Automated Tubular Racking System for Land Rig Safety
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Solution Overview
Problem
Conventional drilling rigs face challenges in efficiently and safely handling and reassembling drill pipes due to the need for frequent disconnection and reconnection of long, heavy drill strings, which increases trip time and poses safety risks, especially on land rigs where solutions from offshore drilling are not directly applicable.
Innovation Solution
A tubular racking system with a racking module connected to the drilling rig mast, featuring an upper and lower racking mechanism with grippers and clamps to securely handle and orient tubular stands, providing redundancy and safety by maintaining vertical orientation and allowing for automated handling and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling of drill pipes is used, then flexibility and adaptability are maintained, but safety risks increase and trip time is extended
Solution Approach 1:
The automated racking system performs drill pipe handling operations autonomously without requiring manual intervention. The system uses sensors to detect pipe positions, automated grippers to secure pipes, and controlled movement mechanisms to transport and rack pipes, enabling the system to serve itself and eliminating safety risks associated with manual handling
Solution Approach 2:
The patent replaces manual mechanical handling with an automated mechanical system. Manual labor is substituted by automated actuators, motors, and control systems that manipulate the drill pipes through standardized interfaces, maintaining operational flexibility while eliminating safety hazards
2Productivity
If frequent disconnection and reconnection of drill strings is performed, then drilling operations can proceed, but trip time increases and operational efficiency decreases
Solution Approach 1:
The automated racking system pre-positions drill pipes in organized racks before they are needed for drilling operations. When a trip occurs, the system can quickly retrieve pre-positioned pipes and connect them to the drill string, eliminating the time-consuming process of searching for and manually positioning pipes during the critical tripping operation
Solution Approach 2:
The system maintains continuous readiness by keeping drill pipes stored and positioned in the automated rack system during non-drilling periods. This ensures that when tripping is required, pipes are immediately available for rapid deployment, maintaining continuous operational flow and minimizing interruptions to drilling activities
3Reliability
If long drill strings are handled manually, then assembly is possible, but safety risks increase due to weight and length
Solution Approach 1:
The automated racking system divides the handling of long drill strings into manageable segments. The system uses multiple standardized gripping points along the drill pipe length, allowing automated actuators to secure and manipulate specific sections independently. This segmentation enables safe handling of heavy, long pipes by distributing control across multiple automated points rather than requiring manual manipulation of the entire assembly
Solution Approach 2:
The patent introduces automated grippers and clamps as intermediary devices between the drill pipes and the racking system. These intermediaries provide secure attachment points that distribute mechanical loads, enabling the system to safely handle heavy drill strings without direct human contact while maintaining precise control through standardized interfaces
Data Source
AI summary
A tubular racking system has a racking module connected to a drilling rig mast. The racking module has a frame, a fingerboard assembly, and a clasp extendable to a stand hand-off position for securing a tubular stand in position. An upper racking mechanism (upper racking mechanism) has a bridge translatably connected to the frame. An arm is rotatably and translatably connected to the bridge. A gripper is translatably connected to the arm. A setback platform module has a platform and an alleyway adjacent the platform. A lower racking mechanism (lower racking mechanism) is translatably connected to the alleyway. The lower racking mechanism is rotatably and extendable with a clasp operable to secure a tubular stand from horizontal movement. Movements of the lower racking mechanism are controlled by movements of the upper racking mechanism.