Automated Drill Pipe Handling System for Rig Safety
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Solution Overview
Problem
The existing methods for handling and storing drill pipes during well drilling and workover operations are hazardous for rig personnel due to manual handling of large pipe sections, and they often require a significant footprint that limits space for vertical storage.
Innovation Solution
A pipe handling system comprising a pipe racker for engaging the upper end of the drill pipe and a setback handling system with a slidable and rotatable table, a pipe guide, and a push-pull mechanism to automate the movement and storage of drill pipes, reducing the need for manual handling and optimizing storage space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling methods are used to move drill pipe sections, then personnel can guide and position the pipe, but safety hazards increase for rig personnel near the drilling mast and drill floor
Solution Approach 1:
The drill pipe moves itself from the wellbore to the storage area using its own weight and gravity, eliminating the need for personnel to manually push or pull the pipe. The pipe guide and sled system allows the pipe to self-position without human contact during the hazardous movement phase
Solution Approach 2:
Manual mechanical handling by personnel is replaced with an automated mechanical system consisting of a sled, pipe guide, and push-pull mechanism that automatically transports the drill pipe sections without human intervention in the hazardous zone
2Quantity of substance
If vertical storage area is provided immediately adjacent to the drilling mast, then drill pipe can be stored vertically, but the footprint space required limits the available storage capacity
Solution Approach 1:
The storage system transitions from purely vertical storage immediately adjacent to the mast to an extended configuration that utilizes the setback area, effectively adding a horizontal dimension to the storage layout. This allows pipe to be stored in a setback rack positioned away from the mast, optimizing space utilization
Solution Approach 2:
The storage system is divided into two functional zones: a vertical storage area immediately adjacent to the mast for quick access, and an extended setback storage area for additional capacity. This segmentation allows the system to optimize both space utilization and operational efficiency
3Object-affected harmful factors
If automated pipe handling system is implemented, then personnel safety is improved by minimizing involvement in hazardous areas, but device complexity increases
Solution Approach 1:
The automated handling system is divided into distinct functional modules: a sled for engagement, a pipe guide for directional control, and a push-pull mechanism for movement. This modular segmentation makes the complex system easier to understand, maintain, and operate while achieving the safety goal
Solution Approach 2:
The sled acts as an intermediary device between the drill pipe and the push-pull mechanism, simplifying the interaction. The sled engages the pipe, and the push-pull mechanism simply pushes or pulls the sled, creating a simple control interface that reduces operational complexity despite the automated nature of the system
Data Source
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AI summary
A pipe handling system (10) includes a frame (12) removably coupled to a drilling mast (20), a gripping arm (18) movably coupled to the frame (12), and a grip jaw (36) extending from the gripping arm (18) to engage a drill pipe (24). The gripping arm (18) and the grip jaw (36) are operable to move a drill pipe (24) from within the drilling mast (20) to a pipe storage area adjacent the drilling mast (20). Other embodiments include a pipe racker (10) and a setback handling system (100) disposed below the pipe racker (10)to engage a lower end of a drill pipe (122). The setback handling system (100) includes a movable pipe guide (104) and a rotating table (102) supporting the pipe guide (104). In some embodiments, the rotating table (102) also supports a pipe mover (106) for moving the drill pipe (122) to desired storage positions in a setback rack. Pipe handling methods are also disclosed.