Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
Elongate Member Handling System
[0001] This application claims priority of Australian provisional
application number
2017904815, filed 29 November 2017, the entire contents of which are
incorporated herein.
TECHNICAL FIELD
[0002] This invention relates to a handling system for a well servicing rig
or drilling rig,
for inserting or removing elongate members (tubulars or sucker rods) from a
well bore,
particularly a well bore under formation pressure.
BACKGROUND ART
[0003] Gas extraction from coal seams is a relatively new method for
extracting clean
gas from the earth. The process involves drilling a hole into a coal seam. The
coal seam is
generally flooded with water, trapping the gas inside the coal. To extract the
gas from the
coal a pump must be inserted into the hole to pump out the water, allowing the
gas to migrate
from the coal. The water and gas are pumped to surface and then separated. The
subsequent
product and by-product are then pumped away, to be dealt with by other means.
[0004] The pumps in the wells require servicing regularly and must be
retrieved from the
well utilising a well servicing rig. As wells mature, it has been identified
that water depletes
and the gas increases, thereby increasing the pressure in the well bore. The
primary methods
for safely removing tubulars from a well for servicing consist of the well
bore being filled
with water to hold the gas in the well. As the gas pressure increases in the
well it becomes
increasingly difficult to maintain a safe and cost effective fluid barrier for
well entry.
[0005] In challenging wells a snubbing/stripping unit is required to be
added to the well
head to safely control the movement of tubulars in and out of the well whilst
maintaining the
security of pressure and hydrocarbon to the well bore. A conventional
snubbing/stripping unit
is an additional non-integrated piece of equipment to the rig carrier
DESCRIPTION OF THE INVENTION
[0006] An object of the present invention is to provide an elongate member
handling
system for inserting or removing elongate members (such as tubulars or sucker
rods) from a
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well bore, preferably a well bore under pressure.
[0007] An alternative object of the present invention is to provide a
servicing or drilling
rig (preferably mobile) that integrates an elongate member handling system to
provide oil
and/or gas well intervention.
[0008] An alternative object of the present invention is to provide a
servicing or drilling
rig that integrates a conventional draw-works hoisting system and an elongate
member
handling system.
[0009] An alternative object of the present invention is to provide a
mobile well
servicing or drilling rig that integrates a conventional draw-works hoisting
system and an
elongate member handling system.
[0010] An alternative object of the present invention is to supplement
conventional rigs
employing a conventional draw-works hoisting system with an elongate member
handling
system, such that there is an easy operation switch-over so as to snub/strip
elongate members
into/from pressurised wells using the elongate member handling system.
[0011] According to a 1s1 aspect of the present invention, there is
provided an elongate
member handling system connected to or connectable to a mast of a rig, said
handling system
comprising:
[0012] a travelling holding assembly for holding an elongate member in
axial alignment
with a well bore; and
[0013] a rack and pinion drive assembly to which is mounted the travelling
holding
assembly such that the travelling holding assembly travels up or down the mast
so as to insert
the elongate member into the well bore or remove the elongate member from the
well bore.
[0014] According to a 2"" aspect of the present invention, there is
provided an elongate
member handling system connected to or connectable to a mast of a rig, said
handling system
comprising:
[0015] a travelling holding assembly for holding an elongate member in
axial alignment
with a well bore; and
[0016] a rack and pinion drive assembly comprising:
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[0017] a rack assembly that is connected to or connectable to the rig;
[0018] a pinion assembly that operatively engages the rack assembly and to
which is
mounted the travelling holding assembly; and
[0019] a drive for moving the pinion assembly such that the travelling
holding assembly
travels up or down the mast so as to insert the elongate member into the well
bore or remove
the elongate member from the well bore.
[0020] According to a 3rd aspect of the present invention, there is
provided a rig
comprising the elongate member handling system according to the 1st or 2"d
aspect of the
present invention.
[0021] According to a 4th aspect of the present invention, there is
provided a method of
servicing a well, said method comprising the steps of:
[0022] optionally connecting an elongate member handling system as
described
according to the 1s1 or 2"d aspect of the present invention to a mast of a
rig, and
[0023] operating the elongate member handling system to insert the elongate
member
into a well bore or remove the elongate member from a well bore.
[0024] According to a 5th aspect of the present invention, there is
provided a method of
inserting or removing an elongate member from a well bore, said method
comprising the step
of:
[0025] optionally connecting an elongate member handling system as
described
according to the 1 or 2nd aspect of the present invention to a mast of a rig;
and
[0026] operating the elongate member handling system so as to insert the
elongate
member into the well bore or remove the elongate member from the well bore.
[0027] The phrase 'elongate member' refers to a tubular or sucker rod or
any other type
of tube, pipe or rod that may be used when servicing or drilling a well.
'Elongate member'
also refers to two or more tubulars or rods connected end to end, such as a
drill string.
[0028] The travelling holding assembly can be connected to any suitable
part of the mast
in any suitable way. The mast can be a stiff (non-scoping) mast or a scoping
mast. The
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travelling holding assembly can be connected or connectable to a bottom, mid
or top section
of a mast, for example. In some embodiments, the travelling holding assembly
can be
connected or connectable to a bottom section of an outer mast. In some
embodiments, the
travelling holding assembly can be connected or connectable to an interior
region of the mast.
[0029] Preferably, the travelling holding assembly is connected or
connectable within a
bottom section of an outer mast.
[0030] The travelling holding assembly can be of any suitable size, shape
and
construction, and can be made of any suitable material or materials, such as
steel.
[0031] The travelling holding assembly can hold the elongate member in
axial alignment
with the well bore in any suitable way. Typically this would involve
temporarily clamping to
the elongate member, and this can be achieved in any suitable way. Typically,
the travelling
holding assembly will comprise a bowl and an inverted slips assembly or
hydraulic rotary
slips inverted assembly capable of sustaining upward and downward forces as
the travelling
holding assembly moves up or down the mast.
[0032] The travelling holding assembly can comprise a bowl and inverted
slips. The
bowl can have a bowl body and a bowl passage extending through the bowl body.
The
inverted slips assembly placed within the passage can wedge a set of dies
against the bowl
and the elongate member being inserted or removed from the well bore. There
can be two
sets of dies in the inverted slips assembly: a lower set for gripping an
elongate member with
forces in an upward direction, and an upper set for gripping an elongate
member with
downward forces.
[0033] In some embodiments the travelling holding assembly can be in the
form of at
least one tubing spider assembly. The tubing spider assembly can comprise a
spider bowl
body, a bodyguard extending from one or more opposing sides of the spider bowl
body, and a
passage extending through the spider bowl body to the opposing sides of the
spider bowl
body. The passage can be in axial alignment with the well bore when inserting
or removing
the elongate member from the well bore.
[0034] The rack assembly can be of any suitable size, shape and
construction, and can be
made of any suitable material or materials. In some embodiments the rack
assembly
comprises a lst rack connected to or connectable to a 1' upright of the mast,
and a 2"d rack
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connected to or connectable to a 2"d upright of the mast. In some embodiments,
1s1 and 2nd
uprights can each be in the form of a beam, such as an I-beam or U-shaped
beam, having a
longitudinally extending passage. In some embodiments, the 1st and 2"d
uprights can
correspond with sides of the mast. In some embodiments, the 1st and 2'd
uprights can
correspond with a spine of the mast (ie. middle of the back, rather than sides
of the mast).
[0035] Each rack can comprise teeth that extend laterally relative to a
length of the mast.
The teeth of each rack can extending in substantially the same plane. The 1st
and 2"d racks can
be of any suitable length. For example, each rack can extend the entire length
of the mast (eg.
if a non-scoping mast) or less than the entire length of the mast. These can
comprise one or
more rack pieces connected and to end or these can be of unitary construction.
[0036] The 1s1 and 211d racks can be connected to the mast uprights in any
suitable way.
Preferably the 1st and rd racks can be retrofitted to the mast of a rig and
can be removed
from the mast of that same rig when well servicing has ended. However, the
racks can be
permanently connected to the mast of the rig.
[0037] In some embodiments the 1st rack can be connected to/extend along a
longitudinal
side of an I-beam mast upright such that the teeth of the 1st rack and a
longitudinal passage of
the upright are diametrically opposed to each other. In some embodiments the
2nd rack can be
connected to/extend along a longitudinal side of an I-beam mast upright such
that the teeth of
the 2"d rack and a longitudinal passage of the upright are diametrically
opposed to each other.
[0038] Preferably the length of each of the 1st and 2"d racks is less than
about 50 m and
greater than about 4 m. This includes the lengths of 4, 5, 6, 7, 8, 9,10, 11,
12, 13, 14, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35,
36, 37, 38, 39, 40, 41,
42, 43, 44, 45, 46, 47, 48, 49 and 50 m, as well as all 10cm increments
between 4 and 50 m.
Preferably the length of each of the 1st and 2','d racks is approximately 5-7
m (eg. -6 m or -5.5
m), such that the travelling holding assembly can move an elongate member a
vertical
distance of approximately 5-7 m and more preferably approximately 5.5 m. (i.e.
a 5-7 m drive
range, and more preferably approximately 5.5 m drive range).
[0039] The pinion assembly can be of any suitable size, shape and
construction, and can
be made of any suitable material or materials. The pinion assembly can engage
the rack
assembly in any suitable way. The pinion assembly can have any suitable number
of pinions
but preferably has at least 2 pinions and more preferably at least one further
pair of pinions.
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Preferably the pinion assembly has 4 pinions. In some embodiments at least a
1st pair of
spaced apart pinions operatively engages the 1st rack and at least a 2"(1 pair
of spaced apart
pinions operatively engages the 2nd rack. The pinions can rotate in
substantially the same
plane.
[0040] The pinion assembly can comprise a pinion carrier for holding each
pinion or
pinion pair relative to each rack. In some embodiments the pinion carrier
together with at
least one pinion or pinion pair can clamp teeth of a rack there between. The
pinion carrier can
be of unitary construction or discrete separate pieces. The pinion carrier can
be of any
suitable size, shape and construction, and can be made of any suitable
material or materials.
The pinion carrier can have a pinion mounting region for each pinion. Each
pinion can be
pinned to a pinion mounting region, for rotation relative to the pinion
carrier.
[0041] The drive for moving the pinion assembly can be of any suitable
size, shape and
construction, and can be made of any suitable material or materials. The drive
can be
hydraulic, pneumatic, electrical, but preferably hydraulic. In some
embodiments the drive
comprises a motor for rotating all of the pinions, or a respective motor for
rotating a
respective pair of pinions, or a respective motor for each pinion. Preferably,
each pinion has
its own motor to which it is connected by way of a drive shaft. The pinion
carrier can
comprise at least one motor mount for mounting at least one motor. A motor can
be mounted
to the pinion carrier such that the drive shaft turns the pinion. Preferably,
four motors turn the
four pinions individually. Preferably the motor is mounted to the pinion
carrier and the drive
shaft extends through the pinion carrier.
[0042] The pinion carrier can comprise a 1St rack mounting region for
mounting to the 18`
rack. The pinion carrier can comprise a second rack mounting region for
mounting to the
second rack. These rack mounting regions can be of any suitable size, shape
and construction.
[0043] In some embodiments each rack mounting region cooperates with the
respective
pinion or pinion pair to hold teeth of the rack there between. In some
embodiments the teeth
of the rack extend between a pinion or pinion pair and rack mounting region.
In some
embodiments the rack mounting region extends from the pinion or pinion pair to
a location
behind the rack, diametrically opposite the teeth of the rack - much like in a
clamping
arrangement. In some embodiments the rack mounting region extends from the
pinion or
pinion pair to within a longitudinal passage of an I-beam mast upright to
which the rack is
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connected or along which the rack extends.
[0044] In some embodiments each rack mounting region comprises one, two,
three or
more retainers that locate within a longitudinal passage of an I-beam mast
upright.
[0045] The pinion carrier can comprise a first bracket and a second
bracket. These
brackets can extend substantially parallel with one another. The brackets can
have one or
more pinion mounting regions. A first pinion or a first pair of spaced apart
pinions can be
pinned to the first bracket at pinion mounting regions of the bracket. A
second pinion or a
second pair of spaced apart pinions can be pinned to the second bracket at
pinion mounting
regions of the bracket.
[0046] In some embodiments the pinion carrier can comprise a first bracket
associated
with the first rack and a second bracket associated with the second rack. The
first and second
brackets can each comprise a main body extending along a respective
longitudinal side of
each rack. The main bodies can extend substantially parallel with one another.
Each bracket
or bracket main body can comprise one or more pinion mounting regions to which
the pinion
or pinion pair is pinned. Likewise, each bracket or bracket main body can
comprise one or
more motor mounting regions for mounting one or more motors. Typically a
pinion and
motor will be pinned to opposite sides of a bracket or bracket main body.
[0047] Each bracket can comprise a rack mounting region that extends from
the pinion
or pinion pair or bracket main body to a location behind the rack, as
described for previous
embodiments of the invention.
[0048] The rack and pinion drive assembly can be mounted to the travelling
holding
assembly in any suitable way. For example, the travelling holding assembly can
be fixedly
mounted to the rack and pinion drive assembly or can be adjustably mounted to
the travelling
holding assembly.
[0049] In some embodiments, the travelling holding assembly is adjustably
mounted to
the rack and pinion drive assembly such that the travelling holding assembly
is able to be
moved relative to the mast between a retracted stored/transportable position
substantially
within the mast and an extended working position substantially externally of
the mast such
that the travelling holding assembly bowl is axially aligned with the centre
of the well bore.
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[0050] In some embodiments, the handling system comprises a positioning
mechanism
for positioning the travelling holding assembly relative to the mast. The
positioning
mechanism can move the travelling holding assembly between a substantially
retracted
stored/transportable position within the mast and a substantially extended
working position
externally of the mast such that the travelling holding assembly is able to
clamp to an
elongate member.
[0051] The positioning mechanism can be of any suitable construction. In
some
embodiments the pinion carrier comprises a holding assembly mounting region
for mounting
to the travelling holding assembly. The holding assembly mounting region can
be connected
to or extend from each bracket main body. The holding assembly mounting region
can be of
any suitable size, shape and construction. The holding assembly mounting
region can be
connected to any suitable part or parts of the travelling holding assembly or
indirectly
connected to any suitable part or parts of the travelling holding assembly.
The holding region
can comprise a support table. The support table can extend from the bowl body
and it can be
of any suitable shape and construction. In some embodiments, opposed sides of
the support
table slide within or along the pair of rails.
[0052] In some embodiments the holding assembly mounting region is directly
connected to the bowl or bowl body of the travelling holding assembly. In some
embodiments the holding assembly mounting region is indirectly connected to
the bowl or
bowl body of the travelling holding assembly. In some embodiments the holding
assembly
mounting region is telescoping or telescopic in nature, enabling extension to
the working
position.
[0053] In some embodiments the holding assembly mounting region comprises a
sliding
rail system (similar to a sliding drawer), whereby the pinion carrier
comprises a pair of rails
and the travelling holding assembly is slidable relative to the pair of rails
between the stored
and working positions. The rails can extend substantially parallel with each
other in
substantially the same plane, preferably at a right angle to the longitudinal
length of the racks
or mast. In some embodiments opposed sides of the travelling holding assembly
slide within
or along the pair of rails.
[0054] In some embodiments the travelling holding assembly can comprise a
support
table. The support table can extend from the bowl body and it can be of any
suitable shape
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and construction. In some embodiments, opposed sides of the support table,
bowl or bowl
body slide within or along the pair of rails.
[0055] In some embodiments the holding assembly mounting region comprises a
telescopic sliding rail system, whereby the pinion carrier comprises a pair of
rails and a pair
of telescoping members that are slidable relative to the pair of rails,
wherein the telescoping
members are connected to the travelling holding assembly or part thereof, such
as the support
table, bowl or bowl body. The rails and telescoping members can extend
substantially parallel
with each other in substantially the same plane, preferably at a right angle
to the longitudinal
length of the racks or mast. The telescoping members can slide along or within
the rails, and
the sides of the support table, bowl or bowl body can slide along or within
the telescoping
members.
[0056] In some embodiments the positioning system can comprise at least one
hydraulic
or pneumatic cylinder connected to the pinion carrier or holding assembly
mounting region,
for moving the travelling holder assembly between the substantially retracted
stored/transportable position within the mast and the substantially extended
working position
externally of the mast. A piston rod of a cylinder can be pivotally mounted to
the travelling
holder assembly or part thereof, eg. bowl, bowl body or support table.
Preferably, retraction
of the piston rod causes the bowl body to be substantially retracted for
storage or transport
within the mast, and extension of the piston rod causes the bowl body to be
moved externally
of the mast to the working position.
[0057] In some embodiments the positioning system can comprise two, three
or four
hydraulic or pneumatic cylinders connected to the pinion carrier or holding
assembly
mounting region for moving the travelling holder assembly between the
substantially
retracted stored/transportable position within the mast and the substantially
extended working
position externally of the mast.
[0058] In embodiments where the holding assembly mounting region comprises
a
telescopic sliding rail system, one or two hydraulic or pneumatic cylinders
can extend in a
substantially parallel manner from the rails to the pair of telescoping
members. Likewise, one
or two additional hydraulic or pneumatic cylinders can extend in a
substantially parallel
manner from the rails or pinion carrier to the travelling holding assembly or
part thereof, such
as the support table, bowl or bowl body.
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[0059] In some embodiments, a first pair of hydraulic or pneumatic
cylinders is
connected to the rails and to the telescoping members, and an additional
hydraulic or
pneumatic cylinder is connected to one of the rails and the support table of
the travelling
holder assembly. In this embodiment, opposed sides of the support table are
able to slide
within a respective longitudinal passage of each telescoping member, and each
telescoping
member is able to slide within a respective longitudinal passage of each rail,
such that in the
retracted/stored position the sides of the support table are substantially
nested within the
telescoping members and the telescoping members are substantially nested
within the rails.
[0060] The handling system can have an approximately 9,000 kg push and pull
capacity,
although this may vary. For example, depending on the rig size, the capacity
could be lower
or higher, eg. 10,000 kg.
[0061] The handling system can comprise an inverted slip assembly fixed to
a top of a
BOP stack. The inverted slip assembly can contain upward and downward forces.
The
inverted slip assembly can be utilised to hold the elongate member in place so
the travelling
holding assembly can be released from the elongate member and re-positioned as
required.
[0062] The handling system can comprise a control and monitoring system to
manage
the operation and status of all major components of the handling system. The
system can
provide save control through a series of status monitoring sensors providing a
programmed
PLC logic control unit that can decode information and provide relevant
programmed
interlock output signals. The system can monitor and store parameters for
historical analytics.
The system can have a fault diagnostic function and can be accessed
wirelessly. The system
can be controlled by a number of apparatus and monitoring can be displayed at
an operator's
station.
[0063] In some embodiments, the holding assembly can have at least one load
sensor for
sensing a load. For example, the support table or travelling holding assembly
can have a load
sensor for sensing a load placed on it when holding an elongate member or when
inserting or
removing an elongate member.
[0064] The rig can be of any suitable size, shape and construction. The rig
is preferably
mobile. The rig can be any suitable type of rig, such a well servicing rig or
drilling rig.
[0065] The rig can be in the form of a self-propelled truck, self-propelled
purpose built
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carrier, or it could be a trailer that can be used as a base to mount a mast,
crown block,
travelling block and travelling block winch (draw-works). The rig can utilise
two independent
systems for hoisting and handling elongate members.
[0066] The rig can have one or more features of conventional rigs. The rig
can have a
wire rope winching system for hoisting and lowering travelling blocks which
can insert and
remove elongate members from a well bore. To control the wire rope
hoisting/lowering
system, a direct driven winch (draw works) can be powered by either a truck
diesel engine, or
a hydrostatic or electric motor power. The draw works can incorporate a main
and an optional
sand line drum fixedly mounted to a carrier base. The draw works can hoist the
travelling
block vertically in the mast over a crown block sheave cluster located at a
top of the mast.
The tail of the wire rope can be anchored to a rig chassis via a fixed dead
man anchor.
[0067] A travelling block assembly can hoist elongate members from the well
bore and
lower elongate members into a well bore assembly whilst the well bore has no
pressure or is
in an overbalanced (greater tubing string weight vs well bore pressure)
situation. The draw
works can utilise a clutch assembly to transfer drive from a power unit to a
hoisting drum
where cable is wrapped up during the drum rotation, and the travelling block
assembly can
then raise in a mast section thereby removing the elongate member/drill string
from the well
bore. The travelling block can also be lowered for inserting elongate members
into the well
bore by disconnecting the clutch from the hoisting drum and releasing a set of
brakes that
holds the drum from rotating.
[0068] The rig can be designed to be used as a snubbing/stripping unit. The
function of a
stripping unit is to safely control insertion and removal of elongate members
from a well bore
whilst it is under natural formation pressure. Each elongate member can be
approximately
9.5m in length but may vary to shorter or longer lengths. Each section of
elongate member is
top and bottom threaded and can be connected together whilst being inserted
into the well
bore to make a tubing string. The elongate member above surface can be secured
and forced
into the well bore under pressure. An annular BOP stack with a modified
element (stripping
element) can be used to seal the well bore to the elongate member so no
pressure or
hydrocarbons can escape during the stripping operation where the elongate
member descends
into the well bore.
[0069] The stripping unit can comprise three major items integrated into
the rig or
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utilised with to move, hold and seal an elongate member being inserted or
removed from the
well bore. The rig can utilise a vertical mast with a handling system as
described above,
located in the bottom section of a telescoping single mast. The travelling
holding assembly
can be hydraulically extended from its storage position in the mast to over
the well bore
centre line, in which case it is in its working elongate member handling
position.
[0070] The rig can comprise a top head drive rotating system that can be
hoisted
vertically in the mast using the travelling block. A top head drive unit has
the ability to rotate
tubing for drilling. The top head drive unit has the capability of attaching
hydraulically tilting
elevator links used for handling tubulars whilst inserting and removing a
tubular from a well
bore. The top head drive unit can also tilt for making up (threading into)
tubulars in a
horizontal plane. The top head drive unit has a torque reaction system for a
rotating operation
that is transferred into the main mast structure through a full length
integral guide beam(s).
[0071] Any of the features described herein can be combined in any
combination with
any one or more of the other features described herein within the scope of the
invention. For
example, a feature or integer of a product (or product claim) can be a feature
or integer of a
method (or method claim) of the present invention, and vice-versa.
[0072] The reference to any prior art in this specification is not, and
should not be taken
as an acknowledgement or any form of suggestion that the prior art forms part
of the common
general knowledge.
BRIEF DESCRIPTION OF DRAWINGS
[0073] Various embodiments of the invention will be described with
reference to the
following drawings, in which:
[0074] Figure la is a driller's side view showing a rig in
snubbing/stripping operation
with a handling system having a travelling holding assembly in a working
position holding a
tubular, according to an embodiment of the invention.
[0075] Figure lb is a magnified view of part of figure 1.
[0076] Figure 2 depicts the travelling holding assembly in a retracted
position such that a
top head drive unit can handle a tubular independently of the handling system.
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[0077] Figure 3 is an isometric view of part of the travelling holding
assembly of figure
1, with the travelling holding assembly in an extended working position.
[0078] Figure 4 is a side view of that shown in figure 3.
[0079] Figure 5 is a front end view of that shown in figure 3.
[0080] Figure 6 is a side view of that shown in figure 3, but with the
travelling holding
assembly in a retracted position.
[0081] Figure 7 is an isometric view of part of the handling system of
figure 1, with the
travelling holding assembly in a retracted stored/transportable position
within a mast of the
rig.
[0082] Figure 8 is a side view of part of the handling system of figure 7
but shown
holding a tubular, with the travelling holding assembly in an extended working
position
external of the mast.
[0083] Figure 9 is an isometric view of part of the handling system of
figure 7 but shown
holding a tubular, with the travelling holding assembly in an extended working
position
external of the mast, but not showing an inverted slips assembly.
[0084] Figure 10 is an isometric view of the handling system of figure 7,
extended and
holding a tubular.
[0085] Figure 11 is a front view of part of the handling system shown in
figure 7,
holding a tubular.
[0086] Figure 12 depicts the travelling holding assembly in a retracted
stored/transportable position (within a mast ¨ not shown).
[0087] Figure 13 depicts the travelling holding assembly in an extended
working
position (externally of a mast ¨ not shown), as well as an inverted slips
assembly normally
connected to a BOP stack (not shown).
[0088] Figure 14 depicts the travelling holding assembly, part of a rack
and pinion drive
assembly as well as an inverted slips assembly normally connected to a BOP
stack.
[0089] Figure 15 depicts in perspective that shown in figure 14.
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DESCRIPTION OF PREFERRED EMBODIMENTS
[0090] In the figures like reference numerals refer to like features.
[0091] The figures show a handling system 1 (1 a, lb) connected to or
connectable to a
mast 101 of a well servicing rig 100 (although it could be a drilling rig),
for inserting or
removing tubulars or sucker rods 102 (elongate members' 102) from a well bore
103. The
handling system 1 includes a travelling holding assembly la for holding a
tubular or sucker
rod 102, a rack and pinion drive assembly 2, 3, 4, and an inverted slips
assembly lb fixed to a
top of a BOP stack 104.
[0092] The rack and pinion drive assembly 2, 3, 4 includes a rack assembly
2 that is
connected to or connectable to a rear end of the mast 101, a pinion assembly 3
that
operatively engages the rack assembly 2 and to which is mounted the travelling
holding
assembly la, and a drive 4 for moving the pinion assembly 3 and travelling
holding assembly
la up or down the mast 101.
[0093] The travelling holding assembly la is in the form of a tubing spider
assembly la.
The tubing spider assembly la has a spider bowl body 10, a bodyguard 1 la, llb
extending
from each opposing side of the bowl body 10, and a passage 12 extending
through the bowl
body 10 to the opposing sides of the bowl body 10 (see figure 3).
[0094] The travelling holding assembly la includes an inverted slips
assembly 13 (not
always illustrated in the figures) capable of sustaining upward and downward
forces as the
tubing spider assembly la moves relative to the rack assembly 2 and mast 101.
The inverted
slips assembly 13 wedges a set of dies against the bowl body 10 and the
tubular or sucker rod
102 being inserted or removed from the well bore 103. There can be two sets of
dies in the
inverted slips assembly 13: a lower set 14a for gripping a tubular with forces
in an upward
direction, and an upper set 14b for gripping a tubular 102 with downward
forces.
[0095] As seen in figure 9, the rack assembly 2 includes a 1st rack 20
connected to or
connectable to a 1 st upright 101a of the mast 101, and a 2nd rack 21
connected to or
connectable to a 2nd upright 101b of the mast 101. Uprights 101a and 101b are
each in the
form of an I-beam, having a longitudinally extending passage 112a, 112b. Each
rack 20, 21
has teeth 20a, 21a that extend laterally relative to a length of the mast 101.
The teeth 20a, 21a
are diametrically opposed to the passages 112a, 112b. The and
2' racks 20, 21 can be
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retrofitted to a mast 101 of a well servicing rig 100 and can be removed from
the mast 101 of
that same well servicing rig 100 when well servicing has ended. However, the
racks 20, 21
can be permanently connected to a mast 101 of a well servicing rig 100.
[0096] The length of each of the 1 st and 2nd racks 20, 21 is approximately
6190 mm such
that the tubing spider assembly la can move a tubular or sucker rod 102 a
vertical distance of
approximately 5.5 m (i.e. a 5.5 m stroke through the rack and pinion drive
range).
[0097] The pinion assembly 3 includes a 1st pair of spaced apart pinions
30a, 30b that
engage the 1st rack 20, and a 2nd pair of spaced apart pinions 31a, 31b that
engage the 2nd rack
21.
[0098] The pinion assembly 3 includes a pinion carrier 33 for guiding each
pinion pair
30, 31 relative to each rack 20, 21.
[0099] The pinion carrier 33 includes a first bracket 34 and a second
bracket 35. Each
bracket 34, 35 includes a main body 34a, 35a extending along a respective
longitudinal side
of each rack 20, 21. The main bodies 34a, 35a extend substantially parallel
with one another.
The bracket main bodies 34a, 35a have pinion mounting regions to which the
pinions 30, 31
are pinned. Each bracket main body 34a, 35a includes motor mounting regions
for mounting
motors 41 of the drive 4. A pinion 30, 31 and motor 41 are pinned to opposite
sides of the
bracket main body 34a, 35a. The pinion carrier 33 includes
adjustment/retaining rods 75 for
retaining the main body 34a, 35a, as seen in figure 5.
[00100] Each bracket 34, 35 includes a rack mounting region 34b, 35b that
extends from
the bracket main body 34a, 35a and pinions 30, 31 to a location behind the
rack 20, 21 within
a longitudinal passage 112a, 112b of the uprights 101a and 101b, as best seen
in figures 3 and
9. Each rack mounting region 34b, 35b includes three retaining lugs 34c, 35c
that are
received within and slide within the longitudinal passages 112a, 112b, as best
seen in figures
4 and 6.
[00101] The drive 4 is hydraulically driven and includes a motor 41 for
turning each
pinion 30, 31 (hydraulic hoses not shown). Each pinion 30, 31 has its own
motor 41 to which
it is connected by way of a drive shaft extending through the respective
pinion mounting
region 34b, 35b/bracket main body 34a, 35a.
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[00102] The handling system 1 includes a travelling holding assembly
positioning
mechanism 60 for positioning the travelling holding assembly la relative to
the mast 101.
The positioning mechanism 60 can move the travelling holding assembly la
between a
retracted stored transportable position 61 within the mast 101 (see circle 61
in figure 3) and
an extended working position 62 externally of the mast 101 (see circle 62 in
figure 3) such
that the travelling holding assembly la is able to clamp to a tubular or
sucker rod 102 and is
positioned centrally of the well bore 103.
[00103] The positioning mechanism 60 or travelling holding assembly 1 a
includes a
support table 66 that is secured to and extends from the spider bowl body 10.
[00104] The positioning mechanism includes the pinion carrier 33 having a
holding
assembly mounting region 36, 37 for mounting to the travelling holding
assembly I a. The
holding assembly mounting region 36, 37 is connected to and extends from each
bracket
main body 34a, 35a.
[00105] The holding assembly mounting region 36, 37 includes a telescopic
sliding rail
system whereby a rail 36a, 37a extends substantially horizontally across each
bracket main
body 34a, 35a. Each rail 36a, 37a is in the form of a U- or C-shaped beam
having a
longitudinally extending passage. The holding assembly mounting region 36, 37
further
includes a pair of telescoping members 36b, 37b, each of which is received
within and
slidable within a rail 36a, 37a. The holding assembly mounting region 36, 37
further includes
the telescoping members 36b, 37b each being connected to a side 36c, 37c of
the support
table 66.
[00106] The positioning mechanism includes three hydraulic cylinders. A
first pair of
hydraulic cylinders 64, 65 is pivotally connected to the rails 36a, 37a as
well as to the
telescoping members 36b, 37b. A further hydraulic cylinder 69 is pinned to
rail 36a as well as
to side 36c of the support table 66.
[00107] In this way, opposed sides 36c, 37c of the support table 66 are
able to slide within
a respective longitudinal passage of each telescoping member 36b, 37b, and
each telescoping
member 36b, 37b is able to slide within a respective longitudinal passage of
each rail 36a,
37a, such that in the retracted/stored position the sides 36c, 37c of the
support table 66 are
substantially nested within the telescoping members 36b, 37b and the
telescoping members
36b, 37b are substantially nested within the rails 36a, 37a.
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[00108] Retraction of each piston 64, 65, 69 rod causes the spider bowl
body 10 to be
retracted for storage or transport within the mast 101 (as seen in figure 2,
6, 7 and 12), and
extension of each piston rod 64, 65, 69 causes the spider bowl body 10 to be
moved
externally of the mast 101 to the working position (as seen in figures 1, 2,
3, 4, 8, 9, 10 and
15).
[00109] The holding assembly la has at least one load sensor for sensing a
load. For
example, the support table 66 or pinion carrier 33 can have a load sensor 70
for sensing a
load placed on it when holding a tubular 102 or when inserting or removing a
tubular 102.
[00110] Referring now to figures 1 and 2, these show a rig 100 in the form
of a self-
propelled truck/self-propelled purpose built carrier (or it could be a
trailer) that is used as a
base to mount a mast 101, crown block 110, travelling block 111 and travelling
block winch
112 (draw-works). The rig 100 utilises two independent systems for hoisting
and handling
tubulars 102:
[00111] 1. A wire rope winching system 115 is utilised as the primary
method to hoist and
lower the travelling blocks 111 which will insert and remove tubulars 102 from
a well bore
103. To control the wire rope hoisting/lowering system a direct driven winch
(draw-works) is
powered by either a truck diesel engine, or a hydrostatic or electric motor
power. The draw-
works incorporates a main and an optional sand line drum fixedly mounted to
the carrier
base. The draw-works hoists the travelling block 111 vertically in the mast
101 over a crown
block 110 sheave cluster located at the top of the mast 101. The tail of the
wire rope is then
anchored to the rig chassis via a fixed dead man anchor. This method is used
to insert/remove
tubular 102 and sucker rods from a well bore 103.
[00112] The travelling block assembly 111 is suitable for hoisting tubulars
102 from the
well bore 103 and lowering tubulars 102 into the well bore assembly 114 whilst
the well bore
103 has no pressure or is in an overbalanced (greater tubing string weight vs
well bore
pressure) situation. The draw works utilises a clutch assembly to transfer
drive from the
power unit to a hoisting drum where cable is wrapped up during the drum
rotation, and the
travelling block 111 assembly then raises in the mast 101 section thereby
removing the
tubular 102 from the well bore 103 tube by tube. The travelling block 111 can
also be
lowered for inserting tubulars 102 into the well bore 103 by disconnecting the
clutch from the
hoisting drum and releasing a set of brakes that holds the drum from rotating.
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[00113] 2. The rig 100 is designed to be used as a snubbing/stripping unit.
The function of
the stripping unit is to safely control insertion and removal of tubulars 102
from a well bore
103 whilst it is under natural formation pressure. Each tubular 102 is
approximately a 9.5m
but may vary to shorter or longer lengths. Each section of tubular 102 is top
and bottom
threaded and is connected together whilst being inserted into the well bore
103 to make a
tubing string. The tubular 102 above surface must be secured and forced into
the well bore
103 under pressure. An annular BOP stack 104 with a modified element
(stripping element)
is used to seal the well bore 103 to the tubular 102 so no pressure or
hydrocarbons can escape
during the stripping operation where the tubular 102 descends into the well
bore 103.
[00114] The stripping unit consists of three major items integrated into
the rig 100
assembly or utilised with to move, hold and seal a tubular 102 being inserted
or removed
from the well bore 103. The rig 100 utilises a vertical mast 101 with a
handling system 1 as
described above, located in the bottom section of a telescoping single mast
101. The
travelling holding assembly la can be hydraulically extended from its storage
position in the
mast 101 section to over the well bore 103 centre line, in which case it is in
its working
tubular handling position. The travelling holding assembly 1 a includes an
inverted slips
assembly 13 or hydraulic rotary inverted slips assembly capable of sustaining
upward and
downward forces as it transverses vertically along the lower section of the
mast 101. The
inverted slips assembly 13 wedges a set of dies against the travelling spider
bowl body 10 and
the tubular 102 being inserted or removed from the well bore 103.
[00115] There are two sets of dies in the inverted slips assembly 13 - a
lower set 14a for
gripping a tubular 102 with forces in an upward direction and an upper set 14b
for gripping a
tubular 102 with downward forces. It is anticipated that this design will
allow a ¨5.5 m stroke
through the rack and pinion range with approximately 9,000 kg push and pull
capacity. The
travelling holding assembly la is able to be retracted into the mast 101 into
a
stored/transportable position by use of the hydraulic cylinders 64, 65, 69 and
slide assembly
when not in use. At this point the rig 100 will function utilising its
travelling block 111 and
top drive assembly 114 hoisted by the draw-works.
[00116] In addition to the travelling holding assembly la, an inverted
slips assembly lb is
fixed to the top of the BOP stack 104. Again this assembly lb is inverted for
containing
upward and downward forces. This inverted slips assembly lb is utilised to
hold the tubulars
102 in place so the travelling holding assembly la can be released and re-
positioned as
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required.
[00117] A spherical BOP 104 with a sacrificial element (stripping BOP) is
utilized for the
stripping operation. The item will be located above the primary class 3 well
control stack
114. The stripping BOP 104 is controlled by the driller at the stripping
control station.
Available at the control station are controls required to run the stripping
system.
[00118] The design utilizes a top head drive rotating system 116 that is
hoisted vertically
in the mast 101 using the travelling block 111. The top head drive rotating
system 116 has the
ability to rotate tubing for drilling. The top head drive rotating system 116
has the capability
of attaching hydraulically tilting elevator links used for handling tubulars
102 whilst inserting
and removing from well bore 103. The top head drive rotating system 116 can
also tilt for
making up (threading into) to tubulars 102 in a horizontal plane. The top head
drive rotating
system 116 has a torque reaction system for rotating operation that is
transferred into the
main mast structure through a full length integral guide beam(s).
[00119] Although not shown, the handling system 1 includes a control and
monitoring
system to manage the operation and status of all components of the handling
system 1. The
system provides safe control through a series of status monitoring sensors
providing a
programmed PLC logic control unit that can decode information and provide
relevant
programmed interlock output signals. The system monitors and stores parameters
for
historical analytics. The system has a fault diagnostic function and can be
accessed
wirelessly. The system is controllable by a number of apparatus and monitoring
is displayed
at an operator's station.
[00120] In the present specification and claims (if any), the word
'comprising' and its
derivatives including 'comprises" and 'comprise' include each of the stated
integers but does
not exclude the inclusion of one or more further integers.
[00121] Reference throughout this specification to 'one embodiment' or 'an
embodiment'
means that a particular feature, structure, or characteristic described in
connection with the
embodiment is included in at least one embodiment of the present invention.
Thus, the
appearance of the phrases 'in one embodiment' or 'in an embodiment' in various
places
throughout this specification are not necessarily all referring to the same
embodiment.
Furthermore, the particular features, structures, or characteristics may be
combined in any
suitable manner in one or more combinations.
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[00122] In compliance with the statute, the invention has been described in
language more
or less specific to structural or methodical features. It is to be understood
that the invention is
not limited to specific features shown or described since the means herein
described
comprises preferred forms of putting the invention into effect. The invention
is, therefore,
claimed in any of its forms or modifications within the proper scope of the
appended claims
(if any) appropriately interpreted by those skilled in the art.
