The present disclosure relates to catwalk systems and processes for handling drill pipe and casing relative to drill rig operations. In particular, the invention relates to catwalk systems and processes that are maneuverable and flexible to suit most applications such as multi-well pad, batch, batched section and infill drilling operations.
Current catwalk systems create hazardous work environments and present problems and issues during batch and infill drilling operations. Current catwalks do not provide either easy safe accessibility to the cellars or maneuverability over objects above the ground level. Unfortunately, the narrow space below known catwalks limit safe accessibility to cellars below the catwalks. Further, objects above ground level present problems for current catwalks because they are unable or have difficulty to walk or skid over the objects. Walking and skidding over objects above the ground level, e.g. live wells with caged x-trees, are difficult and hazardous tasks for most presently known catwalks. Typically, cranes must be used to lift catwalks over above-ground objects, if it is even possible for the catwalk to be positioned over or adjacent the above-ground objects. Thus, there is a need for catwalk systems and processes that accommodate above- and below-ground objects on well sites.
In accordance with the teachings of the present disclosure, disadvantages and problems associated with existing drill rig control systems are alleviated.
Multi-Application Catwalk System (MACS) is a comprehensive fit for purpose catwalk. MACS is designed to suit most applications such as multi-well pad, batch, batched section and infill drilling operations. Most important features of this catwalk are easy “maneuverability/flexibility” and safe “accessibility” to its beneath. MACS can be expanded horizontally and elevated vertically as desired to make feasible the operations with x-tree underneath and cellar with different sizes. Flexibility of different components of the rig is so important to allow different drilling operations under variety of circumstances. MACS will not need crane or other means of lifting to operate safely over the cellars or objects above the ground level. MACS will decrease non-productive time-NPT of the operations.
According to one aspect of the invention, there is provided a pipe-handling apparatus for moving a pipe relative to a drilling floor of a drilling rig, the pipe-handling apparatus comprising: a main support structure; a pipe delivery mechanism in mechanical communication with the main support structure for delivering pipe between a pipe load/unload position and a drilling floor position; at least one walking unit in mechanical communication with the main support structure so as to support the main support structure, wherein the at least one walking unit comprises: a jack in mechanical communication with the main support structure capable of lifting the main support structure in a substantially vertical direction; and a foot in mechanical communication with the main support structure capable of moving the main support structure in a substantially horizontal direction.
A further aspect of the invention provides a process for moving pipe relative to a drilling floor of a drilling rig, the process comprising: providing a pipe-handling apparatus to a position adjacent the drill rig; delivering pipe via the pipe-handling apparatus between a loading/unloading position and a rig floor delivery position; walking the pipe-handling apparatus from one wellbore location to another wellbore location; and reconfiguring the pipe-handling apparatus to avoid at least one obstacle during walking.
According to another aspect of the invention, there is provided a pipe-handling apparatus for moving a pipe relative to a drilling floor of a drilling rig, the pipe-handling apparatus comprising: a main support structure; a pipe delivery mechanism in mechanical communication with the main support structure for delivering pipe between a pipe load/unload position and a drilling floor position, the pipe delivery mechanism comprising a lower skate, an upper skate, a rig up system that moves the upper and lower skates between a pipe loading/unloading configuration and a pipe sliding configuration, and a pipe pusher configured to move relative to the upper and lower skates; at least one walking unit in mechanical communication with the main support structure so as to support the main support structure, wherein the at least one walking unit comprises: a jack in mechanical communication with the main support structure capable of lifting the main support structure in a substantially vertical direction; and a foot in mechanical communication with the main support structure capable of moving the main support structure in a substantially horizontal direction; a swivel in mechanical communication with the walking unit to rotate the foot around a substantially vertical axis; at least one leg in mechanical communication with the main support structure, wherein the at least one leg is extendable to raise at least a portion of the main support structure in a substantially vertical direction; and a cross brace in mechanical communication with the main support structure and the at least one leg, wherein the cross brace is extendable to extend the leg further away from the main support structure.
A more complete understanding of the present embodiments may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features.
The objects and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements.
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
Preferred embodiments are best understood by reference to
Regarding the jack 151, a jack inner barrel 154 connects to the leg connector 164 via a swivel 162. The jack inner barrel 154 telescopes within a jack outer barrel 152 and is moved relative thereto by a jack actuator 156. The jack actuator 156 is attached to the jack inner barrel 154 via an inner barrel anchor 158 and to the jack outer barrel 152 via an outer barrel anchor 160. A jack pad 166 is attached to the lower end of the jack outer barrel 152 for making contact with the ground. This connection is a swivel connection so the swivel 162 may rotate the foot 141 around the jack 151 when the jack 151 has lifted the foot 141 off the ground. The jack components work together to lift the catwalk 100 vertically.
Regarding the foot 141, it is for moving the catwalk in horizontal directions. A buttress 168 extends from the jack inner barrel 154 and has a foot sled 144 at its lower most end. The foot 141 has a foot pad 142 for resting on the ground and providing a broad surface area sufficient to support the weight of the catwalk 100 without sinking into the earthy material of the drilling pad site. The foot sled 144 is engaged with the upper surface of the foot pad 142 so as to slide relative thereto. A foot actuator 146 moves the foot sled 144 laterally relative to the foot pad 142. The foot actuator 146 is attached to the foot pad 142 via a pad anchor 148 and to the foot sled 144 via a sled anchor 150.
The actuators 146 and 156 may be hydraulic or pneumatic pistons, worm gears, rack and pinion gears, etc. or any movement inducing devices known to persons of skill in the art. The walking unit 140 may further comprise a control unit to coordinate movements of the jack and foot. When the catwalk has a plurality of walking units 140, the control units may be linked together for coordinated movements of the walking units 140. In particular, it is preferable that all of the walking units 140 move in the same direction at the same time, so that the catwalk 100 moves as a single unit. However, they must not always move in harmony as it may be advantageous to rotate the position of the catwalk around a vertical axis, in addition to translating the position of the catwalk in a horizontal direction.
An alternative embodiment of the walking unit 140 is shown in
During drilling operations, the drill rig is typically positioned directly over the wellbore with the catwalk immediately adjacent thereto. To drill a second wellbore, the drill rig typically moves in the direction of the catwalk. For example, referring to
To perform multi-well pad, batch, batched section and infill drilling, Multi-Application Catwalk System (MACS) can expand horizontally and elevated vertically safely based on desired length and height. There are many ways to build the MACS, but its most important characteristics are easy “maneuverability/flexibility” over any object on a pad and safe “accessibility” to the cellars beneath. Some of the key functionalities of MACS include: (1) being able to expands horizontally to not interfere with the cellar's diameter or width; (2) being able to adjust its height from the ground level to different elevation depending to circumstances; (3) being able to walk or skid safely over the cellars with any diameter and width and objects with different heights above the ground level; (4) being able to operate safely and easily over live wells with caged x-trees above the ground levels; (5) having simplicity to operate rather than complexity with fancy movements; (6) having horizontal pipe racking system that can be easily transformed from horizontal position to vertical position to act as elevator as height of MACS changes; (7) requiring minimal usage of fork lift, crane or other similar lifting systems; (8) being able to transported easily while rig move; (9) being able to walk and skid smoothly, precisely and safely within the pads; (10) not interfere with the v-door and rig floor space to create hazardous environment. MACS may reduce non-productive time (NPT) because there is no need to waste time to rig up and rig down the catwalk to perform safely the operations such as batch and infill drilling.
Aspects of the invention may be implemented with catwalks having a variety of pipe handling mechanisms. For example, catwalks of the present invention may comprise a pipe delivery mechanism having a pipe carrying carriage and a device for moving the carriage between a substantially horizontal position to a position having a vertical component. Examples are illustrated by U.S. Pat. Nos. 7,540,338; 8,215,887; 6,695,559; 7,163,367 and 9,476,266 the disclosures of which are incorporated herein in their entireties by reference.
It should be noted that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. In addition, the composition used/disclosed herein can also comprise some components other than those cited. In the summary of the invention and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary of the invention and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors possessed knowledge of the entire range and all points within the range. The statements made herein merely provide information related to the present disclosure and may not constitute prior art, and may describe some embodiments illustrating the invention.
The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
If used herein, the term “substantially” is intended for construction as meaning “more so than not.”
Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
Although the disclosed embodiments are described in detail in the present disclosure, it should be understood that various changes, substitutions and alterations can be made to the embodiments without departing from their spirit and scope.
Catwalks for drilling rigs of the of the present invention have many industrial applications including but not limited to drilling batch well bores for the oil and gas industry.