Cross-Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 62/893,520, filed on August 29, 2019, which is incorporated by reference herein.

Background

[0002] Tubular members may be coupled together at the surface of a wellsite to form a tubular string that is then run into a wellbore formed in a subterranean formation. To increase a length of the tubular string, a first device may grip a tubular member, which may be stored in a pipe rack. The first device may then transport the tubular member from the pipe rack to a position that is above the tubular string in the wellbore. The first device may then lower the tubular member such that a lower end of the tubular member is stabbed into an upper end of the tubular string. The first device may then release the tubular member. After the first device releases the tubular member, a second device may grip the tubular member and rotate the tubular member to connect the tubular member to the tubular string, thereby increasing the length of the tubular string. The second device may be or include an iron roughneck.

Summary

[0003] 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.

[0004] A device includes a loader configured to receive a tubular member in a substantially horizontal position and to pivot the tubular member into a substantially vertical position. The device also includes a barrel coupled to the loader and configured to receive the tubular member from the loader when the tubular member is in the substantially vertical position and to move the tubular member through a path at least partially around a central longitudinal axis through the barrel.

[0005] In another embodiment, the device includes a base that is substantially horizontal. The device also includes a first tubular raising machine coupled to the base. The first tubular raising machine is configured to receive a first tubular member that is in a substantially horizontal position. The first tubular raising machine is configured to pivot the first tubular member from the substantially horizontal position into a substantially vertical position. The device also includes a second tubular raising machine coupled to the base. The second tubular raising machine is configured to receive a second tubular member that is in a substantially horizontal position. The second tubular raising machine is configured to pivot the second tubular member from the substantially horizontal position into a substantially vertical position. The device also includes a support table configured to receive lower ends of the first and second tubular members when the first and second tubular members are in the substantially vertical position. The support table is configured to rotate, which moves the first and second tubular members through a path. The device also includes a racking arm configured to grip the first and second tubular members. The racking arm is configured to actuate from a retracted position to an extended position to sequentially move the first and second tubular members into alignment with a well center.

Brief Description of the Drawings

[0006] 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:

[0007] Figure 1 illustrates a perspective view of a device for handling one or more tubular members, according to an embodiment.

[0008] Figure 2 illustrates another perspective view of the device with racking arms in an extended position, according to an embodiment.

[0009] Figure 3 perspective view of a wellsite including two devices that may operate in parallel, according to an embodiment.

[0010] Figure 4 illustrates a flowchart of a method for handling one or more tubular members, according to an embodiment.

Detailed Description

[0011] 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.

[0012] 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.

[0013] 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.

[0014] Figure 1 illustrates a perspective view of a device 100 for handling one or more tubular members (four are shown: 102A-102D), according to an embodiment. The device 100 may be referred to as a barrel buffer racker (BBR). The device 100 may be used at a wellsite to transfer the tubular members 102A-102D between a substantially horizontal position and a substantially vertical position, and to transfer the tubular members to and/or from a well center 104 when the tubular members 102A-102D are in the substantially vertical position. The tubular members 102A-102D may be or include drill pipe segments, liner segments, casing segments, or a combination thereof.

[0015] The device 100 may include a first (e.g., substantially horizontal) portion 110 and a second (e.g., substantially vertical) portion 150. The first portion 110 may also be referred to as a loader, and the second portion 150 may be referred to as a barrel. The loader 110 may include a substantially horizontal base 112 having a first axial end 114 and a second axial end 116. The first axial end 114 may be positioned farther away from the barrel 150 than the second axial end 116. In other words, the first axial end 114 may be distal to the barrel 150, and the second axial end 116 may be proximal to the barrel 150. The base 112 may define one or more tracks (two are shown: 118 A, 118B).

[0016] The loader 110 may also include one or more tubular raising machines (two are shown: 120A, 120B). The tubular raising machines 120A, 120B may be substantially parallel to one another (e.g., side-by-side) and configured to operate in parallel with one another (e.g., sequentially or simultaneously), as described below. The first tubular raising machine 120A is shown in a first (e.g., substantially horizontal) position, and the second tubular raising machine 120B is shown in a second (e.g., substantially vertical) position.

[0017] The first tubular raising machine 120 A may include a support 122 A having a first axial end 124 A and a second axial end 126 A. The first axial end 124 A of the first tubular raising machine 120A may be positioned farther away from the second axial end 116 of the base 112 than the second axial end 126A of the first tubular raising machine 120A. The first tubular raising machine 120A may also include a gripper 128A that is coupled to the support 122A and configured to grip a tubular member 102A. The first tubular raising machine 120A may also include a guide 130A that is coupled to the support 122A and configured to help maintain the tubular member 102 A in alignment with the support 122 A when gripped by the gripper 128 A. The gripper 128 A may be positioned axially offset from the guide 130A along the support 122A. The first tubular raising machine 120A may also include a slidable element 132A that is engaged with the track 118A and configured to slide axially along the track 118 A.

[0018] The second tubular raising machine 120B may be similar to the first tubular raising machine 120A. Thus, the second tubular raising machine 120B may include a support 122B, a gripper 128B, a guide 130B, and a slidable element 132B. As mentioned above, the second tubular raising machine 120B is shown in a second (e.g., substantially vertical) position. To actuate from the first position to the second position, an actuator (e.g., a motor, hydraulic cylinder, etc.) may cause the slidable element 132B to slide axially along the track 118B toward the second axial end 116 of the base 112 and the barrel 150, as shown by arrow 134. As the slidable element 132B slides in this direction, a linkage arm 136B may cause the support 122B and the tubular member 102B to pivot around a pivot point 138B from a substantially horizontal position to a substantially vertical position, as shown by arrow 140. The linkage arm 136B may be coupled to and positioned between the support 122B and the slidable element 132B. The pivot point 138B may be coupled to and positioned between the second axial end 116 of the base 122 and the second axial end 126B of the support 122B. [0019] The barrel 150 may include a substantially vertical shaft 152 having a first (e.g., lower) axial end 154 and a second (e.g., upper) axial end 156. The lower axial end 154 may be positioned closer to the second axial end 116 of the base 112 and the second axial ends 126 A, 126B of the supports 122 A, 122B than to the first axial ends 114, 124 A, 124B thereof. [0020] The barrel 150 may also include a first (e.g., lower) guard 160A and a second (e.g., upper) guard 160B. The guards 160 A, 160B may be positioned radially outward from the shaft 152. The lower guard 160A may extend axially upward (e.g., from about 1 foot to about 5 feet) from the lower axial end 154, and the upper guard 160B may extend axially downward (e.g., from about 1 foot to about 5 feet) from the upper axial end 156. The guards 160A, 160B may help to secure the tubular members 102C, 102D within the barrel 150 (e.g., between the shaft 152 and the guards 160 A, 160B).

[0021] The lower guard 160A may include one or more doors (two are shown: 164A, 166A), and the upper guard 160B may include one or more doors (two are shown 164B, 166B). The lower doors 164A, 166A may be circumferentially offset from one another (e.g., by about 180 degrees), and the upper doors 164B, 166B may be circumferentially offset from one another (e.g., by about 180 degrees). The first lower door 164A may be circumferentially aligned with the first upper door 164B, and the second lower door 166 A may be circumferentially aligned with the second upper door 166B. The loader 110 (e.g., the tubular raising machines 120A, 120B) may be configured to transfer the tubular members 102A-102D to/from the barrel 150 through the aligned first doors 164A, 164B, and one or more racking arms (described below) may be configured to transfer the tubular members 102A-102D to/from the barrel 150 through the aligned second doors 166A, 166B.

[0022] The barrel 150 may also include a support table 170 proximate to the lower axial end 154. The support table 170 may be positioned at least partially within the lower guard 160A. The support table 170 may include an upper surface that is configured to receive lower axial ends (e.g., male ends or pin ends) of the tubular members 102A-102D. The support table 170 may be configured to rotate around a central longitudinal axis through the shaft 152, as shown by arrow 172.

[0023] The barrel 150 may also include a first (e.g., lower) set of racking fingers 174A and a second (e.g., upper) set of racking fingers 174B. The racking fingers 174A, 174B may be positioned at least partially within the guards 160 A, 160B. The racking fingers 174 A, 174B may be configured to rotate together with the support table 170 around the shaft 152, as shown by arrow 172. Each set of racking fingers 174A, 174B may include a plurality of circumferentially offset radial protrusions, and a slot is defined between each pair of circumferentially adjacent protrusions. Each slot in the lower set of racking fingers 174 A may be circumferentially aligned with a corresponding slot in the upper set of racking fingers 174B, and each aligned pair of slots may be configured to receive one of the tubular members 102A-102D.

[0024] The barrel 150 may also include a first (e.g., lower) racking arm 180A and a second (e.g., upper) racking arm 180B. The racking arms 180A, 180B may be coupled to the shaft 152. The racking arms 180A, 180B may be configured to grip a tubular member 102A-102D and to actuate from a first (e.g., retracted) position to a second (e.g., extended) position. As shown in Figure 1, when in the retracted position, the gripped tubular member 102D and the racking arms 180A, 180B and may be (e.g., entirely) positioned within an outer diameter 182 of the barrel 150. In other words, the racking arms 180A, 180B may not extend radially outward farther than the guards 160A, 160B or the support table 170 when in the retracted position. As shown in Figure 2, when in the extended position, the gripped tubular member 102D and at least a portion of the racking arms 180 A, 180B and may be positioned outside of the outer diameter 182 of the barrel 150. For example, when in the extended position, the racking arms 180 A, 180B may hold the gripped tubular member 102D in alignment with the well center 104.

[0025] Figure 3 perspective view of a wellsite 300 including two devices 100A, 100B that may operate in parallel, according to an embodiment. Each of the devices 100A, 100B may be similar to the device 100 described above. The first device 100 A may be configured to handle a plurality of first tubular members (e.g., tubular members 102A), the second device 100B may be configured to handle a plurality of second tubular members (e.g., tubular members 102B). The first and second tubular members 102A, 102B may be the same or different. For example, the first tubular members 102 A may be or include drill pipe segments, and the second tubular members 102B may be or include casing segments.

[0026] In an embodiment, the first device 100 A may be configured to transfer the first tubular members 102 A from a first inventory 310A to the well center 104, or vice versa. Similarly, the second device 100B may be configured to transfer the second tubular members 102B from a second inventory 310B to the well center 104, or vice versa. This described in greater detail below.

[0027] Figure 4 illustrates a flowchart of a method 400 for handling one or more tubular members 102A-102D, according to an embodiment. The method 400 may be performed by the device 100 (or the devices 100 A, 100B), or the method 400 may be performed by one or more other/different devices. An illustrative order of the method 400 is provided below; however, one or more portions of the method 400 may be performed in a different order, repeated, performed simultaneously/in parallel, combined, or omitted.

[0028] The method 400 may include receiving the first tubular member (e.g., tubular member 102A) in the loader 110, as at 402. Receiving the first tubular member 102A may include transferring the first tubular member 102A from an inventory (e.g., inventory 310A in Figure 3) into the gripper 128A and the guide 130A of the first tubular raising machine 120A. The first tubular member 102A may be in a substantially horizontal position while in the inventory and/or the first tubular raising machine 120A.

[0029] The method 400 may also include receiving the second tubular member (e.g., tubular member 102B) in the loader 110, as at 404. Receiving the second tubular member 102B may include transferring the second tubular member 102B from an inventory (e.g., inventory 310B in Figure 3) into the gripper 128B and the guide 130B of the second tubular raising machine 120B. The second tubular member 102B may be in a substantially horizontal position while in the inventory and/or the second tubular raising machine 120B. The steps 402, 404 may happen sequentially or simultaneously. In addition, the steps 402, 404 may repeat while one or more of the following steps occur to receive additional tubular members in the loader 110.

[0030] The method 400 may also include moving the first tubular member 102A into the barrel 150 using the loader 110, as at 406. Moving the first tubular member 102A may include rotating the first tubular member 102A from the substantially horizontal position into the substantially vertical position using the first tubular raising machine 120A. Rotating the first tubular member 102A may include moving the slidable element 132A along the first track 118A, which causes the linkage arm to rotate the support 122A and/or the first tubular member 102A around the pivot point into the substantially vertical position. Once in the substantially vertical position, the first tubular raising machine 120A may move the first tubular member 102 A through the first doors 164 A, 164B in the guards 160 A, 160B and into an aligned pair of slots in the racking fingers 174A, 174B. The first tubular raising machine 120A may then lower the first tubular member 102A such that the lower axial end thereof is received onto the support table 170. The first tubular raising machine 120A may then release first tubular member 102A and actuate back into the substantially horizontal position. The step 406 may happen after the step 402, and before, simultaneously with, or after the step 404.

[0031] The method 400 may also include moving the second tubular member 102B into the barrel 150 using the loader, as at 408. Moving the second tubular member 102B may include rotating the second tubular member 102B from the substantially horizontal position into the substantially vertical position using the second tubular raising machine 120B. Rotating the second tubular member 102B may include moving the slidable element 132B along the second track 118B, which causes the linkage arm 136B to rotate the support 122B and/or the second tubular member 102B around the pivot point 138B into the substantially vertical position. Once in the substantially vertical position, the second tubular raising machine 120B may move the second tubular member 102B through the first doors 164 A, 164B (or a different set of doors) in the guards 160 A, 160B and into an aligned pair of slots in the racking fingers 174A, 174B. The second tubular raising machine 120B may then lower the second tubular member 102B such that the lower axial end thereof is received onto the support table 170. The second tubular raising machine 120B may then release second tubular member 102B and actuate back into the substantially horizontal position. The step 408 may happen after the step 404, and before, simultaneously with, or after the step 402 and/or 406. [0032] The method 400 may also include moving the first tubular member 102A within the barrel 150, as at 410. Moving the first tubular member 102A may include rotating the support table 170 and the sets of racking fingers 174A, 174B around the shaft 152 while the first tubular member 102A is in the substantially vertical position. The first tubular member 102 A may initially be in alignment with the first doors 164 A, 164B, and the rotation may move the first tubular member 102 A through at least a portion of a circumferential path around the shaft 152 until it is in alignment with the second doors 166A, 166B. The guards 160A, 160A may prevent the first tubular member 102A from being removed from (e.g., falling out of) the barrel 150 during the rotation. In one embodiment, the shaft 152 and the guards 160A, 160B may be stationary (e.g., they may not move or rotate). The step 410 may happen before, simultaneously with, or after step 402 and/or 404 being repeated (e.g., receiving additional tubular members into the tubular raising machines 120A, 120B). The step 410 may happen after the step 406. The step 410 may happen before, simultaneously with, or after the step 408.

[0033] The method 400 may also include moving the second tubular member 102B within the barrel 150, as at 412. Moving the second tubular member 102B may include rotating the support table 170 and the sets of racking fingers 174A, 174B around the shaft 152 while the second tubular member 102B is in the substantially vertical position. The second tubular member 102B may initially be in alignment with the first doors 164 A, 164B, (or another set of entry doors), and the rotation may move the second tubular member 102B through at least a portion of a circumferential path around the shaft 152 until it is in alignment with the second doors 166A, 166B (or another set or exit doors). The guards 160A, 160A may prevent the second tubular member 102B from being removed from (e.g., falling out of) the barrel 150 during the rotation. The step 412 may happen before, simultaneously with, or after step 402 and/or 404 being repeated (e.g., receiving additional tubular members into the tubular raising machines 120A, 120B). The step 412 may happen after the step 408. The step 412 may happen before, simultaneously with, or after the step 406 and/or 410.

[0034] Once the first tubular member 102A has been moved (e.g., rotated) into alignment with the second doors 166 A, 166B, the method 400 may also include moving the first tubular member 102A into alignment with the well center 104, as at 414. Moving the first tubular member 102 A may include gripping the first tubular member 102 A with the racking arms 180A, 180B while the racking arms 180A, 180B are in the retracted position. Once gripped, the racking arms 180A, 180B may actuate from the retracted position into the extended position to move the first tubular member 102 A through the second doors 166 A, 166B in the guards 160 A, 160B and into alignment with the well center 104, where the first tubular member 102A may be coupled to a tubular string in a wellbore to increase the length of the tubular string. The racking arms 180A, 180B may then actuate back into the retracted position. The step 414 may happen before, simultaneously with, or after steps 402 and/or 404 being repeated (e.g., receiving additional tubular members into the tubular raising machines 120 A, 120B). The step 414 may also or instead happen after step 406 and/or 410. The step 414 may also or instead happen before, simultaneously with, or after the step 408 and/or 412. [0035] Once the second tubular member 102B has been moved (e.g., rotated) into alignment with the second doors 166A, 166B, the method 400 may also include moving the second tubular member 102B into alignment with the well center 104, as at 416. Moving the second tubular member 102B may include gripping the second tubular member 102B with the racking arms 180A, 180B (or another set of racking arms) while the racking arms 180A, 180B are in the retracted position. Once gripped, the racking arms 180A, 180B may actuate from the retracted position into the extended position to move the second tubular member 102B through the second doors 166 A, 166B (or another set of exit doors) in the guards 160 A, 160B and into alignment with the well center 104, where the second tubular member 102B may be coupled to the tubular string (e.g., to an upper end of the first tubular member 102A). The racking arms 180A, 180B may then actuate back into the retracted position. The step 416 may happen before, simultaneously with, or after steps 402 and/or 404 being repeated (e.g., receiving additional tubular members into the tubular raising machines 120A, 120B). The step 416 may also or instead happen after step 408 and/or 412. The step 416 may also or instead happen before, simultaneously with, or after the step 410 and/or 414.

[0036] The foregoing portion of the method 400 is directed to using the device 100 to move tubular members 102A-102D from a substantially horizontal position (e.g., in an inventory 310A) to a substantially vertical position, and then move the tubular members 102A-102D into alignment with the well center 104. In one embodiment, two or more devices (e.g., devices 100 A, 100B) may be used in parallel (e.g., sequentially or simultaneously) to move the tubular members 102A-102D from a substantially horizontal position (e.g., in inventories 310A, 310B) to a substantially vertical position, and then move the tubular members 102A- 102D into alignment with the well center 104. For example, the device 100A may be used to move one or more of the tubular members 102 A from the inventory 310A into alignment with the well center 104, and then the device 100B may be used to move one or more of the tubular members 102B from the inventory 310B into alignment with the well center 104. In yet another embodiment, the method 400 may be performed in a reverse/opposite order such that the device 100 (or the devices 100 A, 100B) may be used to move the tubular members 102A-102D away from the well center 104, and then to move the tubular members 102A- 102D from the substantially vertical position into the substantially horizontal position.

[0037] As used herein, the terms “inner” and “outer”; “up” and “down”; “upper” and “lower”; “upward” and “downward”; “upstream” and “downstream”; “above” and “below”; “inward” and “outward”; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular direction or spatial orientation. The terms “couple,” “coupled,” “connect,” “connection,” “connected,” “in connection with,” and “connecting” refer to “in direct connection with” or “in connection with via one or more intermediate elements or members.”

[0038] 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.