Abstract:
A method of running a tubular string into or out of a wellbore includes the steps of moving the tubular string relative to the wellbore and making up or breaking a connection between a tubular joint and the tubular string when the tubular string is being moved relative to the wellbore.

Description:
RELATED APPLICATIONS 
   This application claims the benefit of U.S. patent application Ser. No. 11/147,525 filed Jun. 8, 2005. 

   FIELD 
   This invention relates, generally, to methods and systems for attaching single joints of casing, tubing and other oilfield tubulars together, while lowering the string of tubulars into a wellbore, and more particularly, to methods and systems using a top drive apparatus for running oilfield tubulars into wellbores. 
   BACKGROUND 
   With the evolution of top drive assemblies used in running oilfield tubulars into wellbores, recently developed top drives have been equipped with adaptors to grip casing, drill pipe, production tubing and other tubulars for lifting, lowering and rotating the tubular string in the wellbores, and have also included apparatus for torquing such joints together. Such prior art systems can generally be described as attaching a tubular joint into the tubular string, as the tubular string is being held by a spider at the drill floor level and using tongs on the drill floor to screw the joint into the held tubular string, or alternatively, as attaching a tubular joint into the tubular string while the string is being held in the spider at the drill floor and using the top drive to screw the tubular joint into the held string, or alternatively, as attaching a double or triple stand of tubulars using either of the above methods where the double or triple stands are assembled at a different location. 
   SUMMARY 
   An example of an embodiment of a method for making and/or breaking connections between a tubular joint and a tubular string that is disposed in a wellbore includes the steps of aligning a frame with the wellbore; supporting a tubular joint; raising the tubular joint relative to the frame; lifting the tubular joint and the frame relative to the tubular string; connecting the tubular joint to the tubular string; and lowering the tubular string into the wellbore. 
   Another embodiment of a method of making or breaking a connection between a tubular joint and a tubular string that is disposed in a wellbore includes the steps of providing an elongate frame having a pipe manipulator and a pipe handler; suspending a tubular string in the wellbore from a spider disposed at the floor; movably supporting the frame over the wellbore; supporting a tubular joint with the pipe manipulator; raising the tubular joint relative to the frame via the pipe manipulator; lifting the tubular joint and the frame relative to the tubular string; releasing the spider from the tubular string and supporting the tubular string with the pipe handler; connecting the tubular joint to the tubular string; and lowering the frame toward the floor and the tubular string into the wellbore. 
   An embodiment of a method of running a tubular string into or out of a wellbore includes the steps of moving the tubular string relative to the wellbore and making up or breaking a connection between a tubular joint and the tubular string when the tubular string is being moved relative to the wellbore. 
   An embodiment of an apparatus for making and/or breaking a connection between a tubular joint and tubular string that is disposed in a wellbore includes a frame positioned over and vertically moveable relative to the wellbore, the frame having a lower end oriented toward the wellbore and a top end; a manipulator disposed on the frame, wherein the manipulator moves the tubular joint vertically relative to the frame; and a pipe handler carried on the frame selectively supporting the tubular string. 
   The foregoing has outlined some of the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other features and aspects of the present invention will be best understood with reference to the following detailed description of a specific embodiment of the invention, when read in conjunction with the accompanying drawings, wherein: 
       FIG. 1A  is an elevated view of the system according to the invention, illustrating a first joint of tubular being in the initial phase of being picked up while a second joint of tubular is in the final stage of being made up with the tubular string; 
       FIG. 1B  is an elevated view of the system according to the invention illustrating in greater detail the frame illustrated in  FIG. 1A , and the first joint of tubular being moved up to the upper portion of the frame; 
       FIG. 1C  is a second elevated view of the frame illustrated in  FIG. 1B ; 
       FIG. 2  is an elevated view of the system according to the invention, illustrating the first joint illustrated in  FIG. 1A , while the frame of the system according to the invention is being lifted to grab the tubular string with the elevator; 
       FIG. 3  is an elevated view of the system according to the invention, illustrating a fill up and a circulation tool inserted into the hoisted first joint of tubular; 
       FIG. 4  is an elevated view of the system according to the invention, illustrating the tubular string being gripped by the elevator while the first tubular joint is positioned within the frame; and 
       FIG. 5  is an elevated view of the system according to the invention, illustrating the tubular string being lifted while the first tubular joint is being stabbed into the tubular string. 
   

   DETAILED DESCRIPTION 
   Refer now to the drawings wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views. 
   Referring now to  FIG. 1A , there is illustrated, in an elevated view, the system according to the invention, in which a string  10  of oilfield tubulars, for example, steel casing, is being run into an earth wellbore  12 . The conventional, flush-mounted spider  14 , can be used to grip the string  10  when needed.  FIG. 1A  also illustrates a conventional top drive assembly  16 , a mud tool  18 , which may consist of a fill-up and circulation tool, such as is described in U.S. Pat. No. 6,595,288, assigned to Frank&#39;s International, Inc., a stabber  20 , such as is described in U.S. Pat. No. 6,921,386, assigned to Frank&#39;s Casing Crew and Rental Tools, Inc., a conventional spinner  26 , such as illustrated in U.S. Pat. No. 6,634,259, assigned to Frank&#39;s International, Inc., a conventional pipe tong  21 , an elevator  30 , such as is described in U.S. Pat. No. 6,568,479, assigned to Frank&#39;s Casing Crew and Rental Tools, Inc., and a conventional backup tong  32 . A frame  34  used with the invention, is illustrated in greater detail in  FIG. 1B . 
   Referring further to  FIGS. 1A and 1B , the top drive rails  40  are situated on the oilfield derrick  51  (illustrated to allow the frame  34  to move up and down the rail or rails  40  using a plurality of arms  50  and a plurality of rollers  52 , which cause such movement of the frame  34  up or down to be vertically aligned with the vertical alignment of the rail or rails  40 . 
   A single joint manipulator arm  60  is pivotable connected to a first side member  62  of the frame  34  using a rolling or sliding member  64  ( FIG. 1B ) to allow a single joint  66  of oilfield tubular to be raised from the horizontal mode, illustrated in  FIG. 1A , to the vertical mode illustrated in  FIG. 1B . Alternatively, the gripping head  67  can rotate about its center, which coincides with the center of the joint  66 , to enable the tubular joint  66  to move from the horizontal ( FIG. 1A ) to the vertical ( FIG. 1B ). By causing the rolling or sliding member  64  to move upwardly, either by its own motor (not illustrated) or by any conventional hoisting apparatus, the single joint  66  is moved upwardly towards the mud tool  18 . 
   In the operation of the system illustrated in  FIG. 1A , the load of the tubular string  10  is first transferred to the spider  14  after the joint  70  has been added to the string  10  and the mud tool  18  has finished its filling operation. At this point in time, the elevator  30  has opened its slips, the stabber  20  has opened, the guide  24  has opened, the tong  21  jaws are retracted, the backup  32  jaws have been opened and the manipulator arm  60  has gripped the next joint  66  to be installed in the string  10 . 
   The frame  34  is then lifted and the stabber  20  is pivoted up and the mud tool  18  is extracted from the string  10 . As the mud tool  18  clears the upper end of the string  10 , the mud tool  18  is positioned outboard of the frame  34  in a path directly in line with the upwardly moving joint  66  as illustrated in  FIG. 1B . 
   Referring now to  FIG. 2 , the frame  34  is positioned such that the upper end of the tubular string  10  is located to allow the stabbing guide to be installed properly. At this point in time, the joint  66  is ready to be moved laterally and thus be located inside the frame  34 . If desired, as illustrated in  FIG. 1B , the mud tool  18  can be installed within the top of the joint  66  before the joint  66  is moved within the frame  34 . 
   Referring now to  FIGS. 1C and 4 , the slips on the elevator  30  are set and the joint  66  is moved laterally to be within the frame  34 . For such lateral movement to occur, the frame  34  has to have a vertical window  71  at least slightly longer than the length of the joint  66 , and wide enough to allow the manipulator arm to rotate and move the joint  66  to a location within the frame  34 . 
   Referring now to  FIG. 1C , there is illustrated a view of the frame  34  oriented 90 degrees from the view illustrated in  FIG. 1B . In  FIG. 1C , the frame  34  includes the side member  62 , also illustrated in  FIG. 1B , and a second side member  63 . The frame  34 , as illustrated, has four side members  62 ,  63 ,  65  and a fourth side member which is hidden in the view of  FIG. 1C , but lies behind said member  63  just as side member  65  lies behind side member  62 . 
   It should be appreciated that support members can be used between the side members  62  and  65 , and between the side members  63  and other, invisible side member, but the window  71  illustrated in  FIG. 1C  between the side members  62  and  63  must be left open, or as a minimum, be easily opened to allow the next joint, such as the joint  66  to be moved laterally to be within the frame  34 . 
   In theory, at least, instead of moving the next joint  66  laterally into the frame  34 , the joint  66  could be raised high enough to be moved in over the top end of the frame  34  and then into the interior of the frame  34 , or like that of a derrick, with the top of the derrick closed off and the joint  66  moved in through the bottom of the frame  34 . Once the joint  66  is within the interior of the frame  34 , the operation continues essentially as described herein based upon the joint being moved laterally through the window  71 . The window  71  between the side members  62  and  63  is long enough, as measured between the cross members  68  and  69  to accommodate the length of the joint  66 , and wide enough to allow the manipulator arm  60  to rotate and move the joint  66  within the frame  34 . 
   The stabber guide  22  closes on joint  70 , and guide  24 , stabber  20  are closed around the joint  66 . The driller then moves the frame  34  upward slightly as shown in  FIG. 5  and releases the slips in the spider  14 . Immediately thereafter, the manipulator arm  60  lowers the joint  66  into the stabbing guide  22  and into the upper end of the tubular string  10 . As the next step the stabbing guide will open, the manipulator arm  60  will release, the backup tong will close and the spinner  26  grips and rotates the joint  66  while the driller lowers the string  10 , the spinner  26  stops and manipulator arm  60  will lower, the mud tool  18  will activate and the tong  21  finishes the make-up of the joint  66  to the string  10 . The process is then repeated to attach the next joint to the string  10 . 
   Sometimes it is necessary to rotate and reciprocate the string while circulating fluids in order to facilitate installation of the string into the well bore. With the mud tool installed and the elevator gripped on the string, it is apparent that one can reciprocate and circulate. In order to rotate, the frame  34  must be connected to the top drive&#39;s quill and a swivel added to supply hydraulic, air, and electrical services. 
   It should be appreciated that the system according to the present invention in its preferred embodiment, comprises a frame, a manipulator arm, a mud tool, a stabber, a guide, a spinner, a tong, a stabbing guide, a backup tong, an elevator, and optionally comprises a pipe doper and a mud bucket. It should also be appreciated that the frame supplies the mounts for most, if not all of the other equipment. The frame can be attached to the top drive, if available, or to a traveling block. To attach the frame to the traveling block, either a hook adaptor or bails must be used. To attach the frame to a top drive, it can be screwed to a drive quill. When using either the top drive or traveling block there are two methods of attaching the bails. The first method entails connecting the bails to the top of the frame  34  and the elevator  30  to the bottom of the frame  34 , in which the load path of the string is through the frame. The second method connects the bails directly to the elevator and the frame, while attached to the bails, is not in the direct load path of the string. When using a top drive, the frame may be connected by bails, to support the axial load, and to the quill, to provide rotation, at the same time. The frame is also attached to the top drive rails to provide a reaction when lifting the next joint to be installed and for rotational stability. 
   The manipulator arm mounts on the side of the frame and is capable of traversing the entire length of the frame  34 . It uses a gripping head to latch onto the joint and can articulate the joint between the horizontal and the vertical positions. 
   The mud tool is preferably a conventional tool. It will be connected to the mud supply via the top drive quill or swivel. It is mounted on the top of the frame and can be moved perpendicular to the length of the frame to facilitate installation. 
   The stabber, guide, spinner, tong, stabbing guide, backup, elevator, pipe doper and mud bucket are all conventional equipment. The stabber and guide will be located closer to the middle of the frame while the rest of the equipment is located on or near to the bottom of the frame. 
   It should be appreciated that the present invention is not limited to running steel casing into earth wellbores, but can also be used to run a string of other oilfield tubulars, such as, drill pipe, production tubing and the like. Moreover, while the preferred embodiment has designated particular types of equipment to be used in the process, those skilled in this art will immediately recognize that other types of conventional elevators, stabbers, stabber guides, guides, tongs, spinners, backup tongs, mud tools, manipulator arms and top drive assemblies, or their respective equivalents, can also be used in practicing the invention. 
   It should also be appreciated that the frame for practicing the invention can take other forms, for example, such that the frame, which is used in alternative embodiments, if desired, be either partially or totally enclosed. It should also be appreciated that all of the equipment used herein can be attached to the bails without using a frame such as frame  34 . 
   Although the preferred embodiment of the invention contemplates apparatus and methods for adding a single joint of tubular into a string of tubulars, while the string is being moved into and/or towards a wellbore, the invention also contemplates the use of the invention to add two or more joints which have already been made-up, into a string of tubulars as the string is being lowered into and/or towards a wellbore. 
   In understanding the overall function and operation of the system, reference should be made to the drawings,  FIGS. 1A ,  1 B,  1 C and  2 - 5 . As illustrated in  FIGS. 1A ,  1 B and  1 C, the string load has been transferred to the spider, the joint above the elevator has just been connected to the string, the mud tool has finished its filling operation, the elevator has opened its slips, the stabber has opened, the guide has opened, the tong jaws are retracted, the backup opened, and the manipulator arm has gripped the next joint to be installed. As the frame is lifted, the stabber is pivoted up and the mud tool gets extracted from the string. As the mud tool clears the end of the string it is positioned outboard of the frame in a path directly in line with the upward moving joint held by manipulator arm, which is shown in  FIG. 2 . In  FIG. 3 , the frame positioned such that the end of the string is located where the stabbing guide can be installed properly. Also, the joint is ready to be located inside the frame with the mud tool installed. In  FIG. 4 , the slips on the elevator are set and the joint moved inside the frame. The stabbing guide, guide, and stabber are closed around the pipe. The driller will move the frame upward slightly, shown in  FIG. 5 , and release the slips in the spider. At the same time, the manipulator arm will lower the joint into the stabbing guide and the end of the string. Next the stabbing guide will open, the manipulator arm will release, the backup will close, and the spinner will grip and turn the pipe. As the driller lowers the string, the spinner will stop and release, the manipulator arm will lower, the mud tool will activate, and the tong will finish the makeup. The process can now be repeated to attach the next joint. 
   In short, the invention contemplates that the joint of tubular being added to the string of tubulars will be aligned with the string, and will be stabbed, threaded and torqued into the string of tubulars while the string is being lowered into and/or towards the wellbore. With this process, by the time the elevator reaches the rig floor, or is in proximity to the floor, all of the contemplated operations will have been completed and the system will begin again the sequence described herein. Moreover, to pull a tubular string from the well bore, the sequence is reversed.