The present application relates to a drill floor system for performing a plurality of fully automatic work operations on a drill floor, and to a method for performing a plurality of work operations on a drill floor.
When drilling hydrocarbon wells and during offshore production of hydrocarbons, platforms are used which either have platform legs anchored to the seabed or are floating structures in deeper waters. During drilling, new lengths of the drill pipe are screwed on as the well is drilled deeper. At the bottom of the pipe string is arranged a bottom hole assembly (BHA) comprising different components. The bottom hole assembly components have to be assembled and the bottom hole assembly mounted on the pipe string on the drill floor before it is lowered, and more tubular elements are screwed onto the pipe string as it is run into the borehole and as the drilling advances. If some form of intervention has to be made in the well, different types of tools will be used depending on what well operation is to be carried out. These tools must be handled on the drill floor and are handled with varying degrees of involvement by personnel on the drill floor in order to control the different work operations that are being carried out. The presence of personnel on the drill floor when tools and pipe sections are moved is associated with a risk of accidents and serious injuries.
Today no system exists that is able to handle different types of devices on the drill floor without personnel being involved in the operations. It will therefore be desirable to have a system that reduces the need for personnel on the drill floor, partly in order to reduce the chances of accidents occurring when personnel handle the equipment on the drill floor. There is also a desire to boost the efficiency of and rationalise the work operations that are performed on the drill floor and thereby reduce expenditure of time and costs.
The object of the present invention has therefore been to develop a new system for handling different types of work tools and/or downhole tools on the drill floor.
In particular, it has been an object of the present invention to provide a tool for automatic handling of both tubular elements and the different components of a bottom hole assembly and other parts that are to be lowered into the borehole.
It has further been an object of the present invention to develop a system that reduces the risk of injuries to personnel on the drill floor.
It has also been an object of the present invention to save space on the drill floor and reduce installation costs and to rationalise the work flow, thereby saving time and reducing costs in connection with different types of work operations on the drill floor.
These objects are achieved by a pipe handling arm as defined in claim 1, a drill floor system as defined in claim 3, and a method for performing a plurality of work operations on a drill floor as defined in claim 15. Additional embodiments of the pipe handling arm, drill floor system and method are disclosed in the dependent claims.
Accordingly, there is provided a pipe handling arm comprising a pipe gripping tool with gripping devices for gripping and holding a tubular element, wherein the pipe handling tool further comprises a first coupling half arranged on the pipe gripping tool for connection of a work tool. The work tool can, for example, be used to handle a downhole device such as small subs (i.e., short pipes that are to be screwed into the drill string, bit, bit breaker, or to handle work platforms and personnel baskets and parts of other machines on the drill floor. By using an already existing pipe handling arm/apparatus on the drill floor and providing it with a coupling half, preferably a rapid coupling, and using a work tool that has a complementarily shaped second coupling half such that the work tool can be connected to and disconnected from the pipe handling arm as required, it is possible to reduce the number of machines on the drill floor that handle pipes and other devices that have to be moved around on the deck. This saves space on the drill floor and gives lower installation costs.
The pipe handling arm is preferably adapted for fully automatic connection to and disconnection from the work tool.
A drill floor system is also provided for performing a plurality of fully automatic work operations on a drill floor. The drill floor system comprises at least one fully automatic pipe handling arm as described above and at least one work tool for performing a number of different work operations on the drill floor, where the at least one pipe handling arm and the at least one work tool are adapted for fully automatic connection of the at least one work tool to the at least one pipe handling arm and fully automatic disconnection of a connected work tool from the at least one pipe handling arm. The drill floor system further comprises a control system which at least is adapted to control the movements of the pipe handling arm, the automatic connection of the at least one work tool to the at least one pipe handling arm, and the automatic disconnection of the at least one work tool from the at least one pipe handling arm such that a number of work operations on the drill floor can be automated and performed without the assistance of personnel.
A work operation here will typically be taking a downhole device, for example, a bottom hole assembly component, and mounting it on another downhole device, which also may be a component of the bottom hole assembly, or mounting a tubular element on a downhole device, for example, a bottom hole assembly component, or vice versa. A work operation can also involve moving a device, for example, a valve device that is to be used in a downhole operation, from a position in which the device is stored into a position in which the device can be lowered into the well. A work operation can, of course, also consist of dismantling a pipe string and/or downhole devices that are pulled out of the well and placing tubular elements and/or downhole devices in their respective positions on the drill floor.
Different devices that are used down in the well might need different work tools to be moved from a position on the drill floor in which they are stored into a position in which they are ready to be sent down into the well. It may therefore be necessary to have several work tools that can be mounted and removed as required.
That the work operation is fully automatic means that the control system monitors and controls the pipe handling arm and the work tool, if any, connected to the pipe handling arm. The pipe handling arm preferably comprises gripping devices such that when no work tool is mounted on the pipe handling arm, it can preferably be used to handle tubular elements. The control system preferably has control of where the different work tools and/or downhole devices are located, and monitors and controls the operations required to connect a work tool to the pipe handling arm, the operations required to disconnect a work tool from the pipe handling arm, and it monitors and controls the pipe handling arm and the mounted work tool when the pipe handling arm performs a work operation with the work tool on the drill floor, such as gripping and assembling the components of a bottom hole assembly as mentioned above, or moving a downhole device into a position in which it can be run into the well, and moving a downhole device that has been taken up from the well into its storage position on the drill floor. That the work operations required to perform a particular action, such as handling a bottom hole assembly on the drill floor, are fully automatic thus means that no persons are involved in connecting the right work tool, in the movements of the pipe handling arm and the work tool for performing the work operations, such as gripping the right component of the bottom hole assembly and mounting it together with a tubular element or another component of the bottom hole assembly. The only thing the personnel need do is therefore to sit in a control room and start the process. As soon as the control system has received a message as to what is to be done, i.e., what process should be performed, it takes over and controls the pipe handling arm, the connection and disconnection of work tools and the performance of the necessary work operations in order to execute the desired process, as, for example, assembling a bottom hole assembly. Thus, the need to have personnel moving around on the drill floor is obviated, which will reduce significantly the number of personal injuries.
The drill floor system may comprise one or a plurality of work tools for performing a number of different work operations on the drill floor, wherein the at least one pipe handling arm and the work tool or tools are adapted for fully automatic connection to the at least one pipe handling arm and fully automatic disconnection from the at least one pipe handling arm.
The at least one work tool preferably comprises at least one holding device for gripping and holding a downhole device on the drill floor. It may, for example, be a holding device for a tubular element or a downhole tool such as a component of a bottom hole assembly, a valve device, a pipe plug etc.
In order for the control system to have control of where the different work tools are located, the drill floor system may comprise a separate storage space for each work tool and/or each downhole device, where the work tools and/or downhole devices are placed when they are disconnected from the at least one pipe handling arm and are not in use. The position for each work tool and each downhole device is entered in the control system such that the pipe handling arm can move into the right place for connection of the right work tool or downhole device, or disconnection and placing in the correct storage space for downhole devices and work tools after use.
To save space on the drill floor, the drill floor system comprises at least one tool store comprising at least one storage space for a tool that is adapted for connection to the at least one pipe handling arm, and/or a downhole device that is adapted for connection to the work tool. In the cases where the drill floor system comprises many different work tools and/or downhole devices, it is conceivable that the drill floor system may comprise two or more tool stores.
The at least one tool store preferably comprises a plurality of storage spaces for a number of work tools and/or downhole devices. All the work tools and downhole devices preferably have their own storage space in the tool store, unless they are of a shape and/or size which makes it impossible for them to fit into such a tool store. The work tools and/or downhole devices that perhaps for different reasons do not fit into the tool store will preferably have a specific storage space on the drill floor where they are stored when not in use. The tool store preferably comprises a system of shelves, each shelf having one or more compartments depending on the size and shape of the work tools and/or downhole devices and available space on the drill floor.
To ensure that connection of a work tool to the at least one pipe handling arm, or connection of a downhole device to a work tool, takes place without any problems, the storage spaces may comprise a holding device to hold the at least one work tool and/or downhole device or devices in a fixed position in their respective storage spaces. The control system will then know exactly where the different work tools and/or downhole devices are and how they are oriented in the space. This prevents the work tools and/or downhole devices from changing their position as a result of being inadvertently knocked into or jolted when in storage on the drill floor, which would have made it more complicated to ensure performance of a fully automatic connection of a work tool to the at least one pipe handling arm and connection of a downhole device to a work tool on a pipe handling arm. Holding devices can, for example, comprise a depression in the surface of the storage space and a complementarily shaped base on the work tool or downhole device, or a form of gripping device that physically holds the work tools and/or downhole devices in place in their respective storage spaces.
For connection of a work tool to the at least one pipe handling arm, the at least one pipe handling arm is preferably provided with a first coupling half and each work tool is provided with a second coupling half, wherein the first coupling half and the second coupling half are matingly configured for fully automatic connection of the work tools to the at least one pipe handling arm and fully automatic disconnection of a connected work tool from the at least one pipe handling arm. A fully automatic connection and disconnection of the work tools means, as in the above, that the connection and disconnection of the work tools is monitored and controlled by the control system, and that the connection and disconnection takes place without personnel being involved in the process. The mating first and second coupling halves are preferably standard coupling elements that can be controlled by a control system.
The at least one pipe handling arm preferably comprises a permanently mounted tool, for example, one or more gripping tools for tubular elements, in addition to the first coupling half. The at least one pipe handling arm thus normally handles tubular elements that are taken from their storage space and screwed onto the drill pipe as the drilling of the well advances, and, where relevant, tubular elements that are unscrewed and placed in the storage space if the drill pipe has to be taken up from the well. In this embodiment, a first coupling half for fully automatic connection of a work tool and fully automatic disconnection of a connected work tool from the at least one pipe handling arm is preferably provided on the permanently mounted work tool. When there is a need to use a work tool other than the permanently mounted tool, the at least one pipe handling arm can be connected to the desired work tool which is preferably stored in the tool store.
The pipe handling arm and/or the at least one work tool is preferably provided with necessary sensors of various types, such as GPS devices and other position-determining devices, speed sensors etc., the various sensors being signally connected to the control system, such that the control system is able to control the connection and disconnection of the work tool to/from the at least one pipe handling arm, the movement of the pipe handling arm and connected work tool, and the handling of downhole devices and tubular elements on the drill floor through use of the at least one pipe handling arm and the connected work tool. For example, the first coupling half on the at least one pipe handling arm may comprise a position-determining device for determining the position of the first coupling half on the drill floor, which position-determining device is signally connected to the control system, whilst the second coupling half on the work tools may comprise a position-determining device for determining the position of the second coupling half on the drill floor, which position-determining device is signally connected to the control system. The position-determining devices preferably comprise one or more sensors that are signally connected to the control system and which, in a known way, will be able to determine the precise position of the first coupling half and/or the second coupling half.
As mentioned above, the control system is preferably adapted to at least register and remember the respective disconnected positions of the work tools, to monitor and control the movements of the at least one pipe handling arm, and to monitor and control fully automatic connection of a work tool to the at least one pipe handling arm and fully automatic disconnection of a work tool from the at least one pipe handling arm, such that a plurality of work operations on the drill floor, using respective work tools, can be automated and performed without the assistance of personnel.
In the cases where the reach of the at least one pipe handling arm is not sufficient to reach the work tools in their respective storage spaces, the downhole devices to be handled on the drill floor and the storage positions for the downhole tools and the position they are to be moved into, typically above the borehole, the at least one pipe handling arm can be movably arranged on the drill floor for vertical and/or horizontal movement of the at least one pipe handling arm relative to the drill floor. The at least one pipe handling arm can, for example, be arranged on a support element that can be moved up and down along one or more columns for vertical movement of the pipe handling arm. For horizontal movement of the at least one pipe handling arm, it can be arranged on a support element that runs on guides, such as rails, on the drill floor.
In the cases where it is not sufficient to have one pipe handling arm, the drill floor system may comprise a plurality of pipe handling arms that are adapted for fully automatic connection of a work tool to each of the pipe handling arms and fully automatic disconnection of a work tool from each of the pipe handling arms. This means that several different work operations can be performed in quick succession where one work tool is not capable of performing all the work operations. For example, a first pipe handling arm with a work tool can bring a device into a position above the drill pipe where a second pipe handling arm with a second work tool is ready to connect this device to equipment for lowering the device into the well. In some cases, this may be so time-saving that it is worthwhile using two or more pipe handling arms instead of using one pipe handling arm that has to change work tool between the different work operations.
A method is also provided for performing a plurality of work operations on a drill floor, for example, on a floating structure, where the work operations are performed using a pipe handling arm and a drill floor system, as described above, comprising at least one work tool, wherein the method comprises:
If the system comprises several work tools, they are preferably placed, as described above, in separate storage spaces when they are disconnected from the at least one pipe handling arm. As mentioned above, each work tool and/or each downhole device is preferably placed in a tool store comprising a plurality of storage spaces for respective downhole tools and/or work tools that are disconnected from the at least one pipe handling arm.
The at least one fully automatic work operation may comprise connecting at least one downhole device to a pipe string or to another downhole device. The at least one downhole device may comprise at least one component of a bottom hole assembly, and the at least one fully automatic work operation may comprise connecting the at least one component of the bottom hole assembly to a pipe string or to another bottom hole assembly component. The at least one work tool is preferably disconnected from the at least one pipe handling arm before the at least one pipe handling arm is to handle a tubular element.
A non-limiting embodiment of the invention will be described below with reference to the attached figures, wherein:
It should first be mentioned that in all the figures the same reference numerals have been used to designate the same technical features.
On the drill floor 12 there is provided at least one pipe handling arm 38. The pipe handling arm 38 comprises a first arm 39 and a second arm 40 that are connected to one another by a first articulated joint 41, such that the first arm 39 and the second arm 40 are able to rotate relative to each other. At the opposite end, the first arm 39 is connected to a support element 26 by means of an articulated element 27 such that the first arm is rotatable relative to the support element 26, preferably both up and down in a vertical direction and back and forth in a lateral direction.
The support element is preferably arranged movably up and down along a guide element 25, which, for instance, may be a tubular element. To further increase the reach of the pipe handling arm, the support element 26 may also be arranged rotatably about the guide element 25. It will also be possible to configure the support element 26 as a frame that slides up and down on two or more parallel guide elements 25.
The pipe handling arm 38 is shown in the figures with a first arm 39 and a second arm 40, but it may also be equipped with only one arm or with three or more arms if so desired, where the arms are rotatably connected to one another.
At the opposite end of the second arm 40 in relation to the first articulated joint 41, the embodiment of the pipe handling arm 38 shown in
The pipe handling arm 38 shown in
The drill floor system can, if necessary, comprise a plurality of work tools 33, all of which are provided with a second coupling half 34 that is complementarily shaped to the first coupling half 44 on the pipe handling arm 38, such that the work tools 23 can selectively be connected to the pipe handling arm 38. When a work tool 33 is connected to the pipe handling arm 38, the pipe handling arm can be used, for example, to grip a bottom hole assembly component and connect it to another component of the bottom hole assembly that is located above the borehole. As mentioned above, the downhole devices 21, in addition to being borehole assembly components, may be different types of devices that are used in connection with different types of operations in a hydrocarbon well, such as a valve device, a plug etc.
It should also be mentioned that, as indicated above and as shown in
The work tool or tools 33 and downhole devices are preferably arranged in a tool store 22 provided on the drill floor 12 as shown in
The drill floor system 10 also comprises a control system as indicated in
In addition, the embodiment of the drill floor system in
The first arm 39 of the second pipe handling arm 38 is at one end rotatably connected to the second arm 40 by a first articulated joint 41. At the other end, the first arm 39 is rotatably connected to a support element 30 by an articulated element 31, preferably such that the first arm 39 can be pivoted in all directions with a desired angle about the articulated element 31. The support element 30 is preferably, but not necessarily, movably arranged along guide elements 29 that are arranged on the drill floor 12. The reach of the second pipe handling arm 38 is thus significantly increased.
Lastly, it should be noted that to increase and reduce the reach of the pipe handling arm it is conceivable that the first arm 39 or the second arm 40, or possibly both the first and the second arm, may have a telescopic configuration.
Number | Date | Country | Kind |
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20150768 | Jun 2015 | NO | national |
Filing Document | Filing Date | Country | Kind |
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PCT/IB2016/053460 | 6/12/2016 | WO | 00 |