TOP DRIVE WITH AUTOMATIC POSITIONING SYSTEM
An automatic top drive positioning system includes a top drive having a pipe handling system rotator gear, a drive motor rotationally coupled to the rotator gear and a rotational position sensor rotationally coupled to the rotator gear. A controller is configured to operate the drive motor to automatically move the rotator gear to a selected rotational orientation based on measurements from the rotational position sensor.
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTNot applicable.
BACKGROUNDThe main shaft 16 extends through the motor housing 17 and connects to items below the shaft (“stem” or “shaft” can include stems and shafts). The shaft 26 may be non-threadedly connected to an upper end of an IBOP assembly 24 which is the first in a series of items and/or tubular members collectively referred to as the drill string 19. An opposite end of the drill string 19 is threadedly connected to a drill bit 20.
During operation, a motor 15 (shown schematically) encased within the housing 17 rotates the main shaft 16 which, in turn, rotates the drill string 19 and the drill bit 20. Rotation of the drill bit 20 produces a wellbore 21. Drilling fluid pumped into the top drive system 10 passes through an interior passage or conduit in the main shaft 16, the drill stem 18, the drill string 19, the drill bit 20 and enters the bottom of the wellbore 21. Cuttings removed by the drill bit 20 are cleared from the bottom of the wellbore 21 as the pumped fluid passes out of the wellbore 21 up through an annulus formed by the outer surface of the drill bit 20 and the walls of the wellbore 21. A typical elevator 29 is suspended from the top drive system to perform “pipe tripping” operations as will be explained in more detail.
A variety of items can be connected to and below the main shaft 16; for example, and not by way of limitation, the items shown schematically as items 24 and 26 which, in certain aspects, and not by way of limitation, may be an upper internal blowout preventer 24 and a lower internal blowout preventer 26. In other systems according to the present invention the item 24 is a mud saver apparatus, a load measuring device, a flexible sub, or a saver sub. A connection assembly 40 can non-threadedly connect the item 24 to the main shaft 16. The shaft 16 may be a drill stem or a quill.
In typical top drive drilling operations, top drive elevators 29 are set to have a pipe handler (explained below) oriented in one rotational direction to trip pipe (move the drill string into and out of the wellbore) and in another for drilling. The trip pipe orientation limits the extension travel of the elevators 29. Limiting the elevator extension allows the elevators 29 to clear a racking board 42 and/or parts in relation to the racking board 42, and this may include parts of the derrick 11. Such orientation allows the top drive 10 to travel up to or down from the racking board 42 and crown (top of the derrick 11) without the possibility of interference between the top drive pipe handling equipment and other items. The tripping rotational orientation also allows the elevators 29 and associated pipe handling equipment to extend out as close as possible to the derrick man/racking board 42 without interference between the elevators 29 and racking board 42 or the derrick 11. Height of the top drive system 10 above the derrick floor may be determined by any known type of sensor 41, either in drawworks (not shown) or other convenient location proximate the derrick 11.
There is a pre-determined “safe” zone of pipe handler rotational orientation in which the top drive and pipe handler can be rotated from a preset “trip” position. The safe tripping zone allows the pipe handler to be orientated in various trip positions to allow ease of pipe handling, including inserting and removing pipe to/from the elevators 29 for tripping pipe in and out of the wellbore without the risk of making contact with the racking board and/or other parts of the derrick 11.
There is also a predetermined “drilling position”, ordinarily oriented 180 degrees from the “zero” or pipe trip position, which allows the elevators 29 to be retracted far enough to allow the top drive system 10 to reach the drill floor without the elevators interfering with the drill floor. In such retracted position it is possible for the elevators 29 to make contact with the racking board 42 if the top drive system 10 were lifted sufficiently, so without proper monitoring, hoisting or lowering the top drive system 10 can result in damage to equipment and/or personnel.
In ordinary drilling operations, the top drive system 10 is hoisted up to the elevation level of the racking board 42 using the drawworks and the top drive pipe handling system, a “stand” of drill pipe can then be extended out to an operator situated in the derrick (the “derrick man”) and rotationally orientated based on hand signals and/or radio signals to the drilling unit operator (“driller”) as to orientate the elevators in the precise direction needed for ease of the derrick man to install or remove pipe to/from the elevators. The precise location that the elevators need to be rotated to depends on which side of derrick 11 the pipe is being racked or removed from as well as factors such as the configuration of the derrick. The pipe handling system can be rotated from the trip position to the drilling position to allow the top drive to move all the way to the drill floor with the elevators retracted (extended close to horizontal) to prevent the elevators 29 from contacting the drill or derrick floor.
Using hand signals or radio signals to communicate between the derrick man and the driller can be inefficient and sometimes dangerous. There exists a need for an automatic system to determine rotational position of the pipe handling portions of a top drive, and automatic controls to prevent unsafe orientation and positioning of the various top drive components during operations.
SUMMARYOne aspect of the invention is an automatic top drive positioning system including a top drive having a pipe handling system rotator gear, a drive motor rotationally coupled to the rotator gear and a rotational position sensor rotationally coupled to the rotator gear. A controller is configured to operate the drive motor to automatically move the rotator gear to a selected rotational orientation based on measurements from the rotational position sensor.
Other aspects and advantages of the invention will be apparent from the description and claims which follow.
A top drive with automatic pipe handing system may be used in a derrick as explained with reference to
At 114, the displayed bottom three control windows (buttons) allow the system operator (e.g., the driller) to set the pipe handler stop positions to selected rotational orientations. The numerical entry buttons allow the operator to enter rotation stop positions in degrees with respect to a reference, usually the trip position. The stop positions could also be transmitted to the controller (
An example system configuration is shown in block diagram form in
A top drive and pipe handler automated control system according to the various aspects of the invention may save pipe trip time, increase safety and reduce the possibility of damage to drilling unit components.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
Claims
1. An automatic top drive positioning system, comprising:
- a top drive comprising a pipe handling system rotator gear, a drive motor rotationally coupled to the rotator gear and a rotational position sensor rotationally coupled to the rotator gear; and
- a controller in signal communication with the rotator gear and the drive motor, the controller configured to operate the drive motor to automatically move the rotator gear to a selected rotational orientation based on measurements from the rotational position sensor.
2. The automatic top drive positioning system of claim 1 further comprising link cylinders coupled to elevator links coupled to the top drive, the link cylinders configured to move elevator links coupled to the top drive in a direction transverse to a direction of motion of the top drive during drilling operations.
3. The automatic top drive positioning system of claim 2 further comprising at least one sensor coupled to the link cylinders in signal communication with the controller, at least one sensor configured to measure an elevation of the top drive above a drill floor in signal communication with the controller, and wherein the controller is configured to automatically operate the rotator gear and the link cylinders such that an elevation of the top drive and a rotational orientation of the rotator gear prohibit interference between any part of the top drive and a drilling derrick.
4. A method for operating a top drive, comprising:
- measuring a rotational position of a pipe handler rotate gear having elevator links rotationally coupled thereto;
- automatically rotating the pipe handler rotate gear such that the elevator links are disposed in a selected rotational orientation with respect to a drilling derrick.
5. The method of claim 4 further comprising measuring an elevation of the elevator links above a drill floor and at least one of automatically rotating the pipe handler rotate gear to an orientation such that interference between the elevator links and the drilling derrick is avoided when the top drive is elevated in the drilling derrick.
6. The method of claim 4 further comprising automatically operating link extension cylinders to enable elevator extension when the rotator gear is within a selected range of rotational orientations.
7. The method of claim 5 further comprising automatically retracting the link extension cylinders when the rotate gear in within a selected range of rotational orientation.
Type: Application
Filed: Nov 29, 2011
Publication Date: May 30, 2013
Inventors: Keith A. Holliday (Houston, TX), Todd Mironuck (Longview), Paul Nicholson (Montgomery, TX), Dan Flaherty (Alberta)
Application Number: 13/306,458
International Classification: E21B 19/16 (20060101);