Patent Description:
The present disclosure relates to drill pipe handling operations. In particular, the present disclosure relates to devices, systems, and methods for tripping drill pipe into and/or out of a well. More particularly, the present disclosure relates to devices, systems, and methods for tripping drill pipe using one or more robots.

Work of the presently named inventor, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

Drilling of wells involves tripping of the drill string, during which drill pipes are lowered into (tripping in) or pulled out of (tripping out) a well. Tripping may typically occur in order to change all or a portion of the bottom hole assembly, such as to change a drill bit. Where drill pipe is tripped into a well, stands or lengths of drill pipe may be retrieved one-by-one from a storage position in a setback area of the drill rig and connected end-to-end to lengthen the drill string in the well. Where drill pipe is tripped out of a well, stands or lengths of drill pipe may be disconnected from the drill string and may be positioned in the setback area.

Tripping has conventionally been performed with human operators. In particular, while an elevator or top drive may be used to carry the load of a stand of drill pipe during trip in and trip out operations, human operators may typically maneuver the drill pipe stands around the drill floor, such as between the well center and the setback area. For example, a first human operator may be positioned on the drill floor, at or near the well, to maneuver a lower end of drill pipe stands as they are tripped into or out of the well, while a second human operator may be positioned on or above the racking board to maneuver an upper end of drill pipe stands as the stands are moved between the well and the setback area. Operators often use ropes and/or other tools to maneuver the drill pipe stands on or above the drill floor. Such work is laborintensive and can be dangerous. Moreover, trip in and trip out operations may be limited by the speed at which the human operators can maneuver the stands between well center and the setback area.

<CIT> discloses systems and methods for automated drill pipe handling operations, such as trip in, trip out, and stand building operations. A pipe handling system is disclosed with a lifting system for handling a load of a pipe stand, a pipe handling robot configured for engaging with the pipe stand and manipulating a position of the pipe stand, and a feedback device configured to provide information about a condition of the pipe stand, the lifting system, or the pipe handling robot. <CIT> discloses a racking arm assembly adapted to be mounted on a drill floor of a drilling rig including a lift arm assembly having a first arm that is movably coupled to a vertical support column. <CIT> discloses a drilling rig comprising a dual path derrick, racking board robotic arm and drill floor robotic arm. <CIT> discloses a drill rig having a drill pipe standbuilding system.

The following presents a simplified summary of one or more embodiments of the present disclosure in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments, nor delineate the scope of any or all embodiments.

According to a first aspect of the invention, there is provided a pipe handling system as set out in claim <NUM>. Some optional features are set out in the dependent claims.

According to a second aspect of the invention, there is provided a method of tripping pipe as set out in claim <NUM>.

While multiple embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the various embodiments of the present disclosure are capable of modifications in various obvious aspects, all without departing from the scope of the present disclosure.

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the various embodiments of the present disclosure, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying Figures, in which:.

The present disclosure relates to systems and methods for automated drill pipe handling operations. In particular, a pipe handling system may include a lifting system and one or more pipe handling robots and may be configured for performing trip in, trip out, stand building, and/or other drill pipe or drill collar handling operations. Each pipe handling robot may be configured to engage with and manipulate an end of a pipe stand. The robots and the lifting system may operate together to move stands of drill pipe between a setback area of the drill floor and well center for trip in and trip out operations. Each robot may operate to manipulate an end of the pipe stand without the need for a derrick hand or other human operator to physically handle the pipes. In this way, systems and methods of the present disclosure may provide for safer, more precise, and more efficient pipe handling operations as compared with conventional systems and methods.

One or more embodiments described herein may include robot layouts that are particularly well adapted for retrofit of existing rigs or for new rigs having similar space constraints as existing rigs. That is, the particular robot layouts described may be well suited to accommodate space constraints on a drill floor of a drill rig while managing to also maintain the ability to load and/or unload the setback area of drill pipe stands to support tripping operations.

Turning now to <FIG>, an example drilling rig <NUM> is shown. The drilling rig <NUM> may be configured for onshore oil drilling. Other drilling rigs may be configured for other drilling operations, including offshore drilling. The drilling rig <NUM> may be configured to be a mobile or stationary rig. The drilling rig <NUM> may generally have a drill floor <NUM>, a mast <NUM>, and a pipe handling system.

The drill floor <NUM> may include a platform positioned above or over a well and supported by a substructure <NUM>. As shown, the drill floor <NUM> may be configured to provide a working space for drilling operations and/or a storage space for equipment and drill pipe. The drill floor <NUM> may have an opening arranged at or near well center for accessing the well during drilling operations. The drill floor <NUM> may additionally include a setback area <NUM> configured for receiving and/or storing lengths of drill pipe. For example, lengths of drill pipe may be stored as single stands, or may be combined into double stands, triple stands, quadruple stands, or other sized stands <NUM>, and positioned on end in the setback area <NUM>.

The mast <NUM> may extend from the drill floor with a height suitable for accommodating and/or building single, double, triple, quadruple, or other sized drill pipe stands. For example, the mast <NUM> may have a height of up to <NUM> feet (<NUM>), <NUM> feet (<NUM>), <NUM> feet (<NUM>), <NUM> feet (<NUM>), or more. The mast <NUM> may have any other suitable height or height range. A racking board <NUM> may extend from the mast <NUM>. The racking board <NUM> may be configured for managing the top portion of pipe stands to maintain or store stands of pipe in a generally organized manner. Pipe stands <NUM> may be stored with a first or lower end arranged on the drill floor <NUM> in the setback area <NUM>, and a second end or upper end extending in or through a racking board <NUM>. The racking board <NUM> may extend laterally from the mast <NUM> at height of between approximately <NUM> feet (<NUM>) and approximately <NUM> feet (<NUM>) from a ground or pad surface, or between approximately <NUM> feet (<NUM>) and approximately <NUM> feet (<NUM>), or between approximately <NUM> feet (<NUM>) and approximately <NUM> feet (<NUM>). The racking <NUM> board may extend from the mast <NUM> at any other suitable height.

<FIG> shows an overhead view of a racking board <NUM>. The racking board <NUM> may include a plurality of fingers <NUM>, which may be arranged in a parallel configuration, configured to receive stands <NUM> of pipe therebetween so as to maintain the pipe stands in an upright, on-end configuration. The fingers <NUM> of the racking board <NUM> may operate to maintain stands of pipe in organized rows or columns. In particular, the racking board <NUM> may be configured such that a plurality of pipe stands <NUM> may be arranged in a row or column between each pair of racking board fingers <NUM>. Pipe stands <NUM> may be added to the racking board <NUM> as they are built. The racking board <NUM> may store the pipe stands <NUM> until they are added to a drill string during a trip in operation. Moreover, during a trip out operation, pipe stands <NUM> may be removed from the drill string and added to the racking board <NUM> until they are either tripped back into the well or disassembled. The racking board <NUM> may additionally or alternatively be configured to store pipe stands <NUM> during other operations as well.

As may be appreciated, the pipe stands may be placed in the setback area such that the pipe stands lean outwardly so as to be reasonably stable when released. The pipe stands may be placed in the setback area in multiple stacks, groups, or sets of pipe stands and the sets of pipe stands may be separated by an alley (see e.g., <FIG>). Due to the outward lean of the pipe stands, the bottom or drill floor end of the sets of pipe stands may be arranged slightly closer together than the top or racking board end of the sets of pipe stands. As shown for example in <FIG> and <FIG>, the spacing between sets of pipe stands at or near the drill floor may be approximately <NUM> feet (<NUM>), while the spacing between the sets of pipe stands at or near the racking board may be approximately <NUM> feet (<NUM>).

With reference back to <FIG>, the drilling rig may additionally include a pipe handling system. The pipe handling system may be configured for manipulating and moving lengths or stands of pipe, such as for trip in and trip out operations, stand building, and/or other operations. The pipe handling system may include a lifting system, a pipe coupling mechanism <NUM> (see <FIG>), and one or more robots or robotic handlers <NUM>.

The lifting system may be configured for supporting the load of a pipe stand <NUM> and/or drill string during a trip in, trip out, and/or other pipe handling operation. For example, the lifting system may be configured to support a pipe stand load as robots <NUM> or operators maneuver the pipe stand <NUM> between a racking board <NUM> and a well center. The lifting system may include a drill line or cable extending from a draw works. The drill line may be reeved between a crown block, arranged at or ear a top of the mast <NUM>, and a traveling block <NUM>, arranged beneath the crown block and within the mast. The drill line may be a main or primary line that may be otherwise configured for use during drilling operations using a top drive, for example. A pipe elevator <NUM> configured for coupling to a drill pipe may extend from the traveling block <NUM>. In The pipe elevator <NUM> may be incorporated into a top drive, which may be coupled to the traveling block <NUM> via a hook dolly or the pipe elevator <NUM> may be more directly coupled to the traveling block <NUM> via a hook dolly. In either case, the traveling block <NUM> may be configured to raise and lower the pipe elevator <NUM>, so as to raise and lower a length or stand of pipe <NUM>, between the drill floor <NUM> and the crown block. The traveling block <NUM> may include one or more sheaves <NUM> through which the main drill line <NUM> may be reeved.

The pipe handling system may include one or more mechanisms for coupling and/or decoupling lengths of drill pipe. In particular and with reference to <FIG>, one or more iron roughnecks <NUM> may be arranged on the drill floor <NUM>. For example, an iron roughneck <NUM> may be arranged on the drill floor <NUM> near well center, and may be configured to reach drill pipe stands <NUM> above or on the drill floor. The iron roughneck may be configured to couple stands <NUM> of drill pipe together to form the drill string, such as during a trip in operation, and/or may be configured to decouple stands of drill pipe from the drill string, such as during a trip out operation. The iron roughneck <NUM> may additionally operate to couple lengths of drill pipe together to form a pipe stand <NUM>, and/or to decouple lengths of pipe to deconstruct a stand. The iron roughneck <NUM> may generally have static and torque wrenches configured to screw together pipe lengths with threaded ends. The pipe handling system may include additional or alternative pipe coupling devices or mechanisms.

The robots may be configured to manipulate drill pipe lengths or stands <NUM>, drill collar, and/or other piping. The robots <NUM> may each be programmable for carrying out particular sequences of operations. A handling system <NUM> may have one, two, three, four, or any other suitable number of robots <NUM>. For example, a pipe handling system of the present disclosure may include a first robot 116a arranged on or near the drill floor <NUM>, and a second robot or pair of robots 116b arranged on or near the racking board <NUM>. Two robots <NUM> may be generally aligned with one another. For example, the racking board robot 116b may be centrally arranged on a racking board <NUM>, and the drill floor robot 116a may be positioned in a setback area <NUM> of the drill floor <NUM> beneath and generally aligned with the racking board robot. However, as shown in several examples throughout this disclosure, robots <NUM> may be positioned differently.

<FIG> shows a robot 116a arranged on the drill floor <NUM>. The drill floor robot 116a may be configured for handling a first end of pipe stands <NUM>, the first end being an end positioned closest the drill floor <NUM> when the pipe stands are arranged within the racking board <NUM>. The first end of the pipe stand <NUM> may be referred to as a lower end. <FIG> show a robot 116b arranged on the racking board <NUM>. The racking board robot 116b may be configured for handling a second end of pipe stands <NUM>, the second end being an end positioned closest the racking board <NUM> when the pipe stands are arranged within the racking board. The second end of the pipe stand <NUM> may be referred to as an upper end. As shown in <FIG> and <FIG>, each of the robots <NUM> may include a base portion <NUM>, which may be arranged on a track <NUM>.

The robots <NUM> may additionally each include a shoulder portion <NUM>, an articulated arm <NUM>, a wrist portion <NUM>, and an end effector <NUM>. Each robot <NUM> may have a reach capacity of between approximately <NUM> feet (<NUM>) and approximately <NUM> feet (<NUM>), or between approximately <NUM> feet (<NUM>) and approximately <NUM> feet (<NUM>), or between approximately <NUM> feet (<NUM>) and approximately <NUM> feet (<NUM>). Each robot <NUM> may have any other suitable reach capacity. Moreover, each robot <NUM> of the present disclosure may have a load capacity at full reach of between approximately <NUM> pounds (<NUM>. 89kN) and approximately <NUM> pounds (<NUM>. 0kN), or between approximately <NUM> pounds (<NUM>. 3kN) and approximately <NUM> pounds (<NUM>. 1kN), or between approximately <NUM> pounds (<NUM>. 8kN) and approximately <NUM> pounds (<NUM>. Each robot <NUM> may have any other suitable load capacity at full reach.

The base portion <NUM> of each robot <NUM> may be configured to couple the robot to the drill floor <NUM>, racking board <NUM>, or another suitable location on the drilling rig <NUM>. The base may be configured to be stationary and may be secured to the drill floor. The base portion <NUM> may additionally be configured to facilitate movement of the robot <NUM> on the drill floor <NUM>, racking board <NUM>, or other surface of the drill rig <NUM>. For example, the base portion <NUM> may be configured to engage with a track <NUM> or rail, as shown in <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, or, for example, a boom as shown in <FIG>. In the case of a rail or track, the base portion <NUM> may have skids or rollers configured for sliding engagement with the track <NUM>. The track <NUM> may provide a first axis of movement. The track <NUM> may provide a second axis of movement, such that the base portion <NUM> may move in both an X-direction and a Y-direction. The track <NUM> may be positioned so as to be centrally arranged with respect to stored pipe stands <NUM>. For example, where pipe stands <NUM> are stored on two sides of a racking board <NUM> and/or setback area <NUM>, the track <NUM> may be centrally aligned between the two sides, such that the robot may readily access pipe stands stored on both sides of the racking board and/or setback area. In particular, the track <NUM> may be arranged between a driller's side and an off-driller's side of the setback area <NUM>, and may provide an axis of movement extending between the well center and an edge of the drill floor. A shown in <FIG>, the track may be arranged outboard of the setback area and, for example, a track may be provided on each side of the setback area. The track <NUM> may have a length of between approximately <NUM> foot (<NUM>) and approximately <NUM> feet (<NUM>), or between approximately <NUM> feet (<NUM>) and approximately <NUM> feet (<NUM>), or between approximately <NUM> feet (<NUM>) and approximately <NUM> feet (<NUM>). The track <NUM> may have a length of approximately <NUM> feet (<NUM>). The track <NUM> of either or both robots <NUM> may have a length equal to or slightly larger or slightly smaller than a length of the racking board <NUM>. The robots <NUM> may have tracks <NUM> of equal length and configuration, while an upper robot 116b may have a track with a different length and/or different configuration than that of a lower robot. The tracks may extend well beyond the length of the setback area and racking board such that the drill floor robots may be positioned beyond the setback area in a direction toward well center and reach back toward the setback area to retrieve pipe stands, in one or more front rows of the setback area, for example.

The base portion <NUM> may have other movement means for moving the robot <NUM> along a drill floor <NUM>, racking board <NUM>, or other surface. For example, the base portion <NUM> may have wheels or treads or may be configured with a walking mechanism. Other movement means are contemplated as well. In embodiments, as shown in <FIG>, the base portion <NUM> is be mounted on a boom, for example.

Each robot <NUM> may have a shoulder portion <NUM> extending from the base portion <NUM>. The shoulder portion may couple to the base portion via a joint <NUM>, which may be a swivel joint. The swivel joint <NUM> may allow the shoulder portion <NUM> to twist or rotate about a central axis with respect to the base portion <NUM>. The shoulder portion <NUM> may be configured to twist up to <NUM> degrees, up to <NUM> degrees, up to <NUM> degrees, up to <NUM> degrees, up to <NUM> degrees, or up to a different suitable degree of rotation. The shoulder portion <NUM> may couple to the base portion <NUM> with a different joint, or the shoulder may couple to the base portion without a joint. The shoulder portion <NUM> may extend generally upward from the base portion <NUM>, and may extend upward at an angle, such that a longitudinal axis of the shoulder portion may be offset from a longitudinal axis of the base portion by approximately <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> degrees, or any other suitable degree of offset. The shoulder portion <NUM> may have a length of between approximately <NUM> inches (<NUM>) and approximately <NUM> inches (<NUM>), or between approximately <NUM> inches (<NUM>) and approximately <NUM> inches (<NUM>), or between approximately <NUM> inches (<NUM>) and approximately <NUM> inches (<NUM>).

The articulated arm <NUM> may extend from the shoulder portion <NUM>. In particular, where the shoulder portion <NUM> couples at a first, or proximal, end to the base portion <NUM>, the articulated arm <NUM> may extend from a second, or distal, end of the shoulder portion. A joint or elbow <NUM>, which may be a pitch joint, may be arranged between the articulated arm <NUM> and the shoulder portion <NUM>. The pitch joint <NUM> may allow the articulated arm <NUM> to pivot with respect to the shoulder portion <NUM> about an axis extending lateral to the shoulder portion and articulated arm. The pitch joint <NUM> may allow the articulated arm <NUM> to pivot within a range of up to <NUM> degrees, up to <NUM> degrees, up to <NUM> degrees, up to <NUM> degrees, up to <NUM> degrees, or up to any other suitable degree of rotation. The articulated arm <NUM> may couple to the shoulder portion <NUM> via a different joint or without a jointed connection. The articulated arm may have a length of between approximately <NUM> inches (<NUM>) and approximately <NUM> inches (<NUM>), or between approximately <NUM> inches (<NUM>) and approximately <NUM> inches (<NUM>), or between approximately <NUM> inches (<NUM>) and approximately <NUM> inches (<NUM>).

The wrist portion <NUM> may extend from the articulated arm <NUM>. For example, where the articulated arm <NUM> couples at a first, or proximal, end to the shoulder portion <NUM>, the wrist <NUM> may extend from a second, or distal, end of the articulated arm. A joint <NUM> may be arranged between the wrist portion <NUM> and the articulated arm <NUM> and may provide for pivotable or rotational movement of the wrist with respect to the articulated arm about one or more axes. The joint <NUM> may be or include a pitch joint allowing for pivotable movement about a first lateral axis extending lateral to the articulated arm <NUM> and wrist <NUM>, a yaw joint allowing for pivotable movement about a second lateral axis perpendicular to the first lateral axis, and/or a roll joint allowing for pivotable or rotational movement about an axis extending longitudinally through the wrist portion. The wrist portion <NUM> may have pivotable or rotational movement about each axis within a range of up to <NUM> degrees, up to <NUM> degrees, up to <NUM> degrees, up to <NUM> degrees, up to <NUM> degrees, or up to any other suitable degree of rotation. The wrist portion <NUM> may couple to the articulated arm <NUM> via a different joint or without a jointed connection. The wrist <NUM> may be configured to provide a mechanical interface or mounting point for coupling an end effector <NUM> to the robot <NUM>. A joint <NUM>, such as a pitch, yaw, and/or roll joint, may allow for pivotable movement of the end effector with respect to the wrist portion.

The end effector <NUM> may extend from the wrist portion <NUM> and may be configured to provide an operational or tooling hand for various operations performed by the robot <NUM>. For example the end effector <NUM> may include a movable claw or gripper configured for grasping objects. <FIG> shows a close-up view of an end effector <NUM>. <FIG> show additional view of the end effector <NUM>. The end effector <NUM> may be configured for handling lengths or stands of drill pipe, drill collar, and/or other piping. As shown in <FIG>, the end effector <NUM> may have a first finger <NUM>, which may be a fixed or stationary finger, and a second finger <NUM>, which may be a movable finger. The movable finger <NUM> may have a hinged connection to the stationary finger <NUM>. The movable finger <NUM> may have a hinged connection to a bracket <NUM> of the end effector. An actuator <NUM>, such as a hydraulic cylinder, lead screw mechanism, ball screw mechanism, or other actuator may be configured to pivot the movable finger <NUM> about its hinged connection.

The fingers <NUM>, <NUM> may each have a curved shape with an inner contour sized and configured to receive a pipe stand. Inner contours of the two fingers <NUM>, <NUM> may have a same radius of curvature for receiving a same pipe size or range of pipe sizes. The two fingers <NUM>, <NUM> may be arranged such that their inner contours curve toward one another to form a closed or substantially closed loop. The movable finger <NUM> may be configured to pivot between an open configuration and a closed configuration. In an open configuration, as shown in <FIG>, the movable finger <NUM> may pivot away from the fixed finger <NUM> such that a pipe stand <NUM> may be received between the two fingers. In a closed configuration, the fingers <NUM>, <NUM> may be configured to form a closed loop or partially closed loop, so as to close around an outer wall of a pipe stand <NUM>.

The fingers <NUM>, <NUM> may be sized and shaped to receive a particular pipe diameter or a particular range of pipe diameters. The end effector <NUM> may have a coating on one or more surfaces to facilitate handling operations. For example, the end effector <NUM> may have a low-friction coating arranged on an inner contour surface of the movable finger and/or fixed finger. A low-friction coating may include wearable fluoro-plastic or another relatively low-friction metallic alloy having a static coefficient of friction against pipe steel of less than <NUM>, for example. Other relatively low-friction coatings or materials may be used as well. Such a low-friction coating may facilitate sliding engagement of the end effector with a pipe, for example. In this way, a pipe section may be free to rotate or pivot while engaged by the end effector. The end effector <NUM> may have a high-friction coating or surface to facilitate gripping operations. Other coatings may be used as well.

The end effector <NUM> may be configured to engage with one pipe stand <NUM> at a time without disturbing, or substantially without disturbing, adjacent or nearby pipe stands. For example, the movable finger <NUM> may have a thickness or width configured to slide between a pair of pipe stands <NUM> stored in the racking board <NUM> so as to close around a single pipe stand without disturbing an adjacent pipe stand. <FIG> illustrate the end effector <NUM> sleeving around a pipe stand <NUM>. As shown in <FIG>, the end effector <NUM> may approach the pipe stand <NUM> with its movable finger <NUM> in an open configuration. With the movable finger <NUM> in an open configuration, the robot <NUM> may position the fixed finger <NUM> around the pipe stand <NUM>, and may then close the movable finger around the pipe stand, as shown in <FIG>. The movable finger <NUM> may slide between the pipe stand <NUM> and an adjacent pipe stand. In this way, it is to be appreciated that the end effector <NUM> may also be configured to position a pipe stand <NUM> on the setback area <NUM> and/or within the racking board <NUM> without disturbing, or substantially without disturbing, other pipe stands stored nearby.

One or more robots of the present disclosure may have a different end effector or tooling end. The mechanical interface between the end effector and the wrist portion may allow the end effector to be readily removed by an operator. For example, the mechanical interface may include a threaded connection, clamped connection, a ball and plunger mechanism, and/or any other suitable connection or mechanism allowing for the end effector to be disconnected from the wrist portion on demand. In this way, an operator may remove and replace the end effector as needed.

The end effector <NUM> may have one or more sensors or feedback devices. For example, a proximity sensor or other electromagnetic sensor may be arranged on or about the claw for detecting a presence of a pipe or other object positioned within the claw. Additionally or alternatively, a contact switch or other position sensor may be arranged on or about the claw for detecting an open or closed position of the movable finger <NUM>. Each robot <NUM> may have other sensors and/or feedback devices, such torque feedback devices, proximity sensors, position sensors, and/or other devices or sensors configured to indicate other movements or conditions.

It is to be appreciated that each robot <NUM> may have a plurality of movable components and/or a plurality of movement axes with respect to each movable component. Each movable component and/or each axis of movement may be independently controllable and may be configured for coordinate movement with another robot or system. One or more components or axes of movement may be actively controlled during a pipe handling operation. That is, a controller may be configured to actively control a position of the end effector <NUM>, wrist portion <NUM>, articulated arm <NUM>, and/or other components of the robot(s). One or both end robot end effectors <NUM> may be actively controlled during a pipe handling operation. In particular, a position and angle of the end effector <NUM> at joint <NUM> may be controlled to maintain a vector extending perpendicularly between the end effector fingers in parallel or near-parallel alignment with the pipe stand. This may help ensure that the end effector <NUM> can smoothly grab onto and release the pipe stand. Additionally, this may help to reduce excess torsion on the robots themselves.

One or more components or axes of movement of the robot(s) may be permitted to experience free movement. For example, the end effector <NUM> of a robot <NUM> may be permitted to pivot or rotate freely at joint <NUM> with respect to the wrist <NUM>. In this way, movement at the end effector / wrist joint <NUM> may freely respond to a position of the articulated arm <NUM> and wrist <NUM>, a position and angle of a pipe stand <NUM> engaged by the end effector <NUM>, and/or other factors. In particular, to accommodate tilting of the pipe stand <NUM>, the robot <NUM> may be configured or programmed to minimize torque applied by the stand while it is engaged by the end effector <NUM>. This may be accomplished, for example, by relaxing (i.e., not powering) an actuator controlling position of the joint <NUM>.

The pipe handling system may have one or more controllers, each configured for controlling one or more components of the pipe handling system. For example, each of the lifting system, iron roughneck, drill floor robot, and racking board robot may have a controller controlling operations thereof. Each controller may be in wired or wireless communication with one or more associated components of the handling system. For example, a controller may be associated with at least one robot <NUM> and may be encoded with instructions for controlling a position of the robot on the track <NUM>, a position of the shoulder portion <NUM>, a position of the articulated arm <NUM>, a position of the wrist <NUM>, a position of the end effector <NUM>, and/or a position of the movable finger <NUM> or other movable component(s) of the end effector. The controller may additionally be configured to receive feedback from one or more feedback devices or sensors. The controller may be configured to respond to received feedback or sensor information by, for example, making one or more position adjustments of the robot <NUM>.

With respect to particular methods of operation, a pipe handling system of the present disclosure, or components thereof, may be configured to operate as a coordinated system. For example, two robots, such as an upper robot and a lower robot, may operate together to manipulate a single pipe stand, with the upper robot manipulating an upper end of the pipe stand and the lower robot manipulating a lower end of the pipe stand. Movements of the two robots may be coordinated such that the two robots may operate as a team. The two robots may additionally operate in conjunction with operation of a lifting system to handle the load of the pipe stand and to raise/lower the pipe stand as needed to facilitate operations. An iron roughneck may additionally be operated in conjunction with the robots and/or lifting system to perform coordinated operations. This coordination of the various components of a pipe handling system <NUM> of the present disclosure may be appreciated with particular reference to <FIG> and the following discussion.

Several robot configurations are shown, for example, in <FIG>, <FIG>, and <FIG>. Uniquely, in all of these configurations, the drill floor robots may have their bases supported from a location outside of the setback area. That is, the setback area may include a plan view area on the drill floor and the bases of the robots may be supported from a location that is outside the plan view envelope defined by the setback area. For example, <FIG>, <FIG>, and <FIG> show drill floor robots 416a having one or more stationary bases <NUM> mounted in front of the setback area <NUM>. <FIG> shows a drill floor robot 516a with a base <NUM> mounted on a boom <NUM> and, while the robot 516a may swing across the setback area <NUM>, nonetheless, its base <NUM> is supported from a location outside of the setback area <NUM> via the boom. <FIG> shows robots 616a arranged on rails on the outboard side of the setback area <NUM>. Depending on space constraints on the drill floor <NUM>, arranging a robot 616a within the setback area <NUM> and between the drillers's side stack of pipe stands and the off-driller's side stack of pipe stands may be difficult or even unfeasible. <FIG> address this problem with different solutions.

As shown in <FIG>, <FIG>, and <FIG>, a pair of drill floor robots 416a may be provided. The pair of drill floor robots 416a may operate with the racking board robot 416b to assist with tripping operations. As shown, and given the space constraints relating to the size of the setback area <NUM> and its position relative to well center, each robot of the pair of robots may be arranged in a substantially stationary position relatively close to the front of a respective side of the setback area <NUM> and between the setback area and well center. As shown in <FIG> and <FIG>, the base <NUM> of each robot 416a may be arranged to substantially abut a boundary line <NUM> extending directly from and parallel to the outboard edge of its respective side of the setback area <NUM>. One of the robots 416a may be arranged on a track to move in and out of the working area, for example. That is, the robot 416a arranged adj acent the iron rough neck may be arranged on a track and adapted to articulate toward and away from the working area.

As discussed in more detail below, tripping operations with this arrangement of robots 416a may involve the robots reaching across the aisle between the driller's side and off-driller's side of the setback area <NUM> and retrieving or delivering pipe stands from or to the opposing setback area. This may be particularly true for pipe stands that may be too close to the associated robot for it to reach the pipe stand. Accordingly, the robots may be sized and designed to reach/handle the front pipe stands in the stack of pipe stands across the aisle and reach/handle the rear most pipe stands in the adjacent stack of pipe stands. For example, the robot on the driller's side of well center may be configured to reach/handle the front pipe stands in the offdriller's side stack of pipe stands and reach/handle pipe stands in the driller's side stack of pipe stands that are further away from well center. The opposite, for example, may be true of the off-driller's side robot.

Referring now to <FIG>, a drill floor robot 516a may be mounted on a boom <NUM>. That is, as shown, a rotating boom <NUM> may be positioned outside of the footprint of the setback area <NUM>. The boom <NUM> may be a substantially rigid and horizontally extending structure. The boom <NUM> may extend from a rotating turntable <NUM> at one end <NUM> to a free end <NUM> opposite the turntable <NUM>. The boom <NUM> may be a cantilevering structure having lattice work or other framing to support a robot at its free end. As shown, a drill floor robot 516a may be arranged at the free end <NUM>. As such, the boom <NUM> may provide for repositioning of the base <NUM> of the robot 516a and, thus, create a larger area within the reach of the robot. As shown, the base <NUM> of the robot 516a may travel along an arc defined by the distance between the turntable support <NUM> of the boom <NUM> and the position of the robot 516a on the boom <NUM>. The arc may begin outside the setback area <NUM> and may extend into and across the setback area <NUM> to a position at or near the center of the setback area <NUM>. The arc may extend to a position that is substantially centered across the setback area <NUM> and in line with well center and also approximately <NUM>/<NUM> of the distance from the front of the setback area <NUM> to the back of the setback area <NUM> as shown, for example, in <FIG>. A telescoping boom structure may be provided to add further versatility to the robot position. The range of motion of the boom may include a full <NUM> degrees or <NUM> degrees, or <NUM> degrees, for example. As shown in <FIG>, the range of motion of the boom <NUM> may be limited during tripping operations depending on how many pipe stands are present in the setback area <NUM> and where the pipes stands are located. A range of motion of about <NUM> degrees may be sufficient to trip all of the pipe in the setback area into the well.

With reference now to <FIG>, a pair of drill floor robots 616a are shown. Each of the robots <NUM> are arranged on a rail system <NUM> on a respective outboard side of the setback area <NUM>. The rail system <NUM> may include one rail, a pair of rails, or another number of rails adapted to guide the location of the robot 616a as it moves along the setback area <NUM>. The line of motion of the rail system <NUM> (e.g., the orientation of the rails) may be generally parallel to a line extending from well center and bisecting or substantially bisecting the setback area <NUM>. Each robot 616a may be mounted directly on the rail or rails or a skid, trolley, car, or other moveable base may be provided for supporting the robot 616a. The range of motion of the base <NUM> of the robot 616a may include a substantially linear distance extending from the drill floor edge, along the setback area <NUM> and inward toward well center beyond the setback area. For example, the rail or range of motion may extend <NUM>-<NUM> feet (<NUM>-<NUM>) beyond the front of the setback area <NUM> or approximately <NUM>-<NUM> feet (<NUM>-<NUM>), or approximately <NUM>-<NUM> feet (<NUM>-<NUM>). The distance beyond the setback area <NUM> may be selected based on space constraints of the drill floor <NUM> in addition to the size of the robot 616a such that the robot may turn back toward the front row of pipe stands in its adjacent stack of pipe stands and access those pipe stands.

In any of the above-mentioned arrangements of drill floor robots, a racking board robot may also be provided. With reference to <FIG> and <FIG>, a racking board robot 414b may be suspended from a bottom side of a racking board by a rail extending along the racking board and/or racking board walkway. The racking board robot 414b may be moveably secured to the rail with a trolley, for example, allowing the racking board robot to articulate back and forth toward and away from well center. The racking board robot may be an inverted version of the drill floor robot 416a and may include a base <NUM> secured to the trolley and the other articulating aspects of the robot <NUM> may be arranged below the base.

In use, a pipe handling system of the present disclosure may facilitate drill pipe, casing, and/or drill collar handling operations, such as trip in and trip out operations, stand building operations, and/or other pipe handling operations on a drilling rig.

For example, <FIG> illustrate various stages of tripping operations for tripping pipe into a well using a boom mounted robot 516a and a racking board robot. As shown, the method may include tripping drill collar into the well. This operation may include tipping the top of a selected stand of drill collar toward the top drive or other lifting system with the racking board robot. To do so, the racking board robot may articulate toward the front of the setback area on its rail system and may turn its end effector to grasp a drill collar in the front row of the setback area on the side of the setback area closest to the boom system for the drill floor robot. That is, clearing the drill collar from the boom side of the setback area before the other side may begin to allow more range of motion for the boom and, as such, more range of motion for the drill floor robot. The stands may be unloaded from their respective rows by selecting the stands closest to the midline between the setback areas and working outward due to the slots between the fingers in the racking board opening inward toward the racking board robot.

As shown in <FIG>, as the racking board robot manipulates a top end of the drill collar, the drill floor robot may rotate about its secured position on the tip of the boom and secure the plan view position of the base of the drill collar. The top drive system and/or its elevators may grasp the drill collar and lift the drill collar off of the drill floor. The drill floor robot 516a may control the swing of the bottom of the drill collar and guide it toward well center as shown in <FIG>. The top drive and iron roughneck may be used to secure the stand to the drill string and drive or lower the collar into the well. Slips in the drill floor may be used to secure the top end of the drill collar when it reaches the drill floor and the top drive may release the drill string and return to an upper position above the racking board to retrieve an additional stand. This process may be repeated for the front row of drill collar on the boom side of the set back area as shown in <FIG>. The process may then be performed for the drill collar on the other side of the set back area as shown in <FIG>. It is noted that as the drill floor robot reaches to the far side of the setback area, the boom supporting the robot may pivot toward the setback area to increase the reach of the robot. The swing of the boom may be limited by the pipe stands remaining in the boom side of the setback area.

With the drill collar added to the drill string and extending downhole, the tripping operation may turn to adding lengths of drill pipe to the drill string. Like the drill collar, the method may include starting with a row of drill pipe on the boom side of the setback area <NUM> by retrieving the pipe stands from an inside position toward an outside position. However, nothing limits the process to retrieving one row and then turning to the opposite side of the setback area since all of the drill pipes are the substantially the same. Accordingly, and as shown in <FIG>, several rows of drill pipe stands from the boom side of the setback area may be retrieved before beginning to retrieve pipe stands from the other side of the setback area. This approach may be advantageous to free up the range of motion of the boom as shown in, for example, <FIG>. With the boom range of motion more free, the process may continue by retrieving drill pipe stands from the other side of the setback area beginning with the front row and each row may be unloaded from the side closest to the midline of the setback area and working outward. This process is shown in FGIS. <NUM>-<NUM>. As shown, the drill pipe in the boom side of the setback area may again begin to inhibit the range of motion of the boom for purposes of reaching the drill pipe stands on the opposite side of the setback area and, as such, the method may involve retrieving additional drill pipe from the boom side of the setback area as shown in <FIG>. Additional drill pipe may then be retrieved from the opposite side of the setback area as shown in <FIG> and the final stands of drill pipe may be retrieved as shown in <FIG>.

In another example of tripping operations using strategically placed drill floor robots, <FIG> show a process for tripping drill pipe into a well using drill floor robots 616a arranged on respective outboard sides of the setback area <NUM>.

As with the approach using a boom mounted robot 516a, the process may begin by retrieving drill collar from a front row of the setback <NUM> area starting from the inboard side of the stack and working toward the outboard side as shown in <FIG> and then turning to the other side of the setback area as shown in <FIG>. As with the above-described method, each retrieval of the drill collar or pipe stand, as the case may be, may involve moving a top end of the collar/stand toward a top drive, securing a bottom end of the collar/stand with a drill floor robot, lifting the collar/stand to free up the bottom end, and guiding the bottom end to well center using the drill floor robot. The collar/stand may be secured to the drill string with using the top drive and an iron roughneck and the drill string may be lowered into the well until the top of the string approaches the drill floor. The top of the string may be secured to the drill floor with slips allowing the top drive to release the drill string and return to a location above the racking board to retrieve an additional collar/pipe stand.

The two drill floor robots may each unload a row from the setback area and the robots may alternate unloading corresponding rows as shown in <FIG> for the first side of the setback area and then <FIG> the second side. The process may continue row by row throughout the depth of the setback area as shown in <FIG>. Both drill floor robots may be activated and may alternate pipe for pipe rather than row for row to speed up tripping operations. However, while one robot is handling pipe, the other robot may change out its end effector and may handle pipe doping operations or mud bucket operations. Still other uses for the drill floor robot may be provided when not handling pipe.

While <FIG> have described tripping operations relating to particular robot arrangements, the following trip out and trip in descriptions apply to all of the above-described operations and are provided here to supplement these more specific discussions.

<FIG> illustrates a flow diagram of a trip out operation performable using a pipe handling system according to one or more embodiments. As described above, a trip out operation may include disconnecting pipe stands from a drill string. A trip out operation may be performed to replace or change out a drill bit or other downhole components, for example. A trip out operation may also be performed after drilling is completed in a well. There may be other reasons to perform a trip out operation as well. The method <NUM>, or portions thereof, may be encoded on one or more controllers as computer executable instructions. The method <NUM>, or portions thereof, may be performable by an operator such as a human operator controlling components of the pipe handling system. The method <NUM> may include the steps of using a lifting system, raising the drill string to expose a pipe stand <NUM>; positioning slips around the drill string and loosening the pipe stand from the drill string with an iron roughneck <NUM>; causing a first robot to engage with a first end of the pipe stand <NUM>; decoupling the pipe stand from the drill string <NUM>; using the first robot, position the first end of the pipe stand in a setback area <NUM>; using the lifting system, lowering the pipe stand to the drill floor <NUM>; causing a second robot to engage a second end of the pipe stand <NUM>; disengaging the lifting system from the pipe stand <NUM>; using the second robot, positioning the second end of the pipe stand in a racking board <NUM>; lower the lifting system and reengage with the drill string <NUM>; and causing the first and second robots to release the pipe stand <NUM>.

As described above, the lifting system may be or include an elevator coupled to a traveling block, a lifting hook, a main line, an auxiliary line, an auxiliary lifting arm or claw, and/or any other suitable lifting or hoisting mechanism. Different components of the lifting system, or different lifting systems, may be used for different lifting operations throughout the method or other methods described herein. Raising the drill string (<NUM>) may include raising a pipe elevator, or another suitable lifting apparatus, coupled to the drill string. The lifting system may raise the drill string far enough out of the well to expose above the drill floor a first pipe stand, or length of pipe, to be disconnected from the drill string. With the pipe stand exposed, slips may be placed around the drill string (<NUM>) below the pipe stand to maintain a position of the drill string with respect to the drill floor and thus prevent the drill string from falling back into the well. The slips may generally be wedged between an outer diameter of the drill string and an inner diameter of an opening in the drill floor. The slips may be placed manually by an operator or a robot may be used to position the slips or another suitable mechanism for holding a position of the drill string may be used.

With the pipe stand exposed, a first robot, which may be a lower robot positioned on or near the drill floor, may be directed to engage with a first end of the pipe stand (<NUM>). In the case of multiple robots at the drill floor, the first robot may be either one of these multiple robots. The first end of the pipe stand may be an end of the stand located nearest the drill floor and coupled to the remainder of the drill string. The first end of the pipe stand may be referred to herein as a lower end. To engage with the pipe stand, the drill floor robot may be directed to move, on its track or other moving mechanism, toward well center. The articulated arm may be used to reach toward the pipe stand. The end effector of the lower robot 416a may be controlled to grasp the lower end of the pipe stand. In particular, the end effector may be controlled to open or extend the movable finger, position the pipe stand between the movable finger and the fixed finger, and close or retract the movable finger. Decoupling the exposed pipe stand from the remainder of the drill string (<NUM>) may include directing an iron roughneck to disconnect the pipe stand. An iron roughneck <NUM> arranged on the drill floor <NUM> may be used to decouple the drill exposed pipe stand from the drill string. A robot or one or more operators may disconnect the pipe stand from the drill string. It is to be appreciated that with the pipe stand disconnected from the drill string, the pipe elevator or other lifting system may still be supporting the weight of the pipe stand.

With the pipe stand disconnected from the drill string, the first robot may move to position the first end of the pipe stand in the setback area of the drill floor, beneath the racking board (<NUM>). In particular, the first robot may move along its track or other moving apparatus away from the well center to a setback area of the drill floor. The articulated arm may move to position the lower end of the pipe stand beneath the racking board <NUM>. The first robot may position the lower end of the pipe stand aligned with or near a particular racking location where the pipe stand is to be stored in the racking board. The lower robot 416a may position the lower end of the pipe stand beneath the racking board. The lifting system may be used to lower the pipe stand to the drill floor (<NUM>), so as to transfer the load of the pipe to the drill floor. The lower end of the pipe stand may be lowered to a particular location in the setback area, as positioned by the lower robot, where the pipe stand will be stored with respect to the racking board. The elevator <NUM> may swing laterally away from well center to move the top of the pipe stand closer to the racking board and helping to facilitate placement of the bottom of the pipe stand in the set back area.

Additionally, the second robot, which may be an upper robot arranged on or near the racking board, may be directed to engage a second end of the pipe stand (<NUM>). The second end of the pipe stand may be an end opposing the first end, arranged furthest from the drill floor and/or nearest the racking board. The second end of the pipe stand may be referred to herein as the upper end. To engage with the pipe stand, the upper robot may be directed to move, on its track or other moving mechanism, toward well center. The articulated arm may be used to reach toward the pipe stand. The upper robot 416b may be arranged on the racking board and positioned to engage an upper end of the pipe stand. The end effector of the upper robot 416b may be controlled to grasp the upper end of the pipe stand. In particular, the end effector may be controlled to open or extend the movable finger, position the pipe stand between the movable finger and the fixed finger, and close or retract the movable finger. Moreover, the wrist and/or other aspects of the second robot may be manipulated to position the end effector in a manner that accommodates the angle of the pipe stand based on the position of the top and bottom of the pipe, which may be known based on the first robot position and the elevator position. With both ends of the pipe stand engaged by the first and second robots, and with the weight of the pipe stand supported by the drill floor, the pipe elevator or other lifting system may be disengaged from the pipe stand (<NUM>). Additionally, the upper robot may move to position the upper end of the pipe stand within the racking board, such as between two fingers of the racking board (<NUM>). The upper robot may position the upper end of the pipe stand in line with the lower end of the pipe stand as positioned by the lower robot. The upper robot 416b may position the pipe stand <NUM> within the fingers of the racking board. The end effectors of the first and second robots may be manipulated to track and/or follow the changing angle of the pipe stand as the second robot moves the top of the stand into the fingers of the racking board.

After it disengages from the pipe stand, the lifting system may be lowered to begin a next tip out sequence. In particular, the lifting system may be lowered and may reengage the drill string (<NUM>). If slips were placed, they may be removed from around the drill string, and the lifting system may repeat the method <NUM> by raising the drill string to expose another pipe stand. The lifting system may lower the pipe elevator to reengage the drill string while the lower 416a and upper 416b robots manipulate the pipe stand to a stored position between the setback area <NUM> and the racking board. It is to be appreciated that the weight of the pipe stand may be directed to the drill floor <NUM> while the upper robot 416b manipulates the upper end of the pie stand. Additionally, the first and second robots may release the pipe stand once it is positioned in the racking board and may move toward well center to engage with a next pipe stand (<NUM>). The pipe stand may be stored in the setback area <NUM> and racking board, as the lower robot 416a disengages from the pipe stand and moves toward well center to approach a next pipe stand.

Some steps of the method <NUM> may be performed simultaneously or substantially simultaneously. For example, the lifting system may lower the pipe stand toward the drill floor while the lower robot moves to position the lower end of the pipe stand in the setback area, and while the upper robot moves toward well center in preparation for engagement with the upper end of the pipe stand. Additionally, operations of the various components of the pipe handling system may be coordinated together to carry out the method steps. Actions of the various components may be coordinated by timing individual steps or operations with respect to one another. Additionally or alternatively, operations of the various components may be coordinated based upon feedback data received from one or more components. For example, a weight sensor on or arranged in connection with the lifting system may provide an indication as to whether the pipe stand is held within the pipe elevator. As another example, a contact switch arranged on or in connection with each robot end effector may provide an indication as to whether the pipe stand is engaged by the end effector. A proximity sensor arranged on or in communication with each end effector may provide an indication as to whether the end effector is in an open or closed position. Still further, rotational motion of the several joints of the robots may be measured or monitored as the robot moves so as to continually track the position and orientation of the end effectors and, thus, the portion of the pipe stand surrounded by the end effector. Some steps or operations of methods of the present disclosure may be performed based upon such feedback data, as is described in more detail below.

<FIG> illustrates a flow diagram of a trip in operation performable using a pipe handling system according to one or more embodiments. The method <NUM> may be performed automatically, partially automatically, manually, or partially manually. The method <NUM>, or portions thereof, may be encoded on one or more controllers as computer executable instructions. The method <NUM>, or portions thereof, may be performable by an operator such as a human operator controlling components of the pipe handling system. The method <NUM> may include the steps of causing the second (upper) robot to engage with the second (upper) end of a pipe stand (<NUM>); moving the second end of the pipe stand toward well center (<NUM>); using a lifting system, engaging the pipe stand with the lifting system (<NUM>); causing the second robot to release the pipe stand (<NUM>); causing the first (lower) robot to engage with the first (lower) end of the pipe stand (<NUM>); using the lifting system, raising the pipe stand (<NUM>); moving the first end of the pipe stand toward well center (<NUM>); lowering the pipe stand onto the drill string and loosely coupling the pipe stand with the drill floor robot (<NUM>); coupling the pipe stand to the drill string with an iron roughneck (<NUM>); causing the first robot to release the pipe stand (<NUM>); lowering the elevator with the drill string (<NUM>); placing slips around the drill string (<NUM>); and disengaging the lifting system from the drill string and raising the lifting system toward a next pipe stand (<NUM>). It is to be appreciated that a trip in operation may effectively be a reverse of a trip out operation. It is to be appreciated that the nomenclature of the first and second robots, as indicated with respect to the method <NUM>, is maintained with respect to the method <NUM>.

The second robot, which may be an upper robot arranged on or near the racking board, may engage with the second or upper end of a pipe stand (<NUM>). This may be a pipe stand stored in the setback area of the drill floor and arranged within the racking board. The robot may engage with the pipe stand by grasping it with the end effector. The robot may be directed to the pipe stand based on a known location of the pipe stand. That is, the robot may be directed to open and close the end effector at a particular location above the racking board, where it is known that a pipe stand is stored. Alternatively or additionally, the robot may include sensors for determining the position of the pipe stand. As described above, the robot may be configured to engage with a single pipe stand without disturbing surrounding pipe stands stored nearby.

With the pipe stand engaged by the end effector, the upper robot may move the engaged upper end of the pipe stand toward well center (<NUM>). The upper robot may move along its track or other movement means on the racking board, and/or may use the articulating arm to position the upper end of the pipe stand at or near well center. It is to be appreciated that while the upper robot maneuvers the upper end of the pipe stand, the weight of the pipe stand may be held by the drill floor. The second robot may thus position the upper end of the pipe stand so that it may be lifted by a lifting system. A pipe elevator or other lifting system may engage the pipe stand to transfer the load from the drill floor (<NUM>). The upper robot may release its grip on the pipe stand (<NUM>), thus completing a hand-off from the upper robot to the pipe elevator.

Additionally, the first robot, which may be a lower robot arranged on or near the drill floor and may be one of the multiple robots arranged at the drill floor, may engage with a lower end of the pipe stand, which may be arranged within the setback area of the drill floor (<NUM>). As described above, the first robot may engage the pipe stand without disturbing nearby pipe stands. Moreover, the first robot may adjust its end effector to accommodate the changed positioned of a portion of the pipe which may be slightly above the bottom due to the tilted nature of the pipe created by moving the top of the pipe to the pipe elevator or lifting system. The lifting system may operate to lift the pipe stand, so as to transfer the weight of the stand from the drill floor to the lifting system (<NUM>). With the weight of the pipe stand held by the lifting system, the lower robot may move the lower end of the pipe stand toward the well center, and may position the lower end of the pipe stand over the drill string extending from the well (<NUM>). As the lower robot moves the lower end of the pipe, the end effector on the lower robot may continually track the position and orientation of the pipe based on knowledge of the top and bottom positions of the pipe and may adjust the end effector to accommodate the continually changing pipe orientation. The lifting system may lower the pipe stand onto the drill string (<NUM>), and the pipe stand may be coupled to the drill string using, for example, an iron roughneck (<NUM>). The lower robot may release the lower end of the pipe stand (<NUM>).

Slips or another mechanism holding the drill string in place with respect to the drill floor may be removed or disengaged, and the lifting system may operate to lower the drill string so as to lower the newly attached pipe stand at least partially into the well (<NUM>). Slips or another suitable mechanism may be positioned around the drill string to maintain a position with respect to the drill floor (<NUM>). With a position of the drill string held by the slips, the lifting system may disengage from the drill string, and may raise upward toward the racking board to prepare for engagement with a next pipe stand (<NUM>). The method <NUM> may thus repeat in order to attach a next pipe stand to the drill string.

As described above with respect to the method <NUM>, some steps of the method <NUM> may be performed simultaneously or substantially simultaneously. Additionally, operations of the various components of the pipe handling system may be coordinated together to carry out the method steps. Actions of the various components may be coordinated by timing individual steps or operations with respect to one another. Additionally or alternatively, operations of the various components may be coordinated based upon feedback data received from one or more feedback devices, such as a weight sensor, a contact switch, a proximity sensor, and/or other suitable feedback devices.

It is to be appreciated that while the methods <NUM> and <NUM> have been described with respect to the pipe handling system <NUM> of <FIG>, the method may also be performed with the system <NUM> of <FIG>, the system <NUM> of <FIG> and <FIG>, and the system <NUM> of <FIG> and <FIG>. The method may, thus, rely on the use of one or more robots at the drill floor for purposes of handling the bottom ends of the pipe stands. Moreover, the methods described with respect to <FIG> for systems <NUM> and <NUM>, as well as discussion throughout regarding the use of the system <NUM> may supplement the methods <NUM> and <NUM> depending on the robot layout being used.

The devices, systems, and methods described herein provide for automated or partially automated pipe handling operations. The automated and partially automated systems and methods described herein may provide for safer pipe handling operations relative to conventional operations. For example, a pipe handling robot of the present disclosure may perform many operations that may otherwise be performed by a human operator. Derrick hands and other human operators often maneuver upper and lower ends of pipe stands during trip in, trip out, and stand building operations. These operations can be dangerous for human operators, particularly due to the size and weight of drill pipes. The pipe handling robots described herein may thus improve the safety of pipe handling operations.

Additionally, systems and methods described herein may improve the efficiency of pipe handling operations relative to conventional operations. In particular, the state machine operations described above may coordinate the operations of system components in order to reduce or minimize lost time. The synchronization and coordination of system components, as described herein, may greatly improve the efficiency of trip in, trip out, and/or stand building operations. The use of pipe handling robots rather than derrickhands and other human operators may increase efficiency and reduce variability of pipe handling operations.

It is to be appreciated that systems and methods of the present disclosure may be relatively cost effective as compared with other automated or partially automated pipe handling systems. In particular, pipe handling systems of the present disclosure may operate using a lifting system that may be operable independent of one or more pipe handling robots. That is, the pipe handling robots need not have the loading capacity to lift a drill pipe. Rather, the robots may operate to manipulate a length or stand of drill pipe while the lifting system and/or drill floor carries the load of the drill pipe. Pipe handling robots of the present disclosure may thus be more cost effective than robots of other systems. Moreover, the lifting system may be or include components of the primary drill line and draw works of the drilling rig, without the need to introduce a secondary lifting device or mechanism. However, a secondary lifting system, device, or mechanism may be used.

For example, a lifting system may include a secondary or auxiliary line or cable extending from a draw works. The auxiliary line may operate in addition to the primary or main drill line to facilitate pipe handling operations. The lifting system may include a dual activity top drive having the ability to engage with a pipe stand with a first elevator while engaging with the drill string with a second elevator, as described in <CIT>. The lifting system may include a robotic drill floor lifting system, which may be or be similar to systems described in <CIT>. Additionally or alternatively, the lifting system may include an auxiliary lifting arm extending from the drill floor, mast, racking board, or another suitable location on the drilling rig. The lifting arm may be configured for holding a pipe stand above the drill floor while the pipe stand is manipulated by one or pipe handling robots. The lifting arm may be hydraulically or pneumatically actuated. The lifting arm may have a claw or elevator for coupling to or engaging with the pipe stand. Pipe handling operations of the present disclosure may incorporate a first lifting system for handling drill pipe and a second lifting system for handling drill collar.

One or more robots of the present disclosure may be or include commercially available or off-the-shelf components. For example, one or more pipe handling robots may be or include any of the following: YASKAWA MH225, KAWASAKI BX200, ABB IRB <NUM>-<NUM>, ABB IRB <NUM>/<NUM>. Other suitable robots and robot components may be used as well.

As used herein, the terms "substantially" or "generally" refer to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is "substantially" or "generally" enclosed would mean that the obj ect is either completely enclosed or nearly completely enclosed. However, generally speaking, the nearness of completion will be so as to have generally the same overall result as if absolute and total completion were obtained. The use of "substantially" or "generally" is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, an element, combination, embodiment, or composition that is "substantially free of" or "generally free of" an element may still actually contain such element as long as there is generally no significant effect thereof.

Claim 1:
A system of pipe handling robots for handling drill pipe on a drill rig, the system comprising:
a boom (<NUM>) pivotally supported at a location outside a setback area (<NUM>) of a drill floor and extending to a free cantilevered end (<NUM>), the setback area (<NUM>) including a driller's side, an off-driller's side, and an aisle therebetween, the boom configured to swing about a vertical axis and across the drill floor;
a first pipe handling robot (516a) mounted on the free cantilevered end of the boom and configured to pivot about a vertical axis relative to the boom end (<NUM>), and configured for manipulating a bottom end a pipe stand (<NUM>) between the setback area (<NUM>) on the drill floor and well center; and
a second pipe handling robot (414b) arranged at or near a racking board (<NUM>) of the drill rig and configured for manipulating a top end of the pipe stand (<NUM>) between the racking board (<NUM>) and well center.