METHOD AND APPARATUS FOR DELIVERY OF A TUBULAR TO A DRILLING APPARATUS

Abstract

A method for delivering a tubular to a well centered drill axis includes rotating a transfer arm to which a tubular is secured about a first axis from a horizontal position to a vertical position at which a center of gravity of the transfer arm and the tubular is disposed above the first axis; and rotating an upper link of the transfer arm about a second axis while oppositely rotating a clamp support beam about a third axis from the vertical position toward the drilling apparatus while a lower link remains in the vertical position. In delivering the tubular to a drilling apparatus, a tubular supply apparatus controls the speed and acceleration of the tubular without having actuators thereof change between compression and tension states or between rotational states.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

Aspects of the invention relate to delivery of a tubular to a drilling apparatus for vertical and/or slant drilling operations, and a method and an apparatus therefor.

2. Description of the Related Art

Accurate and controlled delivery of lengths of drill pipe or tubulars to a drilling apparatus is difficult to attain. Methods and apparatuses for raising and lowering a transfer arm to deliver tubulars to a well center drilling axis have been devised. However, some such methods and apparatuses use clamps specific to a diameter of the tubular to align the tubular with the well center drilling axis. Other methods and apparatuses used for raising and lowering a transfer arm in a drilling apparatus use a rigid, pivotably-mounted arm mounted adjacent to the drilling mast or mounted at a short offset from the drilling mast. Such methods and apparatuses limit the accessibility of the area in front of the mast. Access at the front of mast is needed to allow installation, removal, and testing of well head equipment, such as a blow out prevent.

Further, other methods and apparatuses offset the mounting point of the transfer arm on the transfer arm skid. Such arrangements result in difficult control of the deceleration and velocity of the transfer arm as it approaches the upper position as such arrangements require a center of gravity of the transfer arm to move over the pivot point of the transfer arm. When linear actuators are used to control the motion thereof, it is required that such linear actuators maintain control of the movement of the transfer arm while changing from compression members to tension members. Alternately, when rotational actuators are used to control the movement of the transfer arm, the rotational actuators must change states from driving to breaking. The switching of the states of the actuators is not easily controllable resulting in poor control of the movement of the transfer arm.

SUMMARY OF THE INVENTION

Aspects of the invention provide a transfer arm over which control of the speed and acceleration thereof as it nears the upper and lower positions is maintained. Aspects of the invention provide access and clearance around the front of the drill floor and drilling mast.

Aspects of the invention provide a method for delivering a tubular to a drill string, the method including: extending a lower actuator connected between a lower link of a transfer arm and a transfer arm skid to raise the transfer arm; and aligning the tubular with a well center drill axis of the drill string by compressing an upper actuator connected between an upper link of the transfer arm and the lower link while extending a third actuator connected between the upper link and a clamp support beam holding the tubular.

Aspects of the invention further provide a method of raising and lowering a transfer arm of a transfer arm skid to deliver a tubular to a well centered drill axis of a drilling apparatus, the method including: rotating a lower link, an upper link, and a clamp support beam of the transfer arm about a first axis to align with an angle of the well centered drill axis, the lower link, the upper link, and the clamp support beam being in a protracted state, and a proximate end of the lower link being pivotably connected to the transfer arm skid at the first axis; and rotating the upper link about a second axis while rotating the clamp support beam about a third axis to align the tubular with the well centered drill axis, a proximate end of the upper link being pivotably connected to a distal end of the lower link at the second axis, and the clamp support beam being pivotably connected to a distal end of the upper link.

Aspects of the invention further provide a method of raising and lowering a transfer arm of a transfer arm skid to deliver a tubular to a well centered drill axis of a drilling apparatus, the method including: rotating a lower link, an upper link, and a clamp support beam of the transfer arm about a first axis from a horizontal position to a vertical position in which a center of gravity of the transfer arm is disposed above the first axis; and rotating the upper link about a second axis while rotating the clamp support beam about a third axis from the vertical position toward the drilling apparatus while the lower link remains in the vertical position.

Aspects of the invention further provide a tubular supply apparatus to supply a tubular to a drilling apparatus, including: a transfer arm skid connectable to a drilling apparatus; and a transfer arm, the transfer arm including: a lower link rotatably connected to the transfer arm skid at a first axis, the lower link being rotatable about the first axis; an upper link rotatably connected to a distal end of the lower link at a second axis, the upper link being rotatable about the second axis; a clamp support beam rotatably connected to a distal end of the upper link at a third axis, the clamp support beam being rotatable about the third axis and being connectable to a tubular.

Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings of which:

FIG. 1 is a side elevational view of a drilling apparatus according to an exemplary embodiment of a tubular supply apparatus, showing the transfer arm at a raised position;

FIG. 2 is side elevational view of the exemplary embodiment of FIG. 1, showing the transfer arm at an intermediate position;

FIG. 3 is side elevational view of the exemplary embodiment of FIG. 1, showing the transfer arm at a lower position;

FIG. 4 is an end elevational view of the exemplary embodiment of FIG. 3, showing an embodiment of the invention including a tubular storage and indexing system with the tubular positioned for loading into the transfer arm and the transfer arm at a lowered position;

FIG. 5. is an end elevational view of the exemplary embodiment of FIG. 3, showing the tubular storage and indexing system with the tubular positioned for loading out of the transfer arm and the transfer arm at a lowered position; and

FIG. 6 is a top plan view of the exemplary embodiment of FIG. 3, showing the tubular storage and indexing system with the tubular positioned for loading into the transfer arm and the transfer arm at a lowered position.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. Exemplary embodiments are described below in order to explain the invention by referring to the figures.

FIGS. 1 through 3 show a drilling apparatus 1 and a tubular supply apparatus 30. The drilling apparatus 1 includes a drilling mast 2 and a drill floor 25. The drilling mast 2 is disposed in a generally vertical position, but the orientation is not limited thereto. The tubular supply apparatus 30 includes a transfer arm skid 4 that is disposed in a generally horizontal position and is connectable to the drilling apparatus 1 via a reaction point 12. Each of the drilling apparatus 1 and the tubular supply apparatus 30 may include wheels so as to be moveable between drilling sites or may be fixed structures. Further, the tubular supply apparatus 30 may be connectable to the drilling apparatus 1 via the reaction point 12 or may be fixed to the drilling apparatus 1. The transfer arm skid 4 may include a locking hydraulic cylinder 26 that properly places the transfer arm skid 4 with respect to the drilling apparatus 1. The locking hydraulic cylinder 26 may extend to level or adjust the height of the transfer arm skid 4 and may be locking such that when hydraulic fluid or pressure is removed therefrom, the locking hydraulic cylinder 26 maintains the position to which it was extended.

The tubular supply apparatus 30 includes the transfer arm skid 4 and a moveable transfer arm 3. The transfer arm skid 4 provides support for the transfer arm 3. The transfer arm skid 4 may further provide support for queue and storage for a plurality of tubulars 23, in a horizontal position, to be transferred to the drilling apparatus 1. The transfer arm skid 4 may include leveling jacks or hydraulic actuators (not shown) to adjust the skid height in both lengthwise and transverse directions. The transfer arm skid 4 may also include indexers to lift one of the tubulars 23 from a storage area to the transfer arm 3 and kickers to move the tubular from the transfer arm 3 back to the storage area.

The transfer arm 3 includes three main sections: a lower link 8, an upper link 9, and a clamp support beam 10. The transfer arm 3 pivots about a first axis 5, which is fixed with respect to the mast 2, between a generally horizontal position (lowered position), and a generally vertical position (raised position). However, aspects of the invention are not limited thereto such that the transfer arm may be rotated about the first axis 5 to an inclined position (i.e., a position between the lowered position and the raised position). A proximate end 8a of the lower link 8 is rotatably connected to the transfer arm skid 4 at the first axis 5 such that the lower link 8 pivots or rotates about the first axis 5 with respect to the transfer arm skid 4. Although the first axis 5 is shown in FIGS. 1 through 3 as being fixed with respect to the transfer arm skid 4, aspects of the present invention are not limited thereto such that the first axis 5 may be moveable along a length of the transfer arm skid 4.

The upper link 9 pivots about a second axis 6. A proximate end 9a of the upper link 9 is rotatably connected to a distal end 8b of the lower link 8 at the second axis 6 such that the upper link 9 pivots or rotates about the second axis 6 with respect to the lower link 8. The clamp support beam 10 is connected to a distal end 9a of the upper link 9 at a third axis 7 such that the clamp support beam 10 pivots or rotates about the third axis 7. The clamp support beam 10 has a first end 10a and a second end 10b. The clamp support beam 10 is connected to the distal end 9b of the upper link 9 such that the first end 10a is closer to the third axis 7 than the second end 10b of the clamp support beam 10 (i.e., the clamp support beam 10 may be connected to the distal end 9b of the upper link 9 at a point one-fifth to one-third of the length of the clamp support beam 10 from the first end 10a of the clamp support beam 10), but the invention is not limited thereto. Although the clamp support beam 10 is illustrated as being connected centrally, with respect to a width or a diameter of the clamp support beam 10, to the distal end 9b of the upper link 9, aspects of the invention are not limited thereto such that the clamp support beam 10 may further include a connected or connectable bracket or coupling. Further, the connection of the clamp support beam 10 may be moveable along the length of the clamp support beam 10.

The clamp support beam 10 supports two grip assemblies 11, which are used to secure a tubular 23 to the transfer arm 3 when the transfer arm 3 is used to raise and lower the tubular 23 between a drill or pipe string (not shown) and pipe storage outriggers 31 (shown in FIG. 4). The two grip assemblies 11 are spaced apart from each other along a length of the clamp support beam 10. The grip assemblies 11 may secure tubulars 23 of different diameters and lengths so as to allow positioning and alignment of such tubulars 23 with a well center drill axis. Although only two grip assemblies 11 are shown in FIGS. 1-3, the clamp support beam 10 is not limited thereto such that more or fewer grip assemblies 11 may be included. Further, the grip assemblies 11 may be moveable along the length of the claim beam 10. The grip assemblies 11 may include linkages actuated with hydraulic or rotational actuators. Further, the clamp support beam 10 may include tubular holders 11a to aid in centering the tubulars 23 in the grip assemblies 11, and allow the tubulars 23 to roll over clamp elements.

A lower actuator 14 (or raising, or first actuator) includes a first end 15, which is pivotably connected to the transfer arm skid 4, and a second end 16, which is pivotably mounted to the lower link 8. The lower actuator 14 is disposed between the transfer arm skid 4 and the lower link 8 to control the lower link 8 to move away from the transfer arm skid 4 and raise the transfer arm 3 from the generally horizontal position (shown in FIG. 3). The lower actuator 14 is connected to an upper side of the transfer arm skid 4 and connected to a lower side of the transfer arm 3 (i.e., a lower side of the lower link 8 when the transfer arm 3 is disposed in the generally horizontal position). The lower actuator 14 may be connected directly to the transfer arm skid 4 and the lower link 8 or may be connected by an additional bracket or coupling.

The lower actuator 14 may extend to raise the transfer arm 3 about the first axis 5 to an intermediate position shown in FIG. 2 from its lower position shown in FIG. 3. As shown in FIG. 2, the transfer arm 3 is disposed directly above the first axis 5 in a protracted, generally vertical position; therefore, the lower actuator 14 extends to raise the transfer arm 3 to a point at which a center of gravity of the transfer arm 3 is disposed above the first axis 5 about which the transfer arm 3 pivots. In such a configuration, the lower actuator 14 controls the movement of the transfer arm 3 without changing states from a compression member to a tension member. The lower actuator 14 may move the transfer arm 3 from the generally horizontal position, as shown in FIG. 3, to the generally vertical position, as shown in FIG. 1, and positions therebetween. The lower actuator 14 may move the transfer arm 3 to inclined positions (i.e., positions between the generally horizontal position and the generally vertical position), so as to deliver the tubular 23 to a slant drill apparatus of which the drilling mast 2 is not vertically oriented, however, delivery of the tubular 23 to the slant drill apparatus is not limited to such. Specifically, the transfer arm 3 may be raised to an inclined position to deliver the tubular 23 to the slant drill apparatus. When the transfer arm 3 is in the generally horizontal position as shown in FIG. 3, the lower actuator 14 is in a short or compressed state; and, when the transfer arm 3 is in the generally vertical position as shown in FIGS. 1 and 2, the lower actuator 14 is in a long or extended state. When the transfer arm 3 is in an inclined position, the lower actuator 14 is in an intermediate state between the compressed and extended states.

The lower actuator 14 may be a hydraulic cylinder or multiple hydraulic cylinders, but the invention is not limited thereto. In order to raise the transfer arm 3, pressurized hydraulic fluid or air may be supplied to the lower actuator 14. Further, when the first axis 5 is moveable along the length of the transfer arm skid 4, the lower actuator 14 may also be moveable along the length of the transfer arm skid 4 (i.e., the first end 15 of the lower actuator 14 may be moveable in association with the first axis 5).

An upper actuator 17 (or rotation, or second actuator) includes a first end 18, which is pivotably mounted to the lower link 8, and a second end 19, which is pivotably mounted to the upper link 9. The first end 18 of the upper actuator 17 is connected to an upper side of the lower link 8 and the second end 19 of the upper actuator 17 is connected to an upper side of the upper link 9 (i.e., the upper actuator 17 is connected to upper sides of the lower link 8 and the upper link 9 with respect to the transfer arm 3 being disposed in the generally horizontal position as shown in FIG. 3). The upper actuator 17 is connected to an upper side of the transfer arm 3, which is opposite to the lower actuator 14 (i.e., the upper actuator 17 and the lower actuator 14 are disposed on opposite sides of the transfer arm 3).

When the transfer arm 3 is in the generally horizontal position as shown in FIG. 3, the upper link 9 and the lower link 8 are generally parallel, and the transfer arm 3 is in a lengthened or protracted state. When the transfer arm 3 is in the protracted state, the upper actuator 17 is in a long or extended state. The upper actuator 17 contracts to a short or compressed state to control the upper link 9 to rotate about the second axis 6 toward the drilling apparatus 1 such that the distal end 9b of the upper link 9 extends beyond the first axis 5 to be disposed over the drill floor 25 of the drilling apparatus 1.

When the upper actuator 17 is in the compressed state, the clamp support beam 10 is disposed over the drill floor 25 such that the tubular 23 may be aligned with the drill string. As shown in FIG. 2, the transfer arm 3 is disposed directly above the first axis 5 in a protracted, generally vertical position; therefore, when the upper actuator 17 contracts to control the rotation of the upper link 9 about the second axis 6 to extend the clamp support beam 10 over the drill floor 25, the upper actuator 17 controls the movement of the transfer arm 3 as a compression member and does not change between a compression state and a tension state when moving to extend the clamp support beam 10, or the distal end 9b of the upper link 9, toward the drilling apparatus 1 (i.e., from FIG. 2 to FIG. 1).

The upper actuator 17 may be connected to the lower link 8 and the upper link 9 directly or may be connected by an additional bracket or coupling (as shown in FIGS. 1 through 3). The upper actuator 17 may be a hydraulic cylinder or multiple hydraulic cylinders but is not limited thereto.

A third actuator 20 includes a first end 21 which is pivotably mounted to the upper link 9, and a second end 22, which is pivotably mounted to the clamp support beam 10. The third actuator 20 is connected to the upper side of the upper link 9 and connected to a lower side of the clamp support beam 10, upper and lower being defined with respect to the transfer arm 3 being disposed in the generally horizontal position shown in FIG. 3. While not required in all aspects, the second end 22 of the third actuator 20 is connected to the clamp support beam 10 between the first end 10a of the clamp support beam 10 and the third axis 7. The third actuator 20 is disposed between the upper link 9 and the clamp support beam 10 to control the first end 10a of the clamp support beam 10 to move away from the upper link 9 and move the clamp support beam 10 to a generally vertical position to align with the drill string as shown in FIG. 1. When the third actuator 20 is in a compressed or short state, the clamp support beam 10 is generally parallel to the upper link 9 as shown in FIGS. 2 and 3. When the third actuator 20 is in an extended or long state as shown in FIG. 1, the clamp support beam 10 is rotated with respect to the upper link 9 such that first end 10a of the clamp support beam 10 is disposed away from the upper link 9. The clamp support beam 10, lower link 8, and the upper link 9 are connected such that when the transfer arm 3 is disposed in the generally horizontal position shown in FIG. 3, the first end 10a of the clamp support beam 10 is disposed closer to the drilling apparatus 1 than the second end 10b of the clamp support beam 10. Further, the third actuator 20 controls the clamp support beam 10 to move without changing states from a tension to a compression state when moving the clamp support beam 10 over the drill floor 25, or moving the clamp support beam 10 from the position shown in FIG. 2 to the position shown in FIG. 1.

It should be understood that the lower link 8, the upper link 9, and the clamp support beam 10 may be exchanged for lower links 8, upper links 9, and clamp support beams 10, respectively, of different lengths so as to accommodate different lengths of the tubulars 23, different sizes and dimensions of different drilling apparatuses 1, and different locations of the drill string with respect to the first axis 5. For example, an upper link 9 having a greater length than shown in FIGS. 1 through 3 may be included in the transfer arm 3 so as to allow for delivery of a tubular 23 to a drilling apparatus 1 having a larger drilling platform.

It should be understood that the transfer arm 3 is suited for a wide variety of drilling devices and transfer arms. The drilling apparatus 1 and the transfer arm 3 have been shown merely to define the environment of this invention. Similarly the transfer arm 3 may be a stressed skin, a monocoque construction, a laminated fiber, or a cross-braced truss. The lower actuator 14, the upper actuator 17, and the third actuator 20 may be a single set of hydraulic actuators, as shown in the drawings, or may be multiplied in sets, identical or otherwise. For example, the lower actuator 14, the upper actuator 17, and the third actuator 20 may be identical hydraulic actuators, having one of each disposed on each side of the transfer arm 3. Similarly, the lower actuator 14, the upper actuator 17, and the third actuator 20 may be linear actuators or may be rotational actuators disposed at axes 5, 6, 7 to provide similar motion of the lower link 8, the upper link 9, and the clamp support beam 10, or may be combinations thereof. Further, the links on the transfer arm 3 may be box-section structures with thick multi-plate fabrications to resist high stress. Moreover, it is understood that additional actuators can be used, such as actuators to control a rotation about an axis parallel to a length of the transfer arm 3 or to control the grip assemblies 11 to rotate about the clamp support beam 10 (i.e., to rotate the tubular 23 about another horizontal axis or to be loaded with the tubular 23 from either side of the transfer arm skid 4).

Although illustrated and described as having only the lower link 8, the upper link 9, and the clamp support beam 10, aspects of the invention are not limited thereto such that the transfer arm 3 may include additional links and actuators capable of aligning the tubular 23 with the well center drilling axis while preventing the actuators from changing states between tension and compression (or forward and reverse rotation) while the transfer arm 3 is being raised to deliver the tubular 23. For example, the upper link 9 may include two portions pivotably or rotatably connected that are rotated by control of an additional actuator.

FIGS. 4 through 6 show a tubular storage and indexing system according to an embodiment of the invention. The tubular storage and indexing system delivers tubulars 23 to the transfer arm 3 according to an aspect of the invention. While shown with the transfer arm 3, it is understood that the invention is not limited thereto, and that the tubular storage and indexing system can be separately provided and can be used with other mechanisms which transfer tubulars 23 to the drilling apparatus 1.

A transfer arm skid 4 includes tubular storage outriggers 31, which are connected to the transfer arm skid 4 by pivot blocks 40, and indexing lifting arms 33, which are connected to mounts 38 of the transfer arm skid 4. The tubular storage outriggers 31 and the indexing lifting arms 33 may be disposed on only one side of the transfer arm skid 4, such that the tubulars 23 may be delivered to the transfer arm 3 from only one side of the transfer arm skid 4, or on both sides of the transfer arm skid 4, such that tubulars 23 may be delivered to the transfer arm 3 from either or both sides of the transfer arm skid 4. The pivot blocks 40 are disposed at one end of the tubular storage outriggers 31 to rotatably or pivotably connect the tubular storage outriggers 31 to the transfer arm skid 4. Further, the pivot blocks 40 may allow the tubular storage outriggers 31 to pivot or rotate horizontally so that the tubular storage outriggers 31 are parallel to the transfer arm skid 4 to be disposed in a stored position for transport or storage. The pivot blocks 40 are disposed on the transfer arm skid 4 below the gripping assemblies 11 disposed on the clamp support beam 10 so that the tubular storage outriggers 31 are disposed at a small distance above the ground on which the transfer arm skid 4 rests.

The tubular storage outriggers 31 can be inclined towards or away from the transfer skid 4 by outrigger actuators 41 attached to the outer end of tubular storage outriggers 31 (i.e., an end of the tubular storage outriggers 31 opposite the end connected to the transfer arm skid 4). By rotating the tubular storage outriggers 31 about the pivot blocks 40 to inclined or declined positions, the tubular storage outriggers 31 deliver or remove tubulars 23 from the transfer arm skid 4 in trip in and trip out operations, respectively. When the outrigger actuators 41 are extended to incline the tubular storage outriggers 31 towards the transfer skid 4 as shown in FIG. 4, the tubulars 23 are moved towards the transfer arm skid 4 to or are positioned to rest against adjustable pins 39. The adjustable pins 39 are positioned on the tubular storage outriggers 31 for different diameters of the tubular 23 so that the tubular 23 is in a correct position to be picked up by indexing lifting arms 33. The adjustable pins 39 may be of different diameters or shapes or at different positions on the tubular storage outriggers 31 according to a diameter of the tubular 23 to be indexed.

The indexing lifting arms 33 are pivotally mounted to mounts 38 of the transfer skid 4 at indexing axis 36. The indexing lifting arms 33 are pivotally rotated with respect to the transfer skid 4 by indexing actuators 35. The outer ends of each of the indexing lifting arms 33 are formed with an indexing finger 42 and an indexing edge 43, the outer ends being the ends of the indexing lifting arms 33 disposed away from the indexing axis 36. When a tubular 23 is resting against the adjustable pin 39, the indexing lifting arms 33 are rotated about axis 36 by the indexing actuators 35 upward from their full line position, a position below the tubular 23 to be picked up, to the dashed line position, a position in which the tubular 23 rolls down the indexing lifting arms 33 toward the tubular holders 11a, as shown in FIG. 4. The tubular 23 is captured by the finger 42 and moved with indexing lifting arms 33 whereupon the tubular 23 rolls along the indexing lifting arm 33 onto the gripping assemblies 11 (described above) and into recesses 44 of the tubular holders 11a where the tubular can be secured to the transfer arm 3 by the gripping assemblies 11. The indexing edges 43 of the indexing lifting arms 33 prevent the awaiting tubular 23, or the next tubular 23 to be picked up, from interfering with the motion of the indexing lifting arm 33 as well as queues the next tubular 23 for the next transfer. Additional, retractable pins may be provided in the tubular holders 11a to prevent the tubular 23 from rolling past the recesses 44 of the tubular holders 11a. The tubulars 23 roll down surfaces of the pipe storage outriggers 31 toward the transfer arm skid 4, are then lifted by the indexing lifting arms 33 from a height of the pipe storage outriggers to a height at least slightly above the gripping assemblies 11, and then roll down surfaces of the indexing lifting arms 33 to be delivered to the recesses 44 of the tubular holders 11a of the transfer arm 3. After delivery of the tubular 23 to the transfer arm 3, the indexing lifting arm 33 may be lowered to pick up the next tubular 23 to be delivered to the transfer arm 3. As the indexing lifting arm 33 is lowered, the next tubular 23 to be delivered to the transfer arm 3 is disposed against the indexing edges 43 of the indexing lifting arms 33 until the fingers 42 of the indexing lifting arms 33 are low enough that the next tubular 23 to be delivered to the transfer arm 3 rolls to rest against the adjustable pins 39. The next tubular 23 to be delivered to the transfer arm 3 is then ready to be picked up and delivered in the manner described above.

Each indexing lifting arm 33 houses a kicker assembly 37 used to return the tubular 23 to the pipe storage outriggers 31. The kicker assembly 37 is disposed at the end of the indexing lifting arm 33 connected to the indexing axis 36 (i.e., the end opposite the indexing finger 42 and the indexing edge 43). The kicker assembly 37 is extendable from the connected end of the indexing lifting arm 33. In order to remove a tubular form the gripping assemblies 11 to a stored position on the tubular storage outriggers 31, the indexing lifting arm 33 is disposed in an upper position as shown in FIG. 5. The kicker assembly 37 is extended from the full line position to the dashed line position of FIG. 5 to extend below the tubular 23 resting in the recesses 44 of the tubular holders 11a. The indexing lifting arms 33 with the kicker assemblies 37 extended are then rotated about the indexing axis oppositely to the rotation of supplying a tubular 23 to the transfer arm 3 as described above (i.e., the indexing lifting arms 33 are rotated from a raised position to a lowered position). Upon lowering of the indexing lifting arms 33, the extended kicker assembly 37 lifts the tubular 23 to be delivered to the tubular storage outriggers 31 out of the recesses 44 of the tubular holders 11a. The tubular 23 then rolls down the surface of the indexing lifting arms 33 to rest against the indexing fingers 42 of the indexing lifting arms 33 as the indexing lifting arms 33 are lowered. The tubular 23 is then delivered back to the tubular storage outriggers 31. The outrigger actuators 41 are compressed or retracted such that the tubular storage outriggers 31 are disposed in a declined position with respect to the transfer arm skid 4 such that when the tubular 23 removed from the recesses 44 of the tubular holders 11a is disposed on the tubular storage outriggers 31, the tubular 23 rolls along the surface of the tubular storage outriggers 31 away from the transfer arm skid 4 to the outer ends of the tubular storage outriggers 31 (i.e., ends of the tubular storage outriggers 31 not connected to the pivot blocks 40).

Although not required in all aspects, the kicker assemblies 37 may be disposed inside the indexing lifting arms 33 and may be attached by and extended and retracted by a linear actuator. Such linear actuator may also be disposed inside the indexing lifting arm 33. The linear actuator may move the kicker assembly 37 into and out of the indexing lifting arm 33. Further, the kicker assemblies 37 may include kicker fingers disposed at distal ends thereof (i.e., ends of the kicker assemblies 37 nearest the gripping assemblies 11 may include the kicker fingers) to hold the tubular while the kicker assemblies 37 are lifted and/or to prevent the tubular 23 to be removed from the recesses 44 of the tubular holders 11a from rolling in a wrong way (i.e., toward an other side of the transfer arm 3 opposite the indexing lifting arms 33 being used to remove the tubular 23).

Operation of the transfer arm 3 to lift a tubular 23 to a desired position for delivery to a drill string will be described hereinafter with respect to FIGS. 1 through 3. With reference to FIG. 3, the transfer arm is in a lowered or generally horizontal position in which the lower actuator 14 is in a compressed state, the upper actuator 17 is in an extended state, and the third actuator is in a compressed state. In the lowered or generally horizontal position, the lower link 8, the upper link 9, and the clamp support beam 10 are connected as described above and are generally parallel with each other and generally parallel with the transfer arm skid 4. At this position, the tubular 23 is loaded. By way of example, the tubular 23 can be loaded using the pipe supply outriggers 31 and the indexing lifting arms 33 as shown in FIG. 4. However, other mechanisms can be used.

In order to raise the transfer arm 3 from the horizontal position of FIG. 3, the lower actuator 14 extends to rotate the transfer arm 3 about the first axis 5 to move the transfer arm 3 through inclined positions to the intermediate position shown in FIG. 2. FIG. 2 shows an intermediate position appropriate for vertical drilling but aspects of the invention are not limited thereto. The lower actuator 14 may or may not extend fully but extends sufficiently to align the tubular 23 with at least an angle of the drill string or the well center drilling axis. For example, as shown in FIG. 2, the lower actuator is extended sufficiently to place the tubular 23 in a vertical position, which is appropriate for vertical drilling. Further, when the lower actuator 14 extends to move the transfer arm 3 to position the tubular 23 in the vertical position, a center of gravity of the transfer arm 3 is disposed above the first axis 5 such that the lower actuator 14 does not change from a compression to a tension state while controlling the transfer arm 3 to move. In a slant drilling operation, the lower actuator 14 may extend to an inclined position to align the tubular 23 with an angle of the slanted drill string. However, in either vertical or slant drilling, the tubular 23 is not yet aligned with a well center drilling axis of the drill string. As the lower actuator 14 extends, the transfer arm 3 is raised as a rigid unit (i.e., the upper actuator 17 remains in the extended state and the third actuator 20 remains in the compressed state similar to when the transfer arm 3 is in the generally horizontal position). While described as lifted as a rigid unit, it is understood that slight movement between the lower link 8, the upper link 9, and the clamp support beam 10 can occur and the lower link 8, the upper link 9, and the clamp support beam 10 need not be substantially parallel in all aspects so long as the center of gravity for the transfer arm 3 does not extend beyond the first axis 5 while the transfer arm 3 is being lifted and/or the lower actuator 14, the upper actuator 17, and the third actuator 20 do not change states between compression states and tensions states.

Upon alignment of the tubular 23 with the angle of the drill string, the lower actuator 14 stops extending so as to maintain such alignment. Then, to move from the intermediate position of FIG. 2 to the vertical position of FIG. 1, the upper actuator 17 begins to retract to a compressed state while the third actuator 20 begins to extend to an extended state such that the upper link 9 is rotated about the second axis 6 toward the drilling apparatus 1 while the clamp support beam 10 is rotated in an opposite direction about the third axis 7. The distal end 9b of the upper link 9 is rotated toward the drilling apparatus 1, and the first end 10a of the clamp support beam 10 is rotated toward the drilling apparatus 1 and away from the upper link 9. The upper actuator 17 retracts and the third actuator 20 extends such that the tubular 23 maintains alignment with the angle of the drill string until the tubular 23 is aligned with the well center drilling axis of the drill string. Upon alignment of the tubular 23 with the well center drilling axis of the drill string, the tubular 23 may then be delivered to the drill string as the grip assemblies 11 are released. Further, a rate at which the transfer arm 3 is controlled to raise the tubular 23 may be dependent upon a size and/or a weight of the tubular 23, may be automatic, and/or may be manually controlled. Further, the indexing and kicking related to the gripper assemblies 11 and a position of the transfer arm 3 may be automatic, and/or may be manually controlled.

For vertical drilling, the lower actuator 14 is extended to place the tubular 23 and the transfer arm 3 in a generally vertical position as shown in FIG. 2 such that the lower actuator 14 does not change states from a compression to a tension state while moving the transfer arm 3. Then, the upper actuator 17 retracts and the third actuator 20 extends while maintaining the tubular 23 in a generally vertical position, to align the tubular 23 with the vertical drill string while the lower actuator 14 remains fixed (i.e., not extending or retracting). The upper actuator 17 retracts and the third actuator 20 extends until the transfer arm 3 is in the raised position shown in FIG. 1. Even when the transfer arm 3 approaches the raised position of FIG. 1, the angular orientation of the upper actuator 17 is such that it provides excellent control over acceleration and velocity of the transfer arm 3. As such, precise, high speed, fully-automated control of the position of the transfer arm 3 and tubular 23 is possible.

For slant drilling, the tubular supply apparatus 30 may be arranged about a slanted drill string such that the slanted drill string extends into the ground beneath the tubular supply apparatus 30. In such case, the lower actuator 14 is extended to place the tubular 23 and the transfer arm 3 in a generally vertical position as shown in FIG. 2 such that the lower actuator 14 does not change states from a compression to a tension state while moving the transfer arm 3. Then, the upper actuator 17 retracts and the third actuator 20 extends, respectively, to align the tubular 23 with a well center drilling axis of the slanted drill string. The upper actuator 17 retracts and the third actuator 20 extends until the transfer arm 3 is in an inclined position beyond the first axis 5 sufficient to deliver the tubular 23 to the slanted drill string (i.e., the upper link 9 is extended beyond the first axis 5 such that the distal end 9b of the upper link 9 and the clamp support beam 10 are disposed to an opposite side of the first axis 5 from the transfer arm skid 4). By way of example, the tubular 23 may be delivered to a slanted drill string having an angle of about 20° with respect to the ground.

The upper actuator 17 and the third actuator 20 may operate simultaneously, but aspects are not limited thereto such that the upper actuator 17 may retract first, then the third actuator 20 may extend to align the tubular 23 with the slanted drill string, or the third actuator 20 may first extend to a position such that when the upper actuator 17 is appropriately retracted, the tubular 23 is aligned with the slanted drill string.

Further, although the upper actuator 17 and the third actuator 20 are described as operating independently and simultaneously, aspects are not limited thereto such that either the upper actuator 17 or the third actuator 20 may be operated before the other of the upper actuator 17 and the third actuator 20 so as to operate independently and not simultaneously. Moreover, the upper actuator 17 and the third actuator 20 may be connected (i.e., share compression fluid) so as to operate simultaneously and not independently. The upper actuator 17 and the third actuator 20 may be connected via a dummy cylinder so as to transfer compression fluid therebetween. Thus, fluid or compression removed or added from one actuator is transfer to the other such that the movements thereof are calibrated and the upper link 9 and the clamp support beam 10 are appropriately rotated about the second axis 6 and the third axis 7, respectively, to align the tubular 23 with the drill string.

To lower the transfer arm 3, from either the vertically raised position or the slanted raised position, the upper actuator 17 extends and the third actuator 20 retracts until the transfer arm 3 is disposed in the lengthened or protracted state such that the clamp support beam 10 and the upper link 9 are generally parallel. Then, the lower actuator 14 retracts to the compressed state such that the transfer arm 3 is in the generally horizontal position shown in FIG. 3. The transfer arm 3 is then ready to deliver another tubular 23 to the drill string. Further, a rate at which the transfer arm 3 is controlled to lower the tubular 23 may be dependent upon a size and/or a weight of the tubular 23. Such method of operation allows the transfer arm 3 to be raised and lowered without changing states of actuators therein between compression and tension states. However, aspects of the invention are not limited thereto such that the lower actuator 14, the upper actuator 17, and the third actuator 20 may simultaneously compress, extend, and compress, respectively, to lower the transfer arm 3 to the generally horizontal position.

While not required in all aspects, the lower actuator 14, the upper actuator 17, and the third actuator 20 can be controlled manually or using a computer controller. As such, aspects of the method can be implemented using software and/or firmware executed using one or more processors. Further, the tubular supply apparatus may include an anti-collision system by which collisions between a loaded tubular or the transfer arm and the drilling apparatus, or other structure, are prevented.

Although a few exemplary embodiments of the invention have been shown and described, it would be appreciated by those skilled in the art that changes might be made in such embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the following claims and their equivalents.

Claims

1. A tubular supply apparatus to supply a tubular to a drilling apparatus, the tubular supply apparatus comprising:

a transfer arm skid connectable to the drilling apparatus; and

a transfer arm which transfers the tubular with respect to the drilling apparatus, the transfer arm comprising: a lower link rotatably connected to the transfer arm skid at a first axis, the lower link being rotatable about the first axis to rotate the transfer arm about the first axis; an upper link rotatably connected to a distal end of the lower link at a second axis, the upper link being rotatable about the second axis; a clamp support beam rotatably connected to a distal end of the upper link at a third axis, the clamp support beam being rotatable about the third axis and being connectable to the tubular.

2. The tubular supply apparatus of claim 1, wherein the transfer arm skid further comprises:

pivot blocks disposed at a side of the transfer arm skid; and

pipe storage outriggers rotatably connected to the pivot blocks to support the tubular thereon.

3. The tubular supply apparatus of claim 2, wherein the transfer arm skid further comprises:

outrigger actuators connected to outside ends of the pipe storage outriggers opposite ends of the pipe storage outriggers connected to the pivot blocks, the outrigger actuators to raise and lower the outside ends of the pipe storage outriggers with respect to the ends of the pipe storage outriggers connected to the pivot blocks.

4. The tubular supply apparatus of claim 2, wherein the transfer arm skid further comprises:

mounts disposed on the transfer arm skid below the transfer arm when the transfer arm is disposed in a generally horizontal position; and

indexing lifting arms rotatably connected to the mounts, the indexing lifting arms to lift the tubular supported by the pipe storage outriggers from the pipe storage outriggers to the clamp support beam.

5. The tubular supply apparatus of claim 4, wherein the indexing lifting arms each comprise:

a kicker assembly extendable from one end of the indexing lifting arm toward the clamp support beam, the one end being closest to the clamp support beam so as to lift the tubular from the clamp support beam to the corresponding pipe storage outrigger.

6. The tubular supply apparatus of claim 4, wherein the indexing lifting arms each comprise:

an indexing finger disposed at an end of the indexing lifting arm away from the transfer arm skid to support the tubular as the tubular is being lifted; and

an indexing edge disposed at the end of the indexing lifting arm away from the transfer arm skid to queue a next tubular to be lifted on the pipe storage outriggers.

7. The tubular supply apparatus of claim 1, further comprising:

a first actuator disposed between the lower link and the transfer arm skid to control rotation of the lower link about the first axis;

a second actuator disposed between the lower link and the upper link to control rotation of the upper link about the second axis; and

a third actuator disposed between the clamp support beam and the upper link to control rotation of the clamp support beam about the third axis.

8. The tubular supply apparatus of claim 7, wherein the first actuator extends to raise the transfer arm to a generally vertical position without changing states between a compression state and a tension state.

9. The tubular supply apparatus of claim 7, wherein the second actuator retracts to extend the distal end of the upper link to a side of the transfer arm skid opposite the first axis.

10. The tubular supply apparatus of claim 7, wherein the third actuator extends as the second actuator retracts to align the tubular with a well center drilling axis.

11. The tubular supply apparatus of claim 7, further comprising:

a controller to control the first actuator to extend so as to raise the transfer arm to a generally vertical position, to control the second actuator to retract to extend the distal end of the upper link to a side of the transfer arm skid opposite the first axis, and to control the third actuator to retract to align the tubular with a well center drilling axis while the second actuator is controlled to retract.

12. The tubular supply apparatus of claim 11, wherein the second actuator is controlled to retract and the third actuator is controlled to extend after the first actuator has extended to raise the transfer arm to the generally vertical position.

13. A tubular supply apparatus to supply a tubular to a drilling apparatus using a transfer arm to deliver the tubular with respect to the drilling apparatus, the tubular supply apparatus comprising:

a transfer arm skid;

pivot blocks disposed at a side of the transfer arm skid;

pipe storage outriggers rotatably connected to the pivot blocks to support the tubular thereon; and

indexing lifting arms rotatably connected to the transfer arm skid to lift the tubular from the pipe storage outriggers to the transfer arm.

14. The tubular supply apparatus of claim 13, wherein each of the indexing lifting arms comprises:

an indexing finger disposed at an end the indexing lifting arm to support the tubular as the tubular is lifted.

15. The tubular supply apparatus of claim 13, wherein each of the indexing lifting arms comprises:

an indexing edge disposed at an end of the indexing lifting arm away from the transfer arm skid to queue a next tubular to be lifted on the pipe storage outriggers.

16. The tubular supply apparatus of claim 13, wherein each of the indexing lifting arms comprises:

a kicker assembly extendable from one end of the indexing lifting arm toward the clamp support beam, the one end being closest to the transfer arm.

17. A method of raising and lowering a transfer arm of a transfer arm skid to deliver a tubular to a well centered drill axis of a drilling apparatus, the method comprising:

rotating a lower link, an upper link, and a clamp support beam of the transfer arm about a first axis from a horizontal position to a vertical position in which a center of gravity of the transfer arm is disposed above the first axis; and

rotating the upper link about a second axis while rotating the clamp support beam about a third axis from the vertical position toward the drilling apparatus while the lower link remains in the vertical position.

18. The method of claim 17, wherein:

the rotating the lower link, the upper link, and the clamp support beam about the first axis comprises extending a lower actuator connected between the lower link of the transfer arm and the transfer arm skid to raise the transfer arm; and

the rotating the upper link about the second axis while rotating the clamp support beam about the third axis comprises aligning the tubular with the well center drill axis of the drill string by compressing an upper actuator connected between the upper link of the transfer arm and the lower link while extending a third actuator connected between the upper link and the clamp support beam holding the tubular.

19. The method of claim 18, wherein the extending of the lower actuator comprises:

maintaining the lower actuator in a compression state while the lower actuator raises the transfer arm.

20. The method of claim 18, wherein the compressing of the upper actuator and the extending of the third actuator follows the extending of the lower actuator.