Robotic Pipe Handler Vertical Orientation Transition
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Solution Overview
Problem
Conventional well drilling operations face inefficiencies in storing and positioning drill pipes, particularly in transitioning them from a horizontal to a vertical orientation and centering them over a wellbore for effective engagement with top drive systems.
Innovation Solution
A pipe handling system comprising robotic pipe handlers and a controller that coordinates the operation of the pipe handling system and top drive system to transition drill pipes from a horizontal to a vertical orientation and position them centrally over the wellbore, utilizing a cage with modular pipe racks for storage and a top drive system for mechanical engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manual pipe handling methods are used, then operational flexibility is maintained, but drilling efficiency and productivity are reduced
Solution Approach 1:
The robotic pipe handler is designed to autonomously perform pipe handling operations including picking up pipes from the pipe rack, transitioning them from horizontal to vertical orientation, and positioning them at the wellbore. The system self-regulates through programmed sequences without continuous human intervention, thereby improving productivity while implementing automation.
Solution Approach 2:
The patent replaces manual mechanical pipe handling operations with an automated robotic system. The robotic pipe handler uses automated mechanisms including robotic arms, clamps, and positioning systems to perform tasks previously done manually, thereby increasing drilling efficiency through consistent, rapid, and fatigue-free operation.
2Productivity
If drill pipes are stored horizontally, then space utilization is improved, but transition to vertical orientation for drilling operations becomes inefficient
Solution Approach 1:
The robotic pipe handler is programmed to perform preliminary actions including approaching the pipe rack, identifying the next pipe to be used, and initiating the transition process before drilling operations require the pipe. This advance preparation minimizes downtime and ensures pipes are ready for immediate vertical orientation and deployment.
Solution Approach 2:
The system employs dynamic motion control to transition pipes from horizontal to vertical orientation. The robotic handler adjusts its movements based on real-time positioning data, optimizing the transition path and speed while ensuring safe and accurate orientation changes, thereby reducing the time lost during pipe orientation changes.
3Measurement precision
If manual pipe positioning is used, then system complexity is reduced, but positioning accuracy and centering precision over the wellbore deteriorate
Solution Approach 1:
The robotic pipe handler incorporates feedback mechanisms including sensors and positioning systems that continuously monitor the pipe's location and orientation. This feedback enables real-time adjustments to achieve precise centering over the wellbore, ensuring accurate positioning while managing system complexity through automated control algorithms.
Solution Approach 2:
The robotic pipe handler is designed as a multi-functional system that combines pipe picking, orientation transition, transportation, and precise positioning capabilities in a single integrated unit. This universality achieves high positioning accuracy without proportionally increasing overall system complexity, as one robotic system performs multiple functions that would otherwise require separate devices.
4Reliability
If robotic pipe handlers are deployed, then operational safety is improved by reducing unsupported pipe risks, but device complexity and initial costs increase
Solution Approach 1:
The robotic pipe handler autonomously manages pipe support and positioning throughout the transition process, eliminating the need for manual handling that could result in unsupported pipes. The system self-regulates pipe support during orientation changes and transportation, thereby improving safety while managing complexity through automated control.
Solution Approach 2:
The robotic pipe handler acts as an intermediary between the pipe rack and the wellbore, providing continuous support and controlled transition for pipes during orientation changes. This intermediary function ensures pipes are never left unsupported, improving reliability and safety while containing complexity within the robotic handling system itself.
Data Source
AI summary
A system includes a cage having a pipe rack configured to store a tubular in a vertical orientation, such that a longitudinal axis of the tubular is substantially perpendicular to a horizontal plane. The system also includes a first robotic pipe handler configured to transition the tubular from a horizontal orientation, in which the longitudinal axis of the tubular is substantially parallel to the horizontal plane, to the vertical orientation. The first robotic pipe handler transitions between a raised position and a lowered position about a first handler axis.