Abstract:
A master control system with remote monitoring that can perform, monitor, and control operations of a portable rig with a pipe handler as the pipe handler installs tubulars into a drill string or breaks out tubulars from a drill string for a wellbore. The master control system can include a processing device communicatively coupled to a data storage. The processing device receives a communication associated with a component of a portable rig. The processing device determines a position of the component of the portable rig based on the received communication. The processing device further provides an executive dashboard that includes at least one drilling rig function associated with the component of the portable rig. The processing device also initiates the portable rig to perform the at least one drilling rig function associated with the component of the portable rig.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 13/679,960, filed on Nov. 16, 2012, which claims the benefit of U.S. Provisional Application No. 61/587,438, filed on Jan. 17, 2012, entitled “MASTER CONTROL SYSTEM WITH REMOTE MONITORING FOR HANDLING TUBULARS,” the content of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The present embodiments generally relate to a master control system with remote monitoring for handling tubulars. 
     BACKGROUND 
     A need exists for a master control system that allows one or more users to remotely monitor the installation, removal, or both of one or more tubulars. 
     A further need exists for a master control system that allows at least partial automation of rig operation to provide a safe work environment for rig personnel. 
     The present embodiments meet these needs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The detailed description will be better understood in conjunction with the accompanying drawings as follows: 
         FIG. 1  depicts a schematic of a master control system configured to perform an operation on a tubular according to one or more embodiments. 
         FIG. 2  depicts a schematic of a portion of the master control system of  FIG. 1  with a retracted top drive. 
         FIGS. 3A and 3B  depict a detailed schematic of data storage according to one or more embodiments. 
         FIG. 4  depicts a detailed schematic of data storage according to one or more embodiments. 
         FIG. 5  is a top view of an embodiment of the drilling rig, vertical pipe handler, and horizontal to vertical pipe handler that can be controlled by the master controller. 
     
    
    
     The present embodiments are detailed below with reference to the listed Figures. 
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Before explaining the present system in detail, it is to be understood that the system is not limited to the particular embodiments and that it can be practiced or carried out in various ways. 
     The present embodiments relate to a master control system with remote monitoring for handling one or more tubulars. 
     The master control system can include a server with a processor connected to a data storage, which can be on a network, connectable to a computing cloud, or both, for installing tubulars connectable into a drill string into a wellbore by a drilling rig. 
     The master control system can include a server with a processor connected to a data storage with a plurality of computer instructions for removing tubulars from a wellbore and breaking down a drill string. 
     The master control system can be used to allow remote monitoring during installation of one or more tubulars in a wellbore using a drilling rig. The remote monitoring can be 100 yards from the well bore or hundreds of miles from the well bore. 
     The invention provides increased safety and reduced accidents around the rig. 
     The invention allows a home office to act quickly when a rig may be experiencing difficulty in making up tubulars into a drill string or breaking down a drill string. 
     The master control system can include a server. The server can be a laptop, a PC, or another type of computing processor that communicates to data storage. The data storage and the processor that form the server can be in communication with a network and a data storage. 
     The server can be based in a computing cloud. The server can be in the home office of a driller, on a network. 
     The network can be a local area network, a wireless network, a satellite network, a similar network, or combinations thereof. 
     The server can be in communication with multiple client devices simultaneously, or with a single client device via the network. The client devices can be cell phones, laptops, PCs, desk top processors with data storage, tablets, and similar devices that can be wired or wirelessly connected to the network or the computing cloud and be configured to present an executive dashboard of rig functions, vertical pipe handler functions, and horizontal to vertical pipe handler functions, to a user of the client device. 
     The server can be in communication with a second client device via the network, a computing cloud, or both. 
     The second client device can be a device similar to the first client device, or different than the first client device. The second client device can be configured to present an executive dashboard of rig functions, vertical pipe handler functions, and horizontal to vertical pipe handler functions to a user of the client device. 
     The data storage can include computer instructions to manage synchronized functions of the rig&#39;s hoist system and a top drive, as well as the functions of a vertical pipe handler, and a horizontal to vertical pipe handler which are operationally connected together in series. 
     The computer instructions in the data storage can receive inputs from monitoring devices connected with components of the drilling rig, and can use the received inputs to determine a location of the top drive and vertical pipe handler, a position of the horizontal to vertical pipe handler, and a speed of the hoist system. 
     Sensors on the rig can also be used with computer instructions in the server to count the number of tubulars that are used on the drill string and to measure the length of each tubular being connected to or removed from a drill string. 
     For example, one or more sensors can be placed at one or more predetermined locations on a mast to detect if the top drive is proximate to the crown, to the tubular, or to the base of the mast. 
     One or more sensors on the rig can measure a rotational speed of the hoist system. 
     One or more sensors on the rig can determine the location of the top drive and computer instructions in the server can be used to continuously calculate the location of the top drive and the depth of the tubular in the well bore based on a sensed position and rotational speed of the hoist system. 
     In operation, the vertical pipe handler and the horizontal to vertical pipe handler can be actuated based on the sensed location of the top drive. 
     The data storage of the master control system can include computer instructions to determine when one or more tubulars are disposed on the horizontal to vertical pipe handler and to instruct the horizontal to vertical pipe handler to grab the one or more tubulars. 
     For example, the computer instructions in the data storage can receive inputs provided to the server by one or more sensors on the horizontal to vertical pipe handler, and when a signal from the sensors indicates that tubulars are disposed thereon, the computer instructions can instruct a processor of the server to actuate one or more cylinders on the horizontal to vertical pipe handler to grip the tubular. 
     The data storage can include computer instructions to raise the horizontal to vertical pipe handler to a vertical position from an initial horizontal position. 
     For example, these computer instructions can instruct the server to initiate movement of the horizontal to vertical pipe handler from a substantial horizontal position to a substantially vertical position once a sensor detects that a gripper has fully closed about the one or more tubulars on the horizontal to vertical pipe handler. 
     The data storage can include computer instructions to extend arms of the vertical pipe handler to grab a tubular from the horizontal to vertical pipe handler, and to rotate and lift the tubular for positioning at a well center. For example, these computer instructions can receive inputs on the location of the horizontal to vertical pipe handler, determine when the horizontal to vertical pipe handler is in an operative position, and instruct the processor to send one or more signals to the vertical pipe handler instructing the vertical pipe handler to extend top and bottom pivoting arms of the vertical pipe handler to grab the tubular from the horizontal to vertical pipe handler. 
     The data storage can include computer instructions to lower the top drive to an end of the tubular. For example, these computer instructions can compare the calculated or detected location of the top drive to a predetermined location, and instruct the processor to instruct a control of the hoist system to lower the top drive until the predetermined location is reached enabling the tubular to be connected to the top drive. 
     The data storage can include computer instructions to engage the top drive with the tubular making up the connection. For example, these computer instructions can instruct the top drive to secure to the tubular in a manner known to one skilled in the art. 
     The data storage can include computer instructions to rotate the tubular with the top drive and drive the tubular into the wellbore. For example, these computer instructions can instruct the processor to instruct the hoist system to lower the top drive when a signal is received indicating that the top drive has secured to the tubular. 
     The data storage can include computer instructions to retract the travelling block with the top drive, and to travel the top drive to a start position. The start position can be adjacent a crown when running tubulars into the wellbore. For example, these computer instructions can instruct the processor to instruct one or more arms connected to the traveling block to move the travelling block with the top drive into a channel formed in a mast when it is determined that the top drive and traveling block are aligned with a space. 
     The data storage can include computer instructions to extend arms of the vertical pipe handler to grab a subsequent tubular from the horizontal to vertical pipe handler, and rotate and lift the subsequent tubular for positioning at the well center. 
     The master control system can retract the traveling block into a recess in the mast and actuate the vertical pipe handler simultaneously. 
     The data storage can include computer instructions to lower the top drive to an end of the subsequent tubular. For example, these computer instructions can instruct the server to send a signal to the hoist system to lower the top drive upon receiving a signal indicating that the subsequent tubular member is in position to be engaged by the top drive. 
     The data storage can include computer instructions to engage the top drive with the subsequent tubular making up the connection. 
     The data storage can include computer instructions to rotate the subsequent tubular with the top drive and make up a connection with the tubular using a roughneck secured to a drilling floor. For example, these computer instructions can instruct the server to initiate rotation of the top drive when a signal is received indicating that the tubular member is engaged by hydraulic power tongs, and to move the subsequent tubular member towards the roughneck. 
     The data storage can include computer instructions to drive the tubulars into the well bore. 
     The data storage can include computer instructions to retract the travelling block with the top drive to the start position. 
     The data storage can include computer instructions to perform the foregoing operations on any number of tubulars. 
     The data storage can be configured to cause any number of tubulars to be ran downhole or removed from the wellbore. 
     The data storage can be configured to reset the horizontal to vertical pipe handler when the horizontal to vertical pipe handler is depleted of tubulars. 
     The data storage can include computer instructions to lower the horizontal to vertical pipe handler to a trailer frame. For example, these computer instructions can instruct the processor to lower the horizontal to vertical pipe handler to the trailer frame when an input is received that all tubulars have been removed from the horizontal to vertical pipe handler. 
     The master control system with remote monitoring can be configured to aid with the removal of tubulars from the well bore. 
     The data storage can be configured to include computer instructions to manage synchronized functions of the hoist system, the top drive, the vertical pipe handler, and the horizontal to vertical pipe handler. 
     The data storage can be configured to lower the top drive to an end of a tubular disposed in the wellbore. 
     The data storage can be configured to engage the top drive with the tubular making up a connection. 
     The data storage can be configured to retract the tubular from the wellbore using the top drive. 
     The data storage can be configured to determine when the hydraulic power tongs have engaged the tubular, and to operate the hydraulic power tongs to break out the tubular from subsequent tubulars located in the wellbore. 
     The data storage can be configured to engage the tubular with the vertical pipe handler. 
     The data storage can be configured to retract the vertical pipe handler to place the tubular in a setback 
     The data storage can also include computer instructions to track how many tubulars are placed in the wellbore. 
     In one or more embodiments, the horizontal to vertical pipe handler can have two arms. Each arm of the horizontal to vertical pipe handler can be configured to hold independently raise the tubulars held therein to a vertical position. 
     Turning now to the Figures,  FIG. 1  depicts a schematic of the master control system configured to perform an operation on a tubular according to one or more embodiments. 
     The master control system can include a server  602   a  which includes a processor and communicates to data storage  610   a  that is connected via a network  608 . 
     Similarly, the master control system can include a cloud based server  602   b  which can include a processor and can communicate to cloud based data storage  610   b  that is in a computing cloud  687  and can communicate with the network  608 . 
     The servers  602   a  and  602   b  can be configured to execute computer instruction in one or more data storages  610 , and to communicate with devices via the network  608 . The servers  602   a  and  602   b  can be a PENTIUM™ processor or similar device. 
     The one or more data storages  610   a  and  610   b  can be connected to, integrated with, or otherwise in communication with the servers  602   a  and  602   b.    
     In embodiments, a cloud based server, a non-cloud based server, or both can be used simultaneously. 
     Similarly, in embodiments, a cloud based data storage, a non-cloud base data storage, or both can be used simultaneously. 
     A first client device  660  and a second client device  670  can be in communication with the network  608 , the computing cloud  687  or both simultaneously. 
     The first client device  660  is configured for receiving and presenting an executive dashboard  663   a  which displays not only rig functions to a first user but also vertical pipe handler operational information and horizontal to vertical pipe handler operational information to the first user  667 . 
     The second client device  670  is configured for receiving and presenting the executive dashboard  663   b  which is identical to the executive dashboard  663   a  of the first client device. Like the executive dashboard  663   a , executive dashboard  663   b  displays not only rig functions to a second user but also vertical pipe handler operational information and horizontal to vertical pipe handler operational information to the second user  669 . 
     The master control system can communicate with a drilling rig  680 . 
     The drilling rig  680  can be sequentially connected and operationally connected to a vertical pipe handler  681 , and a horizontal to vertical pipe handler  688 . 
     The master controller operates a hoist system  682  of the rig, which is shown sitting on a subbase trailer, as this is a portable rig. 
     The hoist system includes a drawworks and a drill line  218  that connects to a top drive  684 . The master control for this embodied portable rig can be used to control a winch  289  that runs a hoist line  287  for raising or lowering the mast  683  of the rig. 
     In this Figure, the master controller can also be used to operate hydraulic power tongs  689 . 
     The drill line  218  passes from the drawworks to the crown  22  and then to the top drive. 
     The hoist system  682  can have a rotational speed monitoring device  916  that communicates to the master controller. 
     The rotational speed monitoring device  916  can be any device capable of determining the rotational speed of the hoist system  682  and transmitting the rotations per minute to the server in the computing cloud or on the network outside of the computing cloud. 
     The vertical pipe handler  681  can have one or more vertical pipe handler monitoring devices  918  that can monitor the presence of each tubular  902  and the device and determine pressure applied to each tubular connected, to the vertical pipe handler. The vertical pipe handler monitoring device  918  then transmits the signal to the server. 
     The vertical pipe handler monitoring devices  918  can be configured to determine: (i) if the arms of the vertical pipe handler  681  are actuated, (ii) a position of the arms, or combinations thereof, and transmit the information to the server in the computing cloud or on the network outside of the computing cloud. 
     The top drive  684  can have one or more top drive monitoring devices  912 . 
     The top drive monitoring devices  912  can be accelerometers, radio frequency identification (RFID) tags, or any other device capable of measuring the acceleration of the top drive  684  and/or aiding in the determination thereof by sending a signal or interacting with another monitoring device to cause a signal to be sent. In embodiments, the top drive monitoring device is a device capable of measuring the location of the top drive. 
     For example, the top drive  684  can have a chip or device configured to interact with one or more mast monitoring devices  914  to cause a signal to be sent to the server  602   a  or  602   b  or both between a crown and a base to detect where a top drive is located. 
     The hydraulic power tongs  689  can be power tongs secured to a drill floor  690  of the drilling rig  680 . The hydraulic power tongs  689  can have one or more hydraulic power tong monitoring devices  928  configured to determine if the hydraulic power tongs  689  are in a closed position or opened position, determine forces applied to the hydraulic power tongs  689 , or combinations thereof. The hydraulic power tong monitoring devices can communicate with the servers in the computing cloud or connected via the network to enable continuous monitoring of the apparatus. 
     The horizontal to vertical pipe handler  688  can have one or more horizontal to vertical pipe handler monitoring devices  920  and  922  configured to detect the location of the horizontal to vertical pipe handler  688 , speed of the horizontal to vertical pipe handler  688 , force applied to the horizontal to vertical pipe handler  688 , the presence of a tubular  902 , how many tubulars are disposed on the horizontal to vertical pipe handler  688 , the like, or combinations thereof. The horizontal to vertical pipe handler monitoring devices  920  and  922  can communicate to the servers in the computing cloud or connected via the network. 
     The crown  22  can have a top crown  685  can have one or more top crown monitoring devices  930  to determine the speed of line passing therethrough and communicate to the servers in the computing cloud or connected via the network. 
     Each of the monitoring devices, including the horizontal to vertical pipe handler monitoring devices  920  and  922 , top crown monitoring devices  930 , rotational speed monitoring device  916 , hydraulic power tong monitoring devices  928 , mast monitoring devices  914 , top drive monitoring devices  912 , and vertical pipe handler monitoring devices  918 , can communicate with a server  602  through any form of telemetry, such as through the network  608  or the computing cloud  687  using individual protocols of each sensor. Illustrative telemetry can include wired, wireless, acoustic, frequency, or combinations thereof. 
     The drilling rig  680  can be operatively aligned with a wellbore  698 . 
     Also shown is a rig mounted sensor  929  that can be: used with computer instructions in the data storage  610  for counting each tubular and/or measuring the length of each tubular that enters the wellbore  698 . 
       FIG. 2  depicts the vertical pipe handler  681  with a tubular  902  adjacent a drilling rig  680 . 
     The vertical pipe handler is shown with the top pivoting arm  904  holding the tubular  902  below a top drive  684  over the well center, and the bottom pivoting arm  905  also grasping the tubular  902 . In this view the vertical pipe handler has raised the tubular from its position when grasped from the horizontal to vertical pipe handler  688  above the base of the rig. 
       FIG. 2  also shows a vertical pipe handler rotation and vertical motion monitor  932 . The vertical pipe handler rotation and vertical motion monitor  932  transmits to the master control system a signal indicating a degree at which the vertical pipe handler is positioned and a height at which either the top pivoting arm  904 , the bottom pivoting arm  905 , or both, are located from a base of the vertical pipe handler. 
     The top pivoting arm  904  can have a first arm monitor  934 , and the bottom pivoting arm  905  can have a second arm monitor  936 , which can communicate with the master control system to determine an angle of extension of each pivoting arm on a vertical pipe handler and transmit the angle of extension to the server. 
     Also shown in  FIG. 2  are sensors that transmit signals on the location of the tubular on the horizontal to vertical pipe handler  688 . 
     The sensors for the horizontal to vertical pipe handler  688  include a horizontal to vertical pipe handler tubular monitoring device  921  transmitting information that a tubular is on the horizontal to vertical pipe handler  688  to the server. 
     The sensors for the horizontal to vertical pipe handler  688  include a horizontal to vertical pipe handler tubular rolling monitoring device  923  transmitting information that a tubular is rolling or stopped rolling on the horizontal to vertical pipe handler to the server. 
     The sensors for the horizontal to vertical pipe handler include a horizontal to vertical pipe handler grip monitoring device  925  transmitting information that a tubular is gripped securely by the horizontal to vertical pipe handler. 
     The mast  683  is also shown in this Figure. 
       FIGS. 3A and 3B  depict a detailed schematic of data storage  610   a  according to one or more embodiments. 
     The data storage  610   a  can include computer instructions  620  to manage synchronized functions of the drilling rig a vertical pipe handler, and a horizontal to vertical pipe handler. 
     The data storage  610   a  can include computer instructions  621  to determine when a tubular is on a horizontal to vertical pipe handler. 
     The data storage  610   a  can include computer instructions  624  to raise the tubular from a horizontal position to a vertical position using the horizontal to vertical pipe handler. 
     The data storage  610   a  can include computer instructions  626  to extend top and bottom pivoting arms of the vertical pipe handler. 
     The data storage  610   a  can include computer instructions  627  to grab the raised tubular from the horizontal to vertical pipe handler using the top and bottom pivoting arms. 
     The data storage  610   a  can include computer instructions  629  to rotate the extended pivoting arms holding the tubular to position the tubular over the well center. 
     The data storage  610   a  can include computer instructions  629  to lift the tubular to a position proximate to the top drive for connection with the top drive. 
     The data storage  610   a  can include computer instructions  630  to lower the top drive down a mast of the drilling rig for connection to an end of the tubular. 
     The data storage  610   a  can include computer instructions  631  to connect the top drive to the tubular. 
     The data storage  610   a  can include computer instructions  632  to rotate the tubular using the top drive to insert the tubular into the wellbore while lowering the top drive towards the well bore. 
     The data storage  610   a  can include computer instructions  634  to disengage the tubular from the top drive once the tubular reaches a preset depth. 
     The data storage  610   a  can include computer instructions  646  to retract the top drive away from the wellbore. 
     The data storage  610   a  can include computer instructions  661  to form an executive dashboard of rig functions, vertical pipe handler functions and horizontal to vertical pipe handler functions. 
     The data storage  610   a  can include computer instructions  638  for simultaneously drilling with the drilling rig while connecting tubulars. 
     The data storage  610   a  can include computer instructions  1000  for measuring the length of each tubular that enters the well bore. 
     The data storage  610   a  can include computer instructions  1002  for counting each tubular with the rig mounted sensor as the top drive inserts the tubulars into the well bore. 
     The data storage  610   a  can include computer instructions  1004  to determine the speed of line passing there through and communicate to the servers via the web. 
     The data storage  610   a  can include computer instructions  1006  to measure acceleration of the top drive. 
     The data storage  610   a  can include computer instructions  1008  to measure location of the top drive. 
     The data storage  610   a  can include computer instructions  1010  for determining a location of the top drive between the crown and the subbase. 
     The data storage  610   a  can include computer instructions  1012  to determine a member of the group consisting of: if the hydraulic power tongs are in a closed position, if the hydraulic power tongs are in an open position, how much torque force is applied to the hydraulic power tongs, or combinations thereof. 
     The data storage  610   a  can include computer instructions  1014  to enable transfer of a tubular between a horizontal to vertical pipe handler and an adjacent vertical pipe handler using signals from a vertical pipe handler monitoring device that can monitor the presence of each tubular and pressure applied to a tubular connected to the vertical pipe handler. 
     The data storage  610   a  can include computer instructions  1016  for receiving signals from: a horizontal to vertical pipe handler monitoring device for transmitting positions of the horizontal to vertical pipe handler holding the tubular to the server; a horizontal to vertical pipe handler tubular monitoring device transmitting information that a tubular is on the horizontal to vertical pipe handler; a horizontal to vertical pipe handler tubular rolling monitoring device transmitting information that a tubular is rolling or stopped rolling on the horizontal to vertical pipe handler; and a horizontal to vertical pipe handler grip monitoring device transmitting information that a tubular is gripped securely by the horizontal to vertical pipe handler. 
     The data storage  610   a  can include computer instructions  1018  for receiving signals from: a vertical pipe handler rotation and vertical motion monitor for transmitting a degree at which the vertical pipe handler is positioned and a height at which either the top pivoting arm the bottom pivoting arm, or both; are located from a base of the vertical pipe handler; and a first arm monitor and a second arm monitor to determine an angle of extension of each pivoting arm on a vertical pipe handler and transmit the angle of extension to the server. 
       FIG. 4  is a detailed schematic of data storage  610   b  according to one or more embodiments. 
     The data storage  610   b  can include computer instructions  620  to manage synchronized functions of the drilling rig, a vertical pipe handler and a horizontal to vertical pipe handler. 
     The data storage  610   b  can include computer instructions  661  to form an executive dashboard of rig functions, vertical pipe handler functions and horizontal to vertical pipe handler functions. 
     The data storage  610   b  can include computer instructions  702  to lower the top drive to an end of a tubular disposed in the well bore. 
     The data storage  610   b  can include computer instructions  704  to engage the top drive with the tubular in the wellbore and rotating the tubular to make up a connection with the top drive. 
     The data storage  610   b  can include computer instructions  706  to withdraw the tubular from the wellbore. 
     The data storage  610   b  can include computer instructions  708  to grab the tubular with a top and a bottom pivoting arms of a vertical pipe handler. 
     The data storage  610   b  can include computer instructions  710  to retract the top and bottom pivoting arms of the vertical pipe handler holding the tubular and rotate the top and bottom arms while lowering the top and bottom arms. 
     The data storage  610   b  can include computer instructions  712  to grab the tubular from the vertical pipe handler with the horizontal to vertical pipe handler. 
     The data storage  610   b  can include computer instructions  714  to lower the horizontal to vertical pipe handler holding the tubular and placing place the tubular in a set back or a pipe tub. 
     The data storage  610   b  can include computer instructions  716  for simultaneously removing a drill string of connected tubulars from a well bore while breaking up tubulars from a drill string. 
     The data storage  610   b  can include computer instructions  2000  for measuring the length of each tubular that are removed from the wellbore, and computer instructions  2002  for counting each tubular with the rig mounted sensor as the tubulars are removed from the wellbore. 
       FIG. 5  is a top view of an embodiment of the rig and vertical pipe handler and horizontal to vertical pipe handler that can be controlled by the master controller. 
     In this view can be seen the bucking machine  590  with a tubular  505  and the pipe tub  592  connected to the vertical pipe handler  681  connected to a drilling rig  680 . 
     While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein.