Cross-Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 62/697,684, filed on July 13, 2019, the entirety of which is incorporated herein.

Background

[0002] A cement unit may be positioned at a wellsite and pump cement into a wellbore. For example, the cement may be pumped into an annulus in the wellbore formed between a steel casing and the surrounding subterranean formation. The cement may also be used to kill the wellbore in the event that the pressure in the wellbore exceeds a predetermined level.

[0003] At some wellsites, the cement unit may be placed 30-60 meters from the well center. In this instance, one or more upstream hoses may run from the cement unit to a catwalk. The catwalk may include one or more pipes, and the upstream hoses may be connected to the pipes proximate to a first end of the catwalk. One or more downstream hoses may also be connected the pipes proximate to a second end of the catwalk and run to the drill floor and/or a blowout preventer (BOP).

[0004] The catwalk may be moved or replaced during drilling, completion, or production operations. Moving or replacing the catwalk may include disconnecting the hoses from the pipes in the catwalk and reconnecting the hoses to the pipes in the catwalk or another catwalk. The hoses, pipes, and connections are then pressure-tested, which may involve ceasing drilling, completion, or production operations for several hours.

Summary

[0005] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0006] A catwalk system is disclosed. The catwalk system includes a skid and a V-door coupled to the skid. The skid, the V-door, or a combination thereof include(s) one or more pipes that are configured to be connected to one or more hoses and to receive cement from the one or more hoses, to introduce the cement into the one or more hoses, or both. The one or more pipes are configured to remain connected to the one or more hoses when a catwalk is removed from the skid. [0007] In another embodiment, the catwalk system includes a skid and a V-door coupled to the skid. The V-door is configured to actuate between a collapsed state and an expanded state. A first pipe is positioned at least partially within the skid and the V-door. A first end of the first pipe is configured to connect to a first upstream hose, and a second end of the first pipe is configured to connect to a first downstream hose. The first upstream hose, the first pipe, and the first downstream hose are configured to provide a first flowpath for cement to flow from a cement unit to a drill floor. A second pipe is positioned at least partially within the skid. A first end of the second pipe is configured to connect to a second upstream hose, and a second end of the second pipe is configured to connect to a second downstream hose. The second upstream hose, the second pipe, and the second downstream hose are configured to provide a second flowpath for the cement to flow from the cement unit to a blowout preventer.

[0008] A method for operating a catwalk system is also disclosed. The method includes positioning the catwalk system on a pad. The catwalk system includes a skid and a V-door that is coupled to the skid. The method also includes connecting a first upstream hose to a first end of a first pipe in the skid. The method also includes connecting a first downstream hose to a second end of the first pipe.

Brief Description of the Drawings

[0009] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present teachings and together with the description, serve to explain the principles of the present teachings. In the figures:

[0010] Figure 1 illustrates a perspective view of a catwalk system, according to an embodiment.

[0011] Figure 2 illustrates a side view of the catwalk system, according to an embodiment.

[0012] Figure 3 illustrates a cross-sectional, side view of the catwalk system with a V-door in a first (e.g., expanded) state, according to an embodiment.

[0013] Figure 4 illustrates an end view of the catwalk system, according to an embodiment.

[0014] Figure 5 illustrates a cross-sectional, side view of the catwalk system with the V- door in a second (e.g., collapsed) state, according to an embodiment.

[0015] Figure 6 illustrates a flowchart of a method for operating the catwalk system, according to an embodiment. Detailed Description

[0016] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings and figures. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0017] It will also be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first object or step could be termed a second object or step, and, similarly, a second object or step could be termed a first object or step, without departing from the scope of the present disclosure. The first object or step, and the second object or step, are both, objects or steps, respectively, but they are not to be considered the same object or step.

[0018] The terminology used in the description herein is for the purpose of describing particular embodiments and is not intended to be limiting. As used in this description and the appended claims, the singular forms“a,”“an” and“the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term“and/or” as used herein refers to and encompasses any possible combinations of one or more of the associated listed items. It will be further understood that the terms“includes,” “including,”“comprises” and/or“comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Further, as used herein, the term “if’ may be construed to mean“when” or“upon” or“in response to determining” or“in response to detecting,” depending on the context.

[0019] Attention is now directed to processing procedures, methods, techniques, and workflows that are in accordance with some embodiments. Some operations in the processing procedures, methods, techniques, and workflows disclosed herein may be combined and/or the order of some operations may be changed. [0020] Figures 1 and 2 illustrate a perspective view and a side view of a catwalk system 100, according to an embodiment. The catwalk system 100 may include a skid 110. The skid 110 may also be referred to as a sub. The skid 110 may be or include a portable frame 112 that includes a first end 114 and a second end 116. As described in greater detail below, the first end 114 may be positioned proximate/closer to a cement unit, and the second end 116 may be positioned proximate/closer to a drill floor 180. The skid 110 may be positioned on a pad (e.g., a cement pad) 111 and configured to be moved on the pad 111 (or onto a different pad) to different locations around the wellsite.

[0021] The catwalk system 100 may also include a V-door 130. In contrast to conventional V-doors, which may be pivotally coupled to a catwalk (and not the skid), the V-door 130 herein is instead pivotally coupled to the skid 110. More particularly, a first (e.g., lower) end 132 of the V-door 130 may be coupled to the skid 110, proximate to the second end 116 of the skid 110. The V-door 130 is shown in a first (e.g., expanded) state in Figures 1 and 2. In the expanded state, the V-door 130 may extend upward at an angle such that a second (e.g., upper) end 134 of the V-door 130 is positioned on and/or coupled to the drill floor 180. The V-door 130 may be configured to facilitate the movement of equipment (e.g., pipes) up to the drill floor 180.

[0022] The catwalk system 100 may also include a catwalk 150 and/or other equipment configured to be positioned on the skid 110 and/or coupled to the skid 110. The skid 100, the V-door 130, the catwalk 150, or a combination thereof may yield the catwalk system 100.

[0023] As shown, the catwalk 150 may include a base 151 that may be positioned on and/or coupled to the skid 110. The catwalk 150 may also include a first (e.g., main) arm 152 and a second (e.g., back) arm 154 that may be coupled to the skid 110 and/or the base 151. The catwalk 150 may also include a trough 156 that may be coupled to upper ends of the first and second arms 152, 154. The trough 156 may extend to and/or be positioned on the drill floor 180. The catwalk 150 may be a hydraulic catwalk or a manual catwalk.

[0024] Figure 3 illustrates a cross-sectional, side view of the catwalk system 100 with the V-door 130 in the expanded state, according to an embodiment. A portion of the catwalk 150 (e.g., the main arm 152, the back arm 154, and the trough 156) is omitted for clarity in Figure 3.

[0025] As mentioned above, conventional catwalks include pipes. However, in embodiments disclosed herein, the skid 110 may also or instead include one or more (e.g., five) pipes 120A-120E. Embodiments with greater or fewer pipes are also contemplated herein. As discussed in greater detail below, having the pipes 120A-120E be a part of the skid 110 instead of the catwalk 150 may save time and labor when the catwalk 150 is moved or replaced. The pipes 120A-120E may be made from metal. For example, the pipes 120A- 120E may be made from AISI 4130 or 4140 steel. The pipes 120A-120E may be rated to withstand pressures up to about 10,000 PSI, about 15,000 PSI, or more.

[0026] The pipes 120A-120E may extend from the first end 114 of the skid 110 to/toward the second end 116 of the skid 110. The V-door 130 may also include one or more (e.g., two) of the pipes 120A, 120B. The pipes 120A, 120B may extend from the first end 114 of the skid 110 to/toward the second end 116 of the skid 110, and then from the first end 132 of the V-door 130 to/toward the second end 134 of the V-door 130. A joint 136 may connect the skid 110 to the V-door 130 and/or connect the pipes 120A, 120B from the skid 110 to the V- door 130. The joint 136 may be or include a chicksan j oint. The pipes 120A, 120B may be rigid or flexible. For example, the pipes 120A, 120B may be rigid within the skid 110 and/or the V-door 130, and flexible proximate to the joint 136.

[0027] Figure 4 illustrates an end view of the catwalk system 100 from lines 4-4 in Figure 3, according to an embodiment. The pipes 120A-120E may be coupled to and/or positioned at least partially within the skid 110. In other embodiments, the pipes 120A-120E may be coupled to, but positioned exterior to, the skid 110. As mentioned above, one or more (e.g., two) of the pipes 120 A, 120B may also be coupled to and/or positioned at least partially within the V-door 130 or coupled to, but positioned exterior to, the V-door 130.

[0028] Referring now to Figures 3 and 4, one or more (e.g., five) upstream hoses 172A- 172E may extend from a cement unit 170 to the skid 110. The upstream hoses 172A-172E may be configured to connect to the (e.g., five) pipes 120A-120E proximate to the first end 114 of the skid 110. One or more (e.g., two) downstream hoses 174A, 174B may be configured to connect to the pipes 120A, 120B proximate to the second end 134 of the V- door 130. The downstream hoses 174A, 174B may extend to the drill floor 180 and/or into a wellbore.

[0029] In addition, one or more (e.g., three) downstream hoses 174C-174E may be configured to connect to the pipes 120C-120E proximate to the second end 116 of the skid 110. In at least one embodiment, the downstream hoses 174C, 174D may be connected to a blowout preventer (BOP) 176, and the downstream hose 174E may be connected to a pneumatic tool 178. The connections between the upstream hoses 172A-172E and the pipes 120A-120E and/or between the pipes 120A-120E and the downstream hoses 174A-174E may be or include flanges, such as bolted flanges or class 1500 flanges (e.g., class 1502 flanges). [0030] Figure 5 illustrates a cross-sectional, side view of the catwalk system 100 with the V-door 130 in a second (e.g., collapsed) state, according to an embodiment. A portion of the catwalk 150 (e.g., the main arm 152, the back arm 154, and the trough 156) is omitted for clarity in Figure 5.

[0031] When the catwalk system 100 is not in use (e.g., during shipping), the V-door 130 may be in the collapsed state. In the collapsed state, the V-door 130 may be folded back onto the skid 110 and/or the catwalk 150. The V-door 130 may be folded such that it is substantially parallel to the skid 110 with the second end 134 of the V-door 130 extending toward the first end 114 of the skid 110. For example, the V-door 130 may be folded such that the base 151 of the catwalk 150 is positioned at least partially between the skid 110 and the V-door 130. As may be seen, the pipes 120A-120E may be/remain coupled to and/or positioned within skid 110, and the pipes 120A, 120B may be/remain coupled to and/or positioned within the V-door 130, when the V-door 130 is in the collapsed state. This may be facilitated by the joint 136 between the skid 110 and the V-door 130.

[0032] Figure 6 illustrates a flowchart of a method 600 for operating the catwalk system 100, according to an embodiment. An illustrative order of the method 600 is described below; however, it will be appreciated that one or more portions of the method 600 may be performed in a different order.

[0033] The method 600 may include positioning the catwalk system 100 on the pad 111, as at 602. This may include positioning the skid 110 on the pad 111. The V-door 130 may be coupled to the skid 110 before or after the skid 110 is positioned on the pad 111. The V-door 130 may be in the collapsed state. The catwalk 150 may be positioned on and coupled to the skid 110 before or after the skid 110 is positioned on the pad 111.

[0034] The method 600 may also include actuating the V-door 130 into the expanded state, as at 604. This may include moving the V-door 130 through an arc such that the second end 134 of the V-door 130 is positioned on and/or coupled to the drill floor 180.

[0035] The method 600 may include connecting the upstream hoses 172A-172E to the pipes 120A-120E, as at 606. This may include connecting the upstream hoses 172A-172E to the pipes 120A-120E proximate to the first end 114 of the skid 110.

[0036] The method 600 may also include connecting the downstream hoses 174A-174E to the pipes 120A-120E, as at 608. This may include connecting the downstream hoses 174A, 174B to the pipes 120A, 120B proximate to the second end 134 of the V-door 130. This may also include connecting the downstream hoses 174C-174E to the pipes 120C-120E proximate to the second end 116 of the skid 110. [0037] The method 600 may also include pressure-testing the hoses 172A-172E, 174A- 174E and the pipes 120A-120E, as at 610. This may include introducing (e.g., pumping) a liquid into the hoses 172A-172E, 174A-174E and the pipes 120A-120E. The liquid may be or include water. The pressure of the liquid may then be increased to a pressure between about 5,000 PSI and about 10,000 PSI, about 10,000 PSI and about 15,000 PSI, about 15,000 PSI and about 20,000 PSI, or greater. The pressure may remain at this elevated level for between about 1 minute and about 5 minutes, about 5 minutes and about 15 minutes, about 15 minutes and about 30 minutes, or longer.

[0038] The method 600 may also include pumping cement to the drill floor 180, as at 612. This may include pumping the cement from the cement unit 170, through the upstream hoses 172A, 172B, and into the pipes 120 A, 120B. The cement may flow through the pipes 120A, 120B in the skid 110, the joint 136, and/or the V-door 130 to the downstream hoses 174A, 174B. The cement may then flow through the downstream hoses 174A, 174B to the drill floor 180. From there, the cement may be directed into the wellbore.

[0039] The method 600 may also include pumping the cement to the BOP 176, as at 614. This may include pumping the cement from the cement unit 170, through the upstream hoses 172C, 172D, and into the pipes 120C, 120D. The cement may flow through the pipes 120C, 120D in the skid 110 to the downstream hoses 174C, 174D. The cement may then flow through the downstream hoses 174C, 174D to the BOP 176 (e.g., to kill the wellbore).

[0040] The method 600 may also include pumping air to the tool 178, as at 616. This may include pumping the air from the cement unit 170 (or a compressor), through the upstream hose 172E, and into the pipe 120E. The air may flow through the pipe 120E in the skid 110 to the downstream hose 174E. The air may then flow through the downstream hose 174E to the tool 178.

[0041] The method 600 may also include moving the catwalk system 100, as at 618. The catwalk system 100 may be moved before, during, or after one or more portions of the method 600 described above. In at least one embodiment, moving the catwalk system 100 may include actuating the V-door 130 into the collapsed state. Moving the catwalk system 100 may also or instead include moving the catwalk system 100 (e.g., the skid 100, the V- door 130, and/or the catwalk 150) on the pad 111 or to another pad.

[0042] The method 600 may also or instead include replacing the catwalk (e.g., a first catwalk) 150 with a second catwalk, as at 620. For example, the first catwalk 150 may be or include a hydraulic catwalk, which may cease to operate properly. The first catwalk 150 may then be removed from the skid 110, and the second catwalk may be positioned on the skid 110. The second catwalk may be another hydraulic catwalk or a manual catwalk. The V- door 130 may remain coupled to the skid 110 during the replacement. The V-door 130 may remain in the expanded state during the replacement, or the V-door 130 may be actuated into the collapsed state during the replacement and then back into the expanded state after the replacement.

[0043] The upstream hoses 172A-172E and downstream hoses 174A-174E may be/remain connected to the pipes 120A-120E while the catwalk 150 is moved (at 618) and/or replaced (at 620). More particularly, the upstream hoses 172A, 172B may be/remain connected to the pipes 120A, 120B proximate to the first end 114 of the skid 110, and the downstream hoses 174A, 174B may be/remain connected to the pipes 120A, 120B proximate to the second end 134 of the V-door 130. The upstream hoses 172C-172E may also be/remain connected to the pipes 120C-120E proximate to the first end 114 of the skid 110, and the downstream hoses 174C-174E may be/remain connected to the pipes 120C-120E proximate to the second end 116 of the skid 110. As a result, additional pressure testing may be omitted after the catwalk 150 is moved and/or replaced, which may reduce the amount of downtime at the wellsite. In addition, the V-door 130 may remain coupled to the skid 110 while the catwalk 150 is moved (at 618) and/or replaced (at 620).

[0044] The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. Moreover, the order in which the elements of the methods are illustrated and described may be re-arranged, and/or two or more elements may occur simultaneously. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.