Multi-purpose robot end effector for riser running process activities

Abstract

A riser filling tool may include a base portion including a coupling mechanism for coupling to a robot and configured for supporting several devices in alignment with one or more aspects of a riser section. The riser filling tool may also include a fluid coupling device arranged on the base portion and configured for facilitating filling of the riser section with fluid and angular alignment of the riser filling tool with the riser section. The riser filling tool may also include an engagement device arranged on the base portion and configured for drawing the riser filling tool into sealing engagement with the riser section. A method of filling a riser with fluid using the riser filling tool and a robot, may also be provided.

Description

MULTI-PURPOSE ROBOT END EFFECTOR FOR RISER RUNNING PROCESS ACTIVITIESCROSS-REFERENCE TO RELATED APPLICATIO S

[0001] The present application claims priority to U.S. Provisional Application No.: 63 / 496,556 entitled Multi-Purpose Robot End Effector for Riser Running Process Activities and fded on April 17, 2023, the content of which is hereby incorporated by reference herein in its entirety.TECHNOLOGICAL FIELD

[0002] The present application relates to tooling for riser installation / removal for offshore drilling operations. Still more particularly, the present application relates to automated tooling for filling and / or pressure testing of riser components during installation. Still more particularly, the present application relates to end effectors for robots that provide for fluid filling, pressure testing, and / or lubrication of riser sections during installation of a riser assembly for offshore drilling.BACKGROUND

[0003] The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventor, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

[0004] Risers in offshore drilling operations often include a large bore pipe extending between a drill rig and the opening of the wellbore at the ocean floor. The large bore pipe accommodates a drill string that extends from the drill rig, through the riser, and into the wellbore. A variety of other pipes or fluid lines may extend along the large bore pipe to accommodate drill fluid, manage pressures in the riser and / or wellbore, and for other purposes.

[0005] When a riser is installed, sections of the riser are lowered through the floor of the drill rig one at a time. When the top of each section reaches the drill floor, the lowering stops, slips or other mechanisms at the deck engage the deployed portion ofthe riser to suspend it from the drill rig, and another section of the riser is retrieved and attached to the top of the previously lowered riser. The riser is, then, further lowered into the ocean. In this manner, the riser is constructed by building onto the top of each section and further lowering the riser until the riser reaches the ocean floor.

[0006] For purposes of managing pressure in the various components of the riser and / or for other purposes, the various fluid lines in the riser may be filled as each section is lowered into the ocean. That is, before attaching another section of riser onto the top of a recently lowered section of riser, the various pipes or fluid lines of the riser may be filled with fluid. When this is performed manually, it can be time consuming as well as dangerous due to the movement of heavy sections of riser and the general movement of heavy equipment on the deck and / or around the riser installation area.SUMMARY

[0007] The following presents a simplified summary of one or more embodiments of the present disclosure in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments, nor delineate the scope of any or all embodiments.

[0008] In one or more examples, a riser filling tool may include a base portion including a coupling mechanism for coupling to a robot and configured for supporting several devices in alignment with one or more aspects of a riser section. The riser filling tool may also include a fluid coupling device arranged on the base portion and configured for facilitating filling of the riser section with fluid and angular alignment of the riser filling tool with the riser section. The riser filling tool may also include an engagement device arranged on the base portion and configured for drawing the riser filling tool into sealing engagement with the riser section.

[0009] In one or more examples, a method of filling a riser with fluid may include, using a first robot, engaging a riser fluid tool with a flange of a riser. Engaging the riser fluid tool with the flange may include engaging filling spears of the riser fluid tool with fluid nipples on the riser. The method may also include filling the riser section with fluid using the riser fluid tool.

[0010] While multiple embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of theinvention. As will be realized, the various embodiments of the present disclosure are capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the various embodiments of the present disclosure, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying Figures, in which:

[0012] FIG. 1 is a schematic view of an offshore drill rig equipped with robots having end effectors configured for performing riser filling operations, according to one or more examples.

[0013] FIG. 2 is a perspective view of the riser spider of the drill rig of FIG. 1, showing the robots and the end effectors performing operations on a riser, according to one or more examples.

[0014] FIG. 3 is a close-up perspective view of the end effector coupled to the robot, according to one or more examples.

[0015] FIG. 4 is a close-up side perspective view of a top end of a riser with the end effectors on the robots approaching the riser flange, according to one or more examples.

[0016] FIG. 5 is a close-up side perspective view of the top end of the riser with a center cap engaging the large bore pipe of the riser and performing a centering function, according to one or more examples.

[0017] FIG. 6 is a close-up side perspective view of the top end of the riser with filling spears engaging auxiliary pipes of the riser and performing an angular alignment function, according to one or more examples.

[0018] FIG. 7 is a close-up side perspective view of the top end of the riser with a second of two end effectors engaging respective auxiliary pipes and bolt holes of the flange of the riser, according to one or more examples.

[0019] FIG. 8 is a close-up side perspective view of the top end of the riser with both end effectors fully landed and in position for pressure testing, according to one or more examples.

[0020] FIG. 9 is a diagram depicting a method of fdling and / or pressure testing riser sections on an offshore drilling platform, according to one or more examples.DETAILED DESCRIPTION

[0021] The present application, in one or more embodiments, relates to a system for automatically fdling and / or pressure testing riser sections as the riser is constructed by lowering it to the ocean floor from a drill rig. The system includes robots as well as end effectors for the robots. The end effectors are particularly suited for filling the riser sections with fluid and performing pressure testing on the riser sections. In addition, the end effectors may provide a cap or cover for the central large bore of the riser to prevent debris, tools, or other undesirable items from entering the large bore of the riser. The end effectors may be part of a set of selectable end effectors that may be engaged or picked up by one or more robots on the deck of the drill rig and used to perform operations on the riser. The system may increase the speed and efficiency of fluid filling and pressure testing of riser sections and may also reduce or minimize human presence and manual handling at and / or around the riser spider.

[0022] FIG. 1 shows a side view of an offshore drill rig 100 constructing a riser 50 and lowering it to the ocean floor. In this particular case, the drill rig 100 is a floating rig that is anchored to the ocean floor. However, a pile-supported rig may also be provided where depths and conditions support it. For example, while a depth comparable to the rig size is shown, much deeper depths may be encountered and are likely. The drill rig 100 may include a riser deck 102, a mast 104 extending upward from the rig 100, a crown block (not shown) supported by the mast 104, a travelling block 108 arranged below the crown block and a drawworks (not shown) that operates to payout and reel in cable to raise and lower the travelling block 108 relative to the crown block. A top drive 110 may be provided for drilling operations and may be arranged in a storage location or supported from the travelling block 108. For purposes of riser installation, the top drive 100 or a drilling riser elevator or other riser handling tool may be provided and may be supported by the travelling block 108 as shown.

[0023] As also shown, the drilling rig 100 may include one or more robots 112 arranged at or around the riser spider 114 to assist with riser installation operations. The robots 112 may be configured with a connecting end 116 adapted to interface with a one of several available end effectors on the drill rig 100. In particular, the robots 112 may engage an end effector using a passive rotation disconnect such as that described inPCT application No. PCT / US2021 / 070488, published as WO2021 / 226622, the content of which is hereby incorporated by reference herein in its entirety. The passive rotation disconnect may be advantageous by allowing the robot to engage / disengage end effectors without further power to the connection such as pneumatic, hydraulic, or electrical power. That is, the passive rotation disconnect may allow for engaging / disengaging end effectors solely through the motion of the connecting end relative to the end effector and / or a saddle or station supporting the end effector. For purposes of the present application, the robot 112 may engage a multi-purpose end effector 118 is particularly configured for performing riser filling operations, pressure testing, and / or other operations.

[0024] Referring now to FIG. 2, a riser spider 114 is shown. The riser spider 114 may be arranged on the riser deck 102 of the drill rig 100 and may be particularly suited for supporting the riser running and / or installation process. In particular, the riser spider 114 may include several retractable jaws or dogs 120 that are arranged around the spider 114 and configured to extend and retract in a radial direction to selectively engage and disengage the riser 50. In particular, the jaws or dogs 120 may be retracted when riser 50 is being lowered and may be extended to engage the riser 50 when the top of a particular section of riser 50 is lowered to the level of the riser deck 102. The jaws or dogs 120 may engage the top of the riser section and may support the portion of the riser 50 extending below the drill rig 100 so that the drilling riser elevator or other riser handling tool can disengage the riser 50 and retrieve an additional section of riser 50.

[0025] As shown, the robots 112 mention with respect to FIG. 1 may be arranged around the perimeter of the riser spider 114 and may configured to handle end effectors 118 to perform operations on the riser section arranged in the riser spider 114. As shown, one or more tool stations such as tool saddles may be provided to allow the robots to exchange tools (e.g., end effectors adapted for a particular purpose) and, in particular, to exchange tools for riser operations. In FIG. 2, the end effectors 118 configured for filling and pressure testing the riser are arranged on the robots 112 and are in position to perform filling / pressure testing operations. However, as shown, torque tools 119 are also shown in position in respective saddles and poised for pickup by the robots 112. These tools 119 are described in more detail in US Patent Application No.: 63 / 496,562 entitled Robot End Effector for Spinning and Torquing Bolts in Riser Flange and filed on April 17, 2023, the content of which is hereby incorporated by reference in its entirety.

[0026] Turning now to FIG. 3, the riser fluid tool 118 is shown. The riser fluid tool 118 may be configured to engage a top end of a riser section, fill respective portions of the riser section with fluid and potentially perform a pressure test on the portion of the riser that has been lowered toward the ocean floor. As shown, the riser fluid tool 118 is connected to the end of the robot 112 with a passive rotation disconnect connection. However, other coupling mechanisms 122 for coupling the robot 112 to the riser fluid tool 118 may be provided. As shown, the riser filling tool 118 may include a base portion 124, a central bore cover 126, a plurality of fluid coupling devices 128, and a plurality of flange engagement devices 130.

[0027] The base portion 124 may extend from the coupling mechanism 122 around a portion of the periphery of the central riser pipe while supporting the other components of the tool 118. That is, the base portion 124 may be configured to support the several features of the tool 118 that interact with the riser 50. As shown the base portion 124 may include a generally crescent shaped plate that is sized and shaped to nest around the central pipe of the riser and align with a portion of the flange of the riser section. As shown, for example, an inner radial edge of the base portion most distal from the robot may have a radiused shape defined by a radius slightly larger than the radius of the central pipe of the riser. The base portion may also have an outer radial edge most proximal to the robot that has a radiused shape defined by a radius similar to the radius of the outer edge of the flange on the riser section. The crescent shape may extend around the central rise pipe defining an included angle approaching 180 degrees or something slightly less than 180 degrees such that a base portion 124 from one tool and a base portion from another tool may generally cover all or most of the flange of the riser section. The base portion 124 may be in the form of a relatively thick plate having a generally flat top surface for arrangement of devices and a generally flat bottom surface for engaging the flange of the riser pipe.

[0028] The central bore cover 126 may extend from the base portion 124 and may be arranged distal of the base portion 124 so as to cover the central bore of the riser 50 when the tool 118 is placed for filling operations. The central bore cover 126 may be configured to assist with aligning the filling tool 118 relative to the central longitudinal axis of the riser 50 and may also be configured to block entry of unwanted items into the bore of the riser 50. As shown in FIG. 4, the central bore cover 126 may include a cover plate and an insertion portion and may be supported off of the base portion 126 by a bracket. The cover plate may be a generally circular plate sized with a diameterslightly larger than the central pipe of the riser and including a downturned peripheral edge so as to engage the top end of the central riser pipe like a cap when the tool is fully seated on the flange of the riser. The insertion portion may extend downward from the cover plate and may be configured to sleevably engage an inside surface of the central riser pipe. The insertion portion may include a generally cylindrical shape have a cylindrical sidewall and a tapered lower edge. The tapered lower edge may function to guide the central bore cover 126 and the attached tool 118 into alignment with the riser as the tool 118 is lowered onto the riser 50. The bracket 126 may be secured to the base portion and may hold the central cover portion away from the base portion in a position relative to the central base portion defined by the riser geometry. That is, the various other devices on the base portion 126 may be arranged to interface with particular aspects of the riser 50 and the geometry and layout of those devices on the tool 118 in addition to the position of the central bore cover 126 may all be based on the riser and riser flange geometry.

[0029] One or more fluid coupling devices 128 may be arranged on the base portion 124. The fluid coupling devices 126 may be configured to engage with fluid openings on the flange of the riser section so as to fill the conduits connected to those openings with fluid and to guide the tool into angular alignment with the several features of the flange of the riser 50. As shown in FIG. 4, the several fluid coupling devices 126 may include a fluid supply interface 132 arranged on a top side of the base portion 124. The fluid supply interface 132 may include a tubing connection port for connection of fluid supply lines. The fluid supply interface 132 may be configured to support the tubing connection, receive the fluid, and deliver the fluid through the base portion to a filling spear 134. The fluid supply interface 132 may be sized and shaped to receive a pipe nipple of the riser 50 when the tool 118 is engaged with the riser. That is, the fluid supply interface 132 may have an inner diameter slightly larger than an outer diameter of the pipe nipple. A filling spear 134 may extend downward from the fluid supply interface 132 and through the base portion 124. The filling spear 134 may include a tapered tip so as to guide the respective filling device into alignment with the central longitudinal axis of the respective conduit to be filled. The filling spear 134 may be sized to sealingly engage an inner surface of the pipe nipple extending upward from the riser 50. As shown, one or more fluid coupling devices 128 may be provided and different sized fluid coupling devices 128 may be provided and selected to accommodate the particular riser being filled with fluid.

[0030] The flange engagement device 130 may be configured to engage the bores of the riser flange and draw the tool 118 into sealing engagement with the several fluid lines on the riser 50. In one or more examples, the flange engagement devices 130 may include a motor coupled to a threaded shaft. The threaded shaft may be sized, be shaped, and include a threading matching that of the threaded bores on the flange of the riser that are used to connect one section of riser to another. The flange engagement devices 130 may also be arranged to match the position of a bolt hole in the flange. The motor may be used to rotate the threaded shaft to draw the tool into engagement with the flange.

[0031] The other riser fluid tool 118 (e.g., on the opposite side of the riser and coupled to a separate robot) may be the same or similar to the described riser fluid tool 118 except the other tool might not include the central bore cover 126. That is, where a pair of riser fluid tools 118 or a plurality of riser fluid tools 118 are provided, one of the multiple riser fluid tools 118 may include a central bore cover 126, but the others might not. In other examples, segments of a central bore cover 126 may be provided by each riser fluid tool 118 and the several segments may cooperate to cover the riser opening and assist with aligning the several devices.

[0032] The system may also include a control module 136 (see FIG. 1) having computer implemented instructions stored thereon for operating the robots 112 to pickup and set down one or more tools 118. The instructions may also include steps for engaging the riser section, filling the riser section with fluid, and performing a pressure test on the riser section or sections. The control module 136 may be part of a computer system on the drill rig and may be in the form of software, hardware, or a combination of software and hardware. The computer implemented instructions may be stored on a computer readable storage medium and may be operable by a processor based on input from an operator station on the drill rig 100 or a remote operator station. Some of the computer-implemented instructions may be automatic and might not be based on input from an operator station.

[0033] In operation and use, and as shown in the progression of FIG. 4-8 and in block diagram form in FIG. 9, a method 200 of filling a riser section may be provided. The method 200 may include the robot 112 causing the tool 118 to approach 202 the riser 50 with a general understanding of the location of the central bore of the riser 50. As shown in FIG. 5, the robot 112 may lower 204 a first riser fluid tool 118 toward the riser 50 such that the central bore cover 126 engages the central bore of the riser 50 andthe tapered tip of the insertion portion of the central bore cover 126 moves the tool 118 into longitudinal alignment with the longitudinal axis of the riser 50. As shown in FIG. 6, the robot 112 may continue to lower 206 the tool 118 allowing the fdling spears 134 of the several fluid coupling devices 128 to engage the several fluid nipples on the riser 50. The engagement of the filling spears 134 with the fluid nipples may rotate 208 the tool 112 into angular alignment with several features of the flange as shown in FIG. 6. That is, when lowering the tool 118, the robot 112 may operate in a compliant mode 210 to allow for the engagement of the tool 118 with the riser 50 to pull the tool 118 into longitudinal and angular alignment with the riser section 50. With the position and angular orientation of the riser section now known, the first robot 112 may communicate 212 this to the second robot 112 so the second robot 112 may lower its respective tool 118 into position as shown in FIG. 7. In this position, and without being if full sealing engagement with the riser 50, the fluid coupling devices 128 may be used to fill 214 the riser section with fluid. That is, respective pumps may be activated to supply fluid to the fluid supply interfaces 132 of the several fluid coupling devices 128 and through the filling spears 134 and into the riser 50. In FIG. 8, the several flange engagement devices 130 may be actuated 216 to draw the tools 118 into sealing engagement with the riser flange. This may be performed if the riser section or sections are to be pressure tested, for example. With the tool 118 in sealed engagement with a top portion of the riser, the several fluid coupling devices may be supplied 218 with fluid pressures to test the connections, lines, and / or other fluid handling aspects of the riser.

[0034] As used herein, the terms “substantially” or “generally” refer to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” or “generally” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking, the nearness of completion will be so as to have generally the same overall result as if absolute and total completion were obtained. The use of “substantially” or “generally” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, an element, combination, embodiment, or composition that is “substantiallyfree of’ or “generally free of’ an element may still actually contain such element as long as there is generally no significant effect thereof.

[0035] To aid the Patent Office and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims or claim elements to invoke 35 U.S. C. § 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.

[0036] Additionally, as used herein, the phrase “at least one of [X] and [Y],” where X and Y are different components that may be included in an embodiment of the present disclosure, means that the embodiment could include component X without component Y, the embodiment could include the component Y without component X, or the embodiment could include both components X and Y. Similarly, when used with respect to three or more components, such as “at least one of [X], [Y], and [Z],” the phrase means that the embodiment could include any one of the three or more components, any combination or sub-combination of any of the components, or all of the components.

[0037] In the foregoing description various embodiments of the present disclosure have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The various embodiments were chosen and described to provide the best illustration of the principals of the disclosure and their practical application, and to enable one of ordinary skill in the art to utilize the various embodiments with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the present disclosure as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally, and equitably entitled.

Claims

CLAIMSWhat is claimed is:

1. A riser filling tool, comprising: a base portion including a coupling mechanism for coupling to a robot and configured for supporting several devices in alignment with one or more aspects of a riser section; a fluid coupling device arranged on the base portion and configured for facilitating filling of the riser section with fluid and angular alignment of the riser filling tool with the riser section; an engagement device arranged on the base portion and configured for drawing the riser filling tool into sealing engagement with the riser section.

2. The riser filling tool of claim 1, further comprising a central bore covered configured to cover a central bore of a riser and configured to draw the riser filling tool into alignment with a longitudinal axis of the riser section.

3. The riser filling tool of claim 1, wherein the fluid coupling device comprises a fluid supply interface for connection of fluid supply lines.

4. The riser filling tool of claim 1, wherein the fluid coupling device comprises a filling spear.

5. The riser filling tool of claim 4, wherein the filling spear comprises a tapered tip configured for to guide the fluid coupling device into alignment with the longitudinal axis of a respective conduit to be filled.

6. The riser filling tool of claim 1, wherein the fluid coupling device comprise a plurality of fluid coupling devices.

7. The riser filling tool of claim 6, wherein the plurality of fluid coupling devices comprises at least one device of a first size and at least on other device of a second size different than the first size.

8. The riser filling tool of claim 1, wherein the engagement device comprises a motor coupled to a threaded shaft.

9. A robot arranged on a drill rig and configured for selectively engaging and operating the riser filling tool of claim 1.

10. A drill rig comprising the robot of claim 9.

11. A method of filling a riser with fluid, the method comprising: using a first robot, engaging a riser fluid tool with a flange of a riser, comprising engaging filling spears of the riser fluid tool with fluid nipples on the riser; and filling the riser section with fluid using the riser fluid tool.

12. The method of claim 11, wherein engaging a riser fluid tool with a flange of a riser further comprises lowering the riser fluid tool such that a central bore cover engages the central bore of the riser.

13. The method of claim 12, wherein a tapered tip of an insertion portion of the central bore cover engages the central bore of the riser.

14. The method of claim 13, further comprising operating the robot in a compliant mode such that the tapered tip engaging the central bore moves the tool into longitudinal alignment with a longitudinal axis of the riser.

15. The method of claim 14, further comprising communicating the riser position and angular alignment information to a second robot.

16. The method of claim 15, further comprising, using the second robot, engaging another riser fluid tool with the flange of the riser.

17. The method of claim 11, further comprising, engaging a bolt hole in the flange of the riser with a flange engagement device of the riser fluid tool.

18. The method of claim 17, further comprising drawing the riser fluid tool into sealing engagement with one or more fluid lines on the riser.

19. The method of claim 18, further comprising pressurizing the one or more fluid lines on the riser and conducting a pressure test.

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