Battery operated catwalk carrier and skate

Abstract

A catwalk assembly includes a main frame, a catwalk carrier, a catwalk lift, a catwalk lift arm, a skate, an actuator, an electric storage device, and a charging system. The electric storage device is coupled to the catwalk carrier and configured to power the actuator. The charging system is coupled to the main frame and configured to charge the electric storage device when the catwalk carrier is in a position to receive the tubular member and electrically disconnect from the electric storage device when the catwalk carrier moves away from the position to receive a tubular member.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM FOR PRIORITY

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 708,646 filed Oct. 17, 2024. The subject matter of the above-identified patent document(s) is incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure relates generally to drilling rig systems, devices and processes, and more particularly, to a catwalk system and related components powered by a rechargeable electric power source.BACKGROUND

[0003] Current catwalk carriers operate by lifting out of the main catwalk frame onto the rig's drill floor. The skate in the carrier pushes the tubular member onto the drill floor. The carrier and skate are powered by a drag chain and / or service loop carrying hydraulics, electrical power and communications cables or lines. This drag chain occupies substantial space in the catwalk, is expensive, and can be damaged during operation. By having an electric power source (e.g., battery) in the carrier, the drag chain is no longer needed.SUMMARY

[0004] This disclosure provides a battery-operated catwalk carrier and skate.

[0005] In some examples, a catwalk assembly includes a main frame, a catwalk carrier, a catwalk lift, a catwalk lift arm, a skate, an actuator, an electric storage device, and a charging system. The catwalk carrier is configured to receive a tubular member. The catwalk ramp is coupled to the main frame and the catwalk carrier and configured to lift the catwalk carrier from the main frame. The catwalk lift arm is coupled to the main frame and the catwalk carrier at an opposite side from the catwalk ramp. The skate is slidingly coupled to the catwalk carrier and configured to position and move the tubular member along the catwalk carrier. The actuator is coupled to the catwalk carrier and configured to move the skate along the catwalk carrier. The electric storage device is coupled to the catwalk carrier and configured to power the actuator. The charging system coupled to the main frame and configured to charge the electric storage device when the catwalk carrier is in a position to receive a tubular member and electrically disconnect from the electric storage device when the catwalk carrier moves away from the position to receive a tubular member and electrically disconnect from the electric storage device when the catwalk carrier moves away from the position to receive a tubular member.

[0006] Any single one or any combination of the following features may be used with the above embodiment. The charging system includes a connection sensor configured to detect a connection of output terminals of the charging system to input terminals of the electric storage device. The charging system is configured to initiate charging when the connection sensor detects that the connection of output terminals of the charging system are connected to the input terminals of the electric storage device. The skate includes a position sensor configured to detect when the catwalk carrier is in the position to receive a tubular member. The charging system is configured to initiate charging when the position sensor detects that the catwalk carrier is in the position to receive a tubular member. The catwalk lift arm does not have support lines or cables from remote electrical or hydraulic supplies. The actuator may be an electrical actuator.

[0007] In other examples, a catwalk system includes one or more tubular member tubs and a catwalk assembly. The one or more tubular member tubs are configured to store tubular members. The catwalk assembly includes a main frame, a catwalk carrier, a catwalk lift, a catwalk lift arm, a skate, an actuator, an electric storage device, and a charging system. The catwalk carrier is configured to receive one of the tubular members. The catwalk ramp is coupled to the main frame and the catwalk carrier and configured to lift the catwalk carrier from the main frame. The catwalk lift arm is coupled to the main frame and the catwalk carrier at an opposite side from the catwalk ramp. The skate is slidingly coupled to the catwalk carrier and configured to position and move the tubular member along the catwalk carrier. The actuator is coupled to the catwalk carrier and configured to move the skate along the catwalk carrier. The electric storage device is coupled to the catwalk carrier and configured to power the actuator. The charging system is coupled to the main frame and configured to charge the electric storage device when the catwalk carrier is in a position to receive the tubular member and electrically disconnect from the electric storage device when the catwalk carrier moves away from the position to receive a tubular member.

[0008] Any single one or any combination of the following features may be used with the above embodiment. The charging system includes a connection sensor configured to detect a connection of output terminals of the charging system to input terminals of the electric storage device. The charging system is configured to initiate charging when the connection sensor detects that the connection of output terminals of the charging system are connected to the input terminals of the electric storage device. The skate includes a position sensor configured to detect when the catwalk carrier is in the position to receive a tubular member. The charging system is configured to initiate charging when the position sensor detects that the catwalk carrier is in the position to receive a tubular member. The catwalk lift arm does not have support lines or cables from remote electrical or hydraulic supplies. The actuator may be an electrical actuator.

[0009] In still other examples, a method includes receiving a tubular member on a catwalk carrier. The method also includes lifting, using a catwalk ramp coupled to a main frame and the catwalk carrier and a catwalk lift arm coupled to the main frame and the catwalk carrier at an opposite side from the catwalk ramp, the catwalk carrier from the main frame and electrically disconnecting an electric storage device from a charging system. The method further includes powering, using an electric storage device coupled to the catwalk carrier, an actuator coupled to the catwalk carrier. In addition, the method includes positioning and moving, using the actuator to move a skate slidingly coupled to the catwalk carrier, the tubular member along the catwalk carrier. The method also includes lowering the catwalk carrier to a position to receive tubular member and electrically connecting the electric storage device to the charging system. The method further includes charging, using a charging system coupled to the main frame, the electric storage device when the catwalk carrier is in the position to receive tubular member.

[0010] Any single one or any combination of the following features may be used with the above embodiment. The method may further include detecting, using connection sensor of the charging system, a connection of output terminals of the charging system to input terminals of the electric storage device. The method may further include initiating charging using the charging system when the connection sensor detects that the connection of output terminals of the charging system are connected to the input terminals of the electric storage device. The method may further include detecting, using a position sensor of the skate, when the catwalk carrier is in the position to receive a tubular member. The method may further include initiating charging using the charging system when the position sensor detects that the catwalk carrier is in the position to receive a tubular member. The catwalk lift arm does not have support lines or cables from remote electrical or hydraulic supplies. The actuator may be an electrical actuator.

[0011] Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For a more complete understanding of this disclosure, reference is made to the following description, taken in conjunction with the accompanying drawings, in which:

[0013] FIG. 1 illustrates an overall drilling rig system in accordance with the present disclosure;

[0014] FIGS. 2A and 2B illustrate an example catwalk system according to this disclosure;

[0015] FIGS. 3A, 3B, 3C and 3D illustrate various views of an example catwalk operation and movements according to this disclosure; and

[0016] FIG. 4 illustrates an example method for operating a battery-operated catwalk carrier and skate according to this disclosure.DETAILED DESCRIPTION

[0017] FIGS. 1 through 3, described below, and the various embodiments used to describe the principles of the present disclosure are by way of illustration only and should not be construed in any way to limit the scope of this disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any type of suitably arranged device or system.

[0018] The present disclosure describes a drilling rig system including a drilling rig and a catwalk system. At least a portion of the catwalk system is powered by a rechargeable electric power source (e.g., batteries) locally mounted on the catwalk carrier of the catwalk system to power certain components and catwalk functions (e.g., skate function). The electric power source is configured to be operably recharged when the carrier is stationary in a first position within the catwalk system with respect to the frame of the catwalk. Wireless communications can provide feedback from the carrier and control operation of the catwalk / actuator / skate.

[0019] The battery-powered catwalk carrier allows for elimination of a drag chain with lengthy cables and hoses. The elimination of the drag chain provides a cost reduction over the long term from no downtime and repairs related to the drag chain. Without a drag chain, there are fewer parts to service and less chance for damage. The absence of a drag chain allows for space savings in the catwalk allowing easier access to other components. The battery technology required for operating components of a catwalk carrier can operate outside of hazardous zones. The battery-powered catwalk carrier has a simplified design of the lift arm as it does not have to carry services to the carrier.

[0020] In an example embodiment, as depicted in FIG. 1, a drilling rig system 10 may include a drilling rig 100 which may be used to drill or otherwise conduct operations on a wellbore. In some embodiments, the drilling rig system 10 may include one or more pump skids / systems 350, a generator skid / system 400, a mud pumping and processing skid / system 500, a mud gas separator skid / system 600, a hydraulic pressure unit (HPU) skid / system 700, and one or more tank skids / systems 800. The one or more pump skids / systems 350 provide drilling fluids, such as drilling mud, to the drilling rig 100 for use during wellbore operations. The generator skid / system 400 may be used to provide electrical power to drilling rig 100 and other components of the drilling rig system 10. The mud pumping and processing skid / system 500 pumps drilling fluids for use in the wellbore, and processes drilling fluids returning from the wellbore by, for example and without limitation, separating out solids and gases from the returning drilling fluid. The mud gas separator skid / system 600 separates gases from the liquid part of drilling fluids returning from the wellbore. The HPU skid / system 700 provides hydraulic power, through the use of high pressure hydraulic fluid, for one or more components of the drilling rig 100 or other components of the drilling rig system 10. The one or more tank skids / systems 800 typically include one or more tanks to hold fluids for use with the drilling rig 100 or other components of the drilling rig system 10.

[0021] The drilling rig 100 includes a rig floor 101 and a substructure 103 for supporting the rig floor 101 above the ground. In some embodiments, the drilling rig 100 may include a mast 119 having a plurality of upright structures that define a frame for the mast 119. The mast 119 may be positioned above a well (or other areas above the rig floor 101) being drilled by the drilling rig 100 and configured to support tubular members, such as a drilling string, being used during a drilling operation. As will be appreciated, the mast 119 may additionally be used to support other components and other tubular members during operations other than drilling operations.

[0022] In some embodiments, the drilling rig 100 includes a pipe handling apparatus 123 having a column 125, a pipe handler 127, and other components (not shown). The pipe handling apparatus 123 may, for example and without limitation, be used to transfer tubular members (such as tubular members 30 as shown in FIGS. 2A, 2B) to / from the catwalk system 200 to an operable location within the mast 119. The tubular members 30 may be any tubular member for use with the drilling rig 100 including, for example and without limitation, drill pipe, casing, collars, pipe stands, casing stands, or other tubular members.

[0023] The pipe handler 127 is configured to engage and move a tubular member between locations on the drilling rig 100 during operations, such as from the catwalk system 200 to a position above the well such that the tubular member may be placed into the well by other components of the drilling rig 100. Though not shown, the pipe handler 127 may include one or more grippers adapted to grip onto and / or rotate a tubular member and other component(s) to further manipulate the tubular member pipe handler 127. The pipe handler 127 can be operatively coupled to the column 125 by a pipe handler carriage configured to move vertically relative to column 125 and allow the pipe handler 127 to move a tubular segment or member vertically. As will be appreciated, other suitable configurations and positioning of the pipe handling apparatus, column and pipe handler may be utilized.

[0024] In some embodiments, as depicted in FIG. 1, the drilling rig 100 may include a top drive 135 mechanically coupled to the mast 119 such that the top drive 135 may move vertically relative to the mast 119. The top drive 135 can be configured and operate to raise, lower, and / or rotate tubular members during operation of the drilling rig 100. In some embodiments, the top drive 135 may be raised and lowered by a cable and a drawworks assembly, a rack and pinion assembly, or other suitable system.

[0025] Though not specifically shown, the drilling rig 100 may include a pipe elevator having one or more components (e.g., jaw, clamp) that engage a tubular member such that the pipe elevator may support and raise / lower the tubular members used by the drilling rig 100. The pipe elevator may be coupled to the top drive 135 such that pipe elevator moves with the top drive.

[0026] The drilling rig system 10 and the drilling rig 100 shown and described in FIG. 1 is one example of a drilling system which may incorporate the teachings and features described in the present disclosure. Further, other component(s) and system(s) may be included, while others may be omitted from, the drilling rig system 10 and / or drilling rig 100. For additional descriptions and examples of drilling rig systems, drilling rigs and components thereof, reference is made to U.S. Pat. No. 10,975,635 which is incorporated herein by reference. Other configurations (and components / devices) may be used for the drilling rig system 10 and drilling rig 100, including those known in the art.

[0027] Now turning to FIGS. 2A and 2B, there is illustrated an example catwalk system 200 in accordance with this disclosure. As shown, the catwalk system 200 can be used to transport tubular members 30, such as drill collars, drill pipes and casings, from ground level to the level of the rig floor 101 of the drilling rig 100 (and vice versa). The catwalk system 200 includes a catwalk assembly 202 having a stationary main frame 208 and a movable catwalk carrier or slide 210 with a movable skate 218 disposed therein.

[0028] The catwalk system 200 also includes one or more tubular member tubs 204 configured to store the tubular members 30 of any appropriate or suitable length (e.g., thirty feet, forty-five feet, etc.). As a non-limiting example, a tubular member tub 204 includes sufficient structure and strength to hold / store a total weight of tubular members of 10,000 lbs. or more. The tubular member tubs 204 may be mechanically coupled to the catwalk assembly 202 by one or more struts 206. The struts 206 may be pivotably coupled to the catwalk assembly 202 and the tubular member tubs 204 such that the tubular member tubs 204 may be pivoted into a position alongside the catwalk assembly 202 for transportation of the catwalk system 200. The tubular member tubs 204 operably function as storage containers to store the tubular members 30 not yet being used by the drilling rig 100 within the catwalk system 200. The tubular member tubs 204 are configured to store and subsequently provide tubular members 30 to the catwalk assembly 202 for use in the drilling rig 100.

[0029] The tubular member tubs 204 may include a frame 228 that defines a tubular storage area 230 used for storing the tubular members 30. The tubular member tubs 204 may include one or more support frames 232 coupled to the frame 228 such that the support frames 232 may be raised or lowered relative to the frame 228. Each support frame 232 may include one or more channels 234 configured substantially horizontal to the ground or angled such that the end of the channels 234 nearest the catwalk assembly 202 is lower than the outside end of channels 234. In some embodiments, the ends of tubular members 30 stored within the tubular member tub 204 may be positioned within the channels 234. In addition, the support frames 232 may allow the tubular members 30 stored within the tubular member tub 204 to be stored in multiple layers. When the tubular members 30 are to be transferred to the catwalk assembly 202 to be used with drilling rig 100, the support frames 232 may be raised such that the uppermost layer of tubular members 30 is at or above the level of the top side of the frame 228. Once above the top of the frame 228, the tubular members 30 may roll along the channels 234 and the struts 206. In some embodiments, the channels 234 and the struts 206 may be tilted to allow tubular members 30 to roll by gravity toward the catwalk assembly 202.

[0030] The catwalk assembly 202 may include one or more indexing arms 212 positioned to selectively allow tubular members to enter the catwalk carrier 210 one at a time. In some embodiments, the indexing arms 212 may hold a foremost tubular member at a standby position. The indexing arms 212 may then lower to allow tubular member 30 to pass over the indexing arms 212 and into / onto the catwalk carrier 210. As a first tubular member 30 passes the indexing arms 212, the indexing arms 212 may raise again to hold / prevent other tubular members 30 from passing the indexing arms 212. The first tubular member 30 continues to roll and moves into position on the catwalk carrier 210.

[0031] In some embodiments, where two tubular member tubs 204 are utilized, each tubular member tub 204 may be configured to store different tubular members. For example, a second tubular member tub 204 may be used to hold larger-diameter tubular members, such as casing. The catwalk assembly 202 may include additional indexing arms (not shown) adapted to handle tubular members of larger diameter than the indexing arms 212. A second tubular member tub 204 may otherwise operate to transfer the larger diameter tubular member (e.g., casing) to the catwalk assembly 202 substantially simultaneously as the tubular member 30 is transferred to the catwalk assembly 202 by a first tubular member tub 204.

[0032] The catwalk assembly 202 includes the main frame 208 for supporting the catwalk carrier 210 and other components. As will be appreciated, the catwalk carrier 210 is adapted or configured to receive a tubular member 30 from the tubular member tubs 204 and transport it from ground level to the level of the rig floor 101. The catwalk carrier 210 can be configured to receive and transport tubular members 30 of different diameters.

[0033] The example catwalk assembly 202 shown includes a catwalk ramp 214 that may include one or more upright members that extend and are mechanically coupled between one end of the main frame 208 of the catwalk assembly 202 and the rig floor 101. For example, the catwalk carrier 210 may mechanically couple to the catwalk ramp 214 at the end of the catwalk carrier 210 proximate to the drilling rig 100 such that an end of the catwalk carrier 210 proximate to the drilling rig 100 moves and slides upward / downward along the catwalk ramp 214. For example, FIG. 3B illustrates the catwalk carrier 210 in an intermediate position (e.g., as it moves upward / downward along the catwalk ramp 214). It will be understood that the catwalk ramp 214 may be configured to raise / lower the end of the catwalk carrier 210 at any suitable angle, including upwards of 90 degrees, however, in various embodiments, the catwalk ramp 214 may be configured with an incline in a range of about 75 degrees to about 45 degrees.

[0034] Turning now to FIGS. 3A, 3B, 3C, and 3D, there are illustrated sides views and a perspective view of one example of the catwalk assembly 202 according to the present disclosure. FIG. 3A illustrates the catwalk assembly 202 in a first position (e.g., collapsed or load position); FIG. 3B illustrates the catwalk assembly 202 in a lifting or intermediate position as the catwalk carrier 210 moves from the first position and lifts a tubular member 30 upwards as shown; and FIG. 3C illustrates the catwalk assembly 202 in a second position (e.g., raised or rig floor position) after the skate 218 has moved the tubular member 30 upward along the slide of the catwalk carrier 210 for presentment to the rig floor 101. FIG. 3D illustrates the catwalk assembly 202 in the second position (e.g., raised or rig floor position) before the skate 218 has moved the tubular member 30 upward along the slide of the catwalk carrier 210 for presentment to the rig floor 101.

[0035] The catwalk system 200 (or catwalk assembly 202) includes one or more motors 215 or actuators (electric, combustion, hydraulic, etc.) coupled mechanically to the catwalk ramp 214 and the end of the catwalk carrier 210. The motor 215 provides a mechanical force to the end of the catwalk carrier 210 such that the catwalk carrier 210 moves up / down along the catwalk ramp 214. This may be accomplished using any suitable mechanical devices and components, such as cables and pulleys coupled to the motor 215 and the end of the catwalk carrier 210. As will be appreciated, the catwalk ramp 214 may be pivotably coupled to main frame 208 of the catwalk assembly 202 such that the catwalk ramp 214 may be lowered to a substantially horizontal position coextensive with the main frame 208, for example and without limitation, for transport of the catwalk assembly 202.

[0036] In some embodiments, the catwalk assembly 202 includes the skate 218 which is a structure slidingly coupled to the catwalk carrier 210 and movable relative thereto that is used to position and move a tubular member 30 along a surface of the catwalk carrier 210. The skate 118 may engage with a lower end of a tubular member 30 and may be used to move a tubular member 30 longitudinally along the catwalk carrier 210. The skate 218 may be used to introduce a tubular member 30 to the rig floor 101 when the catwalk carrier 210 is in the raised (or rig floor) position (or receive a tubular member 30 from the rig floor 101 for lowering). The skate 218 may be coupled to a position sensor 220 configured to identify a position of the skate 218, and therefore the lower end of a tubular member 30 is known. The position sensor 220 can wireless communicate with the different components of the catwalk assembly 202, including the charging system 226. For example, the position sensor 220 can provide a signal to the charging system 226, that the catwalk carrier 210 is in the first position and the charging system 226 can power the electric storage device 222.

[0037] In some embodiments, an end of the catwalk carrier 210 distal to the drilling rig 100 may be adapted to slide relative to the main frame 208 of the catwalk assembly 202. The catwalk carrier 210 may be movably coupled to the main frame 208 of the catwalk assembly 202 by a catwalk lift arm 216 (see FIGS. 3C, 3D). The catwalk lift arm 216 may be slidably coupled to the main frame 208 and pivotably coupled to the catwalk carrier 210 such that as the end of the catwalk carrier 210 proximal to the drilling rig 100 travels up along the catwalk ramp 214, the catwalk lift arm 216 simultaneously raises the end of the catwalk carrier 210 distal to the drilling rig 100 such that the catwalk carrier 210 is at a smaller inclination than when the distal end of the catwalk carrier 210 remains at ground level. For example, reducing the inclination of the catwalk carrier 210 when in the raised position or lowering the end of a tubular member 30 held by the catwalk carrier 210 and introduced at the rig floor 101 reduces the height of the end of a tubular member 30 above the rig floor 101. As a non-limiting example, the height or level of the rig floor 101 for use with the catwalk assembly 202 may be in a range from about 10 feet to 50 feet.

[0038] In accordance with the present disclosure, the catwalk assembly 202 includes an electric storage device 222 disposed and mounted to the catwalk carrier 210. In some embodiments, the electric storage device 222 may be mounted at or near the distal end of the catwalk carrier 210, and in some embodiments, is positioned within ten feet of its end. Similarly, the catwalk assembly 202 includes a motor or actuator 224 disposed and mounted to the catwalk carrier 210. In some embodiments, the electric storage device 222 and / or the motor / actuator 224 is / are mounted at or near the distal end of the catwalk carrier 210, and in some embodiments, are positioned within ten feet from the distal end or otherwise located or positioned between the distal end of the catwalk carrier 210 and a retracted or lowermost position of the skate 218. While the electric storage device 222 and the motor / actuator 224 are depicted on top of the catwalk carrier 210, this is for illustration only, and the electric storage device 222 and the motor / actuator 224 may be positioned within the body or structure of the catwalk carrier 210.

[0039] The electric storage device 222 may be any suitable storage device(s) for storing electric energy / potential, including for example, rechargeable batteries and packs (e.g., lithium-based, nickel-cadmium, nickel-metal-hydride, lead-acid, etc. and the like), electrolytic capacitors and supercapacitors, flow, sodium, or any other suitable battery type, and combinations thereof. In certain embodiments, the electric storage device 222 can include a secondary or auxiliary charger, such as a solar panel, to charge, at least partly, the electric storage device 222.

[0040] The operating voltage (output) of the electric storage device 222 may be any suitable operating voltage level / output compatible with the electric motor / actuator 224 and provide sufficient power to slidably move the skate 218 to carry a tubular member upward to the rig floor 101 (or downward). The electric storage device 222 may also be used to power any components on the catwalk carrier assembly 202 including, but not limited to safety gates, stop pins, lights, pipe ejectors, sensors, communication equipment, etc. In certain embodiments, the electric storage device 222 may have an additional operating voltage level / output compatible for raising and lowering the indexing arms 212 along the catwalk carrier 210. Non-limiting examples for the operating voltage level / output may be 12 VDC, 24 VDC, 48 VDC, and so on, etc. In certain embodiments not shown, the catwalk assembly may also include a DC-AC voltage converter that converts DC voltage output from the electric storage device 222 into an alternating current (AC) voltage when the motor / actuator 224 is implemented with AC motor(s) / actuator(s). This may include step-up and / or step-down conversion, and embodiments, the DC voltage output from the electric storage device 222 is converted to AC voltage, such as 220 VAC, 480 VAC or 600 VAC.

[0041] The electric storage device 222 may be configured to have a power capacity sufficient to power the electric motor / actuator 224 for multiple cycles, e.g., 200 cycles (wherein one cycle involves powering the skate 218 to move upward and lift the tubular member 30 to the rig floor 101 and return to its original position), before recharging is required. In such embodiments, the electric storage device 222 can be removed and replaced in order to continue service of the catwalk assembly 202 without waiting to recharge. In certain embodiments, the electric storage device 222 may be configured to have a power capacity sufficient for a full trip. Non-limiting examples for the power capacity may be 8 KWh, 10 KWh, and so on, etc.

[0042] The electric storage device 222 may be a modular unit composed of multiple modular electric storage devices or packs. The modular storage devices can be smaller units that are more easily manipulable by a user. For example, a 10 KWh battery can weigh around 300 lbs, while a 1 KWh battery may weight around 20 lbs. Using multiple 1 KWh may allow for swapping batteries and reducing an overall extra weight of the catwalk carrier 210.

[0043] Because the motor / actuator 224 (and movement of the skate 218) is powered electrically, the catwalk assembly 202 of the present disclosure reduces or eliminates the need for hydraulic lines extending from a hydraulic pump up to a hydraulic actuator for powering the skate 218. Thus, hydraulic lines that typically run along or within the main frame 208 and / or the catwalk lift arm 216 in prior art designs can be omitted. Further, because the electric storage device 222 is also mounted and located on the catwalk carrier 210, there is no longer a need for electrical lines extending from the main frame 208 and / or along the catwalk lift arm 216. This reduces or eliminates use of a drag chain, and the lack of electric cables and / or hydraulic lines along the main frame 208 and / or along the catwalk lift arm 216 effectively eliminates possible damage to such components during typical operation of the catwalk system 200.

[0044] When the catwalk assembly 202 is set in the first position (e.g., collapsed or load position), as shown in FIG. 3A, a charging system 226 is electrically coupled to the electric storage device 222 and operably charges / recharges the electric storage device 222. The charging system 226 may be a battery charger or other charging circuitry consistent with the configuration and type of the electric storage device 222. Although not shown, an external power supply (e.g., electric power generator) provides power to the charging system 226. For example, the charging system 226 can be powered directly from the rig (e.g., the generator skid / system 400).

[0045] The electric storage device 222 has output terminals for providing electric power to various components of the catwalk assembly 202, including the electric motor / actuator 224 and wireless transceiver circuitry (not shown) configured to control operation of the electric motor / actuator 224 (and thus, movement of the skate 218). The electric storage device 222 includes input terminals configured to receive a charging voltage / current from output terminals of the charging system 226. When the catwalk assembly 202 is in the first position (FIG. 3A), the electric storage device 222 is electrically coupled to the charging system 226 and charging occurs (charging phase / operation). As the catwalk carrier 210 begins its lifting movement / cycle, the electric storage device 222 is electrically decoupled from the charging system 226 (no charging). During the lifting movement / cycle (e.g., FIGS. 3B, 3C) no coupling and no charging occurs. As the catwalk assembly 202 completes the cycle, the catwalk assembly 202 returns to the first position (e.g., FIG. 3A), where a connection and a charging phase / operation begins again.

[0046] In certain embodiments, the catwalk system 200 can determine whether the catwalk carrier 210 is in the first position shown in FIG. 3A for the purposes of charging. While the catwalk carrier is in the first position, the input terminals of the electric storage device 222 are operably coupled to the output terminals of the charging system 226. The position sensor 220 can be used to identify when the catwalk carrier 210 is in the first position. In certain embodiments, the electric storage device 226 can include a connection sensor 236 that can identify when the input terminals of the electric storage device 222 are connected to output terminals of the charging system 226. As non-limiting example, the connection sensor 236 could be a mechanical switch, an electrical connection, etc.

[0047] In some embodiments, one or all components of catwalk system 200 may be electrically driven and controlled. In some embodiments, operation of the catwalk system 200 may be controlled by a central control system of the drilling rig 100 such that the catwalk system 200 is operable with minimal or no human interaction. Once a tubular member 30 is positioned on the catwalk carrier 210, the catwalk carrier 210 can be activated and move from a first position (e.g., a resting or load position, see FIG. 3A) to a second position (e.g., a raised or delivery position, see FIGS. 3C, 3D). The skate 218 may advance tubular member 30 along the catwalk carrier 210.

[0048] Although FIGS. 2A, 2B, 3A, 3B, 3C and 3D illustrate an example catwalk system 200, various changes may be made to the system, and the various components may be combined, further subdivided, replicated, omitted, or rearranged and additional components may be added according to particular needs.

[0049] Now turning to FIG. 4 (and with reference to FIGS. 3A, 3B and 3C), there is illustrated an example method 400 for operating a battery-operated catwalk carrier and skate according to this disclosure. For ease of explanation, the method 400 of FIG. 4 is described as being performed using the catwalk system 200 of FIGS. 1 through 3C. However, the method 400 may be used with any other suitable system and any other suitable drilling rig system.

[0050] As shown in FIG. 4, the catwalk carrier 210 can receive a tubular member 30 when the catwalk carrier 210 is in the first position, as illustrated in FIG. 3A, at step 402. The tubular members 30 can be stored in one or more tubular member tubs 204 prior to use in a drilling column. The tubular member tub 204 can store tubular members 30 of any appropriate or suitable length and outer diameter. The tubular members 30 can be raised above a top of the tubular member tub 204 and transferred from the tubular member tub 204 to the catwalk carrier 210 along the channels 234 and the struts 206. The tubular member 30 can move from the tubular member tub 204 to the catwalk carrier 210 through mechanical means, such as a conveyor belt, or by gravity. Indexing arms 212 on a side of the catwalk carrier 210 adjacent to the tubular member tub 204 can be manually or automatically lowered when the tubular member 30 is being transferred from the tubular member tub 204 to the catwalk carrier 210. The indexing arms 212 can be automatically or manually raised after the tubular member 30 has passed the indexing arms 212 or when the tubular member 30 is situated on the catwalk carrier 210. Indexing arms 212 on a side of the catwalk carrier 210 opposite from the tubular member tub 204 remain raised throughout the transportation of the tubular member 30 to the catwalk carrier 210 to ensure that the tubular member 30 does not roll past the catwalk carrier 210. The tubular member 30 can be positioned on the catwalk carrier 210 in front of the skate 218.

[0051] When the catwalk carrier 210 is in the position to receive the tubular member 30, the electric storage device 222 is aligned with and electrically connected to the charging system 226. The connection sensor 236 can output a signal to indicate that the electric storage device 222 is connected to the charging system 226. The electric storage device 222 can be charged during the loading of the tubular member 30 on the catwalk carrier 210.

[0052] After the tubular member 30 is properly positioned on the catwalk carrier 210, the motor 215 is activated which causes the catwalk carrier 210 to move in both horizontal and vertical directions to a second position, as illustrated in FIG. 3B, at step 404. The movement of the catwalk carrier 210 can cause the electric storage device 222 to electrically disconnect from the charging system 226. The connection sensor 236 can identify when the electric storage device 222 is disconnected from the charging system 226. As the proximate end of the carrier 210 moves up the catwalk ramp 214, the distal end of the carrier 210 moves horizontally toward the drilling rig 100 and the input terminals of the electric power source 222 electrically disconnect from the output terminals of the charging system 226. The catwalk assembly 202 is shown in FIG. 3B in an intermediate position between the first position and the second position.

[0053] As the proximal end of the catwalk carrier 210 continues to elevate along the catwalk ramp 214, an elongated catwalk lift arm 216 coupled to a point at or near the distal end of the catwalk carrier 210 slides along the main frame 208 towards the catwalk ramp 214. Once it reaches a certain stop point, and as the carrier 210 continues up the ramp 214, the end of the catwalk lift arm 216 pivots about the stop point causing the distal end of the carrier 210 and lift arm 216 to elevate upwards from the main frame 208. The catwalk assembly 202 is shown in FIG. 3C now in the second position. Raising both ends of the catwalk carrier 210 allows for less force to move the tubular member 30 along the catwalk carrier 210 to the rig floor 101. The catwalk lift arm 216 can be free of any electrical and hydraulic lines typically used to operate a motor / actuator 224 and indexing arms 212. The catwalk lift arm 216 may also not include drag chains and service loops, which includes hydraulic lines, electrical power lines, and communication lines.

[0054] After the catwalk carrier 210 reaches, or while it is moving towards, this second position, the motor / actuator 224 is activated which causes the skate 218 to control a position of the tubular member 30 along the catwalk carrier 210 at step 406. As the skate moves upward along the carrier 210, the tubular member 30 carried thereon is pushed or moved to a position at or above the rig floor 101 for subsequent use. As will be appreciated, the electric storage device 222 provides power to the motor / actuator 224. Due to the inclusion of the electric power source 222 on the carrier 210, no electrical and / or hydraulic connections from the main frame 208 to the carrier 210 are needed. This can reduce maintenance requirements, eliminate the need for a dragchain, and simplifies design of the catwalk system 200. The motor / actuator 224 controls the skate 218 to move along the carrier and thus, control the positioning of the tubular member 30 as desired.

[0055] After the tubular member 30 is delivered to the rig floor 101 and removed from the carrier 210, the skate 218 is moved back to its original position and the catwalk assembly is reset or placed back into the first position, at step 408. As the proximate end of the carrier 210 begins moving down the catwalk ramp 214, the lift arm 216 retracts and lowers to a horizontal position adjacent the main frame 208 (e.g., FIG. 3B). As the carrier continues down the catwalk ramp 214, the distal end of the carrier 210 moves horizontally toward the charging system 226 and the input terminals of the electric power source 222 electrically connect to the output terminals of the charging system 226, and back into the first position (e.g., FIG. 3A) After reconnection, the charging system 226 begins charging the electric power source 222. When back in the first position, the catwalk carrier 210 is capable of receiving another tubular member 30, and the process can be repeated.

[0056] As will be appreciated, the skate 218 can include one or more position sensors 220 configured to detect a position of the skate 218 and / or a position of the catwalk carrier 210. The position sensor 220 can detect when the catwalk carrier 210 is in the first position or in a position where the catwalk carrier is able to receive a tubular member 30. The charging system 226 can include a connection sensor 236 configured to detect when the carrier 210 is in the first position or identify when the input terminals of the electric storage device 222 are connected to the output terminals of the charging system 226. Upon detection or identification, the charging system automatically activates to begin charging the electric power source 222.

[0057] The charging system 226 can charge the electric storage device 222 while the next tubular member 30 is being loaded on the catwalk carrier 210 and / or during idle period(s) (e.g., between trips). The catwalk assembly 202 can activate the charging system 226 when the position sensor 220 detects when the catwalk carrier 210 is in a collapsed position or in a position where the catwalk carrier is able to receive a tubular member 30. The catwalk assembly 202 can activate the charging system when the connection sensor 236 identifies when the input terminals of the electric storage device 222 are connected to the output terminals of the charging system 226.

[0058] Although FIG. 4 illustrates one example of a method 400 for operating a battery-operated catwalk carrier and skate, various changes may be made to FIG. 4. For example, while shown as a series of steps, various steps in FIG. 4 may overlap, occur in parallel, or occur any number of times.

[0059] It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “application” and “program” refer to one or more computer programs, software components, sets of instructions, procedures, functions, objects, classes, instances, related data, or a portion thereof adapted for implementation in a suitable computer code (including source code, object code, or executable code). The term “communicate,” as well as derivatives thereof, encompasses both direct and indirect communication. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and / or. The phrase “associated with,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. The phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one item in the list may be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.

[0060] The description in the present disclosure should not be read as implying that any particular element, step, or function is an essential or critical element that must be included in the claim scope. The scope of patented subject matter is defined only by the allowed claims. Moreover, none of the claims invokes 35 U.S.C. §112(f) with respect to any of the appended claims or claim elements unless the exact words “means for” or “step for” are explicitly used in the particular claim, followed by a participle phrase identifying a function. Use of terms such as (but not limited to) “mechanism,”“module,”“device,”“unit,”“component,”“element,”“member,”“apparatus,”“machine,”“system,”“processor,” or “controller” within a claim is understood and intended to refer to structures known to those skilled in the relevant art, as further modified or enhanced by the features of the claims themselves, and is not intended to invoke 35 U.S.C. §112(f).

[0061] While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.

Examples

Embodiment Construction

[0017]FIGS. 1 through 3, described below, and the various embodiments used to describe the principles of the present disclosure are by way of illustration only and should not be construed in any way to limit the scope of this disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any type of suitably arranged device or system.

[0018]The present disclosure describes a drilling rig system including a drilling rig and a catwalk system. At least a portion of the catwalk system is powered by a rechargeable electric power source (e.g., batteries) locally mounted on the catwalk carrier of the catwalk system to power certain components and catwalk functions (e.g., skate function). The electric power source is configured to be operably recharged when the carrier is stationary in a first position within the catwalk system with respect to the frame of the catwalk. Wireless communications can provide feedback from the carrier and ...

CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM FOR PRIORITY

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 708,646 filed Oct. 17, 2024. The subject matter of the above-identified patent document(s) is incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure relates generally to drilling rig systems, devices and processes, and more particularly, to a catwalk system and related components powered by a rechargeable electric power source.BACKGROUND

[0003] Current catwalk carriers operate by lifting out of the main catwalk frame onto the rig's drill floor. The skate in the carrier pushes the tubular member onto the drill floor. The carrier and skate are powered by a drag chain and / or service loop carrying hydraulics, electrical power and communications cables or lines. This drag chain occupies substantial space in the catwalk, is expensive, and can be damaged during operation. By having an electric power source (e.g., battery) in the carrier, the drag chain is no longer needed.SUMMARY

[0004] This disclosure provides a battery-operated catwalk carrier and skate.

[0005] In some examples, a catwalk assembly includes a main frame, a catwalk carrier, a catwalk lift, a catwalk lift arm, a skate, an actuator, an electric storage device, and a charging system. The catwalk carrier is configured to receive a tubular member. The catwalk ramp is coupled to the main frame and the catwalk carrier and configured to lift the catwalk carrier from the main frame. The catwalk lift arm is coupled to the main frame and the catwalk carrier at an opposite side from the catwalk ramp. The skate is slidingly coupled to the catwalk carrier and configured to position and move the tubular member along the catwalk carrier. The actuator is coupled to the catwalk carrier and configured to move the skate along the catwalk carrier. The electric storage device is coupled to the catwalk carrier and configured to power the actuator. The charging system coupled to the main frame and configured to charge the electric storage device when the catwalk carrier is in a position to receive a tubular member and electrically disconnect from the electric storage device when the catwalk carrier moves away from the position to receive a tubular member and electrically disconnect from the electric storage device when the catwalk carrier moves away from the position to receive a tubular member.

[0006] Any single one or any combination of the following features may be used with the above embodiment. The charging system includes a connection sensor configured to detect a connection of output terminals of the charging system to input terminals of the electric storage device. The charging system is configured to initiate charging when the connection sensor detects that the connection of output terminals of the charging system are connected to the input terminals of the electric storage device. The skate includes a position sensor configured to detect when the catwalk carrier is in the position to receive a tubular member. The charging system is configured to initiate charging when the position sensor detects that the catwalk carrier is in the position to receive a tubular member. The catwalk lift arm does not have support lines or cables from remote electrical or hydraulic supplies. The actuator may be an electrical actuator.

[0007] In other examples, a catwalk system includes one or more tubular member tubs and a catwalk assembly. The one or more tubular member tubs are configured to store tubular members. The catwalk assembly includes a main frame, a catwalk carrier, a catwalk lift, a catwalk lift arm, a skate, an actuator, an electric storage device, and a charging system. The catwalk carrier is configured to receive one of the tubular members. The catwalk ramp is coupled to the main frame and the catwalk carrier and configured to lift the catwalk carrier from the main frame. The catwalk lift arm is coupled to the main frame and the catwalk carrier at an opposite side from the catwalk ramp. The skate is slidingly coupled to the catwalk carrier and configured to position and move the tubular member along the catwalk carrier. The actuator is coupled to the catwalk carrier and configured to move the skate along the catwalk carrier. The electric storage device is coupled to the catwalk carrier and configured to power the actuator. The charging system is coupled to the main frame and configured to charge the electric storage device when the catwalk carrier is in a position to receive the tubular member and electrically disconnect from the electric storage device when the catwalk carrier moves away from the position to receive a tubular member.

[0008] Any single one or any combination of the following features may be used with the above embodiment. The charging system includes a connection sensor configured to detect a connection of output terminals of the charging system to input terminals of the electric storage device. The charging system is configured to initiate charging when the connection sensor detects that the connection of output terminals of the charging system are connected to the input terminals of the electric storage device. The skate includes a position sensor configured to detect when the catwalk carrier is in the position to receive a tubular member. The charging system is configured to initiate charging when the position sensor detects that the catwalk carrier is in the position to receive a tubular member. The catwalk lift arm does not have support lines or cables from remote electrical or hydraulic supplies. The actuator may be an electrical actuator.

[0009] In still other examples, a method includes receiving a tubular member on a catwalk carrier. The method also includes lifting, using a catwalk ramp coupled to a main frame and the catwalk carrier and a catwalk lift arm coupled to the main frame and the catwalk carrier at an opposite side from the catwalk ramp, the catwalk carrier from the main frame and electrically disconnecting an electric storage device from a charging system. The method further includes powering, using an electric storage device coupled to the catwalk carrier, an actuator coupled to the catwalk carrier. In addition, the method includes positioning and moving, using the actuator to move a skate slidingly coupled to the catwalk carrier, the tubular member along the catwalk carrier. The method also includes lowering the catwalk carrier to a position to receive tubular member and electrically connecting the electric storage device to the charging system. The method further includes charging, using a charging system coupled to the main frame, the electric storage device when the catwalk carrier is in the position to receive tubular member.

[0010] Any single one or any combination of the following features may be used with the above embodiment. The method may further include detecting, using connection sensor of the charging system, a connection of output terminals of the charging system to input terminals of the electric storage device. The method may further include initiating charging using the charging system when the connection sensor detects that the connection of output terminals of the charging system are connected to the input terminals of the electric storage device. The method may further include detecting, using a position sensor of the skate, when the catwalk carrier is in the position to receive a tubular member. The method may further include initiating charging using the charging system when the position sensor detects that the catwalk carrier is in the position to receive a tubular member. The catwalk lift arm does not have support lines or cables from remote electrical or hydraulic supplies. The actuator may be an electrical actuator.

[0011] Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For a more complete understanding of this disclosure, reference is made to the following description, taken in conjunction with the accompanying drawings, in which:

[0013] FIG. 1 illustrates an overall drilling rig system in accordance with the present disclosure;

[0014] FIGS. 2A and 2B illustrate an example catwalk system according to this disclosure;

[0015] FIGS. 3A, 3B, 3C and 3D illustrate various views of an example catwalk operation and movements according to this disclosure; and

[0016] FIG. 4 illustrates an example method for operating a battery-operated catwalk carrier and skate according to this disclosure.DETAILED DESCRIPTION

[0017] FIGS. 1 through 3, described below, and the various embodiments used to describe the principles of the present disclosure are by way of illustration only and should not be construed in any way to limit the scope of this disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any type of suitably arranged device or system.

[0018] The present disclosure describes a drilling rig system including a drilling rig and a catwalk system. At least a portion of the catwalk system is powered by a rechargeable electric power source (e.g., batteries) locally mounted on the catwalk carrier of the catwalk system to power certain components and catwalk functions (e.g., skate function). The electric power source is configured to be operably recharged when the carrier is stationary in a first position within the catwalk system with respect to the frame of the catwalk. Wireless communications can provide feedback from the carrier and control operation of the catwalk / actuator / skate.

[0019] The battery-powered catwalk carrier allows for elimination of a drag chain with lengthy cables and hoses. The elimination of the drag chain provides a cost reduction over the long term from no downtime and repairs related to the drag chain. Without a drag chain, there are fewer parts to service and less chance for damage. The absence of a drag chain allows for space savings in the catwalk allowing easier access to other components. The battery technology required for operating components of a catwalk carrier can operate outside of hazardous zones. The battery-powered catwalk carrier has a simplified design of the lift arm as it does not have to carry services to the carrier.

[0020] In an example embodiment, as depicted in FIG. 1, a drilling rig system 10 may include a drilling rig 100 which may be used to drill or otherwise conduct operations on a wellbore. In some embodiments, the drilling rig system 10 may include one or more pump skids / systems 350, a generator skid / system 400, a mud pumping and processing skid / system 500, a mud gas separator skid / system 600, a hydraulic pressure unit (HPU) skid / system 700, and one or more tank skids / systems 800. The one or more pump skids / systems 350 provide drilling fluids, such as drilling mud, to the drilling rig 100 for use during wellbore operations. The generator skid / system 400 may be used to provide electrical power to drilling rig 100 and other components of the drilling rig system 10. The mud pumping and processing skid / system 500 pumps drilling fluids for use in the wellbore, and processes drilling fluids returning from the wellbore by, for example and without limitation, separating out solids and gases from the returning drilling fluid. The mud gas separator skid / system 600 separates gases from the liquid part of drilling fluids returning from the wellbore. The HPU skid / system 700 provides hydraulic power, through the use of high pressure hydraulic fluid, for one or more components of the drilling rig 100 or other components of the drilling rig system 10. The one or more tank skids / systems 800 typically include one or more tanks to hold fluids for use with the drilling rig 100 or other components of the drilling rig system 10.

[0021] The drilling rig 100 includes a rig floor 101 and a substructure 103 for supporting the rig floor 101 above the ground. In some embodiments, the drilling rig 100 may include a mast 119 having a plurality of upright structures that define a frame for the mast 119. The mast 119 may be positioned above a well (or other areas above the rig floor 101) being drilled by the drilling rig 100 and configured to support tubular members, such as a drilling string, being used during a drilling operation. As will be appreciated, the mast 119 may additionally be used to support other components and other tubular members during operations other than drilling operations.

[0022] In some embodiments, the drilling rig 100 includes a pipe handling apparatus 123 having a column 125, a pipe handler 127, and other components (not shown). The pipe handling apparatus 123 may, for example and without limitation, be used to transfer tubular members (such as tubular members 30 as shown in FIGS. 2A, 2B) to / from the catwalk system 200 to an operable location within the mast 119. The tubular members 30 may be any tubular member for use with the drilling rig 100 including, for example and without limitation, drill pipe, casing, collars, pipe stands, casing stands, or other tubular members.

[0023] The pipe handler 127 is configured to engage and move a tubular member between locations on the drilling rig 100 during operations, such as from the catwalk system 200 to a position above the well such that the tubular member may be placed into the well by other components of the drilling rig 100. Though not shown, the pipe handler 127 may include one or more grippers adapted to grip onto and / or rotate a tubular member and other component(s) to further manipulate the tubular member pipe handler 127. The pipe handler 127 can be operatively coupled to the column 125 by a pipe handler carriage configured to move vertically relative to column 125 and allow the pipe handler 127 to move a tubular segment or member vertically. As will be appreciated, other suitable configurations and positioning of the pipe handling apparatus, column and pipe handler may be utilized.

[0024] In some embodiments, as depicted in FIG. 1, the drilling rig 100 may include a top drive 135 mechanically coupled to the mast 119 such that the top drive 135 may move vertically relative to the mast 119. The top drive 135 can be configured and operate to raise, lower, and / or rotate tubular members during operation of the drilling rig 100. In some embodiments, the top drive 135 may be raised and lowered by a cable and a drawworks assembly, a rack and pinion assembly, or other suitable system.

[0025] Though not specifically shown, the drilling rig 100 may include a pipe elevator having one or more components (e.g., jaw, clamp) that engage a tubular member such that the pipe elevator may support and raise / lower the tubular members used by the drilling rig 100. The pipe elevator may be coupled to the top drive 135 such that pipe elevator moves with the top drive.

[0026] The drilling rig system 10 and the drilling rig 100 shown and described in FIG. 1 is one example of a drilling system which may incorporate the teachings and features described in the present disclosure. Further, other component(s) and system(s) may be included, while others may be omitted from, the drilling rig system 10 and / or drilling rig 100. For additional descriptions and examples of drilling rig systems, drilling rigs and components thereof, reference is made to U.S. Pat. No. 10,975,635 which is incorporated herein by reference. Other configurations (and components / devices) may be used for the drilling rig system 10 and drilling rig 100, including those known in the art.

[0027] Now turning to FIGS. 2A and 2B, there is illustrated an example catwalk system 200 in accordance with this disclosure. As shown, the catwalk system 200 can be used to transport tubular members 30, such as drill collars, drill pipes and casings, from ground level to the level of the rig floor 101 of the drilling rig 100 (and vice versa). The catwalk system 200 includes a catwalk assembly 202 having a stationary main frame 208 and a movable catwalk carrier or slide 210 with a movable skate 218 disposed therein.

[0028] The catwalk system 200 also includes one or more tubular member tubs 204 configured to store the tubular members 30 of any appropriate or suitable length (e.g., thirty feet, forty-five feet, etc.). As a non-limiting example, a tubular member tub 204 includes sufficient structure and strength to hold / store a total weight of tubular members of 10,000 lbs. or more. The tubular member tubs 204 may be mechanically coupled to the catwalk assembly 202 by one or more struts 206. The struts 206 may be pivotably coupled to the catwalk assembly 202 and the tubular member tubs 204 such that the tubular member tubs 204 may be pivoted into a position alongside the catwalk assembly 202 for transportation of the catwalk system 200. The tubular member tubs 204 operably function as storage containers to store the tubular members 30 not yet being used by the drilling rig 100 within the catwalk system 200. The tubular member tubs 204 are configured to store and subsequently provide tubular members 30 to the catwalk assembly 202 for use in the drilling rig 100.

[0029] The tubular member tubs 204 may include a frame 228 that defines a tubular storage area 230 used for storing the tubular members 30. The tubular member tubs 204 may include one or more support frames 232 coupled to the frame 228 such that the support frames 232 may be raised or lowered relative to the frame 228. Each support frame 232 may include one or more channels 234 configured substantially horizontal to the ground or angled such that the end of the channels 234 nearest the catwalk assembly 202 is lower than the outside end of channels 234. In some embodiments, the ends of tubular members 30 stored within the tubular member tub 204 may be positioned within the channels 234. In addition, the support frames 232 may allow the tubular members 30 stored within the tubular member tub 204 to be stored in multiple layers. When the tubular members 30 are to be transferred to the catwalk assembly 202 to be used with drilling rig 100, the support frames 232 may be raised such that the uppermost layer of tubular members 30 is at or above the level of the top side of the frame 228. Once above the top of the frame 228, the tubular members 30 may roll along the channels 234 and the struts 206. In some embodiments, the channels 234 and the struts 206 may be tilted to allow tubular members 30 to roll by gravity toward the catwalk assembly 202.

[0030] The catwalk assembly 202 may include one or more indexing arms 212 positioned to selectively allow tubular members to enter the catwalk carrier 210 one at a time. In some embodiments, the indexing arms 212 may hold a foremost tubular member at a standby position. The indexing arms 212 may then lower to allow tubular member 30 to pass over the indexing arms 212 and into / onto the catwalk carrier 210. As a first tubular member 30 passes the indexing arms 212, the indexing arms 212 may raise again to hold / prevent other tubular members 30 from passing the indexing arms 212. The first tubular member 30 continues to roll and moves into position on the catwalk carrier 210.

[0031] In some embodiments, where two tubular member tubs 204 are utilized, each tubular member tub 204 may be configured to store different tubular members. For example, a second tubular member tub 204 may be used to hold larger-diameter tubular members, such as casing. The catwalk assembly 202 may include additional indexing arms (not shown) adapted to handle tubular members of larger diameter than the indexing arms 212. A second tubular member tub 204 may otherwise operate to transfer the larger diameter tubular member (e.g., casing) to the catwalk assembly 202 substantially simultaneously as the tubular member 30 is transferred to the catwalk assembly 202 by a first tubular member tub 204.

[0032] The catwalk assembly 202 includes the main frame 208 for supporting the catwalk carrier 210 and other components. As will be appreciated, the catwalk carrier 210 is adapted or configured to receive a tubular member 30 from the tubular member tubs 204 and transport it from ground level to the level of the rig floor 101. The catwalk carrier 210 can be configured to receive and transport tubular members 30 of different diameters.

[0033] The example catwalk assembly 202 shown includes a catwalk ramp 214 that may include one or more upright members that extend and are mechanically coupled between one end of the main frame 208 of the catwalk assembly 202 and the rig floor 101. For example, the catwalk carrier 210 may mechanically couple to the catwalk ramp 214 at the end of the catwalk carrier 210 proximate to the drilling rig 100 such that an end of the catwalk carrier 210 proximate to the drilling rig 100 moves and slides upward / downward along the catwalk ramp 214. For example, FIG. 3B illustrates the catwalk carrier 210 in an intermediate position (e.g., as it moves upward / downward along the catwalk ramp 214). It will be understood that the catwalk ramp 214 may be configured to raise / lower the end of the catwalk carrier 210 at any suitable angle, including upwards of 90 degrees, however, in various embodiments, the catwalk ramp 214 may be configured with an incline in a range of about 75 degrees to about 45 degrees.

[0034] Turning now to FIGS. 3A, 3B, 3C, and 3D, there are illustrated sides views and a perspective view of one example of the catwalk assembly 202 according to the present disclosure. FIG. 3A illustrates the catwalk assembly 202 in a first position (e.g., collapsed or load position); FIG. 3B illustrates the catwalk assembly 202 in a lifting or intermediate position as the catwalk carrier 210 moves from the first position and lifts a tubular member 30 upwards as shown; and FIG. 3C illustrates the catwalk assembly 202 in a second position (e.g., raised or rig floor position) after the skate 218 has moved the tubular member 30 upward along the slide of the catwalk carrier 210 for presentment to the rig floor 101. FIG. 3D illustrates the catwalk assembly 202 in the second position (e.g., raised or rig floor position) before the skate 218 has moved the tubular member 30 upward along the slide of the catwalk carrier 210 for presentment to the rig floor 101.

[0035] The catwalk system 200 (or catwalk assembly 202) includes one or more motors 215 or actuators (electric, combustion, hydraulic, etc.) coupled mechanically to the catwalk ramp 214 and the end of the catwalk carrier 210. The motor 215 provides a mechanical force to the end of the catwalk carrier 210 such that the catwalk carrier 210 moves up / down along the catwalk ramp 214. This may be accomplished using any suitable mechanical devices and components, such as cables and pulleys coupled to the motor 215 and the end of the catwalk carrier 210. As will be appreciated, the catwalk ramp 214 may be pivotably coupled to main frame 208 of the catwalk assembly 202 such that the catwalk ramp 214 may be lowered to a substantially horizontal position coextensive with the main frame 208, for example and without limitation, for transport of the catwalk assembly 202.

[0036] In some embodiments, the catwalk assembly 202 includes the skate 218 which is a structure slidingly coupled to the catwalk carrier 210 and movable relative thereto that is used to position and move a tubular member 30 along a surface of the catwalk carrier 210. The skate 118 may engage with a lower end of a tubular member 30 and may be used to move a tubular member 30 longitudinally along the catwalk carrier 210. The skate 218 may be used to introduce a tubular member 30 to the rig floor 101 when the catwalk carrier 210 is in the raised (or rig floor) position (or receive a tubular member 30 from the rig floor 101 for lowering). The skate 218 may be coupled to a position sensor 220 configured to identify a position of the skate 218, and therefore the lower end of a tubular member 30 is known. The position sensor 220 can wireless communicate with the different components of the catwalk assembly 202, including the charging system 226. For example, the position sensor 220 can provide a signal to the charging system 226, that the catwalk carrier 210 is in the first position and the charging system 226 can power the electric storage device 222.

[0037] In some embodiments, an end of the catwalk carrier 210 distal to the drilling rig 100 may be adapted to slide relative to the main frame 208 of the catwalk assembly 202. The catwalk carrier 210 may be movably coupled to the main frame 208 of the catwalk assembly 202 by a catwalk lift arm 216 (see FIGS. 3C, 3D). The catwalk lift arm 216 may be slidably coupled to the main frame 208 and pivotably coupled to the catwalk carrier 210 such that as the end of the catwalk carrier 210 proximal to the drilling rig 100 travels up along the catwalk ramp 214, the catwalk lift arm 216 simultaneously raises the end of the catwalk carrier 210 distal to the drilling rig 100 such that the catwalk carrier 210 is at a smaller inclination than when the distal end of the catwalk carrier 210 remains at ground level. For example, reducing the inclination of the catwalk carrier 210 when in the raised position or lowering the end of a tubular member 30 held by the catwalk carrier 210 and introduced at the rig floor 101 reduces the height of the end of a tubular member 30 above the rig floor 101. As a non-limiting example, the height or level of the rig floor 101 for use with the catwalk assembly 202 may be in a range from about 10 feet to 50 feet.

[0038] In accordance with the present disclosure, the catwalk assembly 202 includes an electric storage device 222 disposed and mounted to the catwalk carrier 210. In some embodiments, the electric storage device 222 may be mounted at or near the distal end of the catwalk carrier 210, and in some embodiments, is positioned within ten feet of its end. Similarly, the catwalk assembly 202 includes a motor or actuator 224 disposed and mounted to the catwalk carrier 210. In some embodiments, the electric storage device 222 and / or the motor / actuator 224 is / are mounted at or near the distal end of the catwalk carrier 210, and in some embodiments, are positioned within ten feet from the distal end or otherwise located or positioned between the distal end of the catwalk carrier 210 and a retracted or lowermost position of the skate 218. While the electric storage device 222 and the motor / actuator 224 are depicted on top of the catwalk carrier 210, this is for illustration only, and the electric storage device 222 and the motor / actuator 224 may be positioned within the body or structure of the catwalk carrier 210.

[0039] The electric storage device 222 may be any suitable storage device(s) for storing electric energy / potential, including for example, rechargeable batteries and packs (e.g., lithium-based, nickel-cadmium, nickel-metal-hydride, lead-acid, etc. and the like), electrolytic capacitors and supercapacitors, flow, sodium, or any other suitable battery type, and combinations thereof. In certain embodiments, the electric storage device 222 can include a secondary or auxiliary charger, such as a solar panel, to charge, at least partly, the electric storage device 222.

[0040] The operating voltage (output) of the electric storage device 222 may be any suitable operating voltage level / output compatible with the electric motor / actuator 224 and provide sufficient power to slidably move the skate 218 to carry a tubular member upward to the rig floor 101 (or downward). The electric storage device 222 may also be used to power any components on the catwalk carrier assembly 202 including, but not limited to safety gates, stop pins, lights, pipe ejectors, sensors, communication equipment, etc. In certain embodiments, the electric storage device 222 may have an additional operating voltage level / output compatible for raising and lowering the indexing arms 212 along the catwalk carrier 210. Non-limiting examples for the operating voltage level / output may be 12 VDC, 24 VDC, 48 VDC, and so on, etc. In certain embodiments not shown, the catwalk assembly may also include a DC-AC voltage converter that converts DC voltage output from the electric storage device 222 into an alternating current (AC) voltage when the motor / actuator 224 is implemented with AC motor(s) / actuator(s). This may include step-up and / or step-down conversion, and embodiments, the DC voltage output from the electric storage device 222 is converted to AC voltage, such as 220 VAC, 480 VAC or 600 VAC.

[0041] The electric storage device 222 may be configured to have a power capacity sufficient to power the electric motor / actuator 224 for multiple cycles, e.g., 200 cycles (wherein one cycle involves powering the skate 218 to move upward and lift the tubular member 30 to the rig floor 101 and return to its original position), before recharging is required. In such embodiments, the electric storage device 222 can be removed and replaced in order to continue service of the catwalk assembly 202 without waiting to recharge. In certain embodiments, the electric storage device 222 may be configured to have a power capacity sufficient for a full trip. Non-limiting examples for the power capacity may be 8 KWh, 10 KWh, and so on, etc.

[0042] The electric storage device 222 may be a modular unit composed of multiple modular electric storage devices or packs. The modular storage devices can be smaller units that are more easily manipulable by a user. For example, a 10 KWh battery can weigh around 300 lbs, while a 1 KWh battery may weight around 20 lbs. Using multiple 1 KWh may allow for swapping batteries and reducing an overall extra weight of the catwalk carrier 210.

[0043] Because the motor / actuator 224 (and movement of the skate 218) is powered electrically, the catwalk assembly 202 of the present disclosure reduces or eliminates the need for hydraulic lines extending from a hydraulic pump up to a hydraulic actuator for powering the skate 218. Thus, hydraulic lines that typically run along or within the main frame 208 and / or the catwalk lift arm 216 in prior art designs can be omitted. Further, because the electric storage device 222 is also mounted and located on the catwalk carrier 210, there is no longer a need for electrical lines extending from the main frame 208 and / or along the catwalk lift arm 216. This reduces or eliminates use of a drag chain, and the lack of electric cables and / or hydraulic lines along the main frame 208 and / or along the catwalk lift arm 216 effectively eliminates possible damage to such components during typical operation of the catwalk system 200.

[0044] When the catwalk assembly 202 is set in the first position (e.g., collapsed or load position), as shown in FIG. 3A, a charging system 226 is electrically coupled to the electric storage device 222 and operably charges / recharges the electric storage device 222. The charging system 226 may be a battery charger or other charging circuitry consistent with the configuration and type of the electric storage device 222. Although not shown, an external power supply (e.g., electric power generator) provides power to the charging system 226. For example, the charging system 226 can be powered directly from the rig (e.g., the generator skid / system 400).

[0045] The electric storage device 222 has output terminals for providing electric power to various components of the catwalk assembly 202, including the electric motor / actuator 224 and wireless transceiver circuitry (not shown) configured to control operation of the electric motor / actuator 224 (and thus, movement of the skate 218). The electric storage device 222 includes input terminals configured to receive a charging voltage / current from output terminals of the charging system 226. When the catwalk assembly 202 is in the first position (FIG. 3A), the electric storage device 222 is electrically coupled to the charging system 226 and charging occurs (charging phase / operation). As the catwalk carrier 210 begins its lifting movement / cycle, the electric storage device 222 is electrically decoupled from the charging system 226 (no charging). During the lifting movement / cycle (e.g., FIGS. 3B, 3C) no coupling and no charging occurs. As the catwalk assembly 202 completes the cycle, the catwalk assembly 202 returns to the first position (e.g., FIG. 3A), where a connection and a charging phase / operation begins again.

[0046] In certain embodiments, the catwalk system 200 can determine whether the catwalk carrier 210 is in the first position shown in FIG. 3A for the purposes of charging. While the catwalk carrier is in the first position, the input terminals of the electric storage device 222 are operably coupled to the output terminals of the charging system 226. The position sensor 220 can be used to identify when the catwalk carrier 210 is in the first position. In certain embodiments, the electric storage device 226 can include a connection sensor 236 that can identify when the input terminals of the electric storage device 222 are connected to output terminals of the charging system 226. As non-limiting example, the connection sensor 236 could be a mechanical switch, an electrical connection, etc.

[0047] In some embodiments, one or all components of catwalk system 200 may be electrically driven and controlled. In some embodiments, operation of the catwalk system 200 may be controlled by a central control system of the drilling rig 100 such that the catwalk system 200 is operable with minimal or no human interaction. Once a tubular member 30 is positioned on the catwalk carrier 210, the catwalk carrier 210 can be activated and move from a first position (e.g., a resting or load position, see FIG. 3A) to a second position (e.g., a raised or delivery position, see FIGS. 3C, 3D). The skate 218 may advance tubular member 30 along the catwalk carrier 210.

[0048] Although FIGS. 2A, 2B, 3A, 3B, 3C and 3D illustrate an example catwalk system 200, various changes may be made to the system, and the various components may be combined, further subdivided, replicated, omitted, or rearranged and additional components may be added according to particular needs.

[0049] Now turning to FIG. 4 (and with reference to FIGS. 3A, 3B and 3C), there is illustrated an example method 400 for operating a battery-operated catwalk carrier and skate according to this disclosure. For ease of explanation, the method 400 of FIG. 4 is described as being performed using the catwalk system 200 of FIGS. 1 through 3C. However, the method 400 may be used with any other suitable system and any other suitable drilling rig system.

[0050] As shown in FIG. 4, the catwalk carrier 210 can receive a tubular member 30 when the catwalk carrier 210 is in the first position, as illustrated in FIG. 3A, at step 402. The tubular members 30 can be stored in one or more tubular member tubs 204 prior to use in a drilling column. The tubular member tub 204 can store tubular members 30 of any appropriate or suitable length and outer diameter. The tubular members 30 can be raised above a top of the tubular member tub 204 and transferred from the tubular member tub 204 to the catwalk carrier 210 along the channels 234 and the struts 206. The tubular member 30 can move from the tubular member tub 204 to the catwalk carrier 210 through mechanical means, such as a conveyor belt, or by gravity. Indexing arms 212 on a side of the catwalk carrier 210 adjacent to the tubular member tub 204 can be manually or automatically lowered when the tubular member 30 is being transferred from the tubular member tub 204 to the catwalk carrier 210. The indexing arms 212 can be automatically or manually raised after the tubular member 30 has passed the indexing arms 212 or when the tubular member 30 is situated on the catwalk carrier 210. Indexing arms 212 on a side of the catwalk carrier 210 opposite from the tubular member tub 204 remain raised throughout the transportation of the tubular member 30 to the catwalk carrier 210 to ensure that the tubular member 30 does not roll past the catwalk carrier 210. The tubular member 30 can be positioned on the catwalk carrier 210 in front of the skate 218.

[0051] When the catwalk carrier 210 is in the position to receive the tubular member 30, the electric storage device 222 is aligned with and electrically connected to the charging system 226. The connection sensor 236 can output a signal to indicate that the electric storage device 222 is connected to the charging system 226. The electric storage device 222 can be charged during the loading of the tubular member 30 on the catwalk carrier 210.

[0052] After the tubular member 30 is properly positioned on the catwalk carrier 210, the motor 215 is activated which causes the catwalk carrier 210 to move in both horizontal and vertical directions to a second position, as illustrated in FIG. 3B, at step 404. The movement of the catwalk carrier 210 can cause the electric storage device 222 to electrically disconnect from the charging system 226. The connection sensor 236 can identify when the electric storage device 222 is disconnected from the charging system 226. As the proximate end of the carrier 210 moves up the catwalk ramp 214, the distal end of the carrier 210 moves horizontally toward the drilling rig 100 and the input terminals of the electric power source 222 electrically disconnect from the output terminals of the charging system 226. The catwalk assembly 202 is shown in FIG. 3B in an intermediate position between the first position and the second position.

[0053] As the proximal end of the catwalk carrier 210 continues to elevate along the catwalk ramp 214, an elongated catwalk lift arm 216 coupled to a point at or near the distal end of the catwalk carrier 210 slides along the main frame 208 towards the catwalk ramp 214. Once it reaches a certain stop point, and as the carrier 210 continues up the ramp 214, the end of the catwalk lift arm 216 pivots about the stop point causing the distal end of the carrier 210 and lift arm 216 to elevate upwards from the main frame 208. The catwalk assembly 202 is shown in FIG. 3C now in the second position. Raising both ends of the catwalk carrier 210 allows for less force to move the tubular member 30 along the catwalk carrier 210 to the rig floor 101. The catwalk lift arm 216 can be free of any electrical and hydraulic lines typically used to operate a motor / actuator 224 and indexing arms 212. The catwalk lift arm 216 may also not include drag chains and service loops, which includes hydraulic lines, electrical power lines, and communication lines.

[0054] After the catwalk carrier 210 reaches, or while it is moving towards, this second position, the motor / actuator 224 is activated which causes the skate 218 to control a position of the tubular member 30 along the catwalk carrier 210 at step 406. As the skate moves upward along the carrier 210, the tubular member 30 carried thereon is pushed or moved to a position at or above the rig floor 101 for subsequent use. As will be appreciated, the electric storage device 222 provides power to the motor / actuator 224. Due to the inclusion of the electric power source 222 on the carrier 210, no electrical and / or hydraulic connections from the main frame 208 to the carrier 210 are needed. This can reduce maintenance requirements, eliminate the need for a dragchain, and simplifies design of the catwalk system 200. The motor / actuator 224 controls the skate 218 to move along the carrier and thus, control the positioning of the tubular member 30 as desired.

[0055] After the tubular member 30 is delivered to the rig floor 101 and removed from the carrier 210, the skate 218 is moved back to its original position and the catwalk assembly is reset or placed back into the first position, at step 408. As the proximate end of the carrier 210 begins moving down the catwalk ramp 214, the lift arm 216 retracts and lowers to a horizontal position adjacent the main frame 208 (e.g., FIG. 3B). As the carrier continues down the catwalk ramp 214, the distal end of the carrier 210 moves horizontally toward the charging system 226 and the input terminals of the electric power source 222 electrically connect to the output terminals of the charging system 226, and back into the first position (e.g., FIG. 3A) After reconnection, the charging system 226 begins charging the electric power source 222. When back in the first position, the catwalk carrier 210 is capable of receiving another tubular member 30, and the process can be repeated.

[0056] As will be appreciated, the skate 218 can include one or more position sensors 220 configured to detect a position of the skate 218 and / or a position of the catwalk carrier 210. The position sensor 220 can detect when the catwalk carrier 210 is in the first position or in a position where the catwalk carrier is able to receive a tubular member 30. The charging system 226 can include a connection sensor 236 configured to detect when the carrier 210 is in the first position or identify when the input terminals of the electric storage device 222 are connected to the output terminals of the charging system 226. Upon detection or identification, the charging system automatically activates to begin charging the electric power source 222.

[0057] The charging system 226 can charge the electric storage device 222 while the next tubular member 30 is being loaded on the catwalk carrier 210 and / or during idle period(s) (e.g., between trips). The catwalk assembly 202 can activate the charging system 226 when the position sensor 220 detects when the catwalk carrier 210 is in a collapsed position or in a position where the catwalk carrier is able to receive a tubular member 30. The catwalk assembly 202 can activate the charging system when the connection sensor 236 identifies when the input terminals of the electric storage device 222 are connected to the output terminals of the charging system 226.

[0058] Although FIG. 4 illustrates one example of a method 400 for operating a battery-operated catwalk carrier and skate, various changes may be made to FIG. 4. For example, while shown as a series of steps, various steps in FIG. 4 may overlap, occur in parallel, or occur any number of times.

[0059] It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “application” and “program” refer to one or more computer programs, software components, sets of instructions, procedures, functions, objects, classes, instances, related data, or a portion thereof adapted for implementation in a suitable computer code (including source code, object code, or executable code). The term “communicate,” as well as derivatives thereof, encompasses both direct and indirect communication. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and / or. The phrase “associated with,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. The phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one item in the list may be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.

[0060] The description in the present disclosure should not be read as implying that any particular element, step, or function is an essential or critical element that must be included in the claim scope. The scope of patented subject matter is defined only by the allowed claims. Moreover, none of the claims invokes 35 U.S.C. §112(f) with respect to any of the appended claims or claim elements unless the exact words “means for” or “step for” are explicitly used in the particular claim, followed by a participle phrase identifying a function. Use of terms such as (but not limited to) “mechanism,”“module,”“device,”“unit,”“component,”“element,”“member,”“apparatus,”“machine,”“system,”“processor,” or “controller” within a claim is understood and intended to refer to structures known to those skilled in the relevant art, as further modified or enhanced by the features of the claims themselves, and is not intended to invoke 35 U.S.C. §112(f).

[0061] While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.

Examples

Embodiment Construction

[0017]FIGS. 1 through 3, described below, and the various embodiments used to describe the principles of the present disclosure are by way of illustration only and should not be construed in any way to limit the scope of this disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any type of suitably arranged device or system.

[0018]The present disclosure describes a drilling rig system including a drilling rig and a catwalk system. At least a portion of the catwalk system is powered by a rechargeable electric power source (e.g., batteries) locally mounted on the catwalk carrier of the catwalk system to power certain components and catwalk functions (e.g., skate function). The electric power source is configured to be operably recharged when the carrier is stationary in a first position within the catwalk system with respect to the frame of the catwalk. Wireless communications can provide feedback from the carrier and ...

Claims

1. A catwalk assembly comprising:a main frame;a catwalk carrier configured to receive a tubular member;a catwalk ramp coupled to the main frame and the catwalk carrier and configured to lift the catwalk carrier from the main frame;a catwalk lift arm coupled to the main frame and the catwalk carrier at an opposite side from the catwalk ramp;a skate slidingly coupled to the catwalk carrier and configured to position and move a tubular member along the catwalk carrier;an actuator coupled to the catwalk carrier and configured to move the skate along the catwalk carrier;an electric storage device coupled to the catwalk carrier and configured to power the actuator; anda charging system coupled to the main frame and configured to charge the electric storage device when the catwalk carrier is in a position to receive a tubular member and electrically disconnect from the electric storage device when the catwalk carrier moves away from the position to receive a tubular member.

2. The catwalk assembly of claim 1, wherein the charging system includes a connection sensor configured to detect a connection of output terminals of the charging system to input terminals of the electric storage device.

3. The catwalk assembly of claim 2, wherein the charging system is configured to initiate charging when the connection sensor detects that the connection of output terminals of the charging system are connected to the input terminals of the electric storage device.

4. The catwalk assembly of claim 1, wherein the skate includes a position sensor configured to detect when the catwalk carrier is in the position to receive a tubular member.

5. The catwalk assembly of claim 4, wherein the charging system is configured to initiate charging when the position sensor detects that the catwalk carrier is in the position to receive a tubular member.

6. The catwalk assembly of claim 1, wherein the catwalk lift arm does not have support lines or cables from remote electrical or hydraulic supplies.

7. The catwalk assembly of claim 1, wherein the actuator is an electric motor.

8. A catwalk system comprising:one or more tubular member tubs configured to store tubular members; anda catwalk assembly coupled to the one or more tubular member tubs, the catwalk assembly comprising:a main frame;a catwalk carrier configured to receive one of the tubular members from the one or more tubular member tubs;a catwalk ramp coupled to the main frame and the catwalk carrier and configured to lift the catwalk carrier from the main frame;a catwalk lift arm coupled to the main frame and the catwalk carrier at an opposite side from the catwalk ramp;a skate slidingly coupled to the catwalk carrier and configured to position and move a tubular member along the catwalk carrier;an actuator coupled to the catwalk carrier and configured to move the skate along the catwalk carrier;an electric storage device coupled to the catwalk carrier and configured to power the actuator; anda charging system coupled to the main frame and configured to electrically couple to the electric storage device when the catwalk carrier is in a position to receive a tubular member and electrically disconnect from the electric storage device when the catwalk carrier moves away from the position to receive a tubular member.

9. The catwalk system of claim 8, wherein the charging system includes a connection sensor configured to detect a connection of output terminals of the charging system to input terminals of the electric storage device.

10. The catwalk system of claim 9, wherein the charging system is configured to initiate charging when the connection sensor detects that the connection of output terminals of the charging system are connected to the input terminals of the electric storage device.

11. The catwalk system of claim 8, wherein the skate includes a position sensor configured to detect when the catwalk carrier is in the position to receive a tubular member.

12. The catwalk system of claim 11, wherein the charging system is configured to initiate charging when the position sensor detects that the catwalk carrier is in the position to receive a tubular member.

13. The catwalk system of claim 8, wherein the catwalk lift arm does not have support lines or cables from remote electrical or hydraulic supplies.

14. The catwalk system of claim 8, wherein the actuator is an electrical actuator.

15. A method for a catwalk assembly, the method comprising:receiving a tubular member on a catwalk carrier;lifting, using a catwalk ramp coupled to a main frame and the catwalk carrier and a catwalk lift arm coupled to the main frame and the catwalk carrier at an opposite side from the catwalk ramp, the catwalk carrier from the main frame and electrically disconnecting an electric storage device from a charging system;powering, using the electric storage device coupled to the catwalk carrier, an actuator coupled to the catwalk carrier;positioning and moving, using the actuator to move a skate slidingly coupled to the catwalk carrier, the tubular member along the catwalk carrier;lowering the catwalk carrier to a position to receive a tubular member and electrically connecting the electric storage device to the charging system; andcharging, using the charging system coupled to the main frame, the electric storage device when the catwalk carrier is in the position to receive the tubular member.

16. The method of claim 15, further comprising:detecting, using connection sensor of the charging system, a connection of output terminals of the charging system to input terminals of the electric storage device.

17. The method of claim 16, further comprising:initiating charging using the charging system when the connection sensor detects that the connection of output terminals of the charging system are connected to the input terminals of the electric storage device.

18. The method of claim 15, further comprising:detecting, using a position sensor of the skate, when the catwalk carrier is in the position to receive a tubular member.

19. The method of claim 18, further comprising:initiating charging using the charging system when the position sensor detects that the catwalk carrier is in the position to receive a tubular member.

20. The method of claim 15, wherein the catwalk lift arm does not have support lines or cables from remote electrical or hydraulic supplies.

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