AU2016221281B2 - Apparatus and methods for tubular makeup interlock - Google Patents

Abstract

A method of connecting casing sections by using a top drive, comprising closing a first member around a first casing section; gripping and supporting a weight of a second casing section with the top drive; rotating the second casing section with the top drive to join the second casing section to the first casing section to form a joint and a casing string; sending data from the top drive to a controller, wherein the controller is preprogrammed with an acceptable torque value of the joint; stopping rotation of the second casing section based on the acceptable torque value of the joint; supporting a weight of the casing string with the top drive; and opening the first member. 8134503_1 (GHMatters) P51607.AU.3.29-Aug-16

Description

APPARATUS AND METHODS FOR TUBULAR MAKEUP INTERLOCK

This application is a divisional application of AU 2008203190, which is a divisional application of AU 2002253377, both of which are incorporated herein by reference in their entirety.

The present invention relates to an apparatus and methods for facilitating the connection of tubulars. More particularly, the invention relates to a method and system for connecting casing sections for use in assembling or disassembling tubulars.

In the construction and completion of oil or gas wells, a drilling rig is constructed on the earth’s surface to facilitate the insertion and removal of tubular strings into a wellbore. The drilling rig includes a platform and power tools such as an elevator and a spider to engage, assemble, and lower the tubulars into the wellbore. The elevator is suspended above the platform by a draw works that can raise or lower the elevator in relation to the floor of the rig. The spider is mounted in the platform floor. The elevator and spider both have slips that are capable of engaging and releasing a tubular, and are designed to work in tandem. Generally, the spider holds a tubular or tubular string that extends into the wellbore from the platform. The elevator engages a new tubular and aligns it over the tubular being held by the spider. A power tong and a spinner are then used to thread the upper and lower tubulars together. Once the tubulars are joined, the spider disengages the tubular string and the elevator lowers the tubular string through the spider until the elevator and spider are at a predetermined distance from each other. The spider then reengages the tubular string and the elevator disengages the string and repeats the process. This sequence applies to assembling tubulars for the purpose of drilling a wellbore, running casing to line the wellbore, or running wellbore components into the well. The sequence can be reversed to disassemble the tubular string.

During the drilling of a wellbore, a drill string is made up and is then necessarily rotated in order to drill. Historically, a drilling platform includes a rotary table and a gear to turn the table. In operation, the drill string is lowered by an elevator into the rotary table and held in place by a spider. A Kelly is then threaded to the string and the rotary table is rotated, causing the Kelly and the drill string to rotate. After thirty feet or so of drilling, the Kelly and a section of the string are lifted out of the wellbore, and additional drill string is added.

The process of drilling with a Kelly is expensive due to the amount of time required to remove the Kelly, add drill string, reengage the Kelly, and rotate the drill string. In order to address these problems, top drives were developed.

For example, International Application Number PCT/GB99/02203, published on February 3, 2000 discloses apparatus and methods for connecting tubulars using a top drive. In another example, Figure 1 shows a drilling rig 100 configured to connect and run casings into a newly formed wellbore 180 to line the walls thereof. As shown, the rig 100 includes a top drive 200, an elevator 120, and a spider 400. The rig 100 is built at the surface 170 of the well. The rig 100 includes a traveling block 110 that is suspended by wires 150 from draw works 105 and holds the top drive 200. The top drive 200 has a gripping means 301 for engaging the inner wall of the casing 15 and a motor 240 to rotate the casing 15. The motor 240 may rotate and thread the casing 15 into the casing string 16 held by the spider 400. The gripping means 301 facilitate the engagement and disengagement of the casing 15 without having to thread and unthread the casing 15 to the top drive 200. Additionally, the top drive 200 is coupled to a railing system 140. The railing system 140 prevents the top drive 200 from rotational movement during rotation of the casing string 16, but allows for vertical movement of the top drive 200 under the traveling block 110.

In Figure 1, the top drive 200 is shown engaged to casing 15. The casing 15 is placed in position below the top drive 200 by the elevator 120 in order for the top drive 200 to engage the casing 15. Additionally, the spider 400, disposed on the platform 160, is shown engaged around a casing string 16 that extends into wellbore 180. Once the casing 15 is positioned above the casing string 16, the top drive 200 can lower and thread the casing 15 into the casing string 16, thereby extending the length of the casing string 16. Thereafter, the extended casing string 16 may be lowered into the wellbore 180.

Figure 2 illustrates the top drive 200 engaged to the casing string 16 after the casing string 16 has been lowered through a spider 400. The spider 400 is shown disposed on the platform 160. The spider 400 comprises a slip assembly 440 including a set of slips 410 and piston 420. The slips 410 are wedge-shaped and constructed and arranged to slidably move along a sloped inner wall of the slip assembly 440. The slips 410 are raised or lowered by the piston 420. When the slips 410 are in the lowered position, they close around the outer surface of the casing string 16. The weight of the casing string 16 and the resulting friction between the casing string 16 and the slips 410 force the slips downward and inward, thereby tightening the grip on the casing string 16. When the slips 410 are in the raised position as shown, the slips 410 are opened and the casing string 16 is free to move axially in relation to the slips 410.

Figure 3 is cross-sectional view of a top drive 200 and a casing 15. The top drive 200 includes a gripping means 301 having a cylindrical body 300, a wedge lock assembly 350, and slips 340 with teeth (not shown). The wedge lock assembly 350 and the slips 340 are disposed around the outer surface of the cylindrical body 300. The slips 340 are constructed and arranged to mechanically grip the inside of the casing 15. The slips 340 are threaded to piston 370 located in a hydraulic cylinder 310. The piston 370 is actuated by pressurized hydraulic fluid injected through fluid ports 320, 330. Additionally, springs 360 are located in the hydraulic cylinder 310 and are shown in a compressed state. When the piston 370 is actuated, the springs 360 decompress and assist the piston 370 in moving the slips 340 relative to the cylindrical body 300. The wedge lock assembly 350 is connected to the cylindrical body 300 and constructed and arranged to force the slips 340 against the inner wall of the casing 15.

In operation, the slips 340, and the wedge lock assembly 350 of top drive 200 are lowered inside the casing 15. Once the slips 340 are in the desired position within the casing 15, pressurized fluid is injected into the piston 370 through fluid port 320. The fluid actuates the piston 370, which forces the slips 340 towards the wedge lock assembly 350. The wedge lock assembly 350 functions to bias the slips 340 outwardly as the slips 340 are slidably forced along the outer surface of the assembly 350, thereby forcing the slips 340 to engage the inner wall of the casing 15.

Figure 4 illustrates a cross-sectional view of a top drive 200 engaged to the casing 15. Particularly, the figure shows the slips 340 engaged with the inner wall of the casing 15 and a spring 360 in the decompressed state. In the event of a hydraulic fluid failure, the springs 360 can bias the piston 370 to keep the slips 340 in the engaged position, thereby providing an additional safety feature to prevent inadvertent release of the casing string 16. Once the slips 340 are engaged with the casing 15, the top drive 200 can be raised along with the cylindrical body 300. By raising the body 300, the wedge lock assembly 350 will further bias the slips 340 outward. With the casing 15 retained by the top drive 200, the top drive 200 may relocate the casing 15 to align and thread the casing 15 with casing string 16.

In another embodiment (not shown), a top drive includes a gripping means for engaging a casing on the outer surface. For example, the slips of the gripping means can be arranged to grip on the outer surface of the casing, preferably gripping under the collar of the casing. In operation, the top drive is positioned over the desired casing. The slips are then lowered by the top drive to engage the collar of the casing. Once the slips are positioned beneath the collar, the piston is actuated to cause the slips to grip the outer surface of the casing.

Figure 5 is a flow chart illustrating a typical operation of running casing using a top drive 200 and a spider 400. The flow chart relates to the operation of an apparatus generally illustrated in Figure 1. At a first step 500, a casing string 16 is retained in a closed spider 400 and is thereby prevented from moving in an axial direction. At step 510, top drive 200 is moved to engage a casing 15 with the aid of an elevator 120. Engagement of the casing 15 by the top drive 200 includes grasping the casing 15 and engaging the inner surface thereof. At step 520, the top drive 200 moves the casing 15 into position above the casing string 16 for connection therewith. At step 530, the top drive 200 threads the casing 15 to casing string 16. At step 540, the spider 400 is opened and disengages the casing string 16. At step 550, the top drive 200 lowers the extended casing string 16 through the opened spider 400. At step 560, the spider 400 is closed around the casing string 16. At step 570, the top drive 200 disengages the casing string 16 and can proceed to add another casing 15 to the casing string 16 as in step 510. The abovedescribed steps may be utilized to run drill string in a drilling operation, to run casing to reinforce the wellbore, or to assemble run-in strings to place wellbore components in the wellbore. The steps may also be reversed in order to disassemble a tubular string.

Although the top drive is a good alternative to the Kelly and rotary table, the possibility of inadvertently dropping a casing string into the wellbore exists. As noted above, a top drive and spider must work in tandem, that is, at least one of them must engage the casing string at any given time during casing assembly. Typically, an operator located on the platform controls the top drive and the spider with manually operated levers that control fluid power to the slips that cause the top drive and spider to retain a casing string. At any given time, an operator can inadvertently drop the casing string by moving the wrong lever. Conventional interlocking systems have been developed and used with elevator/spider systems to address this problem, but there remains a need for a workable system usable with a top drive/spider system such as the one described herein.

It would be advantageous if at least some embodiments of the system as disclosed herein prevented inadvertent release of a tubular string.

Described herein is an electronic control system for handling a tubular, comprising: a first tubular handling tool having radially movable gripping elements for gripping the tubular; a second tubular handling tool; a sensor coupled to the first tubular handling tool; and a controller in communication with the sensor, wherein the controller is configured to control actuation of the second tubular handling tool in response to an electronic signal received from the sensor that corresponds to operational data of the first tubular handling tool.

Also described herein is an electronic control system for handling a tubular, comprising: a first tubular handling tool having radially movable gripping elements for gripping the tubular; a second tubular handling tool; and an electronic interlock system operable to control actuation of the first and second tubular handling tools.

Described herein is a method of controlling a tubular handling system, comprising; measuring an operational position of a first tubular handling tool; communicating the operational position to a controller in the form of an electronic signal; and controlling the actuation of a second tubular handling tool using the controller in response to the operational position of the first tubular handling tool.

Also described herein is a method of handling a tubular string using a top drive, comprising: retaining the tubular string using a spider; retaining the tubular string using a tubular gripping apparatus connected to the top drive; determining a string load on the tubular gripping apparatus; and allowing the tubular gripping apparatus to open or close in response to the determined string load.

Also described herein is an electronic control system, comprising: a first tubular handling tool; a second tubular handling tool; a sensor coupled to the first tubular handling tool; and a controller in communication with the sensor, wherein the controller is configured to control actuation of the second tubular handling tool in response to an electronic signal received from the sensor that corresponds to operational data of the first tubular handling tool, and wherein the controller is programmed to compare the operational data to preprogrammed values to determine whether to open or close fluid communication to the second tubular handling tool. A first aspect of the invention provides a system for connecting casing sections to a casing string, comprising: a top drive system comprising a radially movable gripping member for gripping a casing section; a processing unit for receiving a signal from the top drive system indicative of operational data of a casing connection between the casing section and the casing string, wherein the processing unit is operable to control actuation of the top drive system; and a user interface for conveying the operational data of the casing connection to an operator.

The radially movable gripping member may comprise a slip for engaging an inner surface or an outer surface of the casing section.

The processing unit may be programmable and comprises data storage and memory. The user interface may comprise a display unit.

The processing unit may be operable to compare the operational data to at least one preprogrammed value.

The operational data may comprise at least one of a torque value, a rotation value, a stroke value, an axial load value, and a pressure value.

The operational data may comprise a torque value applied by the top drive system to the casing connection. The top drive system may further comprise a torque sub for measuring the torque value.

The operational data may comprise a rotation value applied by the top drive system to the casing connection. The top drive system may further comprise a rotation counter for measuring the rotation value.

The operational data may comprise a stroke value of the top drive system during makeup of the casing connection. The top drive system may further comprise a compensator to axially stroke the top drive system.

The operational data may comprise an axial load value supported by the top drive system during make-up of the casing connection. The top drive system may further comprise a sensor for measuring the axial load value.

The operational data may comprise a pressure value of the top drive system during make-up of the casing connection. The top drive system may further comprise a sensor for measuring the pressure value.

In another aspect of the invention there is provided a system for connecting casing sections, comprising: a top drive system comprising a radially movable gripping member for gripping a casing section; a processing unit for receiving a signal from the top drive system indicative of operational data of the top drive system, wherein the processing unit is operable to control actuation of the top drive system; and a user interface for conveying the operational data to an operator.

The radially movable gripping member may comprises a slip for engaging an inner surface or an outer surface of the casing section.

The processing unit may be programmable and comprises data storage and memory. The user interface may comprise a display unit.

The processing unit may be operable to compare the operational data to at least one preprogrammed value.

The operational data may comprise at least one of a torque value, a rotation value, a stroke value, an axial load value, and a pressure value.

The top drive system may further comprise a torque sub for measuring the operational data.

The top drive system may further comprise a rotation counter for measuring the operational data.

The operational data may comprise a stroke value of the top drive system. The top drive system may further comprise a compensator to axially stroke the top drive system, and a sensor to measure the stroke value.

The operational data may comprise an axial load value supported by the top drive system. The top drive system may further comprise a sensor for measuring the axial load value.

The operational data may comprise a pressure value of the top drive system. The top drive system may further comprise a sensor for measuring the pressure value.

The top drive system may further comprise one or more sensors coupled to the top drive system for measuring the operational data.

The operational data may comprise a position of the gripping member.

Also described herein is an apparatus for use with tubulars, comprising: a first device for gripping and joining the tubulars; a second device for gripping the tubulars; and an interlock system to ensure that a tubular string is gripped by at least the first or second device.

In the apparatus described above the first device may comprise a top drive disposable on a rig above the second device.

In the apparatus described above the top drive may comprise: a body having a slip assembly disposed on a surface; the slip assembly engageable on a surface of a first end of a tubular; a motor to provide rotational movement to the tubulars; and a compensator disposed on the top drive thereby allowing incremental axial movement of the tubular.

In the apparatus described above the second device may be a spider having a set of slips therein for engaging the tubulars

In the apparatus described above the interlock system may prevent the top drive from disengaging the tubular string, unless the spider is engaged around the tubular string.

In the apparatus described above the interlock system may prevent the spider from disengaging the tubular string, unless the top drive is engaged to the tubular string.

In the apparatus described above the interlock system may further comprise a controller.

In the apparatus described above the controller may collect data relating to a joint formed between the tubulars.

In the apparatus described above data may be generated by a torque sub disposed adjacent the top drive.

In the apparatus described above the data may be generated by a revolution counter.

In the apparatus described above the data may relate to torque generated in the joint.

In the apparatus described above the data may further relate to the number of tubular rotations making up the joint.

In the apparatus described above the controller may compare the data to pre-stored values defining an acceptable joint.

In the apparatus described above data may be generated from the compensator, the data related to the axial movement of the compensator during make up of the joint.

In the apparatus described above the interlock system may further include at least one valve to enable and lock out controls for the top drive and the spider, the valve controllable by the controller based upon the data.

In the apparatus described above the interlock system may further comprise: a physical barrier to control the movement of manual controls controlling the top drive and the spider to engage and release the tubular string; and a sensor assembly in communication with the spider and a locking assembly, the sensor assembly arranged to sense the engagement of the spider and relay the information to the locking assembly, which is arranged to control the movement of the physical barrier.

Also described herein is an apparatus for assembling and disassembly tubulars, comprising: a first member having a motor for rotating and joining tubulars at a joint and forming a tubular string therefrom, and a cylindrical body having a first set of slips and a wedge lock assembly disposed on the cylindrical body, the first set of slips being coupled to a piston that is coupled to a resilient member; a second member having a piston coupled to a second set of slips; and an interlock system.

In the apparatus described above the first set of slips may be engageable with an inner surface of the tubulars.

In the apparatus described above the first set of slips may be engageable with an outer surface of the tubulars.

In the apparatus described above a first member sensor may be coupled to the first member and a second member sensor is coupled to the second member.

In the apparatus described above the first member may further comprise: a counter providing data relating to the tubular rotations making up the joint; a torque sub providing data relating to the amount of torque placed during joining of the tubulars; and a compensator coupling the first member to a rig and providing data regarding whether the first member is engaging the tubular string.

In the apparatus described above the first member may be a top drive and is couplable to a railing system mounted on a rig.

In the apparatus described above the second member may be couplable to a platform of a rig.

In the apparatus described above the second member may be a spider.

In the apparatus described above the interlock system may further comprise: a sensor assembly in communication with the second set of slips; a locking assembly in communication with the sensor assembly; a control plate having a first member lever controlling a first member valve, a second member lever controlling a second member valve, the movement of the control plate is controlled by the locking assembly; and a controller in communication with the first and second member sensors, the torque sub, the counter, a first and second member solenoid valves.

In the apparatus described above the controller may also be in communication with the compensator.

Also described herein is a method for use with assembling and disassembling tubulars, comprising: joining a first tubular engaged by a top drive to a second tubular engaged by a spider, thereby forming a joint therebetween; collecting data related to the formation of the joint; comparing the data to pre-programmed values using a controller; collecting data from the top drive and the spider via sensors to determine if they are engaging the tubulars; opening the spider when predetermined conditions are met; lowering the tubular string through the spider; engaging the tubular string with the spider; and disengaging the tubular string with the top drive when predetermined conditions are met.

In the method described above collecting data related to the formation of the joint may further comprise data relating to torque applied.

In the method described above collecting data related to the formation of the joint may further comprise data relating to revolutions completed.

In the method described above collecting data related to the formation of the joint may further comprise data relating axial movement.

In the method described above collecting data related to the formation of the joint may further comprise data relating to torque and revolutions.

Also described herein is a method for use with assembling and dissembling tubulars comprising: joining a first tubular engaged by a first apparatus to a second tubular engaged by a second apparatus thereby forming a tubular string; providing an interlock system to ensure that at least the first apparatus or the second apparatus is engaging the tubular string; opening the second apparatus thereby disengaging the string; lowering the tubular string through the second apparatus; engaging the second apparatus to the string; and disengaging the first apparatus from the string.

In the method described above the first apparatus may further comprise a motor for joining the tubulars and at least a first set of slips, and the second apparatus has at least a second set of slips.

In the method described above the first set of slips may be engageable with an inner surface of the tubular.

In the method described above the first set of slips may be engageable with an outer surface of the tubular.

In the method described above the interlock system may be arranged to prevent the first set of slips from disengaging the tubular string, unless the second set of slips is closed around the tubular string.

In the method described above the interlock system may be arranged to prevent the second set of slips from opening or disengaging the tubular string, unless the first set of slips are engaged to the tubular string.

In the method described above the first apparatus may be a top drive and the second apparatus is a spider.

Also described herein is a method for use for an apparatus with tubular comprising: closing a first member around a first tubular; engaging a second member to a second tubular; moving the second tubular to a well center; threading the second tubular to the first tubular to form a joint and thereby a tubular string; sending data from the second member to a controller; opening the first member; lowering the tubular string through the first member; closing the first member around the tubular string; and disengaging the second member from the tubular string.

In the method described above closing a first member around a first tubular further may comprise locking the first member in the closed position, and sending a signal to the controller that the first member is in the closed position.

In the method described above the second member may include a counter that relays data relating to tubular rotations making up the joint.

In the method described above the second member may include a torque sub that relays data relating to torque generated in the tubular joint.

In the method described above engaging a second member to a second tubular may include engaging an inner surface of the tubular.

In the method described above engaging a second member to a second tubular may include engaging an outer surface of the tubular.

In the method described above engaging a second member to a second tubular further may comprise sending a signal to the controller that the second member is engaged to the second tubular.

In the method described above the controller may be preprogrammed with an acceptable values of a related joint.

In the method described above sending data from the second member to a controller, may further comprise of sending data from the counter and the torque sub.

In the method described above sending data from the second member to a controller, may further comprise, comparing the data with the acceptable values of the joint.

In the method described above, if the data is within acceptable values then controller may send a signal to the second member to lock in the engaged position, and may send another signal to the first member to unlock.

In the method described above, if the data is not within acceptable parameters then the first member may remain locked and a signal is sent to an operator to rethread the joint.

In the method described above closing the first member around the tubular string may include sending the signal from the first member to the controller.

In the method described above, if the signal from the first member is received by the controller, the controller may then send the signal to the second member to unlock.

In the method described above disengaging the second member from the tubular string may include sending the signal from the controller to the first member to lock.

In the method described above the second member may further comprise a compensator.

In the method described above sending data from the second member to a controller may include sending data from the compensator to indicate that the second member is engaged to the tubular string.

In the method described above the first member may be a spider and the second member may be a top drive.

Also described herein is a method of connecting casing sections by using a top drive, comprising: closing a first member around a first casing section; gripping and supporting a weight of a second casing section with the top drive; rotating the second casing section with the top drive to join the second casing section to the first casing section to form a joint and a casing string; sending data from the top drive to a controller, wherein the controller is preprogrammed with an acceptable torque value of the joint; stopping rotation of the second casing section based on the acceptable torque value of the joint; supporting a weight of the casing string with the top drive; and opening the first member.

The method described above may further comprise lowering the casing string through the first member.

The method described above may further comprise closing the first member around the casing string.

The method described above may further comprise disengaging the top drive from the casing string.

In the method described above the controller may further be preprogrammed with an acceptable rotation value.

In the method described above the acceptable torque value may be a value limit.

In the method described above the first member may comprise a spider.

In the method described above sending may comprise transmitting.

In the method described above the data may be indicative of a torque value of the joint.

In the method described above the top drive may comprise at least one adapter for gripping a casing.

In the method described above the top drive may comprise a torque sub.

In the method described above the adapter may comprise an elevator.

In the method described above the adapter may comprise a spear.

In the method described above the adapter may comprise a torque head.

In the method described above the adapter may comprise movable slips.

In the method described above the adapter may comprise an elevator and a gripping member having movable slips.

In the method described above the top drive may comprise a rotation counter.

In the method described above the gripping and supporting may comprise gripping and supporting with movable slips.

In the method described above the controller may include a data storage device.

In the method described above the controller may be configured to control at least one device connected to it.

In the method described above the controller may include a display unit.

In the method described above the controller may include a clock, a cache, an input control unit and an input/output circuit.

The method described above may further comprise comparing at least a portion of the data with the acceptable torque value using the controller.

The method described above may further comprise initiating remedial action using the controller.

In the method described above the initiating may comprise sending a signal to an operator.

Also described herein is a system for connecting casing sections comprising: a top drive comprising at least one adapter for gripping a casing section; a processing unit for receiving data indicative of a torque value of a casing connection between the casing section and a casing string; and an user interface for conveying the value of the casing connection to an operator.

In the system described above the processing unit may be programmable.

In the system described above the processing unit may comprise a data storage device.

In the system described above the processing unit may comprise a memory.

In the system described above the user interface may comprise a display unit.

In the system described above the processing unit may contain at least one acceptable torque value of the casing connection.

In the system described above the processing unit may further comprise a comparator for comparing the data with the at least one acceptable torque value.

In the system described above the processing unit may further be adapted to receive data indicative of a rotation value.

In the system described above the adapter may comprise movable slips.

In the system described above the adapter may comprise an elevator.

Also described herein is a method of connecting casing sections, comprising: closing a spider around a first casing; engaging a second casing with a top drive having a casing gripping apparatus connected thereto; moving the second casing to a well center; threading the second casing to the first casing to form a joint and a casing string; sending data from the top drive to a processing unit, wherein the processing unit is preprogrammed with at least one acceptable torque value of the joint; opening the spider; lowering the casing string through the spider; closing the spider around the casing string; and disengaging the top drive from the casing string.

In the method described above the top drive may further comprise an elevator operatively coupled thereto.

In the method described above, moving the second casing may comprise: moving the second casing using the elevator.

Also described herein is a method of connecting casing sections, comprising: closing a first member around a first casing; engaging a second casing with a second member; moving the second casing to a well center; threading the second casing to the first casing to form a joint and a casing string; sending data from the second member to a controller, wherein the controller is preprogrammed with an acceptable torque value of the joint; opening the first member; lowering the casing string through the first member; closing the first member around the casing string; and disengaging the second member from the casing string.

In the method described above the controller may further be preprogrammed with an acceptable rotation value.

In the method described above the acceptable torque and rotation values may be value limits.

In the method described above the first member may comprise a spider.

In the method described above, sending may comprise transmitting.

In the method described above the data may be indicative of at least one value of the joint.

In the method described above the at least one value may be torque.

In the method described above the second member may comprise a top drive comprising at least one adapter for gripping a casing.

In the method described above the top drive may comprise a torque sub.

In the method described above the adapter may comprise an elevator.

In the method described above the adapter may comprise a spear.

In the method described above the adapter may comprise a torque head.

In the method described above the adapter may comprise movable slips.

In the method described above the adapter may comprise an elevator and a gripping member having movable slips.

In the method described above the top drive may comprise a rotation counter.

In the method described above, engaging may comprise gripping with movable slips.

In the method described above the controller may include a data storage device.

In the method described above the controller may be configured to control at least one device connected to it.

In the method described above the controller may include a display unit.

In the method described above the controller may include a clock, a cache, an input control unit and an input/output circuit.

The method described above may further comprise comparing at least a portion of the data with the acceptable torque value using the controller.

The method described above may further comprise initiating remedial action using the controller.

The method described above, initiating may comprise sending a signal to an operator.

The method described above may further comprise: preprogramming the controller with an acceptable axial load value of the joint; and comparing at least a portion of the data with the acceptable axial value using the controller.

The system described above may further comprise a torque sub for measuring the torque value.

The system described above may further comprise a rotation counter for measuring a rotation value.

The system described above may further comprise a compensator for compensating movement of the casing section during connection.

The system described above may further comprise a sensor for measuring an axial load on the compensator.

The system described above may further comprise a rotation counter for measuring a rotation value.

The system described above may further comprise a compensator for compensating movement of the casing section during connection.

The system described above may further comprise a sensor for measuring an axial load of the casing connection.

In the system described above the processing unit may further be adapted to receive an axial load value of the casing connection.

The system described above may further comprise a spider for retaining the casing string.

In the system described above, the elevator may be suspended by at least one movable bail.

The method described above may further comprise raising the top drive and thereby raising the casing string.

The method described above may further comprise ensuring that a threaded connection has been made.

In the system described above, the adapter may comprise a gripping member having movable slips.

The system described above may further comprise an elevator.

The system described above may further comprise a torque sub operatively coupled to the gripping member.

In the system described above, the torque sub may be adapted to collect data relating to the casing connection.

In the system described above, the gripping member may engage an interior surface of the casing section.

In the system described above, the gripping member may engage an exterior surface of the casing section.

In the system described above, the processing unit may further be adapted to receive data indicative of a rotation value.

Also described herein is a method of connecting casing sections by using a top drive, comprising: closing a first member around a first casing section; gripping and supporting a weight of a second casing section with the top drive; rotating the second casing section with the top drive to join the second casing section to the first casing section to form a casing string having a joint; sending data from the top drive to a controller, wherein the controller is preprogrammed with an acceptable rotation value of the joint; stopping rotation of the second casing section based on the acceptable rotation value of the joint; supporting a weight of the casing string with the top drive; and opening the first member.

The method described above may further comprise comparing at least a portion of the data with the acceptable rotation value using the controller.

The method described above may further comprise initiating remedial action using the controller.

The method described above may further comprise: preprogramming the controller with an acceptable axial load value of the joint; and comparing at least a portion of the data with the acceptable axial value using the controller.

Also described herein is a system for connecting casing sections comprising: a top drive comprising at least one adapter for gripping a casing section; a processing unit for receiving data indicative of a rotation value of a casing connection between the casing section and a casing string; and a user interface for conveying the value of the casing connection to an operator.

In the system described above, the processing unit may further be adapted to receive an axial load value of the casing connection.

Also described herein is a method of connecting casing sections, comprising: closing a first member around a first casing; engaging a second casing with a second member; moving the second casing to a well center; threading the second casing to the first casing to form a joint and a casing string; sending data from the second member to a controller, wherein the controller is preprogrammed with an acceptable rotation value of the joint; opening the first member; lowering the casing string through the first member; closing the first member around the casing string; and disengaging the second member from the casing string.

The method described above may further comprise comparing at least a portion of the data with the acceptable rotation value using the controller.

The method described above may further comprise: preprogramming the controller with an acceptable axial load value of the joint; and comparing at least a portion of the data with the acceptable axial value using the controller.

The system described above may further comprise a spider for retaining the casing string. BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features, advantages of embodiments of the present invention are attained and can be understood in detail, a more particular embodiment of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings by way of example only.

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.

Figure 1 shows a rig having a top drive and an elevator configured to connect tubulars.

Figure 2 illustrates the top drive engaged to a tubular that has been lowered through a spider.

Figure 3 is a cross-sectional view of a gripping member for use with a top drive for handling tubulars in the un-engaged position.

Figure 4 is a cross-sectional view of the gripping member of Figure 3 in the engaged position.

Figure 5 is a flow chart for connecting tubulars using a top drive and a spider.

Figure 6 shows a flow chart for connecting tubulars using an interlock system for a spider and a top drive according to an embodiment of the present invention.

Figure 7 illustrates an apparatus for connecting tubulars according to an embodiment of the present invention. The top drive is shown before it has engaged the tubular.

Figure 8 illustrates the top drive of Figure 7 after it has engaged the tubular.

Figure 9 illustrates the top drive of Figure 7 after it has lowered the tubular toward the rig floor.

Figure 10 illustrates the mechanics of the interlock system in use with a spider, a top drive and a controller according to an embodiment of the present invention.

Figure 11 illustrates a control plate for a spider lever and a top drive lever according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present disclosure relates to a method and a system for connecting casing sections. The embodiments of the invention may be utilized to assemble tubulars for different purposes including drill strings, strings of liner and casing and run-in strings for wellbore components.

Figure 6 is a flow chart illustrating the use of an interlock system 700 with a spider 400 and a top drive 200, and Figure 10 illustrates the mechanics of the interlock system 700 in use with a spider 400, a top drive 200, and a controller 900. At step 500, a casing string 210 is retained in a closed spider 400 and prevented from moving in an axial direction, as illustrated in Figure 8. The casing string 210 includes a cutting member 219 disposed at a lower end. In one embodiment, the spider 400 is a flush mounted spider that is disposed in the platform 160. Referring to Figure 10, the spider 400 includes a spider piston sensor 990 located at a spider piston 420 to sense when the spider 400 is open or closed around the casing string 210. The sensor data 502 is relayed to a controller 900. A controller 900 includes a programmable central processing unit that is operable with a memory, a mass storage device, an input control unit, and a display unit. Additionally, the controller 900 includes well-known support circuits such as power supplies, clocks, cache, input/output circuits and the like. The controller 900 is capable of receiving data from sensors and other devices and capable of controlling devices connected to it.

One of the functions of the controller 900 is to prevent opening of the spider 400. Preferably, the spider 400 is locked in the closed position by a solenoid valve 980 that is placed in the control line between the manually operated spider control lever 630 and the source of fluid power operating the spider 400. Specifically, the spider solenoid valve 980 controls the flow of fluid to the spider piston 420. The solenoid valve 980 is operated by the controller 900, and the controller 900 is programmed to keep the valve 980 closed until certain conditions are met. While valve 980 is electrically powered in the embodiment described herein, the valve 980 could be fluidly or pneumatically powered so long as it is controllable by the controller 900. Typically, the valve 980 is closed and the spider 400 is locked until a tubular 130 is successfully joined to the string 210 and held by the top drive 200.

At step 510, the top drive 200 is moved to engage a casing 130. In one embodiment, the casing 130 may be stored on a rack 182 next to the wellbore 180. Referring back to Figure 7, the elevator 120 is coupled to the top drive 200 using a piston and cylinder assembly 122 and a pair of bails 124. The piston and cylinder assembly 122 may serve to axially translate the elevator 120 relative to the gripping means 301 of the top drive 200. As shown, the gripping means 301, also known as a gripping head, is an internal gripping apparatus, wherein it may be inserted into the casing 130 to engage an interior surface thereof. In one embodiment, a pivotable mechanism 125 is employed to facilitate the engagement of the gripping means 301 to the casing 130. An example of a suitable pivotable mechanism 125 includes a swivel 125 having a first portion 125A pivotable relative to a second portion 125B. The swivel 125 couples the gripping means 301 to the top drive 200 and allows the gripping means 301 to move or pivot relative thereto.

Particularly, first and second portions 125A, 125B include connections means for connecting to the top drive 200 and the gripping means 301, respectively. Preferably, the pivotable mechanism 125 includes a bore therethrough for fluid communication between the top drive 200 and the gripping means 301.

To engage the casing 130, the piston and cylinder assembly 122 is actuated to position the elevator 120 proximate the casing 130. The elevator 120 is then disposed around the casing 130. The movable bails 124 allow the casing 130 to tilt toward the well center. Thereafter, the gripping means 301 may be pivoted into alignment with the casing 130 for insertion thereof. Particularly, the swivel 125 is actuated to pivot the gripping means 301 as illustrated in Figure 7. Once aligned, the gripping means 301 is inserted into the casing 130, and the slips 340 are actuated to engage the interior of the casing 130.

In one aspect, a top drive sensor 995 (Figure 10) is placed near a top drive piston 370 to determine whether the gripping means 301 is engaged with the casing 130. The sensor data 512 is relayed to the controller 900 for processing.

At step 520, the top drive 200 moves the casing 130 into position above the casing string 210. Particularly, the swivel 125 is actuated to pivot the gripping means 301 toward the well center. In turn, the casing 130 is also positioned proximate the well center, and preferably, into alignment with the casing string 210 in the spider 400. Additionally, the traveling block 110 is actuated to lift the top drive 200 and the attached casing 130. In this manner, the casing 130 is aligned with the casing string 210 in the spider 400, as illustrated in Figure 8.

At step 530, the top drive 200 rotationally engages the casing 130 to the casing string 210, thereby creating a threaded joint therebetween. In one embodiment, the top drive 200 may include a counter 250. The counter 250 is constructed and arranged to measure the rotation of the casing 130 during the make up process. The top drive 200 may also be equipped with a torque sub 260 to measure the amount of torque placed on the threaded connection. Torque data 532 from the torque sub 260 and rotation data 534 from the counter 250 are sent to the controller 900 for processing. The controller 900 is preprogrammed with acceptable values for rotation and torque for a particular connection. The controller 900 compares the rotation data 534 and the torque data 532 from the actual connections and determines if they are within the accepted values. If not, then the spider 400 remains locked and closed, and the casing 130 can be re-threaded or some other remedial action can take place by sending a signal to an operator. If the values are acceptable, the controller 900 locks the top drive 200 in the engaged position via a top drive solenoid valve 970 (Fig. 10) that prevents manual control of the top drive 200.

At step 540, the controller 900 unlocks the spider 400 via the spider solenoid valve 980, and allows fluid to power the piston 420 to open the spider 400 and disengage it from the casing string 210. At step 550, the top drive 200 lowers the casing string 210, including casing 130, through the opened spider 400. Figure 9 shows the casing 130 lowered by the top drive 200.

At step 560, the spider 400 is closed around the casing string 210. At step 562, the spider sensor 990 (Fig. 10) signals to the controller 900 that the spider 400 is closed. If a signal is received confirming that the spider 400 is closed, the controller 900 locks the spider 400 in the closed position, and unlocks the top drive 200. If no signal is received, the top drive 200 stays locked and engaged to casing string 210. At step 570, after a signal is received, the top drive 200 disengages the casing string 210 and may proceed to add another casing 130. In this manner, at least the top drive 200 or the spider 400 is engaging the casing string 210 at all times.

Alternatively, or in addition to the foregoing, a compensator 270 may be utilized to gather additional information about the joint formed between the tubular and the tubular string. In one aspect, the compensator 270 couples the top drive 200 to the traveling block 110. The compensator 270 may function similar to a spring to compensate for vertical movement of the top drive 200 during threading of the casing 130 to the casing string 210. The compensator 270, in addition to allowing incremental movement of the top drive 200 during threading together of the tubulars, may be used to ensure that a threaded joint has been made and that the tubulars are mechanically connected together. For example, after a joint has been made between the tubular and the tubular string, the top drive may be raised or pulled up. If a joint has been formed between the tubular and the string, the compensator will “stoke out” completely, due the weight of the tubular string therebelow. If however, a joint has not been formed between the tubular and the string due to some malfunction of the top drive or misalignment between a tubular and a tubular string therebelow, the compensator will stroke out only a partial amount due to the relatively little weight applied thereto by the single tubular or tubular stack. A stretch sensor located adjacent the compensator, can sense the stretching of the compensator 270 and can relay the data to a controller 900. Once the controller 900 processes the data and confirms that the top drive is engaged to a complete tubular string, the top drive 200 is locked in the engaged position, and the next step 540 can proceed. If no signal is received, then the spider 400 remains locked and a signal maybe transmitted by the controller to an operator. During this “stretching” step, the spider 400 is not required to be unlocked and opened. The spider 400 and the slips 410 are constructed and arranged to prevent downward movement of the string but allow the casing string 210 to be lifted up and moved axially in a vertical direction even though the spider is closed. When closed, the spider 400 will not allow the casing string 210 to fall through its slips 410 due to friction and the shaped of the teeth on the spider slips.

The interlock system 700 is illustrated in Figure 10 with the spider 400, the top drive 200, and the controller 900 including various control, signal, hydraulic, and sensor lines. The top drive 200 is shown engaged to a casing string 210 and is coupled to a railing system 140. The railing system 140 includes wheels 142 allowing the top drive 200 to move axially. The spider 400 is shown disposed in the platform 160 and in the closed position around the casing string 210. The spider 400 and the top drive 200 may be pneumatically actuated, however the spider 400 and top drive 200 discussed herein are hydraulically activated. Hydraulic fluid is supplied to a spider piston 420 via a spider control valve 632. The spider control valve 632 is a three-way valve and is operated by a spider lever 630.

Also shown in Figure 10 is a sensor assembly 690 with a piston 692 coupled to spider slips 410 to detect when the spider 400 is open or closed. The sensor assembly 690 is in communication with a locking assembly 660, which along with a control plate 650 prevents the movement of the spider 400 and top drive lever. The locking assembly 660 includes a piston 662 having a rod 664 at a first end. The rod 564 when extended, blocks the movement of the control plate 550 when the plate is in a first position. When the spider 400 is in the open position, the sensor assembly 690 communicates to the locking assembly 660 to move the rod 664 to block the control plate’s 650 movement. When the spider 400 is in the closed position as shown, the rod 664 is retracted allowing the control plate 650 to move freely from the first to a second position. Additionally, the sensor assembly 660 can also be used with the top drive 200 as well in the same fashion. Similarly, hydraulic fluid is supplied to a top drive piston 370 via a top drive control valve 642 and hydraulic lines. The top drive control valve 642 is also a three-way valve and is operated by a top drive lever 640. A pump 610 is used to circulate fluid to the respective pistons 370, 420. A reservoir 620 is used to re-circulate hydraulic fluid and receive excess fluid. Excess gas in the reservoir 620 is vented 622.

Further shown in Figure 10, controller 900 collects data from a top drive sensor 995 regarding the engagement of the top drive to the casing string 210. Data regarding the position of the spider 400 is also provided to the controller 900 from a spider sensor 990. The controller 900 controls fluid power to the top drive 200 and spider 400 via solenoid valves 970, 980, respectively.

In Figure 10, the top drive 200 is engaged to casing string 210 while the spider 400 is in the closed position around the same casing string 210. At this point, steps 500, 510, 520, and 530 of Figure 6 have occurred. Additionally, the controller 900 has determined through the data received from counter 250 and torque sub 260 that an acceptable threaded joint has been made between casing 130 and casing string 210. In the alternative or in addition to the foregoing, a compensator 270 can also provide data to the controller 900 that a threaded joint has been made and that the casing 130 and the casing string 210 are mechanically connected together via a stretch sensor (not shown). The controller 900 then sends a signal to a solenoid valve 970 to lock and keep a top drive piston 370 in the engaged position within the casing string 210. Moving to step 540 (figure 6), the controller 900 can unlock the previously locked spider 400, by sending a signal to a solenoid valve 980. The spider 400 must be unlocked and opened in order for the top drive 200 to lower the casing string 210 through the spider 400 and into a wellbore. An operator (not shown) can actuate a spider lever 630 that controls a spider valve 632, to allow the spider 400 to open and disengage the casing string 210. When the spider lever 630 is actuated, the spider valve 632 allows fluid to be flow to spider piston 420 causing spider slips 410 to open. With the spider 400 opened, a sensor assembly 690 in communication with a locking assembly 660 will cause a rod 664 to block the movement of a control plate 650. Because the plate 650 will be blocked in the rightmost position, the top drive lever 640 is held in the locked position and will be unable to move to the open position.

As illustrated in Figure 10, the interlock system 700 when used with the top drive 200 and the spider 400 prevents the operator from inadvertently dropping the casing string 210 into the wellbore. As disclosed herein, the casing string 210 at all times is either engaged by the top drive 200 or the spider 400. Additionally, the controller 900 may prevent operation of the top drive 200 under certain situations, even if the top drive control lever 640 is actuated.

In another aspect, the interlock system 700 may include a control plate 650 to control the physical movement of levers 630, 640 between the open and closed positions, thereby preventing the operator from inadvertently actuating the wrong lever. Figure 11 illustrates a control plate 650 for a spider lever 630 and a top drive lever 640 that can be used with the interlock system 700. The control plate 650 is generally rectangular in shape and is provided with a series of slots 656 to control the movement of the spider lever 630, and the top drive lever 640. Typically, the control plate 650 is slideably mounted within a box 652. The slots 656 define the various positions in which the levers 630, 640 may be moved at various stages of the tubular assembly or disassembly. The levers 630, 640 can be moved in three positions: (1) a neutral position located in the center; (2) a closed position located at the top and causes the slips to close; and (3) an open position located at the bottom, which causes the slips to open. The control plate 650 can be moved from a first rightmost position to a second leftmost position with a knob 654. However, both levers 630, 640 must be in the closed position before the control plate is moved from one position to another. The control plate 650 is shown in the first rightmost position with a rod 664 extending from a locking assembly 660 to block the movement of the control plate. In operation, in the first rightmost position of the control plate 650, the spider lever 630 can be moved between the open and close positions, while the top drive lever 640 is kept in the closed position. In the second leftmost position, the top drive lever 640 can be moved between the open and close positions, while the spider lever 630 is kept in the closed position. A safety lock 658 is provided to allow the top drive or spider levers 630, 640 to open and override the control plate 650 when needed.

The interlock system 700 may be any interlock system that allows a set of slips to disengage only when another set of slips is engaged to the tubular. The interlock system 700 may be mechanically, electrically, hydraulically, pneumatically actuated systems. The spider 400 may be any spider that functions to hold a tubular or a tubular string at the surface of the wellbore. A top drive 200 may be any system that includes a gripping means for retaining a tubular by the inner or outer surface and can rotate the retained tubular. The gripping means may include an internal gripping apparatus such as a spear, an external gripping apparatus such as a torque head, or any other gripping apparatus for gripping a tubular as known to a person of ordinary skill in the art. For example, the external gripping apparatus may include a sensor for detecting information from its slips to ensure proper engagement of the casing. The top drive 200 can also be hydraulically or pneumatically activated.

While the foregoing is directed to the preferred embodiment 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.

In the claims which follow and in the preceding description, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the system.

It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

Claims (18)

1. A system for connecting casing sections to a casing string, comprising: a top drive system comprising a radially movable gripping member for gripping a casing section; a processing unit for receiving a signal from the top drive system indicative of operational data of a casing connection between the casing section and the casing string, wherein the processing unit is operable to control actuation of the top drive system; and a user interface for conveying the operational data of the casing connection to an operator.

2. The system of claim 1, wherein the operational data comprises a torque value applied by the top drive system to the casing connection, and wherein the top drive system further comprises a torque sub for measuring the torque value.

3. The system of claims 1 or 2, wherein the operational data comprises a rotation value applied by the top drive system to the casing connection, and wherein the top drive system further comprises a rotation counter for measuring the rotation value.

4. The system of any one of claims 1 to 3, wherein the operational data comprises a stroke value of the top drive system during make-up of the casing connection, and wherein the top drive system further comprises a compensator to axially stroke the top drive system.

5. The system of any one of claims 1 to 4, wherein the operational data comprises an axial load value supported by the top drive system during make-up of the casing connection, and wherein the top drive system further comprises a sensor for measuring the axial load value.

6. The system of any one of claims 1 to 5, wherein the operational data comprises a pressure value of the top drive system during make-up of the casing connection, and wherein the top drive system further comprises a sensor for measuring the pressure value.

7. A system for connecting casing sections, comprising: a top drive system comprising a radially movable gripping member for gripping a casing section; a processing unit for receiving a signal from the top drive system indicative of operational data of the top drive system, wherein the processing unit is operable to control actuation of the top drive system; and a user interface for conveying the operational data to an operator.

8. The system of any one of claims 1 to 7, wherein the radially movable gripping member comprises a slip for engaging an inner surface or an outer surface of the casing section.

9. The system of any one of claims 1 to 8, wherein the processing unit is programmable and comprises data storage and memory, and wherein the user interface comprises a display unit.

10. The system of any one of claims 1 to 9, wherein the processing unit is operable to compare the operational data to at least one pre-programmed value.

11. The system of any one of claims 1 to 10 , wherein the operational data comprises at least one of a torque value, a rotation value, a stroke value, an axial load value, and a pressure value.

12. The system of claim 7 or any one of claims 8 to 11 when dependent on claim 7, wherein the top drive system further comprises a torque sub for measuring the operational data.

13. The system of claim 7 or any one of claims 8 to 12 when dependent on claim 7, wherein the top drive system further comprises a rotation counter for measuring the operational data.

14. The system of claim 7 or any one of claims 8 to 13 when dependent on claim 7, wherein the operational data comprises a stroke value of the top drive system, and wherein the top drive system further comprises a compensator to axially stroke the top drive system, and a sensor to measure the stroke value.

15. The system of claim 7 or any one of claims 8 to 14 when dependent on claim 7, wherein the operational data comprises an axial load value supported by the top drive system, and wherein the top drive system further comprises a sensor for measuring the axial load value.

16. The system of claim 7 or any one of claims 8 to 15 when dependent on claim 7, wherein the operational data comprises a pressure value of the top drive system, and wherein the top drive system further comprises a sensor for measuring the pressure value.

17. The system of claim 7 or any one of claims 8 to 16 when dependent on claim 7, wherein the top drive system further comprises one or more sensors coupled to the top drive system for measuring the operational data.

18. The system of claim 7 or any one of claims 8 to 17 when dependent on claim 7, wherein the operational data comprises a position of the gripping member.