U.S. patent application number 15/046320 was filed with the patent office on 2016-06-09 for well servicing vehicle with method for detecting well string snags.
The applicant listed for this patent is Jonathan V. Huseman, Frederic M. Newman, Kasia L. Robnett, James B. Story, Victor D. Trotter. Invention is credited to Jonathan V. Huseman, Frederic M. Newman, Kasia L. Robnett, James B. Story, Victor D. Trotter.
Application Number | 20160160582 15/046320 |
Document ID | / |
Family ID | 49993736 |
Filed Date | 2016-06-09 |
United States Patent
Application |
20160160582 |
Kind Code |
A1 |
Huseman; Jonathan V. ; et
al. |
June 9, 2016 |
Well Servicing Vehicle With Method for Detecting Well String
Snags
Abstract
Example well servicing vehicles for removing and installing well
strings (e.g., sucker rods and tubing) within wellbores provides a
method for determining and logging snag points within the wellbore.
In some examples, snag points are determined based on a
predetermined change in cable tension, crown load strain and/or
hydraulic pressure. The predetermined change is adjusted based on
the current length of the well string at the time the snag
occurs.
Inventors: |
Huseman; Jonathan V.;
(Midland, TX) ; Newman; Frederic M.; (Midland,
TX) ; Story; James B.; (Highland Village, TX)
; Robnett; Kasia L.; (Midland, TX) ; Trotter;
Victor D.; (Fort Worth, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Huseman; Jonathan V.
Newman; Frederic M.
Story; James B.
Robnett; Kasia L.
Trotter; Victor D. |
Midland
Midland
Highland Village
Midland
Fort Worth |
TX
TX
TX
TX
TX |
US
US
US
US
US |
|
|
Family ID: |
49993736 |
Appl. No.: |
15/046320 |
Filed: |
February 17, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13917405 |
Jun 13, 2013 |
|
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|
15046320 |
|
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|
13556472 |
Jul 24, 2012 |
9115550 |
|
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13917405 |
|
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|
61624273 |
Apr 14, 2012 |
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Current U.S.
Class: |
166/254.1 ;
166/250.01 |
Current CPC
Class: |
E21B 47/007 20200501;
E21B 19/14 20130101; E21B 19/155 20130101; E21B 19/20 20130101;
E21B 19/06 20130101; E21B 47/06 20130101 |
International
Class: |
E21B 19/06 20060101
E21B019/06; E21B 47/00 20060101 E21B047/00; E21B 47/06 20060101
E21B047/06 |
Claims
1. A workover method for handling a well string the extends into a
wellbore, wherein the method involves the use of an elevator
carried by a mast and connected to the well string, the workover
method comprising: supplying oil at a pressure that varies; using
the pressure as means for raising the elevator connected to the
well string; monitoring an elevation of the elevator, wherein the
elevation increases while raising the elevator; monitoring the
pressure while raising the elevator; if the pressure experiences a
certain spike in pressure, a controller noting the elevation at
which the certain spike occurred; and determining a location within
the wellbore based on the elevation at which the certain spike
occurred.
2. A workover method for handling a well string through the use of
an elevator carried by a mast, the workover method comprising:
determining a first anticipated maximum load of the well string;
during a first period, shortening the well string to create a
shorter well string; determining a second anticipated maximum load
of the shorter well string; during a second period, shortening the
shorter well string to create an even shorter well string;
establishing a first oil pressure limit based on the first
anticipated maximum load of the well string; establishing a second
oil pressure limit based on the second anticipated maximum load of
the shorter well string; during the first and second period,
discharging oil at a discharge pressure that varies; limiting the
discharge pressure to the first oil pressure limit during the first
period; and limiting the discharge pressure to the second oil
pressure limit during the second period, wherein the first oil
pressure limit is greater than the second oil pressure limit, and
the second oil pressure limit is less than a minimum discharge
pressure necessary to handle the first anticipated maximum load of
the well string.
3. A workover method for handling a well string that extends into a
wellbore, wherein the workover method involves the use of an
elevator carried by a trolley that travels along a mast, the
workover method comprising: the elevator suspending the well string
while the well string extends into the wellbore; a sensor
determining whether the elevator is descending; monitoring at least
one of a cable tension, a crown load strain and a hydraulic
pressure; identifying a notable decrease in at least one of the
cable tension, the crown load strain and the hydraulic pressure;
and determining a stack-out condition in the event of the notable
decrease occurring while the elevator is descending.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of non-provisional patent
application Ser. No. 13/917,405 filed on Jun. 13, 2013, which is a
continuation-in-part of non-provisional patent application Ser. No.
13/556,472 filed on Jul. 24, 2012, now U.S. Pat. No. 9,115,550,
which in turn claims the benefit of provisional patent application
Ser. No. 61/624,273 filed on Apr. 14, 2012; all of which are
specifically incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The subject invention generally pertains to workover
vehicles for servicing well bores and more specifically to a method
of detecting well string snags while using such workover
vehicles.
BACKGROUND
[0003] Drilling rigs are used for drilling new wellbores, and
workover units typically are for servicing or repairing completed
wells. Drilling rigs usually comprise a broad range of machinery
that is assembled and set up in a modular manner at a well site.
Workover units, on the other hand, comprise a generally
self-contained vehicle carrying various well-servicing equipment.
After traveling to a well site, the workover vehicle and its
equipment are often used for installing and removing tubing and
sucker rods associated with the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a side view of a workover vehicle at a well site
according to some example embodiments of the invention.
[0005] FIG. 2 a front end view of the vehicle of FIG. 1, but with
the mast in a lowered position.
[0006] FIG. 3 is a back end view of the vehicle of FIG. 1, but with
the mast in a lowered position and the robotic jib in a stored
position.
[0007] FIG. 4 is similar to FIG. 2 but showing the mast in a raised
position.
[0008] FIG. 5 is similar to FIG. 3 but showing the mast in the
raised position and the robotic jib in a partially deployed
position.
[0009] FIG. 6 is similar to FIG. 5 but showing the robotic jib in a
fully deployed position.
[0010] FIG. 7 is a back view of FIG. 4.
[0011] FIG. 8 is a perspective view of the workover vehicle in the
process of being aligned to the wellbore.
[0012] FIG. 9 is similar to FIG. 8 but showing the mast in its
raised position and proximate a pump jack with a walking beam.
[0013] FIG. 10 is a side view showing the mast in its lowered
position and a hydraulic tank lowered to a transport position.
[0014] FIG. 11 shows the mast at its raised position and the
hydraulic tank at an operative position.
[0015] FIG. 12 is a top view with the mast in the raised position,
the robotic jib in a partially deployed position, and a rod storage
rack extended to an operative configuration.
[0016] FIG. 13 is a top view with the mast in its lowered position,
the rod storage rack in its transport configuration, and the
robotic jib in its stored position.
[0017] FIG. 14 is a top view similar to FIG. 12.
[0018] FIG. 15 is a top view similar to FIG. 14 but showing the
robotic jib in its stored position.
[0019] FIG. 16 is a top view similar to FIGS. 12, 14 and 15 but
showing the robotic jib at its fully deployed position.
[0020] FIG. 17 is a front view of the upper trolley mechanism about
to engage the upper end of a well rod.
[0021] FIG. 18 is a bottom view of FIG. 17.
[0022] FIG. 19 is a back view of FIG. 17.
[0023] FIG. 20 is a perspective view of the upper trolley
mechanism.
[0024] FIG. 21 is a side view of FIG. 17.
[0025] FIG. 22 is a back view showing the upper trolley mechanism
guiding the upper end of a well tube.
[0026] FIG. 23 is a bottom view of FIG. 22.
[0027] FIG. 24 is a front view of FIG. 22.
[0028] FIG. 25 is a perspective view of FIG. 22.
[0029] FIG. 26 is a side view of FIG. 22.
[0030] FIGS. 27-33 pertain to the upper robot 90.
[0031] FIG. 27 is a perspective view of the articulated arm portion
of the upper robot, wherein the arm portion is shown extended.
[0032] FIG. 28 is a side view of FIG. 27.
[0033] FIG. 29 is a bottom view of FIG. 27.
[0034] FIG. 30 is a back view of FIG. 27.
[0035] FIG. 31 is a perspective view similar to FIG. 27 but showing
the arm portion of the upper robot retracted.
[0036] FIG. 32 is a side view of FIG. 31.
[0037] FIG. 33 is a top view of FIG. 31.
[0038] FIGS. 34-45 pertain to the lower robot 36.
[0039] FIG. 34 is a front view of the articulated arm portion of
the lower robot, wherein the arm portion is extended. The end
effectors of the upper and lower robots 90 and 36 are controlled to
travel horizontally generally in unison.
[0040] FIG. 35 is a bottom view of FIG. 34.
[0041] FIG. 36 is a back view of FIG. 34.
[0042] FIG. 37 is a perspective view of FIG. 34.
[0043] FIG. 38 is a side view of FIG. 34.
[0044] FIG. 39 is a top view of FIG. 34.
[0045] FIG. 40 is a front view similar to FIG. 34 but showing the
arm portion of the lower robot retracted.
[0046] FIG. 41 is a top view of FIG. 40, which is similar to FIG.
39 but with the arm portion of the lower robot retracted.
[0047] FIG. 42 is a back view of FIG. 40.
[0048] FIG. 43 is a perspective view of the articulated arm portion
of the lower robot.
[0049] FIG. 44 is a side view of FIG. 43.
[0050] FIG. 45 is a bottom view of FIG. 43.
[0051] FIGS. 46-49 show various views of an end effector 92 of the
upper robot 90.
[0052] FIGS. 50-54 show various views of an end effector 96 of the
lower robot 36.
[0053] FIG. 55 is a front view of the lower robot 36 with its
articulated arm portion retracted.
[0054] FIG. 56 is a back view of FIG. 55.
[0055] FIG. 57 is a perspective view of the lower robot 36 with its
articulated arm portion retracted.
[0056] FIG. 58 is a side view of the lower robot 36 with its
articulated arm portion retracted.
[0057] FIG. 59 is a top view of the lower robot 36 with its
articulated arm portion retracted.
[0058] FIG. 60 is a perspective view of a gripper portion of the
upper trolley mechanism.
[0059] FIG. 61 is a timing chart showing the workover system's
sequence of operation in pulling sucker rods 66 out from within the
wellbore. Various method steps are plotted versus a horizontal time
reference that progresses generally from left to right. The chart
shows several horizontal lines of method steps, wherein each line
show a series of sequentially performed method steps, and a
comparison of the horizontal lines identifies which method steps
can occur simultaneously to minimize the overall cycle time.
Completion of one cycle of method steps ending at the far right
column of asterisks initiates a subsequent cycle that begins at the
two left asterisks. Encircled hollow arrows function as a gate that
blocks work flow from left to right through the arrow until the
gate is opened by completion of a method step tied to the arrow via
a dotted line. The encircled hollow arrows are analogous to a
transistor or SCR that is triggered open by input to its gate
terminal (dotted line).
[0060] FIGS. 61A, 61B, 61C and 61D are enlarged views of the
corresponding 61A, 61B, 61C and 61D portions identified in FIG.
61.
[0061] FIG. 62 is a timing chart similar to FIG. 61 but showing the
steps involved in inserting sucker rods 66 in the wellbore.
[0062] FIGS. 62A, 62B, 62C and 62D are enlarged views of the
corresponding 62A, 62B, 62C and 61D portions identified in FIG.
62.
[0063] FIG. 63 is a timing chart similar to FIG. 61 but showing the
steps involved in removing tubing 64 out from with the
wellbore.
[0064] FIGS. 63A, 63B and 63C are enlarged views of the
corresponding 63A, 63B and 63C portions identified in FIG. 63.
[0065] FIG. 64 is a timing chart similar to FIG. 61 but showing the
steps involved in inserting tubing member 66 in the wellbore.
[0066] FIGS. 64A, 64B, 64C and 64D are enlarged views of the
corresponding 64A, 64B, 64C and 61D portions identified in FIG.
64.
[0067] FIG. 65 is a back view of the upper robot 90 with its
articulated arm portion that holds end effector 92.
[0068] FIG. 66 is a perspective view of the upper robot 90.
[0069] FIG. 67 is a side view of the FIG. 65.
[0070] FIG. 68 is a top view of FIG. 65.
[0071] FIG. 69 is a perspective view of a hydraulic drive system
that drives the vertical travel of the main trolley which carries
elevator 106. The hydraulic drive system comprises a larger
cylinder 152, a smaller cylinder 152 and a plurality of sheaves and
cables. FIG. 69 shows elevator 106 in its lowermost position.
[0072] FIG. 70 is a perspective view similar to FIG. 70 but showing
the larger cylinder 152 extended to raise elevator 106 to an
intermediate height.
[0073] FIG. 71 is a perspective view similar to FIG. 70 but showing
the both cylinders extended to raise elevator 106 to its uppermost
position.
[0074] FIGS. 72, 73 and 74 are side views corresponding to FIGS.
69, 70 and 71 respectively.
[0075] FIG. 75 is a perspective view showing the upper robot 90
with its articulated arm extended and its end effector 92 at a
laterally centered position.
[0076] FIG. 76 is a perspective view similar to FIG. 75 but showing
the articulated arm retracted.
[0077] FIG. 77 is a perspective view similar to FIG. 76 but showing
the shuttle 122 and the articulated arm both shifted laterally to
one side of carriage 120.
[0078] FIG. 78 is a perspective view similar to FIG. 77 but showing
the shuttle 122 and the articulated arm both shifted laterally to
the other side of carriage 120.
[0079] FIG. 79 is a schematic side view of an example workover
vehicle driving to and parking at a well site.
[0080] FIG. 80 is a schematic side view similar to FIG. 79 but
showing a mast of the workover vehicle being raised.
[0081] FIG. 81 is a schematic side view similar to FIGS. 79 and
80.
[0082] FIG. 82A is a schematic side view of the workover vehicle
being used for removing a well string.
[0083] FIG. 82B is a schematic right end view of FIG. 82A.
[0084] FIG. 83A is another schematic side view of the workover
vehicle being used for removing the well string.
[0085] FIG. 83B is a schematic right end view of FIG. 83A.
[0086] FIG. 84A is another schematic side view of the workover
vehicle being used for removing the well string.
[0087] FIG. 84B is a schematic right end view of FIG. 84A.
[0088] FIG. 85A is another schematic side view of the workover
vehicle being used for removing the well string.
[0089] FIG. 85B is a schematic right end view of FIG. 85A.
[0090] FIG. 86A is another schematic side view of the workover
vehicle being used for removing the well string.
[0091] FIG. 86B is a schematic right end view of FIG. 86A.
[0092] FIG. 87A is another schematic side view of the workover
vehicle being used for removing the well string.
[0093] FIG. 87B is a schematic right end view of FIG. 87A.
[0094] FIG. 88A is another schematic side view of the workover
vehicle being used for removing the well string.
[0095] FIG. 88B is a schematic right end view of FIG. 88A.
[0096] FIG. 89A is another schematic side view of the workover
vehicle being used for removing the well string.
[0097] FIG. 89B is a schematic right end view of FIG. 89A.
[0098] FIG. 90A is another schematic side view of the workover
vehicle being used for removing the well string.
[0099] FIG. 90B is a schematic right end view of FIG. 90A.
[0100] FIG. 91A is another schematic side view of the workover
vehicle being used for removing the well string.
[0101] FIG. 91B is a schematic right end view of FIG. 91A.
[0102] FIG. 92A is another schematic side view of the workover
vehicle being used for removing the well string.
[0103] FIG. 92B is a schematic right end view of FIG. 92A.
[0104] FIG. 93A is another schematic side view of the workover
vehicle being used for removing the well string.
[0105] FIG. 93B is a schematic right end view of FIG. 93A.
[0106] FIG. 94A is another schematic side view of the workover
vehicle being used for removing the well string.
[0107] FIG. 94B is a schematic right end view of FIG. 94A.
[0108] FIG. 95A is another schematic side view of the workover
vehicle being used for removing the well string.
[0109] FIG. 95B is a schematic right end view of FIG. 95A.
[0110] FIG. 96A is another schematic side view of the workover
vehicle being used for removing the well string.
[0111] FIG. 96B is a schematic right end view of FIG. 96A.
[0112] FIG. 97A is another schematic side view of the workover
vehicle being used for removing the well string.
[0113] FIG. 97B is a schematic right end view of FIG. 97A.
[0114] FIG. 98A is another schematic side view of the workover
vehicle being used for removing the well string.
[0115] FIG. 98B is a schematic right end view of FIG. 98A.
DETAILED DESCRIPTION
[0116] FIGS. 79-98B, with further reference to FIGS. 1-78,
illustrate an example method for removing a well string 172 from
within a wellbore 14 at a well site 12. In the illustrated example,
well site 12 includes a pumpjack 174 with a walking beam 34 and a
horse head 176. Pumpjack 174 is used for actuating a reciprocating
downhole pump. Wellbore 14 defines a longitudinal centerline 84.
Well string 172 when assembled comprises a plurality of shafts 180
interconnected end-to-end, wherein the plurality of shafts 180
includes at least an upper shaft 182 having an upper shaft weight,
a lower shaft 184 having a lower shaft weight, and a remaining well
string 186 below lower shaft 184. The term, "shaft" means any solid
or hollow elongate member used within a wellbore. Examples of
shafts include, but are not limited to, sucker rods and tubing. In
some examples, upper shaft 182 comprises a plurality of
interconnected shaft segments (e.g., two or three). In some
examples, upper shaft 182 is a single shaft segment. The same is
true for lower shaft 184.
[0117] Upper shaft 182 and lower shaft 184 can be anywhere along
the full length of the total well string 172. In some examples,
shafts 182 and 184 are near the top of well string 172. In some
examples, shafts 182 and 184 are near the bottom of well string
172. In some examples, shafts 182 and 184 are at some intermediate
elevation along the length of well string 172. The described method
for removing well string 172 will explicitly cover the removal of
two example shafts 182 and 184 and thus also cover the method for
transitioning between the removal of two shafts. The method as
described with reference to shafts 182 and 184 also applies to
other shafts of well string 172.
[0118] The method involves driving a workover vehicle 10 to well
site 12. Workover vehicle 10, in some examples, comprises a mast
20, an upper robot 90, a lower robot 36, an upper trolley mechanism
98, and a main trolley 156 carrying an elevator head 106. Mast 20
includes a trolley track system 88 and a transfer track system 86
that are parallel to each other. In some examples, trolley track
system 88 is one pair of continuous rails. In some examples,
trolley track system 88 comprises an upper set of tracks for upper
trolley mechanism 98 and a lower set of tracks for main trolley
156. In some examples, transfer track system 86 is one pair of
continuous rails. In some examples, transfer track system 86
comprises an upper set of tracks for upper robot 90 and a lower set
of tracks for lower robot 36.
[0119] Upper robot 90 comprises an upper carriage 120, an upper
shuttle 122 and an articulated upper arm assembly 158. Upper
carriage 120 travels vertically along transfer track system 86, as
indicated by arrow 198 in FIG. 82A, thus arrow 198 illustrates
upper robot 90 selectively ascending and descending along transfer
track system 86. Upper shuttle 122 travels along horizontal tracks
on upper carriage 120, as indicated by arrows 160 in FIG. 82B.
Upper arm assembly 158 travels along horizontal tracks on upper
shuttle 122, as indicated by arrows 162 in FIG. 82B. The term,
"robot" and derivatives thereof means any computer or
microprocessor controlled mechanism for moving a part (e.g., a
shaft such as a sucker rod or tubing) in multiple dimensions or
directions simultaneously or sequentially.
[0120] Likewise, lower robot 36 comprises a lower carriage 121, a
lower shuttle 123 and an articulated lower arm assembly 164. Lower
carriage 121 travels vertically along transfer track system 86, as
indicated by arrow 200 in FIG. 82A, thus arrow 200 illustrates
lower robot 36 selectively ascending and descending along transfer
track system 86. Lower shuttle 123 travels along horizontal tracks
on lower carriage 121, as indicated by arrows 166 in FIG. 82B.
Lower arm assembly 164 travels along horizontal tracks on lower
shuttle 123, as indicated by arrows 168 in FIG. 82B. The various
components of robots 36 and 90 are capable of moving independently
and in unison, depending on the need. Arrow 210 of FIG. 83A, for
instance, shows lower carriage 121 descending while upper carriage
120 is stationary to vary a vertical separation distance 212
between robots 36 and 90, thus arrow 210 illustrates varying
vertical separation distance 212 between upper robot 90 and lower
robot 36 as a result of lower robot 36 traveling relative to upper
robot 90.
[0121] After driving vehicle 10 to well site 12, a mast 20 of
vehicle 10 is pivotally raised at well bore 14, as indicated by
arrow 188 of FIG. 80. To provide working clearance 48 (FIG. 82A)
with adjacent pumpjack 174, horse head 176 plus sometimes walking
beam 34 are removed from pumpjack 174, as indicated by arrows 190
and 192 of FIG. 80. FIG. 81, for instance, shows an example where
horse head 176 is removed while walking beam 34 is left in
place.
[0122] In some examples, removing well string 172 involves various
actions, which are illustrated in the drawings but not necessarily
performed in the following order. Arrow 170 of FIG. 79 represents
driving workover vehicle 10 to well site 12, and FIGS. 80, 81 and
82A illustrate leaving at least a portion 174' of pumpjack 174
intact at well site 12. Arrow 170 and FIGS. 79, 80, 81 and 82A
represent parking workover vehicle 10 at well site 12 such that
longitudinal centerline 84 is interposed between workover vehicle
10 and intact portion 174' of pumpjack 174. An imaginary vector
112a' pointing horizontally from intact pumpjack portion 174',
passing through longitudinal centerline 84 toward workover vehicle
10 defines a forward direction, and an imaginary horizontal line
112b perpendicular to forward direction 112a' defines a lateral
direction.
[0123] FIGS. 82A and 82B show a wellhead slip 110 clamping onto
upper shaft 182 and supporting most of the weight of upper shaft
182, lower shaft 184 plus the weight of the remaining well string
186. In some examples, wellhead slip 110 comprises a series of
wedges circumferentially distributed around well string 172. In
some examples, the wedges are selectively clamped (e.g., FIG. 82A)
and released (e.g., FIG. 84A) by air-over-hydraulic actuation under
command of a controller 129 (e.g., computer, programmable logic
controller, etc.).
[0124] In some examples, controller 129 controls the movement and
timing coordination of generally all of the working components
associated with workover vehicle 10. In some examples, controller
129 controls the movement and timing coordination of less than all
of the working components associated with workover vehicle 10.
Examples of such working components include, but are not limited
to, tongs mechanism 132, main trolley 156, elevator head 106, lower
robot 36, upper robot 90, upper trolley mechanism 98, various
sensors, encoders, motors, piston/cylinders, pumps, hydraulic
valves, actuators, pneumatic valves, etc. In some examples, the
movement of the various working components is driven by available
means examples of which include, but are not limited to,
piston/cylinders, electric motors, hydraulic motors, pneumatic
motors, chain and sprockets, etc.
[0125] While wellhead slip 110 is supporting the weight of well
string 172, controller 4 commands main trolley 156 to travel upward
(arrow 194 of FIG. 82A) along trolley track system 88 until
elevator head 106 captures an upper end 196 of upper shaft 182 as
shown in FIGS. 83A and 83B. In some examples, upper end 196 is a
coupling or collar with internal threads for joining two shafts
end-to-end. FIGS. 86A and 86B show the jaws of elevator head 106
retracted and open, and FIGS. 83A and 83B show the jaws of elevator
head 106 extended and closed for capturing upper shaft 182.
Elevator head 106 is schematically illustrated to represent any
device for engaging and lifting a shaft (e.g., shaft 182 and 184).
In some examples, elevator head 106 includes jaws for selectively
engaging and releasing the upper end of a shaft. In some examples,
such jaws clamp onto and capture the shaft or a collar thereon. In
some examples, elevator jaws do not clamp onto the shaft or collar
thereon but instead hook onto or otherwise capture the upper end of
the shaft. Examples of non-clamping elevator jaws include, but are
not limited to, a U-shaped holder, latch, hook, fork, yoke, clevis,
etc. In some examples, elevator head 106 selectively extends and
retracts (in direction 112a) relative to main trolley 156.
[0126] Referring to FIGS. 83A and 83B, arrows 214 represent
wellhead slip 110 releasing upper shaft 182. Arrow 216 represents
transferring most of the upper shaft's weight and the lower shaft's
weight from wellhead slip 110 to elevator head 106. Arrow 216 of
FIGS. 83A and 83B and arrow 218 of FIGS. 84A and 84B represent main
trolley 156 traveling upward at a first peak velocity along trolley
track system 88, thereby raising well string 172 and lifting upper
shaft 182 out from within well bore 14. FIGS. 84A and 84B also show
that in some examples articulated upper arm assembly 158 and
articulated lower arm assembly 164 translate laterally closer to
centerline 84, as indicated by arrows 224 and 226.
[0127] To determine when to stop lifting well string 172 and begin
the operations shown in FIGS. 85A, 85B, 86A, 86B, 92A, 92B, 93A and
93B, some examples of workover vehicle 10 include a coupling sensor
77 (see FIGS. 82A and 82B) for sensing when a well string joint is
at a predetermined desired elevation. Sensor 77 enables the
automation of the well string removal method without the necessity
of manual intervention between each cycle (one cycle being the
removal of one well string shaft). In some examples, joint sensor
77 is a non-contact proximity sensor (e.g., Hall Effect, optical
detection, ultrasonic detection, laser, etc.), that provides a
signal to controller 129 upon sensing the proximity of an
enlarged-diameter section of well string 172, wherein such an
enlarged-diameter section is evidence of a joint. The step of
sensing a joint (first joint, second joint, etc.) is at a
predetermined desired elevation is illustrated in FIGS. 61B and 63A
by way of the encircled action labeled, "Sensor detects collar:
stop."
[0128] Referring to FIGS. 85A and 85B, arrows 220 represent
wellhead slip 110 clamping onto lower shaft 184. Arrow 222
represents main trolley 156 momentarily lowering well string 172
while well head slip 110 is clamping onto lower shaft 184. During
the well string's relatively short perceptible descent (e.g., about
4 inches or even as little as a fraction of an inch) the wedges of
wellhead slip 110 become tightly wedged against lower shaft 184.
The wedges becoming sufficiently tight results in wellhead slip 110
holding lower shaft 184 at a substantially constant elevation for a
first period, as shown in FIGS. 86A and 86B.
[0129] After briefly lowering well string 172 and during the first
period, elevator head 106 releases upper shaft 182, thereby
transferring most of the upper shaft's weight and the lower shaft's
weight from elevator head 106 to wellhead slip 110, as illustrated
by arrows 222 and 228 of FIGS. 85A, 85B, 86A and 86B and
additionally illustrated by elevator head 106 being shown retracted
in forward direction 112a' (FIG. 86A) and being shown open (FIG.
86B) while wellhead slip 110 is shown clamped tightly against lower
shaft 184. To help stabilize the upper end of upper shaft 182,
upper trolley mechanism 98 (which is above elevator head 106)
travels downward (arrow 230 of FIGS. 85A and 85B) along trolley
track system 88 to engage upper shaft 182, as shown in FIGS. 86A
and 86B.
[0130] Arrow 232 of FIG. 85A represents tongs mechanism 132
extending, and arrow 234 of FIG. 86A represents tongs mechanism 132
unscrewing a first joint 236 connecting upper shaft 182 to lower
shaft 184. Tongs mechanism 132 is schematically illustrated to
represent any powered tool suitable for unscrewing joints, collars
or couplings of a well string 172. In some examples, tongs
mechanism 132 includes an actuator (e.g., a hydraulic cylinder) for
selectively extending (arrow 232) and retracting (arrow 246)
relative to centerline 84.
[0131] In some examples, to save overall cycle time, elevator head
106 descends while tongs 132 is unscrewing joint 236. Arrow 228
represents main trolley 156 lowering elevator head 106 while lower
shaft 184 is at a substantially constant elevation and while tongs
mechanism 132 is unscrewing joint 236. To further save cycle time,
in some examples, robots 36 and/or 90 are repositioned or are
traveling while main trolley 156 is raising or lowering elevator
head 106. FIG. 85B, for example, shows arrows 222 and 224 that when
such movement occurs simultaneously, arrows 222 and 224 illustrate
main trolley 156 lowering elevator head 106 while the robotic
system is moving end effectors 92 and/or 96 between shaft storage
area 73 and longitudinal centerline 84. In some examples, robots 36
and/or 90 are repositioned or are traveling while tongs mechanism
132 is unscrewing joint 236.
[0132] After unscrewing first joint 236, after end effectors 92
and/or 96 gripping upper shaft 182, and after upper trolley
mechanism 98 disengages 238 upper shaft 182, the robotic system
(i.e., robots 36 and/or 90) transfers upper shaft 182 from
longitudinal centerline 84 of well bore 14 to a shaft storage area
73 that is horizontally spaced apart from centerline 84, wherein
the robotic system transferring upper shaft 182 from centerline 84
to shaft storage area 73 involves moving upper shaft 182 in
translation in forward direction 112a' and lateral direction 112b.
Such translation allows the robotic system to avoid the danger and
high rotational inertia associated with pivoting or swinging
relatively long and heavy shafts. Examples of shaft storage area 73
include, but are not limited to, tubing storage rack 72 and rod
storage rack 74. FIG. 87A shows articulated arm assemblies 158 and
164 extending and end effectors 92 and 96 gripping upper shaft 182
while upper trolley mechanism 98 is above end effector 92 and/or 96
and while elevator head 106 is below end effector 92 and/or 96.
Arrows 256 of FIG. 87A represent robots 36 and 90 selectively
engaging and releasing upper shaft 182 via the robot's end
effectors 92 and 96.
[0133] In transferring upper shaft 182 from centerline 84 to shaft
storage area 73, arrow 246 represents tongs 132 retracting to
provide clearance for main trolley 156 to descend (arrow 248) below
tongs 132 and to provide some clearance for upper shaft 182 to
travel to shaft storage area 73. Arrow 240 represents arm
assemblies 158 and 164 retracting, whereby shaft 182 translates in
a rearward direction (opposite to forward direction 112a') for
creating clearance during subsequent lateral translation. Arrow 242
represents end effectors 92 and 96 translating (e.g., via relative
lateral movement between arm 158 and upper shuttle 122 and/or via
relative lateral movement between upper shuttle 122 and upper
carriage 120), whereby shaft 182 translates in lateral direction
112b toward shaft storage area 73. Arrow 244 represents arm
assemblies 158 and 164 extending, whereby shaft 182 translates from
its position shown in FIG. 88A to its position shown in FIG. 89A.
Arrows 250 and 252 represent end effectors 92 and 96 releasing
upper shaft 182 at shaft storage area 73.
[0134] Referring to FIGS. 90A, 90B, 91A and 91B, arrow 254
represents robotic arms 158 and 164 retracting after leaving upper
shaft 182 at shaft storage area 73. At this point, after having
removed upper shaft 182, workover vehicle 10 prepares for removing
lower shaft 184 from the remaining well string 172. In FIGS. 90A
and 90B, arrow 256 represents elevator head 106 capturing the upper
end of lower shaft 184. In FIGS. 91A and 91B, arrows 214 represent
wellhead slip 110 releasing lower shaft 184, thereby transferring
most of the lower shaft's weight to elevator head 106. Arrow 218'
of FIGS. 91A and 91B represents main trolley 156 traveling upward
at a second peak velocity along trolley track system 88, thereby
lifting the remaining shaft string 186 and lifting lower shaft 184
out from within well bore 14. To reduce well string disassembly
time by taking advantage of the well string's diminishing weight as
additional shafts are removed, in some examples, said second peak
velocity (see arrow 218' of FIG. 91A) is greater than said first
peak velocity (see arrow 218 of FIG. 84A).
[0135] In FIGS. 92A and 92B, arrows 220' represents wellhead slip
110 clamping onto the remaining shaft string 186. Arrow 222'
represents main trolley 156 momentarily lowering lower shaft 184
and the remaining shaft string 186 while wellhead slip 110 is
clamping onto the remaining shaft string 186. During the well
string's relatively short descent, e.g., about 4 inches, the wedges
of wellhead slip 110 become tightly wedged against the remaining
shaft string 186. The wedges becoming sufficiently tight results in
wellhead slip 110 holding the remaining shaft string 186 at a
substantially fixed elevation for a second period, as shown in
FIGS. 93A and 93B.
[0136] After briefly lowering well string 172 and during the second
period, elevator head 106 releases lower shaft 184, thereby
transferring most of the lower shaft's weight and the weight of the
remaining shaft string 186 from elevator head 106 to wellhead slip
110, as illustrated by arrows 222' and 228' of FIGS. 92A, 92B, 93A
and 93B and additionally illustrated by elevator head 106 being
shown retracted in forward direction 112a' (FIG. 93A) and being
shown open (FIG. 93B) while wellhead slip 110 is shown clamped
tightly against the remaining shaft string 186. To help stabilize
the upper end of lower shaft 182, upper trolley mechanism 98 (which
is above elevator head 106) travels downward (arrow 230 of FIGS.
92A and 92B) along trolley track system 88 to engage the upper end
of lower shaft 184, as shown in FIGS. 93A and 93B.
[0137] Arrow 232 of FIG. 92A represents tongs mechanism 132
extending, and arrow 234 of FIG. 93A represents tongs mechanism 132
unscrewing a second joint 236' connecting lower shaft 184 to the
remaining shaft string 186. In some examples, to save overall cycle
time, elevator head 106 descends while tongs 132 is unscrewing
joint 236'. Arrow 228' represents main trolley 156 lowering
elevator head 106 while the remaining shaft string 186 is at a
substantially constant elevation and while tongs mechanism 132 is
unscrewing joint 236'.
[0138] After unscrewing second joint 236', after end effectors 92
and/or 96 gripping lower shaft 184, and after upper trolley
mechanism 98 disengages 238 lower shaft 184, the robotic system
(i.e., robots 36 and/or 90) transfers lower shaft 184 from
longitudinal centerline 84 of well bore 14 to shaft storage area
73, wherein the robotic system transferring lower shaft 184 from
centerline 84 to shaft storage area 73 involves moving lower shaft
184 in translation in forward direction 112a' and lateral direction
112b. FIG. 94A shows articulated arm assemblies 158 and 164
extending and end effectors 92 and 96 gripping lower shaft 182
while upper trolley mechanism 98 is above end effector 92 and/or 96
and while elevator head 106 is below end effector 92 and/or 96.
[0139] In transferring lower shaft 184 from centerline 84 to shaft
storage area 73, arrow 246 (FIG. 94A) represents tongs 132
retracting to provide clearance for main trolley 156 to descend
(arrow 248) below tongs 132 and to provide some clearance for lower
shaft 184 to travel to shaft storage area 73. Arrow 240 represents
arm assemblies 158 and 164 retracting, whereby shaft 184 translates
in a rearward direction (opposite to forward direction 112a') for
creating clearance during subsequent lateral translation. Arrow 242
(FIG. 94B) represents end effectors 92 and 96 translating (e.g.,
via relative lateral movement between arm 158 and upper shuttle 122
and/or via relative lateral movement between upper shuttle 122 and
upper carriage 120), whereby shaft 184 translates in lateral
direction 112b toward shaft storage area 73. Arrow 244 (FIG. 95A)
represents arm assemblies 158 and 164 extending, whereby shaft 184
translates from its position shown in FIG. 95A to its position
shown in FIG. 96A. Arrows 250' and 252' (FIG. 96A) represent end
effectors 92 and 96 releasing lower shaft 184 at shaft storage area
73. Referring to FIGS. 97A, 97B, 98A and 98B, arrow 254 represents
robotic arms 158 and 164 retracting after leaving lower shaft 184
at shaft storage area 73.
[0140] FIGS. 1-16, 25, 28, 32, 35, 38, 43, 44, 58, 59, 67 and 68,
82A and 82B with further reference to the remaining figures within
the range of FIGS. 1-98B, illustrate an example where mast 20 of
workover vehicle 10 is designed and configurable to have a certain
spatial relationship with tubing storage rack 72, rod storage rack
74, upper robot 90, lower robot 36, upper trolley mechanism 98,
main trolley 156, robotic jib 102 and/or the wellbore's
longitudinal centerline 84. Wellbore 14 typically contains both a
well string of tubing and a well string of sucker rods. Since
tubing generally weighs significantly more than sucker rods, some
examples of workover vehicle 10 have tubing storage rack 72
situated inside of mast 20 for stability. For further stability,
mast 20 in its raised position is substantially vertical as opposed
to being tilted. Rod storage rack 74, in some examples, is mounted
outside of mast 20 so as not to consume the limited storage space
inside of mast 20.
[0141] In some examples, mast 20 is movable selectively to a raised
position (FIGS. 1, 4-7, 9 and 11-16) and a lowered position (FIGS.
2, 3, 8 and 10) such that mast 20 is vertically elongate in the
raised position and horizontally elongate in the lowered position.
In some examples, mast 20 comprises a plurality of outer corner
posts 68 (e.g., structural angles, tracks, channels, rectangular
tubing, and various fabricated combinations thereof, etc.) that are
vertically elongate when mast 20 is in the raised position. In some
examples, outer corner posts 68 can be considered as the weight
bearing derrick legs of mast 20 in that each post 68, extending
along most of the mast's vertical length, supports or transmits at
least ten percent of the mast's total weight. Outriggers 26 are not
considered as post 68 or derrick legs. The plurality of outer
corner posts 68 are distributed in an arrangement that defines a
girth 258 of mast 20, wherein the mast's girth 258 delineates or
encircles a horizontal footprint 260 of mast 20 in the mast's
raised position (horizontal footprint 260 is generally vertical
when mast 20 is tilted down to its lowered position). In other
words, girth 258 is the traced distance around the outer periphery
of mast 20, and footprint 260 is a horizontal cross-sectional area
within the mast's girth 258 or outer periphery, and so the mast's
footprint 260 within girth 258 is not necessarily planted on the
ground. Rather, the mast's footprint 260 can be at any elevation
along the length of mast 20. In some examples, the outer periphery
or girth 258 is the smallest, vertically elongate imaginary
rectangular tube encompassing collectively all of the mast's corner
posts 68.
[0142] In some examples, tubing storage rack 72 is attached to mast
20 and has a plurality of tube-receiving receptacles 262 (e.g.,
slots) that are horizontally spaced apart when mast 20 is in the
raised position. In some examples, shaft segments of tubing removed
from within wellbore 14 have a diametrically enlarged upper
coupling that enables the tubing shaft segments to hang suspended
from rack 72, as the coupling's diameter is larger than the width
of the tube-receiving receptacles 262. In addition or
alternatively, some examples of tubing storage rack 72 include a
floor upon which the lower end of tubing shaft segments can rest.
When mast 20 is in its raised position, most of the tubing storage
rack 72 is within the mast's horizontal footprint 260 to keep the
weight of stored tubing centrally balanced within the mast.
[0143] In some examples, rod storage rack 74 is attached to mast 20
at a pivotal joint 264 (FIG. 4). Rod storage rack 74, in some
examples, has a plurality of rod-receiving receptacles 266 (e.g.,
slots) that are horizontally spaced apart when mast 20 is in the
raised position while rod storage rack 74 is in its extended
operative configuration (FIGS. 4-7, 9, 12 and 14-16). In some
examples, shaft segments of sucker rods removed from within
wellbore 14 have a diametrically enlarged upper coupling or head
that enables the sucker rod shaft segments to hang suspended from
rack 74, as diameter of the sucker rod's coupling or head is larger
than the width of the rod-receiving receptacles 266. In addition or
alternatively, some examples of rod storage rack 74 include a floor
upon which the lower end of sucker rod shaft segments can rest.
When mast 20 is in its raised position and rod storage rack 74 is
in its operative configuration, most of rod storage rack 74 is
beyond the mast's horizontal footprint 260.
[0144] To minimize the total width of vehicle 10 as vehicle 10
travels along a road, rod storage rack 74 is pivoted or otherwise
moved from it operative configuration to a transport configuration.
In some examples, rod storage rack 74 lies along a plane 268 that
is closer to being perpendicular to longitudinal centerline of mast
104 when rod storage rack 74 is in the operative configuration (as
FIG. 4 indicates by reference numeral 74) than when rod storage
rack 74 is in the transport configuration (as FIG. 4 indicates by
reference numeral 74'). In some examples, rod storage rack 74 is
substantially perpendicular to the mast's longitudinal centerline
104 when rod storage rack 74 is in the operative configuration
while mast 20 is in the raised position, and rod storage rack 74 is
substantially parallel to longitudinal centerline 104 when rod
storage rack 74 is in the transport configuration while mast 20 is
in the lowered position.
[0145] To provide a weather and dust shield that helps protect the
upper ends of shaft segments stored in rod storage rack 74 and/or
tubing storage rack 72, some examples of workover vehicle 10
include a rack cover 78 (FIG. 4). To monitor the condition of the
upper ends of shaft segments stored in rod storage rack 74 and/or
tubing storage rack 72, some examples of workover vehicle 10
include video camera 80 (FIG. 4).
[0146] In some cases, it can be desirable to transfer a shaft
(e.g., a sucker rod or tubing) between a lay-down storage area 76
and a vertical area 77 proximate mast 20, as shown in FIG. 6. For
instance, to prevent a damaged shaft from being reinstalled within
wellbore 14, the shaft might be transferred to lay-down storage
area 76 so that the shaft can be repaired or discarded. To add a
new or replacement shaft, such a shaft can be transferred from
lay-down storage area 76 to vertical area 77 proximate mast 20. In
some examples, lay-down storage area 76 has an upward facing
surface 79 (e.g., platform, table, rack, shelf, blocks, ground,
etc.) adapted to support in a horizontally elongate orientation one
or more sucker rods and/or tubing.
[0147] Some examples of workover vehicle 10 include robotic jib 102
pivotally attached to mast 20, wherein robotic jib 102 has at least
one end effector 270 (FIG. 6) that robotic jib 102 moves between
lay-down storage area 76 and vertical area 77 proximate mast 20.
The term, "end effector" (e.g., end effector 270, 92 or 96) as used
in this patent refers to a mechanism for selectively supporting and
releasing a shaft, such as a section of tubing or a sucker rod,
wherein the mechanism is attached to a robot (e.g., robot 36, robot
90, robotic jib 102). To facilitate workover vehicle 10 being
driven down a road, some examples of robotic jib 102 are movable
relative to mast 20 selectively to a stored position (FIGS. 3, 4,
7, 8, 13 and 15) and a fully deployed position (FIGS. 6, 12 and
16). In the stored position, at least some of robotic jib 102
extends into horizontal footprint 260. In the fully deployed
position, most of robotic jib 102 extends beyond horizontal
footprint 260.
[0148] To raise and lower well string 172 and to assist in
transferring sucker rods and/or tubing between the wellbore's
longitudinal centerline 84 and a chosen storage location (e.g.,
tubing storage rack 72, rod storage rack 74 or lay-down storage
area 76), some examples of workover vehicle 10 comprise transfer
track system 86 borne by mast 20 and lying along an imaginary plane
94, upper robot 90 (including upper end effector 92) mounted for
vertical travel along transfer track system 86, and lower robot 36
(including lower end effector 96) mounted for vertical travel along
transfer track system 86. Lower robot 36 is below upper robot
90.
[0149] Robots 90 and 36 use their respective end effectors 92 and
96 to grasp and/or stabilize upper and lower ends of a sucker rod
or tubing shaft as robots 90 and 36 transfer the shaft to or from
the wellbore's longitudinal centerline 84. Upon transferring a
shaft from the wellbore's centerline 84, end effectors 92 and 96
move in unison horizontally from centerline 84, through imaginary
plane 272, and into the mast's horizontal footprint 260. Upon
transferring a shaft to the wellbore's centerline 84, end effectors
92 and 96 move in unison horizontally from within the mast's
horizontal footprint 260, through imaginary plane 272, beyond the
mast's horizontal footprint 260, and to the wellbore's centerline
84. Such an arrangement overcomes the space restraints of mast 20,
the wellbore's centerline 84 and the proximity of pumpjack 174. In
some examples, for instance, a portion of upper robot 90 (or lower
robot 36) extends beyond the mast's horizontal footprint 260, and
the wellbore's centerline 84 is interposed between that portion of
the robot and the mast's horizontal footprint 260.
[0150] Some examples of workover vehicle 10 further comprise
trolley track system 88 borne by mast 20, upper trolley mechanism
98 mounted for vertical travel along trolley track system 88, and a
main trolley 156 mounted for vertical travel along trolley track
system 88. Main trolley 156 is below upper trolley mechanism 98.
Main trolley 156 and upper trolley mechanism 98 are used for
raising, lowering and/or stabilizing well string 172 or sections
thereof. In some examples, since the travel movement of trolleys 98
and 156 is primarily vertical, and robots 36 and 90 move both
vertically and horizontally, transfer track system 86 is wider than
trolley track system 88. FIGS. 5, 25, 59 and 82B show transfer
track system 86 having a first horizontal span 276 that is greater
than a second horizontal span 274 of trolley track system 88.
[0151] More specifically, additionally and/or alternatively, some
example embodiments are described under the following underlined
subtitles (1)-(24):
[0152] (1) X,Y Frame Translation after Deploying Outriggers and
Leveling
[0153] Some example embodiments include a workover method involving
the use of a workover vehicle 10 at a well site 12, wherein the
well site comprises a wellbore 14, and the workover vehicle
comprises a sub frame 16 on vehicle chassis 18 with a mast 20
attached to the sub frame, the workover method comprising:
[0154] parking 22 the workover vehicle at the well site;
[0155] deploying 24 a plurality of outriggers 26 of the workover
vehicle;
[0156] leveling 28 the sub frame;
[0157] horizontally shifting 30 the sub frame relative to the
chassis and the wellbore;
[0158] pivoting the mast upward; and further comprising an optical
sensor 32 (e.g., a camera or laser) assisting in aligning a
reference point of the sub frame to the wellbore.
[0159] (2) Lower Robot Avoids Walking Beam as Mast is Raised
[0160] Some example embodiments include a workover method involving
a workover vehicle 10, a wellbore 14, and a walking beam 34
associated with the wellbore, wherein the workover vehicle
comprises a mast 20 and a robot 36, the workover method
comprising:
[0161] positioning the workover vehicle in proximity with the
wellbore and the walking beam;
[0162] positioning the robot at a predetermined safe location on
the mast;
[0163] pivoting 40 the mast to an upright orientation at a location
38 proximate the walking beam, wherein the robot at the
predetermined safe location clears the walking beam as the mast
pivots to the upright orientation; and
[0164] moving 42 the robot from the predetermined safe location to
an operative location 44 on the mast.
[0165] (3) Detect Interference with Walking Beam
[0166] Some example embodiments include a workover system for use
at a wellbore 14 associated with a walking beam 34, the workover
system comprising:
[0167] a workover vehicle 10;
[0168] a mast 20 extending upright from the workover vehicle;
[0169] a robot 36 mounted for vertical movement along the mast;
and
[0170] a sensor 46 (e.g., proximity sensor, limit switch,
photoelectric eye, etc.) establishing and/or determining whether a
predetermined minimum clearance 48 exists between the robot and the
walking beam or the portion 174' of pumpjack 174 that is left
intact at well site 12.
[0171] (4) Tilting Oil Tank
[0172] Some example embodiments include a workover system,
comprising:
[0173] a vehicle bed 50;
[0174] a mast 20 mounted to the vehicle bed, the mast being
moveable selectively to a lowered position and a raised
position;
[0175] a main trolley 52 mounted for vertical movement along the
mast when the mast is in the raised position, the main trolley
being moveable from a descended position to an elevated
position;
[0176] a hydraulic tank 54 mounted to the vehicle bed, the
hydraulic tank being moveable selectively between a transport
position and an operative position, the hydraulic tank defining a
tank outlet 56, the tank outlet being at a hydraulic pressure that
is greater when the hydraulic tank is in the operative position
than when the hydraulic tank is in the transport position;
[0177] a hydraulic pump 58 mounted to the vehicle bed, the
hydraulic pump defining a suction inlet 60 connected in fluid
communication with the tank outlet; and
[0178] a hydraulic drive unit 62 connected to move the lower
trolley from the descended position to the elevated position,
wherein the hydraulic tank contains more hydraulic fluid when the
hydraulic tank is in the transport position than when the hydraulic
tank is in the operative position.
[0179] (5) Mast Layout
[0180] Some example embodiments include a workover system for
handling at least one of a plurality of tubes 64 and a plurality of
rods 66 at a well site 12 that includes a wellbore 14, the workover
system comprising:
[0181] a mast 20 comprising a plurality of outer corner posts 68
distributed along an outer periphery 70 of the mast, the plurality
of outer corner posts defining a footprint of the mast;
[0182] a tubing storage rack 72 for holding the plurality of tubes
in a generally upright orientation, the tubing storage rack being
mostly within the footprint; and
[0183] a rod storage rack 74 for holding the plurality of rods in a
generally upright orientation, the rod storage rack being mostly
beyond the footprint, and further comprising a lay-down storage
area 76 for storing at least one of a first portion of the
plurality of rods and a second portion of the plurality of tubes,
the lay-down storage area being disposed mostly beyond the
footprint, and further comprising a rack cover 78 disposed above at
least one of the tubing storage rack and the rod storage rack, and
further comprising a camera 80 disposed above at least one of the
tubing storage rack and the rod storage rack, and further
comprising a robot 36 attached to the mast with a portion 82 of the
robot extending beyond the footprint, the wellbore defining a
longitudinal centerline 84 that is interposed between the footprint
of the mast and the portion of the robot, and further
comprising:
[0184] a wider track 86 borne by the mast, the wider track lying
along an imaginary plane 94;
[0185] a narrower track 88 borne by the mast;
[0186] an upper robot 90 mounted for vertical travel along the
wider track, the upper robot having an upper end effector 92
moveable selectively to within the footprint and beyond the
footprint, the upper end effector being moveable to pass through
the imaginary plane;
[0187] a lower robot 36 mounted for vertical travel along the wider
track, the lower robot having a lower end effector 96 moveable
selectively to within the footprint and beyond the footprint, the
lower end effector being moveable to pass through the imaginary
plane;
[0188] an upper trolley 98 mounted for vertical movement along the
narrower track;
[0189] a lower main trolley 100 mounted for vertical movement along
the narrower track;
[0190] and
[0191] a robotic jib 102 pivotally attached the mast.
[0192] (6) Fold-Up Racks for Transport
[0193] Some example embodiments include a workover system
comprising:
[0194] a workover vehicle 10 being selectively configurable to a
operative configuration and a transport configuration;
[0195] a mast 20 attached to the workover vehicle, the mast
defining a longitudinal centerline 104, the mast being
substantially vertical in the operative configuration, the mast
being laid down in the transport configuration; and
[0196] a rod storage rack 74/74' pivotally attached to the mast,
the rod storage rack 74 being substantially perpendicular to the
longitudinal centerline when the workover vehicle is in the
operative configuration, the rod storage rack 74' being
substantially parallel to the longitudinal centerline when the
workover vehicle is in the transport configuration.
[0197] (7) Robotic Jib--Deployed and Transport Positions
[0198] Some example embodiments include a workover system,
comprising:
[0199] a workover vehicle 10 being selectively configurable to an
operative configuration and a transport configuration;
[0200] a mast 20 attached to the workover vehicle, the mast
comprising a plurality of outer corner posts 68 distributed along
an outer periphery of the mast, the plurality of outer corner posts
68 defining a footprint of the mast, the mast being substantially
vertical in a raised position when the workover vehicle is in the
operative configuration, the mast being laid down in a lowered
position when the workover vehicle is in the transport
configuration; and
[0201] a robotic jib 102 attached to the mast, the robot jib being
in a stored position and disposed mostly within the footprint when
the workover vehicle is in the transport configuration, the robot
jib being in a partially or fully deployed position mostly beyond
the footprint when the workover vehicle is in the operative
configuration.
[0202] (8) Set and Update Overload Weight Limit & Minimal Oil
Discharge Pressure
[0203] Some example embodiments include a workover method
comprising:
[0204] determining a first anticipated maximum load for a well
string;
[0205] during a first period, shortening the well string to create
a shorter well string;
[0206] determining a second anticipated maximum load for the
shorter well string;
[0207] during a second period, shortening the shorter well string
to create an even shorter well string;
[0208] establishing a first oil pressure limit based on the first
anticipated maximum load for the well string;
[0209] establishing a second oil pressure limit based on the second
anticipated maximum load for the shorter well string;
[0210] during the first and second period, discharging oil at a
discharge pressure that varies;
[0211] limiting the discharge pressure to the first oil pressure
limit during the first period; and
[0212] limiting the discharge pressure to the second oil pressure
limit during the second period, wherein the first oil pressure
limit is greater than the second oil pressure limit, wherein the
second oil pressure limit is less than a minimum discharge pressure
necessary to handle the first anticipated maximum load for the well
string, and further comprising:
[0213] establishing an upper maximum velocity limit (e.g., 6
ft/sec) for an elevator that is generally unloaded;
[0214] establishing a lower maximum velocity limit (e.g., 2 ft/sec)
for the elevator when the elevator is carrying a load; and
[0215] establishing a maximum acceleration limit (e.g., 0.1 g) for
the elevator.
[0216] (9) Log Snag Points POOH
[0217] Some example embodiments include a workover method
comprising:
[0218] supplying oil at a pressure that varies;
[0219] using the pressure as means for raising an elevator 106
connected to a well string 108;
[0220] monitoring an elevation of the elevator, wherein the
elevation increases while raising the elevator;
[0221] monitoring the pressure while raising the elevator;
[0222] if the pressure experiences a certain spike in pressure, a
controller noting the elevation at which the certain spike
occurred; and
[0223] determining a location within the wellbore based on the
elevation at which the certain spike occurred.
[0224] Some example embodiments include a workover method
comprising:
[0225] determining a first anticipated maximum load for a well
string;
[0226] during a first period, shortening the well string to create
a shorter well string;
[0227] determining a second anticipated maximum load for the
shorter well string;
[0228] during a second period, shortening the shorter well string
to create an even shorter well string;
[0229] establishing a first oil pressure limit based on the first
anticipated maximum load for the well string;
[0230] establishing a second oil pressure limit based on the second
anticipated maximum load for the shorter well string;
[0231] during the first and second period, discharging oil at a
discharge pressure that varies;
[0232] limiting the discharge pressure to the first oil pressure
limit during the first period; and
[0233] limiting the discharge pressure to the second oil pressure
limit during the second period, wherein the first oil pressure
limit is greater than the second oil pressure limit, wherein the
second oil pressure limit is less than a minimum discharge pressure
necessary to handle the first anticipated maximum load for the well
string.
[0234] (10) Detect RIH Stack-Out
[0235] Some example embodiments include a workover method for
handling a well string 108 through the use of an elevator 106
carried by a lower trolley 52 that travels along a mast 20, the
workover method comprising:
[0236] the elevator suspending the well string;
[0237] a sensor (e.g., an encoder) determining whether the elevator
is descending;
[0238] monitoring at least one of: cable tension, crown load strain
and hydraulic pressure;
[0239] identifying a notable decrease in at least one of: cable
tension, crown load strain and hydraulic pressure; and
[0240] determining a stack-out condition in the event of the
notable decrease occurring while the elevator is descending.
[0241] (11) Push/Pull Cable and Sheaves
[0242] Some example embodiments include a workover method for
handling at least one of a tubing string and a rod string, the
workover method involving the use of a workover vehicle 10, a mast
20 attached to the workover vehicle, a main trolley 52 attached to
the mast, an elevator 106 attached to the main trolley, a large
hydraulic cylinder 152, a small hydraulic cylinder 154, the
workover method comprising:
[0243] during a first period, suspending the tubing string and not
the rod string from the elevator;
[0244] while the tubing string is suspended from the elevator,
extending the large hydraulic cylinder and not the small hydraulic
cylinder to lift the elevator and the tubing string;
[0245] during a second period, suspending the rod string and not
the tubing string from the elevator; and
[0246] while the rod string is suspended from the elevator,
extending the large hydraulic cylinder and the small hydraulic
cylinder to lift the elevator and the rod string, and further
comprising:
[0247] during a third period, having the elevator be disengaged
from both the tubing string and the rod string; and
[0248] during the third period, retracting at least one of the
large hydraulic cylinder and the small hydraulic cylinder to
forcibly lower by hydraulic pressure the main trolley and the
elevator.
[0249] (12) Sense Slip and Elevator Weights to Detect Well String
Freefall
[0250] Some example embodiments include a workover method for
handling a well string 108 that under normal operating conditions
has a weight carried by at least one of a wellhead slip 110 and an
elevator 106, wherein the wellhead slip is at a wellhead 112 of a
wellbore 14, and the elevator is carried by a main trolley 52
mounted for vertical travel along a mast 20 at the well site 12,
the workover method comprising:
[0251] sensing a first weight carried by the wellhead slip;
[0252] sensing a second weight carried by the elevator; and
[0253] identifying a freefall hazard based on a sum of the first
weight and the second weight being less than a predetermined
minimum, wherein the predetermined minimum varies as a function of
a length of the well string.
[0254] (13) Upper Gripper Functions with Lost Hydraulic
Pressure
[0255] Some example embodiments include a workover system for
handling a separated section of a well string 108 at a well site 12
that includes a wellbore 14, the workover system comprising:
[0256] a workover vehicle 10;
[0257] a hydraulic power unit 62 supplying active hydraulic
pressure;
[0258] a hydraulic storage system 114 maintaining stored hydraulic
pressure;
[0259] a mast 20 extending upright from the workover vehicle;
[0260] a main trolley 52 mounted for vertical travel along the
mast;
[0261] an elevator 106 carried by the main trolley;
[0262] an upper robot 90 mounted for vertical travel along the
mast; and
[0263] an upper end effector 92 borne by the upper robot, the upper
end effector being mounted for two-dimensional horizontal travel
112a and 112b relative to the mast, the upper end effector having a
full grip mode, a backup grip mode and a release mode, the upper
end effector in the full grip mode engaging the separated section
under impetus of the active hydraulic pressure, the upper end
effector in the backup grip mode engaging the separated section
under impetus of the stored hydraulic pressure, the upper end
effector in the release mode disengaging the separated section,
wherein the hydraulic storage system includes a pilot-operated
check valve 116 and an accumulator 118, and further comprising a
less urgent backup pressure alarm and a more urgent low pressure
alarm.
[0264] (14) Independent Traveling Upper Robot, Lower Robot, Main
Trolley and Upper Trolley
[0265] Some example embodiments include a workover system for
handling a well string 108 at a well site 12 that includes a
wellbore 14, the workover system comprising:
[0266] a workover vehicle 10;
[0267] a mast 20 mounted to the workover vehicle;
[0268] an upper robot 90 mounted for vertical travel along the
mast;
[0269] a lower robot 36 mounted for vertical travel along the mast,
the lower robot being movable relative to the upper robot;
[0270] an upper trolley 98 mounted for vertical travel along the
mast, the upper trolley being movable relative to the upper robot
and the lower robot; and
[0271] a lower trolley 52 mounted for vertical travel along the
mast, the lower trolley being movable relative to the upper robot,
the lower robot and the upper trolley.
[0272] (15) Tube/Rod Gap and Dual Track Translation Provides Robots
with Greater Side Travel
[0273] Some example embodiments include a workover system for
handling a well string member 64 or 66, the workover system
comprising:
[0274] a workover vehicle 10;
[0275] a mast 20 attached to the workover vehicle;
[0276] a carriage 120 mounted for travel in a vertical direction
112c along the mast;
[0277] a shuttle 122 mounted to the carriage, the shuttle being
movable in a lateral direction relative to the carriage, the
lateral direction being substantially perpendicular to the vertical
direction;
[0278] an end effector 92 carried by the shuttle, the end effector
being movable in the lateral direction relative to the shuttle, the
end effector being further movable in an in-out direction 112a
relative to the shuttle, the in-out direction being substantially
perpendicular to the lateral direction and the vertical direction,
wherein the carriage has a maximum width 124 in the lateral
direction, the end effector having a maximum travel distance 125 in
the lateral direction, the maximum travel distance being greater
than the maximum width, wherein the shuttle and the carriage define
therebetween a passageway 126 for the well string member, the
passageway lying substantially perpendicular to the in-out
direction, the passageway extending a lateral distance in the
lateral direction, the lateral distance being greater than the
maximum width of the carriage.
[0279] (16) Robots can Pick from Rack or from Robotic Jib
[0280] Some example embodiments include a workover method for
handling a well string member 64 or 66, the workover method
involving the use of a workover vehicle 10, a mast 20, a storage
rack 74 attached to the mast, a robotic jib 102 attached to the
mast, an upper robot 90 attached to the mast wherein the upper
robot includes an end effector 92, the workover method
comprising:
[0281] pivoting the mast relative to the workover vehicle;
[0282] pivoting 128 the robotic jib relative to the mast;
[0283] moving the upper robot vertically along the mast; and
[0284] transferring the well string member selectively between: (a)
the end effector and the robotic jib, and (b) the end effector and
the storage rack.
[0285] (17) Sort Well String Members
[0286] Some example embodiments include a workover method for
handling a plurality of well string members 64 or 66 associated
with a wellbore 14, the plurality of well string members includes
at least one of a better well string member, a worse well string
member and a seriously flawed well string member, the workover
method involves the use of at least one of a workover vehicle 10, a
mast 20 attached to the workover vehicle, an elevator 106 mounted
for vertical travel along the mast, a robot 90 mounted for vertical
travel along the mast, a first storage area, a second storage area
and a third storage area, the workover method comprising:
[0287] during a first period, the elevator extracting the plurality
of well string members out from within the wellbore;
[0288] during the first period, electronically inspecting the
plurality of well string members;
[0289] generating a plurality of readings as a consequence of
electronically inspecting the plurality of well string members,
[0290] identifying the better well string member based on the
plurality of readings;
[0291] identifying the worse well string member based on the
plurality of readings;
[0292] the robot transferring the better well string member from
the elevator to the first storage area;
[0293] the robot transferring the worse well string member from the
elevator to the second storage area; and
[0294] during a second period, lowering at least some of the
plurality of well string members into the wellbore such that the
better well string member is below the worse well string member,
wherein the step of electronically inspecting the plurality of well
string member involves the use of at least one of an ultrasonic
sensor, Hall effect sensor, means for sensing a magnetic flux
field, and a camera, and further comprising automatically marking
(e.g., painting) at least one of the better well string member and
the worse well string member, and further comprising:
[0295] identifying the seriously flawed well string member based on
the plurality of readings; and
[0296] the robot transferring the seriously flawed well string
member from the elevator toward the third storage area.
[0297] (18) Sense Load on Well String Member to Detect Well String
Member Encountering Floor
[0298] Some example embodiments include a workover method for
handling a well string member 64 or 66, the workover method
involving at least one of a controller 129, a robot 90 with an end
effector 92, and a storage rack 72 with a floor 128,
comprising:
[0299] under command of the controller, the end effector lowering
the well string member into the storage rack;
[0300] sensing a weight carried by the end effector;
[0301] while sensing the weight carried by the end effector,
sensing an appreciable decrease in the weight as the end effector
lowers the well string member into the storage rack;
[0302] and
[0303] in response to sensing the appreciable decrease in the
weight, the controller determining that the well string member has
encountered the floor of the storage rack.
[0304] (19) Means for Detecting Upper End of Variable Length Tubing
During RIH
[0305] Some example embodiments include a workover method,
comprising:
[0306] storing the well tubing member 64 in a storage rack 72;
[0307] under command of the controller, the end effector mechanism
92 ascending at a higher speed toward the shoulder of the well
tubing member;
[0308] the end effector mechanism sensing the shoulder;
[0309] upon sensing the shoulder, the end effector mechanism
decelerating to a lower speed;
[0310] the end effector mechanism engaging the shoulder; and
[0311] the end effector lifting the well tubing member out from
within the storage rack.
[0312] (20) Sense Break-Out
[0313] Some example embodiments include a workover method for
unscrewing a tubing joint 130 and a rod joint 138, the workover
method involving at least one of a controller, a tongs mechanism
132, an upper trolley mechanism 98 above the tongs mechanism, a
first sensor 136 in communication with the controller, and a second
sensor 134 in communication with the controller, the workover
method comprising:
[0314] the tongs mechanism unscrewing the tubing joint;
[0315] while unscrewing the tubing joint, the first sensor sensing
an abrupt upward movement of the tongs mechanism;
[0316] in response to sensing the abrupt upward movement of the
tongs mechanism, the controller recognizing the tubing joint has
separated;
[0317] the upper trolley mechanism unscrewing the rod joint;
[0318] while unscrewing the rod joint, the second sensor sensing an
abrupt upward movement of the upper trolley mechanism; and
[0319] in response to sensing the abrupt upward movement of the
upper trolley mechanism, the controller recognizing the rod joint
has separated.
[0320] (21) Upper Trolley Screws/Unscrews Rods
[0321] Some example embodiments include a workover method for
unscrewing a tube 64 at a tubing joint 130 and a rod 66 at a rod
joint 138, the workover method involving at least one of a tongs
mechanism 132 and an upper trolley mechanism 98 above the tongs
mechanism, the workover method comprising:
[0322] the tongs mechanism unscrewing the tubing joint;
[0323] while unscrewing the tubing joint via the tongs mechanism,
the upper trolley mechanism stabilizing 140 an upper tube end 142
of the tube;
[0324] during a first period, the tongs mechanism partially
unscrewing the rod joint; and
[0325] during a second period following the first period, the upper
trolley mechanism finishing unscrewing 144 the rod joint, wherein
the upper trolley member includes a pinch valve for gripping and
turning the rod.
[0326] Some example embodiments include a workover method for
screwing together a tube 64 at a tubing joint 130 and a rod 66 at a
rod joint 138, the workover method involving at least one of a
tongs mechanism 132 and an upper trolley mechanism 98 above the
tongs mechanism, the workover method comprising:
[0327] the tongs mechanism screwing together the tubing joint;
[0328] while screwing together the tubing joint via the tongs
mechanism, the upper trolley mechanism stabilizing 140 an upper
tube end of the tube;
[0329] during a first period, the upper trolley mechanism partially
screwing 114 together the rod joint; and
[0330] during a second period following the first period, the tongs
mechanism finishing screwing together the rod joint.
[0331] (22) Brush-Clean Box End, Lube Pin End
[0332] Some example embodiments include a workover system for the
handling and treating a well string member 64 or 66 that includes
internal threads and external threads, the workover system being
operable at a wellbore 14 that defines a longitudinal centerline
84, the workover system comprising:
[0333] a workover vehicle having a storage rack area 72 or 74;
[0334] a robot system attached to the workover vehicle, the robot
system 36 and 90 transferring the well string member between the
storage rack area and the longitudinal centerline of the wellbore
such that the internal threads travel along an upper path and the
external threads travel along a lower path;
[0335] a powered cleaner 146 proximate the upper path; and
[0336] a powered lubricator 148 proximate the lower path.
[0337] (23) Overall Logic Sequence: POOH/RIH Simultaneous with Rack
Transfer
[0338] Some example embodiments include a workover method 150 for
removing a well string from a wellbore, wherein the well string
includes an upper well string member and a lower well string
member, the wellbore defines a longitudinal centerline, the
workover method involving the use of a workover vehicle that
includes at least one of a tongs mechanism, a mast, a work area, a
storage rack, a main trolley with an elevator, an upper trolley
mechanism, a robotic system with an end effector, and a robotic
jib, the workover method comprising:
[0339] aligning the work area of the workover vehicle with the
longitudinal centerline of the wellbore;
[0340] the tongs mechanism unscrewing the upper well string member
from the lower well string member concurrently with the main
trolley descending;
[0341] the tongs mechanism unscrewing the upper well string member
from the lower well string member concurrently with the upper
trolley mechanism stabilizing the upper well string member;
[0342] the end effector taking the upper well string member from
the upper trolley mechanism;
[0343] the robotic system transferring the upper well string member
to the storage rack; and
[0344] the elevator lifting the well string concurrently with the
end effector translating in a lateral direction that is
perpendicular to the longitudinal centerline of the wellbore.
[0345] Referring to FIGS. 61-64D, various shaped blocks 300-536
represent various machine conditions, events and operations; and
legends 540-555 list the content corresponding to blocks 300-536.
With reference to FIGS. 61, 61A, 61C, 61D and particularly the far
left blocks of FIGS. 61 and 61A, "Rods POOH" means rods pulling out
of hole, i.e., removing sucker rods. "Upper Trolley Gripper" refers
to upper trolley mechanism 98. "Cylinder A+B" refers to the
actuators for raising and lowering main trolley 156, wherein
"extending" corresponds to lifting main trolley 156, and "lowering"
corresponds to main trolley 156 descending. "Elevator Jaws" refers
to the elevator head 106, wherein "closed" means elevator head 106
is configured and positioned to capture the upper end of a shaft,
and "open" means elevator head 106 is retracted and configured to
release the shaft's upper end. "Rod Tongs" refers to tongs
mechanism 132, wherein "extend" corresponds to arrow 232 (FIG. 85A)
and "retracting" corresponds to arrow 246 (FIG. 87A). "Tubing Arm"
refers to arm assembly 158 of upper robot 90. "Lower Arm" refers to
arm assembly 164 of lower robot 36. "Wellhead Slips" refers to
wellhead slip 110.
[0346] With reference to FIGS. 62, 62A, 62C, 62D and particularly
the far left blocks of FIGS. 62 and 62A, "Rods RIH" means rods
running in hole, i.e., installing sucker rods. "UTG" refers to
upper trolley mechanism 98. "Cylinder A 30" refers to the actuator
for raising and lowering main trolley 156, wherein Cylinder-A
extending corresponds to lifting main trolley 156, and Cylinder-A
lowering corresponds to main trolley 156 descending. "Elevator
Jaws" refers to the elevator head 106, wherein "closed" means
elevator head 106 is configured and positioned to capture the upper
end of a shaft, and "open" means elevator head 106 is retracted and
configured to release the shaft's upper end. "Rod Tongs" refers to
tongs mechanism 132, wherein "extend" corresponds to arrow 232
(FIG. 85A) and "retracting" corresponds to arrow 246 (FIG. 87A).
"Cleaning Lubrication Station" refers to cleaning or lubricating
the upper and lower ends of a shaft. "Tubing Arm" refers to arm
assembly 158 of upper robot 90. "Lower Arm" refers to arm assembly
164 of lower robot 36. "Wellhead Slips" refers to wellhead slip
110.
[0347] With reference to FIGS. 63, 63A, 63B, 63C and particularly
to the far left blocks in FIGS. 63 and 63A, "Tubing POOH" means
tubing pulling out of hole, i.e., removing tubing. "Upper Trolley
Gripper" refers to upper trolley mechanism 98. "Cylinder A 30"
refers to the actuator for raising and lowering main trolley 156,
wherein Cylinder-A extending corresponds to lifting main trolley
156, and Cylinder-A lowering corresponds to main trolley 156
descending. "Elevator Jaws" refers to the elevator head 106,
wherein "closed" means elevator head 106 is configured and
positioned to capture the upper end of a shaft, and "open" means
elevator head 106 is retracted and configured to release the
shaft's upper end. "Tubing Tongs" refers to tongs mechanism 132,
wherein "extend" corresponds to arrow 232 (FIG. 85A) and
"retracting" corresponds to arrow 246 (FIG. 87A). "Tubing Arm"
refers to arm assembly 158 of upper robot 90. "Lower Arm" refers to
arm assembly 164 of lower robot 36. "Wellhead Slips" refers to
wellhead slip 110.
[0348] With reference to FIGS. 64, 64A, 64C, 64D and particularly
the far left blocks of FIG. 64A, "Tubing RIH" means tubing running
in hole, i.e., installing tubing. "UTG" refers to upper trolley
mechanism 98. "Cylinder A 30" refers to the actuator for raising
and lowering main trolley 156, wherein Cylinder-A extending
corresponds to lifting main trolley 156, and Cylinder-A lowering
corresponds to main trolley 156 descending. "Elevator Jaws" refers
to the elevator head 106, wherein "closed" means elevator head 106
is configured and positioned to capture the upper end of a shaft,
and "open" means elevator head 106 is retracted and configured to
release the shaft's upper end. "Tubing Tongs" refers to tongs
mechanism 132, wherein "extend" corresponds to arrow 232 (FIG. 85A)
and "retracting" corresponds to arrow 246 (FIG. 87A).
"Doping/Cleaning Station" refers to cleaning of the upper and lower
ends of a shaft. "Tubing Arm" refers to arm assembly 158 of upper
robot 90. "Lower Arm" refers to arm assembly 164 of lower robot 36.
"Wellhead Slips" refers to wellhead slip 110.
[0349] (24) Hero Valve
[0350] Some example embodiments include a workover system for
servicing a well that includes a tubular well string with an upper
shoulder, the tubular well string defining a fluid passageway
therethrough, the workover system comprising:
[0351] a mast;
[0352] a main trolley mounted for vertical movement along the
mast;
[0353] an elevator carried by the main trolley, the elevator
comprising a shoulder engaging surface being moveable selectively
to an operating mode and a relocating mode, the shoulder engaging
surface engaging the upper shoulder when the elevator is in the
operating mode, and the shoulder engaging surface being spaced
apart from the upper shoulder when the elevator is in the
relocating mode; and
[0354] a hero valve carried by the main trolley, the hero valve
being movable by the main trolley selectively to a clear position
and a deployed position, the hero valve in the clear position being
spaced apart from the tubular well string, and the hero valve in
the deployed position engaging the tubular well string and
obstructing the fluid passageway.
[0355] Although the invention is described with respect to a
preferred embodiment, modifications thereto will be apparent to
those of ordinary skill in the art. The scope of the invention,
therefore, is to be determined by reference to the following
claims:
* * * * *