Apparatus for Aligning Tubulars During Placement in a Well

Abstract

Apparatus is provided for aligning tubulars when a drilling rig is used to lower a string of tubulars into a well. A joint of tubular can be moved to a vertical position above a connector to which it is to be joined and placed at the angle where threads on the joint and connector can be joined at low torque without damage to the threads. The apparatus can be used on a variety of drilling rigs and provides a safer environment for workers on the rig.

Description

BACKGROUND OF INVENTION

1. Field of the Invention

This invention relates to apparatus for placing tubulars in a well using a drilling rig. More particularly, apparatus is provided for remotely controlling alignment of joints of tubulars before joining.

2. Description of Related Art

The placement of tubulars in wells is normally carried out by hoisting a single joint of tubular (normally 30-45 ft. in length) into a vertical position over an assembly of tubulars (string) already placed in the well, aligning the hoisted joint of tubular with the string of tubulars, which is hanging in the well and supported by slips, rotating the hoisted tubular to thread the tubular into the string, raising the extended string to release the slips and lowering the extended string into the well. The process is repeated to make up a tubular string of the required length.

Tubulars having an outside diameter from about 2⅜ inches to about 36 inches are placed in wells. Tubulars placed in a well after the hole is drilled are called “casing,” and the diameter is normally more than 5 inches. Smaller tubulars, used as conduits for fluid flow in the well, are called “tubing.” Tubing is usually placed in a well using a “work over” rig, but it has the same type apparatus for running tubulars as a drilling rig, and is included in the designation “drilling rig” herein. A variety of automated equipment has been developed for placing both tubing and casing in wells. In most wells, where automated equipment is not available or is not economically justified, the placement of tubulars is still a “hands on” operation. The pipe tongs used to rotate tubulars during a placement operation are often hydraulically powered. Slips are usually handled manually, but may be hydraulic. The hoisting of each joint of tubular into a vertical position is performed with a small hoist in a mast over the well. The lowering of the entire string in the well is performed with the block-and-cable apparatus common to drilling rigs. The required lifting capacity of the mast is usually determined by the weight of the casing.

When a joint of tubular is in the vertical position, it must be aligned so that threading into the string of tubulars will not damage threads in the tubular. Generally, the joint being added has the male connection and the process of bringing the joints into position for threading is called “stabbing” the upper joint. When casing is being placed in a well each joint is much heavier than tubing joints, so aligning and stabbing casing are more difficult operations. The alignment operation is normally performed by a man standing on a platform in the mast (“derrick man”), which may be 30-50 ft. above the rig floor. Safety considerations arise when a man is required to stand above the level of the rig floor, because of the danger of falling. At the same time, it is necessary to thread the joints together without damaging threads in the tubular, which, with casing, can cause fluid to leak from the well and require expensive remediation steps to prevent an environmental risk.

U.S. Pat. App. No. 2012/0085550 discloses method and apparatus for stabbing tubular goods using an assembly attached to an elevator in a conventional drilling rig or a casing-running tool used in top drive drilling rigs. U.S. Pat. No. 7,770,654 discloses a pipe handling device for use with a top drive rig.

What is needed is apparatus for aligning tubulars for joining, without the need for a person positioned above the rig floor, that is economical to build and operate and that easily adapts for use with the variety of drilling rigs widely used in industry.

BRIEF SUMMARY OF THE INVENTION

Apparatus is provided to be placed on the floor of a drilling rig, either conventional or top drive, which can be remotely operated to align tubulars, such as casing, for making threaded connections at the drill floor. Hydraulic or pneumatic cylinders or electrically-driven sources of force operate plates and fingers to control the location and orientation of a tubular as it hangs in an elevator and align the tubular with a connector on a mating second tubular, such that lowering and rotation of the first tubular with low torque makes a threaded connection.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 shows an isometric view of the tubular aligning assembly.

FIG. 2 shows an isometric front view of the finger assembly of the tubular arm assembly.

FIG. 3 shows an isometric rear view of the finger assembly of the tubular arm assembly.

FIG. 4 shows an isometric detail view of one embodiment of a driving mechanism for fingers of the tubular arm assembly.

FIG. 5 shows a plan view of fingers of the assembly in an open position.

FIG. 6 shows a plan view of fingers of the assembly in a closed position.

FIG. 7 shows an isometric detail view of a second embodiment of a driving mechanism for fingers of the tubular arm assembly.

FIG. 8 shows a plan view of fingers of the assembly in an open position.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, one embodiment of a tubular aligning assembly 10 is shown. Assembly 10 is adapted to be placed on the drilling floor of a top drive drilling rig or to be placed on the rotary table of a conventional rotary rig. Base plate 11, which may be 2-inch thick steel, forms the base of the assembly. Attached plate 11a contains slot 11b and is preferably removable from base plate 11 by operation of fasteners 11c. The size of slot 11b is determined by the size of the tubulars being placed in a well. Attached plate 11a may have pad eyes 11c that are adapted to receive slots on the bottom of slips. Post base assembly 12a supports gear 12 having teeth that mesh with a motor attached to 12a such that post 13 may be rotated by operation of the motor. Post base assembly 12a may have supports 12b. Post 13 may be adjustable in height by a movable pin passing through holes in two concentric sections of the post and post support 13a, or, in another embodiment, height may be remotely controlled by a hydraulic or pneumatic cylinder inside post 13 (not shown). Extendable box assembly 15 supports finger assembly 20. Fixed box member 14 may be attached to support member 14a and post 13. Movable box member 15 may be extended and retracted within fixed box member 14 by operation of cylinder 16, which is attached to member 14 and member 15. Finger assembly 20 is attached to movable box member 15. Fixed box member 14 may include slot 14b, which allows retraction of finger assembly 20 nearer post 13.

Alternatively, in another embodiment, fixed box member 14 may be attached to a fixed structure of a drilling rig, such as one or more vertical members of the mast of the rig. In this embodiment, base 11 and post 13 are not used, and operations of the apparatus may be performed with other elements as if base 11 and post 13 were supporting fixed box member 14.

FIG. 2 illustrates an isometric front view of finger assembly 20. Finger base plate 21 supports upper pair of fingers 22, having distal pasts 22a and 22b, and lower pair of fingers 23, having distal parts 23a and 23b. Pair of fingers 22 and 23 may include roller bearings or ball bearings (not shown) inside each finger to decrease resistance to rotation of a tubular confined by and being aligned by the fingers. Distal parts 22a and 22b of upper fingers 22 are preferably in different horizontal planes, such that the distal parts of the fingers overlap when the fingers close. The same feature may be used for distal parts 23a and 23b of lower fingers 23. Distal parts of all fingers may not be necessary and may be omitted for some pipe sizes and applications. Rotary bearing 25 provides for rotation of finger base plate 21 around box member 15.

In another embodiment, only one pair of pairs of fingers 22 or 23 may be present in finger assembly 20, but not both. It may not be necessary to have two pairs of fingers, as shown in FIG. 2 and FIG. 3, in some applications. The thickness of the fingers in one pair of fingers may be increased to provide an adequate source of torque transverse to the axis of a tubular. The driving mechanism for only one pair of fingers is required in this embodiment.

FIG. 3 illustrates an isometric rear view of finger assembly 20 having two pairs of fingers. Finger support plate 30 is attached to finger base plate 21 and the extended end of box member 15 by horizontal pin 34, disposed so as to allow tilting of support plate 30 by rotation around the pin. Force for control of tilting is supplied by cylinder 31. Rotation of finger base plate 21 with respect to finger support plate 30 is provided by rotary bearing 25 (FIG. 2). Force for rotation is supplied by cylinder 32. Alternatively, the force may be supplied by an electric motor. Cylinders 37 and 38 supply the forces to operate the finger assembly, as described below.

Referring to FIG. 4, one embodiment of a driving mechanism 40 for upper and lower pairs of fingers is illustrated. The same driving mechanism is used for upper and lower pairs of fingers. The position of piston 41 of cylinder 37, extending through a hole in finger base 18 controls the position of fingers 22. H-member 43 is rigidly attached to piston 41. The proximate ends of links 45 are pivotally and moveably attached to H-member 43 by bushings 44. The distal ends of links 45 are pivotally and moveably attached to fingers 22 by bushings 46. Fingers 22 are pivotally and rigidly attached to horizontal U-member 42 by bushings 47. Therefore, bushings 44 and 46 move linearly (hence, are “movably attached”) in response to linear movement of piston 41, while bushings 47 remain fixed (hence, pivotally and rigidly attached). Driving mechanism 40 converts linear movement of the piston into angular movement of the fingers. In another embodiment, opening and closing of fingers may be achieved by a rack and pinion mechanism, described below. It should be understood that, although hydraulic or pneumatic cylinders are illustrated and described herein to provide driving forces, in other embodiments, driving forces provided by any or all of the cylinders can be provided by electric motors and associated gears.

FIG. 5 illustrates fingers 22 in an open position, to be used for placing the fingers around a tubular and beginning to grasp the tubular. FIG. 6 illustrates fingers 22 in a closed position. Contour 22c may be adapted for different diameters or ranges of diameters of tubulars.

Referring to FIG. 7, another embodiment of a driving mechanism for a pair of fingers is shown. Driving mechanism 70 operates as a rack and pinion. Finger base plate 78 supports horizontal U-member 72. Fingers 79 are pivotally and rigidly attached to member 72 by bushings 77. Movement of piston 71 (or other source of force) causes member 74, having teeth 73, to move linearly. Teeth 75 in fingers 79 translate linear movement into angular movement of fingers 79.

All embodiments of a tubular aligning assembly disclosed herein may be used for placing any tubulars in a well with a rig; only casing will be discussed here. Assembly 10 may be placed on the floor of a drilling or completion rig. In another embodiment, post base assembly may be rigidly attached to one or more rigid members of the rig, such as a vertical member of the mast or the drill floor or substructure. Finger assembly 20 may then be operated to align the tubular being added to the tubulars in the well. A joint of casing, normally with male threads, is suspended in the mast by elevators. Slips support a string of casing that has been placed in a well, with a female connector above the slips. Normally, the position of elevators in a horizontal plane does not allow a joint to align with the connector such that the joint can be rotated at low torque, which is necessary to insure that threads on the joint and connector are properly mated. Preferably, some threads are engaged by manual force before tongs are applied to torque the connection to the recommended level. This minimizes the risk of cross-threading the connection, which is especially important in placing casing in a well. Operation of the cylinders or other apparatus to supply a driving force in the apparatus from a control panel allows alignment of a joint such that it can be joined to a connector by pipe threads at low torque even if the elevator is not vertically above the joint. The control panel may be on or off the drill floor. Observation of tubular alignment may be by visual observation and communication to an operator of the control panel, by a video camera and viewing screen for the panel operator or other sensors and communication channels for detecting the location of a joint with respect to a connector and communicating data to the panel operator.

Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except to the extent that they are included in the accompanying claims.

Claims

1. A tubular alignment apparatus for placing tubulars in a well using a rig, comprising:

a rigid base;

a post attached to the base, the post being rotatable;

a horizontal support attached to the post, the horizontal support being linearly extendable;

a source of force attached to the horizontal support to drive a linear extension;

a finger assembly attached to the horizontal support, the finger assembly being rotatable and tiltable with respect to the horizontal support and comprising a first pair of fingers;

a pair of sources of force to drive the rotation and the tilt of the finger assembly; and

a source of force to drive a first pair of fingers, each finger of the first pair of fingers being connected to a fixed horizontal member and a link, the link being pivotally and moveably attached at a first end to the finger and at a second end pivotally and moveably attached to the source of force, such that the pair of fingers are driven toward open and closed positions in response to movement by the source of force.

2. The tubular alignment apparatus of claim 1 wherein each finger further comprises a distal part, the distal parts of the pair of fingers being in spaced apart horizontal planes such that the end members overlap when the fingers are closed.

3. The tubular alignment apparatus of claim 1 wherein the fingers include a contour adapted for a selected size tubular.

4. The tubular alignment apparatus of claim 1 wherein the post is extendable.

5. The tubular alignment apparatus of claim 4 wherein the post is extended by a source of force.

6. The tubular alignment apparatus of claim 1 wherein the finger assembly further comprises a second pair of fingers and a source of force to drive the second pair of fingers, each finger of the second pair of fingers being connected to a fixed horizontal member and a link, the link being pivotally and moveably attached at a first end to the finger and at a second end pivotally and moveably attached to the source of force, such that the pair of fingers are driven toward open and closed positions in response to movement by the source of force.

7. The tubular alignment apparatus of claim 1 wherein the sources of force are a hydraulic or pneumatic cylinder.

8. The tubular alignment apparatus of claim 1 wherein one or more of the sources of force are an electric motor and gears.

9. The tubular alignment apparatus of claim 1 wherein the base is a plate placed on the drill floor or rotary.

10. The tubular alignment apparatus of claim 1 wherein the base is a rigid attachment to the rig.

11. The tubular alignment apparatus of claim 1 wherein the fingers further comprise bearings disposed so as to decrease resistance to movement of a tubular in contact with the finger.

12. A tubular alignment apparatus for placing tubulars in a well using a rig, comprising:

a rigid base;

a post attached to the base, the post being rotatable;

a horizontal support attached to the post, the horizontal support being linearly extendable;

a source of force attached to the horizontal support to drive a linear extension;

a finger assembly attached to the horizontal support, the finger assembly being rotatable and tiltable with respect to the horizontal support and comprising a first pair of fingers;

a pair of sources of force to drive the rotation and the tilt of the finger assembly;

a source of force to drive a first pair of fingers, each finger of the first pair of fingers having teeth on a radial convex surface and being pivotally connected to a fixed horizontal member;

a linear driving member having teeth and being disposed such that the teeth of the driving member mesh with the teeth on the first pair of fingers; and

a source of force attached to the driving member such that the first pair of fingers can be driven toward open and closed positions in response to movement by the source of force.

13. The tubular alignment apparatus of claim 12 wherein each finger further comprises a distal art, the distal parts of the pair of fingers being in spaced apart horizontal planes such that the end members overlap when the fingers are closed.

14. The tubular alignment apparatus of claim 12 wherein the fingers include a contour adapted for a selected size tubular.

15. The tubular alignment apparatus of claim 12 wherein the post is extendable.

16. The tubular alignment apparatus of claim 15 wherein the post is extended by a source of force.

17. The tubular alignment apparatus of claim 12 wherein the finger assembly further comprises a second pair of fingers and a source of force to drive the second pair of fingers, each finger of the second pair of fingers having teeth on a radial convex surface and being pivotally connected to a fixed horizontal member;

a linear driving member having teeth and being disposed such that the teeth of the driving member mesh with the teeth on the second pair of fingers; and

a source of force attached to the driving member such that the second pair of fingers can be driven toward open and closed positions in response to movement by the source of force.

18. The tubular alignment apparatus of claim 12 wherein the sources of force are a hydraulic or pneumatic cylinder.

19. The tubular alignment apparatus of claim 12 wherein one or more of the sources of force are an electric motor and gears.

20. The tubular alignment apparatus of claim 12 wherein the base is a plate placed on the drill floor or rotary.

21. The tubular alignment apparatus of claim 12 wherein the base is a rigid attachment to the rig.

22. The tubular alignment apparatus of claim 12 wherein the fingers further comprise bearings disposed so as to decrease resistance to movement of a tubular in contact with the finger.