Abstract:
An umbilical manipulator arm for positioning control lines for being secured to a plurality of tubular strings being made up and run into a dual completion wellbore includes a carriage movable on a base that is securable to a rig floor adjacent to two tubular strings. An umbilical manipulator arm is coupled to the carriage and movable relative to the carriage between a pusher arm retracted position distal to a tubular string and a pusher arm engaged position proximal to a tubular string. The carriage is movable between a carriage first position proximal to a first tubular string and a carriage second position proximal to a second tubular string. The umbilical manipulator arm can be used to position control lines for being secured to the plurality of tubular strings as they are being made up and run into the wellbore.

Description:
BACKGROUND 
       [0001]    Field of the Invention 
         [0002]    The present invention relates to a control line pusher arm for use in positioning control lines to be secured to two parallel tubular strings being run into a dual completion well. 
         [0003]    Background of the Related Art 
         [0004]    In a dual well completion, a single wellbore has a plurality of tubular strings in addition to related packers and other tools to enable production from two different and isolated geologic zones. Generally, two tubing strings are used to provide the necessary level of control, safety and segregation between fluids from the two different subsurface geological zones penetrated by a single, dual-completion wellbore. 
         [0005]    A control line pusher arm is used on a rig for positioning an elongate control line, also called an umbilical, so that it can be secured to a tubular string as the tubular string is made up and run into a wellbore. A conventional control line pusher arm moves between a retracted position, distal to the tubular string, and an engaged position, proximal to the tubular string, to move an adjacent portion of a control line proximal to the tubular string so that a clamp or other securing member can be applied to secure the portion of the control line to the adjacent portion of the tubular string. 
         [0006]    What is needed is a control line pusher arm that can be used to position a plurality of control lines for being secured to a plurality of tubular strings being run into a single wellbore. 
       BRIEF SUMMARY 
       [0007]    One embodiment of the present invention provides a control line pusher arm for use in positioning two control lines for securing one of the control lines to a first tubular string and for securing the other of the control lines to a second tubular string wherein the first tubular string and the second tubular string are together being run into a dual-completion wellbore. 
         [0008]    A first embodiment of the apparatus of the present invention comprises a base supportable on a rig floor, a carrier coupled to the base and movable relative to the base between a first position and a second position, a pusher arm pivotally coupled at a lower end to the carrier and pivotable between a retracted position and an engaged position to position a control line head coupled to a second end of the pusher arm, a first motive member coupled intermediate the carrier and the pusher arm to pivot the pusher arm between the retracted position and the engaged position, and a second motive member coupled intermediate the carrier and the base to move the carrier between the first position and the second position. The apparatus may further comprise a worm gear coupled to the base to rotate about an axis by operation of the second motive member, wherein the carrier includes a plurality of teeth engaged by the worm gear. In one embodiment of the apparatus comprising a worm gear coupled to the base to rotate by operation of the second motive member, the second motive member is a hydraulic motor. Alternately, in another embodiment of the apparatus that comprises a worm gear, the worm gear is coupled to the carrier to rotate about an axis by operation of the second motive member, and the base includes a plurality of teeth engaged by the worm gear. In one embodiment of the apparatus comprising a worm gear coupled to the carrier to rotate by operation of the second motive member, the second motive member is a hydraulic motor. 
         [0009]    In one embodiment of the apparatus, the first motive member of the apparatus that moves the pusher arm to pivot between the retracted position and the engaged position may comprise a fluid cylinder coupled at a first end to the carrier and coupled at a second end to the pusher arm and operable to pivot the pusher arm between the retracted position and the engaged position. 
         [0010]    In one embodiment of the apparatus, the second motive member of the apparatus that moves the carrier between the first position and the second position comprises a fluid cylinder. 
         [0011]    In one embodiment of the apparatus, the second motive member of the apparatus that moves the carrier between the first position and the second position comprises a worm gear disposed intermediate the carrier and the base. 
         [0012]    In one embodiment of the apparatus, the carrier is slidably coupled to the base. 
         [0013]    In one embodiment of the apparatus, the carrier is translatably moved between the first position and the second position on the base. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0014]      FIG. 1  is a perspective view of an embodiment of an apparatus of the present invention with a pivotal pusher arm in a first position that is proximal to a first tubular string in a dual completion well and with the pusher arm in the retracted position. 
           [0015]      FIG. 2  is the perspective view of the embodiment of the apparatus of  FIG. 1  after the pusher arm is pivoted from the retracted position illustrated in  FIG. 1  to an engaged position to position a portion of a first control line proximal to the first tubular string in a dual completion well to enable the application of a clamp to secure the portion of the first control line to the first tubular string. 
           [0016]      FIG. 3  is the perspective view of the embodiment of the apparatus of  FIG. 2  after the pusher arm is retracted away from the first tubular string (to the position illustrated in  FIG. 1 ), the pusher arm is translated laterally to a second position that is proximal to a second tubular string adjacent to the first tubular string in the dual completion well, and the pusher arm is pivoted from the retracted position to the engaged position to position a portion of a control line proximal to a second tubular string to enable the application of a clamp to secure the portion of a second control line to the second tubular string. 
           [0017]      FIG. 4  is a plan view of the base and the carrier of the embodiment of the apparatus of  FIGS. 1-3 , and of the motor and threaded shaft arrangement for moving the carrier on the base and between the first position and the second position. 
           [0018]      FIG. 5  is an elevation view of a portion of the apparatus showing the interaction between the pivotal pusher arm and a pivotal first motive member, between the carrier and the base of the apparatus, and between the carrier and the threaded shaft that is driven to rotate about an axis by a second motive member (not shown in  FIG. 5 —see  FIG. 4 ) to move the carrier on the base. 
           [0019]      FIG. 6  is the plan view of  FIG. 4  after the carrier is moved by operation of the second motive member from the first position (see  FIG. 4 ) to the second position. 
           [0020]      FIG. 7  is a flowchart illustrating the logic followed by a safety lockout system that protects the carriage from being moved between the first position and the second position while the pusher arm is engaged with a control line. 
           [0021]      FIG. 8  illustrates an alternate second motive member that is secured to the carriage and operable to engage a rack including a row of teeth along an edge of the base. 
           [0022]      FIG. 9  is an enlarged view of the motive member, the carriage on which it moves and the rack engaged by the motive member through the gear disposed on the motive member. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    One embodiment of the apparatus of the present invention is illustrated in  FIG. 1 .  FIG. 1  is a perspective view of an embodiment of the apparatus  10  supported on a rig floor  13 .  FIG. 1  shows a first tubular string  40  and a second tubular string  42  extending generally vertically into a dual completion well (not shown). The apparatus  10  comprises a pusher arm  30  pivotally coupled at a lower end  37  to a carriage  14 . The pusher arm  30  is pivotally coupled to the carriage  14  and movable relative to the carriage  14  between an arm-retracted position, illustrated in  FIG. 1 , to an arm-engaged position, as illustrated in  FIG. 2  and discussed below. The carrier  14  translates on a base  12  of the apparatus  10  between a carriage first position, proximal to the first tubular string  40  and illustrated in  FIG. 1 , to a carriage second position. 
         [0024]      FIG. 2  is the perspective view of  FIG. 1  after the pusher arm  30  pivots from the arm-retracted position, illustrated in  FIG. 1 , to the arm-engaged position to position a portion of the control line  80  proximal to the first tubular string  40 . The first motive member  32 , a fluid cylinder, is illustrated as being coupled intermediate the pusher arm  30  and the carriage  14 . The first motive member is coupled to the carriage  14  at a location that is spaced-apart from the location where the pusher arm  30  is pivotally coupled to impart on the pusher arm  30  a force having a component that will cause the pusher arm  30  to rotate from the pusher arm-retracted position, illustrated in  FIG. 1 , towards the first tubular string  40  and to the pusher arm-engaged position, illustrated in  FIG. 2 . The movement of the pusher arm  30  to the pusher arm-engaged position moves the control line  80  to a position enabling the application of the clamp  60  to secure the control line  80  to the first tubular string  40 . 
         [0025]      FIG. 3  is the perspective view of  FIG. 2  after the pusher arm  30  is retracted away from the first tubular string  40  (to return to the pusher arm-retracted position illustrated in  FIG. 1 ), translated laterally to a second position that is proximal to a second tubular string  42  that is adjacent to the first tubular string  40 , and then again pivoted from the pusher-arm retracted position to the pusher arm engaged position to position a portion of a second control line  82  proximal to the second tubular string  42  to enable the application of a clamp (not shown) similar to the clamp  60  shown in  FIG. 3  as securing the first control line  80  to the first tubular string  40 . 
         [0026]      FIG. 4  is a plan view of the base  12  and the carrier  14  of the apparatus  10  of  FIGS. 1-3 , and of a motor  25  on the base  12  that, when activated, drives a threaded shaft  19  to rotate.  FIG. 4  further reveals a proximal end  16  of the carriage, a distal end  18  of the carriage  14 , and an internally-threaded nut  17  secured within a well  15  on the carriage  14  between the proximal end  16  and the distal end  18  of the carriage  14 . The shaft  19  is threadably engaged with the internally-threaded nut  17  secured within the well  15  on the carriage  14  intermediate the proximal end  16  and the distal end  18 . Upon activation of the motor  25  by one of an electrical current and a hydraulic circuit (meaning hydraulic pressure on one side, and relatively less hydraulic pressure on the other) through one of electrical and hydraulic conduits  26  and  27 , respectively, the shaft  19  rotates to move the carrier  14  on the base  12  between the carriage first position, illustrated in  FIG. 1 , and the carriage second position illustrated in  FIG. 3 . It will be understood that the carriage  14  could be moved between the carriage first position, illustrated in  FIG. 1 , and the carriage second position illustrated in  FIG. 3 , using other motive members such as, for example, a double-acting fluid cylinder disposed intermediate the base  12  and the carriage  14 , an electromagnet on one of the base  12  and the carriage  14  and a magnet disposed on the other of the base  12  and the carriage  14 , and a worm gear coupled intermediate the base  12  and the carriage  14 . 
         [0027]      FIG. 5  is an elevation view of a portion of the apparatus  10  showing the interaction between the pusher arm  30  and the first motive member  32 , and also between the carrier  14  and the threaded shaft  19  driven by the second motive member (not shown in  FIG. 5 —see  FIG. 4 ).  FIG. 5  shows a proximal end  16  of the carriage  14  and a distal end  18  of the carriage, and the carriage  14  slidably seated within the base  12 . The threaded shaft  19  is threadably received within the internally threaded nut  17  of the carriage  14 . The first motive member  32  is a fluid cylinder that is pivotally coupled to an ear  38  on the carriage  14 . It will be understood that the extension of the first motive member  32  pivots the pusher arm  30  in the clockwise direction about the proximal ear  36  and retraction of the first motive member  32  pivots the pusher arm  30  in the counterclockwise direction about the proximal ear  36 . 
         [0028]      FIG. 6  is the plan view of  FIG. 4  after the carriage  14  is moved on the base  12  from the first position (see  FIGS. 1, 2 and 4 ), with the carriage  14  proximal to the first tubular string  40  (not shown in  FIG. 6 —see  FIG. 1 ), to the second position (see  FIG. 3 ), with the carriage  14  proximal to the second tubular string  42 . 
         [0029]      FIG. 7  is a high-level flowchart illustrating steps for automatically protecting the apparatus  10  and the tubular strings  40  and  42  against damage that may be caused by inadvertently operating the second motive member  25  of the apparatus  10  when the pusher arm  30  is engaged with the first control line  80  or the second control line  82 . The flowchart of  FIG. 7  illustrates the steps performed by a processor and beginning at step  101 . In step  102 , the signal to actuate the second motive member  25  is received. In step  103 , the position of the pusher arm  30  is determined and, if the pusher arm is in the retracted position so that it can be moved along with the carriage between the pusher arm first position and the pusher arm second position then, in step  105 , the position of the carriage  14  on the base  12  is determined. If the carriage  14  is determined to be in one of the carriage first position and the carriage second position, corresponding to a position proximal to the first tubular string  40  and a position proximal to the second tubular string  42  then, in step  107 , the circuit is activated and the second motive member  25  is energized so that the carriage  14  is moved from the carriage first position to the carriage second position, or vice versa. 
         [0030]    In the event that it is determined in step  103  that the pusher arm is not in the retracted position then, in step  104 , an error message is displayed to alert rig personnel that not all of the conditions for energizing the second motive member  25  exist. In the event that it is determined in step  105  that the carriage is not in the first position or the carriage second position then, in step  106 , an error message is displayed to alert rig personnel that not all of the conditions for energizing the second motive member  25  exist. It will be understood that the apparatus  10  may comprise switches and sensors that generate a signal when, for example, the pusher arm  30  is in the pusher arm retracted position or when, for example, the carriage  14  is in the carriage first position and/or in the carriage second position. It will be understood that such switches and sensors are easily and conveniently secured to the base, the carriage, the first motive member and/or the pusher arm of the apparatus. 
         [0031]    It will be understood that the second motive member  25  can, in one embodiment, be an electrically powered motor, and the conduits  26  and  27  in  FIG. 4  are electrical conductors such as, for example, a pair of wires. In another embodiment, the second motive member  25  can be a hydraulically powered motor, and the conduits  26  and  27  in  FIG. 4  are hydraulic conduits such as, for example, metal tubing. In a preferred embodiment, the second motive member  25  is a pneumatically powered motor, and the conduits  26  and  27  in  FIG. 4  are pneumatic conduits such as, for example, metal tubing. 
         [0032]    It will be understood that the second motive member  25  can provide for movement between the base  12  and the carriage  14  in other ways other than through the use of the threaded shaft  19  coupled to the base  12  and the internally-threaded nut  17  on the carriage  14 , as illustrated in  FIG. 4 . For example, but not by way of limitation,  FIG. 8  illustrates an alternate second motive member  52  that is secured to the carriage  14  and operable to engage a rack  54  including a row of teeth along an edge of the base  12 . The alternate second motive member  52  rotates a gear  53  that engages the rack  54  and, depending on the rotational direction of the gear  53 , the carriage  14  will move along the base  12  in response to the rotation of the gear  53  by the alternate second motive member  52 . It should be noted that, in the embodiment of the apparatus  10  illustrated in  FIGS. 8 and 9 , the alternate second motive member  52  moves with the carriage  14 . To provide continuous power to the alternate second motive member  52 , a coiled power delivery conduit  58  can be used. It will be understood that, in  FIG. 8  for example, if the alternate second motive member  52  is operated to move the carriage  14  on the base  12  from left to right in  FIG. 8 , the conduit  58  will extend so that continuous power is delivered through the conduit  58  to the alternate second motive member  52  on the carriage  14  as it moves. It will be further understood that the alternate second motive member in  FIGS. 8 and 9  may be, in one embodiment, an electric motor and the conduit  58  can be a pair of conductive wires or, in another embodiment, the alternate second motive member  52  can be a hydraulic or pneumatic motor and the conduit can be one of a pair of hydraulic hoses or a pneumatic hose. 
         [0033]    The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components and/or groups, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention. 
         [0034]    The corresponding structures, materials, acts, and equivalents of all means or steps plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but it is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.