Patent Grant
10012038
This invention relates to subsurface drilling and specifically to apparatus and methods for presenting sections of drill string at a well center. The application has application, for example, in drilling into the earth to recover hydrocarbons.
Drilling into the earth, for example, to recover hydrocarbons is typically done with a drill rig. The drill rig is located at a well center from which a wellbore is extended into the earth using a rotating drill bit at the downhole end of a drill string. The drill string is made up of tubular sections that are coupled together. These sections are typically called ‘tubulars’ or ‘pipe’ or ‘joints’.
During drilling, drilling fluid, often called ‘mud’ is pumped through a bore of the drill string. The drilling fluid exits at the drill bit and returns to the surface carrying cuttings from the drilling operation in an annulus surrounding the drill string. In addition to carrying the cuttings the drilling fluid may assist in keeping the wellbore open against subsurface pressures.
As the wellbore is extended, more tubulars are added at the uphole end of the drill string. The tubulars are most typically coupled together by threaded couplings. The thread dimensions and geometry can vary but are usually selected to be one of a number of standard threads specified by the American Petroleum Institute (API) in API specification 7-2 (ISO 10424).
In drilling it is sometimes necessary to remove the drill string from the wellbore or to introduce a drill string into a wellbore that has already been partially completed. This is called ‘tripping’. Tripping may be done, for example, to replace a worn drill bit. Tripping can be done much more quickly than drilling.
Most drill rigs have floors that are elevated. The patent literature describes various pipe handling systems that can present an end of a tubular at the rig floor from where the tubular can be hoisted by equipment on the drill rig or that can carry a tubular away from the rig floor. These include the following patent publications: US 2004/0136813; US 2005/0079044; US 2005/0238463; US 2006/0124356; US 2009/0053013; US 2006/0104746; US 2006/0285941; U.S. Pat. No. 7,404,697; U.S. Pat. No. 7,163,367; U.S. Pat. No. 7,021,880; U.S. Pat. No. 6,994,505; U.S. Pat. No. 6,533,519; U.S. Pat. No. 6,079,925; U.S. Pat. No. 5,122,023; U.S. Pat. No. 4,403,898; U.S. Pat. No. 4,386,883; U.S. Pat. No. 4,382,738; U.S. Pat. No. 4,379,676; U.S. Pat. No. 4,347,028; U.S. Pat. No. 4,494,899; U.S. Pat. No. 4,235,566; U.S. Pat. No. 4,067,453; U.S. Pat. No. 3,655,071; U.S. Pat. No. 3,053,401; CA 2510137; WO 99/29999; US 2013/0341096; WO 2005/059299; WO 2013/191733; WO 2013/173459; WO 2013/169700; WO 2011/017471; WO 2009/026205; WO 2006/059910; WO 2009/055590; US 2015/0184472; US 2015/0139773; US 2015/0008038; US 2014/0126979; US 2012/0039688; US 2011/0200412; US 2011/0044787; US 2011/0030942; US 2010/0254784; US 2010/0135750; US 2009/0136326; US 2012/0130537; US 2012/0118639; US 2004/0197166; US 2003/0159854; US 2003/0123955; US 2007/0221385; U.S. Pat. No. 8,469,085; U.S. Pat. No. 8,215,887; U.S. Pat. No. 8,210,279; U.S. Pat. No. 8,186,455; U.S. Pat. No. 8,052,368; U.S. Pat. No. 7,992,646; U.S. Pat. No. 7,967,540; U.S. Pat. No. 8,764,368; U.S. Pat. No. 8,632,111; U.S. Pat. No. 8,584,773; U.S. Pat. No. 8,079,796; U.S. Pat. No. 7,802,636; U.S. Pat. No. 7,762,343; U.S. Pat. No. 7,431,550; U.S. Pat. No. 6,997,265; U.S. Pat. No. 7,918,636; U.S. Pat. No. 7,832,974; U.S. Pat. No. 6,705,414; U.S. Pat. No. 6,695,559; U.S. Pat. No. 6,609,573; U.S. Pat. No. 6,220,807; U.S. Pat. No. 5,451,129; U.S. Pat. No. 5,107,940; U.S. Pat. No. 6,976,540; U.S. Pat. No. 6,719,515; U.S. Pat. No. 4,439,091; U.S. Pat. No. 4,426,182; U.S. Pat. No. 4,365,692; U.S. Pat. No. 4,453,872; GB 2462390; GB 2442430; U.S. Pat. No. 4,040,524; U.S. Pat. No. 3,865,256; U.S. Pat. No. 3,065,865; U.S. Pat. No. 2,958,430; GB 8513524; GB 2152113; GB 2152112; GB 2152111; GB 2125862; GB 2085047; GB 2351985; GB 2162485; GB 2158131; GB 2152561; GB 2152115; GB 1303618; EP 1038088; EP 0061473; EP 2425090; and, EP 1723306.
Many of the prior art systems present the ends of tubulars near the edge of the drill rig floor. When the tubulars are hoisted by the drill rig, the tubulars can pendulum after their trailing ends are lifted free. Drill rig personnel often have the task of steadying the tubulars. This is physically challenging. Tubulars are heavy. Small 2⅜ inch diameter tubulars typically weight about 7 pounds per foot (about 10 kg/m). Larger 5 inch diameter tubulars typically weigh about 25 pounds per foot (about 37 kg/m). Larger drill collars can weigh 300 pounds per foot (about 443 kg/m) or more. This work is also potentially dangerous. Personnel are forced to work near the well center. The floor can be slippery as a result of spilled drilling mud. Drilling is sometimes performed in poor weather which increases the risk to drill rig personnel.
Drill rigs are extremely expensive to operate. It is therefore important to be able to quickly bring in additional tubulars to extend a drill string or to remove tubulars from the well center, especially while tripping.
Tubulars can have various lengths. A typical length is approximately 30 feet (about 10 meters). ‘Range II’ tubulars have lengths of about 31 feet. ‘Range III’ tubulars have lengths of about 46 feet. Each range has a tolerance. For example, Range III tubulars should have a minimum length of 42 feet and a maximum length of 48 feet. Equipment for handling tubulars in a particular length range ought to accommodate tubulars having any length between the minimum and maximum lengths specified for the range. Many drill rigs can accommodate sections of drill string up to about 90 feet long. Sometimes a number of tubulars may be coupled together in advance to yield a ‘stand’. For example, three Range II tubulars may be coupled together to yield a ‘triple’. As another example, two Range III tubulars may be coupled together to make a stand. Handling stands instead of individual tubulars can make the drilling operation (especially tripping) faster. However, stands are generally too long to conveniently transport on land.
There is a need for safe and efficient apparatus and methods for delivering tubulars to or from a drill rig. There is also a need for safe and efficient apparatus for building and unbuilding stands of tubulars.
This invention has a number of aspects. While it is possible to apply these aspects in combination and there are synergies from applying these aspects in combination, these aspects are also capable of independent application. One aspect provides pipe handling apparatus that includes a live surface at least at an end that projects over a portion of the rig floor. Motion of the live surface may be controlled while tubulars are being hoisted to reduce or eliminate pendulum motion of tubulars. Another aspect provides a catwalk having a carriage configured to provide a reversible kink. An angle of the kink may be actively controlled. In some embodiments, a conveyor extends along the carriage and is operable with the catwalk straight or kinked in either direction. Another aspect provides apparatus for offline stand building and unbuilding. Another aspect provides methods for presenting tubulars to a drill rig. Other aspects combine two or more of the above. Embodiments of each of these aspects may have a wide range of details of construction. Elements that would be readily understood by those of skill in the art based on general knowledge and the present description and drawings have not been shown or described in detail to avoid unnecessarily obscuring the invention.
Further aspects and example embodiments are illustrated in the accompanying drawings and/or described in the following description.
The accompanying drawings illustrate non-limiting example embodiments of the invention.
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive sense.
In
Live surface 26 may, for example, be provided by a conveyor (which may be but is not necessarily provided by an endless loop), a sliding plate, a series of rollers, a pair of conveyors facing one another on either side of a gap through which the tail end of a tubular T can pass or the like. As described below, live surface 26 may be operated to control movement of the tail end of tubular T up to the point where the tail end of tubular T leaves pipe handling system 20. This control may be applied to reduce or substantially eliminate swinging of the tubular.
Live surface 26 may also or in the alternative be used to draw the tail ends of tubulars away from well center 14 as the tubulars are being removed from drill rig 10.
In the embodiment illustrated in
In some embodiments, live surface 26 extends along a working length of carriage 24. For example, live surface 26 may be provided by a conveyor that extends all along the working length of the carriage (where the ‘working length’ of the carriage is that portion of a carriage that supports any part of a tubular in normal operation). In some embodiments live surface 26 is a shorter surface located near the point where the tail end of a tubular leaves pipe handling system 20 (i.e. at the end of the carriage that is closest to well center 14).
In some embodiments carriage 24 comprises two sections pivotally coupled to one another such that the carriage may be kinked. In some such embodiments live surface 26 extends along both sections of the carriage. In some such embodiments live surface 26 comprises an endless conveyor that extends along both sections of the carriage and is operable with the carriage kinked. In other embodiments live surface 26 may extend along all or a part of first section 24A only.
Another feature of apparatus 20 in the illustrated embodiment is that live surface 26 extends to a location that is spaced apart horizontally from well center 14 by a distance D2 which is smaller than is typical with prior art pipe handling systems of the type illustrated in
A pipe rack 25 (see
Carriage 24 is configured in such a manner that tubulars placed on its upper surface do not tend to roll off of the upper surface. In the illustrated embodiment, carriage 24 has a trough 24D extending longitudinally along it. Tubulars T are located by trough 24D when they are loaded onto carriage 24. In some embodiments trough 24D is formed in a surface of a conveyor which also provides a live surface 26 extending along carriage 24.
As illustrated in
If tubular T is initially supported in part on carriage section 24B then, at a suitable point, tubular T may be advanced until its tail end is past pivotal joint 24C as shown in
In some embodiments a tubular is advanced by a backstop until a leading end of the tubular projects past leading end 24E of carriage 24 to hit a stop surface (which may, for example, comprise a surface fixed on ramp 23). This may be done with carriage 24 in the configuration shown in
In some embodiments a backstop is of a type that receives or otherwise engages an end of a tubular. A stop surface as described above may be used to hold the tubular still so that it can be fully engaged with a backstop. Various backstop embodiments are possible. In one embodiment a backstop comprises a simple plate that can engage an end of a tubular. In another embodiment a backstop comprises a projection that can be inserted into a bore of a tubular (see e.g. backstop 67A in
In some cases a tubular may be significantly longer than first section 24A of carriage 24. In such cases a backstop may be supported on an arm or arms which position the backstop rearward (i.e. toward second section 24B) from the trailing end of first section 24. For example, in a case where first section 24A has a length of approximately 35 feet (about 11 meters) and is being used to deliver Range III tubulars having lengths of about 45 feet (roughly 14 Meters) then a trailing end of the tubular may extend a few meters behind the trailing end of first section 24A. A cantilevered backstop may be provided to provide positive control over the trailing end of the tubular.
In the configuration shown in
As shown in
Advantageously, first section 24A may be horizontal or nearly horizontal when carriage 24 is in the configuration of
The motion of live surface 26 toward the leading end 24E of carriage 24 is controlled as tubular T is hoisted. For example, live surface 26 may be driven by a variable-speed actuator such that an operator or an automated controller can control the motion of the tail end of tubular T. The tail end of tubular T is prevented from sliding off the leading end of carriage 24 until tubular T is either vertical or nearly vertical. The velocity of the tail end of tubular T may be controlled such that tubular T has either no horizontal velocity or only very small horizontal velocity at the time that it leaves carriage 24.
In some embodiments the angle formed between first and second sections 24A, 24B is directly controlled by an actuator and the presentation angle θ (see
In some alternative embodiments the angle formed between sections 24A and 24B of carriage 24 is controlled indirectly by controlling the positions of the outer ends of sections 24A and 24B.
To facilitate control over the position and speed of the tail end of a tubular, live surface 26 may include features to reduce or prevent slippage of the tail end T′ of the tubular along live surface 26. For example, live surface 26 could include bars or other raised projections, recesses shaped to receive the tail end of tubular T, elastomeric coatings or pads, or the like. Live surface 26 may additionally or in the alternative carry a backstop of any of the types described herein.
Although the embodiment illustrated in
In block 44, the leading end T″ of the tubular T is lifted. As tubular T is lifted, the tail end of tubular T moves along carriage 24. For all or a portion of block 44, the tail end of tubular T is engaged by a live surface 26 which regulates the progress of the tail end of tubular T along carriage 24. For example, the tail end of tubular T may rest on a moving conveyor. In block 44A, the speed of the tail end of tubular T is controlled. In block 45, the tail end of tubular T is moved clear of the leading end 24E of carriage 24. At this point, tubular T may be coupled into the drill string projecting from well center 14.
In some embodiments block 44A comprises, during a first period moving the tail end T′ of tubular T toward well center 14 faster than tail end T′ would move if it were being dragged as a result of leading end T″ being hoisted. This pushes tubular T upward and creates some slack between elevator 13A and the leading end T″ of tubular T. Then, during a subsequent second period live surface may slow the motion of tail end T′ of tubular T. The second period may occur when tubular T is nearly vertical. This sequence may result in tubular T having zero or only a very small angular velocity when elevator 13A catches up and lifts tubular T vertically off of carriage 24.
Method 40 may be reversed to remove a tubular T from the drill rig. In this case, the live surface of carriage 24 may be operated to draw the tail end of tubular T away from well center 14 as tubular T is lowered by a hoisting mechanism of the drill rig onto carriage 24. In some embodiments the live surface of carriage 24 comprises a backstop and the tail end of tubular T is placed on the live surface adjacent to the backstop. The backstop may prevent the tail end of tubular T from sliding along the live surface.
A pipe handling system as described above may be used with single tubulars or with stands made of two or more tubulars. For example, the pipe handling system may operate to present triples to a drill rig. In some other embodiments, the pipe handling system may be used to present doubles made up of two tubulars to the drill rig. In some embodiments the doubles are doubles of Range III tubulars such that the doubles have a length of approximately 90 feet.
In cases where it is desired to provide pipe stands to a drill rig which are each made up of a number of tubulars, it can be desirable to store some or all of the tubulars individually (and not in the form of assembled stands). This is particularly the case in land-based drilling where stands may be too long to transport conveniently from one drill site to another. Furthermore, where a wellbore is very deep the number of stands required may exceed the storage capacity for assembled stands in a setback of the drill rig or other available racks for storing stands.
Whatever the motivation, if tubulars are to be stored individually, for example, in pipe racks, and yet presented to a drill rig in the form of stands, there is a need for a mechanism operable to combine two or more tubulars into a stand prior to presenting the stand to the drill rig and to dismantle the stand into individual tubulars when that stand is removed from the drill rig. Preferably, all couplings between tubulars in the stand are fully torqued when the stand is presented to the drill rig.
Ideally, stand building should be accomplished quickly enough that it can keep up or essentially keep up with operation of the drill rig while drilling. That is, the time taken to make up a stand should be no longer than the interval between the time that a drill rig accepts one stand and a time that the drill rig is ready to accept the next stand. Assembled stands may be stored in racks when tripping a drill string in or out. If the racks do not have enough capacity to contain the required number of stands then some stands may be assembled or dismantled to augment the capacity of the available storage for assembled stands. As an example, when tripping out every third stand (in general every Nth stand) may be dismantled while the remaining stands are placed in a setback area of the drill rig. One out of each N stands may be assembled from individual tubulars while tripping in. This reduces the number of stands that require storage and yet does not require stands to be assembled or dismantled at a rate fast enough to keep up with tripping of the drill string.
It is advantageous for stands to be presented to a drill rig at an angle that is inclined to the vertical. Preferably the stands are presented at an angle in the range of 5 to 25 degrees, more preferably 8 to 20 degrees, most preferably 12 to 18 degrees from vertical. If the angle is too large (stand is more horizontal) then the stand may project too low over the drill rig floor while it is being assembled. This may interfere with operation of the drill rig. If the angle is too small (stand is more vertical) then it may be difficult to couple to the stand and also stand building may occur undesirably close to the activity at well center.
Stand building apparatus 60 comprises a mast 62 which provides an inclined axis 63 along which a pipe stand can be built. In this respect, apparatus 60 is similar to the pipe stand building apparatus described in U.S. patent application Ser. No. 13/573,878 filed on 11 Oct. 2012 and entitled PORTABLE PIPE HANDLING SYSTEM. In some embodiments axis 63 is inclined at an angle of 5 to 25 or 10 to 20 or 12 to 18 degrees to vertical.
Apparatus 60 includes a make/break mechanism 61 operable for coupling and uncoupling tubulars from one another while the tubulars are held aligned with stand building axis 63. In the illustrated embodiment make/break mechanism 61 comprises a backup jaw 64, which may be actuated to hold a tubular against rotation. Backup jaw 64 is located part way up mast 62. Backup jaw 64 may, for example, comprise a plurality of actuators which may be operated to firmly grip a tubular.
A mechanism 65 is provided for bringing tubulars to backup jaw 64. In the illustrated embodiment, mechanism 65 comprises a carriage 66. Carriage 66 is movable on a base 62A relative to mast 62 between a first position (shown in dotted lines) in which it can receive a tubular from a tubular storage area (not shown in
Carriage 66 may be placed into the first position at which it receives a first tubular T1 for assembly into a stand as shown in
Most tubulars are designed to be gripped and rotated at tool joints at either end of the tubular. The tool joints have thicker walls and are more robust than remaining portions of the tubular. Chuck 67 has a deep enough opening in its jaws to receive the trailing end of a tubular T (usually, the pin end) and to grip the tubular on the tool joint.
Since the tool joint may be received within the jaws of chuck 67 as chuck 67 brings the trailing end of the tubular up toward backup jaws 64, there is a need for a way to pass off the tubular from chuck 67 to backup jaws 64 in such a manner that backup jaws 64 end up gripping the tubular on the tool joint. A wide range of transfer mechanisms are possible. Some of these are as follows.
One transfer mechanism, which is suitable for the case where a stand is being built only of two tubulars, is that the jaws of chuck 67 may be closed when bringing a first tubular T1 up to backup jaws 64. The closed jaws of chuck 67 may provide a pushing surface which pushes on the pin end of tubular T1. Chuck 67 may simply be advanced until tubular T1 has been pushed almost all of the way through backup jaw 64 and the tool joint is within the gripping range of backup jaw 64. In some embodiments a ramp, movable roller or the like may be actuated to align the centerline of tubular T1 with the centerline of backup jaw 64 closely enough for backup jaw 64 to grip tubular T1.
Another example transfer mechanism provides a set of feed rollers above backup jaws 64. The feed rollers may grip and advance a tubular until its lowermost tool joint is within the gripping range of backup jaws 64.
Another example transfer mechanism that may be applied if tubular T is received within the jaws of chuck 67 as it is being advanced, is to provide an actuator that can be advanced axially through the jaws of chuck 67 to push the tail end of tubular T1 upwardly until the lower tool joint of tubular T1 is within the gripping range of backup jaws 64.
Another example transfer mechanism is to make the jaws of chuck 67 double acting (so that the jaws of backup jaw 64 may be selectively moved radially outwardly or radially inwardly). Outward movement of the jaws may, for example, be caused by a spring or other bias mechanism, or by hydraulic or pneumatic pressure. The jaws may be coupled by a linkage to a basket which engages the tail end of tubular T1. Driving the jaws outwardly lifts the basket, thereby allowing the tool joint of tubular T1 to be engaged within the gripping range of backup jaw 64. When chuck 67 is closed, the basket may drop to a level low enough such that the tool joint of the tubular can be gripped by the jaws of chuck 67.
Another example transfer mechanism provides a resilient mounting for chuck 67. For example, chuck 67 may be spring loaded. Chuck 67 may be displaced downwardly against a bias mechanism until the upper end of a probe (which may optionally be a fixed probe) projects through the bore of chuck 67. The upper end of the probe may include a basket to receive the pin end of tubular T1. In this embodiment, as chuck 67 is advanced to bring the tubular upwards, chuck 67 can advance only until it is stopped by a stop or by hitting backup jaws 64. As the lifting is continued, the probe continues to lift the tubular as the bias mechanism is compressed until the tool joint at the tubular is within the gripping range of the backup jaw. Providing a spring-loaded chuck 67 also has the advantage that the bias mechanism may allow the chuck to move axially to compensate for thread advance when screwing the connections for tubulars together or apart. A resiliently-mounted chuck may be provided even in cases where another mechanism is used to transfer tubulars to backup jaws 64. The bias mechanism may comprise suitable springs. The springs may be gas springs, for example. Gas springs can provide a reasonably constant force over a large deflection range. Active or passive hydraulic or pneumatic cylinders could be used in place of the spring.
In a further example embodiment, chuck 67 may be advanced toward backup jaws 64. Backup jaws 64 may then be used to grip the exterior of the tubular T1 (even if this is not at a tool joint). The gripping needs to only be tight enough to prevent the tubular from falling down. Chuck 67 can then be retracted to below the pin end of tubular T1 and its jaws may be closed to provide a pushing surface. Chuck 67 may then be advanced so that the pushing surface of the closed jaws engages the tail end of tubular T1. Chuck 67 may then be advanced until the tool joint of tubular T1 is within the gripping range of backup jaws 64.
After a tubular T1 has been gripped by backup jaws 64, carriage 66 may be moved back to its first position to receive another tubular T2 (
Carriage 66 carrying tubular T3 is then moved to its second position at which point chuck 67 may be advanced to engage the coupling on the upper end of tubular T3 with the coupling on the lower end of tubular T2 as illustrated in
Mast 62 may include a structure 68 (see
When a pipe stand is complete, the uppermost end of the pipe stand projects past the top 68B of structure 68. In some embodiments, structure 68 is positioned adjacent to a drill rig such that the uppermost end of a stand is at a location at which the stand can be grabbed by a hoisting equipment of the drill rig (e.g. elevator 13A). For example, in some embodiments, the upper end of structure 68 is placed adjacent to a window through which a pipe stand may be received into a drill rig. In some embodiments, the drill rig comprises a top drive 13 having an elevator 13A that can grab the upper end of a pipe stand which projects out past the top 68B of structure 68.
Structure 68 includes an actuator which can rotate structure 68 around an axis typically, an axis that is coincident with or at least parallel to axis 63, so that the open side 68A of structure 68 is either facing toward drill rig 10 so that a stand may be transferred to or from drill rig 10, or so that the open side 68A of structure 68 is facing in a different direction such that the pipe stand remains cradled by structure 68. It is possible but not mandatory that structure 68 is rotatable by 180 degrees. In some embodiments, rotation of structure 68 is actuated by a single hydraulic cylinder or other linear actuator. In some embodiments structure 68 is rotated by a rotary actuator such as a hydraulic or pneumatic or electric motor. In some embodiments a structure 68 has a range of angular rotation of 120 degrees or less.
If desired, structure 68 may include one or more supports 69 coupled to the drill rig to stabilize structure 68. For example, a support 69 may be provided near top end 68B of structure 68. Support 69 is configured to permit rotation of structure 68 as described above.
To transfer a pipe stand to a drill rig, the upper end of the pipe stand may be grabbed by hoisting equipment on the drill rig. When this has been done, structure 68 may be rotated about its axis of rotation to allow the pipe stand to exit from structure 68 through longitudinal opening 68A and be drawn into the drill rig.
Backup jaw 64 and any support 69 for structure 68 may be constructed to have openings facing toward drill rig 10 so that tubulars extending through backup jaw 64 and/or a support structure, if present, can be passed to drill rig 10.
In some embodiments, when a pipe stand is being carried to the drill rig, motion of the tail end of the pipe stand is controlled by a live surface, as described above. In some embodiments, the live surface is provided on carriage 66 which may be constructed in a similar manner to the pipe handling apparatus 20 which is described above. In some embodiments, the live surface is provided by a separate structure from carriage 66.
In some embodiments carriage 66 comprises two parts 66A and 66B pivotally coupled together so that part 66A can be aligned with stand-building axis 63 while part 66B remains horizontal (or more nearly horizontal than part 66A). This allows the overall height of apparatus 60 to be minimized.
Apparatus according to some embodiments comprises a carriage having two parts that are pivotally connected to one another and an actuator arranged to cause the carriage to kink selectively in either of two directions about a pivot axis. With a positive kink, the first part of the carriage is more nearly horizontal than the second part of the carriage, as illustrated in
In some embodiments, a carriage has a live surface provided by a conveyor that extends along both the first and second sections 66A and 66B of a carriage 66. The conveyor may be operated when the carriage is a straight configuration, has a positive kink, or has a negative kink.
Each conveyor segment 72 includes one or more members or keels 74 that project inwardly. Keels 74 include transversely-projecting features 75 that engage rails or guides 76. In the illustrated embodiment, the transversely-projecting features comprise rollers. The engagement of the transversely-projecting features with rails or guides 76 allows segments 72 to follow a concave path on the concave side of a kink when a carriage is kinked.
As conveyor sections 72 travel around concave or convex curves, the edges of adjacent sections 72 move together or apart. In some embodiments, an example of which is shown in
As changing the angle of kink between carriage sections 66A and 66B can change the length of the path of conveyor 70 somewhat it is desirable to provide a dynamic tensioning mechanism (e.g. a resiliently-biased sprocket) to maintain appropriate tension in conveyor 70. In an example embodiment, conveyor 70 is driven by drive sprockets located at a leading end of carriage 66 and idler sprockets at a trailing end of carriage 66 are resiliently biased (e.g. by gas springs) to maintain a desired tension in conveyor 70.
Features of the various embodiments described herein may be mixed and matched in any sensible combinations to yield further embodiments. Apparatus according to embodiments as described herein can handle drilling tubulars between a horizontal storage and staging position and a rig floor single-joint presentation position and a high-angle stand presentation position. Apparatus 60, 60A or 100 can assemble single tubular joints into fully-torqued stands and disassemble the stands. This may be performed independently of normal rig drilling or tripping operations and with no manual interaction with the tubulars. Apparatus as described herein may facilitate efficient hands-free tripping with Range III double stands or Range II triple stands in a manner compatible with horizontal single racking.
In an example embodiment, apparatus includes the following major components: a pipe deck, ramp, conveyor and stand frame. The pipe deck provides a horizontal surface adjacent to the rig vee-door side of a drill rig. The pipe deck may be close to the ground in some embodiments. For example, the pipe deck may be at a 26 inch elevation (approximately 65 cm) above ground level. The pipe deck may include tubular handling provisions such as: a conveyor top vee-trough surface; rocker beams for selective rolling of tubulars into or out of the conveyor; index pins for loading individual tubulars onto the conveyor; kickers for ejection of tubulars out of the conveyor vee-trough; tilting integrated pipe racks for storage or staging of tubulars. Elevating pipe tubs or traditional pipe racks may be positioned adjacent to the integrated pipe racks. Optional equipment such as a tailing winch, bucking machine, self-propelled moving system, and/or pony sub for well center clearance may also be provided.
The ramp provides an inclined surface or guide from the pipe deck to the rig floor, for manual sliding of tubulars and equipment. The ramp includes guidance and lifting provisions for the conveyor. Lift of the conveyor on the ramp may be controlled by suitable drives such as electrical drives. Redundant drives may be provided. The drives may provide variable speed and torque. Conveyor frame support rollers at the top of the ramp facilitate moving the conveyor into cantilevered positions. The ramp is optionally integral and coaxial with the stand frame, if so equipped. The conveyor may comprise a continuous chain conveyor. In an example embodiment the conveyor is approximately L56 ft (about 17 meters), W28 in (about 70 cm) and D19 in (about 50 cm) with steel vee-trough segments for axial movement of tubulars and/or the tailing in/out of tubulars.
In some example embodiments the conveyor is electrically (e.g. using a VFD—variable frequency drive) driven with infinite speed and torque control. The conveyor may include a bi-directional active hinged frame (kink function) for optimum tubular presentation geometry to high rig floors (positive kink) and to enable stand building (negative kink). The kink may be hydraulically actuated, for example. Retractable sidewalls may be provided for lateral tubular safety retention. The sidewalls may be hydraulically actuated, for example. A backstop may be fixed to the conveyor surface, for reaction of tubular axial loads. The backstop may have any of the configurations described above, for example.
Some embodiments provide a drive chuck or other make/break apparatus for tubular rotation for stand building. The drive chuck may, for example, have torque for making up or breaking open tubulars in excess of 30,000 foot-lb. (about 40,000 N·m) in some embodiments. For example, the chuck drive may be able to torque tubulars to 45,000 ft-lb (about 60,000 N·m), 60,000 ft/-lb (about 80,000 N·m), or the like. Grip and rotation of the chuck may for example be hydraulically actuated. A coaxial drive chuck probe may be provided for axial tubular support and positioning.
An elevate function to align the tubular with the drive chuck may be hydraulically actuated, for example. The elevate function may, for example, lift a section of a conveyor sufficiently so that a tubular located in a trough of the conveyor is made to be coaxial with a chuck or other make-break apparatus.
A stand frame may be provided for supporting a stand being built or taken apart. The stand frame may, for example comprise an open frame above rig floor elevation, for support of a slit tube and the back-up jaw. The rotatable slit tube is provided for support of the upper portion of the stand. The slit tube may be actuated hydraulically to rotate. The tube may be telescoping for transport and service (e.g. via a positioning winch which may also be used to position the backup jaw). The back-up jaw (BUJ) is provided for reaction of the drive chuck torque on the adjacent tool joint. Hydraulic grip and hydraulic winch positioning may be provided along the stand-building axis. The stand frame or its components may be configured so that they can be lowered to the pipe deck for service.
A secondary pipe retainer may be mounted to the bottom of the backup jaw. The secondary pipe retainer may be hydraulically actuated. Adjustable feet may be provided for stabilization of the stand frame against the mast of a drill rig. The adjustable feet do not need to be pinned to the mast legs. Apparatus as described may optionally be used together with a vertical pipe racking system. Apparatus as described may accommodate manual ramp operations, including top drive drag-up.
Apparatus like apparatus 60 or 100 or 100A may be used in various operating modes: For example, in a manual pipe handling mode the ramp facilitates conventional manual pick-up of tubulars and equipment with a tugger winch or the travelling equipment. The ramp may, for example, be used to accommodate rig-up of a top drive using either the drag-up or crane method. Apparatus like apparatus 60 or 100 may be used as a high-floor catwalk: The apparatus may be used, for example to transfer Range II or III tubulars to/from the rig floor, for presentation to top drive elevators. A kink function optimizes the tubular angle of presentation on high rig floors. An optional live surface (e.g. conveyor) tailing feature minimizes tubular pendulum action, eliminating the need for manual interaction with the tubular.
Apparatus 60 or 100 or 100A may be used for offline stand building (and/or unbuilding). In this mode, apparatus 100 may assemble and/or disassemble triple Range II or double Range III stands. Apparatus 100 may provide full connection torque capability. Apparatus 100 may present stands to top drive elevators below (or at) racking board elevation. In this mode, manual interaction with the tubulars is not required.
The conveyor tailing feature minimizes tubular pendulum action for hands-free transfer of the stand to/from the vertical, top-drive-suspended position. An online stand-handling mode provides functionality similar to stand building but faster to enable on-line tripping operations. Enhanced actuation speeds may be provided throughout plus semi-automated control sequencing and coordination to minimize cycle time. Double Range III stands are preferred for efficiency. This mode eliminates the derrickman function. Efficient hands-free tripping may be achieved without a vertical racking system.
The following is an example of an offline stand building operation sequence:
Apparatus as described herein (e.g. apparatus 20 or apparatus 60 or apparatus 100 or any other apparatus as described herein) may be constructed so that it can telescope or fold for transportation.
Various control systems may be provided for a live surface such as a conveyor. In some embodiments motion of a live surface is manually controlled. In some embodiments motion of the live surface is at least semi-automated. A manually controlled embodiment may, for example, provide a control which allows a user to vary a speed of a live surface such as a conveyor 70. In some embodiments apparatus is provided to assist a user to control the live surface in such a manner that the tail end of a tubular or stand is brought to a stop just before the tubular is lifted off of the live surface.
One examples of an assistive device is a camera located to view an elevator that is lifting the tubular and a monitor connected to display images acquired by the camera to an operator. The operator may operate the speed control to push the tubular faster until the user sees that the tubular has pushed through the elevator by a suitable distance. The operator may then slow the live surface as the orientation of the tubular is nearing vertical.
Another example of an assistive construction is the provision of markings along side live surface 26. An operator may view the progress of the tail end of a tubular along the live surface with reference to the markings to determine when to vary the speed of the live surface in order to control swinging of the tubular. In some embodiments the markings are movable to adjust the markings to provide proper control over tubulars of a particular length. Markings may be provided by lamps such as LEDs, projected lights, protrusions, painted strips, or the like.
In some embodiments a controller is configured to automatically or semi-automatically control motion of a tail end of a tubular. The controller may base such control on any of or any combination of a wide range of inputs that are relevant to the position and orientation of the tubular. These inputs can include, for example:
In some embodiments the controller is configured to vary the speed of the conveyor or other live surface in coordination with the position of the top end of the tubular and the rate at which the top end of the tubular is being raised or lowered. In some such embodiments the controller is configured to compute an angle of the tubular relative to an axis (e.g. a vertical axis) and to vary the speed of the conveyor based at least in part on the determined angle. For example, the controller may cause the live surface to reduce a speed of the tail end of the tubular when the tubular is nearly vertical.
In some embodiments the controller uses a known geometry resulting from a length of a tubular, the position and path taken by the live surface and the position and height of the elevator lifting the tubular to advance the tubular along the live surface at a rate sufficient to lift the top end of the tubular relative to the elevator. This may be done ‘blind’—based on the geometry alone. For example, if the live surface is flat then, using the law of cosines, the length of a tubular and the location of the elevator relative to the live surface, one can compute the position that the tail end of the tubular will have along the live surface when there is no slack between the tubular and the elevator. The controller may calculate this position and advance the live surface so that the tail end of the tubular is advanced toward the well center relative to the calculated position. In some simpler embodiments the controller simply operates the live surface to move the tail end of the tubular toward well center at a speed sufficient to cause slack at the elevator for a current known or expected hoisting speed.
In some embodiments the controller monitors sensors to detect slack between the tubular and the elevator. Slack may be detected by any one or more of: measuring weight on the elevator (which goes down when there is slack); measuring weight on the live surface (which goes up when the elevator is slack); detecting that the tubular projects more than a threshold amount above the elevator by a proximity sensor, electric eye or the like or image processing an image obtained by a camera having a view of the elevator and tubular, for example. In some cases the controller may also measure an amount of slack created by the tubular being pushed up relative to the elevator.
After slack has been detected, the controller may operate the live surface to carry the tail end of the tubular toward a release zone from which the tubular will be lifted off of the live surface. On approaching the release zone the controller may automatically reduce speed of the tail end of the tubular such that the tubular has zero or only a very small angular velocity when it arrives in the release zone. For example, the linear speed of the tail end of the tubular along the live surface may be reduced to 10 inches per second (about 25 cm/sec) or less.
In order to track the position of the tail end of the tubular along the live surface the controller may use calculation (e.g. based on a controlled speed of the live surface and/or feedback from a motion control driving the live surface) and/or output from one or more sensors. The sensors may directly detect the position of the tail end of the tubular using optical or other means such as electric eyes, proximity sensors, cameras, or the like. In addition or in the alternative the sensors may sense the location of pressure exerted by the tubular on the live surface.
In some embodiments a controller is configured to warn an operator and/or to perform an emergency stop if the stickout of a tubular past an elevator 13A exceeds some predetermined safe threshold. Such a system may prevent a tubular from spearing a top drive 13, for example.
In some embodiments, the controller is configured to drive a conveyor to move faster during tripping out and to drive the conveyor more slowly when drilling or tripping in.
A controller may be formed from any suitable processing system, such as a custom configured device, such as a micrologic controller, field programmable gate array (FPGA), programmable logic controller (PLC), or a suitably programmed PC, or the like. Control systems may additionally or in the alternative comprise hard-wired logic such as ASICS or dedicated logic circuits.
The control methods described herein may be implemented by computers comprising one or more processors and/or by one or more suitable processors, which may, in some embodiments, comprise components of suitable computer systems. By way of non-limiting example, such processors could comprise part of a computer-based control system which also controls other components of apparatus as described herein or as a stand-alone control system. In general, such processors may comprise any suitable processor, such as, for example, a suitably configured computer, microprocessor, microcontroller, digital signal processor, field-programmable gate array (FPGA), PLC, other type of programmable logic device, pluralities of the foregoing, combinations of the foregoing, and/or the like. Such a processor may have access to software which may be stored in computer-readable memory accessible to the processor and/or in computer-readable memory that is integral to the processor. The processor may be configured to read and execute such software instructions and, when executed by the processor, such software may cause the processor to implement some of the functionalities described herein.
Certain implementations of the invention comprise computer processors which execute software instructions which cause the processors to perform a method of the invention. For example, one or more processors in a computer system or industrial control system may implement data processing steps in the methods described herein by executing software instructions retrieved from a program memory accessible to the processors. The invention may also be provided in the form of a program product. The program product may comprise any medium which carries a set of computer-readable signals comprising instructions which, when executed by a data processor, cause the data processor to execute a method of the invention. Program products according to the invention may be in any of a wide variety of forms. The program product may comprise, for example, physical (non-transitory) media such as magnetic data storage media including floppy diskettes, hard disk drives, optical data storage media including CD ROMs, DVDs, electronic data storage media including ROMs, flash RAM, or the like. The instructions may be present on the program product in encrypted and/or compressed formats.
A simple example control scheme uses signals indicating whether or not the tubular projects past two threshold positions above the elevator. These positions may, for example, correspond to two optical beams or two positions in the field of view of a camera, for example. The controller may operate the live surface in a way that attempts to keep the top of the tubular between the two threshold positions. For example, the controller may accelerate the live surface until the first threshold position is reached and slow the live surface if the second threshold position is reached by the top of the tubular. This relatively crude control may be sufficient to maintain a desired amount of slack between the tubular and the elevator to facilitate stopping travel of the tail end of the tubular before the elevator lifts the tubular off of the live surface.
In one alternative embodiment, instead of or in addition to providing a live surface that is movable relative to a catwalk, the catwalk or carriage is itself moved to control position of the tail end of a tubular up to, or almost up to, the point where the tubular leaves the catwalk. Where a live surface is provided in the form of a conveyor, it is not mandatory that the conveyor have the detailed structure as described herein. Other forms of conveyor comprising flexible belts or chains suitably robust for the demands of the application may also be used as live surfaces and controlled as described herein. A live surface need not be large. A live surface may be provided in the form of a socket or platform just large enough to receive and support the tail end of a tubular as the tubular is transferred to or from a drill rig and controllable to move as described herein.
Unless the context clearly requires otherwise, throughout the description and the claims:
Words that indicate directions such as “vertical”, “transverse”, “horizontal”, “upward”, “downward”, “forward”, “backward”, “inward”, “outward”, “vertical”, “transverse”, “left”, “right”, “front”, “back”, “top”, “bottom”, “below”, “above”, “under”, and the like, used in this description and any accompanying claims (where present), depend on the specific orientation of the apparatus described and illustrated. The subject matter described herein may assume various alternative orientations. Accordingly, these directional terms are not strictly defined and should not be interpreted narrowly.
For example, while processes or blocks are presented in a given order, alternative examples may perform methods having steps occurring in a different order, and some steps or processes may be deleted, moved, added, subdivided, combined, and/or modified to provide alternative or subcombinations. Each of these processes may be implemented in a variety of different ways. Also, while processes or steps are at times shown as being performed in series, these processes or steps may instead be performed in parallel, or may be performed at different times.
Where a component (e.g. a member, actuator, controller, assembly, device, seal, motor, circuit, etc.) is referred to above, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.
Some non-limiting enumerated example embodiments of the technology described herein are as follows:
Specific examples of systems, methods and apparatus have been described herein for purposes of illustration. These are only examples. The technology provided herein can be applied to systems other than the example systems described above. Many alterations, modifications, additions, omissions, and permutations are possible within the practice of this invention. This invention includes variations on described embodiments that would be apparent to the skilled addressee, including variations obtained by: replacing features, elements and/or acts with equivalent features, elements and/or acts; mixing and matching of features, elements and/or acts from different embodiments; combining features, elements and/or acts from embodiments as described herein with features, elements and/or acts of other technology; and/or omitting combining features, elements and/or acts from described embodiments.
It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, omissions, and sub-combinations as may reasonably be inferred. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
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