ANGLED TUBULAR STAB-IN SYSTEM AND METHOD

Abstract

During drilling operations, there is a need to constantly add (or remove) stands of pipe to the drill string to continue the drilling process. Described herein are angled pipe stand tripping in (and tripping out) methods, processes, systems and devices. Faster drilling connections (or disconnections) for tripping in (or tripping out) may be made when the top drive unit can be raised and lowered when the pipe stand is presented (or removed) at an angle for stabbing purposes.

Description

CROSS-REFERENCE TO RELATED AND CLAIM OF PRIORITY

The present application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/799,282 filed on May 2, 2025, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

Embodiments herein are generally directed to pipe handlers and methods mainly for use in well drilling operations and, more particularly, to an angled tubular stab-in system and method for tubular member drilling and tripping connections in well drilling operations.

BACKGROUND

Pipe handling operations were conventionally performed by workers performing manual operations. Well drilling involves drilling and tripping of the drill string during which drill pipes are lowered into or pulled out of a well. Tripping may occur to make changes to the bottom hole assembly, such as to change a drill bit. When drill pipe is tripped into or out of a well, pipe stands (multiple sections of series-connected pipe) may be supplied from or stored in a racking board (storage rack) of the drill rig as the pipe stands are connected (to lengthen) or disconnected (to shorten) to the drill string in the well. When manually performed by workers, an elevator or top drive unit may be used to carry the load of a stand of drill pipe during drilling and tripping operations while workers maneuver the drill pipe stands on the drill floor between the well center and the storage rack. One worker may be positioned on the drill floor near the well center to maneuver the lower end of the drill pipe stands, while another worker may be positioned on or above the storage rack to maneuver the upper end of drill pipe stands as they are moved between the well and the storage rack.

A typical drill pipe section or tubular is around 30 feet long but may be shorter or longer. It is common to store multiple drill pipe sections connected together in series as a pipe “stand” which typically consist of two or three (or more) pipe sections. Multiple section drill pipe stands are longer and heavier than a single length of drill pipe and more difficult to handle due to their length and weight. Manual handling of the drill pipe stands during tripping can be dangerous. Therefore, there have been various efforts to automate the process and remove the need for workers to be present and perform pipe handling activities. One system is described in U.S. Patent Application Publication No. 2021/0293099.

On a drilling rig system, there is a need to constantly add/remove stands of pipe to/from the drill string to continue the drilling process. During the drilling connection and the tripping in process, a number of sequential activities take place. One of these activities is waiting for the top drive unit (and elevator) to move up the mast approximately 90-100 feet from the “stump” (the top end of the drill string positioned in the wellbore) to enable the next pipe stand to be placed and connected to the drill string. The amount of time to move the top drive unit from the stump to a position vertically above (or near the upper end of) the next pipe stand depends on several factors, including length of the pipe stand and vertical travel speed of top drive unit. Once the top drive unit is raised, then the pipe stand can be maneuvered to a vertical position above the drill string, secured by the elevator, and lowered into the connection joint and connected to the drill string.

With the depth of past/current wells, and wells being drilled today on the order of 25,000 feet deep, even a short reduction in the cycle time of the stab-in process for a pipe stand to be connected to the drill string presents substantial savings (e.g., time and cost) for a drilling rig operator.

Others have developed, for offshore drilling rigs, a retract dolly that pulls the top drive unit away from the well center in order to initiate the stab-in process as the top drive unit moves upward. However, this retract dolly is a large and expensive piece of overhead equipment that is not feasible for most land-based or onshore drilling rigs.

Accordingly, there is a need for a new stab-in system and methods that may reduce the cycle time for stabbing in pipe stands to the drill string during drilling and tripping operations. Such system and methods are configured to initiate and perform (and least some of) the stab-in process while the top drive unit is moving upwards to a position to secure the next pipe stand above the wellbore area for connection to the drill string. This enables faster drilling connections and tripping connections and increases drilling or tripping speed of the rig, and without the need for additional large and expensive overhead equipment. There is also needed a system and methods that may reduce the cycle time for wet tripping (stab-out process) to drain drilling fluid (e.g., mud, into a mudbucket) from the disconnected pipe stand while the top drive unit begins moving lower to eventually secure the new top end (stump) of the drill string disposed in the wellbore.

SUMMARY

According to one embodiment of the present disclosure, there is provided a pipe handling system for use in a drilling rig system. The pipe handling system includes a pipe handling apparatus comprising an elongated column structure having a lower end and an upper end in vertical alignment and a first lower arm disposed about the lower end and a second upper arm disposed about the upper end and configured to secure a pipe stand for movement. The pipe handling apparatus is further configured to position the pipe stand at an angle A with respect to a wellbore axis of a wellbore in the drilling rig system and position a lower end of the pipe stand at the wellbore axis.

In another embodiment, there is provided a drilling rig system for use in drilling, the drilling rig system having a mast supporting a top drive unit and a pipe handling system. The pipe handling system includes a pipe storage rack for storing one or more pipe stands, a pipe handling apparatus having an elongated column structure with a lower end and an upper end in vertical alignment and a first lower arm disposed about the lower end and a second upper arm disposed about the upper end and configured to secure a pipe stand for movement. The pipe handling apparatus is further configured to position the pipe stand at an angle A with respect to a wellbore axis of a wellbore in the drilling rig system and position a lower end of the pipe stand near the wellbore axis.

In the above and other various embodiments described herein, the pipe handling apparatus may be further configured to position the pipe stand at the angle A at a time when a top drive unit disposed above the wellbore of the drilling rig system is moving vertically upward or downward, the angle A may be an angle between about 1 and 15 degrees, the length of the pipe stand is equal to or greater than about 90 feet, the pipe handling apparatus is configured to position the pipe stand at the angle A at a time when the top drive unit is moving vertically downward and enable drilling fluid within the pipe stand to drain therefrom, and/or the second upper arm of the pipe handling apparatus may be configured to secure the upper end of the pipe stand beneath the top drive unit and move the upper end horizontally away from the wellbore axis to position the pipe stand at the angle A.

In another embodiment, there is provided a pipe handling method for use in a drilling rig system. The method includes positioning a pipe stand in a first position above a wellbore having a wellbore axis within the drilling rig system at an angle A with respect to the wellbore axis. The pipe stand includes an upper end and a lower end, and in the first position the lower end of the pipe stand is disposed within a box of a drill string within the wellbore.

In the above and other various embodiments described herein, the pipe handling method may further include positioning the pipe stand at the angle A between about 1 and 15 degrees, and/or securing the upper end of the pipe stand to an upper arm of a pipe handling apparatus and securing the lower end of the pipe stand to a lower arm of the pipe handling apparatus, where the pipe handling apparatus comprises an elongated column structure configured to secure and move the pipe stand into the first position. The pipe handling method may further include securing and positioning, by the pipe handling apparatus, the pipe stand in a second position, wherein in the second position the pipe stand is disposed in a vertical direction and parallel to and laterally spaced from the wellbore axis, and moving, by the pipe handling apparatus, the pipe stand between the second position and the first position (e.g., from first position to second position or from second position to first position), and/or moving the pipe stand between the second position and the first position occurs, at least in part, during a vertical movement of a top drive unit disposed above the wellbore and aligned with the wellbore axis.

In yet another embodiment of the present disclosure, there is provided a pipe handling method for use in a drilling rig system, wherein the drilling rig system comprises a mast supporting a top drive unit disposed above a wellbore having a wellbore axis and a pipe handling system having a pipe storage rack for storing one or more pipe stands and a pipe handling apparatus. The method includes securing and positioning, by the pipe handling apparatus, a pipe stand in a first position above the wellbore at an angle A with respect to the wellbore axis, the pipe stand comprising an upper end and a lower end, and in the first position the lower end of the pipe stand is disposed within a box of a drill string within the wellbore. The method also includes securing and positioning, by the pipe handling apparatus, the pipe stand in a second position, wherein in the second position the pipe stand is disposed in a vertical direction and parallel to and laterally spaced from the wellbore axis. The pipe handling apparatus moves the pipe stand between the second position and the first position (e.g., from first position to second position or from second position to first position).

In the above and other various embodiments described herein, the pipe handling method may further include positioning the pipe stand at the angle A between about 1 and 15 degrees, and/or securing the upper end of the pipe stand to an upper arm of a pipe handling apparatus and securing the lower end of the pipe stand to a lower arm of the pipe handling apparatus, the pipe handling apparatus comprising an elongated column structure configured to secure and move the pipe stand into the first position and into the second position. The pipe handling method may further include moving the pipe stand between the second position and the first position occurs, at least in part, during a vertical movement of the top drive unit above the wellbore, and/or moving, by the pipe handling apparatus, the pipe stand from the second position to the first position at least in part during an upward vertical movement of the top drive unit above the wellbore.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments of the present disclosure and are therefore not to be considered limiting of its scope, and the present disclosure may admit to other equally effective embodiments.

FIG. 1 illustrates an overall drilling rig system in accordance with the present disclosure;

FIG. 2 is a side view of a portion of the drilling rig system illustrating a stab-in system and configuration according to certain embodiments of the present disclosure;

FIG. 3 is a close-up, side view portion of the drilling rig system shown in FIG. 2 and illustrates an angled stab-in configuration of a pipe stand and the stump of the drill string in the wellbore area;

FIG. 4 is a side view of a portion of the drilling rig system (similar to FIG. 2) illustrating a stab-out or tripping out system and configuration according to certain embodiments of the present disclosure;

FIGS. 5A-5H are side views illustrating select exemplary (and different) configurations of the drilling rig system (similar to FIG. 2) at different points during a stab-in process or method according to certain embodiments;

FIGS. 6A-6H each include perspective side, perspective top portion (pipe fingerboard area) and perspective bottom portion (well bore area) views, illustrating various exemplary configurations of the drilling rig system at different points during a stab-in process or method according to certain embodiments; and

FIGS. 7A and 7B are side views of a portion of the drilling rig system (similar to FIG. 2) illustrating different exemplary methods of bending a pipe stand to enable the lower end more co-linear with the upper end (stump) of the drilling string.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

DETAILED DESCRIPTION

FIGS. 1-7, described below, and the various embodiments used to describe the principles of the present disclosure are by way of illustration only and should not be construed in any way to limit the scope of this disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any type of suitably arranged device or system.

The present disclosure describes a drilling rig system including a drilling rig and a pipe handling system. Embodiments herein are generally directed to pipe handling equipment and systems utilized and operations performed in conjunction with well drilling operations and, more particularly, to systems and methods for automated pipe handling operations. In particular, the present disclosure relates to pipe stand handling and guiding or securing configured for use with pipe handling manipulation mechanisms, and may be for use with pipe handling robots. Such pipe handling operations may include drill pipe and pipe stand handling operations, such as trip in and trip out (and stab-in and stab-out) operations.

In general terms, the present disclosure is directed to an angled stab-in (and stab-out) system and methods for making faster drilling and tripping connections/operations by allowing other operations to take place while the top drive unit is being raised or lowered. The methods described herein may be performed by a drilling rig and pipe handling system/mechanism, such as the RZR pipe handling system from Nabors Industries, Ltd and known as the iRacker® racking tubular handling system, which is incorporated herein by reference, or other suitable devices or assemblies.

During the drilling connection and the tripping in process, there are a number of sequential activities that take place. One of these activities is waiting for the top drive unit to move up the mast approximately 95' from the stump to the next pipe stand to be placed in the drill string. The present disclosure describes various methods and processes to stab in at an angle, away from the top drive unit. This permits a stab-in process to take place while the top drive unit is moving, rather than waiting for the top drive unit to reach its destination. This may save several seconds per pipe stand, which adds up to significant time savings on deep wells, such as a 25,000 ft well. Such methods and processes can be similarly utilized with slight modifications for tripping out.

In an example embodiment, as depicted in FIG. 1, a drilling rig system 10 may include a drilling rig 100 which may be used to drill or otherwise conduct operations on a wellbore. In some embodiments, the drilling rig system 10 may include one or more pump skids/systems 350, a generator skid/system 400, a mud pumping and processing skid/system 500, a mud gas separator skid/system 600, a hydraulic power unit (HPU) skid/system 700, and one or more tank skids/systems 800. The one or more pump skids/systems 350 provide drilling fluids, such as drilling mud, to the drilling rig 100 for use during wellbore operations. The generator skid/system 400 may be used to provide electrical power to drilling rig 100 and other components of the drilling rig system 10. The mud pumping and processing skid/system 500 pumps drilling fluids for use in the wellbore, and processes drilling fluids returning from the wellbore by, for example and without limitation, separating out solids and gases from the returning drilling fluid. The mud gas separator skid/system 600 separates gases from the liquid part of drilling fluids returning from the wellbore. The HPU skid/system 700 provides hydraulic power, through the use of high pressure hydraulic fluid, for one or more components of the drilling rig 100 or other components of the drilling rig system 10. The one or more tank skids/systems 800 typically include one or more tanks to hold fluids for use with the drilling rig 100 or other components of the drilling rig system 10.

The drilling rig 100 includes a rig floor 101 and a substructure 103 for supporting the rig floor 101 above the ground. In some embodiments, the drilling rig 100 may include a mast 119 having a plurality of upright structures that define a frame for the mast 119. The mast 119 may be positioned above a well (or other areas above the rig floor 101) being drilled by the drilling rig 100 and configured to support tubular members, such as a drilling string, being used during a drilling operation. As will be appreciated, the mast 119 may additionally be used to support other components and other tubular members during operations other than drilling operations.

In some embodiments, the drilling rig 100 includes a pipe handling apparatus 123 having a vertically oriented and elongated pipe handling assembly 125, and may include other components for additional pipe handling, such as from the catwalk system 200 to the pipe handling assembly 125 or to another operable location within the mast 119 or about the rig floor 101 (not shown in FIG. 1). These other components may be configured to engage and move a tubular member between locations on the drilling rig 100 during operations, such as from the catwalk system 200 to a position above the well or rig floor such that the tubular member may be placed into the well by other components of the drilling rig 100 (or build or disassemble pipe stands). These components may also include one or more grippers adapted to grip onto and/or rotate a tubular member, and may include other component(s) to further manipulate a tubular member. The pipe handling assembly 125 may include a pipe handler carriage configured to move vertically relative to assembly 125 and allow it to move a tubular segment or member vertically. As will be appreciated, other suitable configurations and positioning of the pipe handling apparatus, assembly and pipe handler may be utilized.

Pipe and tubular members may be any tubular member for use with the drilling rig 100 including, for example and without limitation, drill pipe, casing, collars, pipe stands, casing stands, or other tubular members. As used herein, “tubular” refers to an elongated cylindrical tube and can include any of the tubulars manipulated around a rig, such as tubular segments, tubular stands, tubulars, and tubular string, but not limited to the tubulars shown in the FIGURES. Therefore, in this disclosure, “tubular” is synonymous with “tubular segment,” “tubular stand,” and “tubular string,” as well as “pipe,” “pipe segment,” “pipe stand,” “pipe string,” “casing string,” “coiled tubing”, or “wireline.”

In some embodiments, as depicted in FIG. 1, the drilling rig 100 may include a top drive unit 135 mechanically coupled to the mast 119 such that the top drive unit 135 may move vertically relative to the mast 119. The top drive unit 135 can be configured and operate to raise, lower, and/or rotate tubular members during operation of the drilling rig 100. In some embodiments, the top drive unit 135 may be raised and lowered by a cable and a drawworks assembly, a rack and pinion assembly, or other suitable system.

Though not specifically shown in FIG. 1, the drilling rig 100 may include a pipe elevator having one or more components (e.g., jaw, clamp) that engage a tubular member such that the pipe elevator may support and raise/lower the tubular members used by the drilling rig 100. The pipe elevator may be coupled to the top drive unit 135 (or form part of the top drive unit) and the pipe elevator may move in conjunction with the top drive unit 135.

The drilling rig system 10 and the drilling rig 100 shown and described in FIG. 1 is one example of a drilling system which may incorporate the teachings and features described in the present disclosure. Further, other component(s) and system(s) may be included, while others may be omitted from, the drilling rig system 10 and/or drilling rig 100. For additional descriptions and examples of drilling rig systems, drilling rigs and components thereof, reference is made to U.S. Patent No. 10,975,635 which is incorporated herein by reference. Other configurations (and components/devices) may be used for the drilling rig system 10 and drilling rig 100, including those known in the art.

Now turning to FIG. 2, there is illustrated a detailed side view of a portion of the drilling rig 100 system showing the main components of the stab-in system and configuration according to certain embodiments of the present disclosure.

As shown, the pipe (or tubular) handling assembly 125 may include an elongated and rotatable column structure 400 that extends vertically upwards from the drilling floor 101 to a pipe storage fingerboard assembly 410 that is affixed to the mast 119 and positioned near the upper end of the column 400. The column structure 400 is configured to rotate about a vertically oriented longitudinal axis and may include a lower tailing arm 430 and an upper lifting (or hoisting) arm 440 coupled to the structure 400. Each of the arms 430, 440 has a proximal end pivotably connected to the column structure 400 and a distal end having one or more tools 450 (e.g., hydraulic gripper) configured to grip and/or secure a tubular pipe at that location. As the proximal ends of the arms 430, 440 rotate about the respective pivot points, their distal ends move laterally away or toward the column structure 400 enabling lateral movement (and some vertical movement) of a secured tubular pipe with respect to the column structure. In some embodiments, either or both of the arms 430, 440 may be slidably coupled to the column structure 400 and operate to move a secured pipe in a vertical direction.

In embodiments, the upper lifting arm 440 is configured, and includes a gripping tool 450a, to provide gripping and lifting functions and support the weight of the secured pipe for manipulation. In embodiments, the lower tailing arm 430 may include a similar gripping tool for gripping, lifting and supporting the secured pipe, or may include a tool that functions to secure (hold laterally steady) the lower end of the pipe from movement but may not grip or support the weight of the pipe.

In some embodiments, the pipe handling assembly 125 is configured such that the column structure 400 (with upper and lower arms) may move and travel in a lateral or horizontal direction along a predetermined path defined by a track (or slot/groove) disposed on or in the rig floor 101 (not shown in the FIGURES).

As will be appreciated, the various positioning and mobility features of the pipe handling assembly 125 and its components, e.g., the rotation of the column 400, the pivoting/swinging (and/or vertically slidable) arms 430, 440, and the lateral movement of the entire column 400, provides for different handlings and movements of tubular pipes in the relevant areas of the drilling rig 100. The pipe handling assembly 125 may be configured to perform pipe handling functions for transferring pipe to/from the catwalk system 200 (horizontal pipe storage), transferring pipe stands to/from the pipe storage rack/fingerboard assembly 410 for tripping in/out, transferring pipe and assisting in pipe stand building, transferring pipe stands to/from the well bore area (and to the top drive unit 135), etc. As noted above, the drilling rig 100 shown in FIG. 1 may include other pipe handling components separate from, or in addition to, the pipe handling assembly 125. Tt will be understood that some embodiments of the pipe handling assembly 125 as described herein may include such additional components to complement or otherwise provide additional handling capabilities, if desired.

Referring still to FIG. 2, there is shown a general arrangement of the angled stab-in system (and used in various method) with the pipe handling assembly 125 securing a first pipe stand 470a in a position for connection (stab-in) to the “stump” end of a drill string 475. It will be understood that the pipe stand 470a may have been previously retrieved from the pipe storage fingerboard assembly 410 by the assembly 125. Although not expressly illustrated in FIG. 2, one or more second pipe stands 470b may be disposed in a stored position within the fingerboard assembly 410 (e.g., illustrated in FIGS. 5 and 6). As will be appreciated, the lower and upper arms 430, 440 are configured to extend/retract (pivot) from/to the column 400 and retrieve a pipe stand from storage, or deliver a pipe stand for storage, at the fingerboard assembly 410. It will be understood that pipe stands 270 are normally stored in rows and adjacent one another in the fingerboard assembly 410, and FIG. 2 illustrates the pipe stand 470a secured and held by the gripping tool 450a of the upper lifting arm 440 and secured by the tool 450b of the lower tailing arm 430. No further description of storing or retrieving pipe stands 470 at the fingerboard assembly 410 is necessary to understand the present disclosure.

At this point in the stab-in process as represented in FIG. 2, the top drive unit 135 is shown moving upwards towards an eventual position above (e.g., vertically higher than) the upper end of the pipe stand 470a. The pipe stand 470a is positioned vertically, but at a stab-in angle A with respect to a longitudinal axis 480 of the well bore and drill string 475. This configuration may be accomplished by further extension of the lower arm 430 in a general horizontal direction away from the pipe handling assembly 125 and towards the wellbore, and by some extension/positioning of the upper hoisting arm 440 closer to the pipe handling assembly 125 as compared to the lower arm 430. In this position shown in FIG. 2 (and shown in FIG. 3), the pipe stand 470a is disposed at a stab-in angle A with respect to the axis 480 of the wellbore and the lower end of the pipe stand 470a is positioned at a point that is at, on or relatively near the axis 480.

Though not shown in FIGS. 2-4, it will be understood that a stabbing guide may be utilized to assist alignment during any stabbing in process. Stabbing guides may be used to align the pin threads (male) of the pipe stand with box threads (female) of the drill string/stump.

As will be appreciated, the angle A in degrees (e.g., the angle in degrees from the longitudinal axis 480) may be within a range sufficient to enable, allow or result in a substantial portion of the upper end of the pipe stand 470a being laterally (horizontally) displaced a distance from the axis 480 so that the upper portion of the pipe stand 470a does not interfere with the top drive unit 135 as it moves vertically upwards near the top end. This enables the top drive unit 135 to move upwards/downwards at a point in the stab-in/stab-out process sooner than is done in conventional prior art processes. FIG. 3 is a more detailed side view illustrating the lower end of the pipe stand 470a positioned with respect to the stump 475a and drill string 475. Although not explicitly illustrated in the Figures, those of ordinary skill in the art understand that the threaded connection end (female) of the stump end 475a of the drill string 475 is referred to as the “box” and the threaded connection end (male) of the lower end of the pipe stand 470a is referred to as the “pin.”

As will be appreciated, the range for angle A may depend at least on pipe stand length and the dimensions of the top drive unit 135. In various embodiments, the angle A may range between 1 and 15 degrees, between 1 and 10 degrees, and/or between 1 and 5 degrees, and the pipe stand length may be suitable and/or conventional lengths utilized in the industry, and may also be greater than about 90 feet in embodiments.

At a point near the upper end of the pipe handling assembly 125 (just below the fingerboard assembly 410), there is disposed a pipe guide 420 configured to selectively secure or otherwise hold the pipe stand 470a at that fixed point. This fixed point provides, or functions as, a rotating or pivoting point/axis about which the pipe stand 470a may rotate (rotating about the axis point in clockwise or counterclockwise directions). Rotation of the pipe stand 470a about the pivot axis in the clockwise direction rotates the upper end laterally away from the mast 119 and well bore axis 480 (to the right in FIG. 2), and rotates the lower end towards the mast 119 and well bore axis 480 (to the left in FIG. 2). The reverse occurs when rotation is in the counterclockwise direction. It will be understood that in other embodiments, the pipe guide 420 is optional, and the pipe stand 470a may be positioned as desired (as described herein) by associated movement of the arms 430, 440 to provide the proper angle at the proper time.

In the configuration shown in FIG. 2, while the top drive unit 135 (and elevator 136) moves upward, a point is reached at which the pipe guide 420 may release the upper end of the pipe stand 270a and the hoisting arm 440 may begin rotating/extending outward which moves the upper end of the pipe stand 470a inwards towards the mast 119 and axis 480. Meanwhile, the lower end of the pipe stand 470a may be held relatively stationary about the stump 475a. As the upper end of the pipe stand 470a travels inward, the angle A between the pipe stand 470a and the axis 480 decreases. Eventually, as the top drive unit 135 travels further upward to a point above the end of the pipe stand 470a, the hoisting arm 440 extends further outward until the angle A is zero (or about zero) degrees. At this point, the elevator 136 secures and supports the pipe stand 470a, and the orientation of the pipe stand 470a is virtually co-linear with the stump 475a and drill string 475 and aligned with the axis 480. As will be appreciated, during this process, the lower arm 430 may be held stationary or extended further outward in conjunction with (or commensurate with) the movement of the upper end of the pipe stand 470a.

Once secured and supported by the elevator 136 of the top drive unit 135, the pipe stand 470a is released from the hoisting arm 440 and the lower arm 430. The pipe stand 470a is now in position for a typical threaded connection to be made between the lower end of the pipe stand 470a and the stump 475a of the drill string 475.

As illustrated, this configuration allows the top drive unit 135 to move upward while the lower portion of the pipe stand 470a is being positioned for stab-in within the working wellbore area (e.g., above the wellbore) instead of having to wait for the top drive unit 135 to reach the full height (e.g., finger board height) before moving any portion of the pipe stand 470a into the working wellbore area.

A conventional drilling connection (i.e., stab-in) process with a pipe handling apparatus may generally include the following:

• • 1. Slips are set (holds drill string/stump weight).
  • 2. Top drive unit unscrews from the drill string at the floor level. The top of the drill string at the floor becomes the stump.
  • 3. Top drive unit raises up (e.g., 95’) to receive next pipe stand.
  • 4. Pipe stand is moved from the pipe handling apparatus (upper arm and lower arm) and delivered to the elevator(s) within the well center area. Elevator(s) secure around the pipe stand in the well center area.
  • 5. Pipe stand is lowered by the pipe handling apparatus to stab into the drilling string/stump.
  • 6. Pipe handling apparatus releases the pipe stand and moves out of well center area (elevator(s) may now support pipe stand).
  • 7. Pipe stand is screwed into drilling string/stump.
  • 8. Top drive unit is lowered to stab into the pipe stand (if drilling).
  • 9. Pipe stand is screwed into top drive unit (if drilling).
  • 10. Slips are released.
  • 11. Top drive unit/elevator(s) lowers pipe stand and drill string into wellbore.
  • 12. Process repeats for next pipe stand.

In accordance with the present disclosure, there is provided a drilling connection process using pipe stand angle manipulation, which may include the following:

• • 1. Slips are set (holds drill string/stump weight).
  • 2. Top drive unit unscrews from the drill string at the floor level. The top of the drill string at the floor becomes the stump.
  • 3. Two relatively concurrent actions take place:
    • a. Top drive unit begins raising up (e.g., 95’ feet) for eventual receipt of next pipe stand.
    • b. While the top drive unit is being raised, the pipe handling apparatus (using upper arm and mostly lower arm) positions the next pipe stand at an angle (e.g., a first position) to stab into the drilling string/stump, while keeping clear of the top drive unit. Pipe stand is lowered for stabbing into the drilling string/stump. It will be understood that the pipe handling apparatus previously obtained and secured the pipe stand from the storage rack and is maintaining/positioning the pipe stand in a vertical direction (e.g., parallel to the wellbore axis) and spaced laterally a distance from the wellbore and wellbore axis (e.g., at a second position). See FIGS. 5A, 6A. From this position, the pipe handling apparatus moves the pipe stand to the angled position while the top drive unit moves upward. See FIGS. 5B, 5C, 6B, 6C.
  • 4. As the top drive unit raises, the upper portion(s) of the pipe stand are continually moved into the wellbore area (e.g., beneath the top drive unit) and when the top drive unit reaches the appropriate height, the pipe stand is vertically positioned into the elevator(s). See FIGS. 5D-5H, 6D-6H. The process generally uses coordinated motion to maintain the tool center point (TCP) of the pin end (male threaded end of pipe stand) in a fixed position within the box (female threaded end of stump of the drill string) – or within the box area of a stabbing guide if used. The elevator(s) support and control the pipe stand at this point (see FIGS. 5H, 6H) and the pipe handling apparatus moves out of the well center area (not shown).
  • 5. Two relatively concurrent actions may take place:
    • a. Pipe stand is screwed into drilling string/stump.
    • b. Top drive unit is lowered to stab into pipe stand.
  • 6. Pipe stand is screwed into top drive unit.
  • 7. Slips are released and top drive unit lowers the drill string (with the stabbed pipe stand) into wellbore.
  • 8. Process repeats for next pipe stand.

By maneuvering and positioning the pipe stand at an angle, parallel activities can take place while the top drive unit is being raised. The method above may optionally allow the top drive unit to make up both connections substantially simultaneously.

In order to accomplish this angled stab-in, the pipe handling system 125 is configured to lift a pipe stand and present the pipe stand at an angle to stab into the drilling string/stump while the top drive unit is being raised. See FIGS. 2 and 3.

Referring now to FIG. 4, there is shown a general arrangement of the angled stab-out system (and used in various methods) with the pipe handling assembly 125 securing a first pipe stand 470a in a position during a wet tripping-out process. In this illustration, the pipe stand 470a has already been disconnected from the drill string 475, the two arms 440, 430 have grabbed and secured the pipe stand 470a, the elevator 136 has relinquished control of the pipe stand 470a to the two arms, the hoisting arm 440 has retracted to a certain position resulting in the pipe stand 470a angled by angle A, and the pipe guide 420 has been activated to secure and hold the pipe stand 470a at that point. In this process, a mudbucket 490 or reservoir/container is shown positioned below the lower end of the pipe stand 470a to receive drilling fluid (e.g., mud) that drains from the pipe stand 470a. As will be appreciated, the mudbucket 490 may have been set in place during disconnection of the threaded connection between the pipe stand 470a and the drill string 475.

As illustrated, this configuration allows the top drive unit 135 to begin moving downward before the entirety of the pipe stand 470a has been removed from the working wellbore area (e.g., above the wellbore) while mud may concurrently drain into the mudbucket 490.

A conventional tripping out process with a pipe handling apparatus may generally include the following:

• • 1. Slips are set (holds drill string/stump weight)
  • 2. Wrench unscrews pipe stand while the top drive unit is at the racking board level holding the pipe stand with the elevator(s).
  • 3. Mudbucket is positioned around stump and lower end of the pipe stand.
  • 4. Top drive unit or pipe handling apparatus lifts the pipe stand out of the drill string/stump.
  • 5. Drilling mud flows (i.e., drains) into the mudbucket and back to the mud circulation system.
  • 6. Mudbucket is removed.
  • 7. Pipe stand is placed in the setback area – pipe handling apparatus secures pipe stand from top drive unit and moves pipe stand away from beneath the top drive unit.
  • 8. Top drive unit is lowered (e.g., 95’) to the drill string/stump.
  • 9. Top drive unit latches onto drill string/stump.
  • 10. Slips are released.
  • 11. Top drive unit lifts drill string up (e.g., 95’, and top drive unit is at the racking board level).
  • 12. Process repeats for next pipe stand.

In accordance with the present disclosure, there is provided a tripping out process using pipe stand angle manipulation, which may include the following:

• • 1. Slips are set (holds drill string/stump weight)
  • 2. Wrench unscrews pipe stand while the top drive unit is positioned at the racking board level holding the pipe stand with the elevator(s).
  • 3. Two relatively concurrent actions take place:
    • a. Mudbucket is positioned around stump and lower end of the pipe stand.
    • b. Pipe handling apparatus (upper arm and lower arm) grab and control the pipe stand.
  • 4. Pipe handling apparatus lifts the pipe stand out of the drill string/stump and moves (mostly using the upper arm) the upper end of the pipe stand away from top drive unit – providing an angled pipe stand with a portion of the pipe stand (upper end portion) outside the well center (e.g., outside of the area directly beneath the top drive unit). See, FIG. 4.
  • 5. Two relatively concurrent actions take place:
    • a. Drilling mud flows (i.e., drains) into the mudbucket and back to the mud circulation system.
    • b. Top drive unit begins lowering towards the drilling string/stump.
  • 6. Mudbucket is removed.
  • 7. As the top drive unit is lowering, the pipe handing apparatus (mostly the lower arm) moves remaining portion of the pipe stand out of well center (away from beneath the tope drive unit).
  • 8. Top drive is lowered the remaining distance (and can be lowering while the bottom portion of the pipe stand is moving out of well center)
  • 9. Top drive unit latches onto drilling string/stump.
  • 10. Slips are released.
  • 11. Top drive lifts drill string up (e.g., 95’, and top drive unit is at the racking board level).
  • 12. Process repeats for next pipe stand.

The above-described trip out process may provide time savings by allowing the top drive unit to begin lowering and partially lower while the drilling fluid is draining from the pipe stand into the mudbucket.

FIGS. 5A-5H are side views illustrating select exemplary (and different) configurations of the drilling rig system (similar to FIG. 2) at different points during the angled pipe stand tripping in (i.e., stab-in) process described above and in accordance with the present disclosure.

FIGS. 6A-6H each include perspective side, perspective top portion (pipe fingerboard area) and perspective bottom portion (well bore area) views, illustrating various exemplary configurations of the drilling rig system at different points during the angled pipe stand tripping in (i.e., stab-in) described above and in accordance with the present disclosure.

Similar figures(such as FIGS. 5A-5H and 6A-6H) that would illustrate the angled pipe stand tripping out process as described above and in accordance with the present disclosure are omitted for brevity and clarity. Persons of ordinary skill in the art would readily understand the teachings of the present disclosure and comprehend the angled pipe stand tripping out process (e.g. FIG. 4 and in accordance with the text description) is similar to the angled pipe stand tripping in process (and Figures similar to FIGS. 5A-5H and 6A-6H could be readily generated and understood by one skilled in the art).

As will be appreciated, the above-described system, components and processes describe various methods of angled stabbing (stabbing in or stabbing out) in accordance with certain embodiments. In these methods, the pipe stand stabbing basically operates due to the configuration (e.g., taper) on the tool joint threads (pipe threads). This allows for some angle and still permit a successful connection (or disconnection) while the pipe stand is oriented at a slight angle with respect to the drill string/stump.

In other embodiments, the pipe stand, being long and slender, has some flexibility and can be bent without causing permanent deformation. The hoisting arm 440, the lower arm 430 and the pipe guide 420 can induce a bend on the pipe stand 470a to make its lower end more co-linear to the drilling string/stump, allowing it to be stabbed in. This may be accomplished by overextending the hoisting arm 440, or by twisting the gripper 450a on the hoisting arm 440 to induce a bending moment into the pipe stand 470a. This is illustrated in FIGS. 7A and 7B.

Turning to FIGS. 7A and 7B, FIG. 7A illustrates one embodiment of bending the pipe stand 470a in which the hoisting arm 440 exerts a predetermined force inward toward the wellbore axis 480 (or outward toward the handling apparatus 125) while the lower arm 430 and the pipe guide 420 hold steady the pipe stand at those two locations. As illustrated, the lower end and upper end of the pipe stand 470a are held in a relatively fixed position by the lower arm 430 and the pipe guide 420, respectively. As force is applied to the pipe stand by hoisting arm 440 (see 470a1), the middle section of the pipe bends and the lower end of the pipe stand reacts by moving to a more co-linear position with respect to the stump 475a of the drilling string 475. This may enable a more aligned position with respect to the stump 475a and may more easily promote stab in (or stab out) of the pipe stand 470a to the drill string 475. Once it is stabbed in, the lower arm 430 and upper arm 440 perform a coordinated movement to keep the lower end of the pipe stand 470a in a fixed position while the top of the pipe stand is brought into alignment and into the elevator(s).

FIG. 7B illustrates another embodiment of bending the pipe stand 470a in which the hoisting arm 440 (gripper tool 450a) exerts a predetermined rotational force while the lower arm 430 and the pipe guide 420 hold steady the pipe stand at those two locations. As illustrated, the lower end and upper end of the pipe stand 470a are held in a relatively fixed position by the lower arm 430 and the pipe guide 420, respectively. As rotational or twisting force is applied to the pipe stand by gripper 450a of the hoisting arm 440 (see 470a1), the middle section of the pipe rotates or twists inducing a bending movement in the pipe stand and the lower end of the pipe stand reacts by moving to a more co-linear position with respect to the stump 475a of the drilling string 475. This may enable a more aligned position with respect to the stump 475a and may more easily promote stab in (or stab out) of the pipe stand 470a to the drill string 475.

In FIGS. 7A and 7B, it will be understood that pipe stand 470a illustrates the pipe stand with no bending forces applied, while reference numeral 470a1 illustrates the pipe stand with one or more bending forces applied.

When introducing elements of the present disclosure or exemplary aspects or embodiments thereof, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of the elements.

The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

The term “coupled” is used herein to refer to the direct or indirect coupling between two objects. For example, if object A physically touches object B and object B touches object C, the objects A and C may still be considered coupled to one another—even if objects A and C do not directly physically touch each other. For instance, a first object may be coupled to a second object even though the first object is never directly in physical contact with the second object.

While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “application” and “program,” if used herein, refer to one or more computer programs, software components, sets of instructions, procedures, functions, objects, classes, instances, related data, or a portion thereof adapted for implementation in a suitable computer code (including source code, object code, or executable code). The term “communicate,” as well as derivatives thereof, encompasses both direct and indirect communication. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrase “associated with,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. The phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one item in the list may be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.

The description in the present disclosure should not be read as implying that any particular element, step, or function is an essential or critical element that must be included in the claim scope. The scope of patented subject matter is defined only by the allowed claims. Moreover, none of the claims invokes 35 U.S.C. § 112(f) with respect to any of the appended claims or claim elements unless the exact words “means for” or “step for” are explicitly used in the particular claim, followed by a participle phrase identifying a function. Use of terms such as (but not limited to) “mechanism,” “module,” “device,” “unit,” “component,” “element,” “member,” “apparatus,” “machine,” “system,” “processor,” or “controller” within a claim is understood and intended to refer to structures known to those skilled in the relevant art, as further modified or enhanced by the features of the claims themselves, and is not intended to invoke 35 U.S.C. § 112(f).

While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.

Claims

1. A pipe handling system for use in a drilling rig system, the pipe handling system comprising:

a pipe handling apparatus comprising an elongated column structure having a lower end and an upper end in vertical alignment and a first lower arm disposed about the lower end and a second upper arm disposed about the upper end and configured to secure a pipe stand for movement;

the pipe handling apparatus further configured to position the pipe stand at an angle A with respect to a wellbore axis of a wellbore in the drilling rig system and position a lower end of the pipe stand at the wellbore axis.

2. The pipe handling system in accordance with claim 1 wherein the pipe handling apparatus is further configured to position the pipe stand at the angle A at a time when a top drive unit disposed above the wellbore of the drilling rig system is moving vertically upward or downward.

3. The pipe handling system in accordance with claim 2 wherein the angle A comprises an angle between about 1 and 15 degrees.

4. The pipe handling system in accordance with claim 3 wherein a length of the pipe stand is equal to or greater than about 90 feet.

5. The pipe handling system in accordance with claim 2 wherein the pipe handling apparatus is configured to position the pipe stand at the angle A at a time when the top drive unit is moving vertically downward and enable drilling fluid within the pipe stand to drain therefrom.

6. The pipe handling system in accordance with claim 5 wherein the second upper arm is configured to secure the upper end of the pipe stand beneath the top drive unit and move the upper end horizontally away from the wellbore axis to position the pipe stand at the angle A.

7. A drilling rig system for use in drilling, the drilling rig system comprising:

a mast supporting a top drive unit;

a pipe handling system comprising,

a pipe storage rack for storing one or more pipe stands,

a pipe handling apparatus comprising an elongated column structure having a lower end and an upper end in vertical alignment and a first lower arm disposed about the lower end and a second upper arm disposed about the upper end and configured to secure a pipe stand for movement,

the pipe handling apparatus further configured to position the pipe stand at an angle A with respect to a wellbore axis of a wellbore in the drilling rig system and position a lower end of the pipe stand near the wellbore axis.

8. The drilling rig system in accordance with claim 7 wherein the pipe handling system is further configured to position the pipe stand at the angle A when the top drive unit disposed above the wellbore is moving vertically upward or downward.

9. The pipe handling system in accordance with claim 8 wherein the angle A comprises an angle between about 1 and 15 degrees.

10. The pipe handling system in accordance with claim 9 wherein a length of the pipe stand is equal to or greater than about 90 feet.

11. A pipe handling method for use in a drilling rig system, the method comprising:

positioning a pipe stand in a first position above a wellbore having a wellbore axis within the drilling rig system at an angle A with respect to the wellbore axis, the pipe stand comprising an upper end and a lower end, and in the first position the lower end of the pipe stand is disposed within a box of a drill string within the wellbore.

12. The pipe handling method in accordance with claim 11 wherein positioning the pipe stand in the first position at the angle A further comprises:

positioning the pipe stand at the angle A between about 1 and 15 degrees.

13. The pipe handling method in accordance with claim 12 wherein positioning the pipe stand in the first position at the angle A further comprises:

securing the upper end of the pipe stand to an upper arm of a pipe handling apparatus and securing the lower end of the pipe stand to a lower arm of the pipe handling apparatus, the pipe handling apparatus comprising an elongated column structure configured to secure and move the pipe stand into the first position.

14. The pipe handling method in accordance with claim 13 further comprising:

securing and positioning, by the pipe handling apparatus, the pipe stand in a second position, wherein in the second position the pipe stand is disposed in a vertical direction and parallel to and laterally spaced from the wellbore axis; and

moving, by the pipe handling apparatus, the pipe stand between the second position and the first position.

15. The pipe handling method in accordance with claim 14 wherein moving the pipe stand between the second position and the first position occurs, at least in part, during a vertical movement of a top drive unit disposed above the wellbore and aligned with the wellbore axis.

16. A pipe handling method for use in a drilling rig system, the drilling rig system comprising a mast supporting a top drive unit disposed above a wellbore having a wellbore axis and a pipe handling system having a pipe storage rack for storing one or more pipe stands and a pipe handling apparatus, the method comprising: securing and positioning, by the pipe handling apparatus, a pipe stand in a first position above the wellbore at an angle A with respect to the wellbore axis, the pipe stand comprising an upper end and a lower end, and in the first position the lower end of the pipe stand is disposed within a box of a drill string within the wellbore; securing and positioning, by the pipe handling apparatus, the pipe stand in a second position, wherein in the second position the pipe stand is disposed in a vertical direction and parallel to and laterally spaced from the wellbore axis; and moving, by the pipe handling apparatus, the pipe stand between the second position and the first position.

17. The pipe handling method in accordance with claim 16 wherein securing and positioning the pipe stand in the first position at the angle A further comprises:

positioning the pipe stand at the angle A between about 1 and 15 degrees.

18. The pipe handling method in accordance with claim 16 wherein securing and positioning the pipe stand in the first position and securing and positioning the pipe stand in the second position further comprises:

securing the upper end of the pipe stand to an upper arm of a pipe handling apparatus and securing the lower end of the pipe stand to a lower arm of the pipe handling apparatus, the pipe handling apparatus comprising an elongated column structure configured to secure and move the pipe stand into the first position and into the second position.

19. The pipe handling method in accordance with claim 16 wherein moving the pipe stand between the second position and the first position occurs, at least in part, during a vertical movement of the top drive unit above the wellbore.

20. The pipe handling method in accordance with claim 19 wherein moving the pipe stand between the second position and the first position occurs, at least in part, during a vertical movement of the top drive unit above the wellbore, further comprises:

moving, by the pipe handling apparatus, the pipe stand from the second position to the first position at least in part during an upward vertical movement of the top drive unit above the wellbore.