Note: Descriptions are shown in the official language in which they were submitted.
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
APPARATUS FOR GRIPPING A TUBULAR ON A DRILLING RIG
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] Embodiments of the present invention generally relate to a gripping
assembly for gripping tubulars. More particularly, the invention relates to a
gripping
apparatus for connecting wellbore tubulars on a drilling rig. More
particularly still, the
invention relates to a gripping apparatus including at least one redundant
device to
keep gripping members in contact with the tubular.
Description of the Related Art
[0002] In the construction and completion of oil and gas wells, a drilling rig
is
located on the earth's surface to facilitate the insertion and removal of
tubular strings
to and from a wellbore. The tubular strings are constructed and run into the
hole by
lowering a string into a wellbore until only the upper end of the top tubular
extends
from the wellbore (or above the rig floor). A gripping device, such as a set
of slips or
a spider at the surface of the wellbore, or on the rig floor, holds the
tubular in place
with bowl-shaped slips while the next tubular to be connected is lifted over
the
wellbore center. Typically, the next tubular has a lower end with a pin end,
male
threaded connection, for threadedly connecting to a box end, female threaded
connection, of the tubular string extending from the wellbore. The tubular to
be added
is then rotated, using a top drive, relative to the string until a joint of a
certain torque is
made between the tubulars.
[0003] A tubular connection may be made near the floor of the drilling rig
using a
power tong. Alternatively, a top drive facilitates connection of tubulars by
rotating the
tubular from its upper end. The top drive is typically connected to the
tubular by using
a tubular gripping tool that grips the tubular. With the tubular coupled to a
top drive,
the top drive may be used to make up or break out tubular connections, lower a
string
into the wellbore, or even drill with the string when the string includes an
earth
removal member at its lower end.
[0004] An internal gripping device or spear may grip the inside diameter of a
tubular to temporarily hold the tubular while building a string or rotating
the string to
drill. An internal gripping device is typically connected at an upper end to
'a top drive
1
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
and at a lower end the internal gripping device includes outwardly extending
gripping
members configured to contact and hold the interior of the tubular in order to
transmit
axial and torsional loads. The result is a rotationally fixed assembly. The
prior art
gripping assemblies, however, are equipped with one primary actuator and one
mechanical spring backup for setting the gripping member. Since the backup is
a
mechanical backup, it is prone to mechanical failure. Further, because the
mechanical backup is simply a spring, there is no way to remotely monitor its
condition.
[0005 There is a need for an improved gripping assembly having additional
safety
systems to prevent inadvertent disconnection of the string from the gripping
apparatus. There is a further need for a safety system which utilizes a
redundant
actuator for the gripping apparatus. There is a further need for an integrated
safety
system between the gripping apparatus and a gripper on the rig floor.
SUMMARY OF THE INVENTION
(0006] Embodiments described herein relate to a method and apparatus for
handling tubular on a drilling rig. The apparatus is adapted for gripping a
tubular and
may be used with a top drive. The apparatus includes a connection at one end
for
rotationally fixing the apparatus to the top drive and gripping members at a
second
end for gripping the tubular. The apparatus has a primary actuator configured
to
move and hold the gripping members in contact with the tubular and a backup
assembly to maintain the gripping member in contact with the tubular.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] So that the manner in which the above recited features of the present
invention may be understood in detail, a more particular description of the
invention,
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 typical embodiments of this invention and
are
therefore not to be considered limiting of its scope, for the invention may
admit to
other equally effective embodiments.
(0008] Figure 1 is a schematic of a drilling rig and a wellbore according to
one
embodiment described herein.
2
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[0009] Figure 2 is a schematic of a gripping member according to one
embodiment
described herein.
[00101 Figure 3 is a schematic of a gripping member according to one
embodiment
described herein.
[0011] Figure 4 is a schematic of an actuator for a gripping member according
to
one embodiment described herein.
[0012] Figure 5 is a schematic of a hydraulic actuator according to one
embodiment described herein.
[0013] Figures 6A-6C show a schematic of a gripping member according to one
embodiment described herein.
[0014] Figure 6D shows a cross sectional view of a swivel according to an
alternative embodiment.
[0015] Figure 7 is a schematic of a hydraulic actuator according to one
embodiment described herein.
[0016] Figures 8A is a schematic of a hydraulic actuator according to one
embodiment described herein.
(0017] Figures 8B-8E show a schematic of multiple gripping members according
to
one embodiment described herein.
10018] Figures 9A-9B show a schematic of a location system according to one
embodiment described herein.'
[0019] Figures 1OA-10B show a schematic of a sensor according to one
embodiment described herein.
[0020] Figures 11, and 11A-11 C show a schematic of an adapter according to
one
embodiment described herein.
[0021] Figures 12A-12B show a schematic of a cement plug launcher according to
one embodiment described herein.
3
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[0022] Figure 13 is a schematic view of a release mechanism according to one
embodiment described herein.
[00231 Figure 14 is a schematic view of a tubular handling system and a
controller
according to one embodiment described herein.
DETAILED DESCRIPTION
[0024] Figure 1 is a schematic view of a drilling rig 100 having a tubular
handling
system 102. As shown, the tubular handling system 102 includes a gripping
apparatus 104, an actuator 106, a drive mechanism 108, and a hoisting system
110.
The tubular handling system 102 is adapted to grip a tubular 112 or a piece of
equipment 114 and lift it over the wellbore 115 and then complete a tubular
running
operation. The actuator 106 for the gripping apparatus 104 may be equipped
with a
backup safety assembly, a locking system and a safety system, described in
more
detail below, for ensuring the tubular 112 is not released prematurely. The
hoisting
system 110 and/or the drive mechanism 108 may lower the tubular 112 until the
tubular 112 contacts a tubular string 116. The drive mechanism 108 may then be
used to rotate the tubular 112 or the piece of equipment 114 depending on the
application in order to couple the tubular 112 to the tubular string 116,
thereby
extending the length of the tubular string 116. After the coupling, a gripper
119 on the
rig floor 118, which initially retains the tubular string 116, may then
release the tubular
string 116. The gripper 119 as shown is a set of slips; however, it should be
appreciated that the gripper 119 may be any gripper on the rig floor 118
including, but
not limited to, a spider. With the gripping apparatus 104 gripping the tubular
112 and
thereby the tubular string 116, the hoisting system 110, and/or drive
mechanism 108
may lower the tubular 112 and the tubular string 116 until the top of the
tubular 112 is
near the rig floor 118. The gripper 119 is then re-activated to grip the
extended
tubular string 116 near the rig floor 118, thereby retaining the extended
tubular string
116 in the well. The actuator 106 releases the gripping apparatus 104 from the
tubular 112. The tubular handling system 102 may then be used to grip the next
tubular 112 to be added to the tubular string 116. This process is repeated
until the
operation is complete. While lowering the tubular string 116, the drive
mechanism
108 may rotate the tubular string 116. If the tubular string 116 is equipped
with a
drilling tool 120, shown schematically, rotation of the tubular string 116 may
drill out
4
CA 02633182 2010-06-28
the wellbore as the tubular string 116 is lowered. The tubular 112 may be any
jointed
tubular or segment including but not limited to casing, liner, production
tubing, drill
pipe.
[0025] Figure 2 shows a schematic view of the tubular handling system 102
according to one embodiment. The tubular handling system 102 includes a swivel
200, a pack off 202, in addition to the drive mechanism 108, the actuator 106,
and the
gripping apparatus 104.
[0026] The gripping apparatus 104, as shown in Figure 2, is an internal
gripping
device adapted to engage the interior of the tubular 112. The gripping
apparatus 104
includes a set of slips 208, a wedge lock 210, and a mandrel 212 coupled to
the
actuator 106. The slips 208 may be any slip or gripping member adapted to grip
the
tubular 112, preferably the slips 208 have wickers (not shown) in order to
provide
gripping engagement. The wedge lock 210 is coupled to mandrel 212, which may
be
coupled to the actuator 106. The actuator 106 moves a sleeve 214, or cage,
down in
order to move the slips 208 down. As the slips 208 move down, the angle of the
slips
208 and the angle of the wedge lock 210 moves the slips 208 radially away from
a
longitudinal axis of the gripping apparatus 104. This outward radial movement
moves
the slips 208 into engagement with the tubular 112. With the slips 208 engaged
with
the tubular 112, the weight of the tubular 112 will increase the gripping
force applied
by the slips 208 due to the angles of the wedge lock 210 and the slips 208.
Although
Figure 2 shows the sleeve 214 moving down in order to actuate the slips 208,
any
suitable configuration may be used in order to engage the slips 208 with the
tubular
112. In another embodiment, the slips 208 actuate by moving the wedge lock 210
up
relative to the slips 208, thus forcing the slips 208 to move radially
outward.
[0027] In an alternative embodiment, the gripping apparatus 104 may be an
external gripper for gripping the exterior of the tubular 112. The external
gripper may
incorporate slips which move toward the longitudinal axis when actuated.
Further, a
combination of an internal and external gripping apparatus 104 may be used.
Further
still, the external gripper may incorporate gripping members which pivot in
order to
engage the tubular. An exemplary external gripper is show in U.S. Patent
Application
Publication No. 2005/0257933.
5
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[0028] The actuator 106 is shown schematically in Figures 1 and 2 and may be
an
electrical, mechanical, or fluid powered assembly designed to disconnect and
to set
the gripping apparatus 104. Further, the actuator 106 may be any combination
of
electrical, mechanical, or fluid powered actuators.
[0029] The swivel 200 allows an electrical or fluid source such as a pump (not
shown) to transmit a fluid and/or electric current to the actuator 106 during
operation,
especially during rotation of the actuator 106. The swivel 200 may be a
conventional
swivel such as a SCOTT ROTARY SEALTM with conventional o-ring type seals. The
swivel 200, in Figures 2 and 3 is part of a sub 215, which has a lower pin end
216 and
an upper box end 217 for coupling the swivel 200 to other rig components such
as a
top drive or the mandrel 212. The upper end of the mandrel 212 may have an
adapter 218, optional, for connecting the gripping apparatus 104 to the swivel
200 or
the drive mechanism 108. The adapter 218 may simply be a threaded connection
as
shown or incorporate a locking feature which will be described in more detail
below.
The drive mechanism 108 may be any drive mechanism known in the art for
supporting the tubular 112 such as a top drive, a compensator, or a combined
top
drive compensator, or a traveling block. The connection between the drive
mechanism 108 and the gripping apparatus 104 may be similar to the adapter 218
and will be discussed in more detail below. The mandrel 212 is configured such
that
the top drive will transfer a rotational motion to the slips 208, as discussed
in more
detail below.
[0030] The actuator 106 may be coupled to the mandrel 212 and operatively
coupled to the swivel 200. The swivel 200 may generally be a hollow or solid
shaft
with grooves or contact rings and an outer ring having fluid ports or brushes.
The
shaft is free to rotate while the ring is stationary. Thus, the fluid is
distributed from a
stationary point to a rotating shaft where, in turn the fluid is further
distributed to
various components to operate the equipment rotating with the mandrel 212,
such as
the actuator 106 to set and release the slips 208.
[0031] In one embodiment, the actuator 106 is two or more annular piston
assemblies 300, as shown in Figure 3. Each annular piston assembly 300 may
include a piston 302, a fluid actuation chamber 304, a control line(s) 308
(shown
schematically), and a fluid inlet 310. Each annular piston assembly 300 is
capable of
6
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
actuating the gripping apparatus 104 independently of the other piston
assemblies
300. Thus, there is a built in redundancy to provide a back up safety system.
That is,
one of the annular piston assemblies 300 is a primary assembly which is
necessary to
operation of the actuator 106. The remaining annular piston assemblies 300 are
redundant and provide an additional backup safety feature. Each annular piston
assembly 300 operates by introducing fluid into the fluid actuation chamber
304. The
fluid in the actuation chamber 304 applies pressure to the upper side of the
piston
302. The pressure on the piston 302 moves the piston 302 down. The piston 302
is
operatively coupled to the gripping apparatus 104 via the sleeve 214. Although
shown as coupled to the sleeve 214, it should be appreciated that any form of
actuating the gripping apparatus 104 with the pistons 302 is contemplated. In
order to
release the gripping apparatus 104 from the tubular 112, fluid may be
introduced into
a release chamber 306. When the fluid pressure in the release chamber 306
acting
on the lower side of the piston 302 is greater than the fluid pressure above
the piston
302, the piston 302 may move up thereby releasing the gripping apparatus 104
from
the tubular 112. Each of the annular piston assemblies 300 may have the
release
chamber 306 or none may be equipped with the release chamber. It is
contemplated
that in order to release the gripping apparatus 104 the pressure in the
actuation
chambers 304 is simply relieved, the drive mechanism 108 may then be used to
release the slips 208, shown in Figure 2 from the tubular 112. Although shown
as
having two annular piston assemblies 300, it should be appreciated that any
number
may be used so long as there is at least one primary piston assembly and one
redundant or backup piston assembly.
[00321 The control lines 308, shown schematically in Figure 3, may be one
control
line or a series/plurality of control lines for supplying fluid to each
individual annular
piston assembly 300. The control lines 308 may include a monitor line to
transmit
information back to a controller 312. The control lines 308 allow an operator
or the
controller 312 to monitor the conditions in the fluid chambers in each
individual
annular piston assembly 300, including but not limited to pressure and
temperature.
Thus, if there is a sudden loss of pressure in one of the annular piston
assemblies
300, the controller 312 or the operator may make adjustments to the other
annular
piston assemblies 300 to ensure that engagement with the tubular 112 is not
lost.
7
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
The control lines 308, although shown as a control line, may be any fluid
source
known in the art such as an annulus surrounding the actuator 106.
[0033] Generally, the controller 312 may have additional control lines
operatively
communicating- with a traveling block, a location system, a sensor, the drive
mechanism, a power tong, and/or a pipe handling apparatus. Further, the
controller
312 receives data from the monitor lines and the drive mechanism. The
controller 312
in various embodiments may be in fluid, wireless (e.g., infrared, RF,
Bluetooth, etc.),
or wired communication with components of the present invention.
Illustratively, the
controller 312 may be communicatively coupled to the drive mechanism, fluid
chambers, gripping apparatus 104, a release, a location system, one or more
sensors, and other drilling rig components. The controller 312 may generally
be
configured to operate and monitor each of the respective components in an
automated fashion (e.g., according to a preprogrammed sequence stored in
memory)
or according to explicit user input.
[0034] Although not shown, the controller 312 may be equipped with a
programmable central processing unit, a memory, a mass storage device, and
well-
known support circuits such as power supplies, clocks, cache, input/output
circuits
and the like. Once enabled, an operator may control the operation of the
gripping
apparatus 104 by inputting commands into the controller 312. To this end,
another
embodiment of the controller 312 includes a control panel, not shown. The
control
panel may include a key pad, switches, knobs, a touch pad, etc.
[0035] With the controller 312 monitoring and operating the drilling rig, an
integrated safety system may easily be adapted to the drilling rig 100. A
safety
system may prevent dropping a tubular 112 or tubular string 116. In one
embodiment, the safety system is adapted to provide an indication of whether
the
gripping apparatus 104 is properly connected to the tubular 112. Thus, the
safety
system would allow an operator or the controller 312 to know that the gripping
apparatus 104 has fully engaged the tubular 112. When engagement of the
gripping
apparatus 104 to the tubular 112, which is now a part of the tubular string
116, is
confirmed by the safety system, the controller 312 or operator may release the
slips
or spider at the rig floor 118. The traveling block would then lower the
tubular string
116 so that the box end of the tubular is located near the rig floor 118. The
controller
8
CA 02633182 2010-06-28
312 or operator may then re-activate the slips or spider to grip the tubular
string 116.
With the slips engaging the tubular string 116, the controller 312 would allow
the
gripping apparatus 104 to release the tubular string 116. The safety system is
also
capable of monitoring the proper amount of torque in the threads of the
tubulars 112
during make up. This ensures that the threads are not damaged during make up
and
that the connection is secure. Examples of suitable safety systems are
illustrated in
U.S. Patent No. 6,742,596 and U.S. Patent Application Publication Nos. U.S.
2005/0096846, 2004/0173358, and 2004/0144547.
[0036] In an alternative embodiment, the actuator 106 of the gripping
apparatus
104 includes one or more piston and cylinder assemblies 400, as shown in
Figure 4.
The piston and cylinder assemblies 400 couple to the mandrel 212 via a collar
402,
and are moveably coupled to the sleeve 214 via a slip ring 404. The slip ring
404
couples to a rod 406 of each of the piston and cylinder assemblies 400. The
slip ring
404 is operatively coupled to the sleeve 214 in order to actuate the gripping
apparatus
104. It should be appreciated that any method known in the art of fixing the
piston
and cylinder assemblies 400 to the mandrel 212 and the sleeve 214 may be used.
Any one of the piston and cylinders assemblies 400 are capable of moving the
slip
ring 404 in order to actuate the gripping apparatus 104, therefore, all but
one of the
piston and cylinder assemblies 400 is redundant or provide a backup, and one
of the
pistons is the primary actuator. It should further be appreciated that other
power
sources besides fluid sources may also be employed to power the gripping
apparatus
104 either separately or in conjunction with the fluid power. These
alternative power
sources include, but are not limited to, electric, battery, and stored energy
systems
such as power springs and compressed gas.
[0037] In another embodiment, the actuator 106 may be electrically powered.
The
electrically powered actuator may be equipped with a mechanical locking
device,
which acts as a backup assembly, which prevents release of the gripping
apparatus
104. Further, the electrically powered actuator may include more than one
actuation
member for redundancy or as a backup. Further still, the electrically powered
actuator may send data to a controller 312 to communicate its position to an
operator.
Thus, if one lock fails, the controller 312 may take steps to prevent the
accidental
release of the tubular 112.
9
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[0038] As described above, in order to provide for redundancy or a backup
safety
assembly, a separately operable redundant actuator may be used to ensure
operation
of the gripping apparatus 104 in the event of failure of the primary actuator.
In one
embodiment, as shown in Figure 3, the actuator 106 includes four the annular
piston
assemblies 300. The primary actuator may be one of the annular piston
assemblies
300, while anyone or all of the remaining annular piston assemblies 300 may
act as
the redundant actuator. The redundant actuator acts in the same manner as the
primary actuator. That is, the redundant actuator applies an actuation force
to the
gripping apparatus 104 when fluid is supplied to the actuation chamber 304 of
the
redundant actuator. As discussed above, the fluid pressure in the actuation
chamber
304 may be monitored by the controller 312. The redundant actuator will
provide the
actuation force upon the gripping apparatus 104 even in the event of a primary
actuator failure. Further, additional redundant actuators may be provided
which are
operated in the same or a similar manner as the redundant actuator.
[0039] In another embodiment, one or more valves 314, shown schematically in
Figure 3, are disposed between the control line(s) 308 and the actuation
chamber 304
to provide the additional and/or alternative backup safety assembly. The valve
314
allows fluid to enter the actuation chamber 304, but does not allow fluid to
exit the
actuation chamber 304. The valves 314 may be set to release the pressure when
the
release chambers 306 are actuated. The valve 314 is typically a one way valve
such
as a check valve; however, it should be appreciated that any valve may be used
including, but not limited to, a counter balance valve. In operation, the
fluid enters the
actuation chamber 304 and actuates the annular piston assembly 300 thereby
engaging the tubular 112 with the slips 208 of the gripping apparatus 104. The
fluid
also acts redundantly to prevent the slips 208 of the gripping apparatus 104
from
disengaging with the tubular 112 until pressure is applied on the opposite end
of the
piston 302. In this embodiment, the valve 314 acts to maintain a substantially
constant pressure on the piston 302, even if fluid pressure is inadvertently
lost in the
control line(s) 308 or selectively turned off. This in turn keeps a constant
locking force
on the slips 208. The valves 314 may be built into the actuator 106 or added
and/or
plumbed in as an add-on to the actuator 106. Further, the valve 314 may be
located
anywhere between the fluid source for operating the annular piston assembly
300 and
the actuation chamber 304. The valve 314 may be attached to each actuation
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
chamber 304 or any number of fluid chambers depending on the requirements of
the
actuator 106. Thus, in operation only one of the actuation chamber 304 is
necessary
to engage the slips 208. The additional actuation chambers 304 may be equipped
with the valve 314 as a safety chamber that once actuated prevents the
gripping
apparatus 104 from accidentally releasing the tubular 112. The valves 314 will
work
on a single piston basis. Thus, if multiple pistons are used and if one piston
is lost or
leaks off pressure due to a failed seal, the redundant actuator will continue
to hold the
setting force on the slips 208.
[0040] In yet another alternative embodiment, the redundant actuator is one or
more of the piston and cylinder assemblies 400, and the primary actuator is
one of the
piston and cylinder assemblies 400, as shown in Figure 4. As described above,
the
primary actuator and each of the redundant actuators are capable of
independently
operating the gripping apparatus 104. Further, the controller 312, shown in
Figure 3,
is capable of monitoring conditions in the primary actuator and the redundant
actuators in order to ensure that gripping apparatus 104 remains engaged with
the
tubular 112 when desired.
[0041] In yet another embodiment, at least some of the piston and cylinder
assemblies 400 are equipped with a valve 500, shown schematically in Figure 5,
in
order to provide the backup assembly as an additional safety feature to
prevent
inadvertent release of the gripping apparatus 104. As shown, each of the
piston and
cylinder assemblies 400 includes a cylinder 502 and a piston 504. There may be
two
fluid control lines connected to each of the piston and cylinder assemblies
400. An
actuation line 506 connects to each cylinder 502. The actuation line 506
applies
hydraulic or pneumatic pressure to each piston 504 in order to actuate the
gripping
apparatus 104 (shown in Figures 1-4). A release line 512 connects to each of
the
cylinders 502 below the piston 504 in order to release the gripping apparatus
104. A
one or more feed lines 508 may couple to each of the actuation lines 506.
Further,
separate feed lines may be used in order to power each of the piston and
cylinder
assemblies 400 separately. Each of the actuation lines 506 may be equipped
with the
valve 500, although shown as each of the actuation lines 506 having the valve
500, it
should be appreciated that as few as one valve 500 may be used.
11
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[0042] To activate the gripping apparatus 104, fluid flows through the one or
more
feed lines 508. The fluid enters each of the actuation lines 506, then flows
past the
valves 500. The valves 500 operate in a manner that allows fluid to flow
toward the
cylinder 502, but not back toward the feed line 508. As the fluid continues to
flow past
the valves 500, it fills up each of the lines downstream of the valves 500.
The fluid
may then begin to exert a force on the pistons 504. The force on the pistons
504
causes the pistons 504 to move the slip ring 404 (shown in Figure 4) and
actuate the
gripping apparatus 104. The slips 208 will then engage the tubular 112. With
the
slips 208 fully engaged, the fluid will no longer move the pistons 504 down.
Introduction of fluid may be stopped at a predetermined pressure, which may be
monitored by the controller 312 or an operator. The only force on the pistons
504 in
the actuated position is the fluid pressure above the pistons 504. The system
will
remain in this state until the pressure is released by switches 510 or the
valves 500 or
in the event of system failure. Each of the valves 500 acts as a safety system
to
ensure that the gripping apparatus 104 does not inadvertently release the
tubular 112.
In operation, the slips 208 may be released by actuating the switches 510 and
allowing fluid to leave the top side of the pistons 504. Fluid is then
introduced into
release lines 512 in order to pressurize the bottom side of the pistons 504.
With the
fluid released above the piston 504, there is no additional force required to
release
the slips 208 other than friction between the slips 208 and tubular 112.
Although the
valves 500 are shown in conjunction with the piston and cylinder assemblies
400, it
should be appreciated that the valves 500 and hydraulic scheme may be used in
conjunction with any actuator disclosed herein.
[0043] In yet another alternative embodiment, one or all of the piston and
cylinder
assemblies 400 may be equipped with an accumulator 514, optional, shown in
Figure
5. The accumulator 514 provides an additional safety feature to ensure that
the
gripping apparatus 104 does not release the tubular 112 prematurely. The
accumulator 514, as shown, is between the valve 500 and the cylinder 502,
within
each of the actuation lines 506. An accumulator line 516 fluidly couples the
accumulator 514 to the actuation lines 506. Each accumulator 514 may include
an
internal bladder or diaphragm (not shown). The bladder is an impermeable
elastic
membrane that separates the piston and cylinder assemblies 400 system fluid
from
the compressible fluid in the accumulator 514. Before operating the piston and
12
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
cylinder assemblies 400 system fluid, the accumulator 514 is filled with
compressible
fluid to a predetermined pressure. With the compressible fluid pressure only
in the
accumulator 514, the bladder will expand to cover the lower end towards the
accumulator line 516 of the accumulator 514. With the bladder in that
position, the
accumulator bladder has reached maximum expansion. When the fluid for
operating
the piston and cylinder assemblies 400 enters the accumulators 514, the
membrane
of the bladder begins to move up relative to the accumulator lines 516. The
bladder
compresses the compressible fluid further as the bladder moves up in the
accumulators 516. With the slips 208 fully engaged, the fluid will no longer
move the
pistons 504 down. The system fluid will continue to expand the bladder while
compressing the compressible fluid in the accumulators 514. Introduction of
system
fluid will be stopped at a predetermined pressure. As discussed above, the
system
may remain in this state until the pressure is released by switches 510 or in
the event
of system failure.
[0044] In the event that the hydraulic system leaks, the system will slowly
begin to
lose its system fluid. However, the compressible fluid in the accumulators 514
maintains the pressure of the system fluid by adding volume as the system
fluid is
lost. As the compressible fluid expands, the bladder expands, thus maintaining
the
pressure of the system fluid by adding volume to the system. The expansion of
the
bladder is relative to the amount of system fluid lost. In other words, the
pressure of
the system fluid and in turn the pressure on the piston 504 remains constant
as the
system fluid is lost due to the expansion of the bladder. The bladder
continues to
move as the system fluid leaks out until the bladder is fully expanded. Once
the
bladder has fully expanded, any further leaking of the system fluid will cause
a loss of
pressure in the system. The pressure in the accumulators 514 may be monitored
by
the controller 312. Thus, upon loss of pressure in the accumulators 514, the
controller 312 or an operator may increase the pressure in the piston and
cylinder
assemblies 400 thereby preventing inadvertently releasing the gripping
apparatus
104. Each of the valves 500 and accumulators 514 act independently for each of
the
piston and cylinder assemblies 400. Therefore, there may be one primary piston
having a valve 500 and an accumulator 514 and any number of redundant pistons
having a valve 500 and an accumulator 514, thereby providing an increased
factor of
safety. The accumulators 514 may be used with any actuator described herein.
13
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[00451 In an alternative embodiment to the swivel 200 discussed above, a
swivel
600 couples directly to the actuator 106, as shown in Figure 6A. This reduces
the
overall length of the gripping apparatus 104 by not requiring the sub 215. The
swivel
600 has a fluid nozzle 602 which attaches to a control line 604 coupled to a
fluid or
electrical source 606 (shown schematically). The swivel 600 additionally has a
fluid
chamber 180 which is in communication with the actuator 106 via a port 608,
for
releasing or engaging the slips 208. The swivel 600 contains a housing 610,
which
may comprise the fluid nozzle 602, two or more seal rings 612, and a base 614,
which
is connected directly to the rotating member. Further, the swivel 600 includes
slip
rings 616, which couple the housing 610 to the base 614 while allowing the
housing
610 to remain stationary while the base 614 rotates. Figure 6B shows the
swivel 600
coupled to an actuator 106A according to an alternative embodiment. Figure 6C
shows two swivels 600 attached to an actuator 106B. The actuator 106B has a
piston
618 which moves up by fluid introduced from the lower swivel 600 and moves
down
by fluid introduced from the upper swivel 600. The piston 618 operates the
gripping
apparatus 104. It should be appreciated that the swivels 600 may be used with
any
actuator 106 arrangement disclosed herein or known in the art. Further, any
number
of swivels 600 may be used.
[0046] In yet another alternative embodiment, the redundancy for any of the
actuators described above may be achieved by a primary fluid system with an
electrically powered backup. Further the primary system may be electrically
powered
and the redundant system may be fluid operated.
[0047] In yet another alternative embodiment, the swivel 200 and/or 600
described
above may be in the form of a rotating union 620, as shown in Figure 6D. The
rotating union 620 includes an inner rotational member 622 and an outer
stationary
member 624. The inner rotational member 622 may be coupled to the rotating
components of the tubular handling system 102, such as the drive mechanism 108
and the actuator 106. The outer stationary member 624 is adapted to couple to
one
or more control lines for operating the tubular handling system 102
components. As
shown the rotating union 620 includes two hydraulic fluid inlets 626 and four
pneumatic fluid inlets 628; however, it should be appreciated any combination
of
pneumatic fluid, hydraulic fluid, electric, and fiber optic inlet may be used,
including
only one hydraulic fluid inlet 626 and/or one pneumatic fluid inlet 628. The
inlets 626
14
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
and 628 may optionally include a valve for controlling flow. A bearing 630 may
be
included between the inner rotational member 622 and the outer stationary
member
624 in order to bear radial and axial forces between the two members. As shown
the
bearing 630 is located at each end of the outer stationary member 624.
[0048] The hydraulic fluid inlet 626 fluidly couples to an annular chamber 632
via a
port 634 through the outer stationary member 624. The annular chamber 632
encompasses the entire inner diameter of the outer stationary member 624. The
annular chamber 632 fluidly couples to a control port 636 located within the
inner
rotational member 622. The control port 636 may be fluidly coupled to any of
the
components of the tubular handling system 102. For example, the control port
636
may be coupled to the actuator 106 in order to operate the primary actuator
and/or
the redundant actuator.
[0049] In order to prevent leaking between the inner rotational member 622 and
the outer stationary member 624, a hydrodynamic seal 638 may be provided at a'
location in a recess 640 on each side of the annular chamber 632. As shown,
the
hydrodynamic seal 638 is a high speed lubrication fin adapted to seal the
increased
pressures needed for the hydraulic fluid. The hydrodynamic seal 638 may be
made
of any material including but not limited to rubber, a polymer, an elastomer.
The
hydrodynamic seal 638 has an irregular shape and/or position in the recess
640. The
irregular shape and/or position of the hydrodynamic seal 638 in the recess 640
is
adapted to create a cavity 641 or space between the walls of the recess 640
and the
hydrodynamic seal 638. In operation, hydraulic fluid enters the annular
chamber 632
and continues into the cavities 641 between the hydrodynamic seal 638 and the
recess 640. The hydraulic fluid moves in the cavities as the inner rotational
member
622 is rotated. This movement circulates the hydraulic fluid within the
cavities 641
and drives the hydraulic fluid between the hydrodynamic seal contact surfaces.
The
circulation and driving of the hydraulic fluid creates a layer of hydraulic
fluid between
the surfaces of the hydrodynamic seal 638, the recess 640 and the inner
rotational
member 622. The layer of hydraulic fluid creates lubricates the hydrodynamic
seal
638 in order to reduce heat generation and increase the life of the
hydrodynamic seal.
In an alternative embodiment, the hydrodynamic seal 638 is narrower than the
recess
640 while having a height which is substantially the same or greater than the
recess
640. The hydrodynamic seal 638 may also be circumferentially longer than the
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
recess. This configuration forces the hydrodynamic seal 638 to bend and
compress
in the recess as shown in the form of the wavy hidden line on Figure 6D. When
rotated, the hydraulic fluid circulates in the cavities 641 as described
above. Each of
the inlets may include the hydrodynamic seal 638. Each of the inlets may have
the
control port 636 in order to operate separate tools of any of the components
of the
tubular handling system 102.
[0050] A seal 642 may be located between the inner rotational member 622 and
the outer stationary member 624 at a location in a recess 640 on each side of
the
annular chamber 632 of the pneumatic fluid inlets 628. The seal 642 may
include a
standard seal 644 on one side of the recess and a low friction pad 646. The
low
friction pad may comprise a low friction polymer including but not limited to
Teflon TM
and PEEKTM. The low friction pad 646 reduces the friction on the standard seal
644
during rotation. Any of the seals described herein may be used for any of the
inlets
626 and/or 628.
[0051] The tubular handling system 102 may include a compensator 700, as
shown in Figure 7. The compensator 700 compensates for the length loss due to
thread make-up without having to lower the drive mechanism 108 and/or top
drive
during the connection of the tubular 112 with the tubular string 116. This
system not
only allows for length compensation as the thread is made up, it also controls
the
amount of weight applied to the thread being made up so that excessive weight
is not
applied to the thread during make up. The compensator 700, as shown, consists
of
one or more compensating pistons 702 which are coupled on one end to a fixed
Iocation 704. The fixed location 704 may couple to any part of the tubular
handling
system 102 that is longitudinally fixed relative to the tubulars 112. The
fixed location
704, as shown, is coupled to the top drive. The other end of the compensating
pistons 702 are operatively coupled to the piston and cylinder assemblies 400
via a
coupling ring 706. The piston and cylinder assemblies 400 are coupled to the
gripping apparatus 104 as described above. The compensating pistons 702 are
adapted to remain stationary until a preset load is reached. Upon reaching the
load,
the compensator pistons will allow the coupling ring 706 to move with the
load,
thereby allowing the gripping apparatus 104 to move.
16
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[0052] In operation, the gripping apparatus 104 grips the tubular 112. With
only
the tubular 112 coupled to the gripping apparatus 104, the compensator piston
702
will remain in its original position. The tubular 112 will then engage the
tubular string
116, shown in Figure 1. The drive mechanism 108 will then rotate the tubular
112 in
order to couple the tubular 112 to the tubular string 116. As the threaded
coupling is
made, an additional load is applied to the gripping apparatus 104 and thereby
to the
compensating pistons 702. The compensator pistons 702 will move in response to
the additional load thereby allowing the gripping apparatus 104 to move
longitudinally
down as the threaded connection is completed. Although the compensator 700 is
shown with the piston and cylinder assemblies 400, it should be appreciated
that the
compensator 700 may be used in conjunction with any actuator described herein.
[0053] The compensator pistons 702 may be controlled and monitored by the
controller 312 via a control line(s) 708. The control line(s) 708 enables the
pressure
in the compensating pistons 702 to be controlled and monitored in accordance
with
the operation being preformed. The controller 312 is capable of adjusting the
sensitivity of the compensator pistons 702 to enable the compensator pistons
to move
in response to different loads.
[0054] In another embodiment, the compensator 700 is simply a splined sleeve
or
collar, not shown. The splined sleeve allows for longitudinal slip or movement
between the drive mechanism 108 and the gripping apparatus 104. In yet another
embodiment, the compensator may include a combination of pistons and the
splined
sleeve.
[0055] The actuator 106 may be adapted for interchangeable and/or modular use,
as shown in Figures 8A-8E. That is, one actuator 106 may be adapted to operate
any
size or variety of a modular gripping apparatus 804. Figure 8A shows the
actuator
106 having the piston and cylinder assemblies 400, one or more compensator
pistons
702, and an adapter 218 for coupling the actuator 106 to the drive mechanism
108
(shown in Figure 1). The adapter 218 may include a torque sub in order to
monitor
the torque applied to the tubular 112. Figures 8B-8E show various exemplary
modular gripping apparatus 804 that may be used with the actuator 106.
Actuation of
the selected gripping apparatus 804 is effected using a modular slip ring 802.
The
modular slip ring 802, which is similar to slip ring 404 described above,
couples to the
17
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
piston and cylinder assemblies 400 and is movable therewith, as described
above.
The modular slip ring 802 is adapted to couple to a mating slip ring 806 of
the
modular gripping apparatus 804. When coupled to the mating slip ring 806, the
modular slip-ring 802 may actuate the gripping apparatus 104 as described
above. In
this respect, the slip rings 802 and 806 move in unison in response to
actuation of the
piston and cylinder assemblies 400, which, in turn, causes engagement or
disengagement the gripping apparatus 104 from the tubular 112. Torque from the
drive mechanism 108 may be transferred to the modular gripping apparatus 804
using
a universal couple 808. As show, the universal couple 808 is positioned at the
end of
a rotational shaft 810 for each modular gripping apparatus 804. The universal
couple
808 is adapted to couple to a shaft within the actuator 106. With the
universal couple
808 coupled to the shaft of the actuator 106, rotation may be transferred from
the
drive mechanism 108 to the rotational shaft 810 and in turn to the tubular via
the
modular gripping apparatus 804.
[0056] In operation, the modular aspect of the tubular handling system 102
allows
for quick and easy accommodation of any size tubular 112 without the need for
removing the actuator 106 and/or the drive mechanism 108. Thus, the external
modular gripping apparatus 804, shown in Figure 8B, may be used initially to
grip,
couple, and drill with the tubular. The external modular gripping apparatus
804 may
then be removed by uncoupling the slip ring 806 from slip ring 802. The
internal
gripping apparatus 804, shown in Figure 8E, may then be used to continue to
couple,
run, and drill with tubulars 112. It is contemplated that gripping apparatus
of any
suitable size may be used during operations. Further, any of the actuators 106
described herein may be used in conjunction with the modular gripping
apparatus
804.
[0057] Figures 9A and 9B show a location system 900 that may be used with any
tubular gripping assembly and any of the actuators 106 disclosed herein. The
location system 900 may be incorporated into the actuator 106 having the
piston and
cylinder assembly 400, as shown. The location system 900 is adapted to track
the
movement of the slip ring 404 or the piston rod 406 as it is moved by the
piston and
cylinder assemblies 400. The location system 900 may be in communication with
the
controller 312 in order to monitor the engagement and disengagement of the
gripping
apparatus 104. The location system 900 tracks the position of pistons thereby,
18
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
tracking the position of the gripping apparatus 104. The location system 900
may
include a wheel 902 coupled to an arm 904, that is coupled to the piston rod
406, or in
the alternative, the sleeve 214, or the slip ring 404. As the piston rod 406
moves the
slip ring 404 from the disengaged to the engaged position, the wheel rolls on
a track
906. The track 906 may include a raised portion 907. As the wheel 902 reaches
the
raised portion 907, it moves the arm 904 radially away from the mandrel 212 of
the
gripping apparatus 104. The arm 904 is coupled to a trigger 908 which actuates
a
location indicator 910. Thus, as the trigger 908 engages the location
indicator 910,
the height and position of the trigger 908 inside the location indicator 910
indicates
the location of the piston rods 406 and or the slip ring 404 and thus of the
location of
the slips 208, not shown. Although shown as the track 906 having one raised
portion
it should be appreciated that the track 906 may have any configuration and
indicate
the entire spectrum of locations the piston rod 406 and/or slip ring 404 may
be during
actuation and disengagement of the gripping apparatus. The location system 900
may send and/or receive a pneumatic and/or hydraulic signal to the controller
312
and/or fluid source and further may send an electronic signal, either
wirelessly or with
a wired communication line. Further, the location system 900 may be any
location
locator including, but not limited to, a hall effect, a strain gauge, or any
other proximity
sensor. The sensor communication signals may be sent back through the swivel
and/or sent via radio frequency.
[0058] In yet another embodiment, the gripping apparatus 104 includes a sensor
1000 for indicating that a stop collar 1002 of the gripping apparatus 104 has
reached
the top of a tubular 112, as shown in Figures 10A and 10B. The stop collar
1002 is
adapted to prevent the tubular 112 from moving beyond the gripping apparatus
104
as the gripping apparatus 104 engages the tubular 112. The sensor 1000 may
detect
the tubular 112 when the tubular 112 is proximate the stop collar 1002. In
use, the
hoisting system 110 and/or the drive mechanism 108 will initially lower the
gripping
apparatus 104 toward the tubular 112 to urge the engagement portion of the
gripping
apparatus 104 to enter the tubular 112, or surround the tubular 112 if the
gripping
apparatus is an external gripper. As the hoisting system 110 and/or drive
mechanism
108 continues to move the gripping apparatus 104 relative to the tubular 112,
the
sensor 1000 will be actuated tubular 112 reaches a predetermined distance from
the
stop collar 1002. The sensor 1000 may send a signal to the controller 312 or
an
19
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
operator in order to indicate that the predetermined proximity of the stop
collar 1002
to the tubular 112 has been reached. The controller 312 and/or the operator
may
then stop the hoisting system 110 and/or the drive mechanism 108 from
continuing
the movement of the gripping apparatus 104 relative to the tubular 112. The
gripping
apparatus 104 may then be activated to grip the tubular 112 to commence
drilling
and/or running operations.
[0059] The sensor 1000, as shown in Figures 10A and 10B, is a mechanical
sensor which rests in a recess 1004 of the stop collar 1002 and is biased to
project
below the bottom surface of the stop collar 1002. Figure 10B shows the sensor
1000
coupled to an activator 1006 which operates a control valve 1008. The
activator
1006, as shown, is a rod which projects through the stop collar 1002 and is
coupled to
the control valve 1008 on one end and to a contact 1010, which is adapted to
engage
the tubular 112, on the other end. The sensor 1000 may include a spring 1007
for
biasing the activator 1006 toward the unengaged position. Thus, as the
gripping
apparatus 104 is lowered into the tubular 112, the contact 1010 approaches the
upper
end of the tubular 112. Once the contact 1010 engages the tubular 112, the
control
valve 1008 is actuated and sends a signal to the controller 312 or the
operator
indicating that the gripping apparatus 104 is in the tubular 112. Although
shown as a
mechanical sensor, it should be appreciated that the sensor 1000 may be any
sensor
known in the art, such as a rod and piston assembly, a strain gage, a
proximity
sensor, optical sensor, infrared, a laser sensor. The sensor 1000 helps to
prevent
placing the full weight of the hoisting system 110, the actuator 106, and the
drive
mechanism 108 onto the top of the tubular 112 before the tubular 112 is
connected to
the tubular string 116. In one embodiment, the sensor 1000 status may be sent
back
through the swivel and/or sent via radio frequency.
[0060] In yet another embodiment, the adapter 218, which may provide the
connection between the components of the tubular handling system 102, contains
a
lock 1100 as shown in Figure 11. The adapter 218 is located between the drive
mechanism 108 and the actuator 106; however, it should be appreciated that the
adapter 218 may be located between any of the tubular handling system 102
components. The lock 1100 prevents the inadvertent release of a connection
between tubular handling system 102 components as a result of rotation of the
components. As shown, the connection includes a pin connector 1102 of the
drive
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
mechanism 108 adapted to couple to the box end 1103 of the actuator 106. Both
the
pin connector 1102 and the box end 1103 have a shaped outer surface 1104. The
shaped outer surface 1104 shown in Figure 11A is an octagonal configuration;
however, it should be appreciated that the shape may be any configuration
capable of
transferring torque, such as a gear or spline, a hex, a square, a locking key
(pin), etc.
The shaped outer surface 1104 is configured to match a shaped inner surface
1106 of
the lock 1100. The lock 1100 may contain a set screw 1108 for coupling the
lock
1100 to the pin connector 1102. Although the set screw 1108 is shown as
connecting
to the pin connector 1102, it should be appreciated that the set screw 1108
may
couple to any part of the connection so long as the lock 1100 engages both the
pin
connector 1102 and the box end 1103. Thus, in operation, the lock 1100 is
placed on
the pin connector 1102 and the box end 1103 is coupled to the pin connector
1102.
The lock 1100 is then moved so that the shaped inner surface 1106 engages the
shaped outer surface 1104 of both the pin connector 1102 and the box end 1103.
The set screws 1108 then couple the lock 1100 to the pin connector 1102. The
drive
mechanism 108 may then be actuated to rotate the tubular 112. As the drive
mechanism 108 torques the connection, load is transferred through the lock
1100 in
addition to the threaded connection. The lock 1100 prevents the overloading or
unthreading of the connections. Although shown as the drive mechanism 108
having
a pin end and the actuator 106 having a box end, any configuration may be used
to
ensure connection. Further, the lock may contain a sprag clutch to engage a
top
drive quill, thus eliminating the requirement to modify the outer diameter of
the top
drive quill, not shown.
[0061] In yet another alternative embodiment, the adapter 218 is an external
locking tool 1110 as shown in Figures 11 C and 11 B. The external locking tool
1110
may comprise two or more link elements 1112 connected to encompass the
connection between tubular handling system 102 components. As shown, the link
elements 1112 are pivotably connected to one another via a pin 1114. The pins
1114
may be removed in order to open the external locking tool 1110 and place the
external locking tool 1110 around the connection. The pin 1114 may then be
reinstalled lock the external locking tool 1110 around the connection.
Further, any
number of link elements 1112 may be removed or added in order to accommodate
the size of the connection. The link elements 1112, when connected, form an
interior
21
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
diameter having two or more dies 1116. Each link element 1112 may have one or
more recess 1117 adapted to house the die 1116. The interior diameter is
adapted to
be equal to or larger than the outer diameter of the connection between
tubular
handling system 102 components. The dies 1116 have an engagement surface 1118
which is adapted to grippingly engage the outer diameter of the connection
between
the tubular handling system 102 components. In one embodiment, the dies 1116
are
large enough to traverse the connection between the tubular handling system
components. Optionally, the dies 1116 may be radially adjustable via one or
more
adjustment screw 1120. The adjustment screw 1120 as shown traverses each of
the
link elements 1112. The adjustment screw 1120 engages the die 1116 on the
interior
of the link element 1112 and is accessible for adjustment on the exterior of
the link
element 1112. Although the adjustment screw 1120 is shown as a screw, it
should be
appreciated that any method of moving the dies radially may be used including
but
not limited to a fluid actuatable piston, an electric actuator, or a pin. In
this manner,
the link elements 1112 with the dies 1116 may be coupled together around a
connection between two components. The dies 1116 may then be adjusted, if
necessary, via the adjustment screws 1120 in order to grippingly engage the
connection. Each die 1116 will transverse the connection and thereby grip both
of the
components. The dies 1116 coupled to the link elements 1112 will prevent the
components from rotating relative to one another, thereby preventing
inadvertent
release of the connection.
[0062] Figure 11 B shows an alternative embodiment of the external locking
tool
1110. As shown, each link element 1112 has at least two separate dies 1116.
The
dies are independently adjustable via the adjustment screw 1120. This allows
each
die 1116 to independently engage each component of the connection. Therefore,
the
components may have varying outer diameters and still be engaged by the
separate
dies 1116 of the external locking tool 1110. With the dies 1116 grippingly
engaged
with components, relative rotations between the components is prevented in the
same
manner as described above.
10063] In another embodiment, equipment 114 is a cementing plug launcher 1200
adapted for use with the gripping apparatus 104, as shown in Figures 12A-12B.
The
cementing plug launcher 1200 may be adapted to be engaged by any tubular
handling system 102 described herein in addition to any drilling rig tubular
running
22
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
device. For example, the cementing plug launcher 1200 may be adapted to couple
to
an internal gripping apparatus, an external gripping apparatus, or any
combination of
an external and/or an internal gripping apparatus. Using the cementing plug
launcher
1200 in conjunction with the gripping apparatus 104 allows an operator to use
a
cementing tool without the need to rig down the gripping apparatus 104 prior
to use.
This saves rig time and reduces the exposure of the tubular string 116 to the
uncemented wellbore. Further, the cementing plug launcher 1200 may be brought
to
the rig floor as one complete assembly, which may be handled and coupled to
the
tubular string 116 with the gripping apparatus. This allows fast operation
while
protecting the plugs inside the casing and the equipment 114. Further, the
cementing
plug launcher 1200 only needs to be attached to the tubular handling system
102
when the cementing operation is to take place. The cementing plug launcher
1200
may allow the tubular string 116 to be cemented in place without the need to
pump
cement through the gripping apparatus 104, the actuator 106, and the drive
mechanism 108.
[0064] The cementing plug launcher 1200 will be described as used with an
internal gripping apparatus 104. As shown in Figure 12A, the launcher 1200 has
an
upper joint 1202 and an optional launcher swivel 1204, a fluid inlet 1205, and
a valve
1206. The swivel 1204 may function in the same manner as the swivels mentioned
above. The valve 1206 is shown as a check valve; however, it may be any valve
including, but not limited to, a ball valve, a gate valve, a one way valve, a
relief valve,
and a TIW valve. The valve 1206 is adapted to prevent cement and/or drilling
fluids
from flowing through the cementing plug launcher 1200 during a cementing
operation.
Further, the valve 1206 may prevent the pumping pressure from affecting the
load
capacity of the gripping apparatus 104 during circulation or cementing. The-
upper
joint 1202 of the launcher 1200 is adapted to be engaged by the gripping
apparatus
104. Thus, after the tubular string 116 has been run and/or drilled or reamed
to the
desired depth, the gripping apparatus 104 may release the tubular string 116
and pick
up the launcher 1200. To grip the launcher 1200, the gripping apparatus 104 is
inserted into the upper joint 1202. The actuator 106 then activates the slips
208 into
gripping engagement with the upper joint 1202. The gripping apparatus 104 and
the
cementing plug launcher 1200 are then lifted by the hoisting system over the
tubular
string 116. The hoisting system may then lower the cementing plug launcher
1200
23
CA 02633182 2010-06-28
toward the tubular string 116 for engagement therewith. The drive mechanism
108
may then rotate the cementing plug launcher 1200 to couple the cementing plug
launcher 1200 to the tubular string 116. Thus, a cementing operation may be
performed with little or no modifications to the tubular handling system 102.
In one
embodiment, the tubular handling system 102 may have the sealing ability to
allow
fluid to be pumped into the inner diameter of the cementing plug launcher 1200
above
the valve 1206.
[0065] The cementing plug launcher 1200, shown in Figure 12A, shows a typical
launching head as is described in U.S. Patent Nos. 5,787,979 and 5,813,457,
and the
additional features of the launcher swivel 1204 and the upper joint 1202
adapted to be
gripped by the gripping apparatus 104. The launcher 1200(a), shown in Figure
12B,
shows the use of a plug launching system that uses conventional plugs as well
as
non-rotational plugs such as described in U.S. Patent No. 5,390,736. The
launcher
1200(a) further includes a launcher swivel 1204 that allows a fluid to be
pumped into
the well while the valve 1206 prevents the fluid from flowing to the gripping
apparatus
104. The fluid may be any fluid known in the art such as cement, production
fluid,
spacer fluid, mud, fluid to convert mud to cement, etc. The plug launching
assembly
1200 and 1200A may allow the tubular string 116 to be rotated during the
cementing
operation. Figure 12C shows the cementing plug launcher 1200(b) adapted for
remote operation as will be described below.
[0066] It should be appreciated that cementing plug launchers 1200 and 1200A
may be used in conjunction with clamps, casing elevators, or even another
gripping
apparatus such as a spear or external gripping device to connect to the
previously run
tubular string 116.
[0067] The cement plug launcher 1200 and 1200(A) are shown having manual
plug releases. In yet another alternative embodiment, the cement plug launcher
1200
and 1200(A) are equipped with a remotely operated actuation system. In this
embodiment the manual plug releases are replaced or equipped with by plug
activators. The plug activators are fluid, electrically or wirelessly
controlled from the
controller 312. Therefore the controller or an operator at a remote location
may
24
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
release each plug 1208 and 1210 at the desired time using the plug activators.
The
plug activators typically remove a member which prevents the plug 1208/1210
from
traveling down the cementing plug launcher 1200/1200(a) and into the tubular
112.
Thus with the member removed after actuation of the plug activator, the plug
120811210 performs the cementing operation. The fluid or electric lines used
to
operate the plug activators may include a swivel in order to communicate with
the
plug activators during rotation of the cementing plug launcher 1200 and
1200(A). In
an alternative, the plug activators may release a ball or a dart adapted for
use with the
plugs 1208 and 1210-
10068] During a cementing operation it may be beneficial to reciprocate and/or
rotate the tubular string 116 as the cement enters the annulus between the
wellbore
115 and the tubular string 116. The movement, reciprocation and/or rotation,
may be
accomplished by the hoisting system 110 and the drive mechanism 108 and helps
ensure that the cement is distributed in the annulus. The remotely operated
actuation
system for the cement plug launcher may be beneficial during the movement of
the.
tubular string 116 in order to prevent operators from injury while releasing
the plugs
1208 and 1210 due to the movement of the cement plug launcher.
[0069] While the cementing plug launcher may be used or discussed with the
redundant safety mechanism for a gripping apparatus, it will be understood
that the
launcher need not be associated with any other aspect or subject matter
included
herein.
[0070] In an additional embodiment, the tubular handling system 102 may
include
a release 1300, shown in Figure 13. During the operation of the tubular
handling
system with a slip type internal gripping apparatus it is possible that the
slips 208,
shown in Figure 2, may become stuck in the tubular 112. This may occur when
the
slips 208 of the gripping apparatus 104 inadvertently engage the tubular 112
at a
position where the gripping apparatus 104 is unable to move relative to the
tubular
112. For instance the stop collar 1002 of the gripping apparatus 104
encounters the
top of the tubular 112 and the slips 208 engage the tubular 112. At this
point, pulling
the gripping apparatus 104 up relative to the tubular 112 further engages the
slips 208
with the tubular 112, additionally movement downward relative to the tubular
112, to
release the slips 208, is prohibited due to the stop collar 1002 and the top
of the
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
tubular 112 being in contact with one another. The release 1300 is adapted to
selectively release the gripping apparatus 104 from the tubular 112 in the
event that
the gripping apparatus is stuck and may be incorporated into the stop collar
1002 or
may be a separate unit. The release 1300 may have a release piston 1302 and a
release chamber 1304. The release chamber 1304 may be coupled to the release
piston via a fluid resistor 1306, such as a LEE AXIAL VISCO JETTM and a valve
1307.
The valve 1307 as shown is a one way valve, or check valve. The fluid resistor
1306
prevents fluid pressure in the release chamber 1304 from quickly actuating the
release piston 1302. The valve 1307 prevents fluid from flowing from the
release
chamber 1304 toward the release piston 1302 while allowing fluid to flow in
the
opposite direction. The release 1300 may further include a biasing member 1308
adapted to biased the release piston 1302 toward the unengaged position as
shown
in Figure 13. The release 1300 operates when stop collar 1002 engages the
tubular
112 and weight is placed on the mandrel 212 of the gripping apparatus 104 by
the
hoisting system, shown in Figure 1. The mandrel 212 may be coupled to the
release
piston 1302 by a coupling device 1309. A downward force placed on the mandrel
212
compresses the fluid in the release chamber 1304. The initial compression will
not
move the release piston 1302 due to the fluid resistor 1306. Continued
compression
of the release chamber 1304 flows fluid slowly through the fluid resistor 1306
and acts
on the release piston 1302. As the release piston 1302 actuates a piston
cylinder
1310, the piston cylinder 1310 moves the mandrel 212 up relative to the stop
collar
1002. Thus, the mandrel 212 slowly disengages the slips 208 from the tubular
112
with continued compression of the release chamber 1304. Further, the fluid
resistor
1306 prevents accidental release of the slips 208 caused by sudden weight on
the
mandrel 212. The continued actuation of the release chamber 1304 to the
maximum
piston stroke will release the slips 208. The gripping apparatus 104 may then
be
removed from the tubular. When weight is removed from the stop collar 1002 the
pressure in the release chamber quickly subsides. The biasing member 1308
pushes
the piston back toward the unengaged position and the valve 1307 allows the
fluid to
return to the release chamber. In another embodiment the release 1300 is
equipped
with an optional shoulder 1312. The shoulder 1312 is adapted to rest on top of
the
tubular 112.
26
CA 02633182 2010-06-28
[0071] Figure 14 is a schematic view of an integrated safety system 1400
and/or
an interlock. The integrated safety system 1400 may be adapted to prevent
damage
to the tubular 112 and/or the tubular string 116 during operation of the
tubular
handling system 102. In one embodiment, the integrated safety system 1400 is
electronically controlled by the controller 312. The integrated safety system
1400 is
adapted to prevent the release of the gripping apparatus 104 prior to the
gripper 119
gripping the tubular 112 and/or the tubular string 116. For example, in a
tubular
running operation, the controller 312 may initially activate the actuator 106
of the
gripping apparatus 104 to grip the tubular 112. The controller 312 may then
activate
rotation of the gripping apparatus 104 to couple the tubular 112 to the
tubular string
116. The controller 312 may then release the gripper 119 while still gripping
the
tubular 112 and the tubular string 116 with the gripping apparatus 104. The
controller
312 will prevent the release of the tubular 112 prior to the gripper 119 re-
gripping the
tubular 112 and the tubular string 116. Once the gripper 119 has re-gripped
the
tubular 112, the controller 312 will allow the release of the tubular 112 by
the gripping
apparatus 104.
[0072] The integrated safety system 1400 may also be capable of monitoring the
proper amount of torque in the threads of the tubulars 112 during make up.
This
ensures that the threads are not damaged during make up and that the
connection is
secure. Examples of suitable safety systems are illustrated in U.S. Patent No.
6,742,596 and U.S. Patent Application Publication Nos. U.S. 2005/0096846,
2004/0173358, and 2004/0144547.
[0073] In another embodiment, the integrated safety system 1400 may
incorporate
the location system 900. The location system 900 sends a signal to the
controller
312, which gives the status of the gripping apparatus 104 in relation to the
tubular
112. In other words, the location system 900 indicates to the controller 312
when the
tubular 112 is gripped or ungripped by the gripping apparatus 104. In
operation, after
the gripping apparatus 104 grips the tubular 112, the location system 900
sends a
signal to the controller 312 indicating that the tubular 112 is gripped and it
is safe to lift
the gripping apparatus 104. The gripping apparatus 104 is manipulated by the
drive
mechanism 108 and/or the hoisting system 110 to couple the tubular 112 to the
tubular string 116. The controller 312 may then open the gripper 119 to
release the
27
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
tubular string 116. The tubular 112 is lowered and regripped by the gripper
119 as
described above. The controller 312 then releases the gripping apparatus 104
from
the tubular 112. The location system 900 informs the controller 312 when the
gripping apparatus 104 is safely disengaged from the tubular 112. The gripping
apparatus 104 may then be removed from the tubular 112 without marking or
damaging the tubular 112.
[0074] The integrated safety system 1400 may incorporate the sensor 1000 in
another embodiment. The sensor 1000 sends a signal to the controller 312 when
the
stop collar 1002 is proximate to the tubular 112. Therefore, as the gripping
apparatus
104 approaches the tubular 112 and/or the tubular string 116, a signal is sent
to the
controller 312 before the stop collar 1002 hits the tubular 112. The
controller 312 may
then stop the movement of the gripping apparatus 104 and, in some instances,
raise
the gripping apparatus 104 depending on the operation. The stopping of the
gripping
apparatus prevents placing weight on the tubular 112 when do so is not
desired. In
another embodiment, the signal may set off a visual and/or audible alarm in
order to
allow an operator to make a decision on any necessary steps to take.
[0075] In yet another embodiment, the integrated safety system 1400 may
incorporate the release 1300. The release 1300 may send a signal to the
controller
312 when the release begins to activate the slow release of the gripping
apparatus
104. The controller 312 may then override the release 1300, lift the gripping
apparatus 104, and/or initiate the actuator 106 in order to override the
release 1300,
depending on the situation. For example, if the slow release of the gripping
apparatus
104 is initiated by the release 1300 prior to the gripper 119 gripping the
tubular 112,
the controller may override the release 1300, thereby preventing the gripping
apparatus 104 from releasing the tubular 112.
(0076] In yet another alternative embodiment, the integrated safety system
1400 is
adapted to control the compensator -700 via the controller 312. When the
compensator 700 is initiated during the coupling of the tubular 112 to the
tubular
string 116, the compensator 700 may send a signal to the controller 312. The
compensator 700 may measure the distance the tubular 112 has moved down during
coupling. The distance traveled by the compensator 700 would indicate whether
the
connection had been made between the tubular 112 and the tubular string 116.
With
28
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
the connection made, the controller 312 may now allow the gripping apparatus
104 to
disengage the tubular 112 and/or the compensator to return to its initial
position.
[0077] in an alternative embodiment, the integrated safety system may be one
or
more mechanical locks which prevent the operation of individual controllers
for one rig
component before the engagement of another rig component.
10078] In operation, the gripping apparatus 104 attaches to the drive
mechanism
108 or the swivel 200, which are coupled to the hoisting system 110 of the rig
100.
The tubular 112 is engaged by an elevator (not shown). The elevator may be any
elevator known in the art and may be coupled to the tubular handling system
102 by
any suitable method known in the art. The elevator then brings the tubular 112
proximate the gripping apparatus 104. In an alternative embodiment, the
gripping
apparatus may be brought to the tubular 112. The gripping apparatus 104 is
then
lowered by the hoisting system 110 or the elevator raises the tubular 112
relative to
the gripping apparatus 104 until the slips 208 are inside the tubular 112.
When the
stop collar 1002 of the gripping apparatus 104 gets close to the tubular 112,
the
sensor 1000 may send a signal to the controller 312. The controller 312 may
then
stop the relative movement between the gripping apparatus 104 and the tubular
112.
[0079] With the gripping apparatus 104 is at the desired location, the
controller 312
either automatically or at the command of an operator activates the actuator
106. At
least the primary actuator of the actuator 106 is activated to urge the slips
208 into
engagement with the tubular 112. One or more redundant actuators may be
actuated
either simultaneously with or after the primary actuator is actuated. The
primary
actuator will ensure that the slips 208 engage the tubular while the redundant
actuators will ensure that the tubular 112 is not prematurely released by the
gripping
apparatus 104. The operation of the primary actuator and the redundant
actuators
are monitored by the controller 312 and/or the operator.
[0080] As the actuator 106 activates the gripping apparatus 104, the location
system 900 may send a signal to the controller 312 regarding the location of
the slips
208 in relation to the tubular 112. After the tubular 112 is engaged, the
drive
mechanism 108 and or hoisting system 110 may bear the weight of the tubular
112
for connection to a tubular string 116. The tubular handling system 102 then
lowers
the tubular 112 until the tubular 112 is engaged with the tubular string 11.6.
The drive
29
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
mechanism 108 may then rotate the tubular 112 in order to couple the tubular
112 to
the tubular string 116. During the coupling of the tubular 112 to the tubular
string 116,
the compensators 700 may compensate for any axial movement of the tubular 112
relative to the drive mechanism 108. The compensation prevents damage to the
tubular 112 threads. The compensator 700 may indicate to the controller 312
the
extent of the connection between the tubular 112 and the tubular string 116.
As the
drive mechanism 108 transfers rotation to the tubular 112 via the gripping
apparatus
104 and the slips 208, the swivel allows for communication between the
rotating
components and the controller 312 or any fluid/electric sources. After the
connection
of the tubular 112 to the tubular string 116 is made up, the gripper 119 may
release
the tubular string 116, while the gripping apparatus 104 continues to support
the
weight of the tubular 112 and the tubular string 116. The hoisting system 110
then
lowers the tubular string 116 to the desired location. The gripper 119 then
grips the
tubular string 116. The controller 312 may then disengage the slips 208 either
by use
of the release 1300 or de-activating the actuator 106 to release the tubular
string 116.
During this sequence, the integrated safety system 1400 may prevent the
tubular
string 116 from being inadvertently dropped into the wellbore 115. The process
may
then be repeated until the tubular string 116 is at a desired length. In one
embodiment the integrated safety system
[oosl] As the tubular string 116 is lowered into the wellbore 115, drilling
fluids may
be pumped into the tubular string 116 through the gripping apparatus 104. The
drilling fluids flow through the flow path 206 (shown in Figure 2) of the
gripping
apparatus 104. The packer 204 of the pack off 202 prevents the drilling fluids
from
inadvertently escaping from the top of the tubular string 116.
[oo82] After the lowering the tubular 112 and the tubular string 116, the
gripping
apparatus 104 may then be used to engage the equipment 114 in the manner
described above. In one embodiment, the equipment is the cement plug launcher
1200/1200A shown in Figures 12A-12B. The gripping apparatus 104 first engages
the upper joint 1202, then the cement plug launcher 1200 couples to the
tubular string
116. Thereafter, a first plug 1208 is dropped into the tubular string 116,
either by the
controller 312 or manually by an operator. Cement may then be pumped into the
cement plug launcher 1200 via the fluid inlet 1205 and flow down the tubular
string
116 behind the first plug 1208. The swivel 1204 allows the cement to be pumped
into
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
the cement plug launcher 1200 while the drive mechanism 108 rotates and/or
reciprocating the tubular string 116, if necessary. After the necessary volume
of
cement has been pumped into the tubular string 116, the controller 312 and/or
operator drops a second plug 1210. The second plug 1210 may be pushed down the
tubular string 116 by any suitable fluid such as drilling fluid. The second
plug 1210
continues to move down the tubular string 116 until it lands on the first plug
1208.
The cement is then allowed to dry in an annulus between the tubular string 116
and
the wellbore 115. The cement plug launcher 1200 may then be removed from the
tubular string 116 and thereafter disconnected from the gripping apparatus
104.
[00833 With the tubular string 116 cemented in place, the gripping apparatus
104
may be removed from the actuator 106. One of the modular gripping apparatus
804,
shown in Figure 8, may then be coupled to the actuator 106 in order to
accommodate
a different sized tubular 112. A new tubular string 116 may be made up and run
into
the cemented tubular string 116 in the same manner as described above. The new
tubular string may be equipped with a milling and/or drilling tool at its
lower end in
order to mill out any debris in the tubular string 116 and/or drill the
wellbore 115. The
same procedure as described above is used to run and set this tubular string
116 into
the wellbore. This process may be repeated until the tubular running is
completed.
This process may be reversed in order to remove tubulars from the wellbore
115.
[00843 In yet another embodiment described herein, an apparatus for gripping a
tubular for use with a top drive is disclosed. The apparatus includes a
connection at
one end for rotationally fixing the apparatus relative to the top drive and
one or more
gripping members at a second end for gripping the tubular. Further, the
apparatus
includes a primary actuator configured to move and hold the gripping members
in
contact with the tubular, and a backup assembly adapted to maintain the
gripping
member in contact with the tubular.
[0085] In yet another embodiment, the primary actuator is fluidly operated.
[0086] In yet another embodiment, the primary actuator is electrically
operated.
[0087] In yet another embodiment, wherein the backup assembly comprises a
selectively powered redundant actuator.
[00883 In yet another embodiment, the backup assembly is hydraulically
operated.
31
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[0089] In yet another embodiment, a monitor is coupled to a controller for
monitoring a condition in the backup assembly.
[0090] In yet another embodiment, the monitor monitors a condition in the
primary
actuator.
[0091] In yet another embodiment, the backup assembly comprises a check valve
operable in conjunction with the primary actuator to ensure the primary
actuator
remains operable in the event of hydraulic failure.
[0092] In yet another embodiment, the backup assembly further includes an
additional source of fluids to ensure the primary actuator remains operable in
the
event of hydraulic failure.
[0093] In yet another embodiment, a first swivel in configured to
communicatively
couple the primary actuator to a fluid source. Additionally a second swivel
may
couple to the backup assembly configured to communicatively couple the backup
assembly to the fluid source. Additionally, a second fluid source may be
provided.
[0094] In yet another embodiment, the connection comprises a lock for
preventing
the apparatus and the top drive from rotating independently of one another.
Further,
the lock may include a shaped sleeve for engaging a shaped outer diameter of
the top
drive and the apparatus. Alternatively, the lock may include two or more link
elements configured to surround the connection, and one or more gripping dies
on an
inside surface of each link element, the one or more gripping dies configured
to
engage the apparatus and the top drive.
[0095] In yet another embodiment, a release may be actuated by applying weight
to the apparatus to actuate a fluid operated piston. Further, the fluid
operated piston
may be coupled to a fluid resistor for constricting fluid flow. Additionally,
the fluid
resistor may act to release the gripping members from the tubular using a
substantially constant force applied over time.
[0096] In yet another embodiment described herein, an apparatus for gripping a
tubular for use in a wellbore is described. The apparatus may include a
gripping
member for gripping the tubular, wherein the gripping member is coupled to a
rotating
mandrel. Further, the apparatus may include an actuator for actuating the
gripping
32
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
member and a locking member for locking the gripping member into engagement
with
an inner diameter of the tubular. Additionally, the apparatus may include a
swivel for
connecting the actuator to the gripping member.
[0097] In yet another embodiment, the actuator comprises one or more chambers
controlled by fluid pressure. Further, the fluid pressure may actuate a
piston.
[00981 In yet another embodiment, the locking member includes one or more
pressure chambers connected to a fluid source configured to provide.
[00991 In yet another embodiment, the locking member is one or more check
valves provided between a fluid source and the one or more pressure chambers.
[00100] In yet another embodiment, a controller for monitoring the fluid
pressure in
the one or more pressure chambers.
[00101] In yet another embodiment, a release actuated by applying weight to
the
gripping apparatus to actuate a fluid operated piston is included. Further,
the fluid
operated piston may be coupled to a fluid resistor for constricting fluid
flow.
Additionally the fluid resistor may act to release the gripping members using
a
constant force applied over time.
1001021 In yet another embodiment described herein, an apparatus for gripping
a
tubular for use in a wellbore comprising is described. The apparatus may
include a
set of slips connectable to a rotating mandrel for engaging an inner diameter
of the
tubular. Further, the apparatus may include a plurality of fluid chambers for
actuating
the slips and a swivel for fluidly connecting a fluid source to the plurality
of fluid
chambers.
[00103] In yet another embodiment, the chambers comprise one or more primary
actuators and one or more redundant actuators.
[00104] In yet another embodiment, the redundant actuator has a locking
member.
[00105] In yet another embodiment, the locking member comprises a check valve
configured to hold pressure in the redundant actuator. Further, the check
valve may
allow one way flow of fluid into at least one of the plurality of fluid
chambers.
33
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[oolo6] In yet another embodiment, the fluid source supplies a hydraulic
fluid.
[00107] In yet another embodiment, the fluid source comprises a pneumatic
fluid.
[00108] In yet another embodiment, a controller for monitoring at least one of
the
plurality of fluid chambers is provided.
[0o1os] In yet another embodiment, a sensor may be coupled to a stop collar,
wherein the sensor is configured to communicate to the controller when the
stop
collar engages the tubular.
[00110] In yet another embodiment, a control line may be connectable to the
swivel
and the plurality of fluid chambers.
[00111] in yet another embodiment described herein, a method for connecting a
tubular is described. The method includes providing a fluid pressure from a
fluid
source and conveying the fluid pressure through a swivel to a plurality of
chambers.
Further, the swivel may have two or more annular seals located in a recess on
each
side of a fluid inlet. The method additionally includes actuating a gripping
member to
grip the tubular, wherein the gripping member is actuated by applying a fluid
pressure
to a piston within the plurality of chambers. The method additionally may
include
rotating the tubular using the gripping member and moving a pressurized fluid
into
cavities between the two or more annular seals and the recess in response to
rotating
the tubular. Further, the method may include continuing to supply the fluid
source
through the swivel and into the chambers via the swivel during rotation.
[00112] In yet another embodiment, the method further includes locking at
least one
chamber of the plurality of chambers upon actuation, wherein locking the at
least one
chamber may include flowing fluid through a check valve.
[00113] In yet another embodiment, the method further includes monitoring at
least
one of the plurality of chambers with a controller. Additionally, the gripping
member
may be operatively coupled to a top drive. Further, the gripping member may be
rotated by the top drive.
[00114] In yet another embodiment described herein, a tubular handling system
is
described. The tubular handling system includes a tubular torque device
coupled to a
34
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
hoisting system and a gripping apparatus. Additionally, the tubular handling
system
includes a cementing plug launcher configured to selectively coupled to the
gripping
apparatus having a tubular housing for receiving the gripping member, and one
or
more plugs located within the tubular housing configured to perform a
cementing
operation.
[001151 In yet another embodiment, a check valve may be disposed within the
tubular housing configured to prevent fluid flow from the launcher to the
gripping
apparatus.
[00116] In yet another embodiment, a swivel that allows for a fluid to be
pumped
into the launcher while the torque device rotates the launcher is provided.
[00117] In yet another embodiment, the gripping member comprises a spear.
[o01181 In yet another embodiment, the gripping member comprises an external
tubular gripper.
[00119] In yet another embodiment described herein, a method of completing a
wellbore is described. The method includes providing a tubular handling system
coupled to a hoisting system, wherein the tubular handling system comprises a
gripping apparatus, an actuator, and a torquing apparatus. The method further
includes gripping a first tubular using the gripping apparatus and coupling
the first
tubular to a tubular string by rotating the first tubular using the torquing
apparatus,
wherein the tubular string is partially located within the wellbore.
Additionally, the
method may include lowering the first tubular and the tubular string and
releasing the
first tubular from the gripping apparatus. The method may further include
gripping a
cementing tool using the gripping apparatus and coupling the cementing tool to
the
first tubular by rotating the cementing tool. Additionally the method may
include
flowing cement into the cementing tool and cementing at least a portion of the
tubular
string into the wellbore.
[001201 In yet another embodiment, the method includes preventing cement from
flowing into contact with the gripping apparatus with a check valve.
[00121] In yet another embodiment described herein, a release for releasing a
gripping apparatus from a tubular is described. The release includes a piston
and a
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
piston cylinder operatively coupled to a mandrel of the gripping apparatus.
The
release further includes a fluid resistor configured to fluidly couple a
release chamber
to the piston by providing a constrained fluid path. Additionally the release
may
include a shoulder adapted to engage a tubular and increase pressure in the
release
chamber as weight is applied to the shoulder, and wherein continued weight on
the
shoulder slowly actuates the piston thereby slowly releasing the gripping
apparatus
from the tubular.
[00122] In yet another embodiment described herein, a safety system for use
with a
tubular handling system is described. The safety system includes a sensor
adapted
to track movement of a slip ring for actuating a gripping apparatus, wherein
the
sensor sends a signal to a controller when the gripping apparatus is in a
position that
corresponds to the gripping apparatus being engaged with the tubular.
[00123] In yet another embodiment, the sensor comprises a trigger which is
actuated by a wheel coupled to an arm, wherein the wheel moves along a track
coupled to an actuator as the actuator moves the slip ring. Additionally, the
track may
have one or more upsets configured to move the wheel radially and actuate the
trigger as the wheel travels.
[00124] In yet another embodiment described herein, a method for monitoring a
tubular handling system is described. The method includes moving a gripping
apparatus toward a tubular and engaging a sensor located on a stop collar of
the
gripping apparatus to an upper end of the tubular. The method further includes
sending a signal from the sensor to a controller indicating that the tubular
is in an
engaged position and stopping movement of the gripping apparatus relative to
the
tubular in response to the signal. Additionally, the method may include
gripping the
tubular with the gripping apparatus.
[00125] In yet another embodiment, the method further includes monitoring a
position of one or more engagement members of the gripping apparatus relative
to
the tubular using a second sensor, and sending a second signal to the
controller
indicating that the gripping apparatus is engaged with the tubular.
36
CA 02633182 2008-06-11
WO 2007/070805 PCT/US2006/061945
[00126] In yet another embodiment, the method further includes coupling the
tubular to a tubular string held by a spider on the rig floor and verifying
that the tubular
connection is secure.
[001271 In yet another embodiment, the method further includes having verified
the
tubular connection is secure and the gripping apparatus is secure the
controller
permits release of the spider.
100128] While the foregoing is directed to embodiments of the present
invention,
other and further embodiments of the invention may be devised without
departing
from the basic scope thereof, and the scope thereof is determined by the
claims that
follow.
37
