Pipe Ejection Mechanism for Automated Tubing Handling
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Solution Overview
Problem
Conventional completion systems for wells, particularly those with long lateral boreholes, face challenges such as slow and unsafe insertion of production tubing, limited maximum horizontal insertion distance, and increased operational costs due to the need for larger and more complex rigs, which hinder efficient hydrocarbon production and fracturing in low permeability reservoirs.
Innovation Solution
A long lateral completion system featuring a compact mast assembly, catwalk-pipe arm, and automated pipe handling mechanisms that allow for precise alignment and insertion of tubing with reduced rig footprint, enabling faster and safer operation, and extending the reach of wellbore completion without the need for extensive rig setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional completion systems are used for long lateral boreholes, then the well can be completed, but the insertion of production tubing is slow and unsafe
Solution Approach 1:
The patent replaces conventional mechanical pipe handling systems with an automated robotic system that uses a robotic arm, gripper, and control system to insert production tubing. This substitution eliminates the need for manual handling by operators, significantly improving safety while increasing insertion speed through automated positioning and placement mechanisms.
Solution Approach 2:
The system incorporates automated feedback control where sensors detect the position and status of the tubing, and the control system automatically adjusts the robotic arm movements to achieve precise placement. The system serves itself by monitoring and correcting its own operations without human intervention, improving both speed and safety.
2Length of stationary object
If conventional rigs are used to extend reach for long lateral boreholes, then insertion distance is increased, but rig size and complexity must increase
Solution Approach 1:
The patent divides the pipe handling function into separate modular components: a robotic arm for positioning, a gripper for holding tubing, a control system for coordination, and a support structure. This segmentation allows the system to achieve extended reach through coordinated movement of multiple components rather than requiring a single large complex rig structure.
Solution Approach 2:
The system achieves extended horizontal insertion distance by utilizing vertical space and three-dimensional movement of the robotic arm. Instead of extending the rig horizontally with longer structures, the robotic arm moves tubing through vertical and lateral movements, placing it into the wellbore from above, thereby achieving long insertion distances without proportionally increasing rig footprint or complexity.
3Reliability
If automated pipe handling mechanisms are implemented, then operation safety is improved, but device complexity increases
Solution Approach 1:
The robotic system is designed with multi-functional components that perform multiple tasks. The robotic arm not only positions tubing but also handles different sizes and types of pipe. The control system manages various operations including positioning, gripping, and coordination with the insertion mechanism. This universality reduces the need for separate specialized equipment, thereby limiting the increase in overall system complexity while maintaining high safety through automation.
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
This system enhances the efficiency and safety of well completion and fracturing operations by allowing for longer lateral wellbores, reducing operator risk, and lowering operational costs through automated and compact equipment, thereby improving hydrocarbon extraction rates.
Implementation Method 1
a first compressed spring positioned above the production tubing in the wellbore and configured to eject the production tubing from the wellbore upon release
Data Source
AI summary
An ejection mechanism, which in one embodiment selectively ejects pipe joints to either side of a pipe arm and method for manufacturing the same. A pipe arm contains a plurality of pipe receptacles for receiving pipe joints. Pipe ejection arms are operatively connected to an ejection control mechanism. In one embodiment, at least one torsional member and/or at least one hydraulic actuator allow an operator to selectively eject pipe joints to either lateral side of the pipe arm as needed during drilling and production operations.