Patent Publication Number: US-9903167-B2

Title: Interlock system and method for drilling rig

Description:
BACKGROUND 
     Embodiments of the present disclosure relate generally to the field of drilling and processing of wells. More particularly, present embodiments relate to a system and method for stabilizing a top drive during a drilling process, a casing process, or another type of well processing operation. 
     Top drives are typically utilized in well drilling and maintenance operations, such as operations related to oil and gas exploration. In conventional oil and gas operations, a well is typically drilled to a desired depth with a drill string, which includes drill pipe and a drilling bottom hole assembly (BHA). During a drilling process, the drill string may be supported and hoisted about a drilling rig by a hoisting system for eventual positioning down hole in a well. As the drill string is lowered into the well, a top drive system may rotate the drill string to facilitate drilling. 
     BRIEF DESCRIPTION 
     In accordance with one aspect of the disclosure, a system includes a top drive system including a gripping device configured to support a length of tubular, power slips configured to support a drill string, and an interlock system configured to coordinate operation of the top drive system and the power slips to ensure that at least one of the top drive system and the power slips is supporting weight of the length of tubular and weight of the drill string. 
     Another embodiment includes a system having a controller configured to coordinate operation of a gripping device of a top drive system and power slips of a drilling rig to ensure that at least one of the gripping device and the power slips is engaged with a length of tubular and/or a drill string to support weight of the length of tubular and weight of the drill string. 
     In accordance with another aspect of the disclosure, a method includes measuring a first weight of a length of tubular and/or a drill string supported by a gripping device of a tubular drive system of a drilling rig, measuring a second weight of the length of tubular and/or the drill string supported by power slips of the drilling rig, and coordinating operation of the gripping device and the power slips based on the first and second weights to ensure that at least one of the gripping device and the power slips is supporting the first and second weights. 
    
    
     
       DRAWINGS 
       These and other features, aspects, and advantages of present embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
         FIG. 1  is a schematic of an embodiment of a well being drilled with an interlock system, in accordance with present techniques; 
         FIG. 2  is a schematic of an embodiment of the interlock system, in accordance with present techniques; 
         FIG. 3  is a schematic of an embodiment of a well, illustrating operation of the interlock system, in accordance with present techniques; 
         FIG. 4  is a schematic of an embodiment of a well, illustrating operation of the interlock system, in accordance with present techniques; 
         FIG. 5  is a schematic of an embodiment of a well, illustrating operation of the interlock system, in accordance with present techniques; 
         FIG. 6  is a schematic of an embodiment of a well, illustrating operation of the interlock system, in accordance with present techniques; 
         FIG. 7  is a schematic of an embodiment of a well, illustrating operation of the interlock system, in accordance with present techniques; 
         FIG. 8  is a schematic of an embodiment of a well, illustrating operation of the interlock system, in accordance with present techniques; and 
         FIG. 9  is a schematic of an embodiment of a well, illustrating operation of the interlock system, in accordance with present techniques. 
     
    
    
     DETAILED DESCRIPTION 
     Present embodiments provide an interlock system configured to regulate and coordinate operation of one or more components of a drilling rig during a casing running or tripping operation to ensure that lengths of tubular and/or a drill string are continually supported by a component of the drilling rig. For example, the interlock system may be configured to regulate operation of a gripping device of a top drive system or other tubular drive system, power slips positioned near a rig floor of the drilling rig, or other component of the drilling rig configured to support the weight of tubular or a drill string. Furthermore, the interlock system may be configured to regulate and coordinate operation of the one or more components of the drilling rig based on measured feedback associated with a casing running or tripping operation. For example, the interlock system may include one or more sensors and/or monitoring systems configured to measure forces (e.g., weight) acting on the one or more components of the drilling rig, such as a weight of a length of tubular or a drill string acting on the gripping device or the power slips. Based on the measured feedback, the interlock system may coordinate operation of the gripping device and the power slips to ensure that at least one of the gripping device and the power slips is supporting the weight of the tubular and the drill string. 
     Turning now to the drawings,  FIG. 1  is a schematic of a drilling rig  10  in the process of drilling a well in accordance with present techniques. The drilling rig  10  features an elevated rig floor  12  and a derrick  14  extending above the rig floor  12 . A supply reel  16  supplies drilling line  18  to a crown block  20  and traveling block  22  configured to hoist various types of drilling equipment above the rig floor  12 . The drilling line  18  is secured to a deadline tiedown anchor  24 , and a drawworks  26  regulates the amount of drilling line  18  in use and, consequently, the height of the traveling block  22  at a given moment. Below the rig floor  12 , a drill string  28  extends downward into a wellbore  30  and is held stationary with respect to the rig floor  12  by a rotary table  32  and slips  34  (e.g., power slips). A portion of the drill string  28  extends above the rig floor  12 , forming a stump  36  to which another length of tubular  38  (e.g., a joint of drill pipe) may be added. 
     A tubular drive system  40 , hoisted by the traveling block  22 , positions the tubular  38  above the wellbore  30 . In the illustrated embodiment, the tubular drive system  40  includes a top drive  42 , a gripping device  44 , and a tubular drive monitoring system  46  (e.g., an operating parameter monitoring system) configured to measure forces acting on the tubular drive system  40 , such as torque, weight, and so forth. For example, the tubular drive monitoring system  46  may measure forces acting on the tubular drive system  40  via sensors, such as strain gauges, gyroscopes, pressure sensors, accelerometers, magnetic sensors, optical sensors, or other sensors, which may be communicatively linked or physically integrated with the system  46 . The gripping device  44  of the tubular drive system  40  is engaged with a distal end  48  (box end) of the tubular  38 . The tubular drive system  40 , once coupled with the tubular  38 , may then lower the coupled tubular  38  toward the stump  36  and rotate the tubular  38  such that it connects with the stump  36  and becomes part of the drill string  28 .  FIG. 1  further illustrates the tubular drive system  40  coupled to a torque bushing system  50 . More specifically, the torque bushing system  50  couples the tubular drive system  40  to a torque track  52 . The torque bushing system  50  and the torque track  52  function to counterbalance (e.g., counter react) moments (e.g., overturning and/or rotating moments) acting on the tubular drive system  40  and further stabilize the tubular drive system  40  during a casing running operation or other operation. 
     The drilling rig  10  further includes an interlock system  54 , which is configured to control the various systems and components of the drilling rig  10  that grip, lift, release, and support the tubular  38  and the drill string  28  during a casing running or tripping operation. For example, the interlock system  54  may control operation of the gripping device  44  and the power slips  34  based on measured feedback (e.g., from the tubular drive monitoring system  46  and other sensors) to ensure that the tubular and the drill string  28  are adequately gripped and supported by the gripping device  44  and/or the power slips  34  during a casing running operation. In this manner, the interlock system  54  may reduce and/or eliminate incidents where lengths of tubular  38  and/or the drill string  28  are unsupported. 
     In the illustrated embodiment, the interlock system  54  includes a controller  56  having one or more microprocessors  58  and a memory  60 . For example, the controller  56  may be an automation controller, which may include a programmable logic controller (PLC). The memory  60  is a non-transitory (not merely a signal), computer-readable media, which may include executable instructions that may be executed by the microprocessor  56 . The controller  56  receives feedback from the tubular drive monitoring system  46  and/or other sensors that detect measured feedback associated with operation of the drilling rig  10 . For example, the controller  56  may receive feedback from the tubular drive system  46  and/or other sensors via wired or wireless transmission. Based on the measured feedback, the controller  56  regulates operation of the gripping device  44  and the power slips  34 . In particular, the operation of the gripping device  44  and the power slips  34  may be coordinated by the controller  56  to ensure that at least one of the gripping device  44  and/or the power slips  34  is adequately gripping and supporting the weight of the tubular  38  and/or the drill string  28  (e.g., during a casing running operation). In certain embodiments, the controller  56  may also be configured to regulate operation of other components of the drilling rig  10 , such as the top drive  42 . The coordinated operation of the gripping device  44  and the power slips  34  is discussed in further detail below. 
     It should be noted that the illustration of  FIG. 1  is intentionally simplified to focus on the interlock system  54  of the drilling rig  10 , which is described in greater detail below. Many other components and tools may be employed during the various periods of formation and preparation of the well. Similarly, as will be appreciated by those skilled in the art, the orientation and environment of the well may vary widely depending upon the location and situation of the formations of interest. For example, rather than a generally vertical bore, the well, in practice, may include one or more deviations, including angled and horizontal runs. Similarly, while shown as a surface (land-based) operation, the well may be formed in water of various depths, in which case the topside equipment may include an anchored or floating platform. 
       FIG. 2  is a schematic representation of the interlock system  54  for the drilling rig  10 . As mentioned above, the interlock system  54  include the controller  56 , which is configured to regulate and coordinate operation of the gripping device  44  and the power slips  34  (e.g., based on measured operating parameter feedback) to ensure that the tubular  38  and the drill string  28  are supported by the gripping device  44 , the power slips  34 , or both. The controller  56  may receive measured feedback via wired or wireless transmission from the tubular drive monitoring system  46 , sensors  100  of the power slips  34 , or other components of the drilling rig  10 . The measured feedback provided by the tubular drive monitoring system  46  and the sensors  100  of the power slips  34  is described in further detail below. Furthermore, it will be appreciated that each of the types of measured feedback described below may be used in any combination with one another to coordinate operation of the gripping device  44  and the power slips  34 . Additionally, other types of feedback may also be used in coordinating operation of the gripping device  44  and the power slips  34 . 
     In the illustrated embodiment, the controller  56  is configured to control operation of the power slips  34  and the gripping device  44  by applying control signals to pressure switches  102  of the interlock system  54 . In particular, the interlock system  54  includes a first pressure switch  104  for actuating the power slips  34  and a second pressure switch  106  for actuating the gripping device  44 . In certain embodiments, the interlock system  54  may also include relays  108  for amplifying the control signals of the controller  56  before the control signals are sent to the pressure switches  102 . The pressure switches  102  may also enable the controller  56  to detect a gripping force of the gripping device  44  and/or the power slips  34  on the tubular  38  and/or the drill string  28 . In certain embodiments, the first pressure switch  104  may detect a gripping force of the power slips  34  on the drill string  28  and the second pressure switch  106  may detect a gripping force of the gripping device  44  on the length of tubular  38 . Additionally, in certain embodiments, the controller  56  may receive feedback from the first pressure switch  104  indicative of the gripping force of the power slips  34  on the drill string and from the second power switch  106  indicative of the gripping force of the gripping device  44  on the length of tubular  38 . As a result, the controller  56  may be configured to detect that the gripping device  44  and/or the power slips  34  are gripping the tubular  38  and/or drill string  28  with sufficient force to ensure that the tubular  38  and/or the drill string  28  do not slip or drop. Additionally, the pressure switches  102  may be configured to block disengagement (e.g., “lockout”) the gripping device  44  and/or the power slips  34  until sufficient pressure is applied to the other of the gripping device  44  and/or the power slips  34  to support the tubular  38  and/or the drill string  28 . For example, the second pressure switch  106  may be configured to block disengagement of the power slips  34  until sufficient pressure is applied to the gripping device  44  for gripping and supporting the tubular  38  and/or the drill string  28 . Similarly, the first pressure switch  104  may be configured to block disengagement of the gripping device  44  until sufficient pressure is applied to the power slips  34  for gripping and supporting the tubular  38  and/or the drill string  28 . 
     The interlock system  54  may also use other measured feedback to coordinate operation of the gripping device  44  and the power slips  34 . For example, the tubular drive monitoring system  46  may be configured to detect a gripping distance (e.g., a radial gripping or closing distance) that the gripping device  44  has traveled (e.g., radially inward) to grip the tubular  38 . In certain embodiments, the gripping distance traveled by the gripping device  44  may be measured using sensors, such as magnetic sensors, Hall-effect sensors, optical sensors, or other suitable types of sensors, which may be coupled to the gripping device  44 . The sensors  100  of the power slips  34  may similarly calculate a gripping distance (e.g., radially gripping or closing distance) that the power slips  34  have traveled to grip the drill string  28 . As will be appreciated, the measured gripping distance traveled by the gripping device  44  and/or power slips  34  may be used to further calculate a gripping force of the power slips  34  and/or gripping device  44 . Additionally, the measured gripping distances may be used to verify that the gripping device  44  and/or power slips  34  have properly gripped the tubular  38  and/or drill string  28  instead of another component, such as a collar. 
     The interlock system  54  further includes mechanical overrides  110 , which may be used to enable releasing or disengagement of the power slips  34  and/or gripping device  44  at a desired time. In other words, the mechanical overrides  110  interrupt control of the power slips  34  and/or gripping device  44  by the controller  56  to enable immediate or instant disengagement of the power slips  34  and/or gripping device  44 . For example, a first mechanical override  112  may be actuated to enable disengagement of the power slips  34 , and a second mechanical override  114  may be actuated to enable disengagement of the gripping device  44 . In certain embodiments, the interlock system  54  may include one mechanical override  110  to enable disengagement of both the power slips  34  and the gripping device  44  at the same time. In one embodiment, the mechanical overrides  110  may be operated with a key that is turned by a user or operator to actuate the mechanical override  110  and disengage the power slips  34  or the gripping device  44 . 
     As will be appreciated, the interlock system  54  shown in  FIG. 2  is simplified to focus on the coordinated control of the components of the drilling rig  10  during a casing running or tripping operation. As such, it will be appreciated that the interlock system  54  may include other components to facilitate operation of the drilling rig  10  components, such as the gripping device  44  and the power slips  34 . For example, the interlock system  54  may include additional valves, electronics, switches, sensors, or other components to enable operation of the gripping device and the power slips  34 . 
       FIGS. 3-9  are schematic representations of an embodiment of the drilling rig  10  and interlock system  54 , illustrating operation of the interlock system  54  during a casing running operation. However, it will be appreciated that the interlock system  54  may also be similarly used during a casing tripping operation. 
     In  FIG. 3 , the tubular drive system  40  has just picked up the tubular  38  for connection to the drill string  28 . As such, the gripping device  44  is in a locked and engaged position. In particular, the controller  56  is controlling the gripping device  44  to ensure that the gripping device  44  is adequately gripping the tubular  38  to support the weight of the tubular  38 . Similarly, the power slips  34  are in a locked and engaged position, and the controller  56  is controlling the power slips  34  to ensure that the power slips  34  are adequately gripping the drill string  28  to support the weight of the drill string  28 . For example, the controller  56  may include an algorithm (e.g., stored in the memory  60 ) configured to calculate a desired gripping force as a function of a weight supported by the gripping device  44  and/or power slips  34 , a distance (e.g., radial gripping or closing distance) that the gripping device  44  and/or power slips have moved to grip the tubular  38  or drill string  28 , or other measured parameter. 
     As shown in  FIG. 4  and indicated by arrow  120 , the tubular drive system  40  lowers the tubular  38  toward the stump  38  of the drill string  28  for connection of the tubular  38  to the drill string  28 . Additionally, as indicated by arrow  122 , the top drive  42  rotates the tubular  38  as the tubular  38  is lowered to the stump  36  of the drill string  28  by the tubular drive system  40 . In the embodiment shown in  FIG. 4 , the controller  56  continues to operate the gripping device  44  and the power slips  34  such that the gripping device  44  and the power slips  34  are both in the locked and engaged position. In this manner, the tubular  38  and the drill string  28  both remain gripped and supported. Furthermore, while the tubular  38  is connected to the drill pipe  38 , the controller  56  continues to regulate the gripping device  44  and power slips  34  such that both are in the engaged and locked position. 
       FIG. 5  illustrates an embodiment of the drilling rig  10  and interlock system  54  once the tubular  38  is connected to the stump  36  of the drill string  28 . In other words, in  FIG. 5 , the tubular  38  is a part of the drill string  28 . Once the tubular  38  is connected to the drill string  28 , the top drive  42  may lift the entire drill string  28  upwards, as indicated by arrow  130 . While the top drive  42  is lifting the drill string  28 , the tubular drive monitoring system  46  may measure a weight or downward force acting on the top drive  42  and/or the gripping device  44 . For example, the tubular drive monitoring system  46  may include strain gauges, accelerometers, or other sensors configured to measure a force acting on the top drive  42  and/or the gripping device  44  (e.g., a weight of the combined tubular  38  and drill string  28 ). Once the tubular drive monitoring system  46  detects that the top drive  42  and/or the gripping device  44  are supporting the weight of the drill string  28 , the controller  56  may then send control signals to the power slips  34  to disengage and unlock the power slips, as indicated by arrows  140  of  FIG. 6 . For example, the controller  56  may be configured to send control signals to the power slips  34  to disengage and unlock the power slips  34  once the tubular drive monitoring system  46  has detected a threshold force (e.g., a preset number of pounds) acting on the top drive  42  and/or the gripping device  44 . 
     After the power slips  34  are unlocked and disengaged, the tubular drive system  40 , which is supporting the entire weight of the drill string  28  via the engagement of the gripping device  44  with the tubular  38 /drill string  28 , will lower the drill string  28  further into the wellbore  30 , as indicated by arrow  150  of  FIG. 7 . Once the drill string  28  is positioned at the proper height (e.g., relative to the power slips  34  and/or rig floor  12 ), the controller  56  may send control signals to the power slips  34  to lock, grip, and engage with the drill string  28 , as indicated by arrows  160  of  FIG. 8 . After the power slips  34  grip the drill string  28 , the weight of the drill string  28  supported by the gripping device  44  may be reduced. Once the tubular drive monitoring system  46  detects that the tubular drive system  40  (e.g., the gripping device  44 ) is supporting zero or negative weight (e.g., zero weight of the drill string  28  and/or an upward force acting on the tubular drive system  40  instead of a downward force), the controller  56  may send control signals to disengage and unlock the gripping system  44 . In other words, the controller  56  may not send control signals to the gripping system  44  to unlock and disengage until the tubular drive monitoring system  46  detects that the gripping device  44  and/or top drive  42  are not supporting any weight or are not supporting weight above a certain threshold (e.g., a preset number of pounds). Thereafter, the tubular drive system  40  may travel up the torque track  52 , as indicated by arrow  162 , and prepare to lift another section of tubular  38  for coupling to the drill string  28 . When the tubular drive system  40  is raised, the controller  56  may send control signals to the gripping device  44  to engage and grip another tubular  38 , as shown in  FIG. 9 , and the process described above may be repeated to add another length of tubular  38  to the drill string  28 . 
     The interlock system  54  and the drilling rig  10  described above may further include various modifications. For example, in certain embodiments, the gripping device  44  and/or the power slips  34  may have a default “closed” or “engaged” position (e.g., a gripping position), and the controller  56  may be configured to apply signals to “open” or “disengage” the gripping device  44  or the power slips  34  to release the tubular  38  or the drill string  28 . In such an embodiment, the manual overrides  110  may be configured to release or open the gripping device  44  or the power slips  34 . 
     Furthermore, in certain embodiments, the controller  56  may be programmed or configured for hysteresis control. For example, in circumstances where a measured weight supported by the gripping device  44  and/or the power slips  34  exceeds a predetermined threshold, the gripping device  44  and/or the power slips  34  may be actuated in a closed or “locked” position (e.g., automatically or by the controller  56 ). Additionally, the controller  56  may be configured to disable or disallow disengagement of the gripping device  44  and/or power slips  34  until the measured weight supported by the gripping device  44  and/or the power slips  34  falls below the predetermined threshold by a predetermined amount. In certain embodiments, the controller  56  may be further configured to disable or disallow disengagement of the gripping device  44  and/or power slips  34  until the measured weight supported by the gripping device  44  and/or the power slips  34  falls below the predetermined threshold by the predetermined amount for a set amount of time. 
     As discussed in detail above, present embodiments provide the interlock system  54 , which is configured to regulate and coordinate operation of one or more components of the drilling rig  10  during a casing running or tripping operation to ensure that lengths of tubular  38  and/or the drill string  28  of the drilling rig  10  are continually supported by the gripping device  44  and/or the power slips  34  of the drilling rig  10 . In particular, the interlock system  54  is configured to regulate and coordinate operation of the gripping device  44  and the power slips  34  based on measured feedback associated with a casing running or tripping operation. For example, the interlock system  54  may utilize feedback from the tubular drive monitoring system  46  and/or sensors  100  of the power slips  34 , which are configured to measure forces (e.g., weight) acting on the gripping device  44  and the power slips  44  due to the tubular  38  and/or the drill string  28 . Based on the measured feedback, the interlock system  54  may coordinate operation of the gripping device  44  and the power slips  34  to ensure that at least one of the gripping device  44  and the power slips  34  is supporting the weight of the tubular  38  and/or the drill string  28 . 
     While the present disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and tables and have been described in detail herein. However, it should be understood that the embodiments are not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims. Further, although individual embodiments are discussed herein, the disclosure is intended to cover all combinations of these embodiments.