Sequencing for pipe handling

A method sequence for handling tubulars into or out of a wellbore, the method comprising: moving a tubular string into or out of a wellbore via a top drive; moving tubular stands to and from a setback position and a stand handoff position via a transfer bridge racker and a setback guide arm; moving tubular stands to and from the stand handoff position and a well center position via a tubular delivery arm and a lower stabilizing arm; building stands and breaking down stands offline via a mousehole and operating a roughneck on joints between the tubular stands and the tubular string.

TECHNICAL FIELD

The present disclosure relates to drilling and pipe handling systems and processes for drilling and handling drill pipe and casing relative to drill rig operations. In particular, the invention relates to sequences for handling pipe and casing on a drill rig.

BACKGROUND ART

In the exploration of oil, gas and geothermal energy, drilling operations are used to create boreholes, or wells, in the earth. Modern drilling rigs not only have drilling capability, but they also have pipe handling capability to allow simultaneous drilling and pipe handling operations

Conventional drilling involves having a drill bit on the bottom of the well. A bottom-hole assembly is located immediately above the drill bit where directional sensors and communications equipment, batteries, mud motors, and stabilizing equipment are provided to help guide the drill bit to the desired subterranean target. A set of drill collars are located above the bottom-hole assembly to provide a noncollapsible source of weight to help the drill bit crush the formation. Heavy weight drill pipe is located above the drill collars for safety. The remainder of the drill string is mostly drill pipe, designed to be under tension. Each drill pipe is roughly 30 feet long, but lengths vary based on the style. It is common to store lengths of drill pipe in “doubles” (two connected lengths) or “triples” (three connected lengths) or even “quadruples” (four connected lengths). A “tubular stand” refers to connected sections of drill pipe, drill collars, or casing.

When the drill bit wears out, or when service, repairs or adjustments need to be made to the bottom-hole assembly, the drill string (drill pipe and other components) is removed from the wellbore and setback. When removing the entire drill string from the well, it is typically disconnected and setback in doubles or triples until the drill bit is retrieved and exchanged. This process of pulling everything out of the hole and running it all back in the hole is known as “tripping.”

Tripping is non-drilling time and, therefore, an expense. Efforts have long been made to devise ways to avoid it or at least speed it up. Running triples is faster than running doubles because it reduces the number of threaded connections to be disconnected and then reconnected. Triples are longer and therefore more difficult to handle due to their length and weight and the natural waveforms that occur when moving them around. Manually handling moving pipe in the derrick and at the drill floor level can be dangerous.

It is desirable to have drilling rig processes for handling pipe in a more efficient and timely manner without sacrificing safety.

Most attempts to automate pipe handling are found offshore. However, solutions for pipe delivery on offshore drilling rigs are seldom transferable to onshore land rigs, due to the many differences in economic viability, size, weight, and transportation considerations.

SUMMARY OF INVENTION

In accordance with the teachings of the present disclosure, disadvantages and problems associated with existing drill rig control systems are alleviated.

According to one aspect of the invention, there is provided a method for performing a wellbore operation via a drill rig, the method comprising: moving a tubular string relative to the wellbore via a top drive; moving a tubular stand between a setback position and a stand handoff position via a transfer bridge racker and a setback guide arm; moving a tubular stand between the stand handoff position and a well center position via a tubular delivery arm and a lower stabilizing arm; and operating a roughneck on a joint between the tubular stand and the tubular string.

Another aspect of the invention provides a method for performing operations via a drill rig, the method comprising: conducting a drilling operation at a well center; conducting a standbuilding operation simultaneously with the drilling operation, wherein the standbuilding operation comprises: moving a first tubular single between a feeding table position and a drill floor pickup position via a catwalk; moving the first tubular single between the drill floor pickup position and a mousehole stickup position via a tubular delivery arm and a lower stabilizing arm; holding the first tubular single in the mousehole stickup position via at least one stand constraint; moving a second tubular single between the feeding table position and the drill floor pickup position via the catwalk; moving the second tubular single between the drill floor pickup position and a mousehole make/brake position via the tubular delivery arm and the lower stabilizing arm; operating a roughneck on a joint between the first and second tubular singles; moving a tubular stand comprising the first and second tubular singles between a mousehole position and a stand handoff position; and moving the tubular stand between a stand handoff position and a setback position via a transfer bridge racker and a setback guide arm.

According to still another aspect of the invention, there is provided a method for performing operations via a drill rig, the method comprising: moving a tubular string relative to the wellbore via a top drive; moving a tubular single between a feeding table position and a drill floor pickup position via a catwalk; moving the tubular single between the drill floor pickup position and a well center position via a top drive and a lower stabilizing arm; and operating a roughneck on a joint between the tubular single and the tubular string in the wellbore.

A further aspect of the invention provides a method for performing operations via a drill rig, the method comprising: moving a casing string relative to the wellbore via a top drive; moving a casing single between a feeding table position and a drill floor pickup position via a catwalk; moving the tubular single between the drill floor pickup position and a well center position; operating a casing running tool between the casing single and the top drive; and operating the top drive on a joint between the casing single and the casing string in the wellbore.

According to a further aspect of the invention, there is provided a method for performing operations via a drill rig, the method comprising: drilling a wellbore by rotating a drill string via a top drive; setting slips at the drill rig floor so that the drill string is at a stickup height relative to the drill rig floor; breaking out the connection between the top drive and the drill string; moving a drill string stand from a setback position to a stand handoff position; moving a drill string stand from a stand handoff position to a well center position; making up a joint between the drill string stand and the drill string; making up a connection between the drill string stand and the top drive; opening the slips at the drill rig floor; and continuing drilling a wellbore by rotating the drill string via the top drive.

The objects and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements.

The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.

DESCRIPTION OF EMBODIMENTS

Preferred embodiments are best understood by reference toFIGS. 1-145Bbelow in view of the following general discussion. The present disclosure may be more easily understood in the context of a high level description of certain embodiments.

According to various aspects of the present invention sequences for pipe handling operations are provided, including: (i) tripping in drill pipe, (ii) tripping out drill pipe, (iii) tripping out drill string wet, (iv) tripping out casing stand wet, (v) tripping in casing stand with no casing running tool, (vi) tripping in drill collar stands; (vii) tripping out drill collar stands; (viii) picking up single drill pipes from catwalk to well center with top drive, (ix) laying down single drill pipes from well center to catwalk with top drive, (x) running single casing from catwalk with casing tong, (xi) laying down single casing from well center to catwalk with casing tong, (xii) running casing from catwalk with top drive and casing running tool, (xiii) running casing from catwalk with tubular delivery arm and casing running tool, (xiv) offline stand building of drill pipe, (xv) offline laying down of drill pipe stands, (xvi) offline stand building of casing, (xvii) offline laying down of casing stands, (xviii) drilling connection, and (xix) back reaming. Sequences may be performed in fully automatic mode or manual mode, wherein the sequence steps may be the same in either mode. Some sequences may be performed simultaneously, such as for example, pipe building sequences may be conducted at the same time as drilling or tripping sequences.

The various embodiments of the drilling rig system may include one or more of the following components:1) Retractable Top Drive2) Tubular Delivery Arm3) Fingerboard/Setback Platform4) Transfer Bridge Racker5) Setback Guide Arm6) Lower Stabilizing Arm7) Upper Stand Constraint8) Intermediate Stand Constraint9) Lower Stand Constraint10) Roughneck on Tong Handling Trolley11) Roughneck on Tong Handling Arm12) Catwalk13) Rotary Table with Slips
The various components may be operated in concert to perform methods for stand building, tripping in, tripping out, etc. Rig operations may be managed by two operators: a driller and a pipe handler. The driller is primarily responsible for the drilling operations which moves drill string in and out of the wellbore. The pipe handler is primarily responsible for moving pipe to/from the well center and making and breaking joint connections. Drilling operations and pipe handling operations may take place simultaneously. A zone management system or anti-collision system may be employed to ensure the components do not run into each other.

Control interface devices, such as joysticks may enable operators to perform all rig operations and functions. For example, during a single operation sequence, any number of component machines may be operated simultaneously by a single operator via two joysticks. Human machine interfaces may provide touchscreen pictures for control.

FIG. 1is an isometric view of an embodiment of a drilling rig system.FIG. 1illustrates drilling rig1having the front portion (V-door portion) removed. In its place, a setback platform900is located near ground level, extending over the base box sections of a substructure2on the ground. In this position, setback platform900is directly beneath racking module300such that any pipe stands80(not shown) located in racking module300will be resting on setback platform900. In this configuration, racking module300is located lower on mast10of drilling rig1than on conventional land rigs, since the tubular stands80are not resting at drill floor level. Additionally, tubular stands80will need to be significantly elevated to reach the level of drill floor6.

As will be seen in the following discussion, this arrangement provides numerous advantages in complementary relationship with the several other unique components of high trip rate drilling rig1. To be most advantageous, it requires a spacious drill floor6to accommodate coupling equipment such as an iron roughneck, and a lower stabilizing arm to control the free movement of tubular stands hoisted by the retractable top drive and the secondary hoisting machine.

FIG. 2shows a top view of the racking module300. A mousehole center40is located on the forward edge of drill floor6and extends downward beneath. An intermediate stand constraint430is located adjacent to drill floor6and centered over mousehole center40. A stand hand-off position50is located on setback platform900, and extends vertically upwards, and is not impeded by any other structure beneath racking module300. A lower stand constraint440is located on setback platform900and centerable over stand hand-off position50. In this embodiment, stand hand-off position50is forward of, and in alignment with, well center30and mousehole center40.FIG. 2shows that racking module300has a fingerboard assembly310with columns of racking positions312.

FIG. 3is an isometric cut-away view of top drive200in drilling mast10as used in an embodiment of the high trip rate drilling rig1. Top drive200has a dolly202that is mounted on guides17in mast10. Guides17are proximate to the rear side14(draw works side) of mast10. Dolly202is vertically translatable on the length of guides17via fittings208. In the embodiment illustrated, top drive200has a split travelling block assembly230including a driller's side block232and an off-driller's side block234. This feature provides mast-center path clearance additional to that obtained by the ability to retract dolly202.

FIG. 4shows that first yoke210pivotally connects block halves232and234to dolly202, and provides their separation and alignment on a common axis of rotation. Second yoke212pivotally connects block halves232and234to dolly202, and stabilizes their separation and alignment. Torque tube260is connected to the intersection of second yoke212and block halves232and234to secure it to the travelling block assembly230. Actuator220extends between yoke210and dolly202to facilitate controlled movement of the top drive between a well center position and a retracted position. Connection264represents a point on block halves232and234of travelling block assembly230where torque tube260is connected.

FIG. 5is a side view of the embodiment of the retractable top drive200ofFIG. 4, showing it retracted from the position shown inFIG. 4.

FIG. 6is a perspective view of the fingerboard shown inFIG. 1.

FIG. 7is an isometric view of an embodiment of transfer bridge racker350, illustrating the travel range and rotation of gripper382connected to sleeve380and arm370, as suspended from bridge358. Transfer bridge racker350has the ability to position its gripper382over the tubular racking position312in the grid. In the embodiment illustrated, second upper racking mechanism351also has the capability of positioning its gripper382over the tubular racking position312on fingerboard assembly310.

FIG. 8is an isometric view of racking module300ofFIG. 6and the transfer bridge racker350ofFIG. 7, shown from the opposite side to illustrate clasp408of upper stand constraint420holding tubular stand80at stand hand-off position50. Mast10is removed from this view for clarity.

FIG. 9is an isometric view of a tubular delivery arm500. Retractable top drive assembly200provides a first tubular handling device that vertically translates in mast10. Tubular delivery arm500provides a second tubular handling device that is vertically translatable along the same mast10of drilling rig1, without physically interfering with retractable top drive assembly200. An incline actuator552is operative to control the angle of tubular clasp550relative to arm532.

FIG. 10illustrates how arms532rotated and tilted to position clasp550over well center30as seen inFIG. 10. Extension of the incline actuator552inclines tubular clasp550to permit tilting of heavy tubular stands, such as large collars, and to position tubular clasp550properly for receiving a tubular section81or tubular stand80from catwalk (also referred to herein as catwalk machine)600. Tubular delivery arm500can be raised and lowered along mast10with only an electronic crown winch.

FIG. 11is an isometric view of an embodiment of a lower stabilizing arm800, illustrating the rotation, pivot, and extension of an arm824. In this embodiment, arm824is pivotally and rotationally connected to a mast bracket802. An arm bracket806is rotationally connected to mast bracket802. Arm824is pivotally connected to arm bracket806. A pivot actuator864controls the pivotal movement of arm824relative to arm bracket806and thus mast bracket802. A rotary table810controls the rotation of arm824relative to arm bracket806and thus mast bracket802. Arm824is extendable as shown. The operation of the various rotational and pivot controls permits placement of tubular guide870over center of each of a wellbore30, a mousehole40, and a stand hand-off position50of drilling rig1.

FIG. 12illustrates lower stabilizing arm800secured to the lower end of tubular section81and preparing to stab it into the box connection of tubular section81located in mousehole40in a stand building procedure. InFIG. 12, tubular section81in mousehole40is secured to drill floor6by a tubular gripping409of intermediate stand constraint430. Lower stabilizing arm800provides a means for locating the pin end of a hoisted tubular stand80into alignment with the box end of another for stabbing, or for other positional requirements such as catwalk retrieval, racking, mousehole insertion, and stand building. Lower stabilizing arm800can accurately position a tubular stand80at wellbore center30, mousehole40, and stand hand-off position50of drilling rig1.

FIG. 13is an isometric view of an embodiment of an intermediate stand constraint430. Intermediate stand constraint430as shown can be connected at or immediately beneath drill floor6, as illustrated inFIG. 1. Intermediate stand constraint430has a frame403that may be configured as a single unit or as a pair, as illustrated. A carriage405is extendably connected to frame403. In the view illustrated, carriage405is extended from frame403. A carriage actuator407is connected between frame403and carriage405and is operable to extend and retract carriage405from frame403. A clasp408is pivotally connected to the end of carriage405. A tubular gripping assembly409is provided and is capable of supporting the vertical load of tubular stand80to prevent downward vertical movement of tubular stand80.

In operation, intermediate stand constraint430can facilitate stand building at mousehole40. For example, intermediate stand constraint430may be used to vertically secure a first tubular section81. A second tubular section81may then be positioned in series alignment by a hoisting mechanism such as the tubular delivery arm500. With the use of an iron roughneck760(seeFIG. 12) movably mounted at drill floor6, the series connection between the first and second tubular sections81can be made to create a double tubular stand80. Gripping assembly409can then be released to permit the double tubular stand80to be lowered into mousehole40. Gripping assembly409can then be actuated to hold double tubular stand80in centered position, as a third tubular section81is hoisted above and stabbed into double tubular section81. Once again, iron roughneck760on drill floor6can be used to connect the third tubular section81and form a triple tubular stand80.

FIG. 14is a top view of setback platform900on which the tubular stands80are stacked in accordance with their respective positions in the fingerboard assembly310. Drilling rig1, catwalk600and tubular stands80are removed for clarity. This embodiment illustrates the relationship between well center30, mousehole40, and stand hand-off position50. As seen in this view, an alleyway912is provided on the front edge of setback platform900. Stand hand-off position50is located in alleyway912, in alignment with mousehole40and well center30. A lower stand constraint440is positioned in the center of the setback platform900.

FIG. 15is an isometric view of the setback platform900, wherein two lower setback guide arms950are shown located in alleyway912. Alleyway912is offset below platform910. Stand hand-off position50is located on alleyway912. A geared rail914is affixed to alleyway912. Each lower setback guide arm950has a base952translatably connected to the rail914. The lower stand constraint440has a clasp408for engaging pipe stands81in the stand hand-off position50.

FIG. 16is an isometric view illustrating tubular stand80supported vertically by transfer bridge racker350and held at its lower end by setback guide arm950, and extended to its designated racking position.

(I) Sequence for Tripping in Drill Pipe

The initial equipment configuration for the tripping in drill pipe sequence is as follows:The top drive200is in a lower position on the well center axis30, and the elevator is closed around a stand of drill pipe80.The stand of drill pipe80is suspended in a spider in the rig floor6so that approximately 1.2 m/4 ft of drill string sticks up from the rig floor6.One stand of drill pipe80is being lifted by the tubular delivery arm500and the lower stabilizing arm800from the stand hand-off position50to a stickup level about the mouse hole40, the elevator is facing the top drive, and the drill floor is on stand by.The stand hand-off position is empty, and both the upper stand constraint and the lower stand constraint are open and retracted.The transfer bridge racker350and setback guide arms950are empty and on their way to pick up a new stand of drill pipe from the fingerboard.

The sequence for tripping in drill pipe comprises the following steps.

Step 1: Release the drill string and move the top drive. The top drive elevator is opened to release the drill string stickup, and the top drive is hoisted to an upper stop in the mast10. As shown inFIG. 17B, the top drive elevator is released from the drill string stickup. As shown inFIG. 17A, the top drive200is being hoisted toward the top of the mast10.

Step 2: Move a stand to the well center. The tubular deliver arm500and the lower stabilizing arm800move a pipe stand80from a stand by position at the drill floor6to the well center30, as shown inFIGS. 18A and 18B. The selected iron roughneck760moves to the well center to make-up the connection.

Step 3: Pick up a new stand. The transfer bridge racker350and a setback guide arm950pick up a tubular stand80from setback platform900, as shown inFIGS. 19A and 19B.

Step 4: Move the new stand to the stand hand-off position. The transfer bridge racker350and the setback guide arm950move the new stand and position it at the stand hand-off position50, as shown inFIGS. 20A and 20B. The upper stand constraint420and the lower stand constraint440close their clasps408to hold the new stand81at the stand hand-off position50. SeeFIGS. 20A and 20B. The doper integrated in the stand hand-off position50washes and dopes the pin end of the pipe stand81. SeeFIG. 20C. The transfer bridge racker350and the setback guide arm950return to the fingerboard310to pick of the next stand.

Step 5: Move the new stand to the well center and make-up connection to drill string. The top drive is retracted away from the well center30on its way up the mast10. A roughneck and stabbing guide engage with the drill string stick-up at the well center30to assist with the stabbing of the next stand. The tubular deliver arm500and the lower stabilizing arm800pick up the next stand from the stand hand-off position50and move it to the well center30. SeeFIGS. 21A and 21B. The tubular deliver arm500and the lower stabilizing arm800then lower the new stand and continue approximately 2 m/6 ft after stabbing the tubular, to allow room for the top drive elevator. The lower stabilizing arm800opens and retreats from the well center30. The iron roughneck760spins and torques to make-up the connection between the new stand and the drill string.

Step 6: Latch top drive elevator to drill string. With the top drive at the correct elevation, the top drive moves to the well center30and the elevator closes around the drill string. SeeFIGS. 22A and 22B. The tubular delivery arm500opens and retracts from the well center. Both the tubular delivery arm500and the lower stabilizing arm800move to pick up the next stand at the stand hand-off position50. The iron roughneck760opens and returns to a standby position relative to the rig floor6.

Step 7: Open slips and lower drill string. The top drive and drawworks hoist to pick up the drill string weight and the slips at the spider are opened. The drill string is then lowered into the wellbore via the top drive. SeeFIG. 23. Both the tubular delivery arm500and the lower stabilizing arm800engage the new stand at the stand hand-off position50. The upper and lower stand constraints420and440open and retract from the new stand. The new stand is lifted (approximately 9 m/30 ft) by the tubular delivery arm500and guided by the lower stabilizing arm to the drill floor6. The top box of the stand can be doped by the tubular delivery arm500, if desired. When the top drive has run the drill string into the borehole, the spider slips are set with the drill string at about 1.2 m stickup.

(II) Sequence for Tripping Out Drill Pipe

The initial equipment configuration for the tripping out drill pipe sequence is as follows:The top drive200is in a lower position on the well center axis30, and the elevator is closed around a stand of drill pipe80.The stand of drill pipe80is suspended in a spider in the rig floor6so that approximately 1.2 m/4 ft of drill string sticks up from the rig floor6.The tubular delivery arm500and the lower stabilizing arm800are open at the stand hand-off position50and have started moving toward the drill floor6.A stand of drill pipe is in the stand hand-off position50, and both the upper stand constraint420and the lower stand constraint440are clasping the stand.The transfer bridge racker350and setback guide arms950are empty and on their way from the fingerboard to get the stand of drill pipe in the stand hand-off position50.

The sequence for tripping out drill pipe comprises the following steps.

Step 1: Open slips and hoist drill string with top drive. The spider slips are opened and the drill string is hoisted via the top drive and drawworks to an upper stop in the mast10, as shown inFIG. 24A, so that approximately 1.2 m drill string stickup will remains after break-out. The spider slips are set and the weight of the drill string is set on the slips. The tubular delivery arm500starts moving from the stand hand-off position50to a position above the drill floor. A roughneck760moves to the well center30to engage the drill string.

Step 2: Move a stand from the stand hand-off position to the fingerboard. The transfer bridge racker350and setback guide arm950move to the stand in the stand hand-off position50and close their clamps and guides. The upper stand constraint420and the lower stand constraint440open their clasps408to release the stand81at the stand hand-off position50, and the clasps retract from the stand. The transfer bridge racker350and setback guide arm950lift the stand and move it to a selected position in the fingerboard310. SeeFIGS. 25A and 25B.

Step 3: The tubular delivery arm, lower stabilizing arm, and rough neck move to the well center. The roughneck760moves to the well center30and elevates to a proper elevation to engage the drill string for break-out of the connection. The tubular delivery arm500and the lower stabilizing arm800move to the well center30from the stand hand-off position50. The tubular delivery arm500extends and closes its clamp on the drill string below the top drive elevator, as shown inFIGS. 26A and 26B.

Step 4: The elevator opens and the roughneck breaks the connection. The top drive elevator opens to release the drill string, and the top drive200retracts from the well center position to a retracted position. The top drive begins to travel back down the mast. The roughneck760breaks-out the joint and spin out the threads between the stand and the drill string, so as to leave a stickup of drill string at the drill floor. SeeFIG. 27.

Step 5: Move the stand from the well center to the stand hand-off position while top drive lowers to stickup. The top drive is retracted away from the well center30on its way down the mast10. A roughneck opens and retracts from the drill string stick-up at the well center30to a standby position on the drill floor. The tubular deliver arm500and the lower stabilizing arm800pick up the broken-out stand at the well center30, lift it off the stickup, and move it to the stand hand-off position50. SeeFIGS. 28A and 28B.

Step 6: Latch top drive elevator to drill string and hand-off the broken-out stand. With the top drive at the correct elevation relative to the drill string stickup, the top drive moves to the well center30and the elevator closes around the drill string. The tubular delivery arm500and the lower stabilizing arm800position the stand on the stand hand-off position50. The upper and lower stand constraints420and430close to hold the stand. The doper integrated in the stand hand-off position washes and dopes the pin of the stand. SeeFIG. 29.

Step 7: The transfer bridge racker and the setback guide arm setback stand. The transfer bridge racker350and the setback guide arm950set back the stand in the fingerboard310. The fingerboard310latches close around the stand. The transfer bridge racker350and the setback guide arm950and return to the stand hand-off position50. SeeFIGS. 30A and 30B.

(III) Sequence for Tripping Out Drill String Wet

The initial equipment configuration for the tripping out wet is the same as described above for tripping out drill pipe.

The sequence for tripping out wet is very similar to the sequence for tripping out drill pipe described above. In fact, steps 1-4 and 6-7 are identical.

Step 5: Mud bucket901extends to well center and the broken-out stand is lifted off the drill string stick-up. A roughneck opens and retracts from the drill string stick-up at the well center30to a standby position on the drill floor. SeeFIG. 31A. The mud bucket901extends to the well center and closes on the broken-out connection. The tubular deliver arm500and the lower stabilizing arm800pick up the broken-out stand at the well center30and lift it off the stickup. SeeFIG. 31B. The fluid in the stand is captured by the mud bucket901. The mud bucket901opens and retracts from the well center to its standby position. The tubular deliver arm500and the lower stabilizing arm800move the broken-out stand to the stand hand-off position50.

(IV) Sequence for Tripping in Casing Stands Wet

A sequence for tripping out casing wet is the same as the sequence for tripping out drill stands wet.

(V) Sequence for Tripping in Casing Stands with No Casing Running Tool

The initial equipment configuration for the casing stand tripping in sequence is the same as described above for tripping in drill pipe.

The sequence for tripping in casing is very similar to the sequence for tripping in drill pipe described above. In fact, steps 1-4 and 6-7 are identical.

Step 5: The connection is made up by the casing tong on the tong handling arm. SeeFIGS. 32A and 32B.

(VI) Sequence for Tripping in Drill Collar Stands

The initial equipment configuration for the tripping in drill collar stands sequence is as follows:The top drive200is in a lower position on the well center axis30, and the elevator is closed around collar stick-up.The stand of drill pipe80is suspended in a spider in the rig floor6so that approximately 1.2 m/4 ft of drill string sticks up from the rig floor6.One drill collar stand is in the stand hand-off position50, held in position by the closed clasps of the upper and lower stand constraints420and440.The lower stabilizing arm800is empty and ready to pick up the drill collar stand from the stand hand-off position.The tubular delivery arm500is parked at a high elevation, out of the way, because it is not to be used in the sequence for drill collar stands.The transfer bridge racker350and setback guide arms950are empty and on their way to pick up a new drill collar stand from the fingerboard.

The sequence for tripping in drill collar comprises the following steps.

Step 1: Open top drive elevator and move top drive to upper stop. The top drive elevator is opened to release the drill collar stickup, and the top drive is hoisted to an upper stop in the mast10. Meanwhile, a drill collar stand is in the stand hand-off position50, held in position by the closed clasps of the upper and lower stand constraints420and440. SeeFIGS. 33A and 33B.

Step 2: Tilt the drill collar stand to the drill collar handover position. The upper stand constraint420is extending significantly and the lower stand constraint440is extended moderately to tilt the drill collar as shown inFIG. 34. The lower pin end of the drill collar stand remains in the alleyway912of the setback platform900(seeFIG. 35D), and the drill collar stand is tilted to a drill collar handover position where the box end leans toward the mast10. The lower stabilizing arm800extends toward the drill collar stand.

Step 3: Latch the top drive elevator on the tilted stand. The top drive is in the correct elevation and extended (well center) position so that the link arms of the elevator may swing toward the drill collar stand. The top drive elevator is closed on the stand. SeeFIG. 35A. The lower stabilizing arm800closes its guide funnel on the tilted drill collar stand. SeeFIG. 35B. The roughneck760on the tong handling trolley moves to the well center30and closes its stabbing guide. SeeFIG. 35B.

Step 4: Lift the stand from the setback level to the drill floor. The upper and lower stand constraints420and440are opened to release the tilted drill collar stand. The drill collar stand is lifted (approximately 9 m/30 ft) by the top drive200and draw works while being guided by the lower stabilizing arm800. The elevator link arms are allowed to float towards the well center. When the drill collar stand is suspended above the stickup, the lower stabilizing arm800guides the lower end of the stand to the well center30. SeeFIG. 36. The lower stabilizing arm800closes its centralizer when the drill collar stand is close to vertical above the stickup height.

Step 5: Stab drill collar stand and make-up connection. The top drive is at the well center30with the drill collar stand. A roughneck stabbing guide is closed to assist stabbing. The top drive200then lowers the new drill collar stand to stab the stand into the string. SeeFIG. 37A. The lower stabilizing arm800opens and retreats from the well center30. The iron roughneck760spins and torques to make-up the connection between the new drill collar stand and the drill collar string. SeeFIG. 37B. The roughneck retreats to a standby position.

Step 6: Open slips and lower drill string. The top drive and drawworks hoist to pick up the drill collar string weight and the slips at the spider are opened. The drill collar string is then lowered into the wellbore via the top drive. SeeFIG. 38.

Step 7: Pick up new drill collar stand from setback. The transfer bridge racker350and the setback guide arm950pick up a drill collar stand from a selected position in the setback900. SeeFIGS. 39A and 39B.

Step 8: Move stand to stand handoff position. The transfer bridge racker350and the setback guide arm950move the drill collar stand to the stand hand-off position50. The upper and lower stand constraints420and440close their clasps to hold the stand. SeeFIGS. 40A and 40B. The doper integrated in the stand hand-off position washes and dopes the pin. The transfer bridge racker350and the setback guide arm950move to pick up another drill collar stand from another selected position in the setback900and fingerboard310.

(VII) Sequence for Tripping Out Drill Collar Stands

The initial equipment configuration for the tripping out drill collar stands sequence is as follows:The top drive200is in a lower position on the well center axis30, and the elevator is closed around the drill collar stick-up.The stand of drill pipe80is suspended in a spider in the rig floor6so that approximately 1.2 m/4 ft of drill string sticks up from the rig floor6.One drill collar stand is in the stand hand-off position50, held in position by the closed clasps of the upper and lower stand constraints420and440.The tubular delivery arm500is parked at a high elevation, out of the way, because it is not to be used in the sequence for drill collar stands.The transfer bridge racker350and setback guide arms950are empty and on their way from the fingerboard310to pick up a broken-out drill collar stand in the stand hand-off position50.

The sequence for tripping out drill collar comprises the following steps.

Step 1: Open slips and hoist the drill collar string. With the top drive and the drawworks, take the weight of the drill collar string and open the slips at the spider in the drill floor. Stop hoisting when the sting is raise to an elevation for a stick-up height. SeeFIGS. 41A and 41B.

Step 2: Move stand from stand handoff position to setback/fingerboard. The transfer bridge racker350and the setback guide arm950engage the drill collar stand in the stand hand-off position50. The upper and lower stand constraints420and440release the stand. SeeFIGS. 42A and 42B. The transfer bridge racker350and the setback guide arm950lift and move the drill collar stand to the setback/fingerboard. The fingerboard latches are opened when the stand is being moved into the row and closed there behind.

Step 3: The lower stabilizing arm and the roughneck move to the drill collar string. The slips are set and the weight of the string is taken off the top drive elevator. SeeFIG. 43. The selected roughneck760moves to the string at well center and elevates to the stickup height. The lower stabilizing arm800moves from the stand hand-off position to a safe standby position proximate the stand. The lower stabilizing arm800moves to the well center and closes its guide on the stand.

Step 4: Roughneck break-out. The iron roughneck760spins and torques to break-out the connection between the new drill collar stand and the drill collar string. SeeFIG. 44. The roughneck retreats to a standby position.

Step 5: The stand is lifted and tilted. The top200drive lifts the broken-out drill collar stand and the guidance is provided by the lower stabilizing arm800. SeeFIGS. 45A and 45B.

Step 6: Tilt stand to stand hand-off position. When the stand clears the stick-up, the lower stabilizing arm800guides the lower end of the drill collar stand as the top drive lowers the stand to the stand hand-off position on the alleyway912of the setback platform900. The top drive link arms tilt toward the stand-off position. The upper and lower stand constraints420and440extend and clasp the drill collar stand. SeeFIGS. 46A-46C. The pin is washed and doped.

Step 7: Open the elevator. The top drive elevator is opened (seeFIG. 47) and the link arms allow the elevator to float back to a vertical position under the top drive. The guide funnel of the lower stabilizer arm800opens and the arm moves to a standby position. The top drive lowers toward the stick-up.

Step 8: Tilt the drill collar stand to vertical at the stand hand-off position. The upper stand constraint420retracts significantly and the lower stand constraint440retracts moderately to tilt the drill collar to vertical at the stand hand-off position. SeeFIG. 48.

Step 9: Move the drill collar stand to the setback platform/fingerboard. The transfer bridge racker350and the setback guide arm950move to engage the drill collar stand at the stand hand-off position. The upper and lower stand constraints420and440are opened to release the drill collar stand. The transfer bridge racker350and the setback guide arm950move the drill collar stand to a selected position in the setback. SeeFIGS. 49A and 49B. Fingerboard latches are closed on the stand. The transfer bridge racker350and the setback guide arm950release the stand and return to the stand hand-off position.

Step 10: The top drive elevator engages the stickup of the drill collar string. SeeFIG. 50.

(VIII) Sequence for Picking Up Singles from Catwalk with Top Drive

The initial equipment configuration for the sequence for picking up singles from the catwalk is as follows:The top drive200is in a lower position on the well center axis30, and the elevator is closed around the pipe stick-up.The drill pipe is suspended in a spider in the rig floor6so that approximately 1.2 m/4 ft of drill string sticks up from the rig floor6.The catwalk machine feeding table is loaded with tubulars (cleaned and doped).The catwalk machine ramp is empty and in a loading position.

The sequence for picking up singles from the catwalk comprises the following steps.

Step 1: Load tubular on the catwalk machine ramp. Use the feeding table to load one tubular on the ramp of the catwalk machine600. SeeFIG. 51.

Step 2: Run the catwalk to the drill floor. The ramp of the catwalk machine600. SeeFIGS. 52A-52C.

Step 3: Open the elevator and hoist to catwalk pick-up position. The top drive200elevator is opened (seeFIG. 53), and the link arms are tilted back so the elevator can clear the tubular joint. The top drive is hoisted to the catwalk pick-up position.

Step 4: Push the tubular. The pipe pusher of the catwalk machine600pushes the tubular up the ramp to the tubular latching position. The top drive link arms are tilted forward to swing the elevator toward the tubular, and the elevator latches onto the tubular. SeeFIGS. 54A and 54B.

Step 5: Pull up the tubular. The tubular is pulled up by hoisting the top drive200so that the box end of the tubular is lifted by the elevator. As the top drive is hoisted, the lower box end of the tubular slides up the ramp of the catwalk machine600. Before the lower box end of the tubular exits the end of the ramp of the catwalk machine600, the lower stabilizing arm800extends and closes its funnel to guide the tubular. As the tubular approaches vertical, the centralizers of the lower stabilizing arm800close on the tubular. SeeFIG. 55.

Step 6: Guide the tubular to well center. The roughneck760is moved to the stick-up as the top drive200continues to hoist the tubular. When the pin end is hoisted above the stick-up, the lower stabilizing arm800guides the tubular to the well center30. The catwalk ramp moves out and down to a position for loading the next tubular. SeeFIG. 57. In an alternative embodiment where a tong handling arm is used, the roughneck on the tong handling trolley may be used for the connection. SeeFIG. 56.

Step 7: Stab the tubular. The stabbing guide of the roughneck is closed above the stick-up. The top drive is lowered to stab the tubular into the stabbing guide. When the tubular is in the stabbing guide, the lower stabilizing arm800is opened and retracted. The top drive is further lowered to stab the tubular into the stickup.

Step 8: Make-up the connection. The roughneck760spins the tubular to thread the tubular's pin end into the stick-up's box end. The roughneck760then applies torque to make-up the joint. SeeFIG. 58.

Step 9: Lower the drillstring. The roughneck is moved to its standby position. Pick up the weight of the drill string with the top drive/drawworks. Open the slips in the spider. Lower the drill string into the wellbore to the stick-up height. Set the slips in the spider. SeeFIG. 59.

(IX) Sequence for Laying Down Singles to Catwalk with Top Drive

The initial equipment configuration for the sequence for laying down singles from the well center to the catwalk is as follows:The top drive200is in a lower position on the well center axis30, and the elevator is closed around the pipe stick-up.The drill pipe is suspended in a spider in the rig floor6so that approximately 1.2 m/4 ft of drill string sticks up from the rig floor6.The catwalk machine feeding table is unloaded and ready to receive tubulars.The catwalk machine ramp is empty and in a drill floor loading position (ready to move to drill floor).The tubular deliver arm is parked outside a collision area.

The sequence for laying down singles from the well center to the catwalk comprises the following steps.

Step 1: Open slips and hoist the drillstring. The slips on the spider are opened. The top drive/drawworks take the weight of the drill string and hoist the drill string out of the well bore. They stop hoisting when a single tubular is above the stick-up height. The slips on the spider are closed. The top drive/drawworks set the weight back on the slips. SeeFIGS. 60A and 60B.

Step 2: Move the catwalk machine ramp and the pipe pusher to the lay down position. The ramp of the catwalk machine600is elevated so that it is straight and positioned at the drill floor. The pipe pusher is moved to the drill floor lay down position relative to the ramp. SeeFIGS. 61A and 61B.

Step 3: The roughneck and the lower stabilizing arm move to the well center. The selected roughneck moved to the well center30and elevates to the stick-up height. The lower stabilizing arm800moves to the well center30above the roughneck working height. The lower stabilizing arm800closes its guide funnel around the tubular. SeeFIG. 62.

Step 4: Roughneck breaks out the stand. The roughneck breaks the connection and spins out the threads of the connection. The roughneck opens and retracts to a standby position. (Alternatively, the roughneck may wait at the well center until the stand is lifted by the top drive). SeeFIG. 63.

Step 5 (optional, if wet): Wet pipe. If tripping out wet, the mud bucket is moved to the well center and closed on the drill string. The top drive hoists the broken-out tubular to allow it to drain into the mud bucket. SeeFIG. 55. The mud bucket is then opened and retracted, while the lower stabilizing arm800guides the tubular above the mud bucket. SeeFIGS. 64A and 64B.

Step 6: The top drive and lower stabilizing arm move the tubular from the well center to the catwalk machine. The top drive lifts the tubular out of the stickup and above the catwalk machine. The lower stabilizing arm guides the pin end above the catwalk machine and positions the pin on the pipe pusher of the catwalk machine, which is in the drill floor lay down position. SeeFIGS. 65A and 65B.

Step 7: Lay down tubular on the catwalk machine. The top drive link arms swing out to position the elevator toward the catwalk machine. As the top drive lowers toward the drill floor, the pipe musher of the catwalk machine simultaneously runs down the ramp to lay the tubular on the ramp. The elevator opens to release the tubular and the link arms rotate back (link tilt float). SeeFIGS. 66A and 66B.

(X) Sequence for Running Casing from Catwalk with Casing Tong

The initial equipment configuration for the sequence for running casing from the catwalk with a casing tong is as follows:The top drive200is in a lower position on the well center axis30, and the elevator is closed around the pipe stick-up.The casing string is suspended in a spider in the rig floor6so that approximately 1.2 m/4 ft of drill string sticks up from the rig floor6.The casing is laid out on the catwalk machine casing side (driller's side). The casing tubulars are cleaned and doped, with no protectors. Casing tally is updated.The ramp of the catwalk machine is empty, and in a loading position.

The sequence for running casing from the catwalk with a casing tong comprises the following steps.

Step 1: Load casing on the catwalk machine ramp. Use the casing loading fingers to load one tubular of casing on the ramp of the catwalk machine600. SeeFIG. 69.

Step 2: Run the catwalk to the drill floor. The ramp of the catwalk machine600. SeeFIGS. 70A-70C.

Step 3: Open the elevator and hoist to catwalk pick-up position. The top drive200elevator is opened, and the link arms are tilted back so the elevator can clear the casing tubular joint. SeeFIG. 71A. The top drive is hoisted to the catwalk pick-up position. SeeFIG. 71B.

Step 4: Push the casing. The pipe pusher of the catwalk machine600pushes the casing up the ramp to the latching position. The top drive link arms are tilted forward to swing the elevator toward the casing, and the elevator latches onto the casing. SeeFIGS. 72A and 72B.

Step 5: Pull up the casing. The casing is pulled up by hoisting the top drive200so that the box end of the casing is lifted by the elevator. As the top drive is hoisted, the lower box end of the casing slides up the ramp of the catwalk machine600. Before the lower box end of the casing exits the end of the ramp of the catwalk machine600, the lower stabilizing arm800extends and closes its funnel to guide the casing. As the casing approaches vertical, the centralizers of the lower stabilizing arm800close on the casing. SeeFIG. 73.

Step 6: Guide the casing to well center. The tong handling arm and casing tong are moved to the stick-up as the top drive200continues to hoist the casing. When the pin end is hoisted above the stick-up, the lower stabilizing arm800guides the casing to the well center30. The catwalk ramp moves out and down to a position for loading the next casing. SeeFIG. 74A. In an alternative embodiment where a tong handling trolley is used, the roughneck on the tong handling trolley may be used for the connection. SeeFIG. 74B.

Step 7: Stab the casing and make-up. The stabbing guide of the casing tong is closed above the stick-up. The top drive is lowered to stab the casing into the stabbing guide. When the casing is in the stabbing guide, the lower stabilizing arm800is opened and retracted. The top drive is further lowered to stab the casing into the stick-up. The casing tong spins the casing to thread the casing's pin end into the stick-up's box end. The casing tong then applies torque to make-up the joint. SeeFIG. 75.

Step 9: Lower the casing string. The casing tong is moved to its standby position. Pick up the weight of the casing string with the top drive/drawworks. Open the slips in the spider. Lower the casing string into the wellbore to the stick-up height. Set the slips in the spider. SeeFIG. 76.

(XI) Sequence for Breaking Out Single Casing with Casing Tong and Laying Down to Catwalk

The sequence for breaking out single casing with a casing tong and laying down the casing single to the catwalk is very similar to the sequence for running casing from the catwalk with the casing tong. The difference is that the steps are performed in reverse order.

(XII) Sequence for Running Casing from Catwalk with Top Drive and Casing Running Tool

The initial equipment configuration for the sequence for running casing from the catwalk with a top drive and casing running tool is as follows:The top drive200is in a lower position on the well center axis30, and the casing running tool is closed around the pipe stick-up.The casing string is suspended in a spider in the rig floor6so that approximately 1.2 m/4 ft of drill string sticks up from the rig floor6.The casing is laid out on the catwalk machine casing side (driller's side). The casing tubulars are cleaned and doped, with no protectors. Casing tally is updated.The ramp of the catwalk machine is loaded with a casing single on the way up.The tubular delivery arm is parked in the top of the mast, and the lower stabilizing arm is ready.

The sequence for running casing from the catwalk with a top drive and casing running tool comprises the following steps.

Step 1: Release casing running tool from the stickup and hoist top drive to pick up position. Release the casing running tool from the stickup. SeeFIG. 77A. Hoist the top drive to the catwalk pick-up position (above the casing). Activate the pipe pusher of the catwalk machine to push the casing forward to the pick-up position. SeeFIGS. 77B-77C.

Step 3: The top drive and lower stabilizing arm hoist casing to well center. The tong handling trolley and back up tong move to the well center and elevate to the stick-up height. The top drive links retract (float) to the well center30so that the casing is suspended with the pin end above the stick-up and guided by the lower stabilizing arm800. The catwalk machine is moved to the casing loading position. SeeFIGS. 79A and 79B.

Step 4: Stab the casing and make-up. The stabbing guide of the back-up tong is closed above the stick-up. The top drive is lowered to stab the casing into the stabbing guide (the pickup elevator will slide on the casing). When the casing is in the stabbing guide, the lower stabilizing arm800is opened and retracted. The top drive is further lowered to stab the casing running tool. SeeFIGS. 80A-80B.

Step 5: Load the next casing on the ramp of the catwalk machine. Casings are placed on the casing side (driller's side) of the catwalk machine. The loading fingers of the catwalk machine load one casing onto the ramp. SeeFIG. 81.

Step 6: Run the ramp of the catwalk machine to the drill floor. The catwalk machine is move to the drill floor position. SeeFIGS. 82A and 82B.

Step 7: Engage the casing running tool and make-up the casing connection. When the casing running tool is stabbed, spin in and make up the connection according to casing running tool operating procedure. SeeFIGS. 83A and 83B.

Step 8: Open the Backup tong and retract the tong handling trolley. Open the backup tong. Move the tong handling trolley to its park or standby position. SeeFIG. 84.

Step 9: Lower the casing string and open elevator. Pick up the weight of the casing string with the tope drive/drawworks. Open the slips in the spider. Lower the casing string to stick-up height while filling the casing with drilling mud. Stop lowering the casing string when the elevator is close to the drill floor. Open the manual elevator. SeeFIG. 85.

Step 10: Tilt the link arms out and set the slips. The link arms are tilted out toward the catwalk machine and the slips are set in the spider. SeeFIG. 86.

(XIII) Sequence for Running Casing from Catwalk with Tubular Delivery Arm and Casing Running Tool

The initial equipment configuration for the sequence for running casing from the catwalk with a tubular delivery arm and casing running tool is as follows:The top drive200is in a lower position on the well center axis30, and the casing running tool is closed around the pipe stick-up.The casing string is suspended in a spider in the rig floor6so that approximately 1.2 m/4 ft of drill string sticks up from the rig floor6.The casing is laid out on the catwalk machine casing side (driller's side). The casing tubulars are cleaned and doped, with no protectors. Casing tally is updated.The ramp of the catwalk machine is empty in a loading position.The tubular delivery arm and lower stabilizing arm are holding a casing in the drilling floor standby position. SeeFIG. 87.

The sequence for running casing from the catwalk with a tubular delivery arm and casing running tool comprises the following steps.

Step 1: Release casing running tool from the stickup and hoist top drive to pick up position. Release the casing running tool from the stickup. Hoist the top drive to clear the stickup. Retract the top drive and tilt link arms to vertical position. Hoist top drive and casing running tool to CRT stabbing position above the casing. SeeFIG. 88.

Step 2: Move the casing to well center. The tubular delivery arm500and the lower stabilizing arm800move the casing section to the well center30and elevate to the stick-up height. The tubular delivery arm500extends to the well center30with pin end above the stick-up, guided by the lower stabilizing arm800. SeeFIGS. 89A and 89B.

Step 3: Stab the casing. The casing tong and the stabbing guide close on the stick-up. The make up spinning tong is positioned and closed on the casing (can be closed before or after stabbing the casing). The tubular delivery arm500lowers to stab the casing. SeeFIG. 90. The lower stabilizing arm opens and retracts when the casing is inside the stabbing guide. The tubular delivery arm500continues to lower the casing (approximately 1 m/3 ft) to allow room for make-up with the casing running tool.

Step 4: Load the casing on the ramp. The casings are placed on the casing side (driller's side) of the ramp of the catwalk machine600. The loading fingers load one casing onto the ramp of the catwalk machine600. SeeFIG. 91.

Step 5: Run the casing to the drill floor. The ramp of the catwalk extends to the drill floor position, and the tool pusher slides the casing up the ramp to deliver the casing to the drill floor. SeeFIGS. 92A and 92B.

Step 6: Make up the casing connection. The tong handling arm and the casing tong make up the connection by spinning the treads and applying torque. The casing tong opens and the tong handling arm retracts, and may optionally be moved to a standby or parking position. SeeFIG. 93A. Alternatively, the casing connection may be made up via the tong handling trolley and casing tong. SeeFIG. 93B. Still another alternative is for the casing connection to be made up with the casing running tool by spinning and torqueing with the top drive.

Step 7: Stab in the casing running tool. The casing running tool is stabbed in and locked in the casing. The tubular delivery arm500is opened and moved to the catwalk pick-up position. SeeFIGS. 94A and 94B.

Step 8: Lower the casing string. The top drive/drawworks pick up the weight of the casing string. The slips in the spider are opened. The top drive/drawworks lower the casing string into the well bore to the stick-up height. Optionally, the casing may be filled with drilling fluid. SeeFIGS. 95A and 95B.

Step 9: Push the casing. The tool delivery arm500is moved to the catwalk machine pick up position so that its elevator may receive a casing section. The pipe pusher pushes a casing section up the ramp. The tool delivery arm latches500its elevator to the casing section. SeeFIG. 96.

Step 10: Pull up the casing. With its elevator closed around the casing, the tubular delivery arm500hoists the casing and the tool pusher pushes the casing up the ramp. Prior to the casing leaving the ramp of the catwalk, the lower stabilizing arm800extends to the casing and prepares for guiding, and the funnel is closed on the casing. As the casing approaches vertical, the centralizer of the lower stabilizing arm800closes on the casing. The ramp of the catwalk returns to load the next casing. SeeFIGS. 97A-97B.

Step 11: Guide the casing. The tubular delivery arm500continues to hoist and retract to bring the casing to a vertical position before it rotates toward the top drive. The lower stabilizing arm800guides the casing to a vertical position. SeeFIGS. 98A-98B.

Step 12: Set the slips. The slips are set to suspend the casing string. SeeFIGS. 99A-99B.

(XIV) Sequence for Offline Drill String Standbuilding

The initial equipment configuration for the sequence for offline standbuilding of drill string is as follows:All machines are empty.The intermediate stand constraint430head is retracted.Pipe is loaded on the catwalk feeding table, cleaned and doped without protectors.Optionally, the doping may be selected as part of the standbuilding sequence.

The sequence for offline standbuilding comprises the following steps.

Step 1: Place tubulars on the feeding table. The feeding table then loads one tubular onto the ramp of the catwalk machine600. SeeFIG. 100.

Step 2: Run the ramp to the drill floor. SeeFIGS. 101A and 101B. The tubular delivery arm500is lowered so that its elevator is below the pipe pickup height. The tubular deliver arm500tilts its arm toward the catwalk600.

Step 3: Push the tubular. The pipe pusher of the catwalk machine600pushes the tubular up the ramp to the latching position. SeeFIGS. 102A and 102B.

Step 4: Pull up the first tubular from the catwalk machine. The tubular delivery arm500is hoisted slightly to latch the elevator to the tubular on the ramp of the catwalk600. The latch of the elevator is closed. The tubular is pulled up by hoisting the tubular delivery arm500up the mast and the pipe pusher follows. Before the tubular leaves the ramp, the lower stabilizing arm800extends to prepare for guiding the tubular. The funnel is then closed on the tubular as the tubular raises. As the tubular approaches vertical, the centralizer of the lower stabilizing arm800closes on the tubular. The ramp of the catwalk600returns to load a second tubular. SeeFIGS. 103A and 103B.

Step 5: Place the first tubular in the mousehole. The first tubular is lowered into the mousehole40by the tubular delivery arm500to a correct stickup height (1 m/3 ft). The head of the intermediate stand constraint430extends and closes on the first tubular. The lower stabilizing arm800releases the first tubular and retracts. The lower stand constraint440extends and closes on the first tubular. The tubular delivery arm500lowers to transfer the weight of the first tubular to the constraints, the elevator opens, and the tubular delivery arm500retracts from the stickup. SeeFIGS. 104A and 104B.

Step 6: Pull up the second tubular. The elevator of the tubular delivery arm500is again positioned below the pipe pickup height with the elevator open and tilted toward the catwalk600. After the second tubular is loaded and the ramp extended, the tool pusher slides the second tubular up the ramp. The tubular delivery arm500is hoisted slightly until the elevator engages the second tubular and the elevator latch is closed thereon. The second tubular is pulled up by hoisting the tubular delivery arm and pushed by the tool pusher. Prior to the second tubular leaving the ramp of the catwalk, the lower stabilizing arm800extends to the tubular and prepares for guiding, and the funnel is closed on the tubular. As the tubular approaches vertical above the mousehole40, the centralizer of the lower stabilizing arm800closes on the second tubular. If doping is desired, the second tubular is moved to the stand hand-off position50prior to moving to the mousehole40. The ramp of the catwalk returns to load the third tubular. SeeFIGS. 105A-105C.

Step 7: Stab and make up the second tubular. The second tubular is moved over the stickup of the first tubular in the mousehole40. The roughneck760on the tong handling arm moves to the stickup. The roughneck stabbing guide is closed on the first tubular stickup. The tubular delivery arm is lowered to stop the second tubular into the first tubular stickup. The roughneck spins in and makes up the connection. The lower stabilizing arm opens and retracts. The roughneck retracts to a standby position. SeeFIGS. 94A and 94B.

Step 8: Lower the double into the mousehole. The tubular delivery arm is hoisted to pick up the weight of the double. The intermediate stand constraint opens to release the double. The lower stand constraint extend to the mousehole position and closes its guide around the double for stabbing mode. The double is lowered by the tubular delivery arm into the mousehole to the correct stickup height, while the lower stand constraint guides the double into the mousehole and opens slightly to allow passage of the tubular joint. The guide of the intermediate stand constraint is then closed and finally the double is clamped to position the double at the stickup height. The tubular delivery arm lowers to transfer the weight of the double to the intermediate stand constraint. The elevator of the tubular delivery arm opens and retracts from the stickup. Repeat steps 6 and 7 to pick up a third single tubular. SeeFIG. 107.

Step 9: Move the stand to the stand handoff position. The lower stand constraint440extends to the pipe at the mousehole position and closes its guide. The tubular delivery arm500is hoisted to pickup the weight of the stand. Both the guide and the clamp of the intermediate stand constraint430are opened. The head of the intermediate stand constraint430is retracted. The tubular delivery arm500lifts the stand (R2 or R3) from the mousehole40and stops when the stand is elevated so that the pin end is above the height of the doper station at the stand handoff position50. The tubular delivery arm500and the lower stabilizing arm800move the stand to a position hanging at the stand handoff position50. The stand is then stabbed into the doper, if selected, where the pin is washed and doped. The upper stand constraint extends to close its guide on the stand. The tubular delivery arm500opens and retracts from the stand. SeeFIGS. 108A and 108B.

Step 10: Set back stand. The transfer bridge racker350and the setback guide arm950move to the stand handoff position50and close their guides and clamps on the stand. The upper and lower stand constraints420and440open and retract. The transfer bridge racker350and the setback guide arm950move to setback the stand to a selected position in the fingerboard310. SeeFIGS. 109A-109D.

(XV) Sequence for Laying Down Drill String Stands (Offline)

The initial equipment configuration for the sequence for laying down stands of drill string (offline) is as follows:All machines are empty.The intermediate stand constraint430head is retracted.The catwalk machine feeding table is empty and ready to receive drill pipe.

The sequence for laying down stands of drill string (offline) comprises the following steps.

Step 1: Pick up stand from setback. The transfer bridge racker350and the setback guide arm950move into the setback to pick up a stand from a selected position in the setback/fingerboard310. SeeFIGS. 110A and 110B.

Step 2: Move stand to the stand handoff position. The transfer bridge racker350and the setback guide arm950move the stand to the stand handoff position50. The upper and lower stand constraints420and440close their grasps to hold the stand. The doper washes and dopes the pin (if selected). The transfer bridge racker350and the setback guide arm950move back into the setback to pick up another stand from another selected position in the setback/fingerboard310. SeeFIGS. 111A and 111B.

Step 3: Move the stand from the stand handoff position to the mousehole. The tubular delivery arm500and the lower stand constraint440move to the stand at the stand handoff position50and close their clasps on the stand. The upper stand constraint420opens and retracts. The tubular delivery arm500lists the stand at the stand handoff position50. The tubular delivery arm500and the lower stand constraint440move and guide the stand from stand handoff position50to the mousehole position40. SeeFIG. 112.

Step 4: Lower the stand into the mousehole. The tubular delivery arm500is lowered to stab the stand into the househole40. The head of the intermediate stand constraint430is extended. The stand is lowered until there is about 1 m/3 ft of stickup. The guide and gripper of the intermediate stand constraint430are closed on the stand and take the weight. The lower stand constraint440opens and retracts. SeeFIG. 113.

Step 5: Break out the top-single. The roughneck760extends to the mousehole40to engage the stand. The lower stabilizing arm800extends to the mousehole40and closes its funnel on the top-single of the stand. The roughneck760breaks out the connection, and spins out the threads. SeeFIGS. 115A and 115B.

Step 6: Lay down the top-single on the catwalk machine. The ramp of the catwalk machine600is moved to the drill floor for tubular laydown. The tubular delivery arm500lifts the broken out top-single from the stickup and with the help of the lower stabilizing arm800it is guided to a position above the ramp of the catwalk600. The lower stabilizing arm800moves the pin end over the ramp and the elevator of the tubular delivery arm500tilts toward the ramp. The tubular delivery arm500moves down the mast10to lower the top-single as the pipe pusher draws the pin end down the ramp of the catwalk600. When the top-single is loaded on the ramp, the elevator of the tubular delivery arm500opens and is tilted back toward the mast10. SeeFIGS. 115A and 115B.

Step 7: Unload the top-single to the catwalk feeding table. The pipe pusher pulls the top-single down the ramp of the catwalk to an unloading position. The ramp of the catwalk600tilts away from the drill floor6to lower itself to be adjacent the feeding table. The top-single is unloaded from the ramp to the feeding table. The ramp of the catwalk600extends again to the drill floor6to receive the next single. SeeFIGS. 116A and 116B.

Step 8: Pick up the double in the mousehole. The tubular delivery arm500rotates and lowers to latch onto the stickup in the mousehole40. The elevator of the tubular delivery arm500closes onto the stickup of the double. The tubular delivery arm500is hoisted to take the weight of the double. The intermediate stand constraint430opens its grasp when the weight of the double is unloaded from it. The double is hoisted to a stickup height in the mousehole40. The grasp of the intermediate stand constraint430is closed on the double and take the weight as the tubular delivery arm500is lowered slightly. SeeFIG. 117.

Step 9: Break out the mid-single. The roughneck760extends to the mousehole40. The lower stabilizing arm800is extended and its funnel closes on the mid-single. The roughneck760breaks out the connection and spins out the threads. The roughneck returns to its standby position. SeeFIGS. 114A and 114B.

Step 10: Lay down the mid-single. The ramp of the catwalk machine600is moved to the drill floor for tubular laydown. The tubular delivery arm500lifts the broken out mid-single from the stickup and with the help of the lower stabilizing arm800it is guided to a position above the ramp of the catwalk600. The lower stabilizing arm800moves the pin end over the ramp and the elevator of the tubular delivery arm500tilts toward the ramp. The tubular delivery arm500moves down the mast10to lower the mid-single as the pipe pusher draws the pin end down the ramp of the catwalk600. When the single is loaded on the ramp, the elevator of the tubular delivery arm500opens and is tilted back toward the mast10. SeeFIGS. 115A and 115B.

Step 11: Unload the mid-single to the catwalk feeding table. The pipe pusher pulls the mid-single down the ramp of the catwalk600to an unloading position. The ramp of the catwalk600tilts away from the drill floor6to lower itself to be adjacent the feeding table. The mid-single is unloaded from the ramp to the feeding table. The ramp of the catwalk600extends again to the drill floor6to receive the next single. SeeFIGS. 116A and 116B.

Step 12: Pick up the bottom-single in the mousehole. The tubular delivery arm500rotates and lowers to latch onto the stickup of the bottom-single in the mousehole40. The elevator of the tubular delivery arm500closes onto the stickup. The tubular delivery arm500is hoisted to take the weight of the bottom-single. The intermediate stand constraint430opens its grasp when the weight of the bottom-single is unloaded from it. The lower stabilizing arm800extends and closes its funnel around the bottom-single.

Step 13: Lay down the bottom-single. The tubular delivery arm500lifts the bottom-single from the mousehole40and with the help of the lower stabilizing arm800it is guided to a position above the ramp of the catwalk600. The lower stabilizing arm800moves the pin end over the ramp and the elevator of the tubular delivery arm500tilts toward the ramp. The tubular delivery arm500moves down the mast10to lower the bottom-single as the pipe pusher draws the pin end down the ramp of the catwalk600. When the single is loaded on the ramp, the elevator of the tubular delivery arm500opens and is tilted back toward the mast10. SeeFIGS. 115A and 115B.

Step 41: Unload the bottom-single to the catwalk feeding table. The pipe pusher pulls the bottom-single down the ramp of the catwalk600to an unloading position. The ramp of the catwalk600tilts away from the drill floor6to lower itself to be adjacent the feeding table. The bottom-single is unloaded from the ramp to the feeding table. SeeFIGS. 116A and 116B.

(XVI) Sequence for Offline Casing Standbuilding

The initial equipment configuration for the sequence for offline standbuilding of casing string is as follows:Drilling may be ongoing.All machines are empty.The intermediate stand constraint430head is retracted.Casing is loaded on the casing feeding table, cleaned and doped without protectors.Optionally, the doping may be selected as part of the standbuilding sequence.

The sequence for offline standbuilding of casing string comprises the following steps.

Step 1: Place casing tubulars on the feeding table. The feeding table then loads one casing tubular onto the ramp of the catwalk machine600. SeeFIGS. 118A and 118B.

Step 2: Run the ramp to the drill floor. SeeFIGS. 119A and 119B. The tubular delivery arm500is lowered so that its elevator is below the pipe pickup height. The tubular deliver arm500tilts its arm toward the catwalk600.

Step 3: Push the casing tubular. The pipe pusher of the catwalk machine600pushes the casing tubular up the ramp to the latching position. SeeFIGS. 120A and 120B.

Step 4: Pull up the first casing tubular from the catwalk machine. The tubular delivery arm500is hoisted slightly to latch the elevator to the casing tubular on the ramp of the catwalk600. The latch of the elevator is closed. The casing tubular is pulled up by hoisting the casing tubular delivery arm500up the mast10and the pipe pusher follows. Before the casing tubular leaves the ramp, the lower stabilizing arm800extends to prepare for guiding the tubular. The funnel is then closed on the casing tubular as the tubular raises. As the casing tubular approaches vertical, the centralizer of the lower stabilizing arm800closes on the tubular. The ramp of the catwalk600returns to load a second casing tubular. SeeFIGS. 121A-121C.

Step 5: Place the bottom-casing tubular in the mousehole. The bottom-casing tubular is lowered into the mousehole40by the tubular delivery arm500to a correct stickup height (1 m/3 ft). The head of the intermediate stand constraint430extends and closes on the first tubular. The lower stabilizing arm800releases the first casing tubular and retracts. The lower stand constraint440extends and closes to guide the first tubular. The tubular delivery arm500lowers to transfer the weight of the first tubular to the constraints, the elevator opens, and the tubular delivery arm500retracts from the stickup. SeeFIG. 122.

Step 6: Pull up the top-casing tubular. The elevator of the tubular delivery arm500is again positioned below the pipe pickup height with the elevator open and tilted toward the catwalk600. After the top-casing tubular is loaded and the ramp extended, the tool pusher slides the top-casing tubular up the ramp. The tubular delivery arm500is hoisted slightly until the elevator engages the tubular and the elevator latch is closed thereon. The top-casing tubular is pulled up by hoisting the tubular delivery arm and pushed by the tool pusher. Prior to the top-casing tubular leaving the ramp of the catwalk, the lower stabilizing arm800extends to the tubular and prepares for guiding, and the funnel is closed on the tubular. As top-casing tubular approaches vertical above the mousehole40, the centralizer of the lower stabilizing arm800closes on the second tubular. If doping is desired, the top-casing tubular is moved to the stand hand-off position50prior to moving to the mousehole40. The ramp of the catwalk returns to load the third tubular. SeeFIGS. 123A and 123B.

Step 7: Stab and make up the top-casing tubular. The top-casing tubular is moved over the stickup of the bottom-casing tubular in the mousehole40. The roughneck760on the tong handling arm moves to the stickup. The roughneck stabbing guide is closed on the bottom-casing tubular stickup. The tubular delivery arm is lowered to stab the top-casing tubular into the bottom-casing tubular stickup. The roughneck spins in and makes up the connection. The lower stabilizing arm opens and retracts. The roughneck retracts to a standby position. SeeFIGS. 124A and 124B.

Step 8: Lower the double into the mousehole (not applicable for Range 3). The tubular delivery arm500is hoisted to pick up the weight of the double. The intermediate stand constraint430opens to release the double. The lower stand constraint440extends to the mousehole position40and closes its guide around the double for stabbing mode. The double is lowered by the tubular delivery arm500into the mousehole40to the correct stickup height, while the lower stand constraint440guides the double into the mousehole40and opens slightly to allow passage of the tubular joint. The guide of the intermediate stand constraint430is then closed and finally the double is clamped to position the double at the stickup height. The tubular delivery arm500lowers to transfer the weight of the double to the intermediate stand constraint430. The elevator of the tubular delivery arm500opens and retracts from the stickup. Repeat steps 6 and 7 to pick up a third single tubular, if Range 2. SeeFIGS. 125A and 125B.

Step 9: Move the casing stand to the stand handoff position. The lower stand constraint440extends to the pipe at the mousehole position and closes its guide. The tubular delivery arm500is hoisted to pickup the weight of the casing stand. Both the guide and the clamp of the intermediate stand constraint430are opened. The head of the intermediate stand constraint430is retracted. The tubular delivery arm500lifts the casing stand (R2 or R3) from the mousehole40and stops when the stand is elevated so that the pin end is above the height of the doper station at the stand handoff position50. The tubular delivery arm500and the lower stabilizing arm800move the stand to a position hanging at the stand handoff position50. The stand is then stabbed into the doper, if selected, where the pin is washed and doped. The upper stand constraint extends to close its guide on the stand. The tubular delivery arm500opens and retracts from the stand. SeeFIGS. 126A and 126B.

Step 10: Set back casing stand. The transfer bridge racker350and the setback guide arm950move to the stand handoff position50and close their guides and clamps on the casing stand. The upper and lower stand constraints420and440open and retract. The transfer bridge racker350and the setback guide arm950move to set back the casing stand to a selected position in the fingerboard310. SeeFIGS. 127A-127D.

(XVII) Sequence for Offline Laying Down Casing Stands

The sequence for offline laying down casing stands is similar to the sequence for offline casing standbuilding, except the steps are performed in reverse order.

(XVIII) Sequence for Drilling Connection

The initial equipment configuration for the sequence for drilling connection is as follows:A stand is drilled all the way down in the wellbore, and reaming, survey, etc. have all been done according to the drilling program.One stand of drill pipe is being lifted by the tubular delivery arm/lower stabilizing arm in the stand handoff position to stickup level above the mousehole, and the elevator of the tubular delivery arm is facing the top drive. The drill floor is on standby.The transfer bridge racker and setback guide arm are empty and on their way to pick up a new stand in the fingerboard/setback.

The sequence for drilling connection comprises the following steps.

Step 1: Stop drilling and break out top drive connection. The drilling operation is stopped. With the drill string stickup at height (approximately 1.5 m/5 ft), the slips in the spider are set. The weight of the drill string is set on the slips. The top drive connection is broken out and the threads are spun out. SeeFIG. 128. The top drive200is then hoisted upward in the mast10.

Step 2: The top drive is hoisted to connection height. With the top drive200retracted by its trolley, the top drive200is hoisted to a height sufficient for connection with the next drill string stand. The elevator link arms tilt to the vertical position below the top drive. SeeFIGS. 129A and 129B.

Step 3: Move the stand from the mousehole position to the well center. The tubular deliver arm500and the lower stabilizing arm800move the stand to the well center30from the drill floor standby position above the mousehole40. The selected roughneck (tong handling trolley) moves to the well center. SeeFIGS. 130A and 130B.

Step 4: Stab the stand in the stickup at well center. The top drive200remains at the correct elevation and retracted from well center30. The roughneck760back up tong and stabbing guide close on the stickup to assist with stabbing. The tubular delivery arm500lowers the stand to stab the stand in the stick, and continues to lower (approximately 2 m/6 ft) after stabbing to allow room for the top drive make up. The lower stabilizing arm800opens and retracts from well center30. One option is for the roughneck to start the sequence for spin in and make up of the lower connection. SeeFIGS. 131A and 131B.

Step 5: Connect the top drive. With the top drive200at the correct elevation, the trolley extends to position the top drive200at the well center30. The link arms are tilted toward the mast10and parked for a drilling position. The top drive is lowered to stab into the stand, and the top drive then rotates to spin in both the upper and lower connections against the roughneck back up tong. The tubular delivery arm500opens its elevator, retracts from the well center30and turns to pick up the next stand in the stand handoff position. The roughneck opens and retracts to its standby position. SeeFIGS. 132A and 132B. Optionally, the roughneck opens and moves to a standby position after make up of the lower connection.

Step 6: Open the slips and resume drilling. The top drive/drawworks hoist the drill string weight. The slips in the spider are opened. Drilling operations are continued. SeeFIG. 133.

Step 7: Pick up the next stand from the setback. The transfer bridge racker350and the setback guide arm950pick up another stand from a selected position in the setback/fingerboard310. SeeFIGS. 134A and 134B.

Step 8: Move the stand to the stand handoff position. The top drive200opens its elevator and retracts from the stickup and hoists to the upper stop. The transfer bridge racker350and the setback guide arm950move the stand to the stand handoff position50. The upper and lower stand constraints420and440close to hold the stand in its position. The doper integrated in the stand handoff position50washes and dopes the pin, if selected. The transfer bridge racker350and the setback guide arm950pick up another stand from a selected position in the setback/fingerboard310. SeeFIGS. 135A and 135B.

The initial equipment configuration for the sequence for backreaming is as follows:The top drive is in a lower position, retracted by the trolley, and the link arms are vertical so the elevator is below the top drive. SeeFIG. 136.The slips are closed on the drill string with a standard stickup (approximately 1.5 m/5 ft).The tubular delivery arm500and lower stabilizing arm800are open in the stand handoff position (a stand is delivered from well center to stand handoff position).The upper and lower stand constraints are closed on the stand in the stand handoff position. The intermediate stand constraint is open and retracted.The transfer bridge racker and setback guide arm are empty and on their way back from the fingerboard/setback to get the next stand in the stand handoff position.

The sequence for backreaming comprises the following steps.

Step 1: Make up the top drive. The top drive trolley extends the top drive200to the well center30. The elevator link arms are tilted backward to the parked position. The top drive is lowered, spun in and made up to the drill string. SeeFIGS. 137A and 137B.

Step 2: Ream out a stand-length of the borehole. The slips are opened and the top drive/drawworks pick up the weight of the drill string. The inside blowout preventer is opened and the mud pump is activated to circulate drilling fluid. The top drive200rotates the drill string and is hoisted in the mast10to ream out the borehole until the top drive reaches the connection height. The top drive200stops rotating the drill string and releases torque on the drill string. The mud pumps are stopped and the inside blowout preventer is closed. The slips in the spider are closed with the drill string at the correct stickup height. The tubular deliver arm500and the lower stabilizing arm800move from the stand handoff position to the drill floor to a safe standby position. The elevator of the tubular delivery arm500faces the top drive200. SeeFIGS. 138A and 138B.

Step 3: Move a stand from the stand handoff position to the setback/fingerboard. The transfer bridge racker350and the setback guide arm950move to the stand in the stand handoff position50and they close their clamps and guides on the stand. The upper and lower stand constraints420and440open and retract. The transfer bridge racker350and the setback guide arm950lift the stand and move it to a selected position in the setback/fingerboard, where it is released and held in position by the fingerboard310. SeeFIGS. 139A and 139B.

Step 4: Prepare to break out stand from drill string. The tubular delivery arm500and the lower stabilizing arm800move to the well center30and close their elevator and guide on the stand in the drill string. The roughneck760moves to the well center and elevates to the stickup height. SeeFIGS. 140A and 140B.

Step 5: Break out the top drive from the stand. The top drive200breaks out and spins out the threads of its connection with the stand. The drawworks hoists the top drive200to clear the top of the stand. The trolley retracts the top drive from the well center30and the elevator link arms are rotated back to vertical so that the elevator floats to a position under the top drive. The drawworks lowers the top drive200down the mast10toward the drill floor6. SeeFIGS. 141A and 141B.

Step 6: Break out the stand from the drill string. The roughneck760breaks out the stand from the stickup and spins out the threads of the joint. SeeFIGS. 142A and 142B.

Step 7: Drain the stand. The roughneck760opens and retracts from the stickup to its standby position. The mud bucket extends to the well center30and closes on the broken connection. The tubular delivery arm500lifts the stand above the stickup to allow the fluid in the stand to drain into the mud bucket. The mud bucket opens from the stand/stickup and retracts to its standby position. SeeFIG. 143.

Step 8: Move the stand from the well center. The tubular delivery arm500and the lower stabilizing arm800move the stand from the well center30to the stand handoff position50. Upon arrival, the tubular deliver arm500lowers the stand to offload the weight at the stand handoff position50. The upper and lower stand constraints420and440close on the stand to hold it in position. If selected, the doper integrated in the stand handoff position washes and dopes the pin. The top drive200continues to lower to the drill floor6. SeeFIGS. 144A and 144B.

Step 9: Set back the stand. Move a stand from the stand handoff position to the setback/fingerboard. The transfer bridge racker350and the setback guide arm950move to the stand in the stand handoff position50and they close their clamps and guides on the stand. The upper and lower stand constraints420and440open and retract. The transfer bridge racker350and the setback guide arm950lift the stand and move it to a selected position in the setback/fingerboard, where it is released and held in position by the fingerboard310. The transfer bridge racker350and the setback guide arm950return to the stand handoff position. SeeFIGS. 145A and 145B.

It should be noted that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. In addition, the composition used/disclosed herein can also comprise some components other than those cited. In the summary of the invention and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary of the invention and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors possessed knowledge of the entire range and all points within the range. The statements made herein merely provide information related to the present disclosure and may not constitute prior art, and may describe some embodiments illustrating the invention.

If used herein, the term “substantially” is intended for construction as meaning “more so than not.”

Although the disclosed embodiments are described in detail in the present disclosure, it should be understood that various changes, substitutions and alterations can be made to the embodiments without departing from their spirit and scope.

INDUSTRIAL APPLICABILITY

Pipe handling systems and processes for drilling rigs of the present invention have many industrial applications including but not limited to drilling well bores for the oil and gas industry.