OPTICAL TOOL JOINT ASSIST FOR IRON ROUGHNECK
A tool joint assist system for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, the tool joint assist system comprising: a roughneck with upper and lower tongs; a camera positioned relative to the roughneck to be capable of capturing an image of tubular and the roughneck; a computer comprising a processor, a non-transitory storage medium, a display, a transmitter/receiver, and a set of computer readable instructions stored in the non-transitory storage medium and when executed by the processor: (i) present a captured image of the tubular, roughneck and an indicator of a proposed height of the roughneck relative to the tubular; receive an instruction from an operator to adjust the indicated proposed height relative to the tubular in the captured image; and (ii) command the roughneck to move to the adjusted height.
The present disclosure relates to pipe handling and drilling operations for hydrocarbons and other formation fluids and gases. In particular, the invention relates to a system and method for determining the position of an iron roughneck relative to a pipe joint.
BACKGROUND ARTDuring drilling operations, drill string is run into a well bore and is made up of a series of connected drill pipes. As the drill string is tripped into the wellbore, additional pipes are added to the top of the drill string to lengthen the string. The drill string is lowered in the wellbore until only an uppermost portion of the drill string sticks up above the drill floor. The distance the upper end of the drill string extends above the drill floor is called the “stick-up height.” When the drill string is positioned at an appropriate “stick-up height” for making up a new section of drill pipe to the drill string, pipe handling equipment position the new section of drill pipe in axial alignment with the drill string immediately above the string. The new section of drill pipe is lowered until the pin end of the new section stings into the box end of the drill string. The new section of drill pipe is then rotated relative to the drill string so as to engage the threads of the pin and box ends to form a pipe joint. An iron roughneck is then positioned at the pipe joint to apply sufficient torque to make up the joint. Typically, the threads are engaged by a low-torque pipe spinner and the joint is made up by mechanical tongs of an iron roughneck, which apply high-torque to the joint to ensure a complete and durable connection where the shoulders of the box and pin fully engage.
Because not all drill pipe sections are the same length and there is there substantial variability in the drilling process, the “stick-up height” varies each time a new pipe joint is to be made up in the drill string. Variable “stick-up height” presents a problem as the low-torque pipe spinner and the iron rough neck must be properly positioned relative to the joint. In particular, the low-torque pipe spinner must be positioned to engage the new pipe section, and the iron roughneck must be positioned so that its upper jaws engage the pin end of the new pipe section and its lower jaws engage the box end of the uppermost section of the drill string.
Current systems use optical cameras to obtain data regarding the position of the pipe joint relative to an iron roughneck. Typically, these system use a computer to process camera images of the pipe joint and control the position of the iron roughneck relative to the pipe joint.
U.S. Pat. No. 9,464,492 discloses a system for determining the position of a downhole drill pipe relative to a pipe handling device. The system comprises: an imaging means arranged to capture an image of the drill pipe in a region of the pipe for engagement by the device; and a processor operable to analyze said captured image and to determine therefrom the position of the drill pipe relative to said device. A processor is operable to analyze captured images and to provide control signals to a control means of the position of the wrench.
U.S. Pat. No. 9,657,539 discloses an automated roughneck including a backup tong and a makeup tong. The makeup tong and backup tong may be selectively movable relative to one another. The makeup tong and backup tong may include spinner and gripper assemblies respectively adapted to make up and break out threaded connections. A positioning sensor may be positioned on an upper surface of makeup tong, wherein the positioning sensor may scan drill string to detect tool joint as makeup tong and backup tong are moved vertically. The positioning sensor may instead be located at any other location on automated roughneck or any other surrounding structure. The positioning sensor may be any sensor capable of detecting the location of tool joint in order to position makeup tong and backup tong. The positioning sensor may be, for example, an optical sensor such as a camera, infrared range finder, or sound based sensor such as an ultrasonic sensor. Multiple positioning sensors may be utilized.
WO 2016/106294 discloses a system and method for positioning oilfield tubulars on a drilling floor (2), having an automated tubular handling system, to permit alignment and automated make up and break out of threading operations between a stationary tubular and a moving tubular, utilizing image information from radially offset cameras, processing the image information to recognize the tubulars within the image and develop position information for said tubulars, combining the position information from the two camera systems to develop three dimensional information for each of the tubulars, developing instructions for the automated tubular handling system to bring the stationary and moving tubulars into vertical alignment and lowering the moving tubular into threaded contact, and engaging an automated hydraulic torque wrench to make up the threaded connection.
Camera image data sometimes proves unreliable in situations where the edges and boundaries of the box and pin ends of the drill pipe are obscured. The edges and boundaries are particularly obscured when tripping drill string out of the wellbore because the pipe is covered in dirt, soil, and minerals. When automated camera systems fail to ensure proper alignment of the iron roughneck, drilling operators are forced to have drill rig personnel make a visual inspection of the iron roughneck position. This requires personnel to be physically present on the drill rig floor, which is not optimal for safety reasons.
While prior automated systems position the iron roughneck relative to the pipe joint based on image data, they do not provide a visual check to the drilling operator for visual confirmation the position is correct. In view of prior systems, there is a need for a pipe joint control system that provides a remote visual check of the iron roughneck during make-up and break-out operations.
SUMMARY OF INVENTIONIn accordance with the teachings of the present disclosure, disadvantages and problems associated with existing drill rig control systems are alleviated.
According to one aspect of the invention, there is provided a tool joint assist system for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, the tool joint assist system comprising: a roughneck with upper and lower tongs; a camera positioned relative to the roughneck to be capable of capturing an image of tubular and the roughneck; a computer comprising a processor, a non-transitory storage medium, a display, a transmitter/receiver, and a set of computer readable instructions stored in the non-transitory storage medium and when executed by the processor: (i) present a captured image of the tubular, roughneck and an indicator of a proposed height of the roughneck relative to the tubular; receive an instruction from an operator to adjust the indicated proposed height relative to the tubular in the captured image; and (ii) command the roughneck to move to the adjusted height.
A further aspect of the invention provides a tool joint assist method for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, the tool joint assist method comprising: capturing an image of a tubular and a roughneck; presenting the captured image on a display to a drilling rig operator; presenting, in the captured image, an indicator of a proposed height of the roughneck relative to the tubular; and receiving an acknowledgment from the drilling rig operator that the proposed height of the roughneck is approved.
According to another aspect of the invention, there is provided a tool joint assist system for joining tubulars in a drill string relative to a drilling rig, the tool joint assist system comprising: a pipe handling device; a camera positioned relative to the pipe handling device to be capable of capturing an image of a tubular being handled by the pipe handling device; a computer comprising a processor, a non-transitory storage medium, a display, a transmitter/receiver, and a set of computer readable instructions stored in the non-transitory storage medium and when executed by the processor: capture an image of a tubular; present the captured image on a display to a drilling rig operator; present, in the captured image, an indicator of a proposed height of the pipe handling device; and receive an acknowledgment from the drilling rig operator that the proposed height of the pipe handling device is approved.
A more complete understanding of the present embodiments may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features.
The objects and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements.
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
DESCRIPTION OF EMBODIMENTSPreferred embodiments are best understood by reference to
The tool joint assist system 5 may comprise one or more digital cameras located either in safe area (DCR) or in ATEX approved camera housings on the drill floor. A computer based system interfaces the cameras, and use vision software to evaluate the images and assist the operator set correct stick-up or tool joint height. The tool joint assist system 5 may enable the drill rig control system to assist the operator to adjust the stick-up or tool joint height, in order to position the iron roughneck 10 at the correct height during auto cycle operation. With the camera based system, the need for a direct visual check of the stick-up height positioning by personnel on the drill floor is highly reduced and in most cases eliminated. The tool joint assist system 5 may therefore assist the operator in efficient and safe make-up and break-out operations.
The tool joint assist system 5 may provide: high quality images from camera(s); integration to the overall drill rig control system; precise height adjustment of the roughneck relative to the drill string; no mechanical wear; fast and efficient auto cycle operation of the iron roughneck; a tool joint finder computer interfacing with the roughneck control system; easy configuration and storage of pre-defined pipe profiles. The tool joint assist system 5 may provide safety enhancements such as: a reduced need for personnel on drill floor; and a confirmation of stick-up height before the roughneck obstructs a direct view by the operator.
The tool joint assist system 5 may accommodate drilling tubular pipe diameters Ø89 to Ø254 mm SI (3½″ to 10″ Imperial (US)). The working area range may be about 600 mm±300 mm of camera height SI (23″±11½″ Imperial (US)). The design temperature minimum/maximum, which may only be relevant for ATEX housing, may be −20° C. to +40° C. SI (−4° F. to +104° F. Imperial (US)). The system may be classified suitable for ATEX Zone 1.
According to a further embodiment of the invention, there is provided a method for make-up and break-out drill pipe joints. A sequence of steps for the method, includes: (1) the roughneck is in an idle condition; (2) the operator confirms sequence start; (3) the tool joint assist system captures an image of the stick-up/tool joint and proposes a height setting for the roughneck; (4) the operator adjusts the height setting for the roughneck to match the detected stick-up/tool joint height; and (5) the tool joint assist system commands the roughneck to move to the adjusted height setting prior to clamping onto the drill string.
Returning again to
A keyboard and mouse are illustrated in
The processor may include a microprocessor, a microcontroller, a digital signal processor (DSP), an application specific integrated controller (ASIC), electrically-programmable read-only memory (EPROM), or a field-programmable gate array (FPGA), or any other suitable processor(s), and may be generally operable to execute instructions for the GUI, as well as providing any other functions of the system. Memory may comprise any one or more devices suitable for storing electronic data, e.g., RAM, DRAM, ROM, internal flash memory, external flash memory cards (e.g., Multi Media Card (MMC), Reduced-Size MMC (RS-MMC), Secure Digital (SD), MiniSD, MicroSD, Compact Flash, Ultra Compact Flash, Sony Memory Stick, etc.), SIM memory, and/or any other type of volatile or non-volatile memory or storage device. The computer code instructions for the system may comprise application software, firmware, and/or any other type of computer-readable instructions and/or any related, required, or useful applications, plug-ins, readers, viewers, updates, patches, or other code for executing the application may be downloaded via the Internet or installed in any other known manner.
The systems and methods disclosed herein may be used for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig. They may also be used during pipe handling operations while racking stands of tubular sections. Certain drilling rigs are capable of building stands of pipe during tripping or drilling operations. Likewise, certain drilling rigs are capable of disassembling stands of pipe during tripping or drilling operations. The systems and methods of the present invention may be applied to any situation in which a roughneck is made to engage a pipe joint for make-up or break-out operations.
Further, the present invention may be applied to other pipe handling operations, such as when a top drive is used to join sections of tubular pipe to a drill string. The auto sequence of the top drive may be used to lower a section of tubular pipe to a drill string suspended by a spider in the drill floor. However, because sections of tubular pipe vary in length and the stick-up height of the suspended drill string varies, the auto sequence may not lower the section of tubular pipe to a proper height for engagement of the tubulars. The systems and methods of the present invention may be used to present the drilling operator an image of the tubulars and an indicator of the proposed height of the lower pin end of the section of tubular pipe. The drilling operator may then adjust the indicator of the height of the lower pin end, so that the top drive may be commanded to position the height of the lower pin end at the adjusted height. The auto sequence may then be commenced to thread the tubulars via the top drive.
The description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
If used herein, the term “substantially” is intended for construction as meaning “more so than not.”
Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
Although the disclosed embodiments are described in detail in the present disclosure, it should be understood that various changes, substitutions and alterations can be made to the embodiments without departing from their spirit and scope.
INDUSTRIAL APPLICABILITYTool joint assist systems for drilling rigs of the present invention have many industrial applications including but not limited to drilling well bores for the oil and gas industry.
Claims
1. A tool joint assist system for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, the tool joint assist system comprising:
- a roughneck with upper and lower tongs;
- a camera positioned relative to the roughneck to be capable of capturing an image of tubular and the roughneck;
- a computer comprising a processor, a non-transitory storage medium, a display, a transmitter/receiver, and a set of computer readable instructions stored in the non-transitory storage medium and when executed by the processor: (i) present a captured image of the tubular, roughneck and an indicator of a proposed height of the roughneck relative to the tubular; receive an instruction from an operator to adjust the indicated proposed height relative to the tubular in the captured image;
- and (ii) command the roughneck to move to the adjusted height.
2. The tool joint assist system for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig as claimed in claim 1, wherein the camera comprises a digital camera capable of capturing digital images of tubular and the roughneck in real time.
3. The tool joint assist system for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig as claimed in claim 1, wherein the set of computer readable instructions when executed by the processor further present a graphic user interface via the display, wherein the graphic user interface is capable of presenting a captured image of the tubular, roughneck and an indicator of a proposed height of the roughneck relative to the tubular, wherein the graphic user interface is capable of receiving an instruction from an operator to adjust the indicated proposed height relative to the tubular in the captured image.
4. The tool joint assist system for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig as claimed in claim 1, wherein the set of computer readable instructions when executed by the processor further adjust, in the presented image, a position of the indicator of the proposed height of the roughneck relative to the tubular.
5. The tool joint assist system for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig as claimed in claim 1, wherein the set of computer readable instructions when executed by the processor further adjusts the position of the indicator in response to a received instruction from an operator to adjust the indicated proposed height relative to the tubular in the captured image.
6. The tool joint assist system for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig as claimed in claim 1, wherein the set of computer readable instructions further comprises a roughneck auto sequence for commanding the roughneck to perform a make-up or break-out operation.
7. A tool joint assist method for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, the tool joint assist method comprising:
- capturing an image of a tubular and a roughneck;
- presenting the captured image on a display to a drilling rig operator;
- presenting, in the captured image, an indicator of a proposed height of the roughneck relative to the tubular; and
- receiving an acknowledgment from the drilling rig operator that the proposed height of the roughneck is approved.
8. A tool joint assist method for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, as claimed in claim 7, wherein the capturing an image comprises capturing a real-time video stream.
9. A tool joint assist method for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, as claimed in claim 7, wherein presenting the captured image and the indicator of a proposed height comprises presenting a graphic user interface via the display, and wherein receiving an acknowledgment from the drilling rig operator comprises receiving the acknowledgment through the graphic user interface.
10. A tool joint assist method for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, as claimed in claim 7, further comprising: receiving an instruction from the drilling rig operator to adjust the indicated proposed height relative to the tubular in the captured image.
11. A tool joint assist method for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, as claimed in claim 10, further comprising: adjusting the position of the indicator in the image in response to a received instruction from the drilling rig operator to adjust the indicated proposed height relative to the tubular.
12. A tool joint assist method for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, as claimed in claim 11, further comprising: commanding the roughneck to move to the height of adjusted position of the indicator in the image.
13. A tool joint assist method for making and breaking pipe joints of tubulars in a drill string relative to a drilling rig, as claimed in claim 11, further comprising: instructing the roughneck to execute a roughneck auto sequence for a make-up or break-out operation.
14. A tool joint assist system for joining tubulars in a drill string relative to a drilling rig, the tool joint assist system comprising:
- a pipe handling device;
- a camera positioned relative to the pipe handling device to be capable of capturing an image of a tubular being handled by the pipe handling device;
- a computer comprising a processor, a non-transitory storage medium, a display, a transmitter/receiver, and a set of computer readable instructions stored in the non-transitory storage medium and when executed by the processor: capture an image of a tubular; present the captured image on a display to a drilling rig operator; present, in the captured image, an indicator of a proposed height of the pipe handling device; and receive an acknowledgment from the drilling rig operator that the proposed height of the pipe handling device is approved.
15. The tool joint assist system for joining tubulars in a drill string relative to a drilling rig as claimed in claim 14, wherein the set of computer readable instructions when executed by the processor further: capture a real-time video stream.
16. The tool joint assist system for joining tubulars in a drill string relative to a drilling rig as claimed in claim 14, wherein the set of computer readable instructions when executed by the processor further: present a graphic user interface via the display, and receive the acknowledgment from the drilling rig operator through the graphic user interface.
17. The tool joint assist system for joining tubulars in a drill string relative to a drilling rig as claimed in claim 14, wherein the set of computer readable instructions when executed by the processor further: receive an instruction from the drilling rig operator to adjust the indicated proposed height in the captured image.
18. The tool joint assist system for joining tubulars in a drill string relative to a drilling rig as claimed in claim 14, wherein the set of computer readable instructions when executed by the processor further: adjust the position of the indicator in the image in response to a received instruction from the drilling rig operator to adjust the indicated proposed height.
19. The tool joint assist system for joining tubulars in a drill string relative to a drilling rig as claimed in claim 14, wherein the set of computer readable instructions when executed by the processor further: command the pipe handling device to move to the height of adjusted position of the indicator in the image.
20. The tool joint assist system for joining tubulars in a drill string relative to a drilling rig as claimed in claim 14, wherein the set of computer readable instructions when executed by the processor further: instructs the pipe handling device to execute an auto sequence for a make-up or break-out operation.
Type: Application
Filed: Nov 16, 2018
Publication Date: May 21, 2020
Inventor: Anstein Jorud (Kristiansand)
Application Number: 16/193,295