Horizontal Stand Builder for Safer Drill Pipe Transfer
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Solution Overview
Problem
The process of adding drill pipe to a drill string is inefficient and poses risks to workers due to frequent manual handling, slowing down drilling operations and increasing safety hazards.
Innovation Solution
A system for horizontally building and transferring double or triple stands of drill pipe and casing using a horizontal stand builder and catwalk, which includes skids, power tongs, pipe handling units, and a catwalk with a skate system to move tubulars safely and efficiently to the rig floor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If drill pipe is added one piece at a time to the drill string, then the connection process can be completed, but the drilling operation is slowed down and worker safety risks increase due to frequent manual handling
Solution Approach 1:
The system pre-assembles multiple drill pipe pieces into stands (double or triple stands) on the ground before drilling operations begin. This preliminary assembly reduces the frequency of pipe additions during drilling, as entire stands can be added in single operations rather than individual pipe pieces, thereby reducing downtime and maintaining higher drilling speeds
Solution Approach 2:
The drill pipe is segmented into pre-assembled stands consisting of multiple pipe pieces connected together. These stands are handled as single units during transfer and assembly operations, reducing the number of separate handling operations required and improving overall drilling efficiency
2Ease of operation
If manual handling of drill pipe is used during connection, then the pipe can be positioned and connected, but worker safety risks increase
Solution Approach 1:
The system replaces manual mechanical handling with automated mechanical systems including a catwalk with conveyor belts, powered pipe handling units, and automated positioning mechanisms. These systems transfer and position drill pipe stands without direct worker contact, eliminating the safety risks associated with manual handling while maintaining full operational capability
Solution Approach 2:
The catwalk system serves as an intermediary mechanism between the ground-level pipe storage area and the rig floor. It provides a controlled, automated transfer path that eliminates the need for workers to manually handle pipe during transfer operations, while still enabling precise positioning and connection
3Productivity
If pre-assembled stands of drill pipe are used, then the number of connection operations is reduced, but the complexity of the transfer system increases
Solution Approach 1:
The catwalk system is designed as a multi-functional apparatus that can handle multiple operations: transporting drill pipe stands, positioning them vertically, transferring them to the rig floor, and facilitating connection operations. This universal design consolidates what would otherwise require multiple separate systems into a single integrated structure, managing complexity while maintaining high productivity
Solution Approach 2:
The system merges the functions of pipe transport, vertical elevation, horizontal transfer, and positioning into a single integrated catwalk structure. By combining these functions rather than using separate systems for each operation, the overall system complexity is managed more effectively while achieving the productivity benefits of pre-assembled stands
Data Source
AI summary
A system and method for horizontally building stands of tubulars and transferring them to a rig floor. The system has a horizontal stand builder which assembles double or triple stands of tubulars. A catwalk and V-door are positioned alongside the horizontal stand builder. A skate is able to push either single, double, or triple stands along the catwalk and up the V-door to a position whereby an elevator on the rig can grip the stand and move it onto the rig. For transferring single stands of tubular, there is a carrier at the upper end of the V-door which can grip the single stand and lift it to the position for the elevator to grip it and move it onto the rig.