SWIVEL JOINT SYSTEM AND METHOD

BACKGROUND

Embodiments of the present disclosure relate generally to the field of drilling and processing of wells. More particularly, present embodiments relate to systems and methods for engaging a tubular element in an angled position (e.g., relative to a wellbore axis).

In conventional oil and gas operations, a well is typically drilled to a desired depth with a drill string (e.g., tubular string), which includes drill pipe (e.g., tubular elements) and a drilling bottom hole assembly. Once the desired depth is reached, the drill string is removed from the hole and casing is run into the vacant hole. During drilling, a top drive or a tubular gripping tool (e.g., casing drive system or pipe drive system) may be used to lift a tubular element, insert the tubular element into a box end of the tubular string, and apply torque to make up a connection between the tubular element and the tubular string. Similarly, the top drive or the tubular gripping tool is used to remove the tubular elements from the wellbore. The lifting components (e.g., top drive or tubular gripping tool) typically use bales and elevators to retrieve, lift, and align the tubular elements vertically with the well center and quill of the top drive. For example, the top drive or a tubular gripping tool hanging from the top drive may have a set of single joint elevators to lift the pipe from a tubular gripping catwalk and bring the tubular element into engagement with the tool in a vertical position. The tubular element connected to the bails and elevators may not be constrained well and may move while a connection is being made. Accordingly, there is a need for an improved system and method for gripping tubulars during mineral production operations.

BRIEF DESCRIPTION

In a first embodiment, a system includes a top drive system, a swivel joint system coupled to the top drive at a position axially below the top drive system, wherein the swivel joint system comprises a first subunit and a second subunit rotatably coupled together, wherein the first sub unit is coupled to the top drive system, and wherein the swivel joint system is configured to pivot between a first position and a second position, and a tubular gripping system coupled to the second subunit of the swivel joint system.

In a second embodiment, a swivel joint system includes a first subunit and a second subunit rotatably coupled together, wherein the first subunit comprises a first central passage and the second subunit comprises a second central passage, wherein the second subunit is configured to rotate within an annulus of the first subunit such that the second central passage moves between a first position and a second position relative to a central axis of the swivel joint system, and wherein the first central passage is aligned with the second central passage when the swivel joint system is in the first position, an actuator coupled to the first subunit and the second subunit, wherein the actuator is configured to pivot the swivel joint system between the first position and the second position, and a control system communicatively coupled to the actuator, wherein the control system is configured to control the actuator to adjust a pivot angle of the swivel joint system, wherein the control system comprises an encoder configured to measure an angular position of a top drive system coupled to the swivel joint system.

In a third embodiment, a method includes coupling a first subunit of a swivel joint system to a top drive system, coupling a tubular gripping system to a second subunit of the swivel joint system, wherein the first subunit and the second subunit of the swivel joint system are pivotally coupled to one another, wherein a first central passage of the first subunit and a second central passage of the second subunit are aligned in a first position, and wherein the first central passage and the second central passage are crosswise in a second position, pivoting the second subunit relative to the first subunit from the first position to the second position, and gripping a tubular element with the tubular gripping system.

DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 is a schematic of an embodiment of a drilling rig having a swivel joint system, in accordance with the present techniques;

FIG. 2 is a partial perspective view of an embodiment of a swivel joint system coupled to a top drive and a tubular gripping tool, in accordance with the present techniques;

FIG. 3 is a perspective side view of an embodiment of the swivel joint system of FIG. 2, in accordance with the present techniques;

FIG. 4 is a perspective side view of an embodiment of the swivel joint system of FIG. 2, in accordance with the present techniques;

FIG. 5 is a perspective side view of an embodiment of the swivel joint system of FIG. 2, in accordance with the present techniques;

FIG. 6 is an exploded view of an embodiment of the swivel joint system of FIG. 2, in accordance with the present techniques;

FIG. 7 is side view of an embodiment of the swivel joint system having a hinge actuator, in accordance with the present techniques;

FIG. 8 is side view of an embodiment of the swivel joint system having a hinge actuator, in accordance with the present techniques;

FIG. 9 is side view of an embodiment of the swivel joint system having a hinge actuator, in accordance with the present techniques;

FIG. 10A is a cut away perspective view of an embodiment of the swivel joint system having a lock sleeve, in accordance with the present techniques;

FIG. 10B is a cut away side view of an embodiment of the swivel joint system having a lock sleeve, in accordance with the present techniques;

FIG. 11A is a cut away perspective view of an embodiment of the swivel joint system having a lock sleeve, in accordance with the present techniques;

FIG. 11B is a cut away side view of an embodiment of the swivel joint system having a lock sleeve, in accordance with the present techniques;

FIG. 12A is a cut away perspective view of an embodiment of the swivel joint system having a lock sleeve, in accordance with the present techniques;

FIG. 12B is a cut away side view of an embodiment of the swivel joint system having a lock sleeve, in accordance with the present techniques;

FIG. 13A is a cross section view of an embodiment of the swivel joint system having a bypass sleeve, in accordance with the present techniques;

FIG. 13B is a cross section view of an embodiment of the swivel joint system having a mud saver valve, in accordance with the present techniques;

FIG. 13C is a cross section view of an embodiment of the swivel joint system having a mud saver valve, in accordance with the present techniques;

FIG. 14A is perspective view of an embodiment of the swivel joint system having actuators coupled to either side, in accordance with the present techniques;

FIG. 14B is perspective view of an embodiment of the swivel joint system having actuators coupled to either side, in accordance with the present techniques;

FIG. 15 is cross section view of an embodiment of the swivel joint system having actuators coupled to either side and having a plug valve, in accordance with the present techniques;

FIG. 16 is a cross section schematic of an embodiment of the swivel joint system having an axial seal, in accordance with the present techniques; and

FIG. 17 illustrates a process for engaging a tubular element in an angled position, in accordance with the present techniques.

DETAILED DESCRIPTION

Embodiments of the present disclosure are directed toward a swivel joint system to enable retrieving and lifting of tubular elements on a drilling rig. The swivel joint system may include a swivel joint that mounts below a top drive of the drilling rig and enables a lower portion of a quill or a tool hanging from the quill or the top drive to pivot towards a tubular element that is positioned on a tubular gripping catwalk or any other suitable tubular element holding location. The swivel joint system may be located below the top drive and may enable a portion of the quill or a tool hanging from the top drive (e.g., casing drive system or pipe drive system) to pivot from a vertical hanging position up to an angled or horizontal orientation (e.g., up to 90 degrees relative to vertical). The pivot action of the swivel joint system may be powered by one or more actuators. The swivel joint system may pivot up to an angled or horizontal orientation, enabling the tubular gripping tool to be directed toward the tubular element on the catwalk system such that the tubular element may be engaged and lifted without the use of lifting elevators or tilt bales. Elimination of the elevators and bales may enable an increase in the accuracy and efficiency of the engagement of the tubular element with the tubular gripping tool. Further, control of the swivel joint system using various sensors and a control system may enable an increase in the accuracy and efficiency of lifting and laying down the tubular element from a sloped or horizontal catwalk system.

In some embodiments, the swivel joint system may include an internal sealing mechanism (e.g., plug valve, axial seal, etc.) that may enable the flow of fluid through the swivel joint system to be blocked when the swivel joint system is in a hinged or angled position. Further in some embodiments, the swivel joint system may include a locking mechanism (e.g., lock sleeve, axial seal, etc.) that may lock the pivot action of the swivel joint system in either an extended position or a hinged position, as discussed below. This locking feature may help reduce some pressure on the actuators of the swivel joint system when in particular positions and may enable the desired position of the swivel joint system to be maintained.

FIG. 1 is a schematic of a drilling rig 10 (e.g., a land-based drilling rig) in the process of drilling a well in accordance with present techniques. The drilling rig 10 features an elevated rig floor 12 and a derrick 14 extending above the rig floor 12. A supply reel 16 supplies drilling line 18 to a crown block 20 and traveling block 22 configured to hoist various types of drilling equipment above the rig floor 12. The drilling line 18 is secured to a deadline tiedown anchor 24, and a drawworks 26 regulates the amount of drilling line 18 in use and, consequently, the height of the traveling block 22 at a given moment. The traveling block 22 supports a top drive 28. In the illustrated embodiment, a tubular gripping tool 30 (e.g., pipe drive system or casing drive system) hangs from the top drive 28. The tubular gripping tool 30 may be employed as a gripping device to engage and lift a tubular element 42.

Below the rig floor 12, a tubular string 32 extends downward into a wellbore 34 and is held stationary with respect to the rig floor 12 by a spider or slips 36 of a rotary table 38. A portion of the tubular string 32 extends above the rig floor 12, forming a stump 40 to which another tubular element 42 (e.g., a joint of drill pipe) is in the process of being added. In the illustrated embodiment, the top drive 28 and the tubular gripping tool 30 will be used to hoist the tubular element 42 to a vertically aligned position over well center. That is, the tubular element 42 will be aligned with a vertical axis 44 that passes through the center of the wellbore 34. When the tubular element 42 is aligned with well center, it is also aligned with the center of the stump 40 (e.g., upper exposed end of the tubular string 32) and the tubular string 32 extending into the wellbore 34. From this position, the tubular element 42 can be lowered (e.g., stabbed) onto the stump 40, rotated to form a threaded connection with the tubular string 32, and eventually lowered into the wellbore 34.

In the illustrated embodiments, the tubular element 42 is transported to the rig floor 12 via a catwalk system 48. The catwalk system 48 is a positive drive pipe conveyor system that may be used to transport tubular elements 42 from a ground surface 46 to the rig floor 12 (e.g., during rig up operations) and from the rig floor 12 to the ground surface 46 (e.g., during laydown operations). As shown, the catwalk system 48 includes a base 52 and columns 54 extending from the base 52, which support a carriage and trough assembly 56. The carriage and trough assembly 56 (which includes a conveyor 58) may be supported by the columns 54. The carriage and trough assembly 56, on which a tubular element 42 may be positioned, may be raised and guided along the columns 54 (e.g., with tracks or other guiding/retaining features) in a substantially horizontal orientation (e.g., plus or minus 0 to 20, 1 to 15, 2 to 10, or 3 to 5 degrees). When the carriage and trough assembly 56 is raised above the rig floor 12, the conveyor 58 and/or trough of the catwalk system 48 may be extended over, or at least partially over, the rig floor 12.

As shown, the columns 54 may be angled toward the drilling rig 10 (e.g., prior to the carriage and trough assembly 56 being lifted) to reduce the distance that the conveyor 58 and/or trough must be extended toward the rig floor 12. Once the carriage and trough assembly 56 is in a lifted position 60, as shown in FIG. 1, the conveyor 58 is operated to deliver the tubular element 42 onto the rig floor 12. For example, the conveyor 58 may be or include a belt and/or apron feeder that is rotated or driven to move the stationary tubular element 42 onto the rig floor 12. Indeed, the tubular element 42 may remain stationary relative to the belt or apron of the conveyor 58 to reduce abrasion between the tubular element 42 and the conveyor 58. As a result, unintentional wear to the tubular element 42 (e.g., threads of the tubular element 42) may be reduced. In other embodiments, the carriage and trough assembly 56 may include a pipe skate (e.g., pipe slide) to direct the tubular element 42 to the rig floor 12 in addition to, or in lieu, of the conveyor 58.

A swivel joint system 62 may be a pivotable joint used to direct or point the tubular gripping tool 30 toward the tubular element 42 that will be lifted and added to the tubular string 32. The swivel joint system 62 may be mounted below the top drive 28, between the top drive 28 and the tubular gripping tool 30 or a quill, if no tubular gripping tool 30 is being used. The swivel joint system 62 may have an extended position 64 in which the swivel joint system 62 is directing the tubular gripping tool 30 toward the tubular string 32, the stump 40, and the wellbore 40 such that the tubular gripping tool 30 aligned with a vertical axis 44 that passes through the center of the wellbore 34. In the extended position 64, the swivel joint system 62 may be positioned such that a lower subunit (e.g., portion coupled to the tubular gripping tool 30) of the swivel joint system 62 vertically in line with an upper subunit (e.g., portion coupled to the top drive 28) of the swivel joint system 62, thus, forming a straight line between the top drive 28 and the tubular gripping tool 30.

Additionally, the swivel joint system 62 may have a hinged position 66 in which the lower subunit of the swivel joint system 62 is pivoted such that the tubular gripping tool 30 is not aligned with a vertical axis 44 that passes through the center of the wellbore 34 and is directed toward the tubular element 42 to be lifted. In the hinged position 66, the lower subunit of the swivel joint system 62 may be positioned at any angle relative to the vertical extended position 64 up to a horizontal orientation (e.g., 30°, 45°, 90°). The pivot action of the swivel joint system 62 may enable more efficient engagement and lifting and/or laying down of the tubular elements 42 and may reduce the use of using bales and elevators in conjunction with the top drive 28 or the tubular gripping tool 30, as discussed in detail below.

It should be noted that the illustration of FIG. 1 is intentionally simplified to focus on the swivel joint system 62. Many other components and tools may be employed during the various periods of formation and preparation of the well. Similarly, as will be appreciated by those skilled in the art, the orientation and environment of the well may vary widely depending upon the location and situation of the formations of interest. For example, rather than a generally vertical bore, the well, in practice, may include one or more deviations, including angled and horizontal runs. Similarly, while shown as a surface (land-based) operation, the well may be formed in water of various depths, in which case the topside equipment may include an anchored or floating platform.

FIG. 2 is a partial perspective view of the swivel joint system 62 coupled to the top drive 28 and the tubular gripping tool 30. As previously discussed, the swivel joint system 62 may be a pivotable joint used to direct or point the tubular gripping tool 30 toward the tubular element 42 that will be lifted and added to the tubular string 32. The swivel joint system 62 may be fluidly coupled between the top drive 28 and the tubular gripping tool 30 on the drilling rig 10. The swivel joint system 62 includes an upper subunit 70 (e.g. clevis portion) and a lower subunit 72 (e.g., T-rotor portion) pivotably coupled together. While the disclosed embodiments discuss the clevis portion of the swivel joint system 62 as the upper subunit coupled to the top drive 28 and the T-rotor portion of the swivel joint system 62 as the lower subunit coupled to the tubular gripping tool 30, it should be understood that, in other embodiments, the clevis portion may be the lower subunit and the T-rotor portion may be the upper subunit. Additionally, components of the swivel joint system 62 described as disposed within or on the upper subunit 70 may, in some embodiments, be disposed within or on the lower subunit 72. Similarly, components of the swivel joint system 62 described as disposed within or on the lower subunit 72 may, in some embodiments, be disposed within or on the upper subunit 70. Details of the connections between the top drive 28, the swivel joint system 62, and the tubular gripping tool 30, as well as mechanisms used to pivot the lower subunit 72 with respect to the extended position 64 (e.g., a vertical position) are described in detail below.

As mentioned above, in the extended position 64, the lower subunit 72 is aligned with an axis 74 (e.g., central axis of the swivel joint system 62), such that the top drive 28 and the tubular gripping tool 30 are aligned (e.g., vertically aligned). The axis 74 may be aligned with the axis 44 that passes through the center of the wellbore 34. The axis 74, corresponding to the position of the lower subunit 72 of swivel joint system 62 in the extended position 64, may place the lifted tubular element 42 in position to be accurately stabbed into the stump 40. In the illustrated embodiment, the swivel joint system 62 is pivoted into the hinged position 66. In the hinged position 66, the lower subunit 72 of the swivel joint system is pivoted radially away from the axis 74 at a pivot angle 76.

The pivot angle 76 may be any angle (e.g., 30°, 45°, 90°) from the axis 74 (e.g., from the extended position 64) up to a horizontal position that is substantially perpendicular to the axis 74 (e.g., central axis of the swivel joint system 62). For example, if the conveyor 58 of the catwalk system 48 is positioned such that it is directing the tubular elements 42 to the rig floor 12 in a manner parallel to the rig floor 1, as illustrated in FIG. 1, the lower subunit 72 may pivoted such that the swivel joint system 62 is in the hinged position 66 at a 90° angle from the axis 74. Thus, the tubular gripping tool 30 will be positioned at the appropriate angle to engage with the tubular element 42. Therefore, the pivot action of the swivel joint system 62, up to a horizontal position, may enable the tubular gripping tool 30 to be angled or directed toward the tubular element 42 to be lifted and added to the tubular string 32 to extend the tubular string 32 deeper into the wellbore 34. Further, directing the tubular gripping tool 30 toward the tubular element 42 on the catwalk system 48 may enable the tubular gripping tool 30 to engage with the tubular element 42 without the use of bales of elevators, thus, improving the accuracy and efficiency of engagement, lifting, and stabbing of the tubular element 42.

FIG. 3 is a perspective side view of an embodiment of the swivel joint system 62. As described above, the upper subunit 70 of the swivel joint system 62 is rotatably coupled to the lower subunit 72. In the illustrated embodiment, the swivel joint system 62 is in the extended position 64 such that the lower subunit 72 of the swivel joint system 62 is in a straight configuration and in a position to direct the tubular gripping tool 30 and/or the engaged tubular element 42 toward the tubular string 32 within the wellbore 34. The upper subunit 70 of the swivel joint system 62 that couples to the top drive 28 of the drilling rig 10 may have a central passage 80 (e.g., bore) that extends from an axial top 81 of the upper subunit 70. Similarly, the lower subunit 72 of the swivel joint system 62 may that couples to the tubular gripping device 30 or the quill may have a central passage 82 (e.g., bore) that extends from an axial bottom 83 of the lower subunit 72.

The central passages 80 and 82 of the upper subunit 70 and lower subunit 72 of the swivel joint system 62, respectively, extend entirely through the subunits 70 and 72. In this manner, when the swivel joint system 62 is in the extended position 64, the central passage 80 of the upper subunit 70 and the central passage 82 of the lower subunit 72 are aligned and fluidly coupled, thereby creating a central passage through the swivel joint system 62. The central passage (e.g. central passage 80 and central passage 82 together) through the swivel joint system 62 may enable fluids (e.g., drilling mud, drilling fluid) to pass through the swivel joint system 62. The lower subunit 72 (e.g., T-rotor) may have an actuator connector 84 that may be used to couple a pivoting mechanism to the swivel joint system 62, as discussed in greater detail with reference to FIGS. 7-9.

FIG. 4 is a perspective side view of an embodiment of the swivel joint system 62. In the illustrated embodiment, the swivel joint system 62 is in the hinged position 66 such that the lower subunit 72 of the swivel joint system 62 is pivoted up at the angle 76 away from the axis 74. The angle 76 may be any angle (e.g., 30°, 45°, 90°) up to 90° or a horizontal orientation that will direct the tubular gripping device 30 coupled below the swivel joint system 62 toward the tubular element 42 on the catwalk system 48 or elsewhere. As discussed in greater detail with reference to FIGS. 7-9, a pivoting mechanism, such as a hinge actuator, may be utilized to pivot the lower subunit 72 of the swivel joint system 62 to the hinged position 64. The pivoting mechanism may be coupled to the actuator connector 84 of the lower subunit 72 of the swivel joint system 62.

FIG. 5 is a perspective side view of an embodiment of the swivel joint system 62 illustrating the side of the swivel joint system 62 opposite the side illustrated in FIGS. 3 and 4. In the illustrated embodiment, the swivel joint system 62 is in the extended position 64 such that the lower subunit 72 of the swivel joint system 62 is in a straight configuration aligned with the axis 74 and in a position to direct the tubular gripping tool 30 and/or the engaged tubular element 42 toward the tubular string 32 within the wellbore 34. Further, the extended position 64 may enable alignment of the coupled tubular gripping tool 30 and the tubular element 42 with the vertical axis 44 that passes through the center of the wellbore 34.

In the extended position 64, the central passage 80 of the upper subunit 70 and the central passage 82 of the lower subunit 72 may be aligned creating a central passage through the swivel joint system 62. The central passage (e.g. central passage 80 and central passage 82 together) through the swivel joint system 62 may enable fluids (e.g., drilling mud, drilling fluid) to pass through the swivel joint system 62. In some embodiments, there may be a radial passage through the lower subunit 72 of the swivel joint system 62 that intersects with the central passage 82, as discussed in greater detail with reference to FIGS. 6 and 14. A plug valve 86 may be disposed within the radial passage and may be used to block and separate the central passage 82 of the lower subunit 72 of the swivel joint system 62 from the central passage 80 of the upper subunit 70. The plug valve 86 may have an actuator connector 88 that may be rotated to separate or otherwise block the central passage 82 from the central passage 80. Rotation of the plug valve 86 will be discussed below in greater detail with reference to FIG. 15.

FIG. 6 is an exploded view of an embodiment of the swivel joint system 62. The swivel joint system 62 may include the upper subunit 70 (e.g., clevis portion). The central passage 80 may extend from the axial top 81 of the upper subunit 70 through the upper subunit 70 and may align with the central passage 82 of the lower subunit 72 when swivel joint system 62 is in the extended position 64. The swivel joint system 62 may include the lower subunit 72 (e.g., T-rotor) that may be rotatably coupled to the upper subunit 70. The upper subunit 70 may form an annulus 90 into which the lower subunit 72 may fit into such that the lower subunit 72 may be pivoted within the annulus 90 of the upper subunit 70. The central passage 82 of the lower subunit 72 may extend from the axial bottom 83 of the lower subunit 72 through the lower subunit 72. The central passage 82 may align with the central passage 80 of the upper subunit 70 when the swivel joint system 62 is in the extended position such that lower subunit 72 is aligned with the axis 74.

The lower subunit 72 of the swivel joint system 62 may include the actuator connector 84 disposed radially on a body 92 of the lower subunit 72. The body 92 of the lower subunit 72 is the portion that fits within the annulus 90 of the upper subunit 70 and rotates within the annulus 90 when the swivel joint system 62 is pivoted. The pivoting action of the swivel joint system 62 may be created by a pivoting mechanism, as discussed in greater detail with reference to FIGS. 7-9. The pivoting mechanism may couple to the actuator connector 84 of the lower subunit 72 and may use the actuator connector 84 to pivot the body 92 of the lower subunit 72 within the annulus 90 of the upper subunit 70, thus, swiveling the lower subunit 72 and the tubular gripping tool 30 to different angles 76 relative to the axis 74. Additionally or alternatively, the pivoting mechanism may be coupled to other locations about the lower subunit 72, the upper subunit 70, the top drive 28, the tubular gripping tool 30, any other suitable location for creating the pivoting action of the swivel joint system 62, or a combination thereof.

The swivel joint system 62 may include the plug valve 86 that may be used to block and separate the central passage 82 of the lower subunit 72 of the swivel joint system 62 from the central passage 80 of the upper subunit 70. The plug valve 86 may fit into a radial passage 94 of the lower subunit 72. The radial passage 94 may extend radially from the central passage 82 to a radial side 96 of the body 92 of the lower subunit 72. The plug valve 86 may fit within the radial passage 94 such that it may be rotated within the radial passage 94. The plug valve 86 may include a passage 98 that may extend from one side of the plug valve 86 to the other. The passage 98 of the plug valve 86 may align with the central passage 82 of the lower subunit 72. The plug valve 86 may be rotated within the radial passage 94 such that the passage 98 of the plug valve 86 is not aligned with the central passage 82 of the lower subunit 72, thus, blocking the central passage 82 and separating the central passage 82 of the lower subunit 72 from the central passage 80 of the upper subunit 70. The plug vale 86 may include the actuator connector 88 that may be coupled to a rotary mechanism. The rotary mechanism that may be used to rotate the plug valve 86 within the radial passage 94 of the lower subunit 72 to block and unblock the central passage 82 of the lower subunit 72 from the central passage 80 of the upper subunit 70 is discussed in greater detail with reference to FIGS. 14-15.

FIGS. 7-9 illustrate examples of pivoting mechanisms that may be utilized to create the pivoting action of the swivel joint system 62. There are many ways that pivoting or rotation of the swivel joint system 62 may be implemented. FIGS. 7-9 illustrate examples of mechanisms that may be used to create the pivoting action of the swivel joint system 62. It should be understood, that any type of actuator may be used to pivot the swivel joint system 62 between the extended position 64 and the hinged position 66, such as winches and cables that may be used as a lightweight actuator.

FIG. 7 illustrates the swivel joint system 62 in the extended positon 64 having a hinge actuator 110. The hinge actuator 110 may be any type of actuator (e.g., electric, hydraulic, pneumatic). The hinge actuator 110 may include a piston 112 and a cylinder 114. The piston 112 may be coupled the tubular gripping tool 30, the top drive 28, the upper subunit 70 of the swivel joint system 62, the lower subunit 72 of the swivel joint system 62, or any other suitable location. Similarly, the cylinder 114 may be coupled to tubular gripping tool 30, the top drive 28, the upper subunit 70 of the swivel joint system 62, the lower subunit 72 of the swivel joint system 62, or any other suitable location. In the illustrated embodiment, the piston 112 is coupled to the tubular gripping tool 30 and the cylinder 114 is coupled to the axial bottom of the top drive 28.

The piston 112 of the hinge actuator 110 may fully stroke out (e.g., approximately fully stroke out) when the swivel joint system 62 is in the extended position 64, as in the illustrated embodiment. Upon receiving a control signal, the hinge actuator 110 will stroke the piston 112 into the cylinder 114 until the swivel joint system 62 is pivoted to the appropriate hinged positon 66 such that the tubular gripping tool 30 is directed toward the tubular element 42 to be lifted. The swivel joint system 62 may enable the movement of the piston 112 to lift the tubular gripping tool 30 to engage with the tubular element 42 without the use of lift elevators or bales. The swivel joint system 62 may be returned to the extended position 64 by the stroking out of the piston 112 to lower the tubular gripping tool 30 and tubular element 42 coupled to the tubular gripping tool 30. In some embodiments, the swivel joint system 62 may include one or more counterweights 116 disposed opposite of the locations of coupling of the piston 112 and the cylinder 114 to the top drive 28, swivel joint system 62, tubular gripping tool 30, or other location. The counterweights 116 may be used to balance the swivel joint system 62 and/or reduce loads on the quill and/or bearings of the top drive 28 during rotation of the top drive 28 and components coupled below the top drive 28.

FIG. 8 illustrates the swivel joint system 62 in the hinged position 66 having the hinge actuator 110 to create the pivot action of the swivel joint system 62. In the illustrated embodiment, the piston 112 is coupled to the tubular gripping tool 30 and the cylinder 114 is coupled to the axial bottom of the top drive 28. The piston 112 may be fully stroked into (e.g., approximately fully stroked in) the cylinder 114 when the swivel joint system 62 is in the hinged positon 64 at 90° (e.g., horizontal to the rig floor 12), as in the illustrated embodiment. This hinged positon 66 in which the lower subunit 72 of the swivel joint system 62 is pivoted from the axis 74 by 90° may be utilized to engage with the tubular element 42 when the catwalk system 48 is horizontally positioned on the rig floor 12. In some instances, the catwalk system 48 may be sloped such that it is not horizontal to the rig floor 12. Therefore, the swivel joint system 62 may be pivoted to a hinged positon 66 lower than 90° (e.g., 45°, 30°) to engage with the tubular element 42.

Upon receiving a control signal, the hinge actuator 110 will stroke the piston 112 out of the cylinder 114 until the swivel joint system 62 is pivoted back to the extended position 64, such that the tubular gripping tool 30 and the coupled tubular element 42 are aligned with the axis 74 and the vertical axis 44 that passes through the center of the wellbore 34. As discussed above, the swivel joint system 62 may enable the movement of the piston 112 to be directed toward the tubular element 42 on the catwalk system 48 to engage with the tubular element 42 without the use of lift elevators or bales and to subsequently lower the tubular gripping tool 30 to align the tubular element 42 with the vertical axis 44 that passes through the center of the wellbore 34 to more accurately make up a connection between the tubular element 42 and the tubular string 32.

FIG. 9 illustrates the swivel joint system 62 having the hinge actuator 110 positioned in a different configuration. In the illustrated embodiment, the cylinder 114 is coupled to the swivel joint system 62, and the piston 112 is coupled to a connection 118 between two hinge connectors 120. One end of each hinge connectors 120 may be coupled to the upper subunit 70, the lower subunit 72 of the swivel joint system 62, the top drive 28, the tubular gripping tool 30, or any other suitable location. The other end of the hinge connectors 120 may be coupled together adjacent to the swivel joint system 62. When the piston 112 is stroked into or fully stroked into (e.g., approximately fully stroked in) the cylinder 114, the piston 112 may pull the connection 118 between the hinge connector 120 toward the swivel joint system 62 such that the hinge connectors 120 are in a vertical orientation with one hinge connector 120 axially above the other. In this manner, straightening the orientation of the hinge connectors 120 may lower the tubular gripping tool 30 and/or the lower subunit 72 of the swivel joint system 62 to pivot the swivel joint system 62 to the extended position 64.

Upon receiving a control signal, the piston 112 may be stroked out of the cylinder 114, thus, pivoting the connection 118 between the hinge connectors 120, lifting the tubular gripping tool 30, and pivoting the lower subunit 72 of the swivel joint system 62 into the hinged position 66. In the illustrated embodiment, the swivel joint system 62 is in the hinged position at 90°. However, the piston 112 may be stroked out to a position to pivot the swivel joint system 62 to any pivot angle 76 from the axis 74 to accurately direct and align the tubular gripping tool 30 with the tubular element 42 on the catwalk system 48. As discussed above, it should be understood that there are many ways that the pivoting action or rotation of the swivel joint system 62 may be implemented. FIG. 7-9 illustrated embodiments of mechanisms that may be used. However, any type of actuator may be used to pivot the swivel joint system 62 between the extended position 64 and the hinged position 66, such as winches and cables.

In some embodiments, the swivel joint system 62 may be controlled to facilitate accurate pivot, position, and direction of the swivel joint system 62 and the coupled tubular gripping tool 30. To facilitate controlling the swivel joint system 62, the swivel joint system 62 may include a control system 124 (e.g., controller). In some embodiments, the control system 124 includes a memory 126, a processor 128, and input/output (I/O) devices 130. The I/O devices may facilitate communication between the control system 124 and a user (e.g., operator). For example, the I/O devices 130 may include a button, a keyboard, a mouse, a trackpad, and/or the like to enable user interaction with the control system 124. Additionally, the I/O devices 130 may include an electronic display to facilitate providing a visual representation of information, for example, a graphical user interface (GUI), an application interface, text, a still image, and/or video content.

In some embodiments, the memory 126 may include one or more tangible, non-transitory, computer-readable media that store instructions executable by the processor 128 and/or data to be processed by the processor 128. For example, the memory 126 may include random access memory (RAM), read only memory (ROM), rewritable non-volatile memory such as flash memory, hard drives, optical discs, and/or the like. Additionally, the processor 128 may include one or more general purpose microprocessors, one or more application specific processors (ASICs), one or more field programmable logic arrays (FPGAs), or any combination thereof.

Further, the control system 124 may include one or more sensors (e.g., sensors 134, 144, 170 discussed below) and an encoder 132. The sensors and encoder 132 may measure operational parameters of the swivel joint system 62 and output the measurements to the control system 124. The control system 124 may receive the sensor and encoder 132 data and may determine some operational parameters based at least in part on the sensor and encoder 132 data. For example, the control system 124 may determine the angle 76 at which the lower subunit 72 of the swivel joint system 62 may be positioned relative to the axis 74 based at least in part on sensor data received from one or more sensors 134 coupled to the tubular gripping tool 30 and/or data received from the encoder 132.

In some embodiments, the encoder 132 may include one or more encoders and/or sensors. The encoder 132 (e.g., rotary encoder) may be used to measure the angular position and/or rotational position (e.g. slewing) of the top drive 28 and/or the swivel joint system 62 positioned axially below the top drive 28. Accurate angular positioning and/or rotation of top drive 28, such as within fractions of a degree (e.g., within the precision tolerance of the tubular gripping tool 30), may enable accurate positioning of the swivel joint system 62 such that, when the swivel joint system 62 is pivoted to the hinged position 66, the tubular gripping tool 30 will be directed toward a centerline of the tubular element 42 on the catwalk system 48 in order to engage with the tubular element 42. Additionally, the encoder 132 may be used to measure the angle 76 at which the lower subunit 72 is positioned relative to the axis 74 and to measure a vertical height of the top drive 28. The encoder 132 may output the angular position, vertical height of the top drive 28, and/or angle 76 of the swivel joint system 62 to the control system 124. The control system 124 may receive the angular position and vertical height data from the encoder 132 and determine whether the top drive 28 is positioned at an angular position and height that will enable the tubular gripping tool 30 be directed toward the centerline of the tubular element 42 on the catwalk system 48. The control system 124 may output a control signal to the top drive 28 or to a control system of the top drive 28 to change the angular position and/or vertical height of the top drive 28 if it is determined that the current angular positioning and/or vertical height of the top drive 28 will not enable the tubular gripping tool 30 to be directed, such as within fractions of a degree of the centerline of the tubular element 42, when the swivel joint system 62 is pivoted to the hinged position 66.

Additionally, the one or more sensors 134 may measure the angle 76 of the swivel joint system 62 to align the tubular gripping tool 30 with the centerline of the tubular element 42 on the catwalk system 48. In the illustrated embodiment, the sensor 134 is disposed on the axial bottom of the tubular gripping tool 30 and may measure the angle 76 at which the swivel joint system 62 is pivoted by measuring the location to which the tubular gripping tool 30 directed. However, the sensor 134 may be disposed within or on the swivel joint system 62, or at any other suitable location for measuring the angle 76 when the swivel joint system 62 is in the hinged position 66. The sensor 134 may output the measured angle 76 to the control system 124. The control system 124 may receive the sensor data and may determine the angle 76 at which the swivel joint system 62 should be pivoted to and/or whether the swivel joint system 62 is pivoted to the angle 76 that will enable the tubular gripping tool 30 to be directed toward the centerline of the tubular element 42. The control system 124 may output a control signal to the hinge actuator 110, or any pivoting mechanism that may be used to pivot the swivel joint system 62, instructing the hinge actuator 110 to stroke the piston 112 either into or out of the cylinder 114 to lift or lower the lower subunit 72 of the swivel joint system 62 to achieve the determined angle 76. The control system 124 may include other sensors discussed below.

Additionally, in some embodiments, the swivel joint system 62 may include a float function (e.g., pressure compensated function) when the tubular gripping tool 30 is engaged with the tubular element 42. In this manner, the hinge actuator 110, or other actuator, may enable the lower subunit 72 of the swivel joint system 62 to pivot with respect to the upper subunit 70 toward the extended position 64 using the weight of the tubular element 42. This may be achieved by opening ports (e.g., hydraulic ports, pneumatic ports) of the hinge actuator 110. Thus, when the top drive 28 is moved upward (e.g., vertical height increased) after the tubular element 42 is engaged with the tubular gripping tool 30, the tail end of the tubular element 42 (e.g., end not engaged with the tubular gripping tool 30) may drag along the catwalk system 48 and the weight of the tubular element 42 may pull the swivel joint system 62 toward the extended position 64. In some embodiments, the float function may involve some resistance from the hinge actuator 110, or other actuator system, based on the weight of the tubular gripping tool 30 and the coupled tubular element 42.

FIGS. 10A and 10B illustrate an embodiment of a lock sleeve 140 of the swivel joint system 62. FIG. 10A is a cut away view of the lock sleeve 140 within the swivel joint system 62 while the swivel joint system 62 is in the extended position 64. FIG. 10B is a side view of the lock sleeve 140 within the swivel joint system 62 while the swivel joint system 62 is in the extended position 64. In FIGS. 10A and 10B, the lock sleeve 140 is positioned axially downward within the swivel joint system 62 and relative to the axis 74, thus locking the pivot action of the swivel joint system 62 and locking the swivel joint system 62 in the extended position 64. In some embodiments, the lock sleeve 140 may be used to lock and release the pivot action of the swivel joint system 62 such that the extended position 64 and the hinged position 66 may be maintained without movement of the swivel joint system 62 when the desired position is achieved. The lock sleeve 140 may have an annular structure and may fit inside of or around the central passage 80 of the upper subunit 70 and the central passage 82 of the lower subunit 72. The lock sleeve 140 may be actuated axially up and down within the swivel joint system 62 and relative to the axis 74 to lock and release the pivoting movement of the swivel joint system 62.

FIGS. 11A and 11B illustrate an embodiment of the lock sleeve 140 of the swivel joint system 62. FIG. 11A is a cut away view of the lock sleeve 140 within the swivel joint system 62 while the swivel joint system 62 is in the extended position 64. FIG. 11B is a side view of the lock sleeve 140 within the swivel joint system 62 while the swivel joint system 62 is in the extended position 64. In FIGS. 11A and 11B, the lock sleeve 140 is positioned axially upward within the swivel joint system 62 and relative to the axis 74, thus releasing the pivot action of the swivel joint system 62. As previously discussed, in some embodiments, the lock sleeve 140 may be used to lock and release the pivot action of the swivel joint system 62 such that the extended position 64 and the hinged position 66 may be maintained without movement of the swivel joint system 62 when the desired position is achieved.

The lock sleeve 140 may be pushed axially downward within the swivel joint system 62 and relative to the axis 74 when the swivel joint system 62 is in the extended position 64, as in the illustrated embodiment, such that the lock sleeve 140 is positioned within both the central passage 80 of the upper subunit 70 and the central passage 82 of the lower subunit 72. In this manner, an axial bottom 142 of the lock sleeve 140 may be within the central passage 82 of the lower subunit 72. Positioning of the lock sleeve 140 within both central passages 80 and 82 may lock the pivoting action of the swivel joint system 62 as the lower subunit 72 may not be pivoted relative to the upper subunit 70 because of the connection between their respective central passages 82 and 80 created by the lock sleeve 140. The annular structure of the lock sleeve 140 may enable fluid (e.g., drilling mud, drilling fluid) to flow through the swivel joint system 62 while the swivel joint system 62 is in the extended position 64.

FIGS. 12A and 12B illustrate an embodiment of the lock sleeve 140 of the swivel joint system 62. FIG. 12A is a cut away view of the lock sleeve 140 within the swivel joint system 62 while the swivel joint system 62 is in the hinged position 66. FIG. 12B is a side view of the lock sleeve 140 within the swivel joint system 62 while the swivel joint system 62 is in the hinged position 66. In both FIG. 12A and 12B, the lock sleeve 140 is positioned axially upward within the swivel joint system 62 and relative to the axis 74. As previously discussed, in some embodiments, the lock sleeve 140 may be actuated axially up and down within the swivel joint system 62 and relative to the axis 74 to lock and release the pivoting movement of the swivel joint system 62. The lock sleeve 140 may be lifted axially upward within the swivel joint system 62 and relative to the axis 74 before the swivel joint system 62 is pivoted to the hinged position 66. In this manner, the lock sleeve 140 may be lifted axially upward within the swivel joint system 62 such that the axial bottom 142 of the lock sleeve 140 is positioned within the central passage 80 of the upper subunit 70 of the swivel joint system (e.g., the lock sleeve 140 is completely within the central passage 80) or within the body 92 of the lower subunit 72 and the annulus 90 of the upper subunit 70 such that the lower subunit 72 may still be pivoted within the annulus 90 of the upper subunit 70. Lifting of the lock sleeve 140 may release the pivot action of the swivel joint system 62 and may enable the swivel joint system 62 to be pivoted to the hinged position 66.

Additionally, the axial actuation of the lock sleeve 140 may be controlled by the control system 124. In some embodiments, the control system 124 may include a sensor 144 that may measure the positon of the lock sleeve 140 or whether the lock sleeve 140 is locked or unlocked. The sensor 144 may be disposed on the lock sleeve 144, within the swivel joint system 62, or at any other location suitable for measuring the axial position of the lock sleeve 140. The sensor 144 may output the measured axial position of the lock sleeve 140 to the control system 124. The control system 124 may receive the sensor data and may determine whether the lock sleeve 140 should be moved axially upward or downward within the swivel joint system 62 and relative to the axis 74 based at least in part on the position data from the sensor 144. When the swivel joint system 62 is to be pivoted from the extended positon 64 to the hinged position 66, the control system 124 may output a control signal to the lock sleeve 140 to actuate a piston 146 (e.g., with hydraulic fluid, pneumatic fluid) of the lock sleeve 140 axially upward within the swivel joint system 62 and relative to the axis 74 such that the lock sleeve 140 is not locking (e.g., blocking) the pivoting action of the lower subunit 72 of the swivel joint system 62. When the extended position 64 of the swivel joint system 62 is to be maintained, the control system 124 may output a control signal to the lock sleeve 140 to actuate the piston 146 of the lock sleeve 140 axially downward within the swivel joint system 62 and relative to the axis 74 such that the axial bottom 142 of the lock sleeve 140 is moved into the central passage 82 of the lower subunit 72, or to maintain the axially downward position, to lock the pivot action of the swivel joint system 62. The lock sleeve 140 may enable a relaxing of the actuator(s) used to pivot the swivel joint system 62 while drilling (e.g., when the swivel joint system 62 is in the extended position 64) by locking the pivot action of the swivel joint system 62 by actuating the lock sleeve 140 across the interface of the central passage 80 of the upper subunit 70 and the central passage 82 of the lower subunit 72.

FIG. 13A illustrates an embodiment of a bypass sleeve 150 that may be included in the swivel joint system 62. The bypass sleeve 150 may be disposed within the annular structure of the lock sleeve 140 and within the central passage 80 of the upper subunit 70. The bypass sleeve 150 may extend axially above an axial top 151 of the lock sleeve 140. The bypass sleeve 150 may be used to keep mud or other fluids from getting within the space between the upper subunit 70 of the swivel joint system 62 and the lock sleeve 140, and/or from flowing on top of the piston 146 of the lock sleeve 140. The bypass sleeve 150 may also keep the flow path area of the central passage 80 of the upper subunit 70 smooth and generally unobstructed. The bypass sleeve 150 may be integrated with the lock sleeve 140, or may be coupled to the lock sleeve 140 and/or the central passage 80 of the upper subunit 70 via a mechanical (e.g., threaded) or other connection.

In some embodiments, there may be one or more seals for sealing internal pressures of the central passages 80 and 82. As in the illustrated embodiment, the swivel joint system 62 may have one or more static pressure seals 152 disposed between the surface of the central passage 80 of the upper subunit 70 and the bypass sleeve 150.

Additionally, as in the illustrated embodiment, the swivel joint system 62 may include one or more sliding pressure seals 153 that be disposed between the bypass sleeve 150 and the lock sleeve 140. The one or more sliding pressure seals 153 may enable the internal pressures of the central passages 80 and 82 to remain sealed while the lock sleeve 140 is actuated axially upward or downward. Additionally, as in the illustrated embodiment, the swivel joint system 62 may include one or more face pressure seals 154 disposed between the axial bottom 142 of the lock sleeve 140 a shoulder 155 of the lower subunit 72 that may be used to contain the pressure within the central passage 82 of the lower subunit 72. Additionally, as in the illustrated embodiment, the swivel joint system 62 may include one or more pressure seals 166 (e.g., hydraulic pressure seals, pneumatic pressure seals) disposed between the lock sleeve 140 and the upper subunit 70 and/or the lower subunit 72 that may contain the pressure of fluid (e.g., hydraulic, pneumatic) used to axially actuate the lock sleeve 140.

In some embodiments, a mud saver valve 156 may be disposed within the bypass sleeve 150 or within the swivel joint system 62 in place of the bypass sleeve 150. The mud saver valve 156 may be used to reduce the spillage of drilling mud or displaced mud when the tubular element 42 is added to or removed from the tubular string 32 and/or when the tubular element 42 is decoupled from the swivel joint system 62. The mud saver valve 156 may be implemented into the swivel joint system 62 in conjunction with bypass sleeve 150. However, the mud saver valve 156 may be included in the swivel joint system 62 without the bypass sleeve 150. In some embodiments, the lock sleeve 140 may be used to activate the mud saver valve 156, examples of which are shown and described in detail with respect to FIGS. 13B and 13C below.

FIG. 13B illustrates an embodiment of the swivel joint system 62 having the lock sleeve 140 and the mud saver valve 156. In the illustrated embodiment, the actuation of the lock sleeve 140 may be used to actuate the mud saver function of the mud saver valve 156. In this manner, when the lock sleeve 140 is actuated axially downward such that it locks the pivot action of the lower subunit 72 with respect to the upper subunit 72 and locks the swivel joint system 62 in the extended position 66, the mud saver valve 156 may be open and may enable the fluid (e.g., drilling mud, drilling fluid) to flow between the central passage 80 and the central passage 82. When the lock sleeve 140 is actuated axially upward such that the pivot action of the swivel joint system 62 is not locked and may be pivoted to the hinged position 66, the mud saver valve 156 may be closed, thus, blocking the flow of fluid between the central passage 80 and the central passage 82.

In the illustrated embodiment, the mud saver valve 156 includes a body 157 that may be disposed within the central passage 80 of the upper subunit 70 of the swivel joint system 62 and axially above the lock sleeve 140. The body 157 may have one or more recesses 158 that extend from the bottom of the body 157. The recess 158 may be an annular recess, such that the lock sleeve 140 fits within the recess 158. When the mud saver valve 156 is open, the fluid may flow around the body 157 of the mud saver valve 156 and through fluid ports 159 in the lock sleeve 140 to flow between the central passage 80 and the central passage 82. However, when the lock sleeve 140 is actuated axially upward, the lock sleeve 140 may extend further into the recess 158 of the body 157 of the mud saver valve 156, thus, closing the mud saver valve 156 and blocking the fluid ports 159 such that fluid may not flow between the central passage 80 and the central passage 82.

In some embodiments, as previously discussed, the swivel joint system 62 may include one or more sliding pressure seals 160 disposed between the lock sleeve 140 and the central passage 80 of the upper subunit 70. The one or more sliding pressure seals 160 may enable the internal pressures of the central passages 80 and 82 to remain sealed while the lock sleeve 140 is actuated axially upward or downward. Additionally, as previously discussed, the swivel joint system 62 may include the one or more face pressure seals 154 disposed between the axial bottom 142 of the lock sleeve 140 a shoulder 155 of the lower subunit 72 that may be used to contain the pressure within the central passage 82 of the lower subunit 72. Additionally, as in the illustrated embodiment, the swivel joint system 62 may include the one or more pressure seals 166 (e.g., hydraulic pressure seals, pneumatic pressure seals) disposed between the lock sleeve 140 and the upper subunit 70 and/or the lower subunit 72 that may contain the pressure of the fluid (e.g., hydraulic, pneumatic) used to axially actuate the lock sleeve 140.

FIG. 13C illustrates an embodiment of the swivel joint system 62 having the lock sleeve 140 and the mud saver valve 156. The mud saver valve 156 of the illustrated embodiment depicts an additional example of the mud saver valve 156 that may be activated by the actuation of the lock sleeve 140. Similar to the mud saver valve 156 described in FIG. 13B, when the lock sleeve 140 is actuated axially downward such that it locks the pivot action of the lower subunit 72 with respect to the upper subunit 72 and locks the swivel joint system 62 in the extended position 66, the mud saver valve 156 may be open and may enable the fluid (e.g., drilling mud, drilling fluid) to flow between the central passage 80 and the central passage 82. When the lock sleeve 140 is actuated axially upward such that the pivot action of the swivel joint system 62 is not locked and may be pivoted to the hinged position 66, the mud saver valve 156 may be closed, thus, blocking the flow of fluid between the central passage 80 and the central passage 82.

In the illustrated embodiment, the mud saver valve 156 includes a cone 167 of the lock sleeve 140. The cone 167 may be the axial top 151 of the lock sleeve 140 and may be disposed within the central passage 80 of the upper subunit 70. When the mud saver valve 156 is open, the fluid may flow around the cone 167 and through fluid ports 159 in the lock sleeve 140 to flow between the central passage 80 and the central passage 82. However, when the lock sleeve 140 is actuated axially upward, the lock sleeve 140 may move the cone 167 of the mud saver valve 156 axially upward. The cone 167 of the mud saver valve 156 may interface with a seat 161 of the central passage 80 of the upper subunit 70. This interface may create a mud saver seal 162, thus, closing the mud saver valve 156 and blocking the fluid flow around the cone 167 of the mud saver valve 156. A first axial length 163 in which the lock sleeve 140 is actuated axially upward when unlocking the pivot action of the swivel joint system 62 may be greater than or approximately equal to a second axial height 164 in which the cone 167 of the mud saver valve 156 may move upward to contact the seat 161 of the central passage 80. In this manner, the axial length 163 greater than, or approximately equal to, the axial length 164 may enable an accurate closure of the mud saver valve 156 and blockage of the flow of fluid between the central passage 80 and the central passage 82 when the lock sleeve 140 is in an unlocked position.

FIGS. 14 and 15 illustrate perspective views of an embodiment of the swivel joint system 62 coupled to actuators 168 (e.g., rotary actuators) that may be used to swivel the lower subunit 72 of the swivel joint system 62 and/or to rotate the plug valve 86. FIG. 14A illustrates the one or more actuators 168 coupled to the either side of the swivel joint system 62 while the swivel joint system is in the extended position 64. FIG. 14B illustrates the one or more actuators 168 coupled to the either side of the swivel joint system 62 while the swivel joint system is in the hinged position 66. FIG. 15 illustrates a cross sectional view of an embodiment of the swivel joint system 62 coupled to the actuators 168.

The actuator(s) 168 may be any type of actuator (e.g., mechanical, hydraulic, pneumatic). As previously discussed, in some embodiments, one or more actuators 168 may be coupled to the actuator connector 84 of the lower subunit 72 on either side of the swivel joint system 62. The actuator 168 may be used to pivot the body 92 of the lower subunit 72 within the annulus 90 of the upper subunit 70. The pivoting action may be used to lift the coupled tubular gripping tool 30 to direct the tubular gripping tool 30 toward the tubular element 42 on the catwalk system 48, and to lower the lower subunit 72 to the extended positon 64 once the tubular gripping tool 30 has engaged with the tubular element 42.

As previously discussed, in some embodiments, the swivel joint system 62 may include the plug valve 86 that may be used to block and separate the central passage 82 of the lower subunit 72 of the swivel joint system 62 from fluid communication with the central passage 80 of the upper subunit 70. The plug valve 86 may fit into the radial passage 94 of the lower subunit 72. The radial passage 94 may extend radially from the central passage 82 to the radial side 96 of the body 92 of the lower subunit 72. The plug valve 86 may fit within the radial passage 94 such that it may be rotated within the radial passage 94. The plug valve 86 may include the passage 98 that may extend from one side of the plug valve 86 to the other. The passage 98 of the plug valve 86 may align with the central passage 82 of the lower subunit 72. The plug valve 86 may be rotated within the radial passage 94 such that the passage 98 of the plug valve 86 is not aligned with the central passage 82 of the lower subunit 72, as in the illustrated embodiment, thus, blocking the central passage 82 and separating the central passage 82 of the lower subunit from the central passage 80 of the upper subunit 70.

The plug valve 86 may include the actuator connector 88 that may be coupled to the actuator 168. The actuator 168 may be used to rotate the plug valve 86 within the radial passage 94 of the lower subunit 72 to block and unblock the central passage 82 of the lower subunit 72 from the central passage 80 of the upper subunit 70. Though the actuator 168 is illustrated as only coupled to the actuator connectors 84 on either side of the lower subunit 72, in some embodiments, the actuator 168 (e.g., rotary actuator) may be coupled to the actuator connector 88 of the plug valve 86. However, a separate actuator may be used to rotate the plug valve 86.

In some embodiments, the control system 124 may include a sensor 170 that may measure the position of plug valve 86, thus, detecting whether the central passage 82 is sealed from the central passage 80. The sensor 170 may be disposed on the plug valve 86, within the swivel joint system 62, or at any other location suitable for measuring the position or rotation of the plug valve 86. The sensor 170 may output the measured position of the plug valve 86, indicative of a sealed positon or unsealed position, to the control system 124. The control system 124 may receive the sensor data and may determine whether the plug valve 86 should be rotated to seal the central passage 82 of the lower subunit 72 or to unseal the central passage 82 such that the passage 98 of the plug valve 86 is aligned with the central passages 80 and 82 of the upper subunit 70 and the lower subunit 72 respectively. When the swivel joint system 62 is to be pivoted from the extended position 64 to the hinged position 66, the control system 124 may output a control signal based at least in part on the sensor data to the actuator coupled to the plug valve 86 to rotate the plug valve 86 within the radial passage 94 such that the passage 98 of the plug valve 86 is not aligned with the central passages 80 and 82 to seal the passage 82 from the flow of fluids (e.g., drilling mud, drilling fluid). When the swivel joint system 62 is to be pivoted to the extended position 64 or the extended position 64 is to be maintained, the control system 124 may output a control signal to rotate the plug valve 86 within the radial passage 94 such that the passage 98 of the plug valve 86 is aligned with the central passages 80 and 82, thus enabling fluid (e.g., drilling mud, drilling fluid) to flow through the swivel joint system 62 for during drilling operations.

Alternatively to the plug valve 86, in some embodiments, the swivel joint system 62 may include an axial seal 180 (e.g., face seal) that may be disposed within the central passage 80 of the upper subunit 70 of the swivel joint system 62. FIG. 16 illustrates a cross sectional view of an embodiment of the swivel joint system 62 having the axial seal 180. The axial seal 180 may be used to seal the central passage 82 of the lower subunit 72 from the central passage 80 of the upper subunit 70. A piston 182 of the axial seal 180 may be actuated (e.g., with hydraulic fluid, pneumatic fluid) downward relative to the axis 74 to interface with one or more shoulders 183 of the central passage 80, the central passage 82, or both to seal the central passage 82 and upward to unseal the passage 82 and enabling fluid flow through the central passages 80 and 82. The interface between the axial seal 180 and the one or more shoulders 183 may create a face pressure seal that may be used to contain the pressure within the central passage 82 and/or the central passage 80.

In some embodiments, the control system 124 may include the sensor 170 that may measure the position of axial seal 180, thus, detecting whether the central passage 82 is sealed from the central passage 80. The sensor 170 may be disposed on the axial seal 170, within the swivel joint system 62, or at any other location suitable for measuring the position of the axial seal 180. The sensor 170 may output the measured position of the axial seal 180, indicative of a sealed positon or unsealed position, to the control system 124. The control system 124 may receive the sensor data and may determine whether the axial seal 180 should be actuated axially upward or downward to seal the central passage 82 of the lower subunit 72 or to unseal the central passage 82. When the swivel joint system 62 is to be pivoted in the hinged position 66, the control system 124 may output a control signal based at least in part on the sensor data to actuate the piston 182 of the axial seal 180 downward relative to the axis 74 to interface with the one or more shoulders 183 to seal the central passage 82 and block the flow of fluids (e.g., drilling mud, drilling fluid). When the swivel joint system 62 in the extended position 64 or the extended position 64 is to be maintained, the control system 124 may output a control signal to actuate the piston 182 of the axial seal 180 axially upward relative to the axis 74 to unseal the central passage 82, thus, enabling fluid (e.g., drilling mud, drilling fluid) to flow through the swivel joint system 62 for during drilling operations.

Additionally, the axial seal 180 may serve a locking function. When the axial seal 180 is actuated axially downward, an axial bottom 184 of the axial seal 180 may extend into the central passage 82 of the lower subunit 72 of the swivel joint system 62. This extension may enable the axial seal 180 to lock the pivot action of the swivel joint system 62 when the axial seal 180 is down. Thus, when the swivel joint system 62 is in the hinged position 66, the axial seal 180 may lock the movement of the lower subunit 72 such that it may not be moved or pivoted. This locking function may enable a reduction in some of the pressure on the actuators used to pivot the lower subunit 72 of the swivel joint system 62.

FIG. 17 illustrates a process 200 for engaging a tubular element 42 in angled position using the swivel joint system 62. First, the control system 124 may determine the angular position of the top drive 28 (process block 202). The encoder 132 may be used to measure the angular position of the top drive 28 and may output the position data to the control system 124. The control system 124 may receive the angular position data from the encoder 132 and determine whether the top drive 28 is positioned at the position that will enable the tubular gripping tool 30 be directed toward the centerline of the tubular element 42 positioned on the catwalk system 48 or elsewhere on the rig floor 12. The control system 124 may output a control signal to the top drive 28 or to a control system for the top drive 28 to change the angular position of the top drive 28 if it is determined that the current angular positioning of the top drive 28 will not enable the tubular gripping tool 30 to be directed within a particular tolerance of the centerline of the tubular element 42 when the swivel joint system 62 is pivoted to the hinged position 66.

In a next step, the control system 124 may determine a desired vertical height of the top drive 28 (process block 203). The encoder 132 may measure the vertical height of the top drive 28 and my output the vertical height data to the control system 124. The control system 124 may receive the vertical height data from the encoder 132 and determine whether the top drive 28 is positioned at the vertical height (e.g., height offset) that will enable the tubular gripping tool 30 be directed toward the centerline of the tubular element 42 positioned on the catwalk system 48 or elsewhere on the rig floor 12. The control system 124 may output a control signal to the top drive 28 or to a control system for the top drive 28 to change the vertical height of the top drive 28 if it is determined that the current vertical height of the top drive 28 will not enable the tubular gripping tool 30 to be directed within a particular tolerance of the centerline of the tubular element 42 when the swivel joint system 62 is pivoted to the hinged position 66.

In a next step, the control system 124 may determine a desired pivot angle 76 of the lower subunit 72 of the swivel joint system 62 to align the tubular gripping tool 30 with the centerline of the tubular element 42 on the catwalk system 48 (process block 204). The sensor 134 and/or the encoder 132 may output the measured angle 76 to the control system 124. The control system 124 may receive the sensor data and may determine the angle 76 at which the swivel joint system 62 should be pivoted to and/or whether the swivel joint system 62 is pivoted to the angle 76 that will enable the tubular gripping tool 30 to be directed toward the centerline of the tubular element 42. The control system 124 may then output a control signal to the hinge actuator 110, or any pivoting mechanism that may be used to pivot the swivel joint system 62, instructing to lift or lower the lower subunit 72 of the swivel joint system 62 to achieve the determined and/or desired angle 76 (process block 206).

In some embodiments, before the swivel joint system 62 is pivoted to the hinged position 66 at the pivot angle 76, the lock sleeve 140 may be actuated axially upward such that the lock sleeve 140 is not locking the pivot action of the lower subunit 72 of the swivel joint system 62. The sensor 144 may output the measured axial position of the lock sleeve 140 to the control system 124. The control system 124 may receive the sensor data and may determine whether the lock sleeve 140 should be moved axially upward or downward based at least in part on the position data from the sensor 144. When the swivel joint system 62 is to be pivoted from the extended position 64 to the hinged position 66, the control system 124 may output a control signal to the lock sleeve 140 to actuate a piston 146 of the lock sleeve 140 axially upward such that the lock sleeve 140 is not locking (e.g., blocking) the pivoting action of the lower subunit 72 of the swivel joint system 62.

Additionally, in some embodiments, the plug valve 86 or the axial seal 180 may be actuated to seal the central passage 82 of the lower subunit 72 from the central passage 80 of the upper subunit 70 to block the flow of fluid (e.g., drilling mud, drilling fluid) from flowing through the central passage 82. In some embodiments, the sensor 170 may output the measured position of the plug valve 86 or the axial seal 180 to the control system 124. The control system 124 may receive the sensor data and may determine whether the plug valve 86 or the axial seal 180 should be actuated to seal the central passage 82 or to unseal the central passage 82. In some embodiments, when the plug valve 86 is included and when the swivel joint system 62 is to be pivoted from the extended position 64 to the hinged position 66, the control system 124 may output a control signal based at least in part on the sensor data to rotate the plug valve 86 within the radial passage 94 such that the passage 98 of the plug valve 86 is not aligned with the central passages 80 and 82 to seal the passage 82 from the flow of fluids. In some embodiments, when the axial seal 180 is included, when the swivel joint system 62 is to be pivoted in the hinged position 66, the control system 124 may output a control signal based at least in part on the sensor data to actuate the piston 182 of the axial seal 180 downward to seal the central passage 82 and block the flow of fluids.

In a next step, once the swivel joint system 62 is in the hinged position 66 at the desired pivot angle 76, the tubular element 42 on the catwalk system 48 may engage with the tubular gripping tool 30 (process block 208). This engagement may occur without the use of elevators or tilt bales because of the pivot action of the swivel joint system 62. The swivel joint system 62 may then be pivoted back to the extended position 64 using similar techniques as those discussed above. This may align the engaged tubular element 42 with the vertical axis 44 that passes through the center of the wellbore 34.

As discussed in detail above, present embodiments provide a system and method for engaging a tubular element in an angled position. The swivel joint system 62 may pivot up to a horizontal orientation, enabling the tubular gripping tool 30 to be directed toward the tubular element 42 on the catwalk system 48 or other area of the drilling rig 10 such that the tubular element may be engaged and lifted without the use of lifting elevators or tilt bales. Elimination of the elevators and bales may enable an increase in the accuracy and efficiency of the engagement of the tubular element 42 with the tubular gripping tool 30. Further, control of the swivel joint system 62 using various sensors (e.g., sensors 134, 144, 170 discussed above) and a control system 114 may enable an increase in the accuracy and efficiency of lifting and laying down the tubular element 42 from a sloped or horizontal catwalk system 48.

In some embodiments, the swivel joint system 62 may include an internal sealing mechanism (e.g., plug valve 86, axial seal 180) that may enable the flow of fluid through the swivel joint system 62 to be blocked when the swivel joint system 62 is in the hinged position 66. Further in some embodiments, the swivel joint system 62 may include a locking mechanism (e.g., lock sleeve 140, axial seal 180) that may lock the pivot action of the swivel joint system 62 in either the extended position 64 or the hinged position 66. This locking may help reduce some pressure on the actuators of the swivel joint system 62 when in particular positions and may enable the desired position of the swivel joint system 62 to be maintained. In some embodiments, the swivel joint system 62 may include a mud saver valve 156 that may be activated by the actuation of the lock sleeve 140, which may enable the swivel joint system 62 to provide a dual functionality.

While the present disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and tables and have been described in detail herein. However, it should be understood that the embodiments are not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims. Further, although individual embodiments are discussed herein, the disclosure is intended to cover all combinations of these embodiments.

SWIVEL JOINT SYSTEM AND METHOD

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