Patent Publication Number: US-10329854-B2

Title: Tubular transfer system and method

Description:
BACKGROUND 
     Field 
     Embodiments of the disclosure relate to a tubular transfer system and method for handling tubulars on a rig. 
     Description of the Related Art 
     On an oil and gas rig, one or more stands of tubulars are often made up and stored in an area, or setback, in proximity to the well center of the rig. An offline activity crane having a single joint elevator is used to handle the tubulars within the setback area for offline stand building, while a top drive having a top drive elevator is used to handle the tubulars at the well center. When needed, the tubular stands have to be transferred from the setback area to the well center and back again. However, the tubular stands can only be lifted at the same point by both the single joint elevator and the top drive elevator. Because of this, a derrickman or more are required to manually handle tubulars from the single joint elevator (or from a racking board) and move them to a position where the tubular can be latched by the top drive elevator and back again. This repetitive human interaction at high elevations on the rig puts the derrickman in close proximity to large moving equipment (e.g. the crane and the elevators) and creates a physically exertive and unsafe working condition. 
     Therefore, there exists a need for new and improved tubular transfer systems and methods. 
     SUMMARY 
     In one embodiment, a method of transferring a tubular from a stored location to a well center of an oil and gas rig using a tubular transfer system comprises moving the tubular from the stored location to a position near the tubular transfer system using a single joint elevator of an offline activity crane; actuating a clamp mechanism of the tubular transfer system to engage the tubular and relieve the weight of the tubular from the single joint elevator; extending and raising the clamp mechanism to move the tubular to a position for engagement with a top drive elevator; and automatically releasing the tubular from the clamp mechanism when the tubular is lifted from the clamp mechanism by the top drive elevator. 
     In one embodiment, a method of transferring a tubular from a well center to a stored location of an oil and gas rig using a tubular transfer system comprises moving the tubular from the well center to a position near the tubular transfer system; actuating a clamp mechanism of the tubular transfer system to engage the tubular and relieve the weight of the tubular from the top drive elevator; retracting and lowering the clamp mechanism to move the tubular to a position for engagement with a single joint elevator of an offline activity crane; and automatically releasing the tubular from the clamp mechanism when the tubular is lifted from the clamp mechanism by the single joint elevator. 
     In one embodiment, a tubular transfer system comprises a boom structure having a first frame telescopically coupled to a second frame; a first actuator configured to extend and retract the first frame relative to the second frame; a clamp mechanism coupled to the first frame and configured to grip and lift a tubular; and a second actuator configured to raise and lower the clamp mechanism relative to the first frame. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1G  illustrate a sequence of transferring a tubular from a stored location to a well center using a tubular transfer system, according to one embodiment. 
         FIGS. 2A-2D  illustrate a sequence of transferring a tubular from the well center to the stored location using the tubular transfer system, according to one embodiment. 
     
    
    
     To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one embodiment may be beneficially utilized with other embodiments without specific recitation. 
     DETAILED DESCRIPTION 
     Embodiments of the disclosure relate to a tubular transfer system for handling tubulars on an oil and gas rig. Embodiments of the disclosure relate to a method of transferring tubulars from a stored location to a well center (and back) on the oil and gas rig. The tubular may comprise a single tubular, or may comprise two, three, or more tubulars connected together forming a tubular stand. The stored location may be a racking board and/or an area on the oil and gas rig that is setback from the well center. 
       FIG. 1A  is an isometric view of a tubular transfer system  100  having a clamp mechanism  120  coupled to a boom structure  110 . The boom structure  110  may be coupled to an oil and gas rig by one or more mount brackets  117 . The boom structure  110  may be fixed to the rig or may be movable horizontally in the X-direction and/or vertically in the Z-direction. The tubular transfer system  100  may be located in a setback area that is in proximity to the well center of the rig. 
     The tubular transfer system  100  is positioned below existing diving board(s) of the rig. A platform  130  may be positioned on top of the boom structure  110  to integrate a diving board to the tubular transfer system  100 . A derrickman  150  can work on the platform  130  to help connect and disconnect a single joint elevator  210  of an offline activity crane  200  to and from a tubular  10 . The derrickman  150  may have a controller  155  configured to operate the crane  200  and the tubular transfer system  100 . One or more tubulars  10  may be made up and stored in the setback area near the tubular transfer system  100 . 
     The boom structure  110  has a first frame, referred to herein as an inner frame  112 , that is telescopically coupled to and disposed within a second frame, referred to herein as an outer frame  111 . The inner frame  112  can be extended and retracted relative to the outer frame  111  by a first actuator, referred to herein as a piston/cylinder assembly  115 . 
     The piston/cylinder assembly  115  can extend and retract the inner frame  112  horizontally in the Y-direction out from and into the outer frame  111 . The piston/cylinder assembly  115  is connected at one end to the outer frame  111  and at an opposite end to the inner frame  112 , for example by a rod that is extendable and retractable from the piston/cylinder assembly  115 . Although described herein with respect to the piston/cylinder assembly  115 , the inner frame  112  can be extended and retracted by other types of hydraulic, pneumatic, electric, and/or mechanical actuated assemblies. 
     The clamp mechanism  120  is coupled to the inner frame  112  and is movable along a pair of beams  114  by a second actuator, referred to herein as a cable/pulley assembly  116  (more clearly shown in  FIG. 1F ). The cable/pulley assembly  116  can raise and lower the clamp mechanism  120  along the beams  114 . The cable/pulley assembly  116  is connected at one end to the clamp mechanism  120  and at an opposite end to the inner frame  112 , for example by a rod that is extendable and retractable from another piston/cylinder assembly. Although described herein with respect to the cable/pulley assembly  116 , the clamp mechanism  120  can be raised and lowered by other types of hydraulic, pneumatic, electric, and/or mechanical actuated assemblies. 
     In an alternative embodiment, the clamp mechanism  120  can be coupled to the outer frame  111  instead of the inner frame  112 . The outer frame  111  can be extended and retracted relative to the inner frame  112  by the first actuator. The clamp mechanism  120  can be raised and lowered along the outer frame  111  by the second actuator. 
     The clamp mechanism  120  can grip, lift, and transfer various sizes of tubulars from the stored location to the well center of the rig. The clamp force of the clamp mechanism  120  is a function of the weight of the tubular  10 , which provides a suitable amount of grip without crushing lighter/thinner walled tubulars or under clamping heavier/thicker walled tubulars. The clamp mechanism  120  will not drop or lose grip on the tubular  10  upon loss of power to the rig. 
       FIGS. 1A-1G  illustrate a sequence of transferring the tubular  10  from a stored location to the well center of the rig using the tubular transfer system  100 , according to one embodiment. 
     In  FIG. 1A , the tubular transfer system  100  is in a retracted position and the tubular  10  is in the stored location. The single joint elevator  210  is connected to the upper end of the tubular  10 , such as by the derrickman  150  standing on the platform  130 . The crane  200 , which can be operated by the derrickman  150  via the controller  155 , lifts the tubular  10  so that the weight of the tubular  10  is supported by the single joint elevator  210 . 
     In  FIG. 1B , the crane  200  moves the single joint elevator  210  and the tubular  10  from the stored location to a location in front of the clamp mechanism  120 . The tubular  10  is positioned near a pair of jaws  125  of the clamp mechanism  120 . The weight of the tubular  10  is still supported by the single joint elevator  210 . 
     In  FIG. 1C , the piston/cylinder assembly  115 , which can be operated by the derrickman  150  via the controller  155 , is actuated to extend the inner frame  112  from the outer frame  111  to move the clamp mechanism  120  closer to the tubular  10 . The inner frame  112  moves across one or more rollers  113  that minimize friction between the relative movement of the frames. The clamp mechanism  120  is moved to a position where the tubular  10  is substantially centered between the pair of jaws  125 . The weight of the tubular  10  is still supported by the single joint elevator  210 . 
     In  FIG. 1D , the clamp mechanism  120 , which can be operated by the derrickman  150  via the controller  155 , is actuated to grip and lift the tubular  10 . The clamp mechanism  120  does not need to engage and grip the tubular  10  at the same location (e.g. the upper box section of the tubular  10 ) as the single joint elevator  210 . The clamp mechanism  120  grips and slightly lifts the tubular  10  to relieve the weight of the tubular  10  from the single joint elevator  210 . The clamp mechanism  120  slightly lifts the tubular  10  without assistance from the cable/pulley assembly  116 . In one embodiment, the clamp mechanism  120  may lift the tubular  10  and/or be raised by the cable/pulley assembly  116  to lift the tubular  10  to relieve the weight of the tubular  10  from the single joint elevator  210 . 
     The single joint elevator  210  can then be disconnected from the tubular  10 , such as by the derrickman  150  standing on the platform  130 . The weight of the tubular  10  is now supported by the clamp mechanism  120 . As a safety measure, the derrickman  150  can confirm that the weight of the tubular  10  is supported by the clamp mechanism  120  before disconnecting the single joint elevator  210  by comparing load measurements received from one or more sensors on the crane  200  and the clamp mechanism  120 . 
     In  FIG. 1E , the piston/cylinder assembly  115 , which can be operated by the derrickman  150  via the controller  155 , is actuated to further extend the inner frame  112  from the outer frame  111  to move the clamp mechanism  120  and the tubular  10  closer to the well center. The inner frame  112  may be in a fully extended position from the outer frame  111 . The weight of the tubular  10  is still supported by the clamp mechanism  120 . 
     In  FIG. 1F , the cable/pulley assembly  116 , which can be operated by the derrickman  150  via the controller  155 , is actuated to move the clamp mechanism  120  and the tubular  10  to a position for transfer over to a top drive elevator  310  of a top drive  300 . The cable/pulley assembly raises the clamp mechanism  120  and the tubular  10  up along the beams  114  to the position for engagement by the top drive elevator  310 . The top drive elevator  310  is connected to the upper end of the tubular  10  and raises the tubular  10  to relieve the weight of the tubular  10  from the clamp mechanism  120 . 
     The clamp mechanism  120  is configured to automatically release the tubular  10  upon lifting of the tubular  10  from the pair of jaws  125  by the top drive elevator  310  to prevent any damage that otherwise may be caused to the tubular transfer system  100  by pulling on the tubular  10  while not releasing the tubular  10 . Before being retracted, the pair of jaws  125  can still prevent the tubular  10  from toppling over in the event that the tubular  10  is inadvertently released from the top drive elevator  310 . The weight of the tubular  10  should now be supported by the top drive elevator  310 . 
     In  FIG. 1G , the pair of jaws  125  of the clamp mechanism  120  are retracted from the tubular  10 , and the top drive elevator  310  can move the tubular  10  down-hole at the well center. The weight of the tubular  10  is still supported by the top drive elevator  310 , and the tubular  10  is moved to the well center for use in an oil and gas recovery or drilling operation. The tubular transfer system  100  is moved back to the retracted position as shown in  FIG. 1A  for transfer of another tubular to the well center. 
       FIGS. 2A-2D  illustrate a sequence of transferring the tubular  10  from the well center to the stored location using the tubular transfer system, according to one embodiment. 
     In  FIG. 2A , the tubular  10  is moved from the well center back to a position near the tubular transfer system  100 . The piston/cylinder assembly  115  and the cable/pulley assembly  116 , which can be operated by the derrickman  150  via the controller  155 , are actuated to extend the inner frame  112  and raise the clamp mechanism  120  to a position for engagement of the tubular  10  from the top drive elevator  310 . The clamp mechanism  120  is moved to a position where the tubular  10  is substantially centered between the pair of jaws  125  and actuated to grip and lift the tubular  10 . 
     The clamp mechanism  120  grips and slightly lifts the tubular  10  to relieve the weight of the tubular  10  from the top drive elevator  310 . The clamp mechanism  120  slightly lifts the tubular  10  without assistance from the cable/pulley assembly  116 . In one embodiment, the clamp mechanism  120  may lift the tubular  10  and/or be raised by the cable/pulley assembly  116  to lift the tubular  10  to relieve the weight of the tubular  10  from the top drive elevator  310 . The top drive elevator  310  can then be disconnected from the tubular  10 . The weight of the tubular  10  is now supported by the clamp mechanism  120 . As a safety measure, the derrickman  150  can confirm that the weight of the tubular  10  is supported by the clamp mechanism  120  before the top drive elevator  310  is disconnected by comparing load measurements received from one or more sensors on the clamp mechanism  120 . 
     In  FIG. 2B , the piston/cylinder assembly  115  and the cable/pulley assembly  116  are actuated to retract the inner frame  112  and lower the clamp mechanism  120  to a position for engagement of the tubular  10  by the single joint elevator  210  near the platform  130 . The weight of the tubular  10  is still supported by the clamp mechanism  120 . 
     In  FIG. 2C , the single joint elevator  210  is connected to the upper end of the tubular  10 , such as by the derrickman  150  standing on the platform  130 . The crane  200  lifts the tubular  10  to relieve the weight of the tubular  10  from the clamp mechanism  120 . The clamp mechanism  120  is configured to automatically release the tubular  10  upon lifting of the tubular  10  from the pair of jaws  125  to prevent any damage that otherwise may be caused to the tubular transfer system  100  by pulling on the tubular  10  while not releasing the tubular  10 . 
     As a safety measure, the derrickman  150  can confirm that the weight of the tubular  10  is supported by the single joint elevator  210  before disconnecting the clamp mechanism  120  by comparing load measurements received from one or more sensors on the crane  200  and the clamp mechanism  120 . Before being retracted, the pair of jaws  125  can still prevent the tubular  10  from toppling over in the event that the tubular  10  is inadvertently released from the single joint elevator  210 . The pair of jaws  125  are then retracted from the tubular  10  and the weight of the tubular  10  is now freely supported by the single joint elevator  210 . 
     In  FIG. 2D , the inner frame  112  is retracted into the outer frame  111  away from interference with the tubular  10 . The crane  200  moves the single joint elevator  210  and the tubular  10  back to the stored location. The tubular transfer system  100  is moved back to the extended position as shown in  FIG. 2A  for transfer of another tubular to the stored location. 
     The tubular transfer system  100  may include integrated communication protocols to allow for 2-way communication with anti-collision systems (ACS) and/or zone management systems (ZMS) to ensure interaction with and prevent collision/interference with other tubular handling equipment on the rig, such as the top drive elevator  310 , the offline activity crane  200 , a catwalk, etc. Because the tubular transfer system  100  moves the tubular  10  from the end of the platform  130  over to the well center, the derrickman  150  is no longer required to manually handle the tubular  10  to and from the top drive elevator  310  while engaging or disengaging the single joint elevator  210 , thereby minimizing any potential risk of fall or injury. The tubular transfer system  100  has full control of the tubular  10  once gripped by the clamp mechanism  120  to transfer the tubular  10  from the platform  130  to the well center with no physical maneuvering of the tubular  10  by the derrickman  150 . 
     While the foregoing is directed to embodiments of the disclosure, other and further embodiments of the disclosure thus may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.