Note: Descriptions are shown in the official language in which they were submitted.
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TUBULAR DRIVE SYSTEM
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application
No.
62/011,964, entitled "TUBULAR DRIVE SYSTEM," filed June 13, 2014, which is
hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Present embodiments relate generally to the field of drilling and
processing of
wells, and, more particularly, to a top drive system for coupling with,
rotating, and
releasing drillpipe elements to facilitate insertion and removal of the
drillpipe elements
into and out of a wellbore during drilling operations and the like.
[0003] In conventional oil and gas operations, a drilling rig is used to
drill a wellbore
to a desired depth using a drill string, which includes drillpipe, drill
collars and a bottom
hole drilling assembly. During drilling, the drill string may be turned by a
rotary table
and kelly assembly or by a top drive to facilitate the act of drilling. As the
drill string
progresses down hole, additional drillpipe is added to the drill string. When
a top drive is
used in such operations, the drillpipe or drill string generally couples with
a rotatable
cylindrical stem of the top drive that may be referred to as the quill. More
specifically,
the drillpipe or drill string couples with the quill via a top drive sub that
threadably
couples with the quill and the drillpipe or drill string. The sub may function
to limit wear
on the quill.
[0004] It is now recognized that certain aspects of existing drilling
techniques are
inefficient and cumbersome because of limitations on other procedural
components
during certain phases of operation.
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BRIEF DESCRIPTION
[0005] In
accordance with one aspect of the disclosure, a tubular drive system
includes a gripping device configured to couple with a length of tubular, a
rotational
system configured to drive rotation of the gripping device, and a load support
feature
coupled to the gripping device and the rotational system and configured to
support the
gripping device and the rotational system.
[0006] In
accordance with another aspect of the disclosure, a method includes
gripping a distal end of a length of tubular with a gripping device; driving
rotation a gear
fixed to the gripping device with at least one motor; and coupling the length
of tubular to
a drill string stump, wherein the gripping device and the at least one motor
are supported
by a load plate.
[0007] In
accordance with a further embodiment of the disclosure, a system includes a
gripping device configured to couple with a distal end of a length of tubular,
a rotational
system comprising a plurality of motors configured to drive rotation of a gear
fixed to the
gripping device, a load plate coupled to the gripping device and the
rotational system and
configured to support the gripping device and the rotational system, and a
thrust bearing
disposed between the gripping device and the load plate, wherein the thrust
bearing is
configured to transfer a load from the gripping device to the load plate.
DRAWINGS
[0008] These
and other features, aspects, and advantages of the present disclosure will
become better understood when the following detailed description is read with
reference
to the accompanying drawings in which like characters represent like parts
throughout the
drawings, wherein:
[0009] FIG. 1
is a schematic of a well being drilled in accordance with present
techniques;
[0010] FIG. 2
is a perspective view of a tubular drive system, in accordance with
present techniques;
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[0011] FIG. 3
is a cross-sectional side view of a tubular drive system, in accordance
with present techniques; and
[0012] FIG. 4
is a cross-sectional side view of a tubular drive system, in accordance
with present techniques.
DETAILED DESCRIPTION
[0013] Present
embodiments are directed to a system for facilitating assembly and
disassembly of tubular (e.g., drill pipe elements). For example, present
embodiments
include a tubular drive system having a gripping device and a rotational
system supported
by a load plate that is suspended by yoke links and a yoke from a traveling
block or other
component of a drilling rig. The gripping/lifting system may include features
configured
to engage and lift a length of tubular (e.g., a drill pipe element) and align
the length of
tubular with a drill string. In certain embodiments, the gripping device may
include
components configured to grip, seal, and engage with the length of tubular
without
creating a threaded connection between the gripping device and the length of
tubular.
Once the tubular drive system positions the length of tubular above the drill
string, the
rotational system may drive rotation of the gripping device, and thus drive
rotation of the
length of tubular. In this manner, the tubular drive system may add the length
of tubular
to the drill string. The gripping device and the rotational drive system may
similarly
function to grip and remove (e.g., unthread) a length of tubular from the
drill string to
disassemble the drill string. As will be appreciated, the disclosed
embodiments may not
include components such as a quill, grabber legs, and so forth, which would
add to the
total overall length of the tubular drive system. As a result, the tubular
drive system may
have a shorter overall length as compared to traditional top drive systems,
which may
improve the operation and functionality of the tubular drive system in
accordance with
present embodiments.
[0014] Turning
now to the drawings, FIG. 1 is a schematic of a drilling rig 10 in the
process of drilling a well in accordance with present techniques. The drilling
rig 10
features an elevated rig floor 12 and a derrick 14 extending above the rig
floor 12. A
supply reel 16 supplies drilling line 18 to a crown block 20 and traveling
block 22
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configured to hoist various types of drilling equipment above the rig floor
12. The
drilling line 18 is secured to a deadline tiedown anchor 24, and a drawworks
26 regulates
the amount of drilling line 18 in use and, consequently, the height of the
traveling block
22 at a given moment. Below the rig floor 12, a drill string 28 extends
downward into a
wellbore 30 and is held stationary with respect to the rig floor 12 by a
rotary table 32 and
slips 34 (e.g., power slips). A portion of the drill string 28 extends above
the rig floor 12,
forming a stump 36 to which another length of tubular 38 (e.g., a joint of
drill pipe) may
be added.
[0015] A tubular drive system 40 (e.g., a top drive system) in accordance
with present
embodiments, hoisted by the traveling block 22, positions the tubular 38 above
the
wellbore 30. In the illustrated embodiment, the tubular drive system 40
includes a
gripping device 42 and a rotational system 44. The gripping device 42 of the
tubular
drive system 40 is engaged with a distal end 46 (e.g., box end) of the tubular
38. The
tubular drive system 40, once coupled with the tubular 38, may then be
utilized to lower
the coupled tubular 38 toward the stump 36, and the rotational system 44 may
rotate the
gripping device 42 and the tubular 38 such that the tubular 38 connects with
the stump 36
and becomes part of the drill string 28. In present embodiments, the tubular
drive system
40 may not include a quill, a sub, and/or other components which would add to
a total
length of the tubular drive system 40. As a result, the tubular drive system
40 may have a
shorter overall length than traditional top drive systems, thereby improving
and
simplifying the functionality and operation of the tubular drive system 40.
[0016] FIG. 2 is a perspective view of an embodiment of the tubular drive
system 40,
including the gripping device 42 and the rotational system 44. In certain
embodiments,
the gripping device 42 may be a system similar to the systems (e.g., gripping
devices)
described in U.S. Patent Application No. 13/655,798, which is published as
U.S. Patent
Application Publication No. 20130168106, and which is hereby incorporated by
reference in its entirety. The gripping device 42 and the rotational system 44
are
supported by a load plate 50 (e.g., a load bearing body, load frame, or other
load support
feature) of the tubular drive system 40. The weight and torque acting on the
gripping
device 42 and the rotational system 44 are transferred to the drilling rig 10
via yoke links
52 and a yoke 54 coupled to the load plate 50. The weight and torque acting on
the
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gripping device 42 and the rotational system 44 may also be transferred to the
drilling rig
by a torque restrained device (e.g., a torque track system), which is not
shown in FIG.
2. As shown, the load plate 50, the yoke links 52, and the yoke 54 are coupled
to one
another via pivotable connections 56 to enable rotation and/or pivoting of the
components
relative to one another. In certain embodiments, the yoke 54 may couple to
hooks or
another component coupled to the traveling block 22 of the drilling rig 10. As
a result,
the tubular drive system 40 may grip the length of tubular 38, and the
traveling block 22,
drawworks 26, and other components may be used to raise and lower the tubular
drive
system 40 and tubular 38, as desired.
[0017] In the illustrated embodiment, the rotational system 44 includes
four motors 58
supported by the load plate 50. However, other embodiments may include other
numbers
of motors 58, such as 1, 2, 3, 5, 6, or more motors 58. For example, the
motors 58 may
be hydraulic motors, electric motors, or other suitable types of motors
configured to
generate and apply a rotational force. As described in detail below, the
motors 58 are
configured to drive rotation of a transmission (e.g., transmission 112 shown
in FIG. 3)
coupled to the gripping device 42. In this manner, the gripping device 42 and
the tubular
38 gripped and supported by the gripping device 42 may be rotated during
assembly
and/or disassembly of the drill string 28.
[0018] FIG. 3 is a cross-sectional side view of an embodiment of the
tubular drive
system 40. As mentioned above, the tubular drive system 40 includes the
gripping device
42 and the rotational system 44, which are both supported by the load plate 50
of the
tubular drive system 40. In the illustrated embodiment, the gripping device 42
is
disposed generally above the load plate 50. Weight and torque acting on the
gripping
device 42 are transferred to the load plate 50 via a thrust bearing 100
disposed between a
body 102 of the gripping device 42 and the load plate 50. Additionally, a
centralizer
bearing 104 is disposed between the load plate 50 and the body 102 of the
gripping
device 42 to enable and improve alignment of the gripping device 42 within the
load
plate 50. In other words, the centralizer bearing 104 and the thrust bearing
100 may
cooperatively align the gripping device 42 along a vertical axis 105 to keep
the gripping
device 42 and the tubular 38 supported by the gripping device 42 in a vertical
orientation.
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[0019] As mentioned above, the gripping device 42 may be similar to the
systems
(e.g., gripping devices) described in U.S. Patent Application No. 13/655,798,
which is
published as U.S. Patent Application Publication No. 20130168106, and which is
hereby
incorporated by reference in its entirety. The gripping device 42 may include
various
pipe or tubular 38 gripping features and a hydraulically energized piston 106
that moves
with the gripping device 42 and seals against the tubular 38. For example, in
the
illustrated embodiment, the gripping device 42 includes elevators 108 and
torsional
clamping actuators 110 (e.g., torsional clamp devices). These features
operatively
cooperate to facilitate surrounding the distal end 46 of the tubular 38,
vertically securing
the tubular 38 within the gripping device 42, creating a sealed engagement
between the
gripping device 42 and the tubular 38, centralizing the tubular 38 within the
gripping
device 42, and applying torque to the tubular 38 via the gripping device 42.
[0020] The rotational system 44 of the tubular drive system 40 includes a
transmission
112 configured to transfer rotational forces generated by the motors 58 to the
gripping
device 42. The transmission 112 includes a main gear 114, which is fixedly
attached to
the main body 102 of the gripping device 42, as indicated by arrows 116. For
example,
the main gear 114 may be bolted, welded, brazed, threaded, or otherwise
mechanically
coupled to the main body 102 of the gripping device 42. Rotational forces
generated by
the motors 58 may be transferred to the main gear 114 by belts, chains, teeth,
cogs,
helical surfaces, beveled surfaces, crown surfaces, worm gears, and/or other
suitable
connections configured to transfer rotational movement.
[0021] FIG. 4 is a cross-sectional side view of another embodiment of the
tubular
drive system 40. The illustrated embodiment includes similar elements and
element
numbers as the embodiment shown in FIG. 3. In the illustrated embodiment, the
gripping
device 42 is supported by the load plate 50 near a top of the gripping device
42. That is,
an upper end 120 of the main body 102 of the gripping device 42 includes a
flange 122
that engages with the thrust bearing 100 of the tubular drive system 40.
Weight and
torque acting on the gripping device 42 may be transferred from the main body
102 to the
thrust bearing 100 and further to the load plate 50 of the tubular drive
system 40.
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[0022] During a
process of installing or removing lengths of tubular 38, it may be
desirable to circulate fluids (e.g., drilling mud) through the drill string
28. Operation of
the gripping device 42 may include gripping an outer portion of the tubular 38
with the
elevators 108 and/or torsional clamping actuators 110 rather than attaching a
sub via
threaded engagement. For example, the upper distal end 46 of the tubular 38
being added
may be gripped around its outer perimeter with the gripping device 42 without
making-up
an extension of the tubular drive system 40 to threads of the distal end 46
such that more
rapid positioning of the drillpipe element is facilitated. This may result in
difficulty
flowing fluids from the tubular drive system 40 through the tubular 38 being
added or the
drill string 28 during certain phases of the process.
[0023] To
enable fluid (e.g., drilling mud) circulation through the tubular drive system
40, the tubular 38, and the drill string 28, the tubular drive system 40
includes a variety of
fluid flow components and associated sealing elements and/or sealing features.
For
example, the tubular drive system 40 includes a gooseneck connection 124 and a
washpipe 126, which may receive a flow of fluid and direct the flow of fluid
through the
hydraulically energized piston 106 and into the tubular 38. The tubular drive
system 40
also includes various seals to block fluid from exiting the flow path through
the
gooseneck connection 124, the washpipe 126, the hydraulically energized piston
106, and
the tubular 38. For example, the tubular drive system 40 includes a rotary
seal 128
disposed between the washpipe 126 and an outer shell 130 surrounding the
washpipe 126.
The tubular drive system 40 also includes an upper seal 132 disposed between
the
hydraulically energized piston 106 and the main body 102 of the gripping
device 42 and a
lower seal 134 configured to be disposed between the hydraulically energized
piston 106
and the tubular 38. The seals 128, 132, and 134 enable proper circulation of
fluids during
certain portions of the drill string 28 assembly and/or disassembly process.
That is,
present embodiments are directed to providing a seal between the tubular drive
system 40
and the tubular 38 such that fluid can efficiently pass from the tubular drive
system 40
into the drillpipe element or tubular 38.
[0024] In
certain embodiments, the tubular drive system 40 may include other
features, such as one or more control features. For example, the tubular drive
system 40
may include a controller configured to regulate operation of the gripping
device 42, the
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rotational system 44 (e.g., the motors 58), the elevators 108, the torsional
clamping
actuators 110, and/or other components of the tubular drive system 40.
Additionally, the
tubular drive system 40 may include sensors configured to detect one or more
operating
parameters of one or more components of the tubular drive system 40. The one
or more
operating parameters may be used as feedback by the controller, and the
controller may
further control operation of one or more components of the tubular drive
system 40 based
on the feedback (e.g., the operating parameters measured by the sensors).
[0025] As
discussed in detail above, present embodiments are directed towards a
tubular drive system 40 having the gripping device 42 and the rotational
system 44 which
are supported by the load plate 50. The load plate 50 is suspended by yoke
links 52 and
the yoke 54 from the traveling block 22 or other component of the drilling rig
10. As
discussed above, the gripping system 42 may include features configured to
engage and
lift the tubular 38 and align the tubular 38 with the stump 36 of the drill
string 28. For
example, the gripping device 42 may include components, such as elevators 108
and or
torsional clamping actuators 110, configured to grip, seal, and engage with
the length of
tubular 38 without creating a threaded connection between the gripping device
42 and the
length of tubular 38. Once the tubular drive system 40 positions the length of
tubular 38
above the drill string 28, the rotational system 44 may drive rotation of the
gripping
device 42, and thus drive rotation of the length of tubular 38. In this
manner, the tubular
drive system 40 may add the length of tubular 38 to the drill string 28.
Furthermore, the
gripping device 42 and the rotational system 44 may similarly function to grip
and
remove (e.g., unthread) the tubular 38 from the drill string 28 to disassemble
the drill
string 28. As discussed above, the disclosed embodiments may not include
components
such as a quill, grabber legs, and so forth, which may add to the total
overall length of the
tubular drive system 40. As a result, the tubular drive system 40 may have a
shorter
overall length as compared to traditional top drive systems, which may improve
the
operation and functionality of the tubular drive system 40.
[0026] While
only certain features of the present disclosure have been illustrated and
described herein, many modifications and changes will occur to those skilled
in the art. It
is, therefore, to be understood that the appended claims are intended to cover
all such
modifications and changes as fall within the true spirit of the present
disclosure.
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