Mobile Snubbing System Robotic Pipe Handler
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Solution Overview
Problem
Conventional snubbing units in the oil and gas industry require extensive equipment and personnel, posing safety risks due to the need for personnel to be positioned near the wellhead during operations, and result in high capital and operating costs.
Innovation Solution
A mobile snubbing system with a truck-mounted platform that includes a snubbing unit, a programmable robotic pipe-lifting handler, automated tongs, and a pressure integrity testing system, allowing for remote operation and reduced equipment and personnel requirements, with the ability to pivot and stabilize the snubbing unit over the wellhead for efficient tubular handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional snubbing units are used with extensive equipment and personnel, then tubular handling capability is achieved, but safety risk increases due to personnel positioning near wellhead
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system. The robotic arm with gripper performs tubular handling, connection, and disconnection operations automatically, eliminating the need for personnel to position themselves near the wellhead during high-risk operations. This substitution of mechanical automation for human operation directly addresses the safety concern while maintaining operational capability.
Solution Approach 2:
The system incorporates self-servicing capabilities through automated functions. The robotic system autonomously performs tubular handling, the blowout preventor stack automatically tests itself, and the system self-stabilizes using outriggers. This reduces dependency on extensive personnel and simplifies the operational complexity while maintaining safety.
2Productivity
If conventional snubbing units with extensive equipment are deployed, then complete operational capability is achieved, but capital and operating costs increase
Solution Approach 1:
The patent merges multiple functions into a single integrated mobile system. The truck-mounted platform combines the robotic arm, blowout preventor stack, control systems, and stabilization mechanisms into one unified unit. This consolidation reduces the need for separate equipment and personnel, thereby lowering both capital and operating costs while maintaining complete operational capability.
Solution Approach 2:
The robotic system is designed with multi-functionality to perform various operations including tubular handling, connection, disconnection, and wellhead management. The blowout preventor stack serves multiple safety functions. This universality allows a single system to replace multiple specialized equipment, reducing overall equipment requirements and costs.
3Reliability
If automated robotic pipe handler is used, then personnel safety is improved by remote operation, but device complexity increases
Solution Approach 1:
The patent replaces complex manual coordination and human positioning with a programmed robotic system. The robotic arm with programmable motion control and automated gripper operation eliminates the need for multiple personnel to coordinate manually near the wellhead. While the automation system itself is complex, it trades control complexity for safety by removing personnel from hazardous zones.
4Area of stationary object
If mobile truck-mounted platform is used, then equipment footprint is reduced, but stability requirements increase
Solution Approach 1:
The patent employs dynamic stabilization mechanisms including outriggers that can be deployed to stabilize the mobile platform during operations. The system transitions from a mobile state during transport to a stabilized state during operation, adapting its stability characteristics to the operational requirements. This dynamic approach allows compact footprint while maintaining necessary stability.
Solution Approach 2:
The mobile platform incorporates counterweight mechanisms to balance the heavy robotic arm and blowout preventor stack. The counterweights offset the gravitational forces and moments generated by the extended robotic arm during tubular handling, maintaining platform stability without requiring excessive structural reinforcement or increasing the footprint.
Data Source
AI summary
A mobile snubbing system and method of operation transports a snubbing unit to a wellhead on a mobile platform. The snubbing unit is supported by a frame pivotable about a wellhead end of the platform for aligning the snubbing unit with the wellhead. A pipe handler boom is operable between a platform position for loading and off-loading tubulars at an open side of the platform and a second snubbing position for loading and off-loading tubulars at the top end of the snubbing unit. The boom can be telescopic for extending to the top of the snubbing unit and can be automated after learning tubular manipulation at the wellhead. Pipe racks can be deployable from the open side of the platform and an indexer and kicker in the platform enables loading and off-loading tubulars at the pipe handler.