Hoisting system, robotic manipulator and method for handling tubulars on a drilling rig and tubular handling system and method
阅读说明：本技术 钻机上处理管件的提升系统、自动机械手和方法以及管件处理系统和方法 (Hoisting system, robotic manipulator and method for handling tubulars on a drilling rig and tubular handling system and method ) 是由 刘喜林 罗伯特·本杰明·唐纳利 安德鲁·伊恩·麦肯齐 格雷厄姆·亚历山大·卡内基 杰伊·约翰 于 2018-11-28 设计创作，主要内容包括：钻机包括钻台,从钻台竖立的井架,位于井架一侧的钻台上有一个立根箱,或位于井架相对侧上的钻台上的两个立根盒,以及在立根盒上方连接到井架的一个或两个指板。提升系统构造成将顶驱器停置在井架后面。提升系统可以包括升降机和提升爪,所述提升爪可沿着垂直导轨独立移动使得可在升降机定位以拾取钻柱的同时操纵钻杆支架。上机械手,下机械手和提升爪或升降机协作以自动化地将支架存放在立根盒中和/或从立根盒供应支架。(The drilling rig comprises a drill floor, a derrick erected from the drill floor, a setback box on the drill floor on one side of the derrick, or two setback boxes on the drill floor on the opposite side of the derrick, and one or two fingerboards connected to the derrick above the setback boxes. The hoist system is configured to park the top drive behind the derrick. The lifting system may include an elevator and lifting dogs that are independently movable along the vertical rails so that the drill pipe holder may be manipulated while the elevator is positioned to pick up the drill string. The upper robot, lower robot and lifting dogs or elevators cooperate to automatically store and/or supply racks in and/or from the setback.)
1. A lift system for a drilling rig, comprising: a vertical guide connected to a mast of a drilling rig; a hook trolley connected to the vertical guide rail and to a main drill line; a lift releasably connected to the hooking trolley; a pipe handling trolley connected to a vertical guide rail above the hooking trolley and connected to an auxiliary drilling line; and a lifting claw connected to the pipe handling trolley, wherein the main drill line and the auxiliary drill line are each connected to a corresponding reel.
2. The hoisting system of claim 1, wherein the drawbar trolley is connected to the main drill line by a moving block connected to the drawbar trolley.
3. The lift system of claim 2, wherein the moving mass comprises two spaced apart arms, each of the two arms connected to at least one pulley.
4. The hoisting system of claim 1, wherein the pipe handling trolley is directly connected to the auxiliary drill line.
5. The hoisting system of claim 1, further comprising a controller programmed to sequentially automatically raise the hooking trolley with a tubular caught in the elevator, the lifting dogs to catch the tubular, lower the hooking trolley when the elevator is opened, and raise the pipe handling trolley with the tubular caught in the lifting dogs.
6. The lifting system of claim 5, wherein the lifting claw comprises a cylinder and a pair of prongs configured to open or close in unison upon actuation by the cylinder.
7. The lift system of claim 5, wherein the lift comprises a cylinder and a spider configured to open or close upon actuation of the cylinder.
8. The hoisting system of claim 1, further comprising a controller programmed to sequentially automatically raise the pipe handling trolley with a tubular jammed in the lifting jaws, raise the hooking trolley while the elevator is jamming the tubular, open the lifting jaws, and lower the hooking trolley with the tubular jammed in the elevator.
9. The lifting system of claim 8, wherein the lifting claw comprises a cylinder and a pair of prongs configured to open or close in unison upon actuation by the cylinder.
10. The lift system of claim 8, wherein the lift comprises a cylinder and a spider configured to open or close upon actuation of the cylinder.
11. The lift system of claim 2, comprising: a top drive system connected to a top drive trolley, wherein the top drive trolley is selectively disconnected from the traveling block, and two doors, each of which is connected to the drilling rig mast, e.g., to rotate relative to the mast; and two track sections, each of the two track sections being connected to a respective one of the two doors, e.g., to rotate relative to the respective one of the two doors, wherein either of the two track sections selectively forms part of the vertical track, and wherein the top drive trolley is selectively suspended from one of the two track sections.
12. The lift system of claim 11, wherein the hook trolley is selectively disconnected from the top drive trolley.
13. The lift system of claim 11, wherein each of the two track sections comprises at least one stand pin, wherein the upper track section of the vertical guide comprises at least one vertical hole sized to receive the at least one stand pin, and wherein each of the two track sections is vertically movable relative to the mast.
14. The lift system of claim 13, wherein each of the two track portions further comprises at least one second vertical hole, wherein the lower track portion of the vertical guide track comprises at least one second stand pin sized to be received in the at least one second vertical hole, and wherein the lower track portion is connected to the mast of the rig, for example, to selectively move vertically relative to the mast.
15. The hoisting system of claim 14, further comprising an actuator connected to a lower track portion of the vertical guide rail configured to move the lower track portion vertically relative to the mast.
16. The hoisting system of claim 14, further comprising a horizontal pin to secure the lower track portion to a vertically upper position of a mast.
17. The hoist system of claim 11, wherein the mast of the drilling rig includes two spaced apart trusses, wherein each of the two doors is connected to a respective one of the two trusses, and wherein each of the two doors is rotatable between a first position in which the door is located in a space between the two trusses and a second position rotated approximately a quarter turn from the first position.
18. The lift system of claim 11, wherein each of the two track portions is rotatable approximately one-half turn from a first position on one side of the respective one of the two doors to a second position on an opposite side of the door.
19. The hoisting system of claim 11, further comprising a controller programmed to automatically disconnect a first track portion of the two track portions from an upper track portion of the vertical guide in a first sequence, rotate a first door of the two doors connected to the first track portion relative to the mast to an outer position beside the mast, rotate the first track portion relative to the first door from one side of the first door to an opposite side of the first door, and rotate the first door relative to the mast to an inner position below the mast.
20. The lift system of claim 19, wherein the controller is further programmed to automatically rotate a second door of the two doors to an outer position beside the mast in a second sequence interspersed in the first sequence, the second track portion of the two track portions being rotated relative to the second door from one side of the second door to an opposite side of the second door, the second door being rotated relative to the mast to an inner position below the mast, and the second track portion being connected with the upper track portion of the vertical guide rail.
21. A method, comprising: providing a vertical rail connected to a derrick of a drilling rig, a hooking carriage connected to the vertical rail, a hoist releasably connected to the hooking carriage, a pipe handling carriage connected to the vertical rail above the hooking carriage, and a lifting dog connected to the pipe handling carriage; and moving the hooking trolley along the vertical guide rail independently of the pipe handling trolley.
22. The method of claim 21, further comprising, in order: raising the hooking trolley with a tubular jammed in the elevator; gripping the tubular with the lifting dogs; lowering the hook trolley while opening the elevator; and storing the tubular in a setback while lowering the hanger trolley.
23. The method of claim 22, wherein storing the tubular in the setback comprises raising and lowering the pipe handling trolley with the tubular caught in the lifting dogs.
24. The method of claim 21, further comprising, in order: raising the hook trolley while supplying tubulars from a setback; raising the hooking trolley while clamping the pipe by using the lifter; opening the lifting claw; and lowering the hooking trolley with the tubular caught in the elevator.
25. The method of claim 24, wherein supplying the tubular from the setback comprises raising and lowering the pipe handling trolley with the tubular caught in the lifting dogs.
26. A tubular handling system for a drilling rig comprising a drill floor, a hoist system (10) including a derrick (14) erected from the drill floor, a setback (90,100) located on the drill floor, and a fingerboard (104,106) connected to the derrick (14) above the setback (90,100), the tubular handling system comprising:
a lower robot (60), wherein the lower robot (60) is located above the drill floor, the lower robot (60) comprising a wrist (66) connected to a distal end of an articulated arm (64), a mechanical interface (70) connected to the wrist (66) via a rolling joint (114), and an end effector (72) protruding from the mechanical interface (70), and wherein the end effector (72) comprises a jaw (74), the jaw (74) comprising a first feedback device for detecting the presence of a tubular (92,96) in the jaw (74);
the hoisting system (10) comprising a vertical guide rail (20) connected to the derrick (14), a trolley (46,54) connected to the vertical guide rail (20) and to a drilling line (44,56), a hoist (48) or a hoisting claw (58) connected to the trolley (46,54), wherein the hoisting system (10) comprises a second feedback device for detecting a hoisting weight and a third feedback device for detecting the presence of the tubular (92,96) in the hoist (48) or the hoisting claw (58); and
the controller (202,204,205,206) is programmed to automatically perform in sequence: -holding an upper end of the tubular (92,96) using the elevator (48) or a lifting claw (58), -detecting the presence of the tubular (92,96) in the elevator (48) or the lifting claw (58) using the third feedback device, -holding a lower end of the tubular (92,96) using the lower robot (60) with the claw (74), -detecting the presence of the tubular (92,96) in the claw (74) of the lower robot (60) using the first feedback device, -lifting the tubular (92,96) using the lifting system (10), -detecting the weight of the tubular (92,96) using the second feedback device, -positioning a lower end of the tubular (92,96) at a predetermined position on the setback (90,100) using the lower robot (60), and-lowering the tubular (92) on the setback (90,100) using the lifting system (10), 96) (ii) a
Wherein the lower end of the tubular (92,96) is located at a predetermined position on the setback (90,100) without using the articulated arm (64) of the lower robot (60) to lift the weight of the tubular (92, 96).
27. The tubular handling system of claim 26, wherein the roll joint (114) of the lower robot (60) includes a torque feedback device, the controller (202,204,205,206) further programmed to selectively actuate the articulated arm (64) to maintain the wrist (66) of the lower robot (60) substantially horizontal and to selectively minimize torque applied to the lower end (92,96) of the tubular by the roll joint (114) of the lower robot (60).
28. The tubular handling system of claim 26, further comprising:
an upper manipulator (62), wherein the upper manipulator (62) is located above the fingerboards (104,106), the upper manipulator (62) comprising a wrist (66) connected to a distal end of an articulated arm (64), a mechanical interface (70) connected to the wrist (66) by a rolling joint (114), and an end effector (72) protruding from the mechanical interface (70), and wherein the end effector (72) comprises a jaw (74) comprising a fourth feedback device for detecting the presence of a tubular (92,96) in the jaw (74); and
the controller (202,204,205,206) is further programmed to automatically perform in sequence:
checking for absence of weight using the second feedback device, holding an upper end of the tubular (92,96) using the jaws (74) of the upper robot (62), detecting the presence of the tubular (92,96) in the jaws (74) of the upper robot (62) using the fourth feedback device, releasing the upper end (92,96) of the tubular from a hoist (48) or from the lifting jaws (58), and positioning the upper end of the tubular (92,96) at a predetermined position in a finger plate (104,106) using the upper robot (62);
wherein the upper ends of the tubulars (92,96) are located in predetermined positions in the fingerboards (104,106) without lifting the weight of the tubulars (92,96) by the articulated arm (64) of the upper robot (62).
29. The tubular handling system of claim 28, wherein the rolling joint (114) of the upper robot (62) includes a torque feedback device, the controller (202,204,205,206) further programmed to actuate the articulated arm (64) to selectively maintain the wrist (66) of the upper robot (62) substantially horizontal and to selectively minimize torque applied to an upper end of the tubular (92,96) by the rolling joint (114) of the upper robot (62).
30. The tubular handling system of claim 28:
the lower robot (60) further comprising fifth feedback means for detecting open and closed positions of the jaws (74) of the lower robot (60), wherein the controller (202,204,205,206) is further programmed to actuate the jaws (74) of the lower robot (60) based on a signal generated by the fifth feedback means;
the upper manipulator (62) further comprises sixth feedback means for detecting the open and closed position of the jaw (74) of the upper manipulator (62), wherein the controller (202,204,205,206) is further programmed to actuate the jaw (74) of the upper manipulator (62) based on a signal generated by the sixth feedback means; and
the lift system (10) further includes a seventh feedback device for detecting open and closed positions of the lift (48) or the lift fingers (58), wherein the controller (202,204,205,206) is further programmed to actuate the lift (48) or the lift fingers (58) based on a signal generated by the seventh feedback device.
31. The tubular handling system of claim 26:
the jaw (74) of the lower robot (60) comprises a fixed arcuate finger (76) substantially in line with the wrist (66) of the lower robot (60) and fixed to the mechanical interface (70) of the lower robot (60); and a movable arcuate finger (82) hinged on a proximal end of the fixed arcuate finger (76), wherein each of the fixed arcuate finger (76) and the movable arcuate finger (82) includes a layer of low friction material in a raised portion thereof.
32. The tubular handling system of claim 28:
the claw (74) of the upper manipulator (62) comprises a fixed arc-shaped finger (76) substantially in line with the (66) of the upper manipulator (62) and fixed to the mechanical interface (70) of the upper manipulator (62); and a movable arcuate finger (82) hinged on a proximal end of the fixed arcuate finger (76), wherein each of the fixed arcuate finger (76) and the movable arcuate finger (82) includes a layer of low friction material in a raised portion thereof.
33. A method, comprising:
providing a tubular handling system on a drilling rig, the drilling rig comprising a drill floor, a hoist system (10) comprising a derrick (14) erected from the drill floor, a setback (90,100) located on the drill floor, and a fingerboard (104,106) connected to the derrick (14) above the setback (90,100), the tubular handling system comprising: a lower robot (60), wherein the lower robot (60) is located above the drill floor, the lower robot (60) comprising a wrist (66) connected to the distal end of the articulated arm (64), a mechanical interface (70) connected to the wrist (66) via a rolling joint (114), and an end effector (72) protruding from the mechanical interface (70), and wherein the end effector (72) comprises a claw (74), the claw (74) comprising first feedback means for detecting the presence of a tubular (92,96) in the claw (74), the hoisting system (10) comprising a vertical rail (20) connected to the derrick (14), a trolley (46,54) connected to the vertical rail (20) and to a drill line (44,56), and a hoist (48) or a hoisting claw (58) connected to the trolley (46,54), wherein the lifting system (10) comprises a second feedback device for detecting a lifting weight and a third feedback device for detecting the presence of the tubular (92,96) in the elevator (48) or the lifting claw (58);
holding the upper end of the tubular (92,96) using the elevator (48) or the lifting claw (58);
detecting the presence of the tubular (92,96) in the elevator (48) or the lifting dogs (58) using the third feedback device;
holding a lower end of the tubular (92,96) using the jaws (74) of the lower robot (60);
detecting the presence of the tubular (92,96) in the jaws (74) of the lower robot (60) using the first feedback device;
lifting the tubular (92,96) using the lifting system (10);
detecting a weight of the tubular (92,96) using the second feedback device;
positioning a lower end of the tubular (92,96) at a predetermined location on the setback (90,100) using the lower robot (60); and
lowering the tubular (92,96) on the setback (90,100) using the hoist system (10),
wherein the lower end of the tubular (92,96) is located at the predetermined position on the setback (90,100) without lifting the weight of the tubular (92,96) by the articulated arm (64) of the lower robot (60).
34. The method of claim 33, further comprising:
selectively actuating the articulated arm (64) to maintain the wrist (66) of the lower robot (60) substantially horizontal; and
selectively minimizing torque applied to the lower end of the tubular (92,96) by the rolling joint (114) of the lower robot (60).
35. The method of claim 33, further comprising:
providing an upper manipulator (62), wherein the upper manipulator (62) is located above the fingerboards (104,106), the upper manipulator (62) comprising a wrist (66) connected to a distal end of an articulated arm (64), a mechanical interface (70) connected to the wrist (66) by a rolling joint (114), and an end effector (72) protruding from the mechanical interface (70), and wherein the end effector (72) comprises a jaw (74) comprising a fourth feedback device for detecting the presence of a tubular (92,96) in the jaw (74); and
checking for no weight using the second feedback means;
holding the upper end of the tubular (92,96) using the jaws (74) of the upper robot (62);
detecting the presence of the tubular (92,96) in the jaw (74) of the upper robot (62) using the fourth feedback device;
releasing the upper end of the tubular (92,96) from the elevator (48) or from the lifting dogs (58); and
positioning an upper end of the tubular (92,96) at a predetermined position in a fingerboard (104,106) using the upper robot (62);
wherein the upper ends of the tubulars (92,96) are located in predetermined positions in the fingerboards (104,106) without lifting the weight of the tubulars (92,96) by the articulated arm (64) of the upper robot (62).
36. The method of claim 35, further comprising:
actuating the articulated arm (64) to selectively maintain the wrist (66) of the upper robot (62) substantially horizontal; and
selectively minimizing torque applied to the upper end of the tubular (92,96) by the rolling joint (114) of the upper robot (62).
37. A tubular handling system for a drilling rig comprising a drill floor, a hoist system (10) including a derrick (14) erected from the drill floor, a setback (90,100) located on the drill floor, and a fingerboard (104,106) connected to the derrick (14) above the setback (90,100), the tubular handling system comprising:
an upper manipulator (62), wherein the upper manipulator (62) is located above the fingerboards (104,106), the upper manipulator (62) comprising a wrist (66) connected to a distal end of an articulated arm (64), a mechanical interface (70) connected to the wrist (66) by a rolling joint (114), and an end effector (72) protruding from the mechanical interface (70), and wherein the end effector (72) comprises a jaw (74) comprising a first feedback device for detecting the presence of a tubular (92,96) in the jaw (74); and
the hoisting system (10) comprising a vertical guide rail (20) connected to the derrick (14), a trolley (46,54) connected to the vertical guide rail (20) and to a drilling line (44,56), and a hoist (48) or a lifting claw (58) connected to the trolley (46,54), wherein the hoisting system (10) comprises a second feedback device for detecting a hoisting weight and a third feedback device for detecting the presence of the tubular (92,96) in the lifting claw (74); and
the controller (202,204,205,206) is programmed to automatically perform in sequence: holding the upper end of the tubular (92,96) in a predetermined position in a fingerboard (104,106) using the jaws (74) of an upper robot (62); detecting the presence of a tubular (92,96) in the jaws (74) of the upper manipulator (62) using a first feedback device; positioning an upper end of the tubular (92,96) in the elevator (48) or the lifting claw (58) using an upper robot (62); holding the upper end of the tubular (92,96) with the elevator (48) or the lifting claw (58); detecting the presence of the tubular (92,96) in the elevator (48) or the lifting dogs (58) using a third feedback device; and releasing the upper end of the tubular (92,96) from the jaws (74) of the upper robot (62);
wherein the upper end of the tubular (92,96) is positioned in the elevator (48) or the lifting claw (58) without the articulated arm (64) of the upper robot (62) lifting the weight of the tubular (92, 96).
38. The tubular handling system of claim 37, wherein the rolling joint (114) of the upper robot (62) includes a torque feedback device, the controller (202,204,205,206) further programmed to actuate the articulated arm (64) to selectively maintain the wrist (66) of the upper robot (62) substantially horizontal and minimize torque applied to the upper end of the tubular (92,96) by the rolling joint (114) of the upper robot (62).
39. The tubular handling system of claim 37, further comprising:
a lower robot (60), wherein the lower robot (60) is located above the drill floor, the lower robot (60) comprising a wrist (66) connected to a distal end of an articulated arm (64), a mechanical interface (70) connected to the wrist (66) via a rolling joint (114), and an end effector (72) protruding from the mechanical interface (70), and wherein the end effector (72) comprises a claw (74), the claw (74) comprising fourth feedback means for detecting the presence of the tubular (92,96) in the claw (74);
the controller (202,204,205,206) is further programmed to automatically perform an installation sequence: holding a lower end of the tubular (92,96) using the jaws (74) of the lower robot; detecting the presence of a tubular (92,96) in the jaw (74) of the lower robot using a fourth feedback device; detecting a weight of the weight (92,96) of the tubular using the second feedback device; positioning a lower end of the tubular (92,96) at a predetermined position above a well center (94), and lowering the tubular (92,96) on the well center (94,96),
wherein the lower end of the tubular (92,96) is located above the well center (94) without lifting the weight of the tubular (92,96) by the articulated arm (64) of the lower robot (60).
40. The tubular handling system of claim 39, wherein the roll joint (114) of the lower robot (60) includes a torque feedback device, the controller (202,204,205,206) further programmed to actuate the articulated arm (64) to selectively maintain the wrist (66) of the lower robot (60) substantially horizontal and minimize torque applied to the lower end of the tubular (92,96) by the roll joint (114) of the lower robot (60).
41. The tubular handling system of claim 39:
-the upper manipulator (62) further comprises fifth feedback means for detecting the open and closed position of the jaw (74) of the upper manipulator (62), wherein the controller (202,204,205,206) is further programmed to actuate the jaw (74) of the upper manipulator (62) based on a signal generated by the fifth feedback means;
the lower robot (60) further comprising a sixth feedback device for detecting the open and closed positions of the jaws (74) of the lower robot (60), wherein the controller (202,204,205,206) is further programmed to actuate the jaws (74) of the lower robot (60) based on a signal generated by the sixth feedback device; and
the lift system (10) further includes a seventh feedback device for detecting open and closed positions of the lift (48) or the lift fingers (58), wherein the controller (202,204,205,206) is further programmed to actuate the lift (48) or the lift fingers (58) based on a signal generated by the seventh feedback device.
42. The tubular handling system of claim 37:
the claw (74) of the upper manipulator (62) comprises a fixed arcuate finger (76) substantially in line with the wrist (66) of the upper manipulator (62) and fixed to the mechanical interface (70), and a movable arcuate finger (82) hinged on a proximal end of the fixed arcuate finger (76), wherein each of the fixed arcuate finger (76) and the movable arcuate finger (82) comprises a layer of low friction material in a raised portion thereof.
43. The tubular handling system of claim 39:
the jaw (74) of the lower robot (60) includes a fixed arcuate finger (76) substantially in line with the wrist (66) of the lower robot (60) and secured to the machine interface (70), and a movable arcuate finger (82) hinged on a proximal end of the fixed arcuate finger (76), wherein each of the fixed arcuate finger (76) and the movable arcuate finger (82) includes a layer of low friction material in a raised portion thereof.
44. A method, comprising:
providing a tubular handling system on a drilling rig, the drilling rig comprising a drill floor, a hoisting system, the hoisting system (10) comprising a mast (14) erected from the drill floor, a setback (90,100) located on the drill floor, and a fingerboard (104,106) connected to the mast (14) above the setback (90,100), the tubular handling system comprising an upper manipulator (62), wherein the upper manipulator (62) is located above the fingerboard (104,106), the upper manipulator (62) comprising a wrist (66) connected to a distal end of the articulated arm (64), a mechanical interface (70) connected to the wrist (66) by a roll joint (114), and an end effector (72) protruding from the mechanical interface (70), and wherein the end effector (72) comprises a jaw (74) comprising a first feedback device for detecting a tubular (92) in the jaw (74), 96) presence of (a); the hoisting system (10) comprising a vertical guide rail (20) connected to the derrick (14), a trolley (46,54) connected to the vertical guide rail (20) and to a drilling line (44,56), and a hoist (48) or a lifting claw (58) connected to the trolley (46,54), wherein the hoisting system (10) comprises a second feedback device for detecting a hoisting weight and a third feedback device for detecting the presence of the tubular (92,96) in the claw (74);
holding the upper end of the tubular (92,96) in a predetermined position in the fingerboards (104,106) using the jaws (74) of the upper robot (62);
detecting the presence of the tubular (92,96) in the jaws (74) of the upper robot (62) using the first feedback device;
positioning the upper end of the tubular (92,96) in the elevator (48) or the lifting claw (58) using the upper robot (62);
holding the upper end of the tubular (92,96) with the elevator (48) or the lifting claw (58);
detecting the presence of the tubular (92,96) in the elevator (48) or the lifting dogs (58) using the third feedback device; and
releasing the upper end of the tubular (92,96) from the jaws (74) of the upper robot (62);
wherein the upper end of the tubular (92,96) is positioned in the elevator (48) or the lifting claw (58) without the articulated arm (64) of the upper robot (62) lifting the weight of the tubular (92, 96).
45. The method of claim 44, further comprising:
actuating the articulated arm (64) to selectively maintain the wrist (66) of the upper robot (62) substantially horizontal; and
minimizing torque applied to the upper end of the tubular (92,96) by the rolling joint (114) of the upper robot (62).
46. The method of claim 44, further comprising:
providing a lower robot (60), wherein the lower robot (60) is located above the drill floor, the lower robot (60) comprising a wrist (66) connected to a distal end of an articulated arm (64), a mechanical interface (70) connected to the wrist (66) via a rolling joint (114), and an end effector (72) protruding from the mechanical interface (70), and wherein the end effector (72) comprises a claw (74), the claw (74) comprising fourth feedback means for detecting the presence of the tubular (92,96) in the claw (74);
holding a lower end of the tubular (92,96) using the jaws (74) of the lower robot;
detecting the presence of a tubular (92,96) in the jaw (74) of the lower robot using the fourth feedback device;
lifting the tubular (92,96) using the lifting system (10);
detecting a weight of the weight (92,96) of the tubular using the second feedback device;
positioning a lower end of the tubular (92,96) at a predetermined location above a well center (94), an
Lowering the tubular (92,96) on the well center (94),
wherein the lower end of the tubular (92,96) is located above the well center (94) without lifting the weight of the tubular (92,96) by the articulated arm (64) of the lower robot (60).
47. The method of claim 46, further comprising:
actuating the articulated arm (64) to selectively maintain the wrist (66) of the lower robot (60) substantially horizontal; and
minimizing the torque applied by the rolling joint (114) of the lower robot (60) to the lower end of the tubular (92, 96).
48. A robot for handling tubulars on a drilling rig, the robot comprising:
an articulated arm (64) having a wrist (66) connected to a distal end of the articulated arm (64) by a yaw joint arrangement (68), a mechanical interface (70) connected to the wrist (66) by a roll joint (114), and an end effector (72) protruding from the mechanical interface (70), wherein the end effector (72) comprises:
a fixed arcuate finger (76) disposed substantially in line with the wrist (66) and fixed to the mechanical interface (70);
a bracket (84) disposed substantially perpendicular to the wrist (66) and secured to a proximal end of the fixed arcuate finger (76);
a movable arcuate finger (82) hinged on a proximal end of the fixed arcuate finger (76); and
an actuator disposed substantially along the bracket (84), the actuator having a first end connected to the bracket (84) and a second end connected to the movable arcuate finger (82).
49. The manipulator of claim 48, wherein the yaw joint arrangement (68) includes a pitch joint and a roll joint connected thereto.
50. The robot hand of claim 48, wherein the fixed arcuate finger (76) includes a first plate (78) and a second plate (80) offset from the first plate (78), and wherein the movable arcuate finger (82) is located between the first plate (78) and the second plate (80).
51. The robot hand of claim 48, wherein each of the fixed arcuate fingers (76) and the movable arcuate fingers (82) includes a layer of low friction material in a raised portion thereof.
52. A method for handling tubulars (92,96) on a drilling rig, the drilling rig comprising a drill floor, a hoist system (10) comprising a derrick (14) erected from the drill floor, and two setback boxes (90,100) on opposite sides of the derrick on the drill floor, the method comprising:
provided is a manipulator (60) comprising: an articulated arm (64) having a wrist (66) connected to a distal end of the articulated arm (64) by a yaw joint arrangement (68), a mechanical interface (70) connected to the wrist (66) by a roll joint (114), and an end effector (72) protruding from the mechanical interface (70);
holding a first tubular (92) suspended above a well center (94) from the hoist system (10) with the end effector (72);
using the yaw joint arrangement (68) to orient the wrist (66) towards a first of two setback boxes (90, 100);
orienting a lower end of the first tubular (92) with the articulated arm (64) toward a first predetermined position on the first setback (90);
rotating the end effector (72) about one-half turn using a rolling joint (114);
holding a second tubular (96) suspended from the hoist system (10) above the well center (94) with the end effector (72);
using a yaw joint arrangement (68) to orient the wrist (66) towards a second of the two setback boxes (90, 100); and
positioning a lower end of the second tubular (96) at a second predetermined location on the second setback (100) using the articulated arm (64).
53. The method of claim 52, wherein the first tubular (92) suspended above the well center (94) is maintained while maintaining the articulating arm (64) substantially in a neutral direction (88), and the lower end of the first tubular (92) is positioned in the first predetermined position while maintaining the articulating arm (64) in a direction within about less than one eighth of a turn from the neutral direction (88).
54. The method of claim 53, wherein the second tubular (96) suspended above the well center (94) is maintained while maintaining the articulating arm (64) generally in a neutral direction (88), and wherein a lower end of the second tubular (96) is positioned in the second predetermined position while maintaining the articulating arm (64) in a direction within about less than one-eighth of a turn from the neutral direction (88).
55. A method for handling tubulars (92,96) on a drilling rig, the drilling rig comprising a drill floor, a hoist system (10) including a derrick (14) erected from the drill floor, and two setback boxes (90,100) on opposite sides of the derrick (14) on the drill floor, and two fingerboards (104,106), each of the two fingerboards (104,106) connected to the derrick (14) over a respective one of the two setback boxes (90,100), the method comprising:
provided is a manipulator (60) comprising: an articulated arm (64) having a wrist (66) connected to a distal end of the articulated arm (64) by a yaw joint arrangement (68), a mechanical interface (70) connected to the wrist (66) by a roll joint (114), and an end effector (72) protruding from the mechanical interface (70);
holding a first tubular (92) lowered from the lift system (10) on a first of the two setback boxes (90,100) using the end effector (72);
using the yaw joint arrangement (68) to orient the wrist (66) towards a first one (104) of the two fingerboards (104, 106);
positioning an upper end of the first tubular member (92) in a first predetermined position on the first fingerboard (104) using the articulating arm (64);
rotating the end effector (72) about one-half turn using the rolling joint (114);
holding a second tubular (96) lowered from the hoist system (10) on a second of the two setback boxes (90,100) using the end effector (72);
using a yaw joint arrangement (68) to orient the wrist (66) towards a second of the two fingerplates (104, 106); and
positioning an upper end of the second tubular member (96) at a second predetermined location on the second fingerboard (106) using the articulating arm (64).
56. The method of claim 55 wherein the first tubular (92) lowered on the first setback (90) is held while maintaining the articulated arm (64) generally in a neutral direction (88), and the upper end of the first tubular (92) is positioned at the first predetermined location while maintaining the articulated arm (64) in a direction within about less than one-eighth of a turn from the neutral direction (88).
57. The method of claim 56, wherein the second tubular (96) lowered on the second setback (90) is held while maintaining the articulated arm (64) generally in a neutral direction (88), and an upper end of the second tubular (96) is positioned at the second predetermined location while maintaining the articulated arm (64) direction within about less than one-eighth of a turn from the neutral direction (88).
Background
The present disclosure relates generally to methods and apparatus for handling tubulars (e.g., drill pipe stands) on a drilling rig.
Drilling involves tripping of the drill string, during which the drill string is pulled out of the well or lowered into the well without drilling. Tripping may typically occur to change all or a portion of the bottom hole assembly, such as the drill bit. During tripping, a plurality of drill pipe stands are disconnected from the rest of the drill string and stored in, or supplied from, a setback of the drilling rig and connected to the rest of the drill string. The drill string can be moved rapidly between two successive disconnections or connections of the drill rod holder. Thus, storing or supplying the stand to or from the setback can be an operation that limits the tripping speed of the drill string.
Traditionally, tripping is performed by human operators, such as crane operators and drilling workers. In a typical tripping operation, the drill string is pulled out of the well using an elevator connected to a traveling block, and the drill string is placed in slips. Then, the weight of the 'bracket to be disconnected' is carried by the moving block, and the bracket connection is disconnected by using the clamp. The drilling worker manually positions the lower end of the hanger bracket on the setback box and the weight of the bracket is reduced on the setback box. Finally, the upper end of the stand is disengaged from the hoist and the crane operator positions the upper end of the stand in the fingerboard.
To speed up the tripping, a drilling rig having an unconventional setback and racking module may be designed, such as shown in PCT application publication WO 2017/190120. The upper and lower arms and the telescoping top drive can be used to utilize such unconventional setback and racking modules and to accelerate tripping. A lift arm (such as shown in U.S. application publication No. 2016/0160586) or a combination rotary table and pipe mover (such as shown in U.S. patent No. 8,550,761) may be used to accelerate the storage of the racks into the setback.
Despite recent advances, there remains a need in the art for apparatus and methods for accelerating drill string tripping, which preferably can be retrofitted on conventional land drilling rigs.
Disclosure of Invention
The present disclosure describes a lift system that may be part of a tubular handling system for a drilling rig.
The lift system may include two doors. Each of the two doors may be connected to a mast of the drilling rig for rotation relative to the mast. For example, a derrick of a drilling rig may include two spaced apart trusses. Each of the two doors may be connected to a respective one of the two trusses. Each of the two doors is rotatable between a first position in which the door is located in the space between the two trusses and a second position rotated approximately a quarter turn from the first position.
The lifting system may comprise two track sections. Each of the two track portions may be connected to a respective one of the two doors for rotation relative to the respective one of the two doors. For example, each of the two track portions may be rotatable about half a turn from a first position on one side of a respective one of the two doors to a second position on the opposite side of the door.
The lift system may include a vertical rail connectable to a mast of a drilling rig. Either of the two track portions may optionally form part of the vertical guide rail and/or may be integrated and fixed to the vertical guide rail. For example, each of the two track portions may comprise at least one stud. The upper track portion of the vertical guide track may include at least one vertical aperture sized to receive at least one stand pin. Each of the two track portions may comprise at least one second vertical hole. The lower track portion of the vertical guide track may include at least one second vertical pin sized to be received in the at least one second vertical hole. The lower track portion may be connected to a mast of a drilling rig for selective vertical movement relative to the mast. For example, the actuator may be connected to the lower rail portion of the vertical guide rail. The actuator may be configured to move the lower track section vertically relative to the mast. The horizontal pin may secure the lower track section to a vertically upper position of the mast. Furthermore, each of the two track sections is vertically movable relative to the mast.
The lifting system may comprise a moving mass. The moving mass may comprise two spaced apart arms. Each of the two arms may be connected to at least one pulley. The main drill string may be connected to a pulley of the traveling block. The main drill line may be connected to a first reel.
The lift system may include a hook trolley. The hooking trolley may be slidably connected to the vertical guide rail. The hooking trolley may also be connected to a moving block. The elevator may be releasably connected to the hook trolley. The elevator may include a cylinder and a spider configured to open or close upon actuation of the cylinder.
The lift system may include a top drive trolley. The top drive trolley may be selectively suspended from one of the two track sections and/or may be slidably attached to the vertical guide rail. The top drive trolley may be selectively disconnected from the traveling block and/or the hook trolley. The top drive system may be connected to a top drive trolley.
The lift system may include a controller. The controller may be programmed to automatically disconnect a first of the two track portions from the upper track portion of the vertical guide in a first order, rotate a first of the two doors connected to the first track portion relative to the mast to an outer position beside the mast, rotate the first track portion relative to the first door from one side of the first door to an opposite side of the first door, and rotate the first door relative to the mast to an inner position below the mast. The controller may be further programmed to automatically rotate a second one of the two doors to an outer position beside the mast with respect to the mast, rotate a second one of the two track sections with respect to the second door from one side of the second door to an opposite side of the second door, rotate the second door to an inner position below the mast with respect to the mast, and connect the second track section with the upper track section of the vertical guide in a second sequence interspersed in the first sequence.
The lift system may include a pipe handling trolley that may be connected to a vertical rail above the hook trolley. The auxiliary drill line may be connected to the pipe handling trolley. For example, the auxiliary drill line may be connected directly to the pipe handling trolley. The auxiliary drill line may be connected to a second reel, which may be different from the first reel. The lifting dogs may be attached to a pipe handling trolley. The lifting dogs may include a cylinder and a pair of prongs configured to open and close in unison upon actuation by the cylinder.
The controller may alternatively or additionally be programmed to sequentially automatically raise the drawbar trolley with the tubular gripped in the elevator, the lifting jaws gripping the tubular, lower the drawbar trolley when the elevator is opened, and raise the pipe handling trolley with the tubular gripped in the lifting jaws. Alternatively or additionally, the controller may be programmed to sequentially automatically raise the pipe handling trolley with a pipe stuck in the lifting dogs, raise the hooking trolley while the elevator is stuck, open the lifting dogs, and lower the hooking trolley with a pipe stuck in the elevator.
The present disclosure describes methods of using a hoisting system, which may be part of a tubular handling system for a drilling rig.
The method may comprise the steps of: a vertical guide rail is provided that is connected to a derrick of a drilling rig, a hooking carriage connected to the vertical guide rail, a hoist releasably connected to the hooking carriage, a pipe handling carriage connected to the vertical guide rail above the hooking carriage, and a lifting claw connected to the pipe handling carriage.
The method may include the step of moving the hooking trolley along the vertical guide independent of the pipe handling trolley. In some embodiments, the method may comprise the following sequence of steps: the method includes raising the hooking carriage with the tubular gripped in the elevator, gripping the tubular with the lifting jaws, lowering the hooking carriage while opening the elevator, and storing the tubular in the setback while lowering the hooking carriage. In some embodiments, the method may additionally or alternatively comprise the following sequence of steps: the method includes the steps of supplying pipe from a stand box while raising a hitching carriage, raising the hitching carriage while gripping the pipe with a hoist, opening a lifting claw, and lowering the hitching carriage with the pipe gripped in the hoist.
Storing and/or supplying tubulars in and/or from a setback can include the steps of: the tubular is gripped in the lifting jaws to raise and lower the pipe handling trolley.
The present disclosure describes a method for treating tubulars on a drilling rig. The drilling rig includes a drill floor, a hoist system including a derrick erected from the drill floor, a setback on the drill floor, and a fingerboard connected to the derrick above the setback.
The lifting system may include: a vertical guide rail connectable to the mast. The lift system may also include a trolley that may be connected to the vertical rail. The trolley may also be connected to a drill line. The lifting system may also include a lift and/or a lifting claw, which may be connected to the trolley. In some embodiments, the lifting pawl may include a pair of prongs configured to open or close together. The lift and/or lifting dogs may include feedback devices for detecting the open and closed positions of the lift and/or lifting dogs, respectively. The controller may be programmed to actuate the elevator and/or the lifting dogs based on signals generated by feedback devices that detect the open and closed positions. The lifting system may further comprise a feedback device for detecting the lifting weight. The lifting system may further comprise feedback means for detecting the presence of a tubular in the elevator and/or the lifting dogs.
The tubular handling system may include a lower robot positionable above the drill floor and an upper robot positionable above the fingerboard. The lower and/or upper manipulators may comprise a wrist connected to the distal end of the articulated arm via a yaw joint. For example, the yaw joint arrangement may include a pitch joint and a roll joint connected thereto. The lower and/or upper manipulators may further comprise a mechanical interface connected to the wrist by a rolling joint. The rolling joint may include a torque feedback device. The controller may be programmed to actuate the articulated arm to maintain the wrist substantially horizontal. The controller may also be programmed to minimize the torque applied to the tubular by the rolling joint. The lower and/or upper robots may further comprise an end effector. The end effector may extend from the mechanical interface.
The end effector of the lower and/or upper robot may comprise a claw. The jaws may include one or more layers of low friction material. In some embodiments, the jaw may include a fixed arcuate finger disposed substantially in line with the wrist and fixed to the mechanical interface. The fixed arc finger may include a first plate and a second plate offset from the first plate. The jaw may further include a movable arcuate finger hinged on a proximal end of the fixed arcuate finger. The movable arcuate fingers may be located between the first and second plates forming the fixed arcuate fingers. Each of the fixed and movable arcuate fingers may include a layer of low friction material in the raised portion thereof. The jaws may also include feedback means for detecting the presence of a tubular in the jaws. The jaws may further include feedback means for sensing the open and closed positions of the jaws. The controller may also be programmed to actuate the jaws based on a signal generated by a feedback device that detects the open and closed positions.
In some embodiments, the end effector may further comprise a bracket disposed substantially perpendicular to the wrist and secured to the proximal end of the fixed arc finger. The end effector may also include a jaw actuator, which may be disposed substantially along the scaffold. The jaw actuator may have a first end connected to the bracket and a second end connected to the movable arcuate finger. For example, the jaw actuator may include a hydraulic cylinder, a lead screw mechanism, a ball screw mechanism.
In some embodiments, a tubular handling system may include a controller programmed to automatically perform all or a subset of the following actions in sequence: holding the upper end of the tubular using the elevator and/or the lifting claw; detecting the presence of a tubular in the elevator and/or the lifting claw; holding the lower end of the tubular with the jaws of the lower manipulator; detecting the presence of a tubular in a jaw of the lower manipulator; lifting the tubular using a lifting system; detecting the weight of the pipe fitting; positioning the lower end of the pipe fitting at a preset position on the stand box by using a lower manipulator; lowering the tubular on the stand box using a lifting system; detecting that no weight exists, and using a claw of the upper manipulator to hold the upper end of the pipe fitting; detecting the presence of a tubular in the jaws of the upper manipulator, releasing the upper end of the tubular from the elevator or and/or lifting the jaws; and positioning the upper end of the tubular at a predetermined position in the fingerboard using the upper robot.
In some embodiments, a tubular handling system may include a controller programmed to automatically perform all or a subset of the following actions in sequence: the method includes holding an upper end of a tubular at a predetermined location in a fingerboard with a jaw of an upper robot, detecting a presence of a tubular in a jaw of the upper robot, holding a lower end of a tubular with a jaw of a lower robot, detecting a presence of a tubular in a jaw of the lower robot, positioning an upper end of a tubular in a hoist and/or lifting jaw with the upper robot, holding an upper end of a tubular with the hoist and/or lifting jaw, detecting a presence of a tubular in the hoist and/or lifting jaw, releasing an upper end of a tubular from the jaw of the upper robot, lifting a tubular with a lifting system, detecting a weight of a tubular, positioning a lower end of a tubular at a predetermined location above a well center, and lowering the tubular onto the well center.
The present disclosure also describes a method of treating tubulars on a drilling rig. The drilling rig may comprise two stand boxes arranged on opposite sides of the derrick on the drill floor.
A method of treating a tubular may include the steps of providing a lower robot and/or an upper robot as described herein.
A method of treating tubulars may include the step of holding a first tubular suspended by a hoist system above the well center using an end effector of a lower robot. The gripping of the first tubular suspended above the well center may be performed while keeping the articulated arm of the lower robot substantially in the neutral direction of the lower robot. The method of handling tubulars may include the step of orienting a wrist of the lower robot towards a first of the two rhizomes pods using an articulated arm of the lower robot. The method of handling tubulars may include the step of positioning a lower end of a first tubular at a first predetermined location on a first stand box using an articulated arm of a lower robot. The positioning of the lower end of the first tubular at the first predetermined position may be performed while maintaining the orientation of the articulated arm of the lower robot within about less than one-eighth of a turn from the neutral direction of the lower robot. The method of handling tubulars may include the step of holding a first tubular lowered by the hoist system on a first of the two stands using an end effector of the upper robot. The gripping to lower the first tubular on the first stand box may be performed while maintaining the articulated arm of the upper robot substantially in the neutral direction of the upper robot. The method of handling tubulars may comprise the step of using an articulated arm of the upper robot to orient a wrist of the upper robot towards a first of two fingerboards, which may be located above a first of two stile boxes. The method of treating tubulars may include the step of positioning the upper end of the first tubular at a first predetermined location in the first fingerboard using an articulated arm of the upper robot. The positioning of the upper end of the first tubular at the first predetermined position may be performed while maintaining the orientation of the articulated arm of the upper robot within less than about one-eighth of a neutral orientation of the upper robot.
A method of treating a tubular may comprise the steps of: the end effector of the lower robot is rotated about half a turn using the rolling joint of the lower robot, and the end effector of the upper robot is rotated about half a turn using the rolling joint of the upper robot.
A method of treating a tubular may include the step of holding a second tubular suspended from a hoist system above a well center using an end effector of a lower robot. Gripping of the second tubular suspended above the well center may be performed while keeping the articulated arm of the lower robot substantially in the neutral direction of the lower robot. The method of handling tubulars may comprise the step of orienting a wrist of the lower robot towards a second of the two stile boxes using a yaw joint arrangement of the lower robot. The method of handling tubulars may include the step of positioning a lower end of a second tubular at a second predetermined location on a second stand box using an articulated arm of the lower robot. Positioning of the lower end of the second tubular at the second predetermined position may be performed while maintaining the orientation of the articulated arm of the lower robot within less than about one-eighth of a turn from the neutral direction of the lower robot. The method of handling tubulars may include the step of holding a second tubular lowered by the lift system on a second of the two stands box using the end effector of the upper robot. The holding of the second tubular lowered onto the second stand box may be performed while maintaining the articulated arm of the upper robot substantially in the neutral direction of the upper robot. The method of handling tubulars may comprise the step of orienting the wrist of the upper robot towards the second of the two fingerboards, which may be located above the second of the two stile boxes, using the yaw joint arrangement of the upper robot. The method of handling tubulars may comprise the step of positioning the upper end of the second tubular at a second predetermined position in the second fingerboard using the articulated arm of the upper robot. Positioning of the upper end of the second tubular in the second predetermined position may be performed while maintaining the orientation of the articulated arm of the upper robot within about less than one eighth of a turn from the neutral orientation of the upper robot.
Drawings
For a more detailed description of embodiments of the present disclosure, reference will now be made to the accompanying drawings in which:
FIG. 1 is a perspective view of a lift system according to an embodiment of a tubular handling system and showing two track sections that can be replaced with one another in vertical rails of the lift system;
FIG. 2 is a perspective view of the lift system shown in FIG. 1, with the lift system shown in an operating configuration;
FIG. 3 is a perspective view of the lift system shown in FIG. 1, with the lift system shown in a resting configuration;
FIG. 4A is a schematic top view of a portion of a controller programmed to place the lift system shown in FIG. 1 in a run or park configuration, with the dashed lines showing the park configuration as viewed from the top;
FIG. 4B is a schematic elevation view of a portion of a controller programmed to place the lift system shown in FIG. 1 in a run or park configuration;
FIG. 5 is a perspective view of a hoist system according to an embodiment of the tubular handling system and showing a hook trolley connected to a vertical rail of the hoist system;
FIG. 6 is a perspective view of the hoist system shown in FIG. 5 and showing the hook trolley and the pipe handling trolley, both connected to the vertical rails of the hoist system;
FIG. 7 is a schematic view of a controller programmed to synchronize the interface of the drill pipe stands between the retaining devices provided on the drawbar trolley and the retaining devices provided on the pipe handling trolley;
FIG. 8 is a perspective view of the lower robot in accordance with an embodiment of the tubular handling system and showing the lower robot positioning a lower end of a tubular on a first setback;
FIG. 9 is a perspective view of an upper robot according to an embodiment of the tubular handling system and showing the upper robot positioning an upper end of a tubular on a first fingerboard located above a first setback;
FIG. 10 is a perspective view of an end effector portion of the lower robot shown in FIG. 8;
FIG. 11 is a schematic view of a controller programmed to adjust the tilt of the drill rod carriage when the carriage of drill rods is positioned by either the lower robot shown in FIG. 8 or the upper robot shown in FIG. 9;
figures 12A and 12B are top views of the end effector portion of the lower robot shown in figure 8 or the upper robot shown in figure 9 in open and closed positions, respectively;
FIG. 13 is a schematic diagram of a controller programmed to strip a pipe according to an embodiment of a tubular handling system;
14A-14I illustrate a series of positions of a tubular handling system during tubular stripping (tripping);
15A-15C are flow charts of methods performed by the hoist system and slips for tubular stripping (tripping);
FIGS. 16A-16B are flow charts of methods performed by an upper robot for tubular stripping (tripping);
17A-17B are flow charts of methods performed by a lower robot for pipe stripping (drilling);
18A-18B are flow diagrams of methods performed by a drilling worker for tubular ripping (tripping) according to embodiments of a tubular handling system; and
fig. 19A and 19B are perspective views of the lower robot shown in fig. 8 with its end effector rotated approximately half a turn to deposit tubulars on two setboxes located on opposite sides of the derrick.
Detailed Description
It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures or functions of the invention. Exemplary embodiments of components, arrangements and constructions are described below to simplify the present disclosure; however, these exemplary embodiments are provided as examples only and are not intended to limit the scope of the present invention. In addition, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and in the figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various figures. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment without departing from the scope of the present disclosure.
Unless specifically stated otherwise, all numbers in this disclosure may be approximate. Thus, various embodiments of the disclosure may deviate from the quantities, values, and ranges disclosed herein without departing from the intended scope. Further, forming a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.
Certain terms are used throughout the following description and claims to refer to particular components. As one of ordinary skill in the art will appreciate, various entities may refer to the same component by different names, and thus, the naming convention for the elements described herein is not intended to limit the scope of the present invention unless specifically defined otherwise herein. Moreover, the naming convention used herein is not intended to distinguish between components that differ in name but not function.
Systems for handling tubulars on a drilling rig are disclosed herein. In some embodiments, a drilling rig includes a drill floor, a derrick erected from the drill floor, two setback boxes located on the drill floor on opposite sides of the derrick, and two fingerboards connected to the derrick above each of the two setback boxes. In some embodiments, a system for handling tubulars includes a hoist system configured to park a top drive behind a derrick. In some embodiments, a system for handling tubulars includes a lifting system including an elevator and a lifting claw that are independently movable along a vertical guide such that a drill rod holder can be manipulated while the elevator is positioned to pick up a drill string. In some embodiments, a system for handling tubulars includes a lower robot, an upper robot, and an elevator or lifting claw that cooperate to automatically store and/or supply racks from two setback magazines.
Fig. 1, 2, 3, 4A and 4B illustrate an embodiment of a
Referring to fig. 1, a hoist
The
To replace one of the two
To selectively secure either of the two
Referring to fig. 4A and 4B, the
In some embodiments, the two
Although fig. 1, 2, 3, 4A and 4B depict the parking of the
Fig. 5, 6 and 7 show an embodiment of a
Referring to fig. 5, to clear the space in front of traveling
Referring to fig. 6, the
The
Referring to FIG. 7, the lift controller 202 is programmed to actuate the
During drill string tripping up (i.e., a tripping operation), the
The
During drill string down-hole operations (i.e., drill-down operations), the
Fig. 8 shows an embodiment of the
The lower and/or
Fig. 10 illustrates the
To avoid the lifting force exerted on the
To accommodate tilting of the carriage when it is positioned by either the lower or
In some embodiments, the
In some embodiments, the
Referring to fig. 11, the
Referring to fig. 12A-12B, the
Referring to fig. 13, in an embodiment where the tubular handling system is used to trip a drill pipe (i.e., a trip operation), in an embodiment where the tubular handling system is used to trip a string up, the tubular handling system includes a kick-off controller 206 programmed to automatically cause all or a subset of the following actions in sequence: (i) holding the upper end of the rack using the lifting claw 58 or the elevator 48, (ii) detecting the presence of the rack in the lifting claw 58 or the elevator 48, (iii) holding the lower end of the rack using the claw 74 of the lower robot 60, (iv) detecting the presence of the rack in the claw 74 of the lower robot 60, (v) lifting the rack using the lifting system 10, (vi) detecting the weight of the rack, (vii) positioning the lower end of the rack in a predetermined position on the setback 90 or 100 using the lower robot 60, (viii) lowering the rack on the setback 90 or 100 using the lifting system 10, (ix) detecting the absence of weight, (x) holding the upper end of the rack using the claw 74 of the upper robot 62, (xi) detecting the presence of the rack in the claw 74 of the upper robot 62, (xii) releasing the upper end of the rack from the lifting claw 58 or the elevator 48, and (xiii) positioning the upper end of the bracket in a predetermined position in the fingerboard 104 or 106 using the upper robot 62.
In embodiments where the rack handling system is used to drill a string down (i.e., a drill-down operation), the kick-off controller 206 may alternatively or additionally be programmed to automatically cause all or a subset of the following actions in sequence: (i) holding the upper end of the rack positioned at a predetermined position in the fingerboard 104 or 106 using the claw 74 of the upper robot 62, (ii) detecting the presence of the rack in the claw 74 of the upper robot 62, (iii) holding the lower end of the rack using the claw 74 of the lower robot 60, (iv) detecting the presence of the rack in the claw 74 of the lower robot 60, (v) positioning the upper end of the rack in the lifting claw 58 or the elevator 48 using the upper robot 62, (vii) holding the upper end of the rack using the lifting claw 58 or the elevator 48, (viii) detecting the presence of the rack in the lifting claw 58 or the elevator 48, (ix) releasing the upper end of the rack from the claw 74 of the upper robot 62, (x) lifting the rack using the lifting system 10, (xi) detecting the weight of the rack, (xii) positioning the lower end of the rack at a predetermined position above the well center 94, and (xiii) lowering the rack on the well center 94.
While the present disclosure relates to a
Referring to FIGS. 14A-14I, a tubular handling system is shown in various positions during a tripping operation according to one embodiment. In this embodiment, as shown, for example, in FIG. 5, the hoist
In the elevation view of the hoist
In the front view shown in fig. 14D, the
In the front view shown in fig. 14G, the
14A-14I illustrate the location of a tripping sequence, one skilled in the art will readily appreciate, given the benefit of this disclosure, that a tubular handling system may be used to perform a tripping operation, and that the location of the tripping sequence is similar to the chronologically reverse tripping sequence. Further, while figures 14A-14I show the tubular handling system with the auxiliary line, pipe handling trolley and lifting dogs omitted, these elements may be used to hold and/or lift the upper end of the
Referring back to fig. 13, the kick-off controller 206, the
The kick-off controller 206 may be programmed to set the state for one finite state machine based on another finite state machine changing state so that the operation of the hoist
The hoist controller 202 may be programmed as a finite state machine that implements the operation of the automated hoist
Turning to fig. 15B, the pickoff controller 206 may then transition the finite state machine that causes automatic control of the operation of the hoist
Turning to fig. 15C, pickoff controller 206 may then transition a finite state machine that automates the operation of hoist
The robot controller 205 may be programmed as a finite state machine that implements the operation of the automated
Turning to fig. 16B, the kick-off controller 206 may then transition the finite state machine that automates the operation of the
The robot controller 204 may be programmed as a finite state machine that implements the operations of the automated
Turning to fig. 17B, the kick-off controller 206 may then transition the finite state machine that automates the operation of the
The iron roughneck controller 207 may be programmed as a finite state machine that implements the operations of the
Turning to FIG. 18B, the output of state 240 is a twisted connection. State 240 receives input 242 from a feedback device for detecting the torque applied by the torque wrench. Upon detection of the torque set point, the finite state machine transitions to state 244. The output of state 244 opens the jaws of a static and/or torque wrench of
15A-18B show a flow chart of a drill-in operation, one skilled in the art will readily appreciate, given the benefit of this disclosure, that a tubular handling system may be used to perform a drill-out operation, and that the sequence of positions of the drill-out is similar to a chronologically inverted drill-in sequence.
Fig. 19A and 19B show how the configuration of the
Referring to fig. 19A, the
Although fig. 19A illustrates manipulation of the
Turning now to fig. 19B, the roll joint 114 of the
Similarly, the rolling joint 114 of the
Although the tubular handling system shown in fig. 8-19B includes a
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and the description. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the claims to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the claims.
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