PIPE HANDLING ARM, AND A DRILLING FLOOR SYSTEM AND A METHOD FOR PERFORMING FULLY AUTOMATIC WORK OPERATIONS ON A DRILLING FLOOR

A pipe handling arm is described comprising a permanently mounted pipe gripping tool with gripping devices for gripping and holding a tubular element. The pipe handling arm further comprises a first coupling half arranged on the pipe gripping tool for connection of a work tool capable of gripping, holding and moving a downhole device. There is also a drill floor system and a method for performing a plurality of fully automatic work operations on a drill floor, the drill floor system comprising at least one fully automatic pipe handling arm and at least one work tool for performing work operations on the drill floor. The at least one pipe handling arm and the at least one work tool are adapted for fully automatic connection of the at least one work tool to the at least one pipe handling arm and fully automatic disconnection of a connected work tool from the at least one pipe handling arm. The drill floor system further comprises a control system which at least is adapted for controlling the movements of the pipe handling arm, the automatic connection of a work tool to the at least one pipe handling arm and the automatic disconnection of a work tool from the at least one pipe handling arm such that a number of work operations on the drill floor, with the use of respective work tools, can be automated and performed without the assistance of personnel.

The present application relates to a drill floor system for performing a plurality of fully automatic work operations on a drill floor, and to a method for performing a plurality of work operations on a drill floor.

When drilling hydrocarbon wells and during offshore production of hydrocarbons, platforms are used which either have platform legs anchored to the seabed or are floating structures in deeper waters. During drilling, new lengths of the drill pipe are screwed on as the well is drilled deeper. At the bottom of the pipe string is arranged a bottom hole assembly (BHA) comprising different components. The bottom hole assembly components have to be assembled and the bottom hole assembly mounted on the pipe string on the drill floor before it is lowered, and more tubular elements are screwed onto the pipe string as it is run into the borehole and as the drilling advances. If some form of intervention has to be made in the well, different types of tools will be used depending on what well operation is to be carried out. These tools must be handled on the drill floor and are handled with varying degrees of involvement by personnel on the drill floor in order to control the different work operations that are being carried out. The presence of personnel on the drill floor when tools and pipe sections are moved is associated with a risk of accidents and serious injuries.

Today no system exists that is able to handle different types of devices on the drill floor without personnel being involved in the operations. It will therefore be desirable to have a system that reduces the need for personnel on the drill floor, partly in order to reduce the chances of accidents occurring when personnel handle the equipment on the drill floor. There is also a desire to boost the efficiency of and rationalise the work operations that are performed on the drill floor and thereby reduce expenditure of time and costs.

The object of the present invention has therefore been to develop a new system for handling different types of work tools and/or downhole tools on the drill floor.

In particular, it has been an object of the present invention to provide a tool for automatic handling of both tubular elements and the different components of a bottom hole assembly and other parts that are to be lowered into the borehole.

It has further been an object of the present invention to develop a system that reduces the risk of injuries to personnel on the drill floor.

It has also been an object of the present invention to save space on the drill floor and reduce installation costs and to rationalise the work flow, thereby saving time and reducing costs in connection with different types of work operations on the drill floor.

These objects are achieved by a pipe handling arm as defined in claim1, a drill floor system as defined in claim3, and a method for performing a plurality of work operations on a drill floor as defined in claim15. Additional embodiments of the pipe handling arm, drill floor system and method are disclosed in the dependent claims.

Accordingly, there is provided a pipe handling arm comprising a pipe gripping tool with gripping devices for gripping and holding a tubular element, wherein the pipe handling tool further comprises a first coupling half arranged on the pipe gripping tool for connection of a work tool. The work tool can, for example, be used to handle a downhole device such as small subs (i.e., short pipes that are to be screwed into the drill string, bit, bit breaker, or to handle work platforms and personnel baskets and parts of other machines on the drill floor. By using an already existing pipe handling arm/apparatus on the drill floor and providing it with a coupling half, preferably a rapid coupling, and using a work tool that has a complementarily shaped second coupling half such that the work tool can be connected to and disconnected from the pipe handling arm as required, it is possible to reduce the number of machines on the drill floor that handle pipes and other devices that have to be moved around on the deck. This saves space on the drill floor and gives lower installation costs.

The pipe handling arm is preferably adapted for fully automatic connection to and disconnection from the work tool.

A drill floor system is also provided for performing a plurality of fully automatic work operations on a drill floor. The drill floor system comprises at least one fully automatic pipe handling arm as described above and at least one work tool for performing a number of different work operations on the drill floor, where the at least one pipe handling arm and the at least one work tool are adapted for fully automatic connection of the at least one work tool to the at least one pipe handling arm and fully automatic disconnection of a connected work tool from the at least one pipe handling arm. The drill floor system further comprises a control system which at least is adapted to control the movements of the pipe handling arm, the automatic connection of the at least one work tool to the at least one pipe handling arm, and the automatic disconnection of the at least one work tool from the at least one pipe handling arm such that a number of work operations on the drill floor can be automated and performed without the assistance of personnel.

A work operation here will typically be taking a downhole device, for example, a bottom hole assembly component, and mounting it on another downhole device, which also may be a component of the bottom hole assembly, or mounting a tubular element on a downhole device, for example, a bottom hole assembly component, or vice versa. A work operation can also involve moving a device, for example, a valve device that is to be used in a downhole operation, from a position in which the device is stored into a position in which the device can be lowered into the well. A work operation can, of course, also consist of dismantling a pipe string and/or downhole devices that are pulled out of the well and placing tubular elements and/or downhole devices in their respective positions on the drill floor.

Different devices that are used down in the well might need different work tools to be moved from a position on the drill floor in which they are stored into a position in which they are ready to be sent down into the well. It may therefore be necessary to have several work tools that can be mounted and removed as required.

That the work operation is fully automatic means that the control system monitors and controls the pipe handling arm and the work tool, if any, connected to the pipe handling arm. The pipe handling arm preferably comprises gripping devices such that when no work tool is mounted on the pipe handling arm, it can preferably be used to handle tubular elements. The control system preferably has control of where the different work tools and/or downhole devices are located, and monitors and controls the operations required to connect a work tool to the pipe handling arm, the operations required to disconnect a work tool from the pipe handling arm, and it monitors and controls the pipe handling arm and the mounted work tool when the pipe handling arm performs a work operation with the work tool on the drill floor, such as gripping and assembling the components of a bottom hole assembly as mentioned above, or moving a downhole device into a position in which it can be run into the well, and moving a downhole device that has been taken up from the well into its storage position on the drill floor. That the work operations required to perform a particular action, such as handling a bottom hole assembly on the drill floor, are fully automatic thus means that no persons are involved in connecting the right work tool, in the movements of the pipe handling arm and the work tool for performing the work operations, such as gripping the right component of the bottom hole assembly and mounting it together with a tubular element or another component of the bottom hole assembly. The only thing the personnel need do is therefore to sit in a control room and start the process. As soon as the control system has received a message as to what is to be done, i.e., what process should be performed, it takes over and controls the pipe handling arm, the connection and disconnection of work tools and the performance of the necessary work operations in order to execute the desired process, as, for example, assembling a bottom hole assembly. Thus, the need to have personnel moving around on the drill floor is obviated, which will reduce significantly the number of personal injuries.

The drill floor system may comprise one or a plurality of work tools for performing a number of different work operations on the drill floor, wherein the at least one pipe handling arm and the work tool or tools are adapted for fully automatic connection to the at least one pipe handling arm and fully automatic disconnection from the at least one pipe handling arm.

The at least one work tool preferably comprises at least one holding device for gripping and holding a downhole device on the drill floor. It may, for example, be a holding device for a tubular element or a downhole tool such as a component of a bottom hole assembly, a valve device, a pipe plug etc.

In order for the control system to have control of where the different work tools are located, the drill floor system may comprise a separate storage space for each work tool and/or each downhole device, where the work tools and/or downhole devices are placed when they are disconnected from the at least one pipe handling arm and are not in use. The position for each work tool and each downhole device is entered in the control system such that the pipe handling arm can move into the right place for connection of the right work tool or downhole device, or disconnection and placing in the correct storage space for downhole devices and work tools after use.

To save space on the drill floor, the drill floor system comprises at least one tool store comprising at least one storage space for a tool that is adapted for connection to the at least one pipe handling arm, and/or a downhole device that is adapted for connection to the work tool. In the cases where the drill floor system comprises many different work tools and/or downhole devices, it is conceivable that the drill floor system may comprise two or more tool stores.

The at least one tool store preferably comprises a plurality of storage spaces for a number of work tools and/or downhole devices. All the work tools and downhole devices preferably have their own storage space in the tool store, unless they are of a shape and/or size which makes it impossible for them to fit into such a tool store. The work tools and/or downhole devices that perhaps for different reasons do not fit into the tool store will preferably have a specific storage space on the drill floor where they are stored when not in use. The tool store preferably comprises a system of shelves, each shelf having one or more compartments depending on the size and shape of the work tools and/or downhole devices and available space on the drill floor.

To ensure that connection of a work tool to the at least one pipe handling arm, or connection of a downhole device to a work tool, takes place without any problems, the storage spaces may comprise a holding device to hold the at least one work tool and/or downhole device or devices in a fixed position in their respective storage spaces. The control system will then know exactly where the different work tools and/or downhole devices are and how they are oriented in the space. This prevents the work tools and/or downhole devices from changing their position as a result of being inadvertently knocked into or jolted when in storage on the drill floor, which would have made it more complicated to ensure performance of a fully automatic connection of a work tool to the at least one pipe handling arm and connection of a downhole device to a work tool on a pipe handling arm. Holding devices can, for example, comprise a depression in the surface of the storage space and a complementarily shaped base on the work tool or downhole device, or a form of gripping device that physically holds the work tools and/or downhole devices in place in their respective storage spaces.

For connection of a work tool to the at least one pipe handling arm, the at least one pipe handling arm is preferably provided with a first coupling half and each work tool is provided with a second coupling half, wherein the first coupling half and the second coupling half are matingly configured for fully automatic connection of the work tools to the at least one pipe handling arm and fully automatic disconnection of a connected work tool from the at least one pipe handling arm. A fully automatic connection and disconnection of the work tools means, as in the above, that the connection and disconnection of the work tools is monitored and controlled by the control system, and that the connection and disconnection takes place without personnel being involved in the process. The mating first and second coupling halves are preferably standard coupling elements that can be controlled by a control system.

The at least one pipe handling arm preferably comprises a permanently mounted tool, for example, one or more gripping tools for tubular elements, in addition to the first coupling half. The at least one pipe handling arm thus normally handles tubular elements that are taken from their storage space and screwed onto the drill pipe as the drilling of the well advances, and, where relevant, tubular elements that are unscrewed and placed in the storage space if the drill pipe has to be taken up from the well. In this embodiment, a first coupling half for fully automatic connection of a work tool and fully automatic disconnection of a connected work tool from the at least one pipe handling arm is preferably provided on the permanently mounted work tool. When there is a need to use a work tool other than the permanently mounted tool, the at least one pipe handling arm can be connected to the desired work tool which is preferably stored in the tool store.

The pipe handling arm and/or the at least one work tool is preferably provided with necessary sensors of various types, such as GPS devices and other position-determining devices, speed sensors etc., the various sensors being signally connected to the control system, such that the control system is able to control the connection and disconnection of the work tool to/from the at least one pipe handling arm, the movement of the pipe handling arm and connected work tool, and the handling of downhole devices and tubular elements on the drill floor through use of the at least one pipe handling arm and the connected work tool. For example, the first coupling half on the at least one pipe handling arm may comprise a position-determining device for determining the position of the first coupling half on the drill floor, which position-determining device is signally connected to the control system, whilst the second coupling half on the work tools may comprise a position-determining device for determining the position of the second coupling half on the drill floor, which position-determining device is signally connected to the control system. The position-determining devices preferably comprise one or more sensors that are signally connected to the control system and which, in a known way, will be able to determine the precise position of the first coupling half and/or the second coupling half.

As mentioned above, the control system is preferably adapted to at least register and remember the respective disconnected positions of the work tools, to monitor and control the movements of the at least one pipe handling arm, and to monitor and control fully automatic connection of a work tool to the at least one pipe handling arm and fully automatic disconnection of a work tool from the at least one pipe handling arm, such that a plurality of work operations on the drill floor, using respective work tools, can be automated and performed without the assistance of personnel.

In the cases where the reach of the at least one pipe handling arm is not sufficient to reach the work tools in their respective storage spaces, the downhole devices to be handled on the drill floor and the storage positions for the downhole tools and the position they are to be moved into, typically above the borehole, the at least one pipe handling arm can be movably arranged on the drill floor for vertical and/or horizontal movement of the at least one pipe handling arm relative to the drill floor. The at least one pipe handling arm can, for example, be arranged on a support element that can be moved up and down along one or more columns for vertical movement of the pipe handling arm. For horizontal movement of the at least one pipe handling arm, it can be arranged on a support element that runs on guides, such as rails, on the drill floor.

In the cases where it is not sufficient to have one pipe handling arm, the drill floor system may comprise a plurality of pipe handling arms that are adapted for fully automatic connection of a work tool to each of the pipe handling arms and fully automatic disconnection of a work tool from each of the pipe handling arms. This means that several different work operations can be performed in quick succession where one work tool is not capable of performing all the work operations. For example, a first pipe handling arm with a work tool can bring a device into a position above the drill pipe where a second pipe handling arm with a second work tool is ready to connect this device to equipment for lowering the device into the well. In some cases, this may be so time-saving that it is worthwhile using two or more pipe handling arms instead of using one pipe handling arm that has to change work tool between the different work operations.

A method is also provided for performing a plurality of work operations on a drill floor, for example, on a floating structure, where the work operations are performed using a pipe handling arm and a drill floor system, as described above, comprising at least one work tool, wherein the method comprises:fully automatic connection of the at least one work tool to the at least one pipe handling arm;performance of at least one fully automatic work operation using the at least one work tool;fully automatic disconnection of the at least one work tool from the at least one pipe handling arm.

If the system comprises several work tools, they are preferably placed, as described above, in separate storage spaces when they are disconnected from the at least one pipe handling arm. As mentioned above, each work tool and/or each downhole device is preferably placed in a tool store comprising a plurality of storage spaces for respective downhole tools and/or work tools that are disconnected from the at least one pipe handling arm.

The at least one fully automatic work operation may comprise connecting at least one downhole device to a pipe string or to another downhole device. The at least one downhole device may comprise at least one component of a bottom hole assembly, and the at least one fully automatic work operation may comprise connecting the at least one component of the bottom hole assembly to a pipe string or to another bottom hole assembly component. The at least one work tool is preferably disconnected from the at least one pipe handling arm before the at least one pipe handling arm is to handle a tubular element.

It should first be mentioned that in all the figures the same reference numerals have been used to designate the same technical features.

FIG. 1is a schematic illustration of an embodiment of the present drill floor system10with an opening13for passage of the drill string50and various downhole devices21, as for instance bottom hole assembly (BHA) components, or valve devices that are run into the well to perform different types of operations downhole. The downhole devices21are illustrated shown purely schematically inFIGS. 1 and 2and will normally have another form in reality.

On the drill floor12there is provided at least one pipe handling arm38. The pipe handling arm38comprises a first arm39and a second arm40that are connected to one another by a first articulated joint41, such that the first arm39and the second arm40are able to rotate relative to each other. At the opposite end, the first arm39is connected to a support element26by means of an articulated element27such that the first arm is rotatable relative to the support element26, preferably both up and down in a vertical direction and back and forth in a lateral direction.

The support element is preferably arranged movably up and down along a guide element25, which, for instance, may be a tubular element. To further increase the reach of the pipe handling arm, the support element26may also be arranged rotatably about the guide element25. It will also be possible to configure the support element26as a frame that slides up and down on two or more parallel guide elements25.

The pipe handling arm38is shown in the figures with a first arm39and a second arm40, but it may also be equipped with only one arm or with three or more arms if so desired, where the arms are rotatably connected to one another.

At the opposite end of the second arm40in relation to the first articulated joint41, the embodiment of the pipe handling arm38shown inFIG. 1, has mounted thereto a permanently mounted work tool45. The permanently mounted work tool45preferably comprises a pipe gripping tool with gripping elements46that are capable of gripping a tubular element placed in a pipe racking device20arranged on or in connection with the drill floor, and moving it into a position above the drill string50so as to allow the tubular element to be screwed onto the top of the drill string50by suitable pipe handling tools16,17(seeFIG. 4). Similarly, the pipe handling arm38can, of course, also grip a tubular element at the top of the drill string50and put it back in the pipe racking device20. The permanently mounted work tool can be rotatably connected to the second arm40by a second articulated joint42as indicated inFIGS. 1 and 2.

The pipe handling arm38shown inFIG. 1comprises, in addition to the permanently mounted work tool45, a first coupling half44for connecting a work tool33. The first coupling half44is, in the embodiment of the pipe handling arm shown inFIG. 1, preferably provided on the permanently mounted work tool45, but can of course be arranged immediately on the pipe handling arm38itself, if so desired.

The drill floor system can, if necessary, comprise a plurality of work tools33, all of which are provided with a second coupling half34that is complementarily shaped to the first coupling half44on the pipe handling arm38, such that the work tools23can selectively be connected to the pipe handling arm38. When a work tool33is connected to the pipe handling arm38, the pipe handling arm can be used, for example, to grip a bottom hole assembly component and connect it to another component of the bottom hole assembly that is located above the borehole. As mentioned above, the downhole devices21, in addition to being borehole assembly components, may be different types of devices that are used in connection with different types of operations in a hydrocarbon well, such as a valve device, a plug etc.

It should also be mentioned that, as indicated above and as shown inFIG. 2, the pipe handling arm38must not necessarily have a permanently mounted work tool45as shown inFIG. 1.

The work tool or tools33and downhole devices are preferably arranged in a tool store22provided on the drill floor12as shown inFIGS. 1 and 2. The tool store22is preferably provided with a plurality of storage spaces23for work tools33and/or downhole devices21. To save space on the drill floor, the tool store22can advantageously be configured with shelf-like storage spaces23arranged vertically one above the other. It should be stressed that work tools33and/or downhole devices21as shown inFIGS. 1-2, are in a purely schematic form and the work tools and downhole devices will of course have other configurations in reality.

The drill floor system10also comprises a control system as indicated inFIGS. 1 and 2. This control system comprises necessary sensors that are arranged on the pipe handling arm38and/or the work tools33and/or the downhole devices21so as to allow the performance of at least the connection of a work tool33that is in its storage space23in the tool store22to the pipe handling arm38; the placing of a connected work tool in its storage space33in the tool store22and subsequent disconnection of the work tool33from the pipe handling arm33; and the control of the pipe handling arm38and connected work tool33such that the pipe handling arm38is able to manipulate the downhole devices21between desired positions and in a desired sequence. Such sensors are prior art and are commercially available, and will not be described in more detail here. The sensors are signally connected to a control unit19by signal cables (not shown in the figures) or preferably by wireless technology such as Bluetooth. The control unit19comprises at least one computer that monitors and controls the drill floor system10such that all operations performed by the pipe handling arm38, and connection and disconnection of work tools33as required, are carried out fully automatically by the drill floor system without the assistance of personnel on the drill floor12. All the work operations that are to be performed by the pipe handling arm can thus be started by personnel who are in a control room, preferably with a full view of the drill floor, so that control of the drill floor system can be taken over manually should there occur an emergency situation or other situations that require personnel to intervene and stop or control the pipe handling arm. When the control system has received a message to perform one or more actions, all the necessary operations that the pipe handling arm has to perform are entered in the control system so that they are performed in the correct order and without physical assistance of personnel on the drill floor12. As performance of operations on the drill floor is associated with a relatively high risk of injury to personnel on the drill floor, the fully automatic performance of work operations on the drill floor, which previously have been performed with the assistance of personnel, results in a reduced risk of injury to personnel, which will be almost zero. In addition, there is expected to be an increase in efficiency and associated cost savings when using the fully automatic drill floor system12.

FIG. 2shows a drill floor system10that has all the elements shown inFIG. 1. These will not be described again.

In addition, the embodiment of the drill floor system inFIG. 2has a second pipe handling arm38that preferably, but not necessarily, is almost identical in form to the first pipe handling arm. The second pipe handling arm38is however normally not provided with a permanently mounted work tool45. The second pipe handling arm38comprises a first coupling half44for connection of a work tool33. The first coupling half44can be mounted on a support element43that is rotatably connected to the second arm40on the pipe handling arm by a second articulated joint42, such that a work tool33connected to the pipe handling arm can be pivoted about the second arm40.

The first arm39of the second pipe handling arm38is at one end rotatably connected to the second arm40by a first articulated joint41. At the other end, the first arm39is rotatably connected to a support element30by an articulated element31, preferably such that the first arm39can be pivoted in all directions with a desired angle about the articulated element31. The support element30is preferably, but not necessarily, movably arranged along guide elements29that are arranged on the drill floor12. The reach of the second pipe handling arm38is thus significantly increased.

FIG. 3shows a more detailed embodiment of a pipe handling arm38that comprises a permanently mounted work tool45as explained in more detail in the description ofFIG. 1above. The structure of the pipe handling arm is essentially as described in connection with the pipe handling arm inFIG. 1, and it comprises a first arm39rotatably connected to a second arm40by a first articulated joint41. At the other end, the first arm39is rotatably connected to a mounting support48that is adapted for permanent mounting on the drill floor or for mounting to one or more guide elements25such that the mounting arm38can be moved vertically. The permanently mounted work tool45is rotatably connected to the second arm40by a second articulated joint42. As shown inFIG. 3, the permanently mounted work tool45is preferably, but not necessarily, a pipe gripping device comprising pipe gripping elements46for gripping and holding tubular elements that are to be moved between a pipe racking device20, as indicated inFIGS. 1 and 2, and a position in which it can be screwed onto the top of the drill string50, or for moving a tubular element that has been unscrewed from the drill string50back to the pipe racking device20. Drive units47for driving the pipe handling arm are also indicated inFIG. 3.

FIG. 3further shows a work tool33that is connected to the pipe handling arm38. Preferably, the permanently mounted work tool45comprises the first coupling half44that is connected the second coupling half34on the work tool33as indicated inFIG. 3. The work tool comprises a gripping element36or a similar device for gripping, holding and moving a downhole device21between desired positions on the drill floor12. In the embodiment of the invention inFIG. 3, the gripping element36is arranged on a projecting support element such that the gripping element more easily reaches and grips the downhole device21that preferably is placed in its storage position in the tool store22.

FIG. 4indicates how a pipe handling arm as shown inFIG. 3can be arranged on one or more guide elements25using support elements26as described above, such that the pipe handling arm38can be moved upwards and downwards along the guide element or elements25in a vertical direction. There is further shown a tower15with two pipe handling tools16,17that are used to screw tubular elements to and unscrew them from the drill string50(not shown inFIG. 4). The pipe handling tools16,17can also be configured in such a way that they are also able to handle downhole devices21that are to be used for purposes and operations of different types in the well. The pipe handling arm38will then be adapted such that it fully automatically connects to a desired work tool33that is located in its storage space23and then grips and moves the desired downhole device21, as for example, a bottom hole assembly component, to the pipe handling tools16,17which take over the handling of the downhole devices.

Lastly, it should be noted that to increase and reduce the reach of the pipe handling arm it is conceivable that the first arm39or the second arm40, or possibly both the first and the second arm, may have a telescopic configuration.