Automated Pipe Connection System with Slip Wedge and Mud Bucket
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Solution Overview
Problem
The existing pipe connection and disconnection processes in the hydrocarbon production industry are inefficient and pose safety concerns due to the manual handling of pipe sections and the challenges of managing hydrostatic pressure during tripping operations, which limits the productivity and safety on the drill rig floor.
Innovation Solution
A modular pipe connection system that includes a stationary support frame, a slip control system with actuators, a thread lubricator, stabbing arms, and a mud bucket subsystem, allowing for automated and controlled engagement and disengagement of pipe joints, thereby reducing manual labor and managing hydrostatic pressure effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling of pipe sections is used for connection and disconnection, then the process requires simple apparatus, but productivity is low and safety concerns arise
Solution Approach 1:
The automated pipe connection system performs operations that would otherwise require manual handling by rig crew. The system uses self-contained actuators, lubricators, and stabbing mechanisms to automatically connect and disconnect pipe sections, eliminating the need for manual intervention while improving productivity and safety
Solution Approach 2:
Manual mechanical operations are replaced with an automated mechanical system featuring electric or hydraulic actuators for slip control, automated lubrication systems, and motorized stabbing arms. This substitution transforms manual labor into an automated process, significantly improving efficiency while reducing safety risks to personnel
2Reliability
If hydrostatic pressure is managed during breakout, then safety is improved, but the mud bucket requires significant structural strength to contain the pressure
Solution Approach 1:
The harmful hydrostatic pressure is extracted and contained within a dedicated mud bucket structure designed specifically for pressure containment. By isolating the pressure management function into a separate, purpose-built component, the system can handle breakout safely without requiring the entire apparatus to be overly robust
Solution Approach 2:
The mud bucket is positioned and ready before breakout occurs to contain the hydrostatic pressure. The system prepares the pressure containment mechanism in advance, allowing safe management of the pressure surge that occurs during pipe joint breakout without compromising structural integrity
3Productivity
If multiple subsystems are integrated for automated operation, then productivity and safety are improved, but the system complexity increases
Solution Approach 1:
The automated pipe connection system is divided into distinct functional subsystems: slip control subsystem with actuators, thread lubricator subsystem, stabbing arms subsystem, and mud bucket subsystem. Each subsystem performs a specific function and can be independently controlled, making the overall complex system manageable through modular organization
Solution Approach 2:
The integrated system performs multiple functions within a unified apparatus: slip control for suspension, lubrication for thread protection, stabbing for connection/disconnection, and mud bucket for pressure containment. This multi-functionality consolidates what would otherwise require separate equipment into a single coordinated system, improving productivity while managing complexity through functional integration
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances efficiency and safety by automating the pipe connection and disconnection process, minimizing manual handling, and effectively containing hydrostatic pressure, thus improving operational safety and reducing the footprint on the drill rig floor.
Implementation Method 1
at least one actuator coupled between the slip wedge and the stationary support frame, wherein the actuator is operable to move the slip wedge between a retracted position and an extended position in engagement with a downhole tubular string
Implementation Method 2
The column of fluid in the pipe joint creates hydrostatic pressure
Implementation Method 3
a mud bucket may be manually disposed about the pipe connection to contain the hydrostatic pressure and capture or divert excess flow of mud from breakout
Data Source
AI summary
A pipe connection system (200) includes a stationary support frame (202, 204) and a slip control system (300) coupled to the stationary support frame including a slip wedge (302) and at least one actuator (306, 308) coupled between the slip wedge and the stationary support frame, wherein the actuator is operable to move the slip wedge between a retracted position and an extended position in engagement with a downhole tubular string (118). A pipe connection system also includes a stationary support frame (202, 204), a slip control subsystem including a slip wedge moveable between a retracted position and an extended position in engagement with a downhole tubular string, a support frame subsystem (400) movably coupled to the stationary support frame, a stabbing arm subsystem (600) movably coupled to the moveable support frame subsystem, a thread lubricator subsystem (500) movably coupled to the moveable support frame subsystem, and a mud bucket subsystem (700) movably coupled to the moveable support frame subsystem.