred embodiment of the present 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 benefit of U.S. Provisional Patent Application Ser. No. 60/460,193, filed Apr. 4, 2003, which application is herein incorporated by reference in its entirety.
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