U.S. patent application number 16/979397 was filed with the patent office on 2021-03-11 for integrated well construction system operations.
This patent application is currently assigned to Schlumberger Technology Corporation. The applicant listed for this patent is SCHLUMBERGER TECHNOLOGY CORPORATION. Invention is credited to Njal AARSLAND, Espen BOTNAN, Anstein JORUD, Christian Doennestad NILSSEN.
Application Number | 20210071486 16/979397 |
Document ID | / |
Family ID | 1000005276342 |
Filed Date | 2021-03-11 |
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United States Patent
Application |
20210071486 |
Kind Code |
A1 |
BOTNAN; Espen ; et
al. |
March 11, 2021 |
INTEGRATED WELL CONSTRUCTION SYSTEM OPERATIONS
Abstract
An integrated well construction system (IWCS) operable for
constructing a well via integrated control of integrated control
devices (901, 911, 921, 931, 941, 951, 961, 971) that collectively
control integrated subsystems of the IWCS. The IWCS includes an
IWCS communication network (900), the integrated control devices
(each directly connected with the IWCS communication network), the
integrated subsystems, and a control workstation (850, 852)
directly connected with the IWCS communication network and operable
to control each of the integrated control devices to thereby
control the integrated subsystems.
Inventors: |
BOTNAN; Espen;
(Kristiansand, NO) ; AARSLAND; Njal;
(Kristiansand, NO) ; JORUD; Anstein;
(Kristiansand, NO) ; NILSSEN; Christian Doennestad;
(Kristiansand, NO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SCHLUMBERGER TECHNOLOGY CORPORATION |
Sugar Land |
TX |
US |
|
|
Assignee: |
Schlumberger Technology
Corporation
Sugar Land
TX
|
Family ID: |
1000005276342 |
Appl. No.: |
16/979397 |
Filed: |
March 11, 2019 |
PCT Filed: |
March 11, 2019 |
PCT NO: |
PCT/US2019/021688 |
371 Date: |
September 9, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62641021 |
Mar 9, 2018 |
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62640999 |
Mar 9, 2018 |
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62640976 |
Mar 9, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 19/165 20130101;
E21B 21/08 20130101; E21B 19/20 20130101; E21B 19/155 20130101;
E21B 44/02 20130101 |
International
Class: |
E21B 19/16 20060101
E21B019/16; E21B 19/20 20060101 E21B019/20; E21B 21/08 20060101
E21B021/08; E21B 44/02 20060101 E21B044/02; E21B 19/15 20060101
E21B019/15 |
Claims
1. An apparatus comprising: an integrated well construction system
(IWCS) operable for constructing a well via integrated control of a
plurality of integrated control devices that collectively control a
plurality of integrated subsystems of the IWCS, wherein the IWCS
comprises: an IWCS communication network; the integrated control
devices, each directly connected with the IWCS communication
network; the integrated subsystems; and a control workstation
directly connected with the IWCS communication network and operable
to control each of the integrated control devices to thereby
control the integrated subsystems.
2. The apparatus of claim 1 wherein each integrated control device
controls a corresponding one of the integrated subsystems.
3. The apparatus of claim 1 wherein the IWCS communication network
is a single, fiberoptic, ring-topology network.
4. The apparatus of claim 1 wherein the integrated subsystems
include at least: a rig control subsystem comprising a drawworks, a
top drive, an iron roughneck, automated slips, and automated pipe
handling equipment; a fluid circulation subsystem comprising a
drilling fluid pump and drilling fluid reconditioning equipment; a
managed pressure drilling control subsystem; a choke pressure
control subsystem; a well pressure control subsystem; and a
closed-circuit television subsystem.
5. The apparatus of claim 1 wherein each subsystem comprises: a
subsystem network directly connected with the integrated control
device of that subsystem; and a plurality of subsystem components
each directly connected with the subsystem network.
6. The apparatus of claim 5 wherein the subsystem components each
control, perform, sense, measure, and/or monitor an aspect of well
construction performed in association with the subsystem comprising
that subsystem component.
7. The apparatus of claim 1 wherein the control workstation
comprises a processor and a memory storing a construction program
that, when executed by the processor, controls each integrated
control device at least partially in response to data received from
at least one other one of the integrated control devices.
8. The apparatus of claim 1 wherein the control workstation
comprises a processor and a memory storing a construction program
that, when executed by the processor, controls each integrated
control device during each of a plurality of predetermined
operational sequences.
9. The apparatus of claim 8 wherein the plurality of predetermined
operational sequences comprises: picking up single tubulars; making
drilling connections; building tubular stands; tripping-in drill
collar stands; tripping-out drill collar stands; tripping-out wet;
backreaming; moving single tubulars from a well center to a catwalk
using a top drive; moving tubular stands from the well center to
the catwalk; moving casing from the catwalk to the well center
using a casing tong; moving casing from the catwalk to the well
center using a tubular delivery arm and a casing running tool;
moving large diameter casing from the catwalk to the well center
using the top drive and the casing running tool; building casing
stands; and tripping-in casing stands without using the casing
running tool.
10. The apparatus of claim 9 wherein the construction program, when
executed by the processor, controls the top drive, a drawworks,
automated slips, a top drive elevator, an iron roughneck, a
drilling fluid pumping system, the catwalk, an automated racker, an
automated fingerboard, and the tubular delivery arm, via control of
the integrated control devices, during performance of the
predetermined operational sequences.
11. The apparatus of claim 8 wherein the construction program is
configurable by a human operator to permit the operator to select
human interaction levels during performance of the predetermined
operational sequences.
12. The apparatus of claim 8 wherein the construction program is
configurable by a human operator to permit the operator to select
levels of automation of the IWCS during performance of the
predetermined operational sequences.
13. The apparatus of claim 8 wherein the construction program is
configurable by a human operator to permit the operator to select
which machines of the IWCS will be controlled by the construction
program during performance of each predetermined operational
sequence.
14. The apparatus of claim 8 wherein the construction program is
configurable by human operators to permit the operators to select
which machines of the IWCS will be controlled by the construction
program, and to select which machines of the IWCS will be
supervised by which operator, during performance of each
predetermined operational sequence.
15. The apparatus of claim 8 wherein the construction program is
configurable by human operators to permit the operators to select
which steps of each predetermined operational sequence will be
performed and/or confirmed manually, and by which operator.
16. The apparatus of claim 1 wherein the IWCS is operable for
constructing a well without operation of other components not
controlled by, monitored by, or otherwise in communication with any
of the integrated control devices.
17. The apparatus of claim 1 wherein the IWCS is operable for
constructing a well without operation of other components not
controlled by any of the integrated control devices.
18. An apparatus comprising: a control workstation directly
connected with a communication network and operable to control each
of a plurality of integrated control devices each directly
connected with the communication network; wherein each integrated
control device controls a corresponding component of an integrated
well construction system; and whereby control of the integrated
control devices, via operations of the control workstation,
controls the integrated well construction system.
19. The apparatus of claim 18 wherein the integrated well
construction system is operable, via operations of the control
workstation, for constructing a well exclusive of any component not
controlled by any of the integrated control devices.
20. A computer program product comprising: a tangible,
computer-readable, non-transitory medium having instructions stored
thereon for: automatically controlling a plurality of integrated
control devices that control integrated subsystems of an integrated
well construction system (IWCS) to perform combinations of a
plurality of predetermined operational sequences for constructing a
well; receiving, via operation of a control workstation by a human
operator, a selection of one of the operational sequences to be
performed by the IWCS; receiving, via operation of the control
workstation by the human operator, settings for first machines of
the IWCS to be operated during the selected operational sequence;
and in response to receiving a single commencement input via
operation of the control workstation by the human operator,
automatically starting and controlling the first machines and
second machines of the IWCS to perform the selected operational
sequence using the received settings.
21. The computer program product of claim 20 wherein the automatic
start and control of the first and second machines performs the
selected operational sequence without further human action.
22. A method comprising: operating an integrated well construction
system (IWCS) comprising a fiberoptic ring network, wherein the
fiberoptic ring network comprises a plurality of nodes comprising:
programmable logic controllers (PLCs) of individual pieces of
machinery forming the IWCS; video feed; drilling operator control;
high-level supervisory control; and combinations thereof.
23. The method of claim 22 wherein the IWCS machinery PLCs
comprise: a drilling fluid pumping system PLC; a top drive PLC; a
drawworks PLC; an automated slips PLC; an iron roughneck PLC; a
catwalk PLC; an automated racker PLC; an automated fingerboard PLC;
and a tubular delivery arm PLC.
24. The method of claim 22 wherein the fiberoptic ring network
exchanges data between the PLCs for coordinated control of the
machinery.
25. The method of claim 22 wherein the fiberoptic ring network
exchanges data between one or more of the PLCs and the drilling
operator for manual or semi-automatic control of the IWCS.
26. The method of claim 22 wherein the fiberoptic ring network
exchanges data between one or more of the PLCs and a supervisory
controller for automatic and optimized control of the IWCS.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S.
Provisional Application No. 62/641,021, titled "SYSTEM AND METHOD
FOR INTEGRATING MULTIPLE DRILLING EQUIPMENT INTO A SINGLE CONTROL
NETWORK", filed Mar. 9, 2018, and U.S. Provisional Application No.
62/640,976, titled "SYSTEM AND METHOD FOR CONTROLLING DRILLING
OPERATIONS", filed Mar. 9, 2018, and U.S. Provisional Application
No. 62/640,999, titled "SYSTEM AND METHOD FOR REAL-TIME ANALYSIS OF
DRILLING OPERATIONS", filed Mar. 9, 2018 and the entire disclosures
of which are hereby incorporated herein by reference.
BACKGROUND OF THE DISCLOSURE
[0002] Wells are generally drilled into the ground or ocean bed to
recover natural deposits of oil, gas, and other materials that are
trapped in subterranean formations. Such wells are drilled into the
subterranean formations at the wellsite utilizing a well
construction system having various surface and subterranean
wellsite equipment operating in a coordinated manner. The wellsite
equipment may be grouped into various subsystems, wherein each
subsystem performs a different operation controlled by a
corresponding local and/or a remotely located controller. The
subsystems may include a rig control system, a fluid control
system, a managed pressure drilling control system, a gas
monitoring system, a closed-circuit television system, a choke
pressure control system, and a well pressure control system, among
other examples.
[0003] The wellsite equipment is monitored and controlled from a
control center located at a wellsite surface. A typical control
center contains a wellsite control station utilized by several
human wellsite operators (e.g., drillers) to monitor and control
the wellsite equipment. Although the equipment subsystems may
operate in a coordinated manner, there is little or no
communication between the subsystems and their controllers.
Accordingly, monitoring and control of the wellsite equipment or
equipment subsystems may be performed via corresponding control
panels of the wellsite control station. Each control panel
comprises an associated video output device (e.g., a video monitor)
and a plurality of input devices (e.g., buttons, switches,
joysticks, etc.).
[0004] Because there is no communication between the equipment
subsystems, interactions and coordination between the various
wellsite equipment are typically initiated by the wellsite
operators. For example, the wellsite operators may monitor the
equipment subsystems to identify operational and safety events and
manually implement processes to counteract such events.
Accordingly, a typical wellsite control center may be manned by
multiple wellsite operators, each monitoring and controlling
different wellsite equipment or equipment subsystem via a
corresponding control panel. Relying on multiple wellsite operators
to monitor and manually control the wellsite equipment increases
cost and limits speed, efficiency, and safety of well construction
operations.
SUMMARY OF THE DISCLOSURE
[0005] This summary is provided to introduce a selection of
concepts that are further described below in the detailed
description. This summary is not intended to identify indispensable
features of the claimed subject matter, nor is it intended for use
as an aid in limiting the scope of the claimed subject matter.
[0006] The present disclosure introduces an integrated well
construction system (IWCS) operable for constructing a well via
integrated control of integrated control devices that collectively
control integrated subsystems of the IWCS. The IWCS includes an
IWCS communication network; the integrated control devices, each
directly connected with the IWCS communication network; the
integrated subsystems; and a control workstation directly connected
with the IWCS communication network and operable to control each of
the integrated control devices to thereby control the integrated
subsystems.
[0007] The present disclosure also introduces a control workstation
directly connected with a communication network and operable to
control each of multiple integrated control devices each directly
connected with the communication network. Each integrated control
device controls a corresponding component of an IWCS, whereby
control of the integrated control devices, via operations of the
control workstation, controls the IWCS.
[0008] The present disclosure also introduces a computer program
product including a tangible, computer-readable, non-transitory
medium having instructions stored thereon for: automatically
controlling integrated control devices that control integrated
subsystems of an IWCS to perform combinations of predetermined
operational sequences for constructing a well; receiving, via
operation of a control workstation by a human operator, a selection
of one of the operational sequences to be performed by the IWCS;
receiving, via operation of the control workstation by the human
operator, settings for first machines of the IWCS to be operated
during the selected operational sequence; and in response to
receiving a single commencement input via operation of the control
workstation by the human operator, automatically starting and
controlling the first machines and second machines of the IWCS to
perform the selected operational sequence using the received
settings.
[0009] The present disclosure also introduces a method including
operating an IWCS that includes a fiberoptic ring network. Nodes of
the fiberoptic ring network include: programmable logic controllers
(PLCs) of individual pieces of machinery forming the IWCS; video
feed; drilling operator control; high-level supervisory control;
and combinations thereof.
[0010] The present disclosure also introduces an apparatus that
includes a communication network and integrated control devices
each directly connected with the communication network. Each
integrated control device controls a corresponding component of an
IWCS. The IWCS is operable for constructing a well without other
components not controlled by any of the integrated control devices.
The apparatus also includes a control workstation directly
connected with the communication network and operable to control
each of the integrated control devices to thereby control the
IWCS.
[0011] The present disclosure also introduces an apparatus
including a communication network and integrated control devices
each directly connected with the communication network. The
integrated control devices control corresponding IWCS components.
The IWCS components are collectively operable for constructing a
well exclusive of any component not controlled by any of the
integrated control devices. The apparatus also includes a control
workstation directly connected with the communication network and
operable to control each of the integrated control devices to
thereby control the IWCS. The present disclosure also introduces an
apparatus including a communication network and integrated control
devices each directly connected with the communication network.
Each integrated control device controls a corresponding one or more
of integrated well construction components. The integrated well
construction components form an integrated well construction system
operable for constructing a well without any other components. A
control workstation is directly connected with the communication
network and is operable to control each integrated control device
to thereby control the integrated well construction components.
[0012] The present disclosure also introduces a method including
causing a well construction system to perform a well construction
operation, whereby data associated with the well construction
operation is automatically collected and analyzed in real-time to
determine parameters based on the data, and at least some of the
determined parameters are used for controlling the well
construction operation.
[0013] The present disclosure also introduces a method including
causing a well construction system to perform a well construction
operation, whereby data associated with the well construction
operation is automatically collected and analyzed in real-time to
determine parameters based on the data, and at least some of the
determined parameters each provide a basis for triggering at least
one real-time well construction operation alarm.
[0014] The present disclosure also introduces an apparatus that
includes an analysis-while-drilling (AWD) control system utilized
in conjunction with a well construction system during a well
construction operation. Inputs for the AWD control system include:
intended configuration of a well being constructed by the well
construction system during the well construction operation;
configuration of a drill string being used by the well construction
system during the well construction operation; signals from
drilling parameter sensors; and drilling equipment parameters.
Outputs from the AWD control system include real-time determination
of: depth and trajectory of the well; bit depth; number of drill
string tubulars and/or stands in the well; drill string volume,
displacements, and weight; drilling fluid tank volumes and tank
selections; drilling fluid loss and/or gain; trip tank difference
volume; trip tank accumulated volume; total and/or per-section
strokes and/or strokes-to-go of drilling fluid pumping system;
total stroke rate of drilling fluid pumping system; drilling fluid
pumping system liner capacities and efficiencies; individual and
total drilling fluid flow into the well; annular drilling fluid
velocity; total and/or per-section drilling fluid volumes; total
minutes and/or minutes-to-go per section; drilling fluid return
flow; bit runtime and revolutions; weight-on-bit; rate of
penetration; hook load; and standpipe pressure. The outputs from
the AWD control system may further include a kick calculator and a
kill sheet. The outputs from the AWD control system may further
include sensors and calculations for storage in a historian
associated with the well construction system. The outputs from the
AWD control system may further include well construction operation
warnings and alarms.
[0015] The present disclosure also introduces an apparatus that
includes a control workstation directly connected with a
communication network and operable to control multiple control
devices each directly connected with the communication network.
Each control device controls a corresponding component of an IWCS,
whereby control of the control devices, via operations of the
control workstation, controls the IWCS. The control workstation
includes a display, a processor, and a memory storing: a
construction program that, when executed by the processor, controls
each control device; and an AWD program. Inputs for the AWD system
include intended configuration of a well being constructed by the
well construction system during the well construction operation,
configuration of a drill string being used by the well construction
system during the well construction operation, signals from
drilling parameter sensors, and drilling equipment parameters. When
executed by the processor, the AWD program generates in real-time,
and displays in real-time in an AWD screen on the display, one or
more of: a graphic display of the intended configuration and/or an
actual configuration of the well, including depths; a graphic
display of a shoe in the well; an animation of the intended and
actual configurations of the well; an animation of the drill string
in the well; value textual and/or graphic display of drilling fluid
front tracking and/or depth; annular velocity per section; open
hole volume; total strokes and minutes, strokes and minutes-to-go,
and volume for one or more of: surface to bit; bit to shoe; bit to
blow-out preventer; bit to surface; well circulation; full
circulation; drill string displacement, open end and closed end;
drill string weight; number of tubulars in the well; active volume;
drilling fluid flow into the well; bit revolutions; and bit
runtime.
[0016] The present disclosure also introduces an apparatus
including a control workstation for use with an IWCS. The IWCS is
operable for constructing a well via integrated control of
integrated control devices that collectively control integrated
subsystems of the IWCS. The control workstation includes a
human-machine interface (HMI) that includes a display, a
touchscreen, a joystick, and a processing system that includes a
processor and a memory having a construction program thereon that,
when executed by the processor: presents a human operator of the
control workstation with a setup wizard guiding the operator
through entering operating parameters for one or more well
construction machines of the integrated subsystems to perform a
well construction sequence; and controls the integrated control
devices, and thus the integrated subsystems, to perform the well
construction sequence based on the entered operating
parameters.
[0017] The present disclosure also introduces an apparatus
including an IWCS operable for constructing a well via integrated
control of integrated control devices that collectively control
integrated subsystems of the IWCS. The IWCS includes a processing
system including a processor and a memory having a construction
program thereon that, when executed by the processor: controls each
integrated control device, and thus each integrated subsystem,
during each of multiple predetermined operational sequences; and
prevents collisions between machines of the IWCS.
[0018] The present disclosure also introduces a method including
constructing a well utilizing each of multiple automatically
controlled well construction machines, including: a drawworks; an
iron roughneck; a tong-handling trolley; a tong-handling arm; a
catwalk; a tubular delivery arm; a lower stabilizing arm; an upper
tubular restraint; an intermediate tubular restraint; a lower
tubular restraint; a top drive; a top drive elevator; a
fingerboard; a transfer bridge racker; a setback guide arm; a
mousehole; a mousehole; a drilling fluid pumping system; and a
drilling fluid recondition system.
[0019] The present disclosure also introduces a system operable to
completely control each of multiple predetermined operational
sequences of a well construction operation. The sequences include:
picking up single tubulars; making drilling connections; building
tubular stands; tripping-in drill collar stands; tripping-out drill
collar stands; tripping-out wet; backreaming; moving single
tubulars from a well center to a catwalk using a top drive; moving
tubular stands from the well center to the catwalk; moving casing
from the catwalk to the well center using a casing tong; moving
casing from the catwalk to the well center using a tubular delivery
arm and a casing running tool; moving large diameter casing from
the catwalk to the well center using the top drive and the casing
running tool; building casing stands; and tripping-in casing stands
without using the casing running tool.
[0020] These and additional aspects of the present disclosure are
set forth in the description that follows, and/or may be learned by
a person having ordinary skill in the art by reading the materials
herein and/or practicing the principles described herein. At least
some aspects of the present disclosure may be achieved via means
recited in the attached claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The present disclosure is best understood from the following
detailed description when read with the accompanying figures. It is
emphasized that, in accordance with the standard practice in the
industry, various features are not drawn to scale. In fact, the
dimensions of the various features may be arbitrarily increased or
reduced for clarity of discussion.
[0022] FIG. 1 is a schematic view of at least a portion of an
example implementation of apparatus or a system according to one or
more aspects of the present disclosure.
[0023] FIG. 2 is a schematic view of at least a portion of an
example implementation of apparatus or a system according to one or
more aspects of the present disclosure.
[0024] FIG. 3 is a schematic view of at least a portion of an
example implementation of apparatus or a system according to one or
more aspects of the present disclosure.
[0025] FIG. 4 is a schematic view of at least a portion of an
example implementation of apparatus or a system according to one or
more aspects of the present disclosure.
[0026] FIG. 5 is a perspective view of at least a portion of an
example implementation of apparatus according to one or more
aspects of the present disclosure.
[0027] FIG. 6 is a perspective view of a portion of the apparatus
shown in FIG. 5 according to one or more aspects of the present
disclosure.
[0028] FIG. 7 is a top view of a portion of an example
implementation of the apparatus shown in FIG. 6 according to one or
more aspects of the present disclosure.
[0029] FIGS. 8-10 are example implementations of software controls
displayed by the apparatus shown in FIG. 7 according to one or more
aspects of the present disclosure.
[0030] FIGS. 11-21 are example implementations of screens displayed
by the apparatus shown in FIG. 7 according to one or more aspects
of the present disclosure.
[0031] FIG. 22 is a schematic view of at least a portion of an
example implementation of apparatus or a system according to one or
more aspects of the present disclosure.
[0032] FIG. 23 is a schematic view of at least a portion of an
example implementation of apparatus or a system according to one or
more aspects of the present disclosure.
[0033] FIG. 24 is a schematic view of at least a portion of an
example implementation of apparatus or a system according to one or
more aspects of the present disclosure.
DETAILED DESCRIPTION
[0034] It is to be understood that the following disclosure
describes many example implementations for different aspects
introduced herein. Specific examples of components and arrangements
are described below to simplify the present disclosure. These are
merely examples, and are not intended to be limiting. In addition,
the present disclosure may repeat reference numerals and/or letters
in the various examples. This repetition is for simplicity and
clarity, and does not in itself dictate a relationship between the
various implementations described herein. Moreover, the formation
of a first feature over or on a second feature in the description
that follows may include implementations in which the first and
second features are formed in direct contact, and may also include
implementations in which additional features may be formed
interposing the first and second features, such that the first and
second features may not be in direct contact.
[0035] FIG. 1 is a schematic view of at least a portion of an
example implementation of an integrated well construction system
100 (i.e., a drill rig) according to one or more aspects of the
present disclosure. The well construction system 100 represents an
example environment in which one or more aspects of the present
disclosure described below may be implemented. Although the well
construction system 100 is depicted as an onshore implementation,
the aspects described below are also applicable to offshore
implementations.
[0036] The well construction system 100 is depicted in relation to
a wellbore 102 formed by rotary and/or directional drilling from a
wellsite surface 104 and extending into a subterranean formation
106. The well construction system 100 includes surface equipment
110 located at the wellsite surface 104 and a drill string 120
suspended within the wellbore 102. The surface equipment 110 may
include a mast, a derrick, and/or other support structure 112
disposed over a rig floor 114. The drill string 120 may be
suspended within the wellbore 102 from the support structure 112.
The support structure 112 and the rig floor 114 are collectively
supported over the wellbore 102 by legs and/or other support
structures 113.
[0037] The drill string 120 may comprise a bottom-hole assembly
(BHA) 124 and means 122 for conveying the BHA 124 within the
wellbore 102. The conveyance means 122 may comprise drill pipe,
heavy-weight drill pipe (HWDP), wired drill pipe (WDP), and/or
other means for conveying the BHA 124 within the wellbore 102. A
downhole end of the BHA 124 may include or be coupled to a drill
bit 126. Rotation of the drill bit 126 and the weight of the drill
string 120 collectively operate to form the wellbore 102. The drill
bit 126 may be rotated from the wellsite surface 104 and/or via a
downhole mud motor (not shown) connected with the drill bit
126.
[0038] The BHA 124 may also include various downhole tools 180,
182, 184. One or more of such downhole tools 180, 182, 184 may be
or comprise an acoustic tool, a density tool, a directional
drilling tool, an electromagnetic (EM) tool, a formation sampling
tool, a formation testing tool, a gravity tool, a monitoring tool,
a neutron tool, a nuclear tool, a photoelectric factor tool, a
porosity tool, a reservoir characterization tool, a resistivity
tool, a rotational speed sensing tool, a sampling-while-drilling
(SWD) tool, a seismic tool, a surveying tool, a torsion sensing
tool, and/or other measuring-while-drilling (MWD) or
logging-while-drilling (LWD) tools.
[0039] One or more of the downhole tools 180, 182, 184 may be or
comprise an MWD or LWD tool comprising a sensor package 186
operable for the acquisition of measurement data pertaining to the
BHA 124, the wellbore 102, and/or the formation 106. One or more of
the downhole tools 180, 182, 184 and/or another portion of the BHA
124 may also comprise a telemetry device 187 operable for
communication with the surface equipment 110, such as via mud-pulse
telemetry. One or more of the downhole tools 180, 182, 184 and/or
another portion of the BHA 124 may also comprise a downhole
processing device 188 operable to receive, process, and/or store
information received from the surface equipment 110, the sensor
package 186, and/or other portions of the BHA 124. The processing
device 188 may also store executable computer programs (e.g.,
program code instructions), including for implementing one or more
aspects of the operations described herein.
[0040] The support structure 112 may support a driver, such as a
top drive 116, operable to connect (perhaps indirectly) with an
uphole end of the conveyance means 122, and to impart rotary motion
117 to the drill string 120 and the drill bit 126. However, another
driver, such as a kelly and rotary table (neither shown), may be
utilized instead of or in addition to the top drive 116 to impart
the rotary motion 117. The top drive 116 and the connected drill
string 120 may be suspended from the support structure 112 via
hoisting equipment, which may include a traveling block 118, a
crown block (not shown), and a draw works (DW) 119 storing a
support cable or line 123. The crown block may be connected to or
otherwise supported by the support structure 112, and the traveling
block 118 may be coupled with the top drive 116, such as via a
hook. The DW 119 may be mounted on or otherwise supported by the
rig floor 114. The crown block and traveling block 118 comprise
pulleys or sheaves around which the support line 123 is reeved to
operatively connect the crown block, the traveling block 118, and
the DW 119 (and perhaps an anchor). The DW 119 may thus selectively
impart tension to the support line 123 to lift and lower the top
drive 116, resulting in vertical motion 135. The DW 119 may
comprise a drum, a frame, and a prime mover (e.g., an engine or
motor) (not shown) operable to drive the drum to rotate and reel in
the support line 123, causing the traveling block 118 and the top
drive 116 to move upward. The DW 119 is also operable to reel out
the support line 123 via a controlled rotation of the drum, causing
the traveling block 118 and the top drive 116 to move downward.
[0041] The top drive 116 may comprise a grabber, a swivel (neither
shown), tubular handling assembly links 127 terminating with an
elevator 129, and a drive shaft 125 operatively connected with a
prime mover (not shown), such as via a gear box or transmission
(not shown). The drill string 120 may be mechanically coupled to
the drive shaft 125 with or without a saver sub between the drill
string 120 and the drive shaft 125. The prime mover of the top
drive 116 is selectively operable to rotate the drive shaft 125 and
the drill string 120 coupled with the drive shaft 125. Hence, the
top drive 116 and the DW 119 cooperate to advance the drill string
120 into the formation 106 to form the wellbore 102. The tubular
handling assembly links 127 and the elevator 129 of the top drive
116 may handle tubulars (e.g., drill pipes, drill collars, casing
joints, etc.) that are not mechanically coupled to the drive shaft
125. For example, when the drill string 120 is being tripped into
or out of the wellbore 102, the elevator 129 may grasp the tubulars
of the drill string 120 such that the tubulars may be raised and/or
lowered via the hoisting equipment mechanically coupled to the top
drive 116. The grabber may include a clamp that clamps onto a
tubular when making-up and/or breaking-out a connection of a
tubular with the drive shaft 125. The top drive 116 may have a
guide system (not shown), such as rollers that track up and down a
guide rail on the support structure 112. The guide system may aid
in keeping the top drive 116 aligned with the wellbore 102, and in
preventing the top drive 116 from rotating during drilling by
transferring reactive torque to the support structure 112.
[0042] The well construction system 100 may further include a well
control system for maintaining well pressure control. For example,
the drill string 120 may be conveyed within the wellbore 102
through various blowout preventer (BOP) equipment disposed at the
wellsite surface 104 on top of the wellbore 102 and perhaps below
the rig floor 114. The BOP equipment may be operable to control
pressure within the wellbore 102 via a series of pressure barriers
(e.g., rams) between the wellbore 102 and the wellsite surface 104.
The BOP equipment may include a BOP stack 130, an annular preventer
132, and/or a rotating control device (RCD) 138 mounted above the
annular preventer 132. The BOP equipment 130, 132, 138 may be
mounted on top of a wellhead 134. The well control system may
further include a BOP control unit 137 (i.e., a BOP closing unit)
operatively connected with the BOP equipment 130, 132, 138 and
operable to actuate, drive, operate, or otherwise control the BOP
equipment 130, 132, 138. The BOP control unit 137 may be or
comprise a hydraulic fluid power unit fluidly connected with the
BOP equipment 130, 132, 138 and selectively operable to
hydraulically drive various portions (e.g., rams, valves, seals) of
the BOP equipment 130, 132, 138.
[0043] The well construction system 100 may further include a
drilling fluid circulation system operable to circulate fluids
between the surface equipment 110 and the drill bit 126 during
drilling and other operations. For example, the drilling fluid
circulation system may be operable to inject a drilling fluid from
the wellsite surface 104 into the wellbore 102 via an internal
fluid passage 121 extending longitudinally through the drill string
120. The drilling fluid circulation system may comprise a pit, a
tank, and/or other fluid container 142 holding the drilling fluid
(i.e., mud) 140, and a pump 144 operable to move the drilling fluid
140 from the container 142 into the fluid passage 121 of the drill
string 120 via a fluid conduit 146 extending from the pump 144 to
the top drive 116 and an internal passage extending through the top
drive 116. The fluid conduit 146 may comprise one or more of a pump
discharge line, a stand pipe, a rotary hose, and a gooseneck (not
shown) connected with a fluid inlet of the top drive 116. The pump
144 and the container 142 may be fluidly connected by a fluid
conduit 148, such as a suction line.
[0044] During drilling operations, the drilling fluid may continue
to flow downhole through the internal passage 121 of the drill
string 120, as indicated by directional arrow 158. The drilling
fluid may exit the BHA 124 via ports 128 in the drill bit 126 and
then circulate uphole through an annular space (annulus) 108 of the
wellbore 102 defined between an exterior of the drill string 120
and the wall of the wellbore 102, such flow being indicated in FIG.
1 by directional arrows 159. In this manner, the drilling fluid
lubricates the drill bit 126 and carries formation cuttings uphole
to the wellsite surface 104. The returning drilling fluid may exit
the annulus 108 via a bell nipple 139, the RCD 138, and/or a ported
adapter 136 (e.g., a spool, a wing valve, etc.) located below one
or more portions of the BOP stack 130.
[0045] The drilling fluid exiting the annulus 108 via the bell
nipple 139 may be directed toward drilling fluid reconditioning
equipment 170 via a fluid conduit 145 (e.g., gravity return line)
to be cleaned and/or reconditioned, as described below, prior to
being returned to the container 142 for recirculation. The drilling
fluid exiting the annulus 108 via the RCD 138 may be directed into
a fluid conduit 160 (e.g., a drilling pressure control line), and
may pass through various wellsite equipment fluidly connected along
the conduit 160 prior to being returned to the container 142 for
recirculation. For example, the drilling fluid may pass through a
choke manifold 162 (e.g., a drilling pressure control choke
manifold) and then through the drilling fluid reconditioning
equipment 170. The choke manifold 162 may include at least one
choke and a plurality of fluid valves (neither shown) collectively
operable to control the flow through and out of the choke manifold
162. Backpressure may be applied to the annulus 108 by variably
restricting flow of the drilling fluid or other fluids flowing
through the choke manifold 162. The greater the restriction to flow
through the choke manifold 162, the greater the backpressure
applied to the annulus 108. The drilling fluid exiting the annulus
108 via the ported adapter 136 may be directed into a fluid conduit
171 (e.g., rig choke line), and may pass through various equipment
fluidly connected along the conduit 171 prior to being returned to
the container 142 for recirculation. For example, the drilling
fluid may pass through a choke manifold 173 (e.g., a rig choke
manifold, well control choke manifold, etc.) and then through the
drilling fluid reconditioning equipment 170. The choke manifold 173
may include at least one choke and a plurality of fluid valves
(neither shown) collectively operable to control the flow through
the choke manifold 173. Backpressure may be applied to the annulus
108 by variably restricting flow of the drilling fluid or other
fluids flowing through the choke manifold 173.
[0046] Before being returned to the container 142, the drilling
fluid returning to the wellsite surface 104 may be cleaned and/or
reconditioned via the drilling fluid reconditioning equipment 170,
which may include one or more of liquid gas separators, shale
shakers, centrifuges, and other drilling fluid cleaning equipment.
The liquid gas separators may remove formation gasses entrained in
the drilling fluid discharged from the wellbore 102, and the shale
shakers may separate and remove solid particles 141 (e.g., drill
cuttings) from the drilling fluid. The drilling fluid
reconditioning equipment 170 may further comprise equipment
operable to remove additional gas and finer formation cuttings from
the drilling fluid and/or modify physical properties or
characteristics (e.g., rheology) of the drilling fluid. For
example, the drilling fluid reconditioning equipment 170 may
include a degasser, a desander, a desilter, a mud cleaner, and/or a
decanter, among other examples. Intermediate tanks/containers (not
shown) may be utilized to hold the drilling fluid while the
drilling fluid progresses through the various stages or portions of
the drilling fluid reconditioning equipment 170. The
cleaned/reconditioned drilling fluid may be transferred to the
fluid container 142, the solid particles 141 removed from the
drilling fluid may be transferred to a solids container 143 (e.g.,
a reserve pit), and the removed gas may be transferred to a flare
stack 172 via a conduit 174 (e.g., a flare line) to be burned or to
a container (not shown) for storage and removal from the
wellsite.
[0047] The surface equipment 110 may include tubular handling
equipment operable to store, move, connect, and disconnect tubulars
(e.g., drill pipes) to assemble and disassemble the conveyance
means 122 of the drill string 120 during drilling operations. For
example, a catwalk 131 may be utilized to convey tubulars from a
ground level, such as along the wellsite surface 104, to the rig
floor 114, permitting the tubular handling assembly links 127 to
grab and lift the tubulars above the wellbore 102 for connection
with previously deployed tubulars. The catwalk 131 may have a
horizontal portion 147 and a ramp or inclined portion 149, wherein
the inclined portion extends between the horizontal portion and the
rig floor 114. The catwalk 131 may comprise a skate 133 movable
along a groove (not shown) extending longitudinally along the
horizontal and inclined portions of the catwalk 131. The skate 133
may be operable to convey (e.g., push) the tubulars along the
catwalk 131 to the rig floor 114. The skate 133 may be driven along
the groove by a drive system (not shown), such as a pulley system
or a hydraulic system. Additionally, one or more racks (not shown)
may adjoin the horizontal portion of the catwalk 131. The racks may
be feeding tables (not shown), such as may have a spinner unit
and/or other means for transferring tubulars to the groove of the
catwalk 131.
[0048] An iron roughneck (RN) 151 may be positioned on the rig
floor 114. The RN 151 may comprise a torqueing portion 153, such as
may include a spinner and a torque wrench comprising a lower tong
and an upper tong. The torqueing portion 153 of the RN 151 may be
moveable toward and at least partially around the drill string 120,
such as may permit the RN 151 to make-up and break-out connections
of the drill string 120. The torqueing portion 153 may also be
moveable away from the drill string 120, such as may permit the RN
151 to move clear of the drill string 120 during drilling
operations. The spinner of the RN 151 may be utilized to apply low
torque to make-up and break-out threaded connections between
tubulars of the drill string 120, and the torque wrench may be
utilized to apply a higher torque to tighten and loosen the
threaded connections. The system 100 may include more than one
instance of the RN 151.
[0049] Reciprocating slips 161 may be located on the rig floor 114,
such as may accommodate therethrough the downhole tubulars during
make-up and break-out operations and during the drilling
operations. The reciprocating slips 161 may be in an open position
during drilling operations to permit advancement of the drill
string 120 therethrough, and in a closed position to clamp near an
upper end of the conveyance means 122 (e.g., assembled tubulars) to
thereby suspend and prevent advancement of the drill string 120
within the wellbore 102, such as during the make-up and break-out
operations.
[0050] During drilling operations, the hoisting equipment lowers
the drill string 120 while the top drive 116 rotates the drill
string 120 to advance the drill string 120 within the wellbore 102
and into the formation 106. During the advancement of the drill
string 120, the reciprocating slips 161 are in an open position,
and the RN 151 is moved away or is otherwise clear of the drill
string 120. When the upper portion of the tubular in the drill
string 120 that is made up to the drive shaft 125 is near the
reciprocating slips 161 and/or the rig floor 114, the top drive 116
ceases rotating and the reciprocating slips 161 close to clamp the
tubular made up to the drive shaft 125. The grabber of the top
drive 116 then clamps the upper portion of the tubular made up to
the drive shaft 125, and the drive shaft 125 rotates in a direction
reverse from the drilling rotation to break-out the connection
between the drive shaft 125 and the made up tubular. The grabber of
the top drive 116 may then release the tubular of the drill string
120.
[0051] Multiple tubulars may be loaded on the rack of the catwalk
131 and individual tubulars may be transferred from the rack to the
groove in the catwalk 131. The tubular positioned in the groove may
be conveyed along the groove by the skate 133 until an end of the
tubular projects above the rig floor 114. The elevator 129 of the
top drive 116 may then grasp the protruding end, and the DW 119 is
operated to lift the top drive 116, the elevator 129, and the new
tubular.
[0052] The hoisting equipment then raises the top drive 116, the
elevator 129, and the tubular until the tubular is aligned with the
upper portion of the drill string 120 clamped by the slips 161. The
RN 151 is moved toward the drill string 120, and the lower tong of
the torqueing portion 153 clamps onto the upper portion of the
drill string 120. The spinning system rotates the new tubular into
the upper portion of the drill string 120. The upper tong then
clamps onto the new tubular and rotates with high torque to
complete making-up the connection with the drill string 120. In
this manner, the new tubular becomes part of the drill string 120.
The RN 151 then releases and moves clear of the drill string
120.
[0053] The grabber of the top drive 116 may then clamp onto the
drill string 120. The drive shaft 125 (or a saver sub or other
device extending from the drive shaft 125) is brought into contact
with the drill string 120 and rotated to make-up a connection
between the drill string 120 and the drive shaft 125. The grabber
then releases the drill string 120, and the reciprocating slips 161
are moved to the open position. The drilling operations may then
resume.
[0054] The tubular handling equipment may further include a pipe
handling manipulator (PHM) 163 disposed in association with a
vertical pipe rack 165 for storing tubulars 111 (or stands of two
or three tubulars). The vertical pipe rack 165 may comprise or
support a fingerboard (FIB) 166 defining a plurality of slots
configured to support or otherwise hold the tubulars 111 within or
above a setback 164 (e.g., a platform or another area) located
adjacent to, along, or below the rig floor 114. The FIB 166 may
comprise a plurality of fingers (not shown), each associated with a
corresponding slot and operable to close around and/or otherwise
interpose individual tubulars 111 to maintain the tubulars 111
within corresponding slots of the setback 164. The vertical pipe
rack 165 may be connected with and supported by the support
structure 112 or another portion of the wellsite system 100. The
FIB 166/setback 164 provide storage (e.g., temporary storage) of
tubulars 111 during various operations, such as during and between
tripping out and tripping of the drill string 120. The PHM 163 may
be operable to transfer the tubulars 111 between the FIB
166/setback 164 and the drill string 120 (i.e., space above the
suspended drill string 120). For example, the PHM 163 may include
arms 167 terminating with clamps 169, such as may be operable to
grasp and/or clamp onto one of the tubulars 111. The arms 167 of
the PHM 163 may extend and retract, and/or at least a portion of
the PHM 163 may be rotatable and/or movable toward and away from
the drill string 120, such as may permit the PHM 163 to transfer
the tubular 111 between the FIB 166/setback 164 and the drill
string 120.
[0055] The surface equipment 110 of the well construction system
100 may also comprise a control center 190 from which various
portions of the well construction system 100, such as the top drive
116, the hoisting system, the tubular handling system, the drilling
fluid circulation system, the well control system, and the BHA 124,
among other examples, may be monitored and controlled. The control
center 190 may be located on the rig floor 114 or another location
of the well construction system 100, such as the wellsite surface
104. The control center 190 may comprise a facility 191 (e.g., a
room, a cabin, a trailer, etc.) containing a control workstation
197, which may be operated by a human wellsite operator 195 to
monitor and control various wellsite equipment or portions of the
well construction system 100. The control workstation 197 may
comprise or be communicatively connected with a processing device
192 (e.g., a controller, a computer, etc.), such as may be operable
to receive, process, and output information to monitor and/or
control operations of one or more portions of the well construction
system 100. For example, the processing device 192 may be
communicatively connected with the various surface and downhole
equipment described herein, and may be operable to receive signals
from and transmit signals to such equipment to perform various
operations described herein. The processing device 192 may store
executable program code, instructions, and/or operational
parameters or set-points, including for implementing one or more
aspects of methods and operations described herein. The processing
device 192 may be located within and/or outside of the facility
191.
[0056] The control workstation 197 may be operable for entering or
otherwise communicating control commands to the processing device
192 by the wellsite operator 195, and for displaying or otherwise
communicating information from the processing device 192 to the
wellsite operator 195. The control workstation 197 may comprise a
plurality of human-machine interface (HMI) devices, including one
or more input devices 194 (e.g., a keyboard, a mouse, a joystick, a
touchscreen, etc.) and one or more output devices 196 (e.g., a
video monitor, a touchscreen, a printer, audio speakers, etc.).
Communication between the processing device 192, the input and
output devices 194, 196, and the various wellsite equipment may be
via wired and/or wireless communication means. However, for clarity
and ease of understanding, such communication means are not
depicted, and a person having ordinary skill in the art will
appreciate that such communication means are within the scope of
the present disclosure.
[0057] Well construction systems within the scope of the present
disclosure may include more or fewer components than as described
above and depicted in FIG. 1. Additionally, various equipment
and/or subsystems of the well construction system 100 shown in FIG.
1 may include more or fewer components than as described above and
depicted in FIG. 1. For example, various engines, motors,
hydraulics, actuators, valves, and/or other components not
explicitly described herein may be included in the well
construction system 100, and are within the scope of the present
disclosure.
[0058] FIG. 2 is a schematic view of an example implementation of a
wellsite system 200 comprising a plurality of pipe handling
equipment, each comprising or carrying one or more sensors operable
to generate sensor measurements indicative of corresponding
operational parameters (e.g., position, speed, acceleration, etc.)
of such equipment. According to one or more aspects of the present
disclosure, the various pieces of equipment of the wellsite system
200 may be operable to move tubulars 111 between various positions
of the wellsite system 200, to perform processes described herein,
including assembly and disassembly of a drill string 120. The
wellsite system 200 may form a portion of and/or operate in
conjunction with the well construction system 100 shown in FIG. 1,
including where indicated by the same numerals. Accordingly, the
following description refers to FIGS. 1 and 2, collectively.
[0059] The wellsite system 200 may comprise a support structure 112
supporting various automated pipe handling equipment operable to
transport tubulars 111 (e.g., drill pipes, stands of drill pipe,
casing joints) between different areas of the wellsite system 200.
The wellsite system 200 may further comprise a catwalk 131 operable
to transport tubulars 111 from a storage area (not shown) at a
ground level (e.g., wellsite surface 104) to a rig floor 114.
[0060] The support structure 112 or another portion of the wellsite
system 200 may support a tubular delivery arm (TDA) 202 operable to
grab the tubulars 111, one at a time, from an FIB 166 and/or the
catwalk 131 and lift or otherwise move the tubulars 111 to
predetermined positions. For example, the TDA 202 may move a
tubular 111 over the wellbore 102, such that the tubular 111 is
aligned with the wellbore center 203 above the reciprocating slips
161 and fluid control equipment 213 (e.g., BOP equipment 130, 132,
138 mounted on top of a wellhead 134, etc.) located below the rig
floor 114. The TDA 202 may also move a tubular 111 over a mouse
hole (MOH) 204, such that the tubular 111 is aligned with a mouse
hole center 205, permitting one or more tubulars 111 to be disposed
therein such that two or more tubulars 111 can be coupled together
to form a stand.
[0061] The TDA 202 may also move a tubular 111 to a doping stand or
area 206, such that the tubular 111 may be prepared for make-up
operations by a washer/doper device (doper) 209. For example the
doper 209 may apply dope to pin ends of tubulars 111 in preparation
for being made-up, and/or may wash pin ends of tubulars 111 prior
to transfer to the FIB 166/setback 164. Accordingly, the doper 209
may be positioned in conjunction with the doping area 206, the MOH
204, and/or other areas, such as for performing the washing/doping
operations on a tubular 111 while the tubular 111 is engaged by the
TDA 202. The doper 209 may also be positioned in conjunction with
the TDA 202.
[0062] Portions of the TDA 202 may be operable to move horizontally
and/or vertically, as indicated by arrows 208, such as may permit a
grabber or clamp 210 of the TDA 202 to grab or otherwise receive a
tubular 111 being transferred to the rig floor 114 by the catwalk
131. A DW 119 may be operable to move the TDA 202 vertically along
the support structure 112, as indicated by arrows 212. The DW 119
may be operatively connected with the TDA 202 via a support line
214 extending between the TDA 202 and a drum 216 of the DW 119.
[0063] One or more sensors 211 may be disposed in association with
the clamp 210, such as may permit the sensor 211 to generate sensor
signals indicative of presence or proximity of a tubular 111
received by the clamp 210. One or more sensors 218 may be disposed
in association with the DW 119, such as may permit the sensor 218
to generate sensor measurements (e.g., electrical sensor signals or
data) indicative of rotational position of the drum 216. Such
sensor measurements may be further indicative of vertical position
of the TDA 202 along the support structure 112. The TDA 202 may
carry or comprise one or more sensors 220 operable to generate
sensor measurements indicative of tension applied to and, thus,
weight supported by the TDA 202. The support structure 112 may
further support a plurality of sensors 226, each located at a
predetermined or otherwise known reference position 221-224 (i.e.,
height) along the support structure 112. Such known reference
positions 221-224 may be known in the oil and gas industry as flags
or targets. Each sensor 226 may be operable to generate a sensor
signal indicative of presence or proximity of the TDA 202 when the
TDA 202 passes the sensor 226, thereby indicating a corresponding
known position 221-224 of the TDA 202 at such time.
[0064] The support structure 112 or another portion of the wellsite
system 200 may further support a lower stabilization arm (LSA) 228
operable to receive (e.g., catch) and stabilize via a holding
device 230 a tubular 111 supported by the TDA 202 after the tubular
111 is lifted off of the catwalk 131 and swings toward the support
structure 112. The LSA 228 may then pivot 231 to horizontally move
233 the tubular 111 to align the tubular 111 with the mouse hole
center 205 or the doping area 206. The holding device 230 may be
extended around (at least partially) a tubular 111 to provide
additional stability, such as during stabbing prior to make-up
operations. The LSA 228 may carry or comprise one or more sensors
232 operable to generate sensor measurements indicative of
stabilization arm extension (i.e., length) and/or angle 234 between
the LSA 228 and the support structure 112 or a reference plane.
[0065] The support structure 112 or another portion of the wellsite
system 200 may support a vertical rack 165 comprising or supporting
the FIB 166 defining a plurality of slots configured to support or
otherwise hold the tubulars 111 within or above a setback 164
located adjacent to, along, of below the rig floor 114. The support
structure 112, the vertical rack 165, or another portion of the
wellsite system 200, such as the PHM 163, may support an upper
tubular constraint (UTC) 242 and a lower tubular constraint (LTC)
244, each operable to grab a corresponding upper and lower portion
of a tubular 111 via a corresponding grabber or clamp 246, 248. The
UTC 242 and LTC 244 may stabilize the tubular 111 and/or
horizontally move the corresponding upper and/or lower portions of
the tubular 111, as indicated by arrows 247, 249, to align the
tubular 111 with the mouse hole center 205 or the doping area 206.
The UTC 242 and LTC 244 may also horizontally move the
corresponding upper and/or lower portions of the tubular 111, as
indicated by arrows 247, 249, to position the tubular 111 along a
tubular handoff position (THP) 207, at which the TDA 202 can grab
and align the tubular 111 with the wellbore center 203 for
connection with the drill string 120 or align the tubular 111 with
a portion of the catwalk 131, permitting the tubular 111 to be
lowered onto the catwalk 131, which may then move the tubular 111
from the rig floor 114 to the ground level (e.g., the wellsite
surface 104). The THP 207 may be horizontally aligned with the
doping area 206, such as may permit a tubular 111 to be doped
and/or washed by the doper 209 before the TDA 202 aligns the
tubular along the wellbore center 203 for connection with the drill
string 120 or positions the tubular 111 to be lowered by the
catwalk 131. The UTC 242 and LTC 244 may each carry or comprise one
or more corresponding sensors 250, 252 operable to generate sensor
measurements indicative of extension or horizontal positions 247,
249 of the corresponding clamps 246, 248.
[0066] The support structure 112, the vertical rack 165, or another
portion of the wellsite system 200 may further support an
intermediate tubular constraint (ITC) 236 operable to grab a
tubular 111 supported by the TDA 202 via a grabber or clamp 238,
stabilize the tubular 111, and/or horizontally move 235 the tubular
111 to align the tubular 111 with the mouse hole center 205 or the
doping area 206. The ITC 236 may carry or comprise one or more
sensors 240 operable to generate sensor measurements indicative of
extension or horizontal position 235 of the clamp 238.
[0067] The support structure 112, the vertical rack 165, or another
portion of the wellsite system 200 may further support a transfer
bridge racker (TBR) 254 and a setback guide arm (SGA) 262, a
collectively operable to store (e.g., hang, rack) the tubulars 111
in the FIB 166 of the vertical rack 165 within or above the setback
164. For example, the TBR 254 may be operable to grab an upper
portion of a tubular 111 via a grabber or clamp 256 and move the
tubular 111 horizontally and/or vertically between the FIB 166 and
the THP 207, as indicated by arrows 258. The TBR 254 may carry or
comprise one or more corresponding sensors 260 operable to generate
sensor measurements indicative of the horizontal and/or vertical
position 258 of the clamp 256. The SGA 262 may be operable to grab
a lower portion of the tubular 111 via a grabber or clamp 264 and
guide the lower portion of the tubular 111 horizontally and/or
vertically between the setback 164 and the THP 207, as indicated by
arrows 266, in unison (i.e., synchronously) with the TBR 254. The
SGA 262 may carry or comprise one or more corresponding sensors 268
operable to generate sensor measurements indicative of the
horizontal and/or vertical position 266 of the clamp 264. When the
tubular 111 is aligned with the THP 207, the TDA 202 can grab and
align the tubular 111 with the wellbore center 203 for connection
with the drill string 120 or align the tubular with a portion of
the catwalk 131, permitting the tubular 111 to be lowered onto the
catwalk 131.
[0068] The UTC 242, the ITC 236, and the LTC 244 may temporarily
grasp a tubular 111 while in the THP 207, such as while the TBR
254, the SGA 262, and the TDA 202 are performing other operations.
One or more of the UTC 242, the ITC 236, and the LTC 244 may also
be extendable to grasp a tubular 111 in (or move the tubular 111
to) the MOH 204. For example, the tubular 111 may be temporarily
stored in the MOH 204 while awaiting addition to the drill string
120 or while awaiting transfer to the THP 207 and/or the FIB
166/setback 164.
[0069] The catwalk 131 may comprise a skate 133 movable along a
groove (not shown) extending longitudinally along the catwalk 131.
The skate 133 may be driven along the groove by a drive system 270,
such as a winch system comprising a spool 272 driven by a motor
(not shown). The drive system 270 may be selectively operable to
pull the skate 133 in opposing directions along the catwalk 131 via
a line 274 extending between the spool 272 and the skate 133.
Actuated by the drive system 270, the skate 133 may be operable to
convey (e.g., push) a tubular 111 along the catwalk 131 to the rig
floor 114. The skate 133 may move the box end of the tubular 111
into the clamp 210 of the TDA 202, such that the tubular 111 can be
lifted by the TDA 202. The drive system 270 may carry or comprise
one or more corresponding sensors 276 operable to generate sensor
measurements indicative of rotational position of the spool 272
and, thus, position of the skate 133 along the catwalk 131.
[0070] The sensors 218, 276 may be or comprise, for example,
encoders, rotary potentiometers, and/or rotary
variable-differential transformers (RVDTs). The sensors 220 may be
or comprise, for example, strain gauges and/or load cells. The
sensors 211, 226 may be or comprise, for example, proximity sensors
and Hall effect sensors. The sensors 232, 240, 250, 252, 260, 268
may be or comprise, for example, encoders, rotary potentiometers,
linear potentiometers, or rotary variable-differential transformers
(RVDTs).
[0071] The present disclosure further provides various
implementations of systems and/or methods for controlling one or
more portions of the well construction system 100 and the wellsite
system 200. Because the wellsite system 200 may form a portion of
and/or operate in conjunction with the well construction system
100, the well construction system 100 and the wellsite system 200
are hereinafter referred to collectively as a well construction
system 100, 200. FIG. 3 is a schematic view of at least a portion
of an example implementation of a monitoring and control system 300
for monitoring and controlling various equipment, portions, and
subsystems of the well construction system 100, 200 according to
one or more aspects of the present disclosure. The following
description refers to FIGS. 1-3, collectively.
[0072] The control system 300 may be in real-time communication
with the well construction system 100, 200 and may be utilized to
monitor and/or control various portions, components, and equipment
of the well construction system 100, 200. The equipment of the well
construction system 100, 200 may be grouped into several
subsystems, each operable to perform a corresponding operation
and/or a portion of the well construction operations described
herein. The subsystems may include a rig control (RC) system 311, a
fluid circulation (FC) system 312, a managed pressure drilling
control (MPDC) system 313, a choke pressure control (CPC) system
314, a well pressure control (WC) system 315, and a closed-circuit
television (CCTV) system 316, among other examples. The control
workstation 197 may be utilized to monitor, configure, control,
and/or otherwise operate one or more of the well construction
subsystems 311-316.
[0073] The RC system 311 may include the support structure 112, the
drill string hoisting system or equipment (e.g., the DW 119), the
drill string rotational system (e.g., the top drive 116 and/or the
rotary table and kelly), the reciprocating slips 161, the drill
pipe handling system or equipment (e.g., the catwalk 131, the TDA
202, the setback 164, the FIB 166, the TBR 254, the SGA 262, the
LTC 244, the ITC 236, the UTC 242, the LSA 228, and the RN 151),
electrical generators, and other equipment. Accordingly, the RC
system 311 may perform power generation and/or distribution, and
may control drill pipe handling, hoisting, and rotation operations.
The RC system 311 may also serve as a support platform for drilling
equipment and staging ground for rig operations, such as connection
make-up and break-out operations described above.
[0074] The FC system 312 may include the drilling fluid 140, the
pumps 144, drilling fluid loading and/or mixing equipment, the
drilling fluid reconditioning equipment 170, the flare stack 172,
and/or other fluid control equipment. Accordingly, the FC system
312 may perform fluid operations of the well construction system
100.
[0075] The MPDC system 313 may include the RCD 138, the choke
manifold 162, downhole pressure sensors 186, and/or other
equipment. The CPC system 314 may comprise the choke manifold 173
and/or other equipment. The WC system 315 may comprise the BOP
equipment 130, 132, 138, the BOP control unit 137, and a BOP
control station (not shown) for controlling the BOP control unit
137.
[0076] The CCTV system 316 may include the video cameras 198 and
corresponding actuators (e.g., motors) for moving or otherwise
controlling direction of the video cameras 198. The CCTV system 316
may be utilized to capture real-time video of various portions or
subsystems 311-315 of the well construction system 100 and display
video signals from the video cameras 198 on the video output
devices 196 to display in real-time the various portions or
subsystems 311-315.
[0077] Each of the well construction subsystems 311-316 may further
comprise various communication equipment (e.g., modems, network
interface cards/circuits, etc.) and communication conductors (e.g.,
cables), communicatively connecting the equipment (e.g., sensors
and actuators) of each subsystem 311-316 with the control
workstation 197 and/or other equipment. Although the wellsite
equipment listed above and shown in FIGS. 1 and 2 is associated
with certain wellsite subsystems 311-316, such associations are
merely examples that are not intended to limit or prevent such
wellsite equipment from being associated with two or more wellsite
subsystems 311-316 and/or different wellsite subsystems
311-316.
[0078] The control system 300 may include a wellsite computing
resource environment 305, which may be located at the wellsite 104
as part of the well construction system 100, 200. The control
system 300 may also include a remote computing resource environment
306, which may be located offsite (i.e., not at the wellsite 104).
The control system 300 may also include various local controllers
(e.g., controllers 341-346 shown in FIG. 4) associated with the
subsystems 311-316 and/or individual components or equipment of the
well construction system 100, 200. As described above, each
subsystem 311-316 of the well construction system 100, 200 may
include actuators (e.g., actuators 331-336 shown in FIG. 4) and
sensors (e.g., sensors 321-326 shown in FIG. 4) for performing
operations of the well construction system 100, 200. These
actuators and sensors may be monitored and/or controlled via the
wellsite computing resource environment 305, the remote computing
resource environment 306, and/or the corresponding local
controllers. For example, the wellsite computing resource
environment 305 and/or the local controllers may be operable to
monitor the sensors of the wellsite subsystems 311-316 in
real-time, and to provide real-time control commands to the
subsystems 311-316 based on the received sensor data. Data may be
generated by sensors and/or computation and may be utilized for
coordinated control among two or more of the subsystems
311-316.
[0079] The control system 300 may be in real-time communication
with the various components of the well construction system 100,
200. For example, the local controllers may be in communication
with various sensors and actuators of the corresponding subsystems
311-316 via local communication networks (not shown), and the
wellsite computing resource environment 305 may be in communication
with the subsystems 311-316 via a data bus or network 309. As
described below, data or sensor signals generated by the sensors of
the subsystems 311-316 may be made available for use by processes
(e.g., processes 374, 375 shown in FIG. 4) and/or devices of the
wellsite computing resource environment 305. Similarly, data or
control signals generated by the processes and/or devices of the
wellsite computing resource environment 305 may be automatically
communicated to various actuators of the subsystems 311-316,
perhaps pursuant to predetermined programming, such as to
facilitate well construction operations and/or other operations
described herein.
[0080] The remote computing resource environment 306, the wellsite
computing resource environment 305, and the subsystems 311-316 of
the well construction system 100, 200 may be communicatively
connected with each other via a network connection, such as via a
wide-area-network (WAN), a local-area-network (LAN), and/or other
networks also within the scope of the present disclosure. A "cloud"
computing environment is one example of a remote computing resource
environment 306. The wellsite computing resource environment 305
may be or form at least a portion of the processing device 192 and,
thus, may form a portion of or be communicatively connected with
the control workstation 197.
[0081] FIG. 4 is a schematic view of an example implementation of
the control system 300 shown in FIG. 3 communicatively connected
with the subsystems 311-316 of the well construction system 100,
200, including the RC system 311, the FC system 312, the MPDC
system 313, the CPC system 314, the WC system 315, and the CCTV
system 316. The following description refers to FIGS. 1-4,
collectively.
[0082] The well construction system 100, 200 may include one or
more onsite user devices (OUD) 302 communicatively connected with
the wellsite computing resource environment 305. The onsite user
devices 302 may be or comprise stationary user devices intended to
be stationed at the well construction system 100, 200 and/or
portable user devices. For example, the onsite user devices 302 may
include a desktop computer, a laptop computer, a smartphone and/or
other portable smart device, a personal digital assistant (PDA), a
tablet/touchscreen computer, a wearable computer, and/or other
devices. The onsite user devices 302 may be operable to communicate
with the wellsite computing resource environment 305 of the well
construction system 100, 200 and/or the remote computing resource
environment 306. At least one of the onsite user devices 302 may be
or comprise at least a portion of the control workstation 197 shown
in FIG. 1 and/or the processing device 192 shown in FIGS. 1 and 3,
which may be located within the facility 191.
[0083] The wellsite computing resource environment 305 and/or other
portions of the well construction system 100, 200 may further
comprise an information technology (IT) system 319 operable to
communicatively interconnect various portions of the wellsite
computing resource environment 305 and/or to communicatively
connect the wellsite computing resource environment 305 with other
portions of the well construction system 100, 200. The IT system
319 may include communication conduits, software, computers, and/or
other IT equipment facilitating communication among one or more
portions of the wellsite computing resource environment 305 and/or
between the wellsite computing resource environment 305 and another
portion of the well construction system 100, 200, such as the
remote computing resource environment 306, the onsite user device
302, and the subsystems 311-316.
[0084] The control system 300 may include (or otherwise be utilized
in conjunction with) one or more offsite user devices 303. The
offsite user devices 303 may be or comprise a desktop computer, a
laptop computer, a smartphone and/or other portable smart device, a
PDA, a tablet/touchscreen computer, a wearable computer, and/or
other devices. The offsite user devices 303 may be operable to
receive and/or transmit information (e.g., for monitoring
functionality) from and/or to the well construction system 100,
200, such as by communication with the wellsite computing resource
environment 305 via the network 308. The offsite user devices 303
may be utilized just for monitoring functions. However, one or more
of the offsite user devices 303 may be utilized to provide control
processes for controlling operation of the various subsystems
311-316 of the well construction system 100, 200. The offsite user
devices 303 and/or the wellsite computing resource environment 305
may also be operable to communicate with the remote computing
resource environment 306 via the network 308. The network 308 may
be a WAN, such as the internet, a cellular network, a satellite
network, other WANs, and/or combinations thereof.
[0085] The subsystems 311-316 of the well construction system 100,
200 and the control system 300 may include sensors 321-326,
actuators 331-336, and local controllers 341-346. The controllers
341-346 may be programmable logic controllers (PLCs) and/or other
controllers having aspects similar to the example processing device
1000 shown in FIG. 23. The RC system 311 may include one or more
sensors 321, one or more actuators 331, and one or more controllers
341. The FC system 312 may include one or more sensors 322, one or
more actuators 332, and one or more controllers 342. The MPDC
system 313 may include one or more sensors 323, one or more
actuators 333, and one or more controllers 343. The CPC system 314
may include one or more sensors 324, one or more actuators 334, and
one or more controllers 344 (e.g., a BOP control station 470 shown
in FIG. 6). The WC system 315 may include one or more sensors 325,
one or more actuators 335, and one or more controllers 345. The
CCTV system 316 may include one or more sensors 326, one or more
actuators 336, and one or more controllers 346.
[0086] The sensors 321-326 may include sensors utilized for
operation of the various subsystems 311-316 of the well
construction system 100, 200. For example, the sensors 321-326 may
include cameras, position sensors, pressure sensors, temperature
sensors, flow rate sensors, vibration sensors, current sensors,
voltage sensors, resistance sensors, gesture detection sensors or
devices, voice actuated or recognition devices or sensors, and/or
other examples.
[0087] The sensors 321-326 may be operable to provide sensor data
to the wellsite computing resource environment 305, such as to the
coordinated control device 304. For example, the sensors 321-326
may provide sensor data 351-356, respectively. The sensor data
351-356 may include signals or information indicative of equipment
operation status (e.g., on or off, up or down, set or release,
etc.), drilling parameters (e.g., depth, hook load, torque, etc.),
auxiliary parameters (e.g., vibration data of a pump), flow rate,
temperature, operational speed, position, and pressure, among other
examples. The acquired sensor data 351-356 may include or be
associated with a timestamp (e.g., date and/or time) indicative of
when the sensor data 351-356 was acquired. The sensor data 351-356
may also or instead be aligned with a depth, time, and/or other
drilling parameter.
[0088] Acquiring the sensor data 351-356 at the coordinated control
device 304 may facilitate measurement of the same physical
properties at different locations of the well construction system
100, 200, wherein the sensor data 351-356 may be utilized for
measurement redundancy to permit continued well construction
operations. Measurements of the same physical properties at
different locations may also be utilized for detecting equipment
conditions among different physical locations at the wellsite
surface 104 or within the wellbore 102. Variation in measurements
at different wellsite locations over time may be utilized to
determine equipment performance, system performance, scheduled
maintenance due dates, and the like. For example, slip status
(e.g., set or unset) may be acquired from the sensors 321 and
communicated to the wellsite computing resource environment 305.
Acquisition of fluid samples may be measured by a sensor, such as
the sensors 186, 323, and related with bit depth and time measured
by other sensors. Acquisition of data from the video cameras 198,
325 may facilitate detection of arrival and/or installation of
materials or equipment at the well construction system 100, 200.
The time of arrival and/or installation of materials or equipment
may be utilized to evaluate degradation of material, scheduled
maintenance of equipment, and other evaluations.
[0089] The coordinated control device 304 may facilitate control of
one or more of the subsystems 311-316 at the level of each
individual subsystem 311-316. For example, in the FC system 312,
sensor data 352 may be fed into the controller 342, which may
respond to control the actuators 332. However, for control
operations that involve multiple systems, the control may be
coordinated through the coordinated control device 304. For
example, coordinated control operations may include the control of
downhole pressure during tripping. The downhole pressure may be
affected by each of the FC system 312 (e.g., pump rate), the MPDC
313 (e.g., choke position of the MPDC), and the RC system 311
(e.g., tripping speed). Thus, when it is intended to maintain
certain downhole pressure during tripping, the coordinated control
device 304 may be utilized to direct the appropriate control
commands to two or more (or each) of the participating
subsystems.
[0090] Control of the subsystems 311-316 of the well construction
system 100, 200 may be provided via a three-tier control system
that includes a first tier of the local controllers 341-346, a
second tier of the coordinated control device 304, and a third tier
of the supervisory control system 307. Coordinated control may also
be provided by one or more controllers 341-346 of one or more of
the subsystems 311-316 without the use of a coordinated control
device 304. In such implementations of the control system 300, the
wellsite computing resource environment 305 may provide control
processes directly to these controllers 341-346 for coordinated
control.
[0091] The sensor data 351-356 may be received by the coordinated
control device 304 and utilized for control of the subsystems
311-316. The sensor data 351-356 may be encrypted to produce
encrypted sensor data 371. For example, the wellsite computing
resource environment 305 may encrypt sensor data from different
types of sensors and systems to produce a set of encrypted sensor
data 371. Thus, the encrypted sensor data 371 may not be viewable
by unauthorized user devices (either offsite user devices 303 or
onsite user devices 302) if such devices gain access to one or more
networks of the well construction system 100, 200. The encrypted
sensor data 371 may include a timestamp and an aligned drilling
parameter (e.g., depth), as described above. The encrypted sensor
data 371 may be communicated to the remote computing resource
environment 306 via the network 308 and stored as encrypted sensor
data 372.
[0092] The wellsite computing resource environment 305 may provide
the encrypted sensor data 371, 372 available for viewing and
processing offsite, such as via the offsite user devices 303.
Access to the encrypted sensor data 371, 372 may be restricted via
access control implemented in the wellsite computing resource
environment 305. The encrypted sensor data 371, 372 may be provided
in real-time to offsite user devices 303 such that offsite
personnel may view real-time status of the well construction system
100, 200 and provide feedback based on the real-time sensor data.
For example, different portions of the encrypted sensor data 371,
372 may be sent to the offsite user devices 303. The encrypted
sensor data 371, 372 may be decrypted by the wellsite computing
resource environment 305 before transmission, and/or decrypted on
the offsite user device 303 after encrypted sensor data is
received. The offsite user device 303 may include a thin client
(not shown) configured to display data received from the wellsite
computing resource environment 305 and/or the remote computing
resource environment 306. For example, multiple types of thin
clients (e.g., devices with display capability and minimal
processing capability) may be utilized for certain functions or for
viewing various sensor data 351-356.
[0093] The wellsite computing resource environment 305 may include
various computing resources utilized for monitoring and controlling
operations, such as one or more computers having a processor and a
memory. For example, the coordinated control device 304 may include
a processing device (e.g., processing device 1000 shown in FIG. 23)
having a processor and memory for processing the sensor data,
storing the sensor data, and issuing control commands responsive to
the sensor data. As described above, the coordinated control device
304 may control various operations of the subsystems 311-316 via
analysis of sensor data 351-356 from one or more of the wellsite
subsystems 311-316 to facilitate coordinated control between the
subsystems 311-316. The coordinated control device 304 may generate
control data 373 (e.g., signals, commands, coded instructions) to
execute control of the subsystems 311-316. The coordinated control
device 304 may transmit the control data 373 to one or more
subsystems 311-316. For example, control data 361 may be sent to
the RC system 311, control data 362 may be sent to the FC system
312, control data 363 may be sent to the MPDC system 313, control
data 364 may be sent to the CPC system 314, control data 365 may be
sent to the WC system 315, and control data 366 may be sent to the
CCTV system 316. The control data 361-366 may include, for example,
wellsite operator commands (e.g., turn on or off a pump, switch on
or off a valve, update a physical property set-point, etc.). The
coordinated control device 304 may include a fast control loop that
directly obtains sensor data 351-356 and executes, for example, a
control algorithm. The coordinated control device 304 may include a
slow control loop that obtains data via the wellsite computing
resource environment 305 to generate control commands.
[0094] The coordinated control device 304 may intermediate between
the supervisory control system 307 and the local controllers
341-346 of the subsystems 311-316, such as may permit the
supervisory control system 307 to control the subsystems 311-316.
The supervisory control system 307 may include, for example,
devices for entering control commands to perform operations of the
subsystems 311-316. The coordinated control device 304 may receive
commands from the supervisory control system 307, process such
commands according to a rule (e.g., an algorithm based upon the
laws of physics for drilling operations), and provide control data
to one or more subsystems 311-316. The supervisory control system
307 may be provided by the wellsite operator 195 and/or process
monitoring and control program. In such implementations, the
coordinated control device 304 may coordinate control between
discrete supervisory control systems and the subsystems 311-316
while utilizing control data 361-366 that may be generated based on
the sensor data 351-356 received from the subsystems 311-316 and
analyzed via the wellsite computing resource environment 305. The
coordinated control device 304 may receive the control data 351-356
and then dispatch control data 361, including interlock commands,
to each subsystem 311-316. The coordinated control device 304 may
also or instead just monitor the control data 351-356 being
dispatched to each subsystem 321-326 and then initiate the machine
interlock commands to the relevant local controller 341-346.
[0095] The coordinated control device 304 may run with different
levels of autonomy. For example, the coordinated control device 304
may operate in an advice mode to inform the wellsite operators 195
to perform a specific task or take specific corrective action based
on sensor data 351-356 received from the various subsystems
311-316. While in the advice mode, the coordinated control device
304 may, for example, advise or instruct the wellsite operator 195
to perform a standard work sequence when gas is detected on the rig
floor 114, such as to close the annular BOP 132. Furthermore, if
the wellbore 102 is gaining or losing drilling fluid 140, the
coordinated control device 304 may, for example, advise or instruct
the wellsite operator 195 to modify the density of the drilling
fluid 140, modify the pumping rate of the drilling fluid 140,
and/or modify the pressure of the drilling fluid within the
wellbore 102.
[0096] The coordinated control device 304 may also operate in a
system/equipment interlock mode, whereby certain operations or
operational sequences are prevented based on the received sensor
data 351-356. While operating in the interlock mode, the
coordinated control device 304 may manage interlock operations
among the various equipment of the subsystems 311-316. For example,
if a pipe ram of the BOP stack 130 is activated, the coordinated
control device 304 may issue an interlock command to the RC system
controller 341 to stop the DW 119 from moving the drill string 120.
However, if a shear ram of the BOP stack 130 is activated, the
coordinated control device 304 may issue an interlock command to
the controller 341 to operate the DW 119 to adjust the position of
the drill string 120 within the BOP stack 130 before activating the
shear ram, so that the shear ram does not align with a shoulder of
the tubulars forming the drill string 120.
[0097] The coordinated control device 304 may also operate in an
automated sequence mode, whereby certain operations or operational
sequences are automatically performed based on the received sensor
data 351-356. For example, the coordinated control device 304 may
automatically activate an alarm and/or stop or reduce operating
speed of the pipe handling equipment when a wellsite operator 195
is detected close to a moving RN 151, the TDA 202, the LSA 228, the
LTC 244, or the catwalk 131. As another example, if the wellbore
pressure increases rapidly, the coordinated control device 304 may
automatically close the annular BOP 132, close one or more rams of
the BOP stack 130, and/or adjust the choke manifold 162.
[0098] The wellsite computing resource environment 305 may comprise
or execute a monitoring process 374 (e.g., an event detection
process) that may utilize the sensor data 351-356 to determine
information about status of the well construction system 100, 200
and automatically initiate an operational action, a process, and/or
a sequence of one or more of the subsystems 311-316. The monitoring
process 374 may initiate the operational action to be caused by the
coordinated control device 304. Depending on the type and range of
the sensor data 351-356 received, the operational actions may be
executed in the advice mode, the interlock mode, or the automated
sequence mode.
[0099] For example, the monitoring process 374 may determine a
drilling state, equipment health, system health, a maintenance
schedule, or combination thereof, and initiate an advice to be
generated. The monitoring process 374 may also detect abnormal
drilling events, such as a wellbore fluid loss and gain, a wellbore
washout, a fluid quality issue, or an equipment event based on job
design and execution parameters (e.g., wellbore, drilling fluid,
and drill string parameters), current drilling state, and real-time
sensor information from the surface equipment 110 (e.g., presence
of hazardous gas at the rig floor, presence of wellsite operators
in close proximity to moving pipe handling equipment, etc.) and the
BHA 124, initiating an operational action in the automated mode.
The monitoring process 374 may be connected to the real-time
communication network 309. The coordinated control device 304 may
initiate a counteractive measure (e.g., a predetermined action,
process, or operation) based on the events detected by the
monitoring process 374.
[0100] The term "event" as used herein may include, but not be
limited to, an operational and/or safety related event described
herein and/or another operational and safety related event that can
take place at a well construction system 100, 200. The events
described herein may be detected by the monitoring process 374
based on the sensor data 351-356 (e.g., sensor signals or
information) received and analyzed by the monitoring process
374.
[0101] The wellsite computing resource environment 305 may also
comprise or execute a control process 375 that may utilize the
sensor data 351-356 to optimize drilling operations, such as the
control of drilling equipment to improve drilling efficiency,
equipment reliability, and the like. For example, the acquired
sensor data 352 may be utilized to derive a noise cancellation
scheme to improve electromagnetic and/or mud-pulse telemetry signal
processing. The remote computing resource environment 306 may
comprise or execute a control process 376 substantially similar to
the control process 375 that may be provided to the wellsite
computing resource environment 305. The monitoring and control
processes 374, 375, 376 may be implemented via, for example, a
control algorithm, a computer program, firmware, or other hardware
and/or software.
[0102] The wellsite computing resource environment 305 may include
various computing resources, such as a single computer or multiple
computers. The wellsite computing resource environment 305 may
further include a virtual computer system and a virtual database or
other virtual structure for collected data, such as may include one
or more resource interfaces (e.g., web interfaces) that facilitate
the submission of application programming interface (API) calls to
the various resources through a request. In addition, each of the
resources may include one or more resource interfaces that
facilitate the resources accessing each other (e.g., to facilitate
a virtual computer system of the computing resource environment to
store data in or retrieve data from the database or other structure
for collected data). The virtual computer system may include a
collection of computing resources configured to instantiate virtual
machine instances. A wellsite operator 195 may interface with the
virtual computer system via the offsite user device 303 or the
onsite user device 302. Other computer systems or computer system
services may be utilized in the wellsite computing resource
environment 305, such as a computer system or computer system
service that provides computing resources on dedicated or shared
computers/servers and/or other physical devices. The wellsite
computing resource environment 305 may include a single server (in
a discrete hardware component or as a virtual server) or multiple
servers (e.g., web servers, application servers, or other servers).
The servers may be, for example, computers arranged in physical
and/or virtual configuration.
[0103] The wellsite computing resource environment 305 may also
include a database that may be or comprise a collection of
computing resources that run one or more data collections. Such
data collections may be operated and managed by utilizing API
calls. The data collections, such as the sensor data 351-356, may
be made available to other resources in the wellsite computing
resource environment 305, or to user devices (e.g., onsite user
device 302 and/or offsite user device 303) accessing the wellsite
computing resource environment 305. The remote computing resource
environment 306 may include computing resources similar to those
described above, such as a single computer or multiple computers
(in discrete hardware components or virtual computer systems).
[0104] FIGS. 5 and 6 are perspective and sectional views of at
least a portion of an example implementation of a control center
400 according to one or more aspects of the present disclosure. The
control center 400 may be or form at least a portion of the control
center 190 shown in FIG. 1. The following description refers to
FIGS. 1-6, collectively.
[0105] The control center 400 comprises a facility 405 (e.g., a
room, a cabin, a trailer, etc.) containing various control devices
for monitoring and controlling the subsystems 311-316 and other
portions of the well construction system 100, 200. The facility 405
may comprise a front side 401 and a rear side 403. The front side
401 may be directed toward or located closest to the drill string
120 being constructed by the well construction system 100, 200. The
rear side 403 may be directed away from the drill string 120. The
facility 405 may comprise a floor 402, a front wall 404, a left
wall 406, a right wall 408, a rear wall 410, and a roof 412. The
facility 405 may also have a side door 414, a rear door 416, and a
plurality of windows 421-428 in one or more of the walls 404, 406,
408, 410 and/or the roof 412. Each of the windows 421-428 may be
surrounded by structural framing 430 connected with the walls and
supporting window safety guards 432 (e.g., bars, grills) in front
of or along the windows 421-428.
[0106] The facility 405 may have an observation area 440 at the
front side 401 of the facility 405 from which a wellsite operator
195 may have a direct view of the drill string 120, the rig floor
114, and/or other portions of the well construction system 100,
200. The observation area 440 may be surrounded or defined by
windows 423-428 on several sides to increase the wellsite
operator's 195 horizontal and vertical angle of view of the well
constriction system 100. A portion 442 of the observation area 440
(e.g., windows 423-427) may protrude or extend out past other
portions of the facility 405 (e.g., front wall 404) to facilitate
the view of the well construction system 100, 200 by the wellsite
operators 195. The observation area 440 may be located on a side of
the facility 405. The observation area 440 may be surrounded by or
at least partially defined by a front window 424 permitting the
wellsite operator 195 to look forward, two side windows 423, 425
permitting the wellsite operator 195 to look sideways (i.e., left
and right), a lower window 426 permitting the wellsite operator 195
to look downwards, and one or more upper windows 427, 428
permitting the wellsite operator 195 to look upwards. The lower
window 426 and/or at least one upper window 427 may extend
diagonally with respect to the front window 424.
[0107] The control center 400 may comprise one or more wellsite
operator control workstations within the facility 405. The
workstations may be utilized by the wellsite operators 195 to
monitor and control the subsystems 311-316 and other portions of
the well construction system 100, 200. For example, the observation
area 440 may contain a first control workstation 450 located
adjacent the windows 423, 424, 425, 426, 428 and at least partially
within the extended portion 442 of the observation area 440, such
as may permit the wellsite operator 195 utilizing the control
workstation 450 to have an unobstructed view of the drill string
120, the rig floor 114, and/or other portions of the well
construction system 100, 200. The observation area 440 may also
contain a second control workstation 452 located adjacent (e.g.,
behind) the first control workstation 450 and adjacent the window
425, but perhaps not within the extended portion 442 of the
observation area 440. The control workstation 452 may be elevated
at least partially above the control workstation 450 to reduce the
obstruction of view caused by the control workstation 450 and,
thus, permit the wellsite operator 195 utilizing the control
workstation 452 to view the drill string 120, the rig floor 114,
and/or other portions of the well construction system 100, 200 over
the control workstation 450 via the front window 424. The control
center 400 may also comprise a third control workstation 454
located adjacent the control workstations 450, 452 and adjacent the
windows 421, 422, but not within the observation area 440.
[0108] The control center 400 may further comprise a processing
device 456 (e.g., a controller, a computer, a server, etc.)
operable to provide control to one or more portions of the well
construction system 100, 200 and/or operable to monitor operations
of one or more portions of the well construction system 100, 200.
For example, the processing device 456 may be communicatively
connected with the various surface and downhole equipment described
herein, and may be operable to receive signals from and transmit
signals to such equipment to perform various operations described
herein or otherwise within the scope of the present disclosure. The
processing device 456 may store executable programs, instructions,
and/or operational parameters or set-points, including for
implementing one or more aspects of the operations described
herein. The processing device 456 may be communicatively connected
with the control workstations 450, 452, 454. Although the
processing device 456 is shown located within the facility 405, the
processing device 456 may be located outside of the facility 405.
Furthermore, although the processing device 456 is shown as a
single device that is separate and distinct from the control
workstations 450, 452, 454, one or more of the control workstations
450, 452, 454 may comprise a corresponding processing device 456
disposed in association with or forming at least a portion of such
corresponding processing device 456.
[0109] The control workstations 450, 452, 454 may be operable to
enter or otherwise communicate commands to the processing device
456 by the wellsite operator 195 and to display or otherwise
communicate information from the processing device 456 to the
wellsite operator 195. One or more of the control workstations 450,
452, 454 may comprise an operator chair 460 and an HMI system
comprising one or more input devices 462 (e.g., a keyboard, a
mouse, a joystick, a touchscreen, a microphone, etc.) and one or
more output devices 464 (e.g., a video monitor, a printer, audio
speakers, a touchscreen, etc.). The input and output devices 462,
464 may be disposed in association with and/or integrated with the
operator chair 460 to permit the wellsite operator 195 to enter
commands or other information to the processing device 456, and to
view, hear, and/or otherwise receive information from the
processing device 456 and other portions of the well construction
system 100, 200. One or more of the control workstations 450, 452,
454 may be or form at least a portion of the control workstation
197 shown in FIG. 1, and the processing device 456 may be or form
at least a portion of the processing device 192 shown in FIG.
1.
[0110] The control center 400 may further contain a BOP control
station 470 (e.g., control panel) of the WC system 315 operable to
monitor and control one or more portions of the WC system 315. For
example, the BOP control station 470 may be communicatively
connected with the BOP control unit 137 and the BOP equipment 130,
132, and may be operable to monitor and control operations of the
BOP control unit 137 and the BOP equipment 130, 132.
[0111] The BOP control station 470 may be operable communicate to
the BOP control unit 137 control commands entered by the wellsite
operator 195 for controlling the BOP equipment 130, 132 and to
display or otherwise communicate information indicative of
operational status of the BOP equipment 130, 132 and the BOP
control unit 137 to the wellsite operator 195. The BOP control
station 470 may comprise a processing device (e.g., processing
device 1000 shown in FIG. 23) operable to store executable
programs, instructions, and/or operational parameters or
set-points, including for implementing one or more BOP operations
described herein. The BOP control station 470 may further comprise
an HMI system comprising one or more input devices 472 (e.g.,
buttons, keys, a touchscreen, etc.) and one or more output devices
474 (e.g., a video monitor, gauges, audio speakers, a touchscreen,
etc.). The input and output devices 472, 474 may be disposed in
association with and/or integrated with a housing or enclosure of
the BOP control station 470 to permit the wellsite operator 195 to
enter commands or other information to the BOP control station 470
to control the BOP equipment 130, 132 and receive information from
the BOP control station 470 to monitor operational status of the
BOP equipment 130, 132.
[0112] The BOP control unit 470 may be communicatively connected
with one or more of the control workstations 450, 452, 454, such as
may permit monitoring and control of one or more portions of the WC
system 315 via the control workstations 450, 452, 454. For example,
one or more of the control workstations 450, 452, 454 or the
processing device 456 may be communicatively connected directly
with the processing device of the BOP control station 470 or
indirectly, such as via the input and output devices 472, 474 of
the BOP control station 470. Such connection may permit the control
workstations 450, 452, 454 to receive information indicative of
operational status of the BOP control unit 137 and the BOP
equipment 130, 132 via the BOP control station 470. Such connection
may further permit the control workstations 450, 452, 454 to
transmit control commands to the BOP control unit 137 and the BOP
equipment 130, 132 via the BOP control station 470. Such connection
may also or instead facilitate control of the BOP control station
470 via the control workstations 450, 452, 454, such as may cause
the BOP control station 470 to control the BOP control unit 137 and
the BOP equipment 130, 132 as directed by or from the control
workstations 450, 452, 454.
[0113] The control workstations 450, 452, 454 may be operable to
display the information indicative of operational status of the BOP
control unit 137 and the BOP equipment 130, 132 to the wellsite
operator 195 via the output devices 464 to permit the wellsite
operator to monitor the operational status of the BOP control unit
137 and the BOP equipment 130, 132 while sitting in the
corresponding operator chair 460. The control workstations 450,
452, 454 may be further operable to receive the control commands
from the wellsite operator 195 via the input devices 462 while
sitting in the corresponding operator chair 460 for transmission to
the BOP control station 470 to control the BOP control unit 137 and
the BOP equipment 130, 132.
[0114] FIG. 7 is a top view of a portion of an example
implementation of a wellsite operator control workstation 500
communicatively connected with and operable to control the well
construction system 100, 200 according to one or more aspects of
the present disclosure. The control workstation 500 depicted in
FIG. 7 is an example implementation of the control workstations
450, 452, 454 described above. The control workstation 500 may
facilitate receiving and displaying various information, such as
sensor signals or information (e.g., sensor data 351-356), control
commands (e.g., control data 361-366), processes taking place,
events being detected, and operational status of various equipment
of the subsystems 311-316 of the well construction system 100, 200.
The following description refers to FIGS. 1-7, collectively.
[0115] The control workstation 500 comprises an operator chair 502
(e.g., driller's chair) and an HMI system comprising a plurality of
input and output devices integrated with, supported by, or
otherwise disposed in association with the operator chair 502. The
input devices permit the wellsite operator 195 to enter commands or
other information to control the wellsite equipment of the well
construction system 100, 200, and the output devices permit the
wellsite operator 195 to receive sensor signals and other
information indicative of operational status of the wellsite
equipment. The operator chair 502 may include a seat 504, a left
armrest 506, and a right armrest 508.
[0116] The input devices of the control workstation 500 may include
a plurality of physical controls, such as a left joystick 510, a
right joystick 512, and/or other physical controls 514, 515, 516,
518, such as buttons, keys, switches, knobs, dials, slider bars, a
mouse, a keyboard, and a microphone. One or more of the joysticks
510, 512 and/or the physical controls 514, 515, 516 may be
integrated into or otherwise supported by the corresponding
armrests 506, 508 of the operator chair 502 to permit the wellsite
operator 195 to operate these input devices from the operator chair
502. Furthermore, one or more of the physical controls 518 may be
integrated into the corresponding joysticks 510, 512 to permit the
wellsite operator 195 to operate these physical controls 518 while
operating the joysticks 510, 512. The physical controls may
comprise emergency stop (E-stop) buttons 515, which may be
electrically connected to E-stop relays of one or more pieces of
wellsite equipment (e.g., the RN 151, the TDA 202, the DW 119, the
LSA 228, the LTC 244, the SGA 262, the top drive 116, etc.), such
that the wellsite operator 195 can shut down the wellsite equipment
during emergencies and other situations.
[0117] The output devices of the control workstation 500 may
include one or more video output devices 526 (e.g., video
monitors), printers, speakers, and other output devices disposed in
association with the operator chair 502 and operable to display to
the wellsite operator 195 sensor signals and other information
indicative of operational status of the well construction system
100, 200. The video output devices 526 may be implemented as one or
more LCD displays, LED displays, plasma displays, cathode ray tube
displays, and/or other types of displays.
[0118] The video output devices 526 may be disposed in front of or
otherwise adjacent the operator chair 502. The video output devices
526 may include a plurality of video output devices 532, 534, 536,
each dedicated to displaying predetermined information in a
predetermined (e.g., programmed) manner. Although the video output
devices 526 are shown comprising three video output devices 532,
534, 536, the video output devices 526 may be or comprise one, two,
four, or more video output devices.
[0119] The video output devices 532, 534, 536 may each display in a
predetermined manner selected sensor signals or information
indicative of operational status of a selected portion of the well
construction system 100, 200. For example, the video output devices
534, 536 may display sensor signals or information 540 (e.g.,
sensor data 351-356) generated by the various sensors (e.g.,
sensors 321-326) of the well construction system 100, 200 to permit
the wellsite operator 195 to monitor operational status of the
subsystems 311-316. The information 540 may be displayed in the
form of virtual or computer-generated lists, menus, tables, graphs,
bars, gauges, lights, and schematics, among other examples.
[0120] One or more of the video output devices 526 may be
configured to display video signals (i.e., video feeds) generated
by one or more of the video cameras 198. For example, the video
output device 532 may be dedicated for displaying the video signals
generated by one or more of the video cameras 198. When displaying
the video signals from multiple video cameras 198, the video output
device 532 may display multiple video windows, each displaying a
corresponding video signal. Furthermore, one or more of the other
video output devices 534, 536 may also display the video signals
from one or more of the video cameras 198. For example, one or both
of the video output devices 534, 536 may display one or more
picture-in-picture (PIP) video windows 544, each displaying a video
signal from a corresponding one of the video cameras 198. The PIP
video windows 544 may be embedded or inset along or adjacent the
sensor information 540. Sourcing (i.e., selection) of the video
cameras 198 whose video signals are to be displayed on the video
output devices 526 may be selected manually by the wellsite
operator 195 or automated via the control system 300, such as based
on operational events (e.g., drilling events, well construction
operation stage, etc.) at the well construction system 100, 200,
such that video signals relevant to an event currently taking place
are displayed.
[0121] The control workstation 500 may further comprise combination
devices operable as both input and output devices to display
information to the wellsite operator 195 and receive commands or
information from the wellsite operator 195. Such devices may be or
comprise touchscreens 522, 524 operable to display a plurality of
software (e.g., virtual, computer generated) buttons, switches,
knobs, dials, icons, and/or other software controls 530 permitting
the wellsite operator 195 to operate (e.g., click, select, move)
the software controls 530 via finger contact with the touchscreens
522, 524 to control the various wellsite equipment of the
subsystems 311-316. The software controls 530 may also be operated
by the physical controls 514, 516, the joysticks 510, 512, or other
input devices of the control workstation 500. The software controls
530 and/or other features displayed on the touchscreens 522, 524
may also display sensor signals or information (e.g., sensor data
351-356), operational settings, set-points, and/or status of
selected wellsite equipment for viewing by the wellsite operator
195. For example, the software controls 530 may change color, move
in position or direction, and/or display the sensor information,
set-points, and/or operational values (e.g., temperature, pressure,
position). The touchscreens 522, 524 may be disposed on, supported
by, or integrated into the armrests 506, 508 or other parts of the
operator chair 502 to permit the wellsite operator 195 to operate
the software controls 530 displayed on the touchscreens 522, 524
from the operator chair 502.
[0122] Each video output device 526 and touchscreen 522, 524 may
display (i.e., generate) a plurality of display screens (i.e., an
integrated display system), each displaying to the wellsite
operator 195 selected sensor signals or information 540 indicative
of operational status of the well construction system 100, 200 and
software controls 530 for controlling selected portions of the well
construction system, respectively. Each display screen may
integrate the software controls 530 and/or sensor information 540
from one or more pieces of wellsite equipment (e.g., subsystems
311-316) with information generated by the control system 300
(e.g., the monitoring process 374, the control process 375, and the
control data 361-366, 373) for viewing and/or operating by the
wellsite operator 195. The display screens may be shown or
displayed alternately on one or more of the video output devices
526 and/or the touchscreens 522, 524 or simultaneously on one or
more of these devices. The display screens intended to be displayed
on the video output devices 526 and/or the touchscreens 522, 524
may be selected by the wellsite operator 195 via the physical
controls 514, 516, 518 and/or software controls 530. The display
screens intended to be displayed on the video output devices 526
and/or the touchscreens 522, 524 may also or instead be selected
automatically by the control system 300 based on operational events
detected (e.g., equipment failures, hazardous drilling conditions)
or planned (e.g., changing phases or stages of the well
construction operations) at the well construction system 100, 200,
such that information relevant to the event currently taking place
is displayed. Each display screen generated by the touchscreens
522, 524 may display software controls 530 operable by the wellsite
operator 195 to control the wellsite equipment associated with the
software controls 530, and each display screen generated by the
video output devices 526 may display information 540 indicative of
operational status of the wellsite equipment associated with the
information 540. Accordingly, the display screens displayed on the
touchscreens 522, 524 may be referred to hereinafter as control
screens, and the display screens displayed on the video output
devices 526 may be referred to hereinafter as status screens.
[0123] The touchscreens 522, 524 may be operable to display one or
more control screens (e.g., configuration screens), which may be
utilized to operate, set, adjust, configure, or otherwise control
the subsystems 311-316 or other wellsite equipment. Each control
screen may display one or more software controls 530, such as may
permit the wellsite operator 195 to operate, set, adjust,
configure, or otherwise control the subsystems 311-316 or other
wellsite equipment via finger contact with the touchscreens 522,
524 from the operator chair 502. FIGS. 8-10 are example
implementations of software controls 552, 554, 556 that may be
displayed on the touchscreens 522, 524 and operated by the wellsite
operator 195 to operate, set, adjust, configure, or otherwise
control the subsystems 311-316 or other wellsite equipment of the
well construction system 100, 200. The following description refers
to FIGS. 7-10, collectively.
[0124] The software controls 552, 554, 556 may be pressed, clicked,
selected, moved, or otherwise operated via the physical controls
514, 516 and/or via finger contact by the wellsite operator 195 to
increase, decrease, change, or otherwise enter operational
parameters, set-points, and/or instructions for controlling one or
more pieces of wellsite equipment of the well construction system
100, 200. The software controls 552, 554, 556 may also display the
entered and/or current operational parameters on or in association
with the software controls 552, 554, 556 for viewing by the
wellsite operator 195. The operational parameters, set-points,
and/or instructions associated with the software controls 552, 554,
556 may include equipment operational status (e.g., on or off, up
or down, set or release, position, speed, temperature, etc.),
drilling parameters (e.g., depth, hook load, torque, etc.),
auxiliary parameters (e.g., vibration data of a pump), and fluid
parameters (e.g., flow rate, pressure, temperature, etc.), among
other examples. The software controls 552 may be or comprise
software buttons, which may be operated to increase, decrease,
change, or otherwise enter different operational parameters,
set-points, and/or instructions for controlling one or more
portions of the well construction system 100, 200 associated with
the software controls 552. The software controls 554 may be or
comprise a list or menu of items (e.g., equipment, processes,
operational stages, equipment subsystems, etc.) related to one or
more aspects of the well construction system 100, 200, which may be
operated to select one or more items on the list. The selected
items may be highlighted, differently colored, or otherwise
indicated, such as via a checkmark, a circle, a dot, or other
characters/icons appearing in association with the selected items.
The software controls 556 may be or comprise a combination of
different software controls, which may be operated to increase,
decrease, change, or otherwise enter different operational
parameters, set-points, and/or instructions for controlling one or
more portions of the well construction system 100, 200 associated
with the software controls 556, such as a pump of the well
construction system 100, 200. The software controls 556 may include
a slider 553, which may be moved or otherwise operated along a
graduated bar to increase, decrease, or otherwise change pump speed
or another operational parameter associated with the slider bar
553. The entered pump speed may be shown in a display window 555.
The software controls 556 may also include software buttons 557,
such as may be operated to start, pause, and stop operation of the
pump or another portion of the well construction system 100, 200
associated with the software buttons 557.
[0125] FIGS. 11-15 are example implementations of control screens
601-605 (e.g., configuration screens or menus) that may be
displayed on the touchscreens 522, 524 according to one or more
aspects of the present disclosure. Each control screen 601-605 may
be operated via finger contact with the touchscreens 522, 524
(and/or other input means) by the wellsite operator 195 to operate,
set, adjust, configure, or otherwise control the subsystems 311-316
or other wellsite equipment of the well construction system 100,
200 associated with or displayed on the control screen 601-605. The
following description refers to FIGS. 11-15, collectively.
[0126] Each control screen, including the control screens 601-605,
may display a selection bar 610 for switching between or selecting
which control screen is to be displayed on the corresponding
touchscreen 522, 524 and/or which status screen is to be displayed
on each of the video output devices 526. Each control screen may
also comprise an equipment control area 618 for displaying software
controls for controlling well construction operations and/or
wellsite equipment associated with the control screen. The
selection bar 610 may comprise an equipment menu button 612, which
when operated by the wellsite operator 195, may cause a control
screen selection menu 614 (e.g., a dropdown or pop-up menu) to
appear. The selection menu 614 may contain a plurality of buttons
616, each associated with and listing a corresponding well
construction operation or wellsite equipment to be controlled. The
wellsite operator 195 may operate (e.g., click on, touch, and/or
otherwise select) one of the buttons 616 to select a well
construction operation or wellsite equipment, thereby causing a
corresponding control screen for controlling the associated well
construction operation or wellsite equipment to be displayed.
[0127] After one of the buttons 616 is selected, a plurality of
software controls 630 (shown in FIGS. 12-15) may appear in the
equipment control area 618, and the well construction operation or
wellsite equipment that is selected may be listed or otherwise
identified in a control screen identification area 620. The
software controls 630 or other information displayed in the
equipment control area 618 will change when the wellsite operator
195 switches between the various control screens by selecting
different buttons 616. As shown in FIG. 11, example control screens
that may be selected for display on the touchscreens 522, 524 may
include a tripping control screen displaying software controls for
controlling automatic operation of wellsite equipment collectively
operable to perform tripping operations, a drilling control screen
displaying software controls for controlling automatic operation of
wellsite equipment collectively operable to perform drilling
operations, a drill pipe handling control screen displaying
software controls for controlling automatic operation of wellsite
equipment collectively operable to move drill pipes at the
wellsite, and a plurality of individual equipment control screens
each displaying software controls for automatically and/or manually
controlling operation of individual wellsite equipment, such as the
catwalk 131, the TDA 202, the setback 164, the FIB 166, the TBR
254, the SGA 262, the LTC 244, the ITC 236, the UTC 242, the LSA
228, the setback 164, the catwalk 131, the top drive 116, the RN
151, the choke 162, and fluid reconditioning equipment 170, among
other examples. Although not described herein, the control screens
within the scope of the present disclosure may include control
screens displaying software controls of other individual wellsite
equipment and/or wellsite equipment subsystems (e.g., subsystems
311-316).
[0128] Each control screen, including the control screens 601-605,
may also be utilized to switch between or select which status
screen is to be displayed on which video output device 532, 534,
536. For example, the selection bar 610 may comprise status screen
selection buttons 622, each associated with a corresponding one of
the video output devices 532, 534, 536 and, when operated by the
wellsite operator 195, operable to cause a corresponding status
screen selection menu 624 (e.g., a dropdown or pop-up menu) to
appear. Each selection menu 624 may contain a plurality of buttons
626, each associated with and listing a corresponding well
construction operation, wellsite equipment, and/or subsystem (e.g.,
subsystem 311-316) of the well construction system 100, 200 to be
displayed. The wellsite operator 195 may operate (e.g., click on,
touch, and/or otherwise select) one of the buttons 622 and buttons
626 to select one of the video output devices 532, 534, 536 and a
well construction operation, wellsite equipment, or subsystem,
thereby causing a corresponding status screen displaying sensor
signals or information 540 indicative of operational status of the
selected well construction operation, wellsite equipment, or
subsystem to be displayed on the selected video output device 532,
534, 536. The status screens that may be displayed on the video
output devices 532, 534, 536 are described in more detail
below.
[0129] When operated, the software controls 630 may activate,
deactivate, start, stop, configure, or otherwise control operation
of the wellsite equipment associated with the software controls
630. The software controls 630 may initiate automatic operation of
the wellsite equipment associated with the control screen, such as
by operating an "AUTO" software button. The software controls 630
may also cause manual control of the wellsite equipment associated
with the control screen to be given to the wellsite operator 195,
such as by operating a "MANUAL" software button. The software
controls 630 may be grouped by related equipment and/or related
operations, which may be identified by text 632 associated with
each group of software controls 632.
[0130] Furthermore, each software control 630 may list or otherwise
identify the piece of equipment or operation that is controlled or
otherwise associated with the software control 630. One or more of
the software controls 630 may list or otherwise indicate the
operational status (i.e., feedback) of the wellsite equipment or
operation associated with the software control 630. For example,
one or more of the software controls 630 may change color, text,
shape, or otherwise change to indicate that a piece of wellsite
equipment associated with the software control 630 is activated,
deactivated, or in a predetermined position, or that an operation
associated with the software control 630 has commenced, stopped, or
is in a particular stage.
[0131] FIG. 12 is an example implementation of a "DRILLING" control
screen 602 that may be utilized to control automated,
semi-automated, and/or manual operation of wellsite equipment
associated with and/or collectively operable to perform drilling
operations according to one or more aspects of the present
disclosure. The control screen 602 may display in the equipment
control area 618 various software controls 630 for controlling
various wellsite equipment and/or operational parameters of the
drilling operations performed by well construction system 100, 200.
For example, when operated, the software controls 630 may activate,
deactivate, start, stop, configure, or otherwise control automated,
semi-automated, and/or manual operation of the wellsite equipment
associated with the drilling operations. Such wellsite equipment
may include the top drive 116, the DW 119, the pump 144, and the
BOP equipment 130, 132, among other examples.
[0132] FIG. 13 is an example implementation of an "PIPE HANDLING"
control screen 603 that may be utilized to control automated,
semi-automated, and/or manual operation of wellsite equipment
associated with and/or collectively operable to perform drill pipe
handling (e.g., moving, storing) operations according to one or
more aspects of the present disclosure. The control screen 603 may
display in the equipment control area 618 various software controls
630 for controlling various wellsite equipment and/or operational
parameters of the drill pipe handling operations performed by well
construction system 100, 200. For example, when operated, the
software controls 630 may activate, deactivate, start, stop,
configure, or otherwise control automated, semi-automated, and/or
manual operation of the wellsite equipment associated with the
drill pipe handling operations. Such wellsite equipment may include
the catwalk 131, the TDA 202, the setback 164, the FIB 166, the TBR
254, the SGA 262, the LTC 244, the ITC 236, the UTC 242, the LSA
228, the RN 151, and the reciprocating slips 161, among other
examples.
[0133] FIG. 14 is an example implementation of a "TOP DRIVE"
control screen 604 that may be utilized to control automated,
semi-automated, and/or manual operation of the top drive 116
according to one or more aspects of the present disclosure. The
control screen 604 may display in the equipment control area 618
various software controls 630 for configuring and/or controlling
automated, semi-automated, and/or manual operations performed by
the top drive 116 and/or operational parameters associated with the
top drive 116. For example, when operated, the software controls
630 may activate, deactivate, start, stop, configure, or otherwise
control operation of one or more portions of the top drive 116,
such as the drive shaft 125, the grabber, the swivel, the tubular
handling assembly 127, and other portions of the top drive 116. The
software controls 630 may also be utilized to control other
wellsite equipment that may be directly or closely associated with
or operate in close association with the top drive 116, such as the
RN 151.
[0134] FIG. 15 is an example implementation of a "ROUGHNECK 1"
control screen 605 that may be utilized to control automated,
semi-automated, and/or manual operation of one of the RNs 151
according to one or more aspects of the present disclosure. The
control screen 605 may display in the equipment control area 618
various software controls 630 for configuring or controlling
automated, semi-automated, and/or manual operations performed by
the RN 151 and/or operational parameters associated with the RN
151. For example, when operated, the software controls 630 may
activate, deactivate, start, stop, configure, or otherwise control
operation of one or more portions of the RN 151, such as the
spinner and the torque wrench, including the upper and lower tongs
and the associated clamps. The software controls 630 may also be
utilized to control other wellsite equipment that may be directly
or closely associated with or operate in close association with the
RN 151.
[0135] The video output devices 126 and/or the touchscreens 522,
524 may also display manual control guide menus or screens utilized
by the wellsite operator 195 to guide or assist the wellsite
operator 195 to manually control selected operations of the well
construction system 100, 200 or an individual piece of wellsite
equipment. The guide screens may display control functions of a
selected one of the joysticks 510, 512, the associated physical
controls 518, and/or other physical controls 514, 516 with respect
to a selected operation or a piece of wellsite equipment. Manual
control may be initiated, for example, when the "MANUAL" software
control 630 button is selected on one of the control screens
displayed on one of the touchscreens 522, 524. Thereafter, the
control system 300 may abort automatic operation of the associated
wellsite equipment, transfer operational control to a predetermined
joystick 510, 512 and/or other physical controls 514, 516, and
display a corresponding manual control guide listing the control
functions for manually controlling the wellsite equipment
associated with the control screen.
[0136] FIG. 16 is an example implementation of a manual control
guide screen 606 displaying control functions for controlling
drilling operations via the left joystick 510 and physical controls
514. The guide screen 606 may display a title bar 640 identifying
an operation or wellsite equipment to be controlled and the
joystick 510 and/or physical controls 514 for controlling such
operation or wellsite equipment. The guide screen 606 may comprise
a joystick control area 642 displaying a schematic view 644 of the
joystick 510 and a schematic view 646 of the associated physical
controls 518 (e.g., joystick buttons and thumb lever). Each
schematic button 646 is associated with text 638 describing control
functions of each corresponding physical button 518 of the joystick
510. The joystick control area 642 may further display arrows 648
and corresponding text 650 describing control functions associated
with movements of the joystick 510, and arrows 652 and
corresponding text 654 describing control functions associated with
movement of the joystick thumb lever 518. The guide screen 606 may
also comprise a button control area 656 displaying schematic views
658 of the corresponding physical controls 514. The button control
area 656 may further display text 660 describing control functions
associated with operation of each of the corresponding physical
controls 514. The guide screen 606 may further display an "EXIT"
software control 662, which may be operated to abort manual control
of the drilling operations and close the guide screen 606.
[0137] As described above with respect to FIG. 7, an operator
workstation within the scope of the present disclosure may display
on one or more of the video output devices 526 a plurality of
status screens, each displaying selected sensor signals or
information (e.g., sensor data 351-356) generated by various
sensors (e.g., sensors 321-326) of the wellsite construction system
100, such as may permit the wellsite operator to monitor
operations, wellsite equipment, and/or equipment subsystems (e.g.,
subsystems 311-316) described herein. FIGS. 17-21 are views of
example implementations of status screens 701-706 displayed on one
or more of the video output devices 526 according to one or more
aspects of the present disclosure. The following description refers
to FIGS. 1-4, 7, and 17-21, collectively.
[0138] The status screens, including the status screens 701-706,
may be displayed alternatingly on one of the video output devices
526. Some of the status screens may display operational status of a
well construction operation (e.g., tripping, drilling, pipe
handling, etc.) involving a plurality of pieces of wellsite
equipment operating in a coordinated manner to perform such
operation, which may permit the wellsite operator 195 to monitor
operational status or parameters of such operation on a single
status screen. Some of the status screens may display operational
status of a single piece of wellsite equipment or a subsystem
(e.g., subsystem 311-316) of wellsite equipment, such as may also
permit the wellsite operator 195 to monitor operational status or
parameters of a single piece of equipment or an equipment
subsystem. As described above, the status screen and the
corresponding operation, wellsite equipment, or equipment subsystem
may be selected via the touchscreens 522, 524. As shown in FIG. 11,
example status screens that may be selected for display may include
a tripping status screen displaying information indicative of
operational status of the tripping operations, a drilling status
screen displaying information indicative of operational status of
the drilling operations, a pipe handing status screen displaying
information indicative of operational status of the drill pipe
handling operations, and a plurality of subsystem status screens
each displaying information indicative of operational status of the
corresponding subsystem of the well construction system 100, 200.
Although not described herein, the status screens within the scope
of the present disclosure may also or instead include status
screens displaying information indicative of operational status of
individual pieces of wellsite equipment described herein.
[0139] The status screens, including the status screens 701-706,
may comprise a wellsite status screen indicator and alarm window or
area 710, which may visually indicate which operation or wellsite
equipment is being displayed on a selected video output device 526
and if safety or operational alarms associated with an operation or
wellsite equipment are active. For example, the area 710 may
include a plurality of indicators 712 (e.g., text, icons, graphics,
etc.) listing operations, wellsite equipment, and/or equipment
subsystems that may be displayed via corresponding status screens.
The indicator 712 corresponding to the operation, wellsite
equipment, or equipment subsystem of the currently displayed status
screen may appear or become lit, highlighted, or otherwise marked
to indicate to the wellsite operator 195 which status screen is
displayed. The area 710 may further include a plurality of alarm or
event indicators 714 (e.g., lights), each associated with a
corresponding operation, wellsite equipment, or equipment subsystem
indicator 712. One or more of the indicators 714 may activate
(e.g., light up, change color, etc.), such as via operation of the
control system 300 (shown in FIG. 4), to visually inform the
wellsite operator 195 of an alarm or operational event taking place
at or associated with a corresponding operation, wellsite
equipment, or equipment subsystem. Responsive to the event
indicator 714 being activated, the wellsite operator 195 may switch
to a status screen corresponding to the activated event indicator
714 to assess the event and/or implement appropriate counteractive
measures or actions. Instead of manually changing between the
status screens, the status screens may change automatically to show
the status screen corresponding to the operation, wellsite
equipment, or equipment subsystem experiencing the event.
[0140] The status screens, including the status screens 701-706,
may further comprise a primary operational status window or area
716, displaying selected sensor signals or information indicative
of operational status of the operation, wellsite equipment, or
equipment subsystem associated with the displayed status screen.
The information displayed in the primary operational status area
716 may be generated by the actual wellsite equipment performing
the operation or forming the equipment subsystem associated with
the displayed status screen. The information displayed in the
primary operational status area 716 may change when a different
display screen is displayed. The information in the primary
operational status area 716 may be displayed in the form of lists,
menus, tables, graphs, bars, gauges, lights, and/or schematics,
among other examples.
[0141] The status screens, including the status screens 701-706,
may further comprise a secondary operational status window or area
718, displaying selected sensor signals or information indicative
of operational status of drilling operations and/or general status
of the well construction operations, such as may permit the
wellsite operator to monitor progress of the drilling operations
and/or other well construction operations while monitoring a
specific operation, wellsite equipment, or equipment subsystem
displayed in the primary operational status area 716. The secondary
operational status area 718 may also display sensor signals or
information indicative of operational status of other wellsite
equipment that is related to, but not necessarily performing, the
drilling operations. The information that is displayed in the
secondary operational status area 718 may remain unchanged or
change partially when a different status screen is displayed, such
as may permit the wellsite operator 195 to monitor progress of the
drilling operations and/or other well construction operations while
monitoring different operations, wellsite equipment, or equipment
subsystems associated with the different status screens.
[0142] However, the information that is displayed in the secondary
operational status area 718 may change when a different status
screen is displayed. The changing information may permit the
wellsite operator 195 to monitor operational status of other
wellsite equipment that is related to, but not necessarily directly
performing, the operation displayed in the primary operational
status area 716, and/or to monitor operational status of other
wellsite equipment that is related to the wellsite equipment or
equipment subsystem displayed in the primary operational status
area 716. The information in the secondary operational status area
718 may be displayed in the form of lists, menus, tables, graphs,
bars, gauges, lights, and/or schematics, among other examples.
[0143] Each status screen, including the status screens 701-706,
may also comprise a detailed description window or area 720 listing
and/or describing one or more aspects related to the operation,
wellsite equipment, or equipment subsystem displayed in the primary
operational status area 716 or another aspect of the well
construction operations. For example, as shown in FIGS. 17 and 18,
the description area 720 may display general and/or detailed
description of work or activities (e.g., a construction or job
plan) that was, is, or will be performed or overseen at the
wellsite by the wellsite operator 195. The description area 720 may
display proactive information regarding the work and/or
call-to-actions guiding future work. The description of work may
include a title or name of the project stage or phase, an estimated
completion date (i.e., deadline) for completing the project stage,
and/or a list of operational steps or actions to be implemented by
the wellsite operator 195 during the project stage. However, the
control system 300 may automatically operate the wellsite equipment
or subsystem to automatically implement such steps or actions
pursuant to the construction or job plan, such as by transmitting
predetermined control commands to a corresponding piece of wellsite
equipment or subsystem. Such automated operations may be initiated,
for example, by operating an "AUTO" software button 630 on an
associated control screen, as described above.
[0144] As shown in FIGS. 19-21, the description area 720 may also
or instead display detailed description or information related to
the events detected or otherwise taking place at the well
construction system 100, 200. The description area 720 may also
list and/or describe one or more counteractive measures (e.g.,
corrective actions, operational sequences) related to the event
that may be performed or otherwise implemented in response to the
event. Depending on the event and/or mode (e.g., advice, interlock,
automated) in which the control system 300 (e.g., the computing
resource environment 305) is operating, the description area 720
may describe the corrective action to be initiated or otherwise
implemented by the wellsite operator 195. However, the control
system 300 may automatically implement the corrective action, or
cause the corrective action to be automatically implemented, such
as by transmitting predetermined control commands to a
corresponding piece of wellsite equipment or subsystem. The
information displayed in the description area 720 may just display
events and/or corrective actions related to the operation, wellsite
equipment, or equipment subsystem shown in the primary operational
status area 716 and, thus, change when switching between the status
screens. However, the information displayed in the description area
720 may not change when switching between the status screens, and
may list each detected event and/or corresponding corrective
action, such as in chronological order or in the order of
importance. As described above, the control system 300 may
automatically change the status screen to show the operation,
wellsite equipment, or equipment subsystem experiencing the
event.
[0145] Each status screen, including the status screens 701-706,
may further include one or more PIP video windows 722 (shown in
FIGS. 20 and 21), each displaying in real-time a video signal from
a predetermined video camera 198 to display wellsite equipment
associated with the operation, wellsite equipment, or equipment
subsystem displayed in the primary operational status area 716. The
PIP video windows 722 may be embedded or inset on the corresponding
status screens, such as within the primary operational status area
716. The view shown in the PIP video window 722 may be manually or
automatically switched between different video cameras 198 to show
different wellsite equipment or different views of the wellsite
equipment.
[0146] As described above, the status screens to be displayed on
the video output devices 526 may be selected via the touchscreens
522, 524. However, the status screens, including the sensor signals
or information displayed in the indicator and alarm area 710, the
primary operational status area 716, the secondary operational
status area 718, the detailed description area 720, and/or the PIP
windows 722, may automatically change based on successive stages of
the well construction operations. For example, while the well
construction operations progress through successive stages (e.g.,
tripping, drilling, pipe handling, etc.), the control system 300
may cause the video output devices 526 to automatically change and
display a status screen comprising information indicative of
operational status of wellsite equipment performing or otherwise
associated with a current stage of the well construction
operations.
[0147] Each status screen, including the status screens 701-706,
may be adjusted or otherwise configured by the wellsite operator
195 to display one or more of the various information areas 710,
716, 718, 720 in a chosen position on each status screen. For
example, the indicator and alarm area 710 may be displayed at the
top of the status screens, the detailed description area 720 may be
displayed at the bottom of the status screens, the primary
operational status area 716 may be displayed in the middle on the
left side of the status screens, and the secondary operational
status area 718 may be displayed on the right side of the status
screens. Furthermore, the location and/or size (i.e., dimensions)
of the PIP video windows 722 displayed on each status screen may
also be adjusted or otherwise selected. The relative location of
the information areas 710, 716, 718, 720 and the PIP video windows
722 on the status screens may also be selected, for example, via
one or more of the physical controls 514, 516, 518, such as by
dragging and dropping the information areas 710, 716, 718, 720
and/or the PIP video windows 722 to a chosen location on the status
screens.
[0148] FIG. 17 is an example implementation of a status screen 701
displaying sensor signals or information indicative of operational
status of various wellsite equipment associated with and
collectively operable to perform drill pipe tripping operations
according to one or more aspects of the present disclosure. When
the wellsite operator 195 or the control system 300 causes the
tripping operations status screen 701 to be displayed on one of the
video output devices 526, the indicator 712 associated with the
tripping operations, such as letters "TR," may appear or become
highlighted to visually indicate to the wellsite operator 195 that
the tripping operations status screen is being displayed. The
primary operational status area 716 may display information, such
as hook load, weight-on-bit, travelling block position, roughneck
torque, trip tank accumulation or volume, and return flow, among
other examples. The secondary operational status area 718 may
display information related to drilling operations, such as hook
load, traveling block position, drill bit depth, wellbore depth,
number of stands or tubulars in the wellbore, standpipe pressure,
top drive dolly location, inside BOP position, top drive pipe
connection status, elevator status, stick-up connection status, and
slips status, among other examples. The description area 720 may
display a work plan (i.e., well construction plan) related to the
tripping operations, including actions or steps that will be
performed or overseen at the wellsite by the wellsite operator 195
during the tripping operations. However, the description area 720
may also or instead display information indicative of operational
events, as described above.
[0149] FIG. 18 is an example implementation of a status screen 702
displaying sensor signals or information indicative of operational
status of various wellsite equipment associated with and
collectively operable to perform drilling operations according to
one or more aspects of the present disclosure. When the wellsite
operator 195 or the control system 300 causes the drilling
operations status screen 702 to be displayed on one of the video
output devices 526, the indicator 712 associated with the drilling
operations, such as letters "DR," may appear or become highlighted
to visually indicate to the wellsite operator 195 that the drilling
operations status screen is being displayed. The primary
operational status area 716 may display information, such as hook
load, travelling block speed, weight-on-bit, rate of penetration,
standpipe pressure, top drive torque, torque wrench torque, top
drive rotational speed, drilling fluid loss/gain, and drilling
fluid return flow, among other examples. The secondary operational
status area 718 may display information related to drilling
operations, such as information related to or indicative of
drilling fluid (i.e., mud) operational status and/or active tank
operational status. The description area 720 may display a work
plan (i.e., well construction plan) related to the drilling
operations, including actions or steps that will be performed or
overseen at the wellsite by the wellsite operator 195 during the
drilling operations. However, the description area 720 may also or
instead display information indicative of operational events, as
described above.
[0150] As described above, the status screens may display sensor
signals or information indicative of operational status of wellsite
equipment subsystems (e.g., subsystems 311-316). FIG. 19 is an
example implementation of an RC system status screen 703 displaying
sensor signals or information indicative of operational status of
the RC system 311 according to one or more aspects of the present
disclosure. When the wellsite operator 195 or the control system
300 causes the RC system status screen 703 to be displayed on one
of the video output devices 526, the indicator 712 associated with
the RC system 311, such as letters "RC," may appear or become
highlighted to visually indicate to the wellsite operator 195 that
the RC system status screen 703 is being displayed. The primary
operational status area 716 may display sensor signals or
information related to various pieces of wellsite equipment forming
the RC system 311, such as the catwalk 131, the TDA 202, the
setback 164, the FIB 166, the TBR 254, the SGA 262, the LTC 244,
the ITC 236, the UTC 242, the LSA 228, and the RN 151, among other
examples. The primary operational status area 716 may also display
schematic representations 730 of such wellsite equipment to
visually display to the wellsite operator 195 operational status
(e.g., position) of such wellsite equipment. For example, the
schematic representations 730 of the drill floor 114, catwalk 131,
the setback 164, the FIB 166, the RN 151, and the TDA 202 may
visually indicate to the wellsite operator 195 in real-time
movements and positions of various portions of such wellsite
equipment. The RC system status screen 703 may include schematic
representations 730 of the skate 133 of the catwalk 131, the TDA
202, the LSA 228, the SGA 262, the ITC 236, and the LTC 244, and of
the vertical pipe rack assembly 165 (e.g., setback 164 and FIB 166)
containing the tubulars 111, among other examples. Portions of the
schematic representations 730 (e.g., various arms of the TDA 202)
may change position and/or color to visually indicate to the
wellsite operator 195 various positions and movements of the
represented wellsite equipment. The primary operational status area
716 may also display sensor signals or information indicative of
operational status of the wellsite equipment within text boxes 732
located in association with the schematic representations 730 of
the wellsite equipment. The secondary operational status area 718
may display information related to drilling operations and/or
additional information related to operational status of the RC
system 311, such as additional information that is not displayed in
the primary operational status area 716. The description area 720
may display information indicative of operational events, as
described above. However, the description area 720 may also or
instead display a work plan related to tripping, drilling, or other
wellsite construction operations.
[0151] FIG. 20 is an example implementation of a CPC system status
screen 705 displaying sensor signals or information indicative of
operational status of the CPC system 314 according to one or more
aspects of the present disclosure. When the wellsite operator 195
or the control system 300 causes the CPC system status screen 705
to be displayed on one of the video output devices 526, the
indicator 712 associated with the CPC system 314, such as letters
"CPC," may appear or become highlighted to visually indicate to the
wellsite operator 195 that the CPC system status screen 705 is
being displayed. The primary operational status area 716 may
display sensor signals or information related to various pieces of
wellsite equipment forming the CPC system 314, such as the choke
manifold 162 and related wellsite equipment. The primary
operational status area 716 may also display schematic
representations 730 of the wellsite equipment to visually display
to the wellsite operator 195 operational status of such wellsite
equipment. The schematic representations 730 may include, for
example, various fluid control valves (e.g., ball valves,
adjustable chokes) of the choke manifold 162 and a plurality of
fluid control valves fluidly connected with the choke manifold 162.
The primary operational status area 716 may visually indicate to
the wellsite operator 195 in real-time operational status, fluid
flow rates, fluid pressures, and valve positions of the wellsite
equipment forming the CPC system 314. Portions of the schematic
representations 730 (e.g., fluid valves) may change position and/or
color to indicate to the wellsite operator 195 operational status
(e.g., positions) of such wellsite equipment. The primary
operational status area 716 may also display sensor signals or
information indicative of operational status of the wellsite
equipment within text boxes 732 located in association with the
schematic representations 730 of the wellsite equipment. The
secondary operational status area 718 may display information
related to drilling operations and/or additional information
related to operational status of the CPC system 314, such as
additional information that is not displayed in the primary
operational status area 716. The description area 720 may display
information indicative of operational events, as described above.
However, the description area 720 may also or instead display a
work plan related to tripping, drilling, or other wellsite
construction operations. A PIP video window 722 showing a real-time
view of the choke manifold 162 or another portion of the CPC system
314 may be displayed in the primary operational status area 716 or
another area of the CPC system status screen 705.
[0152] FIG. 21 is an example implementation of a WC system status
screen 706 displaying sensor signals or information indicative of
operational status of the WC system 315 according to one or more
aspects of the present disclosure. When the wellsite operator 195
or the control system 300 causes the WC system status screen 706 to
be displayed on one of the video output devices 526, the indicator
712 associated with the WC system 315, such as letters "WC," may
appear or become highlighted to visually indicate to the wellsite
operator 195 that the WC system status screen 706 is being
displayed. The primary operational status area 716 may display
sensor signals or information related to various pieces of wellsite
equipment forming the WC system 315, such as the BOP equipment 130,
132. Information displayed in the primary operational status area
716 may include, for example, information related to
risers/diverters, POD controls, POD regulators, analog sensor
values (e.g., pressure, position), BOP event alarm signals, and
inclination sensors. The primary operational status area 716 may
visually indicate to the wellsite operator 195 in real-time
operational status, fluid pressures, and operational positions of
the wellsite equipment forming the CPC system 314. The primary
operational status area 716 may also display schematic
representations 730 of the wellsite equipment to visually display
to the wellsite operator 195 operational status of such wellsite
equipment. The schematic representations 730 may include, for
example, the BOP stack 130 and the annular fluid control device
132, and visually indicate to the wellsite operator 195 operational
status (e.g., position) of the various rams and valves of the BOP
stack 130 and the annular fluid control device 132. Portions of the
schematic representations 730 (e.g., fluid valves, rams) may change
position and/or color to indicate to the wellsite operator 195
operational status (e.g., positions) of such wellsite equipment.
The primary operational status area 716 may also display sensor
signals or information indicative of operational status of the
wellsite equipment within text boxes 732 located in association
with the schematic representations 730 of the wellsite equipment.
The secondary operational status area 718 may display information
related to drilling operations and/or additional information
related to operational status of the WC system 315, such as
additional information that is not displayed in the primary
operational status area 716. The description area 720 may display
information indicative of operational events, as described above.
However, the description area 720 may also or instead display a
work plan related to tripping, drilling, or other wellsite
construction operations. A PIP video window 722 showing a real-time
view of the BOP equipment 130, 132 or another portion of the WC
system 315 may be displayed in the primary operational status area
716 or another area of the WC system status screen 706.
[0153] FIG. 22 is a schematic view of at least a portion of an
example implementation of a system (or processing device) 800
according to one or more aspects of the present disclosure. The
system 800 may form at least a portion of one or more electronic
devices utilized at the well construction system 100, 200. For
example, the system 800 may be or form at least a portion of the
processing devices 188, 192, 456, and the control workstations 450,
452, 454, 500. The system 800 may form at least a portion of the
control system 300, including the wellsite computing resource
environment 305, the coordinated control device 304, the
supervisory control system 307, the local controllers 341-346, the
onsite user devices 302, and the offsite user devices 303. The
following description refers to FIGS. 1-7 and 22, collectively.
[0154] The well construction system 100, 200 also includes
stationary and/or mobile video cameras 198 disposed or utilized at
various locations within the well construction system 100, 200. The
video cameras 198 capture videos of various portions, equipment, or
subsystems of the well construction system 100, 200, and perhaps
the wellsite operators 195 and the actions they perform, during or
otherwise in association with the wellsite operations, including
while performing repairs to the well construction system 100, 200.
For example, the video cameras 198 may capture digital images (or
video frames) of the entire well construction system 100, 200
and/or specific portions of the well construction system 100, 200,
such as the top drive 116, the RN 151, the TDA 202, the FIB 166,
the setback 164, the catwalk 131, and/or the areas through which
tubulars 111 are transferred between components of the well
construction system 100, 200, among other examples. The video
cameras 198 generate corresponding video signals (i.e., feeds)
comprising or otherwise indicative of the captured digital images.
The video cameras 198 may be in signal communication with the
processing device 192, such as may permit the video signals to be
processed and transmitted to the control workstation 197 and, thus,
permit the wellsite operators 195 to view various portions or
components of the well construction system 100, 200 on one or more
of the output devices 196. The processing device 192 or another
portion of the control workstation 197 may be operable to record
the video signals generated by the video cameras 198.
[0155] The system 800 may include a network ring 900 that
electronically interconnects multiple drilling/analysis apparatus
and/or control mechanisms for at least partially automating such
apparatus. On the network ring 900, there may be a plurality of
ring network nodes 801 that electronically connect various elements
of the well construction system 100, 200 or the control system 300
to each other. For example, a first control workstation 850 (e.g.,
which may include or be the first control workstation 450 shown in
FIGS. 5 and 6 and/or the wellsite operator control workstation 500
shown in FIG. 7) and optionally a second control workstation 852
(e.g., which may include or be the second control workstation 452
shown in FIGS. 5 and 6 and/or the wellsite operator control
workstation 500 shown in FIG. 7) may be electronically connected to
the network ring 900 through one or more of the plurality of ring
network nodes 801. Optionally, the network ring 900 may be
electronically interconnected, via one or more ring network nodes
801, to a phone system comprising one or more phone lines. For
example, five VOIP (Voice over Internet Protocol) lines 881-885 are
represented in FIG. 22, but there may be more or fewer phone lines
to accommodate various numbers of users, workstations, or the
like.
[0156] Programmable logic controllers (PLCs) 901, 911, 921, 931,
941, 951, 961, 971, 981, 991 are also connected to the network ring
900, each through a corresponding ring network node 801, thus
facilitating communication between the first and second control
workstations 850, 852 and the well construction and/or control
subsystems (e.g., the RC subsystem 311, the FC subsystem 312, the
MPDC subsystem 313, the CPC subsystem 314, the WC subsystem 315,
and the CCTV subsystem 316, inter alia). Each PLC 901, 911, 921,
931, 941, 951, 961, 971, 981, 991 may be electronically connected
to its own subsystem network ring 909, 919, 929, 939, 949, 959,
969, 979, 989, 999, each of which electronically connect to its
corresponding PLC and/or to one or more other pieces of equipment
via subsystem ring network nodes 809, 819, 829, 839, 849, 859, 869,
879, 889, 899. For example, programmable logic subsystem
controllers, processing devices, and/or sensors 902, 903, 904, 905
may be electronically connected, each through a corresponding
subsystem ring network node 809, to the subsystem network ring 909
that is also electronically connected to the PLC 901 through its
own subsystem ring network node 809, thereby forming a ring network
subsystem. Although four PLCs/sensors/processing devices 902-905
are represented as being connected to PLC 901 via the subsystem
network ring 909 in FIG. 22, it should be understood that more or
fewer such devices may be electronically connected thereto and/or
that there may be more than one class of such devices
electronically connected thereto in a given ring network subsystem.
Similar ring network subsystems are shown in FIG. 22 as being
connected to the network ring 900, each via a corresponding ring
network node 801 electronically connecting additional PLCs 911,
921, 931, 941, 951, 961, 971, 981, 991 and additional
PLCs/sensors/processing devices 912-915, 922-925, 932-935, 942-945,
952-955, 962-965, 972-975, 982-924, 992-995, through corresponding
subsystem ring network nodes 819, 829, 839, 849, 859, 869, 879,
889, 899 via their corresponding subsystem network rings 919, 929,
939, 949, 959, 969, 979, 989, 999. Again, although four
workstations 992-995 are represented as being connected to PLC 991
via subsystem network ring 999 and although three cameras 982-984
are represented as being connected to PLC 981 via subsystem network
ring 989 in FIG. 22, it should be understood that more or fewer
such devices may be electronically connected thereto and/or that
there may be more than one class of such devices electronically
connected thereto in any given ring network subsystem.
[0157] FIG. 23 is a schematic view of at least a portion of an
example implementation of a processing device 1000 according to one
or more aspects of the present disclosure. One or more electronic
devices utilized at the well construction system 100, 200 may each
be, comprise, or be formed by at least a portion of the processing
device 1000. For example, the processing devices 188, 192, 456, the
BOP control station 470, the control workstations 450, 452, 454,
500, 850, 852, 992, and the CPUs 901-981, may each be, comprise, or
be formed by at least a portion of an instance the processing
device 1000. Instances of the processing device 1000, or portions
thereof, may form at least a portion of the control system 300,
including the wellsite computing resource environment 305, the
coordinated control device 304, the supervisory control system 307,
the local controllers 341-346, the onsite user devices 302, and the
offsite user devices 303.
[0158] The processing device 1000 may be in communication with
various sensors, actuators, controllers, and other devices of the
subsystems 311-316 and/or other portions of the well construction
system 100, 200. The processing device 1000 may be operable to
receive coded instructions 1032 from the wellsite operators 195 via
the wellsite control workstation 500, 850, 852 and the sensor data
351-356 generated by the sensors 321-326, process the coded
instructions 1032 and the sensor data 351-356, and communicate the
control data 361-366 to the local controllers 341-346 and/or the
actuators 331-336 of the subsystems 311-316 to execute the coded
instructions 1032 to implement at least a portion of one or more
example methods and/or operations described herein, and/or to
implement at least a portion of one or more of the example systems
described herein.
[0159] The processing device 1000 may be or comprise, for example,
one or more processors, special-purpose computing devices, servers,
personal computers (e.g., desktop, laptop, and/or tablet
computers), personal digital assistants, smartphones, internet
appliances, and/or other types of computing devices. The processing
device 1000 may comprise a processor 1012, such as a
general-purpose programmable processor. The processor 1012 may
comprise a local memory 1014, and may execute coded instructions
1032 present in the local memory 1014 and/or another memory device.
The processor 1012 may execute, among other things, the
machine-readable coded instructions 1032 and/or other instructions
and/or programs to implement the example methods and/or operations
described herein. The programs stored in the local memory 1014 may
include program instructions or computer program code that, when
executed by the processor 1012 of the processing device 1000, may
cause the subsystems 311-316 and/or individual pieces of wellsite
equipment of the well construction system 100, 200 to perform the
example methods and/or operations described herein. The processor
1012 may be, comprise, or be implemented by one or more processors
of various types suitable to the local application environment, and
may include one or more of general-purpose computers,
special-purpose computers, microprocessors, digital signal
processors (DSPs), field-programmable gate arrays (FPGAs),
application-specific integrated circuits (ASICs), and processors
based on a multi-core processor architecture, as non-limiting
examples. Of course, other processors from other families are also
appropriate.
[0160] The processor 1012 may be in communication with a main
memory 1016, such as may include a volatile memory 1018 and a
non-volatile memory 1020, perhaps via a bus 1022 and/or other
communication means. The volatile memory 1018 may be, comprise, or
be implemented by random access memory (RAM), static random access
memory (SRAM), synchronous dynamic random access memory (SDRAM),
dynamic random access memory (DRAM), RAMBUS dynamic random access
memory (RDRAM), and/or other types of random access memory devices.
The non-volatile memory 1020 may be, comprise, or be implemented by
read-only memory, flash memory, and/or other types of memory
devices. One or more memory controllers (not shown) may control
access to the volatile memory 1018 and/or non-volatile memory
1020.
[0161] The processing device 1000 may also comprise an interface
circuit 1024. The interface circuit 1024 may be, comprise, or be
implemented by various types of standard interfaces, such as an
Ethernet interface, a universal serial bus (USB), a third
generation input/output (3GIO) interface, a wireless interface, a
cellular interface, and/or a satellite interface, among others. The
interface circuit 1024 may also comprise a graphics driver card.
The interface circuit 1024 may also comprise a communication
device, such as a modem or network interface card to facilitate
exchange of data with external computing devices via a network
(e.g., Ethernet connection, digital subscriber line (DSL),
telephone line, coaxial cable, cellular telephone system,
satellite, etc.). One or more of the local controllers 341-346, the
sensors 321-326, and the actuators 331-336 may be connected with
the processing device 1000 via the interface circuit 1024, such as
may facilitate communication between the processing device 1000 and
the local controllers 341-346, the sensors 321-326, and/or the
actuators 331-336.
[0162] One or more input devices 1026 may also be connected to the
interface circuit 1024. The input devices 1026 may permit the
wellsite operators 195 to enter the coded instructions 1032, such
as control commands, processing routines, and/or operational
settings and set-points. The input devices 1026 may be, comprise,
or be implemented by a keyboard, a mouse, a joystick, a
touchscreen, a track-pad, a trackball, an isopoint, and/or a voice
recognition system, among other examples. One or more output
devices 1028 may also be connected to the interface circuit 1024.
The output devices 1028 may be, comprise, or be implemented by
video output devices (e.g., an LCD, an LED display, a touchscreen,
etc.), printers, and/or speakers, among other examples. The
processing device 1000 may also communicate with one or more mass
storage devices 1030 and/or a removable storage medium 1034, such
as may be or include floppy disk drives, hard drive disks, compact
disk (CD) drives, digital versatile disk (DVD) drives, and/or USB
and/or other flash drives, among other examples.
[0163] The coded instructions 1032 may be stored in the mass
storage device 1030, the main memory 1016, the local memory 1014,
and/or the removable storage medium 1034. Thus, the processing
device 1000 may be implemented in accordance with hardware (perhaps
implemented in one or more chips including an integrated circuit,
such as an ASIC), or may be implemented as software or firmware for
execution by the processor 1012. In the case of firmware or
software, the implementation may be provided as a computer program
product including a non-transitory, computer-readable medium or
storage structure embodying computer program code (i.e., software
or firmware) thereon for execution by the processor 1012. The coded
instructions 1032 may include program instructions or computer
program code that, when executed by the processor 1012, may cause
the various subsystems 311-316 or individual pieces of wellsite
equipment of the well construction system 100, 200 to perform
intended methods, processes, and/or operations disclosed
herein.
[0164] In the example operations sequences described below, among
others within the scope of the present disclosure, the pipe
handling equipment may be operated automatically via the
Construction Program, and the step execution of the pipe handling
equipment may be controlled automatically by one or two operators
195 at the associated workstation(s) 450, 452, 454. The
Construction Program may also feature configurable step
confirmations. Each sequence controlled by the Construction Program
may be stopped or interrupted at any time, and some or all
functions may be operated manually by the one or two operators 195
at the associated workstation(s) 450, 452, 454.
[0165] Various well construction operations may be performed
utilizing different combinations of the aspects described above.
For example, when a tripping-in operation is to be performed, an
operator 195 on the rig floor 114 may verify that various pieces of
equipment are properly shut down and locked out, and then perhaps
perform other preparations such as the examples set forth below in
Table 1A.
TABLE-US-00001 TABLE 1A Tripping-In Preparations Equipment
Responsible Verifications FIB 166 Operator 195 on Tubulars 111
exist per HMI/tally. Setback 164 rig floor 114. Fingers are closed.
Travel path is unobstructed. TBR 254 Operator 195 on Travel path is
unobstructed. SGA 262 rig floor 114. Gripper inserts/dies are
clean, not worn. LTC 244 Operator 195 on Travel path is
unobstructed. ITC 236 rig floor 114. Gripper inserts/dies are
clean, UTC 242 not worn. ITC 236 is open and retracted. THP
Operator 195 on Travel path is unobstructed. Doper 209 rig floor
114. Water, correct dope available for doper 209. LSA 228 Operator
195 on Travel path is unobstructed. rig floor 114. TDA 202 Operator
195 on Travel path is unobstructed. rig floor 114. Correct dope
available for doper 209. Correct inserts/dies in gripper/ elevator.
Inserts/dies are clean, not worn. RN 151 Operator 195 on Drill pipe
tong (DPT) is connected. rig floor 114. Gripper dies are clean, not
worn. Travel path is unobstructed. Slips 161 Operator 195 on
Correct inserts/dies. rig floor 114; and/or Inserts/dies are clean,
not worn. "Driller" 195 at workstation 452. TD 116 Operator 195 on
rig Correct inserts/dies in elevator. floor 114; and/or Correct
saver sub status. "Driller" 195 at Travel path is unobstructed.
workstation 452. DW 119 Operator 195 on rig Checked. floor 114;
and/or "Driller" 195 at workstation 452.
[0166] The well construction system 100, 200 can then be set-up for
the trip-in sequence. Examples of such set-up may be as set forth
below in Table 1B.
TABLE-US-00002 TABLE 1B Tripping-In Set-Up Equipment Responsible
Set-Up HMI Pipe Driller/ Verify operator 195 on rig floor 114
Verify Setback screen. handling: Pipe completed pre-checks and
deactivated Construction Program TBR 254, Handler emergency stop
for all pipe handling setup wizard. SGA 262, equipment. After
startup: Check for UTC 242, Open Construction Program screen on
green light in LTC 244, touchscreen 522, 524. Construction Program
ITC 236, Select Trip In mode. status header on front THP 207,
Select setup wizard to open pop-up on screen 532, 534, 536. TDA
202, front screen 532, 534, 536. Verify LSA 228, settings: RN 151
Select slot, direction for picking pipe. Select Pipe type. Select
RN 151 to use in the operations. RN 151 MU torque. Select pin/box
doping. Stick-up target. Select "activate all machines" to startup
and prepare all machines. TD 116, Driller Verify operator 195 on
rig floor 114 Verify Setback screen. DW 119, completed pre-checks
and deactivated Construction Program MP 144, emergency stop for all
pipe handling setup wizard. Trip tank equipment. After startup:
Check for Open Construction Program screen on green light in
touchscreen 522, 524. Construction Program Select Trip In mode.
status header on front Select setup wizard to open pop-up on screen
532, 534, 536. front screen 532, 534, 536. Verify settings:
Stick-up target. Set DW 119 upper/lower stops. Set maximum lowering
speed. Set minimum slack off weight. Trip tank 1/2/auto. Trip tank
low/high levels. Select "activate all machines" to startup and
prepare all machines. TD 116 Driller Verify operator 195 on rig
floor 114 Verify operator screen, completed pre-checks. system
status/alarms. Activate TD 116 from touchscreen 522, 524. Select
Operation screen on touchscreen 522, 524. DW 119 Driller Activate
DW 119 from touchscreen 522, Verify operator screen, 524. system
status/alarms. All Driller Verify all relevant machines are enabled
Verify operator screen, machines in zone management system and
system status/alarms. tubular interlock system.
[0167] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
The tripping-in sequence starts with the top drive 116 in a lower
position with the elevator 129 closed, with the slips 161 closed,
and with a portion (e.g., about one meter) of the drill string 120
(referred to as "stick-up") protruding above the slips 161. A
tubular 111 has been lifted by the TDA 202 (and perhaps the LSA
228) from the THP 207 to stick-up level above the MOH 204. The THP
207 is empty, and the UTC 242 and the LTC 244 are open and
retracted. The TBR 254 and the SGA 262 may also be empty and
perhaps moving to pick up a new tubular 111 from the vertical pipe
rack assembly 165. The top drive elevator 129 is then opened and
retracted from the stick-up.
[0168] The top drive 116 is then moved to an upper stop via
operation of the DW 119. The TDA 202 (perhaps with cooperation from
the LSA 228) then moves the new tubular 111 to over the well center
203 (WC). The RN 151 also moves toward the WC 203. During this
time, the TBR 254 and the SGA 262 operate to remove another tubular
111 from the setback 164 and the FIB 166. The position from which
this additional tubular 111 is removed may be selected
automatically or via input from the operator 195 at a control
workstation 450, 452, 454. For example, a "Pipe Handler" operator
195 seated at control workstation 450 may generally control/monitor
pipe handling equipment (e.g., equipment that is handling tubulars
111 that not connected to the drill string 120), while a "driller"
operator 195 seated at control workstation 452 may generally
control/monitor the remaining equipment (or at least the equipment
that is handling the drill string 120). The TBR 254 and the SGA 262
then cooperate to move the currently held tubular 111 to the THP
207. The UTC 242 and the LTC 244 then close to hold the new tubular
111. The doper 209 may be integrated in or otherwise associated
with the THP 207 may then wash and dope the pin end of the new
tubular 111. The TBR 254 and the SGA 262 may then return to select
the next tubular 111 from the vertical pipe rack assembly.
[0169] A stabbing guide and/or back up tong (BUT) of the RN 151 may
then be closed to assist stabbing. The TDA 202 then lowers the new
tubular 111 to stab into the stick-up, perhaps continuing a short
distance (e.g., about one meter) after stabbing to provide room for
the top drive elevator 129. The LSA 228 may then open and retract
from WC 203. The RN 151 then performs low-torque spinning and
subsequent high-torque "wrenching" to make-up the tubular 111 to
the drill string 120.
[0170] The top drive 116, which during this time was hoisted to an
elevation generally near the top end of the new tubular 111, then
extends to WC 203 and closes the elevator 129 around the new
tubular 111. At the same time, the TDA 202 and (perhaps) the LSA
228 move to the THP 207 for the next tubular 111, and the RN 151
opens and retracts away from the WC 203 to a standby position.
[0171] The DW 119 then lifts the top drive 116 to pick up the
now-extended drill string 120 and open the slips 161, and then
lowers the top 116 to lower the drill string 120 into the wellbore
102. The slips 161 are closed again, leaving a stick-up ready for
the next tubular 111. During this time that the drill string 120 is
being lowered into the wellbore, the TDA 202 and (perhaps) the LSA
228 extend and latch onto another new tubular 111 currently in the
THP 207, and then the UTC 242 and the LTC 244 and opened and
retracted. The new tubular 111 is lifted from setback level to
drill (rig) floor level (e.g., about 9 meters), perhaps guided by
the LSA 228. The box (top) end of the new tubular 111 can be doped
by another washing/doping device, if selected.
[0172] This trip-in sequence is summarized in Table 1C set forth
below.
TABLE-US-00003 TABLE 1C Tripping-In Operation Operator Line of
Equipment Equipment 195 Operation Sight Precondition Functionality
HMI 1. Driller Open elevator 129: Visual/ Slips 161 closed.
Elevator open is not Elevator 129 to Verify slips 161 are CCTV
selectable if slips Open state. closed. 161 are not closed. Open
elevator 129. 1.1. Pipe TBR 254 and SGA 262 Visual/ TBR 254 and TBR
254 will move TBR 254 and Handler pick up new tubular 111: CCTV SGA
262 are open. above open latches. SGA 262 grip/ Move TBR 254 and
Position selected TBR 254 and SGA guide to Closed SGA 262 to
selected in FIB 166 is "valid." 262 grip/guide will state.
finger/slot in FIB 166. close. Close guides and clamp on tubular
111. 2. Driller Retract and move TD Visual/ TD 116 pipe DW 119
upper 116 to latching height: CCTV handler position stop setting.
Verify elevator 129 is facing TDA 202. open. Retract TD 116 to
clear tool joint (TJ). Hoist elevator 129 to tubular latch height
(upper stop or calculated stop point). 2.1. Pipe Move RN 151 to WC
Visual/ Only possible with RN 151 will move TJ (stick-up) Handler
203: CCTV tong handling to WC 203. assist indication. Verify TD 116
is trolley (THT). If Elevate to stick-up. hoisted above working
tong handling arm area of RN 151. (THA) is used, then Start RN 151
make-up wait for tubular 111 sequence to move RN located above
stick- 151 to WC 203. up. RN 151 tongs are open. WC 203 is
selected. 2.2 Pipe TDA 202 moves tubular Visual/ TD 116 is
retracted. Tilt towards WC TDA 202 load Handler 111 to WC 203: CCTV
203. indication. TDA 202 moves TDA 202 dope top tubular 111 to WC
203. box if preselected LSA 228 guides to WC (automatic). 203. 2.3.
Pipe Guide tubular 111 with CCTV Tubular 111 is held Close RN 151
Stabbing guide Handler RN 151 in WC 203: by TDA 202/LSA BUT. Closed
indication. Verify tubular 111 is 228 above stick-up Close stabbing
BUT Closed over WC 203. at WC 203. guide. indication. Adjust
elevation if needed. Continue RN 151 sequence. 2.4. Pipe TDA 202
stabs tubular Visual/ RN 151 is at WC Continue lowering TDA 202
load Handler 111 in stick-up: CCTV 203 with stabbing (e.g., about
two indication Lower tubular 111 to guide closed. meters) after
verify (unloading). stab into stick-up. set of weight. Continue
lowering to permit room for elevator 129. LSA 228 opens and
retracts when RB 151 stabbing guide is closed on tubular 111. 2.5.
Pipe RN 151 spin-in and Visual/ Tubular 111 is Spin-in and make-
Torque log Handler make-up: CCTV stabbed in stick-up. up
connection. updated. Verify RN 151 is in TDA 202 is Open spinner,
Make-up (MU) correct elevation. unloaded. guide, and clamps. torque
presented Continue RN 151 RN 151 returns to to driller. sequence to
spin-in and park position. make-up. 2.6. Pipe TBR 254 and SGA 262
Visual/ THP 207 is empty. TBR 254 cannot Indicate FIB 166 Handler
move tubular 111 to CCTV UTC 242 and LTC open with weight. latches
Open. THP 207: 244 are open. TBR 254 opens TBR 254 load Open FIB
166 latches Correct pipe when unloaded. indication. for selected
row. detected in TBR FIB 166 latches will Verify latches open. 254
and SGA 262. not open with TBR TBR 254 and SGA 262 254 in low
position. move tubular 111 to THP 207. FIB 166 latches will close
as the tubular 111 is moved out. Wash and/or dope pin of tubular
111 if preselected. 2.7. Pipe UTC 242 and LTC 244 Visual/ TBR 254
and SGA UTC 242 and LTC UTC 242 and Handler extend to THP 207 and
CCTV 262 have tubular 244 extend and LTC 244 to then close. 111 in
THP 207. close. Closed state. 2.8. Pipe TBR 254 and SGA 262 Visual/
UTC 242 and LTC Handler open and move towards CCTV 244 closed on
FIB 166: tubular 111. Open TBR 254 and SGA 262 damps/ guides. Move
TBR 254 and SGA 262 toward FIB 166 (next tubular 111). Continue
step 1.1. 3. Driller Extend TD 116 and latch Visual/ TDA 202 below
TJ. Elevator 129 to elevator 129: CCTV Closed state. Extend TD 116
to WC Indicate TD 203. 116 at WC 203. Latch elevator 129 (automatic
close on impact). 3.1. Pipe TDA 202 opens and Visual/ TD elevator
129 is TDA 202 will rotate TDA 202 to Handler moves to THP 207:
CCTV closed. and lower when Open state. Verify elevator 129 is
vertical until facing closed. toward THP 207. Move TDA 202 to
tubular 111 in THP 207. 4. Driller Open slips 161: Visual TD
elevator 129 Slips 161 to Open slips 161 is closed. Open state.
(command). RN 151 has DW 119 load. Hoist to open slips completed
the 161. make-up sequence with correct torque. 5. Driller Lower
drill string 120: Visual Slips 161 are Settings: DW 119 Verify
slips 161 are open. lowering speed open before lowering and minimum
drill string 120. slack-off weight. 5.1. Pipe TDA 202 and LSA 228
Visual/ TDA 202 is TDA 202 moves Handler extend to tubular 111 in
CCTV open. until contact with THP 207: LSA 228 guide tubular 111 in
THP Move TDA 202 until funnel is open. 207. contact with tubular
111 in THP 207, below TJ. 5.2. Pipe TDA 202 and LSA 228 Visual/ TDA
202 is at The closing Confirm TDA Handler latch onto tubular 111 in
CCTV THP 207. sequence is 202 is closed on THP 207: verified to
assure tubular 111. Close TDA 202. proper grip on LSA 228 guide
Close LSA 228 guide tubular 111. is closed. funnel. 5.3. Pipe UTC
242 and LTC 244 Visual/ TDA 202 is UTC 242 and LTC UTC 242 and
Handler open and retract. CCTV closed. 244 open and LTC 244 to Open
retract. state. 5.4. Pipe TDA 202 moves tubular Visual/ UTC 242 and
LTC TDA 202 hoists, TDA 202 load Handler 111 to THP 207: CCTV 244
are open. tilts to vertical, indication. TDA 202 lifts tubular
rotates 180 111, guided by LSA degrees to face TD 228, to THP 207.
116. Continue step 2.2. TDA 202 dopes top box if preselected
(automatic). 6. Driller Set slips 161: Visual Stick-up at correct
Slips 161 to Set slips 161 at correct height. Closed state.
stick-up height. DW 119 load Set off weight. indicator. Tally
update. 7. Driller Check trip tank volume, Visual Slips 161 are
Trip tank gain/loss is Trip sheet/ gain/loss: closed. calculated
and volume control. Determine trip tank displayed. gain/loss.
Repeat all steps for next tubular 111.
[0173] When a tripping-out operation is to be performed, an
operator 195 on the rig floor 114 may verify that various pieces of
equipment are properly shut down and locked out, and then perhaps
perform other preparations such as the examples set forth above in
Table 1A. The well construction system 100, 200 can then be set-up
for the trip-out sequence. Examples of such set-up may be as set
forth below in Table 2A.
TABLE-US-00004 TABLE 2A Tripping-Out Set-Up Equipment Responsible
Set-Up HMI Pipe Driller/ Verify operator 195 on rig floor 114
Verify Setback screen. handling: Pipe completed pre-checks and
deactivated Construction Program TBR 254, Handler emergency stop
for all pipe handling setup wizard. SGA 262, equipment. After
startup: Check for UTC 242, Select Trip Out mode. green light in
LTC 244, Select setup wizard to open pop-up on Construction Program
ITC 236, front screen 532, 534, 536. Verify status header on front
THP 207, settings: screen 532, 534, 536. TDA 202, Select slot,
direction for picking pipe. LSA 228, Select pipe type. RN 151
Select RN 151 to use in the operations. Select pin/box doping.
Stick-up target. Select "activate all machines" to startup and
prepare all machines. TD 116, Driller Verify operator 195 on rig
floor 114 Verify Setback screen. DW 119, completed pre-checks and
deactivated Construction Program MP 144, emergency stop for all
pipe handling setup wizard. Trip tank equipment. After startup:
Check for Open Construction Program screen on green light in
touchscreen 522, 524. Construction Program Select Trip Out mode.
status header on front Select setup wizard to open pop-up on screen
532, 534, 536. front screen 532, 534, 536. Verify settings:
Stick-up target. Set DW 119 upper/lower stops. Set maximum lowering
speed. Set over pull. Trip tank 1/2/auto. Trip tank low/high
levels. Select "activate all machines" to startup and prepare all
machines. TD 116 Driller Verify operator 195 on rig floor 114
Verify operator screen, completed pre-checks. system status/alarms.
Activate TD 116 from touchscreen 522, 524. Select Operation screen
on touchscreen 522, 524. DW 119 Driller Activate DW 119 from
touchscreen 522, Verify operator screen, 524. system status/alarms.
All Driller Verify all relevant machines are enabled Verify
operator screen, machines in zone management system and system
status/alarms. tubular interlock system.
[0174] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example trip-out sequence may start with the TD 116 in lower
position over WC 203 with closed slips 161 and elevator 129, with a
stick-up of about one meter. The TDA 202 and LSA 228 are open in
THP position 207 (tubular 111 delivered from WC 203 to THP 207).
The UTC 242 and LTC 244 are closed on the tubular 111 in the THP
207. The TBR 254 and SGA 262 are empty, on the way from the FIB 166
to get a new tubular 111 in the THP 207. Example steps of the
trip-out sequence may be as set forth below in Table 2B.
TABLE-US-00005 TABLE 2B Tripping-Out Operation Operator Line of
Equipment Equipment 195 Operation Sight precondition Functionality
HMI 1. Driller Open slips 161 and Visual/ Elevator 129 must be
Slips 161 Open is Slips 161 to hoist to upper stop: CCTV closed
before opening not selectable if Open state. Verify that elevator
129 slips 161. elevator 129 is not Settings: is closed. closed. DW
119 Open slips 161 The slips 161 hoisting (command). Open command
is speed and Hoist to take weight reset after a set time maximum
and verify slips 161 if the slips 161 are overpull. opening. not
opened. 1.1. Pipe TBR 254 and SGA 262 Visual/ TBR 254 and SGA 262
TBR 254 and Handler pick up next tubular 111 CCTV open. SGA 262
grips/ from THP 207: guides to Closed TBR 254 and SGA 262 state.
move to tubular 111 in THP 207. Close TBR 254 and SGA 262
guides/clamps on tubular 111. 1.2. Pipe UTC 242 and LTC 244 Visual/
TBR 254 and SGA 262 UTC 242 and LTC 244 UTC 242 and Handler open
and retract: CCTV closed on tubular 111 open and retract. LTC 244
to Open UTC 242 and LTC in THP 207. state - retracted. 244 open.
UTC 242 and LTC 244 retract from THP 207. 1.3. Pipe TBR 254 and SGA
262 Visual/ Valid FIB 166 position TBR 254 and SGA TBR 254 load.
Handler move toward FIB 166 CCTV selected. 262 will follow with
tubular 111: predefined path. Lift tubular 111 from FIB 166 latches
will THP 207. open when tubular 111 Move to selected is outside
selected FIB position in FIB 166. 166 row. FIB 166 latches will
close prior to setting down the tubular 111. Set down tubular 111
on selected position. 1.4. Pipe TDA 202 and LSA 228 Visual/ TDA 202
retract to TDA 202 load Handler move to WC 203: CCTV vertical,
hoist, and indication. TDA 202 move to WC rotate, extend to WC 203.
203 at about two LSA 228 move to WC meters below stick-up. 203. TDA
202 and LSA 228 will stop/wait outside WC 203 area if TD 116 is
moving. 1.5. Pipe Move RN 151 to WC RN 151 tongs open. RN 151 will
move to TJ (Stick-up) Handler 203: WC 203 selected. WC 203. assist
indication. Verify TD 116 is Elevate RN 151 to hoisted above RN 151
stick-up. working area. RN 151 will stop/ Start 151 RN break- wait
outside WC 203 out sequence to move area if TD 116 is RN 151 to WC
203. moving. 2. Driller Set slips 161: Visual/ DW 119 upper Verify
required stick-up CCTV stop setting. height. Set slips 161
(command). Set off weight. 2.1. Pipe TDA 202 close and LSA Visual/
Slips 161 closed. TDA 202 and LSA 228 TDA 202 to Handler 228 guide
close: CCTV will not close in WC Closed state. Verify TDA 202 and
203 if slips 161 are not TDA 202 and LSA 228 at WC 203. closed. LSA
228 in WC Close TDA 202. 203. Close LSA 228 guide LSA 228 guide
funnel. funnel to Closed state. 2.2. Pipe RN 151 break-out and CCTV
Slips 161 closed. Break-out and spin- RN 151 Handler spin-out: out.
Double break-out indication. Verify slips 161 closed available if
required. and weight set off. Open RN 151 Adjust RN 151 spinner,
guide, and elevation if required. clamps. Continue RN 151 Return RN
151 to sequence. park position. RN 151 may wait in WC 203 until TDA
202 has lifted tubular 111. 3. Driller Open TD elevator 129,
Visual/ TDA 202 closed. TD elevator retract, and lower: CCTV Slips
161 closed. 129 to Closed Verify TDA 202 is state. closed. TD 116
Open TD elevator 129 retracted and retract. position. Lower TD 116
(e.g., to rig floor 114. 3.1. Pipe TDA 202 lift tubular 111 Visual/
RN 151 finished TDA 202 will hoist TDA 202 load Handler out of
stick-up: CCTV spin-out, RN 151 about two meters indication. Hoist
TDA 202 to pick BUT is open. before lifting tubular LSA 228 up
weight. TD 116 retracted. 111. centralizer. LSA 228 centralizer
Tubular 111 is lifted will close on tubular 111 carefully. Lifting
is above stick-up. stopped if tubular RN 151 may return to 111 is
catching on park position when threads in TJ. tubular 111 is
lifted. LSA 228 centralizer closes after lifted above the box. 3.2.
Pipe TDA 202 and LSA 228 Visual/ TDA 202 closed. TDA 202 will
retract TDA 202 load Handler move tubular 111 to CCTV LTC 244
closed when to vertical position indication. THP 207: tubular 111
is below above MOH (or rig TDA 202 and TDA 202 and LSA 228 LTC 244.
floor 114), then rotate, LSA 228 move toward THP 207. lower, and
extend to position. LTC 244 extends to THP 207. LSA 228 THP 207 and
closes TDA 202 will slow extend. guide when tubular is down above
THP LTC 244 to close to THP 207. 207. Closed state. Set down
tubular at LTC 244 is extended THP 207. and closed. Wash and dope
pin if LSA 228 is open. preselected. 3.3. Pipe UTC 242 extend to
THP Visual/ TDA 202 and LSA 228 UTC 242 extend to UTC 242 and
Handler 207 and close. CCTV in THP 207 with tubular THP 207. LTC
244 to 111. UTC 242 guide closed state. close. 4. Driller Extend TD
116 and Visual RN 151 parked. Elevator 129 latch elevator 129:
Closed state. Extend TD 116 to WC Indicate TD 203. 116 in WC 203.
Latch elevator 129 (automatic close on impact). 5. Driller Check
trip tank volume, Visual Trip tank gain/loss is Trip sheet/
Gain/Loss: determined and volume control. Determine trip tank
displayed. gain/loss. Repeat all steps for next tubular 111.
Continue on step 1. 5.1. Pipe TDA 202 open and Visual/ UTC 242
closed. TDA 202 to Handler retract from THP 207: CCTV Open state.
Verify UTC 242 and LTC 244 are closed. Open TDA 202. Open LSA 228
guide funnel. Continue on step 1.4. 5.2. Pipe TBR 254 and SGA 262
UTC 242 and LTC 244 TBR 254 clamp and TBR 254 clamp Handler move to
THP 207: closed on tubular 111. guide and SGA 262 and guide and
Open TBR 254 and guide will open. SGA 262 guide SGA 262. TBR 254
will hoist to Open state. Move TBR 254 and before it retracts out
of SGA 262 toward THP FIB 166. 207/next tubular. Continue step
1.1.
[0175] When a drilling connection is to be made, an operator 195 on
the rig floor 114 may verify that various pieces of equipment are
properly shut down and locked out, and then perhaps perform other
preparations such as the examples set forth above in Table 1A. The
well construction system 100, 200 can then be set-up for making the
drilling connection. Examples of such set-up may be as set forth
below in Table 3A.
TABLE-US-00006 TABLE 3A Drilling Connection Set-Up Equipment
Responsible Set-Up HMI Pipe Driller/ Verify operator 195 on rig
floor 114 Verify Setback handling: Pipe completed pre-checks and
deactivated screen. TBR 254, Handler emergency stop for all pipe
handling Construction SGA 262, equipment. Program setup UTC 242,
Open Construction Program screen on wizard. LTC 244, touchscreen
522, 524. After startup: Check ITC 236, Select Drilling Connection
mode. for green light in THP 207, Select setup wizard to open
pop-up on front Construction TDA 202, screen 532, 534, 536. Verify
settings: Program status LSA 228, Select slot, direction for
picking pipe. header on front RN 151 Select pipe type. screen 532,
534, Select RN 151 to use in the operations. 536. Select RN 151 as
back-up only (only selectable for THT). RN 151 MU torque. Select
pin/box doping. Stick-up target. Select "activate all machines" to
startup and prepare all machines. TD 116, Driller Verify operator
195 on rig floor 114 Verify Setback DW 119, completed pre-checks
and deactivated screen. MP 144 emergency stop for all pipe handling
Construction equipment. Program setup Open Construction Program
screen on wizard. touchscreen 522, 524. After startup: Check Select
Drilling mode. for green light in Select setup wizard to open
pop-up on front Construction screen 532, 534, 536. Verify settings:
Program status Stick-up target. header on front Set DW 119
upper/lower stops. screen 532, 534, Set relevant Autodriller
parameters 536. (ROP, WOB, delta-P, torque, etc.) Verify correct TD
116 make-up torque setting. Assign TD 116 rotation to armrest
control 514, 515, 516. Verify/set TD 116 ramp parameters. Verify
correct drilling torque setting. Verify liner size setting and pump
efficiency. Verify MP 144 pressure limit setting. Assign pumps to
MP 144 master slider. Verify/set MP 144 ramp-up parameters. Verify
active tanks are selected and lined up. Select "activate all
machines" to startup and prepare all machines. All Driller Verify
all relevant machines are enabled in Verify operator machines zone
management system and tubular screen, system interlock system.
settings.
[0176] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example drilling connection sequence may start with the drill
string 120 drilled all the way down, reaming, survey, up/down
weights, etc., performed according to drilling program. A tubular
111 to be added to the drill string 120 and in the TDA 202/LSA 228
is lifted from stick-up level above the MOH 204. The THP 207 is
empty, and the UTC 242 and LTC 244 are open and retracted. The TBR
254 and SGA 262 are empty, on the way to pick a new tubular 111
from the FIB 166. Example steps of the drilling connection sequence
may be as set forth below in Table 3B.
TABLE-US-00007 TABLE 3B Drilling Connection Operation Operator Line
of Equipment Equipment 195 Operation Sight precondition
Functionality HMI 1. Driller Set slips 161: Visual Slips 161 to
Verify MPs 144 are Closed state. stopped and torque is DW 119 hook
released from drill load. string 120. TD 116 torque Set slips 161
at release. required stick-up height. Set off weight. 2. Driller TD
116 break-out Visual Slips 161 must be TD 116 Break-Out TD 116
thread connection: closed before TD 116 function will activate
compensator Verify slips 161 are BUT Break-Out the clamp and
indication. closed. function is available. increase the torque to
TD 116 not Break-out connection break the connection. connected.
(joystick button + TD 116 break-out TD 116 Break- joystick). will
activate the TD Out function- Deactivate break-out 116 thread
joystick button- button when compensator and push and hold.
connection is broken pipe handler lock. Clamp on/ (torque dropping
and When connection is break-out may shaft rotating). broken,
release be operated button. The torque will separately on be
released and touch screen backup clamp (BUC) 522, 524. opened. TD
116 torque DW 119 is dropping and interlocked from shaft rotating.
hoisting when the BUC is closed. 3. Driller TD 116 spin-out: Visual
Slips 161 must be Spin-Out will TD 116 thread Verify break-out is
closed. activate the TD 116 compensator completed. Break-Out not
thread compensator indication. Spin-out. (Direct active. system.
continue from break- BUC open. Spin-Out function out). will
spin-out per Hoist out of stick-up. settings. Deactivate TD 116
thread compensator. 4. Driller Retract and move TD Visual/ Hoisting
will be TD 116 pipe handler Indicate upper 116 to connection CCTV
stopped if TD 116 is has pre-set position stop position. height:
retracted and links facing TDA 202. Link tilt Verify TD 116 is
tilted to parked position. above stick-up. position. Retract TD 116
and activate link tilt float. Hoist TD 116 to tubular 111
connection height (upper stop). 4.1. Pipe Move RN 151 to WC Only
possible with RN 151 will move to TJ assist Handler 203: THT. If
THA is used, WC 203. indication. Verify TD 116 is then wait for
tubular Elevate to stick-up. hoisted above RN 151 111 located above
working area. stick-up. Start RN 151 make- RN 151 tongs open. up
sequence to move WC 203 selected. RN 151 to WC 203. 4.2. Pipe TDA
202 move tubular Visual/ TD 116 retracted. Tilt towards WC TDA 202
Load Handler 111 to WC 203: CCTV 203. indication. Continue to lift
TDA TDA 1613 dope top 202 and extend to WC box. 203 (above
stick-up). LSA 228 guide to WC 203 when pin end above rig floor
114. 4.3. Pipe Guide tubular 111 with CCTV Tubular 111 held by
Close RN 151 BUT. Stabbing Handler RN 151 in WC 203: TDA 202/LSA
228 Close stabbing guide closed Verify tubular 111 is above
stick-up in WC guide. indication. located in WC 203. 203. BUT
closed Adjust RN 151 indication. elevation if required. Continue RN
151 sequence. 4.4. Pipe TDA 202 lower to stab Visual/ RN 151 in WC
203 Continue lowering TDA load Handler tubular 111 in stick-up:
CCTV with stabbing guide about two meters indication Lower tubular
111 to closed. after verifying set of (unloading). stab into
stick-up. weight (to allow room Continue lowering for TD 116 to
latch on about two meters after top). stabbing complete. LSA 228
open and retract when RN 151 stabbing guide closed on tubular 111.
4.5. Pipe RN 151 back-up (pre- Visual/ Tubular 111 stabbed Option:
Torque log Handler selected): CCTV in stick-up. Spin-in and make-up
updated. Option: Spin-in and TDA 202 unloaded. connection. MU
torque make-up with RN 151: Open spinner, presented to RN 151 BUT
will stay guide, and clamps. driller. on for back-up. Return to
park Option: Make-Up with position. RN 151: Continue RN 151
sequence to spin-in and make-up. 5. Driller Extend TD 116 to WC
Visual/ TDA 202 below TJ. Indicate TD 203: CCTV 116 in WC 203.
Extend TD 116 to WC Link tilt. 203. Deactivate link tilt float.
Tilt elevator 129 to parked position. 6. Driller TD 116 spin-in
(both Visual/ TD 116 in WC 203. Spin-in with spin-in Thread
connections): CCTV THT/DPT BUC on. settings (RPM/ compensator
Verify RN 151/THT torque). indication (mid BUT closed. Spin-in will
activate stroke). Activate TD 116 spin- the TD 116 thread in.
compensator system. Lower TD 116 to stab and spin-in. Optional:
Lower connection made-up by RN 151: See step 7. 7. Driller TD 116
make-up (both Visual/ TD 116 spin-in TD 116 Make-up RN 151 BUC
connections): CCTV completed. function will change on. Verify TD
116 spin-in THT BUT closed. TD 116 torque to set TD 116 make-
function is finished. make-up torque. up torque. Make-up the
Release torque TD 116/RN connection(s) (joystick when button is 151
torque log button + joystick). released and joystick updated (both
Release button when to center. connections). make-up torque is DW
119 is TD 116 reached. interlocked from connected state hoisting
when RN 151 when make-up BUC is closed. (Rig torque is tong or
slips 161 may reached. be used as backup Make-up per setting).
function may be TD 116 thread operated compensator system manually
from is deactivated. touchscreen 522, 524. 8. Driller Option: TD
116 spin-in Visual/ TD 116 in WC 203. Spin-in with spin-in Thread
upper connection CCTV RN 151 finished/ settings (RPM/ compensator
(lower connection open (retracted). torque). (mid stoke). made-up
by RN 151): Spin-in will activate Verify RN 151/THT the TD 116
thread finished (tubular 111 compensator system. connected).
Activate TD 116 Spin- in. Lower TD 116 to stab and spin-in. 9.
Driller Option: TD 116 make- Visual/ RN 151 make-up TD 116 make-up
will TD 116 BUC up upper connection CCTV finished. automatically
activate on. (lower connection TD 116 spin-in pipe handler lock, TD
116 MU made-up by RN 151): finished. close the TD 116 torque.
Verify TD 116 spin-in Clamp on - make- BUC, and increase TD 116
torque is finished. up available from TD 116 torque to set updated.
Make-up connection touch panel 522, 524 make-up torque. TD 116
(joystick button + without spin-in. Release button (and Connected
joystick). joystick to center) to state when MU Release button when
open BUC and torque is make-up torque is release torque. reached.
reached. DW 119 is TD 116 MU interlocked from maybe moving when BUC
is operated closed. manually on TD thread touchscreen compensator
system 522, 524. is deactivated. 9.1. Pipe TDA 202 open and TD 116
spin-in TDA 202 will tilt to TDA 202 to Handler move to THP 207:
finished. vertical, rotate to face Open state. Verify TD 116 is
toward THP 207, and connected. lower to pick up next Open TDA 202.
tubular 111. Retract and rotate TDA 202 towards THP 207. 10.
Driller Open slips 161: Visual/ TD 116 connected. Slips 161 to Open
slips 161. CCTV Open state. Hoist to open slips DW 119 hook 161.
load. 11. Driller Continue drilling per Visual Slips 161 open. IBOP
to Open drilling program: status. Open IBOP. TD 116 RPM. Continue
drilling per TD 116 drilling program. torque. MP 144 strokes per
minute (SPM). Standpipe pressure. 11.1. Pipe TBR 254 and SGA 262
Visual/ TBR 254 and SGA TBR 254 will move TBR 254 and Handler pick
up new tubular CCTV 262 grip/guide open. into FIB 166 elevated SGA
262 grip/ 111: Selected FIB 166 above open latches. guide to Closed
Move TBR 254 and position is "valid." Adjustments state. SGA 262 to
selected available. finger/slot in FIB 166. TBR 254 and SGA Close
guides and 262 grip/guide will clamp on tubular 111. close. 11.2.
Pipe TBR 254 and SGA 262 Visual/ THP 207 empty. TBR 254 cannot
Indicate open Handler move tubular 111 to CCTV UTC 242 and LTC open
with weight. FIB 166 latches. THP 207: 244 are open. TBR 254
gripper TBR 254 load Open FIB 166 latches Correct pipe open when
unloaded. indication. for selected row. detected in TBR 254 FIB 166
latches will Verify latches open and SGA 262. not open with TBR
(visual/CCTV). 254 head in low TBR 254 lifts tubular position. 111
and moves to THP 207. FIB 166 latches will close as the tubular 111
moves out of FIB 166. Set down tubular in THP 207. Wash and dope
pin if preselected. 11.3. Pipe UTC 242 and LTC 244 Visual/ TBR 254
and SGA UTC 242 and LTC UTC 242 and Handler extend to THP 207 and
CCTV 262 with tubular in 244 extend and close. LTC 244 to close.
THP 207. Closed state. 11.4. Pipe TBR 254 and SGA 262 UTC 242 and
LTC Handler open and move toward 244 closed on tubular FIB 166:
111. Open TBR 254 clamps and guide and SGA 262 guide. Move toward
FIB 166/ next tubular 111.
[0177] It is noted that the example drilling connection sequence
set forth above describes the RN 151 and THT used as the BUT for
the TD 116 during make-up, as well as the option of making-up the
lower connection with the RN 151 and the upper connection with the
TD 116.
[0178] Different combinations of the aspects described above may
also be utilized for building stands of two or more tubulars 111.
Such stand building may be performed during drilling and other
operations performed at WC 203. Such simultaneous operations,
however, are coordinated to avoid conflicts and obstructions
between the different machines and systems. For example, the
elevator of the TDA 202 may have two different sizes of inserts to
permit building casing stands while drilling. The change of head
size may be done remote from the Pipe Handler's workstation 450 (or
452 or 454). When a stand building operation is to be performed, an
operator 195 on the rig floor 114 may verify that various pieces of
equipment are properly shut down and locked out, and then perhaps
perform other preparations such as the examples set forth below in
Table 4A.
TABLE-US-00008 TABLE 4A Stand Building Preparations Equipment
Responsible Verifications Catwalk Operator 195 on Travel path is
unobstructed. (CW) 131 rig floor 114. Feeding table (FT) indexer
pins. FIB 166 Pipe Handler Stands in FIB 166 slots per HMI. Fingers
closed. Travel path is unobstructed. TBR 254 Pipe Handler Travel
path is unobstructed. SGA 262 Pipe Handler Travel path is
unobstructed. LTC 244 Operator 195 on Travel path is unobstructed.
ITC 236 rig floor 114. Dies are clean and not worn. UTC 242 THP
Operator 195 on Travel path is unobstructed. Doper 209 rig floor
114. Water and correct dope available for doper 209. LSA 228
Operator 195 on Travel path is unobstructed. rig floor 114. TDA 202
Operator 195 on Travel path is unobstructed. rig floor 114. Correct
dope is available for associated doper 209. Correct inserts
installed. RN 151: Operator 195 on DPT is assembled. THA-DPT rig
floor 114. Dies are clean and not worn. Travel path is
unobstructed. Tubulars Operator 195 on Tubular 111 to be loaded on
FT. 111 rig floor 114. Tubulars 111 to be cleaned and doped,
protectors removed.
[0179] The well construction system 100, 200 can then be set-up for
the stand building operation. Examples of such set-up may be as set
forth below in Table 4B.
TABLE-US-00009 TABLE 4B Stand Building Set-Up Equipment Responsible
Set-Up HMI Pipe Pipe Verify operator 195 on rig floor 114 Verify
Setback handling: Handler completed pre-checks and deactivated
screen. TBR 254, emergency stop for all pipe handling Construction
SGA 262, equipment. Program setup UTC 242, Open Construction
Program screen on wizard. LTC 244, touchscreen 522, 524. After
startup: Check ITC 236, Select Stand Building mode. for green light
in THP 207, Select setup wizard to open pop-up on front
Construction TDA 202, screen 532, 534, 536. Verify settings:
Program status LSA 228, Select slot, direction for racking stands
header on front RN 151, 111. screen 532, 534, CW 131 Select pipe
size/type. 536. Select RN 151 (with THA) to use in the operations.
RN 151 MU torque. Perform pin/box doping. Stick-up target. Select
"activate all machines" to startup and prepare all machines. All
Pipe Verify all relevant machines are enabled in machines Handler
zone management system and tubular interlock system. Tubulars Pipe
All tubulars 111 to be registered in 111 Handler electronic tally
system.
[0180] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example stand building sequence may start with the MOH 204 and
THP 207 empty, the ITC 236 retracted, and the CW 131 feeding table
pre-loaded with tubulars (perhaps already cleaned and doped).
Example steps of the stand building sequence may be as set forth
below in Table 4C. In such example, among others within the scope
of the present disclosure, the pipe handling equipment may be
operated automatically via the Construction Program, and the step
execution of the pipe handling equipment may be controlled
automatically by one or two operators 195 at the associated
workstation(s) 450, 452, 454. The Construction Program may also
feature configurable step confirmations. The stand building
sequence controlled by the Construction Program may be stopped or
interrupted at any time, and some or all functions may be operated
manually by the one or two operators 195 at the associated
workstation(s) 450, 452, 454.
TABLE-US-00010 TABLE 4C Stand Building Operation Operator Line of
Equipment Equipment 195 Operation Sight precondition Functionality
HMI 1. Pipe Load tubular 111 into Visual/ FT pre-loaded with
Handler the CW 131: CCTV pipe (cleaned and Verify that CW 131 is
doped). empty and in position. CWM in loading Use FT of CW 131 to
position. load tubular 111 into CW 131. 2. Pipe Run tubular 111 in
CW Visual/ Tubular 111 loaded in Ramp 149 will tilt to Handler 131
to pick-up position: CCTV ramp 149. rig floor 114 tubular Verify
tubular 111 is position. loaded in ramp 149. Skate 133 will move
Move skate 133 to towards rig floor 114. move tubular 111 Skate 133
will stop toward pick-up with tubular 111 box position. on ramp
149. 3. Pipe Move TDA 202 to pick- Visual TDA 202 open. Handler up
position: Tilt TDA 202. Lower and extend TDA 202 to CW 131 pick-up
position (above THP 207). 4. Pipe Present tubular 111 for Visual
Ramp 149 in pick-up Skate 133 will move CW 131 Handler TDA 202:
position. forward a defined position. Run skate 133 until TDA 202
in pipe- distance depending tubular 111 is receive position. on
pipe size. positioned for TDA 202. 5. Pipe Latch TDA 202: Visual
Tubular 111 is Tubular interlock TDA 202 Handler Hoist TDA 202 to
positioned correctly prevents hoisting to Closed state. latch onto
tubular 111. for TDA 202. without closed TDA Close TDA 202. 202
(above preset height). 6. Pipe Lift tubular 111 to Visual TDA 202
closed. Hoisting will stop LSA 228 guide Handler vertical position
above Verify LSA 228 is prior to lifting tubular to Closed state.
MOH 204: positioned to receive 111 out of CW 131 LSA 228 Verify TDA
202 is pipe bottom before without guiding. centralizer to closed.
hoisting. LSA 228 centralizer Closed state. Hoist TDA 202 to pick
TDA 202 above LSA closes when tubular Indicate TDA up single
tubular joint 228 operating area. 111 nears vertical. 202/LSA 228
in from CW 131. TDA 202 and LSA MOH 204 Move LSA 228 to 228 will
position position. preset position to tubular 111 above prepare for
guiding. MOH 204/ITC 236. Before the tubular 111 lower end leaves
CW 131, close LSA 228 funnel. Dope box when pipe is vertical (If
selected). Continue hoisting TDA 202 until tubular 111 is above MOH
204. 6.1. Pipe Skate 133 retract to Visual/ Skate 133 will move
Handler loading position: CCTV to loading position. Verify tubular
111 pin Ramp 149 will tilt to end is clear of ramp loading
position. 149. Move skate 133 toward FT loading position. 6.2. Pipe
CW 131 load and Visual/ See steps 1 and 2. Handler present next
tubular CCTV 111: Pick up next tubular 111 per steps 1 and 2. 7.
Pipe Stab/position first Visual Pipe bottom clear of TDA 202 is
rotated Indicate LSA Handler tubular 111 in MOH CW 131. when the
single 111 228, ITC 236, 204/ITC 236: LSA 228 close when is lowered
into the LTC 244 guide/ If THP 207 (pin) tubular 111 nears MOH 204
to permit grip states. doping is selected: vertical. open and
retract Indicated LSA Move single 111 to outside WC 203 228, ITC
236, THP 207. area. LTC 244 Extend and close positions. LSC 228 for
guiding. Open and retract LSA 228. Wash and dope pin. TDA 202 move
single 111 to ITC 236/MOH 204. LSC 228 guide open and retract.
Verify TDA 202/LSA 228 is above MOH 204. Lower single 111 into LSC
228. Open LSA 228 and retract. Close LSC 228 guide when pin end
below guide. Continue lowering tubular 111 inside MOH 204 until
stick-up of about one meter. 8. Pipe Close ITC 236 on Visual/ ITC
236 head Handler tubular 111: CCTV extend. Verify tubular 111 ITC
236/LTC inside ITC 236/LTC 244 Closed 244. state. Extend ITC 236
head. Close ITC 236 guide and clamps. Open and retract LTC 244 (if
doping next pin). 9. Pipe Transfer weight to ITC Visual/ ITC 236
closed. Verify weight TDA 202 load Handler 236 and open TDA CCTV
transferred prior to indicator. 202: open TDA 202. TDA 202 to Lower
TDA 202 to Open state. transfer tubular 111 weight to ITC 236. Open
TDA 202 and retract from stick-up. Move TDA 202 to CW 131 pick-up
position. 10. Pipe Present second tubular Visual Ramp 149 in
tubular Skate 133 will move Handler 111 above TDA 202: 111 pick-up
position. forward a Verify TDA 202 open TDA 202 in tubular
predetermined and below tubular 111 111 pick-up position. distance
depending pick-up position. on tubular 111 size Move skate 133
until (see step 4). tubular 111 is positioned above TDA 202
elevator. 11. Pipe Latch TDA 202 on Visual Tubular 111 is Tubular
interlock to TDA 202 to Handler second tubular 111: positioned
correctly prevent hoisting Closed state. Hoist TDA 202 to for TDA
202. without closed TDA latch onto tubular 111. 202 (above preset
Close TDA 202. height). 12. Pipe Lift tubular 111 to Visual TDA 202
closed. Hoisting will stop Indicate LSA Handler vertical above MOH
Verify LSA 228 is prior to lifting tubular 228 guide 204:
positioned to receive 111 out of CW 131 position. Verify TDA 202 is
tubular 111 bottom without guiding. Indicate TDA closed. before
hoisting. LSA 228 centralizer 202/LSA 228 in Hoist TDA 202 to TDA
202 above LSA closes when tubular MOH 204 pick-up single 111 from
228 operating area. 111 nears vertical. position. CW 131. TDA 202
and LSA Move LSA 228 to 228 will position preset position to
tubular 111 above prepare for guiding. MOH 204/ITC 236. Before the
tubular 111 lower end leaves CW 131, close LSA 228 funnel. Dope box
when tubular 111 is vertical (if selected). Continue hoisting TDA
202 until tubular 111 is above MOH 204. 13. Pipe CW 131 retract to
Visual/ Skate 133 will move Handler loading position: CCTV to
loading position. Verify tubular 111 pin Ramp 149 will tilt to end
is clear of ramp loading position. 149. Move CW 131 toward FT
loading position. 14. Pipe CW 131 load and Visual/ Reference steps
1 Handler present third tubular CCTV and 2. 111 (if needed): Pick
up next tubular 111 per steps 1 and 2. 15. Pipe Move RN 151 to MOH
Visual TDA 202/LSA 228 in RN 151 (THA) will Handler 204 position:
MOH 204 position. move to MOH 204 Activate RN 151 and elevate to
sequence. selected stick-up Activate RN 151 height. stabbing guide.
16. Pipe Stab second tubular Visual Tubular 111 bottom Indicate
weight Handler 111 in MOH 204 stick- clear of CW 131. transfer. up:
LSA 228 open, RN Open and retract LSA 151 stabbing guide 228.
active. Lower single 111 into MOH 204 stick-up. Continue lowering
(e.g., at least about 0.2 meters to permit spin- in). 17. Pipe RN
151 spin-in and Visual/ Single 111 stabbed in RN 151 will Torque
log Handler make-up: CCTV stick-up (TDA 202 automatically spin-in
updated. Verify pin is stabbed unloaded, elevator and make-up to in
the box. below TJ). preset torque. Activate RN 151 Open RN 151
sequence to continue spinner, guide, and make-up sequence. clamps.
Return RN 151 to park position. 18. Pipe Lower double 111 into
Visual/ RN 151 has TDA 202/LSA Handler MOH 204 (if needed): CCTV
completed MU 228 Closed/ Verify connection is sequence with correct
Open status. made-up. torque. TDA 202 load. Hoist TDA 202 to pick
LTC 244/ITC up weight. 236 status. Open ITC 236 guide and clamps.
Lower double 111 to correct stick-up. LTC 244 in position for
guiding if doping not selected (else, LTC 244 retracted). Stop at
selected stick- up (e.g., about one meter). Close ITC 236 guide and
clamps. Lower TDA 202 to transfer tubular 111 weight to ITC 236.
Open TDA 202 and retract from stick-up. 19. Pipe Repeat steps 10-17
for Handler third single 111 (if needed) 20. Pipe Move stand 111 to
Visual/ RN 151 has Weight Handler THP 207: CCTV completed MU
transfer. LTC 244 extends to sequence with correct ITC 236 stand
111 in MOH 204 torque. Retracted. position and closes Complete
stand 111 LTC 244 guide. in MOH 204. Extended. Hoist TDA 202 to
pick LTC 244
up stand 111 weight. Closed. Open ITC 236 guide ITC 236 Open. and
clamps. UTC 242 ITC 236 head Extended. retracted. UTC 242 TDA 202
will lift stand Closed. 111 from MOH 204 TDA 202 until pin end
above Open. THP doper 209. TDA 202 and LTC 244 move stand 111 above
THP 207. Stab stand 111 in THP 207 and initiate wash and dope, if
selected. UTC 242 extends to stand 111 and closes guide. TDA 202
opens and retracts from stand 111. 21. Pipe Set back stand 111:
Visual/ UTC 242 and LTC TBR 254/SGA Handler TBR 254 and SGA CCTV
244 closed on stand 262 status. 262 move to THP 207 111 in THP 207.
TBR 254 load. and close guide and TDA 202 retracted clamps on stand
111. from stand 111 in UTC 242 and LTC THP 207. 244 open and
retract. TBR 254 and SGA 262 set back stand 111 to selected
position in FIB 166.
[0181] To lay down stands (offline), an operator 195 on the rig
floor 114 may verify that various pieces of equipment are properly
shut down and locked out, and then perhaps perform other
preparations such as the examples set forth above in Table 4A. The
well construction system 100, 200 can then be set-up for performing
the lay-down operation. Examples of such set-up may be as set forth
below in Table 5A.
TABLE-US-00011 TABLE 5A Stand Lay-Down Set-Up Equipment Responsible
Set-Up HMI Pipe Pipe Verify operator 195 on rig floor 114 Verify
Setback handling: Handler completed pre-checks and deactivated
screen. TBR 254, emergency stop for all pipe handling Construction
SGA 262, equipment. Program setup UTC 242, Open Construction
Program screen on wizard. LTC 244, touchscreen 522, 524. After
startup: Check ITC 236, Select Stand Building mode. for green light
in THP 207, Select setup wizard to open pop-up on front
Construction TDA 202, screen 532, 534, 536. Verify settings:
Program status LSA 228, Select slot, direction for racking stands
header on front RN 151, 111. screen 532, 534, CW 131 Select Pipe
size/type. 536. Select RN 151 (with THA) to use in the operations.
Select pin/box doping. Stick-up target. Select "activate all
machines" to startup and prepare all machines. All Pipe Verify all
relevant machines are enabled in machines Handler zone management
system and tubular interlock system. Tubulars Pipe Electronic tally
system to be updated. 111 Handler
[0182] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example stand lay-down sequence may start with all machines
empty, the ITC 236 retracted, and the CW 131 FT empty and ready to
receive single tubulars 111. Example steps of the stand lay-down
sequence may be as set forth below in Table 5B.
TABLE-US-00012 TABLE 5B Stand Lay-Down Operation Operator Line of
Equipment Equipment 195 Operation Sight precondition Functionality
HMI 1. Pipe TBR 254 and SGA 262 Visual/ TBR 254 and SGA TBR 254
will move TBR 254 and Handler pick up new stand 111: CCTV 262
grip/guide open. into FIB 166 elevated SGA 262 grip/ Move TBR 254
and Selected FIB 166 above open latches. guide to Closed SGA 262 to
selected position "valid." Adjustments available. state.
finger/slot in FIB 166. TBR 254 and SGA Close guides and 262
grip/guide will clamp on stand 111. close. 2. Pipe TBR 254 and SGA
262 Visual/ THP 207 empty. TBR 254 cannot Indicate open Handler
move stand 111 to THP CCTV UTC 242 and LTC open with weight.
latches. 207: 244 open. TBR 254 grip open TBR 254 load Open FIB 166
latches Correct pipe when unloaded. indication. for selected row.
detected in TBR 254 FIB 166 latches will Verify latches open and
SGA 262. not open with TBR (Visual/CCTV). 254 head in low TBR 254
lift stand position. 111 and move out of FIB 166 to THP 207. FIB
166 latches will close as the stand 111 moves out of FIB 166. Set
stand 111 on THP 207. Wash and dope pin if preselected. 3. Pipe UTC
242 and LTC 244 Visual/ TBR 254 and SGA UTC 242 and LTC UTC 242 and
Handler extend to THP 207 and CCTV 262 with stand 111 in 244 extend
and LTC 244 to close: THP 207. close. Closed state. UTC 242 and LTC
244 extend to THP 207. UTC 242 and LTC 244 close. 4. Pipe TBR 254
and SGA 262 UTC 242 and LTC Handler open and move toward 244 closed
on stand FIB 166: 111. Open TBR 254 clamps and guide and SGA 262
guide. Move toward FIB 166 (next stand 111). Continue step 1. 5.
Pipe TDA 202 extend to Visual/ TDA 202 must be TDA 202 tilt/extend
Handler stand 111 in THP 207: CCTV open. until contact with
Tilt/extend TDA 202 stand 111 in THP until contact with stand 207.
111 in THP 207, below TJ. Note: LSA 228 used for guiding pin end.
6. Pipe TDA 202 latch onto Visual/ TDA 202 must be in The closing
sequence Confirm TDA Handler stand 111 in THP 207: CCTV THP 207
position. is verified to assure 202 closed on Close TDA 202. proper
grip. tubular 111. 7. Pipe UTC 242 open and Visual/ TDA 202 must be
UTC 242 open and UTC 242 to Handler retract: CCTV closed. retract.
Open state. UTC 242 opens. LSA 228 to UTC 242 retracts. Guide mode.
LSA 228 to guide mode. 8. Pipe TDA 202 and LSA 228 Visual/ UTC 242
open. TDA 202 hoist, tilt to TDA 202 Load Handler move stand 111 to
MOH CCTV vertical. indication. 204: TDA 202 dope top TDA 202 lift
stand box if preselected 111 guided by the LSA (automatic). 228 to
MOH 204. 9. Pipe Lower stand 111 in Visual/ LSA 228 guide mode.
Indicate ITC Handler MOH 204/ITC 236: CCTV 236 and LSA Verify LSA
228 is 228 position guiding above MOH and guide/grip 204. states.
TDA 202 lowers stand 111 into MOH 204. Stop with one single 111
above rig floor 114 and stick-up of about one meter. 10. Pipe Close
ITC 236 on Visual/ ITC 236 Handler stand 111: CCTV Extended. Verify
stand 111 ITC 236 in inside ITC 236. Closed state. Extend ITC 236.
Close ITC 236. 11. Pipe Transfer stand 111 Visual/ ITC 236 closed.
TDA 202 load Handler weight to ITC 236: CCTV indicator. Lower TDA
202 to TDA 202 to transfer stand 111 Open state. weight to ITC 236.
12. Pipe Open and retract LTC Visual/ LTC 244 in Handler 244: CCTV
Open and Open and retract LTC Retracted state. 244 to THP 207. 13.
Pipe Move second RN 151 Visual ITC 236 closed. Second RN 151
Handler to MOH 204 (stand): (with THA) will Verify TDA 202 move to
MOH 204 unloaded in MOH 204. and elevate to Move second RN 151
selected stick-up to MOH 204. height. 14. Pipe Move LSA 228 to MOH
Visual ITC 236 closed. Handler 204 (stand): Move LSA 228 to MOH
204. Close LSA 228 guide funnel. 15. Pipe Tilt CW 131 ramp 149
Visual/ Tubular 111 loaded Handler and move skate 133 to CCTV onto
ramp 149. rig floor 114 lay-down position: Verify tubular 111 is
unloaded from ramp 149 (CW 131 ready). Activate CW 131 sequence.
16. Driller RN 151 break-out and Visual/ ITC 236 closed (TDA RN 151
will spin-out (upper single CCTV 202 unloaded, gripper
automatically break- 111): below TJ). out and spin-out the Verify
ITC 236 is upper single 111. closed and TDA 202 Open RN 151
unloaded. spinner, guide, and Activate RN 151 clamps. sequence to
continue Return RN 151 to break-out sequence. park position. 17.
Pipe TDA 202 and LSA 228 Visual/ RN 151 has Handler move upper
single 111 CCTV completed break-out from MOH 204 to CW sequence.
131: CW 131 in lay-down Verify connection is position. spun-out.
Hoist TDA 202 to lift upper tubular 111 from stick-up and above CW
131, guided by LSA 228. Rotate TDA 202 to face CW 131. Tilt TDA 202
toward CW 131. 18. Pipe LSA 228 guide upper Visual/ CW 131 in
lay-down LSA 228 Handler tubular 111 pin to CW CCTV position.
position. 131: Verify pin is above CW 131. Guide pin above skate
133. 19. Pipe Lay down upper single Visual/ CW 131 in lay-down
Handler 111 on CW 131: CCTV position. Verify TDA 202 is rotated and
tilted toward CW 131. Lower TDA 202 and set upper tubular 111 pin
on skate 133. Continue lowering until upper tubular 111 rests on CW
131. 20. Pipe Open and retract LSA Visual/ LSA 228 to Handler
(upper single 111): CCTV Open state. Verify pin rests on CW 131.
Open and retract LSA 228. 21. Pipe Lay down upper single Visual/
Skate 133 will move Handler 111 on CW 131 and CCTV out synchronized
open TDA 202: with TDA 202. Verify TDA 202 is tilted toward CW 131
and LSA 228 is out of TDA 202 area. Lower TDA 202 until upper
single 111 rests on ramp 149. 22. Pipe Open TDA 202: Visual TDA 202
to Handler Verify upper single Open state. 111 is resting on CW
131. Open TDA 202. Tilt TDA 202 to vertical above MOH 204 stick-up.
Rotate TDA 202 (e.g., 90 degrees). 23. Pipe Move upper tubular
Visual/ TDA 202 open. Skate 133 will pull Skate 133 to Handler 111
to FT and unload: CCTV upper tubular 111 to unloading Activate CW
131 unloading position. position. sequence to move out Ramp 149
will tilt to CW 131 to and unload upper unloading position.
unloading tubular 111. FT will unload upper position. tubular 111.
FT unloading active. Second Single 111 of Stand: 24. Pipe Lower TDA
202 to Visual TDA 202 to Handler stick-up and close: Closed state.
Lower TDA 202 to stick-up. Close TDA 202 on stick-up. 25. Pipe
Hoist double in MOH Visual/ TDA 202/LSA Handler 204 (not applicable
for CCTV 228 close/open tripe stands): status. Hoist TDA 202 to
pick TDA 202 load. up weight. LTC 244/ITC Open ITC 236 guide 236
status. and clamps. Stop at selected stick-up (e.g., about one
meter). Close ITC 236 guide and clamps. Lower TDA 202 to transfer
weight to ITC 236. 26. Driller Move second RN 151 Visual ITC 236
closed. Second RN 151 (with to MOH 204: THA) will move to Verify
TDA 202 MOH 204 and elevate unloaded in MOH 204. to selected
stick-up Move second RN2 to height. MOH 204. 27. Pipe Move LSA 228
to MOH Visual ITC 236 closed. Handler 204: Move LSA 228 to MOH 204.
Close LSA 228 guide funnel. 28. Pipe Tilt ramp 149 and Visual/
Tubular 111 loaded Skate 133 will move CW 131 lay- Handler move
skate 133 to lay- CCTV onto ramp 149. to lay-down position. down
ready. down position: Verify tubular 111 is unloaded from ramp 149
(CW 131 ready). Activate CW 131 sequence. 29. Driller RN 151
break-out and Visual/ ITC 236 closed (TDA RN 151 will
spin-out: CCTV 202 unloaded, gripper automatically break- Verify
ITC 236 is below TJ). out and spin-out the closed and TDA 202 is
single 111. unloaded. Open RN 151 Activate RN 151 spinner, guide,
and sequence to continue clamps. break-out sequence. Return RN 151
to park position. 30. Pipe TDA 202 and LSA 228 Visual/ RN 151 has
Handler move pipe from MOH CCTV completed break-out 204 to CW 131:
sequence. Verify connection is CW 131 in lay-down spun-out.
position. Hoist TDA 202 to lift tubular 111 from stick- up and
above CW 131 (guided by LSA 228). Rotate TDA 202 to face CW 131.
Tilt TDA 202 toward CW 131. 31. Pipe LSA 228 will guide pin Visual/
CW 131 in lay-down LSA 228 Handler to CW 131: CCTV position.
position. Verify pin end is above CW 131. Guide pin to above skate
133. 32. Pipe Lay down pipe on CW Visual/ CW 131 in lay-down
Handler 131: CCTV position. Verify TDA 202 is rotated and tilted
toward CW 131. Lower TDA 202 and set pin on skate 133. Continue
lowering until pipe rests on CW 131. 33. Pipe Open and retract LSA
Visual/ LSA 228 to Handler 228: CCTV Open state. Verify pin is
resting on CW 131. Open and retract LSA 228. 34. Pipe Move pipe to
FT and Visual/ TDA 202 open. Skate 133 will pull Skate 133 to
Handler unload: CCTV the pipe to unloading unloading Activate CW
131 position. position. sequence to move out Ramp 149 will tilt to
CW 131 to and unload the pipe. unloading position. unloading FT
will unload the position. pipe. FT unloading active. Third Single
111 of Stand (If Applicable): 35. Pipe Lower TDA 202 to Visual TDA
to Closed Handler stick-up and close: state. Lower TDA 202 to
stick-up. Close TDA 202 on stick-up. 36. Pipe Hoist single 111 from
Visual/ TDA 202/LSA Handler MOH 204: CCTV 228 close/open Hoist TDA
202 to pick status. up weight. TDA 202 load. Open ITC 236 guide LTC
244 and and clamps. ITC 236 status. Retract ITC 236 (Note: pipe not
guided). 37. Pipe Move LSA 228 to MOH Visual ITC 236 closed.
Handler 204: Verify TDA 202 above LSA 228 working height. Move LSA
228 to MOH 204. Close LSA 228 guide funnel. 38. Pipe Tilt ramp 149
and Visual/ Tubular 111 loaded Skate 133 will move CW 131 lay-
Handler move skate 133 to lay- CCTV onto ramp 149. to lay-down
position. down ready. down position: Verify tubular 111 is unloaded
from ramp 149 (CW 131 ready). Activate CW 131 sequence. 39. Pipe
TDA 202 and LSA 228 Visual/ CW 131 in lay-down Handler move pipe
from MOH CCTV position. 204 to CW 131: Verify ITC 236 is open.
Hoist TDA 202 to lift tubular 111 above CW 131 (guided by LSA 228).
Rotate TDA 202 to face CW 131. Tilt TDA 202 toward CW 131. 40. Pipe
LSA 228 will guide pin Visual/ CW 131 in lay-down LSA 228 Handler
to CW 131: CCTV position. position. Verify pin end is above CW 131.
Guide pin end to above skate 133. 41. Pipe Lay down tubular 111
Visual/ CW 131 in lay-down Handler on CW 131: CCTV position. Verify
TDA 202 is rotated and tilted toward CW 131. Lower TDA 202 and set
pin on skate 133. Continue lowering until tubular 111 rests on CW
131. 42. Pipe Open and retract LSA Visual/ LSA 228 to Handler 228:
CCTV Open state. Verify pin is resting on CW 131. Open and retract
LSA 228. 43. Pipe Move tubular 111 to FT Visual/ TDA 202 open.
Skate 133 will pull Skate 133 to Handler and unload: CCTV tubular
111 to unloading Activate CW 131 unloading position. position.
sequence to move out Ramp 149 will tilt to CW 131 to and unload
tubular unloading position. unloading 111. FT will unload the
position. Continue step 1. tubular 111. FT unloading active.
[0183] Different combinations of the aspects described above may
also be utilized for picking up single tubulars 111 before assembly
into stands of two or more tubulars. Such operations may be
performed during drilling and other operations performed at WC 203.
Such simultaneous operations, however, are coordinated to avoid
conflicts and obstructions between the different machines and
systems. Preparations for picking up single tubulars 111 may
include the examples set forth below in Table 6A.
TABLE-US-00013 TABLE 6A Singles Pick-Up Preparations Equipment
Responsible Verifications CW 131 Operator 195 on Travel path is
unobstructed. rig floor 114. Feeding table (FT) indexer pins
adjusted for pipe size. Prepare to pick up pipe. RN 151 Operator
195 on DPT is rigged up in THT. (THT + DPT rig floor 114. Travel
path is unobstructed. as primary, Dies are clean and not worn. THA
+ DPT as backup) LSA 228 Operator 195 on Travel path is
unobstructed. rig floor 114. Slips 161 Operator 195 on Correct
inserts in slips 161. Rotary rig floor 114. Dies are clean and not
worn. Table Rotary table rotation lock activated. TD 116 Operator
195 on Correct inserts in elevator 129. rig floor 114. Elevator
rotator (tilt) installed. Operator screen, system status. Travel
path is unobstructed. DW 119 Operator 195 on Checked. rig floor
114. Tubulars Operator 195 on Tubular 111 to be loaded on FT. 111
rig floor 114. Tubulars 111 to be cleaned and doped, protectors
removed.
[0184] The well construction system 100, 200 can then be set-up for
the pick-up operation. Examples of such set-up may be as set forth
below in Table 6B.
TABLE-US-00014 TABLE 6B Singles Pick-Up Set-Up Equipment
Responsible Set-Up HMI Pipe Pipe Verify operator 195 on rig floor
114 Verify Setback handling: Handler completed pre-checks and
deactivated screen. LSA 228, emergency stop for all pipe handling
Construction RN 151, equipment. Program setup CW 131 Open
Construction Program screen on wizard. touchscreen 522, 524. After
startup: Check Select Trip In mode. for green light in Select
target: CW 131 Construction Select setup wizard to open pop-up on
front Program status screen 532, 534, 536. Verify settings: header
on front Select pipe size/type. screen 532, 534, Select RN 151 to
use in the operations. 536. RN 151 MU torque. Stick-up target.
Select "activate all machines" to startup and prepare all machines.
TD 116, Driller Verify operator 195 on rig floor 114 Verify Setback
DW 119, completed pre-checks and deactivated screen. MP 144,
emergency stop for all pipe handling Construction Trip tank
equipment. Program setup Open Construction Program screen on
wizard. touchscreen 522, 524. After startup: Check Select Trip In
mode. for green light in Select setup wizard to open pop-up on
front Construction screen 532, 534, 536. Verify settings: Program
status Stick-up target. header on front Set DW 119 upper/lower
stops. screen 532, 534, Set maximum lowering speed. 536. Set
minimum slack off weight. Trip tank 1/2/auto. Trip tank low/high
levels. Select "activate all machines" to startup and prepare all
machines. TD 116 Driller Verify operator 195 on rig floor 114
Verify operator completed pre-checks. screen, system Activate TD
116 from touchscreen 522, status/alarms. 524. Verify correct
elevator 129 setting (manual/remote). Select Operation screen on
touchscreen 522, 524. DW 119 Driller Activate DW 119 from
touchscreen 522, Verify operator 524. screen, system Set maximum
lowering speed. status/alarms. Set minimum slack off weight. Slips
161, Driller Verify correct setting for slips 161 Verify operator
Rotary (manual/remote). screen, system table status/alarms. All
Driller Verify all relevant machines are enabled in machines zone
management system and tubular interlock system. Tubulars Pipe All
types of tubulars 111 are registered. 111 Handler
[0185] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example singles pick-up sequence may start with a stick-up at WC
203, and the CW 131 FT pre-loaded with a tubular 111, perhaps
cleaned and doped. Example steps of the stand building sequence may
be as set forth below in Table 6C.
TABLE-US-00015 TABLE 6C Singles Pick-Up Operation Operator Line of
Equipment Equipment 195 Operation Sight precondition Functionality
HMI 1. Pipe Load tubular 111 to Visual/ FT pre-loaded with Handler
ramp 149: CCTV tubular 111 (e.g., Use FT to load cleaned and
doped). tubular to ramp 149. CW 131 in loading position. 1.1. Pipe
Move ramp 149 to rig Visual/ Tubular 111 loaded to CW 131 Handler
floor 114/WC 203: CCTV ramp 149. animated. Verify tubular 111 is
loaded in ramp 149 and run skate 133 towards WC 203. 2. Driller
Open TD 116 elevator Visual/ Slips 161 must be Elevator 129 Open
not Elevator 129 to 129: CCTV closed before opening selectable if
slips 161 Open state. Verify slips 161 are elevator 129. are not
closed. closed. Open elevator 129. 3. Driller Move TD 116 to pick-
Visual Elevator 129 is open. TD 116 pipe handler up position:
Elevator 129 is has pre-set position Tilt links back to clear
rotated to receive facing CW 131. TJ. tubular 111. Hoist elevator
129 above stick-up. Tilt out elevator 129 and move TD 116 to
pick-up position. 3.1. Pipe Push tubular 111 to Visual Ramp 149 in
rig floor CW 131 will push CW 131 in pick- Handler pick-up
position: 114 position. tubular 111 a preset up position. Run skate
133 until distance forward (up tubular 111 is ramp 149). positioned
above elevator 129. 4. Driller Latch elevator 129: Visual Tubular
111 is Tubular interlock will Elevator 129 to Hoist/tilt TD 116 to
positioned correctly prevent hoisting Closed state. latch elevator
129. above elevator 129. without closed elevator 129 (above preset
height). 5. Driller Lift tubular 111: Visual Elevator 129 closed.
Hoisting will stop prior Hoist TD 116 to pick Link tilt float: to
lifting tubular 111 up single 111 from CW elevator 129 above out of
CW 131 without 131. RN 151 working area. guiding. Activate TD 116
to move elevator 129 to vertical position. 5.1. Pipe LSA 228 extend
to Visual/ TD 116 above LSA LSA 228 funnel Handler guide tubular
111 CCTV 228 operating area. to Closed state. above CW 131: Move
LSA 228 to preset position to receive tubular 111 above CW 131.
Before tubular 111 lower end leaves CW 131, close LSA 228 funnel.
5.2. Pipe Move RN 151 to WC Only possible with RN 151 will move to
Handler 203: THT. If THA is used, WC 203. Verify TD 116 above wait
for stand located Elevate RN 151 to RN 151 working area. above
stick-up. stick-up. Start RN 151 RN 151 clamps open. ZMS will
prevent RN sequence to move RN WC 203 selected. 151 start if TD 116
is 151 to WC 203. too low. 5.3. Pipe LSA 228 tail in tubular Visual
Tubular 111 bottom LSA 228 centralizer LSA 228 Handler 111 to WC
203: clear of CW 131 and will close when centralizer to TD 116
continue elevated above stick- tubular 111 nears Closed state.
hoisting. up. WC 203. LSA 228 guide closes LSA 228 centralizer and
tails in tubular 111 close: Tubular 111 toward WC 203 when near
vertical. pin end is above stick- up. 5.4. Pipe Guide single 111
with Visual/ RN 151 in WC 203. Close RN 151 BUT. Handler RN 111 in
WC 203: CCTV LSA 228 in WC 203. Close RN 151 Verify single 111 is
stabbing guide. located in WC 203. Continue RN 151 sequence. 6.
Driller Stab tubular 111: Visual/ TD 116 link tilt float. Lower TD
116 to stab CCTV RN 151 in WC 203 tubular 111. with stabbing guide
closed. 6.1. Pipe Open and retract LSA Visual/ RN 151 stabbing LSA
228 to Handler 228. CCTV guide closed. Open status. 6.2. Pipe RN
151 spin-in and Visual/ Single 111 stabbed RN 151 will Tally
update. Handler make-up: CCTV in stick-up. automatically spin-in
Torque log Continue RN 151 TD 116 unloaded, and make-up. updated.
sequence. elevator 129 below TJ Open RN 151 MU torque to permit
spinning. spinner, guide, and presented to clamps. Driller. Return
RN 151 to park position. 7. Driller Opening slips 161: Visual
Elevator 129 must be Slips 161 to Open slips 161 closed. Open
state. (command). RN 151 has DW 119 load. Hoist to open slips
completed MU 161. sequence with correct torque. 8. Driller Lower
drill string 120: Visual Slips 161 open. Verify slips 161 are open
before lowering drill string 120. 9. Driller Set slips 161: Visual
Stick-up at correct Slips 161 to Set slips 161 at height. Closed
state. correct stick-up height. DW 119 load Set-off weight.
indicator. Tally update. 10. Driller Check trip tank Visual Trip
tank gain is Volume control. volume, gain/loss. determined and
displayed. 11. Repeat sequence for next single 111.
[0186] Different combinations of the aspects described above may
also be utilized for laying down single tubulars 111 from WC 203
using the top drive 116. Such operations may be performed during
drilling and other operations performed at WC 203. Such
simultaneous operations, however, are coordinated to avoid
conflicts and obstructions between the different machines and
systems. Preparations for this lay-down operation may include the
examples set forth below in Table 7A.
TABLE-US-00016 TABLE 7A Preparations for Singles Lay-Down from WC
to CW with TD Equipment Responsible Verifications CW 131 Operator
195 on Travel path is unobstructed. rig floor 114. Feeding table
(FT) indexer pins adjusted for pipe size. Prepare for lay-down
tubulars 111. Adjust skate 133 and other aspects of CW 131 for
tubulars 111. RN 151 Operator 195 on DPT is rigged up in THT. (THT
+ DPT) rig floor 114. Travel path is unobstructed. Dies are clean
and not worn. THT + Mud Operator 195 on MB is connected. bucket
(MB) rig floor 114. Inserts are correct size, not worn or damaged.
Travel path is unobstructed. LSA 228 Operator 195 on Travel path is
unobstructed. rig floor 114. Slips 161 Operator 195 on Correct
inserts in slips 161. rig floor 114. Dies are clean and not worn.
Rotary table rotation lock activated. Pipe viper mounted inside or
on top of slips 161. TD 116 Operator 195 on Correct inserts in
elevator 129. rig floor 114. Elevator rotator (tilt) installed.
Operator screen, system status. Travel path is unobstructed. DW 119
Operator 195 on Checked. rig floor 114. Tubulars Operator 195 on
Tubular 111 to be loaded on FT. 111 rig floor 114.
[0187] The well construction system 100, 200 can then be set-up for
the pick-up operation. Examples of such set-up may be as set forth
below in Table 7B.
TABLE-US-00017 TABLE 7B Set-Up for Singles Lay-Down from WC to CW
with TD Equipment Responsible Set-Up HMI Pipe Pipe Verify operator
195 on rig floor 114 Verify Setback handling: Handler completed
pre-checks and deactivated screen. LSA 228, emergency stop for all
pipe handling Construction RN 151, equipment. Program setup CW 131
Open Construction Program screen on wizard. touchscreen 522, 524.
After startup: Check Select Trip Out mode. for green light in
Select target: CW 131 Construction Select setup wizard to open
pop-up on front Program status screen 532, 534, 536. Verify
settings: header on front Select pipe size/type. screen 532, 534,
Select MB (THA), if applicable. 536. Select RN 151 to use in the
operations. RN 151 MU torque. Stick-up target. Select "activate all
machines" to startup and prepare all machines. TD 116, Driller
Verify operator 195 on rig floor 114 Verify Setback DW 119,
completed pre-checks and deactivated screen. MP 144, emergency stop
for all pipe handling Construction Trip tank equipment. Program
setup Open Construction Program screen on wizard. touchscreen 522,
524. After startup: Check Select Trip Out mode. for green light in
Select setup wizard to open pop-up on front Construction screen
532, 534, 536. Verify settings: Program status Stick-up target.
header on front Set DW 119 upper/lower stops. screen 532, 534, Set
maximum hoisting speed. 536. Set maximum pull/overpull. Trip tank
1/2/auto. Trip tank low/high levels. Select "activate all machines"
to startup and prepare all machines. TD 116 Driller Verify operator
195 on rig floor 114 Verify operator completed pre-checks. screen,
system Activate TD 116 from touchscreen 522, status/alarms. 524.
Verify correct elevator 129 setting (manual/remote). Select
Operation screen on touchscreen 522, 524. DW 119 Driller Activate
DW 119 from touchscreen 522, Verify operator 524. screen, system
status/alarms. Slips 161, Driller Verify correct setting for slips
161 Verify operator Rotary (manual/remote). screen, system table
status/alarms. All Driller Verify all relevant machines are enabled
in machines zone management system and tubular interlock system.
Tubulars Pipe All types of tubulars 111 are registered. Verify
operator 111 Handler screen, system settings.
[0188] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
This sequence may start with the top drive 116 in lower position at
WC 203 with the elevator 129 closed, with the slips 161 closed, and
with the catwalk ramp 149 empty and in rig floor 114 loading
position (ready to move to the rig floor 114). The catwalk feeding
table may be unloaded and ready to receive tubulars 111, and the
TDA 202 may be parked outside of the potential collision area.
Example steps of the sequence may be as set forth below in Table
7C.
TABLE-US-00018 TABLE 7C Sequence for Set-Up for Singles Lay-Down
from WC to CW with TD Operator Line of Equipment Equipment 195
Operation Sight precondition Functionality HMI 1. Driller Open
slips 161 and Visual/ Elevator 129 must be Slips 161 Open not Slips
161 to hoist drill string 120: CCTV closed before opening
selectable if elevator Open state. Verify elevator 129 is slips
161. 129 is not closed. Settings: DW closed. Slips 161 Open 119
hoisting Open slips 161 command is reset speed and (command). after
a preset time if maximum Hoist to take weight slips 161 are not
overpull. and verify slips 161 opened. opening. Hoist one single
111. Stop with required stick-up. 1.1. Pipe Tilt ramp 149 and
Visual/ Tubular 111 loaded Skate 133 will tilt CW 131 lay- Handler
move skate 133 to lay- CCTV onto Ramp 149. to WC 203 down ready.
down position: (straight). Verify tubular 111 is CW 131 will
unloaded from ramp move to lay-down 149 (CW 131 ready). position.
Activate CW 131 sequence. 2. Driller Set slips 161: Visual/ DW 119
upper Verify required stick- CCTV stop setting. up height. Slips
161 to Set slips 161 Closed state. (command). Set-off weight. 2.1.
Pipe Move RN 151 to WC RN 151 tongs open. RN 151 will move to TJ
(stick-up) Handler 203: WC 203 selected. WC 203. assist indication.
Verify TD 116 is LSA 228 outside Elevate RN 1515 to RN 151 in WC
hoisted above RN 151 working area. stick-up. 203. working area.
Activate RN 151 BUC RN 151 BUC Start RN 151 break- and position
tong to Closed state. out sequence to move (when slips 161 RN 151
to WC 203. closed). RN 151 will stop/wait outside WC 203 area if TD
116 is moving. 2.2. Pipe LSA 228 move to WC Visual/ TD 116 above
LSA 228 will stop/wait LSA 228 funnel Handler 203: CCTV working
area. outside WC 203 area to Closed state. Verify TD 116 is RN 151
outside if TD 116 is moving. hoisted above LSA 228 working area.
working area. LSA 228 move to WC 203. LSA 228 guide funnel closes.
2.3. Pipe RN 151 break-out and CCTV Slips 161 closed. Break-out and
spin- RN 151 Handler spin-out: out. Double break-out operation
Verify slips 161 available if required status. closed and weight
set- (per set-up). off. Open RN 151 Adjust RN 151 spinner, guide,
and elevation if required. clamps. Continue RN 151 Return RN 151 to
sequence. park position. Option: RN 151 will wait in WC 203 until
TDA 202 has lifted the stand. 2.4. Pipe Option: Wet tubular Visual
RN 151 sequence MB to WC 203. Handler 111: finished. Verify RN 151
is out LSA 228 above of working area. THA/MB working Extend MB to
WC area. 203. Close MB. Driller DW 119 hoist to drain MB to Closed
tubular 111. state. Pipe Open and retract MB. MB to Open Handler
state 3. Driller TD 116 and LSA 228 Visual/ Elevator 129 closed. TD
116 move tubular 111 from CCTV Slips 161 closed. retracted WC 203
to CW 131: position. Verify connection is spun-out. Hoist TD 116 to
lift tubular 111 from stick- up to above CW 131. Tilt TD 116 links
toward CW131 (guided by LSA 228). 3.1. Pipe LSA 228 will guide
Visual/ CW 131 in lay-down LSA 228 Handler tubular 111 pin to CW
CCTV position. position. 131: Verify pin end is above CW 131. Guide
pin end to above skate 133. 4. Driller Set tubular 111 on CW
Visual/ CW 131 in lay-down Skate 133 will move 131: CCTV position.
out as TD 116 lowers. Verify elevator 129 is tilted toward CW 131.
Lower TD 116 and set tubular 111 pin on skate 133. Continue
lowering until tubular 111 rests on CW 131. 4.1. Pipe Open and
retract LSA Visual/ LSA 228 to Handler 228: CCTV Open state. Verify
tubular 111 pin is resting in CW 131. Open and retract LSA 228. 5.
Driller Lay down tubular 111 Visual/ Skate 133 will move on CW 131
and open CCTV out as TD 116 lowers. elevator 129: Verify elevator
129 is tilted toward CW 131 and LSA 228 is out of TD 116 area.
Lower TD 116 until tubular 111 rests on ramp 149. 6. Driller Open
elevator 129: Visual Elevator 129 to Verify tubular 111 is Open
state. resting on CW 131. Open elevator 129. Tilt TD 116 links back
(link tilt float). 6.1. Pipe Move tubular 111 to FT Visual/
Elevator 129 open. Skate 133 will pull Skate 133 to Handler and
unload: CCTV tubular 111 to unloading Activate CW 131 unloading
position. position. sequence to move out Ramp 149 will tilt to CW
131 to and unload tubular unloading position. unloading 111. FT
will unload position. Continue step 1.1. tubular 111. FT unloading
active. 7. Driller Lower TD 116 to stick- Visual Elevator 129 to up
and close elevator Closed state. 129: TD 116 links are tilted back
to clear stick-up (or retract TD 116 with vertical links). Lower TD
116 to stick-up. Tilt links (or extend TD 116) to close elevator
129. 8. Driller Check trip tank Visual Trip tank gain/loss is Trip
Sheet/ volume, gain/loss: determined and Volume control. Trip tank
gain/loss. displayed. Repeat all steps for next tubular 111.
Continue on step 1.
[0189] Different combinations of the aspects described above may
also be utilized for running casing from the CW 131 with a casing
tong (CTO). Preparations for such operation may include the
examples set forth below in Table 8A.
TABLE-US-00019 TABLE 8A Preparations for Running Casing from CW
with CTO Equipment Responsible Verifications CW 131 Operator 195 on
Travel path is unobstructed. rig floor 114. Casings are laid out
correct with aft end in line with skate 133 for correct loading.
Prepare to pick up casing. CTO: Operator 195 on CTO is rigged up in
THA (or THT). THA + CTO rig floor 114. Correct adapters and
stabbing guide as primary, funnel installed. THT + CTO Dies are
correct, clean, and not worn. as backup Travel path is
unobstructed. LSA 228 Operator 195 on Travel path is unobstructed.
rig floor 114. Slips 161 Operator 195 on Correct inserts in slips
161. Rotary rig floor 114. Dies are clean and not worn. Table
Rotary table rotation lock activated. TD 116 Operator 195 on
Correct inserts in elevator 129. rig floor 114. Elevator rotator
(tilt) installed. Operator screen, system status. Travel path is
unobstructed. DW 119 Operator 195 on Checked. rig floor 114.
Tubulars Operator 195 on Tubulars 111 to be laid out on CW 131. 111
rig floor 114. Tubulars 111 to be cleaned and doped, protectors
removed (other implementations may be used for casing with
protectors). Casings measured, marked, and tally undated.
[0190] The well construction system 100, 200 can then be set-up for
the operation. Examples of such set-up may be as set forth below in
Table 8B.
TABLE-US-00020 TABLE 8B Set-Up for Running Casing from CW with CTO
Equipment Responsible Set-Up HMI Pipe Pipe Verify operator 195 on
rig floor 114 Verify Setback handling: Handler completed pre-checks
and deactivated screen. LSA 228, emergency stop for all pipe
handling Construction CTO, equipment. Program setup CW 131 Open
Construction Program screen on wizard. touchscreen 522, 524. After
startup: Check Select Running Casing from CW with CTO for green
light in mode. Construction Select setup wizard to open pop-up on
front Program status screen 532, 534, 536. Verify settings: header
on front Select casing type and verify casing screen 532, 534, data
(size, weight, MU loss, torque 536. settings, weight, etc.). Select
CTO to use in the operations. Stick-up target. Select "activate all
machines" to startup and prepare all machines. TD 116, Driller
Verify operator 195 on rig floor 114 Verify Setback DW 119,
completed pre-checks and deactivated screen. MP 144 emergency stop
for all pipe handling Construction equipment. Program setup Open
Construction Program screen on wizard. touchscreen 522, 524. After
startup: Check Select Running Casing from CW with CTO for green
light in mode. Construction Select setup wizard to open pop-up on
front Program status screen 532, 534, 536. Verify settings: header
on front Stick-up target. screen 532, 534, Set DW 119 upper/lower
stops. 536. Set maximum lowering speed. Set minimum slack off
weight. Trip tank 1/2/auto. Trip tank low/high levels. Verify
active tanks are selected and lined up. Select MP 144 (to fill
casing, optional). Verify MP 144 pressure limit setting. Assign
pumps to master slider. Set number of strokes and SPM to fill
casing (optional). Set ramp-up parameters. Select "activate all
machines" to startup and prepare all machines. TD 116 Driller
Verify operator 195 on rig floor 114 Verify operator completed
pre-checks. screen, system Activate TD 116 from touchscreen 522,
status/alarms. 524. Verify correct elevator 129 setting
(manual/remote). Select Operation screen on touchscreen 522, 524.
DW 119 Driller Activate DW 119 from touchscreen 522, Verify
operator 524. screen, system Set maximum lowering speed.
status/alarms. Set minimum slack off weight. Slips 161, Driller
Verify correct setting for slips 161 Verify operator Rotary
(manual/remote). screen, system table status/alarms. All Driller
Verify all relevant machines are enabled in machines zone
management system and tubular interlock system. Tubulars Pipe All
types of tubulars 111 are registered. 111 Handler
[0191] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example of this sequence may start with a casing stick-up at WC
203, with the slips 161 and the TD 116 elevator 129 closed. Casing
may be laid out on the CW 131 casing side (e.g., Driller's side),
having been cleaned, doped, and tallied, and with protectors
removed. The catwalk ramp 149 may be empty and in the loading
position. Example steps of the sequence may be as set forth below
in Table 8C.
TABLE-US-00021 TABLE 8C Sequence for Running Casing from CW with
CTO Operator Line of Equipment Equipment 195 Operation Sight
precondition Functionality HMI 1.1. Pipe Load casing into ramp
Visual/ Casing ready in Handler 149: CCTV loading position. Use
loading fingers to CW 131 in loading load casing into ramp
position. 149. 1.2. Pipe Run ramp 149 to rig Visual/ Casing loaded
onto Ramp 149 will tilt to CW 131 Handler floor 114: CCTV ramp 149.
rig floor 114 casing animated. Verify casing is position. loaded in
ramp 149. Skate 133 will move Move ramp 149 towards rig floor 114.
toward pick-up Skate 133 will stop position. with casing box inside
ramp. 2. Driller Open elevator 129: Visual/ Slips 161 must be
Elevator 129 Open not Elevator 129 to Verify slips 161 are CCTV
closed before opening selectable if slips 161 Open state. closed.
elevator 129. are not closed. Open elevator 129. 3. Driller Move TD
116 to CW Visual Elevator 129 open. TD 116 pipe handler 131 pick-up
position: Elevator 129 rotated has pre-set position Tilt links to
clear TJ. to receive casing. facing CW 131. Hoist elevator 129
above stick-up. Tilt out elevator 129 and run TD 116 to CW 131
pick-up position. 3.1. Pipe Push casing to pick-up Visual Ramp 149
in rig floor Skate 133 will push CW 131 in pick- Handler position:
114 position. casing a defined up position. Run skate 133 until
distance forward. casing is positioned above elevator 129. 4.
Driller Latch elevator 129: Visual Casing is positioned Elevator
129 close on Elevator 129 to Hoist/tilt TD 116 to correctly above
mechanical impact. Closed state. latch elevator 129. elevator 129.
Tubular interlock prevents hoisting without closed elevator 129
(above certain height). 5. Driller Lift casing: Visual Elevator 129
closed. Hoisting will stop prior Hoist TD 116 to pick Link tilt
float: Elevator to lifting casing out of up casing from CW 129
above RN 151 CW 131 without 131. working area. guiding. Activate
link tilt float to move elevator 129 to vertical position. 5.1.
Pipe LSA 228 extend to Visual/ TD 116 above LSA 228 LSA 228 funnel
Handler guide casing above CCTV operating area. to Closed state. CW
131: Move LSA 228 to preset position to receive casing above CW
131. Before casing lower end leaves CW 131, close LSA 228 funnel.
5.2. Pipe Option: Move Only possible with CTO will move to WC THT
in WC 203. Handler THT/CTO to WC 203: THT. If THA is used, 203.
Verify TD 116 hoisted wait for stand located Elevate to stick-up.
above CTO working above stick-up. ZMS will prevent area. CTO open.
CTO start if TD 116 is Start CTO sequence WC 203 selected. too low.
to move THT to WC 203. 5.3. Pipe LSA 228 tail in casing Visual
Casing bottom clear LSA 228 centralizer LSA 228 Handler to WC 203:
of CW 131 and will close when casing centralizer to TD 116
continues elevated above stick- nears WC 203. Closed state.
hoisting. up. LSA 228 guide closes LSA 228 centralizer and tail in
casing closes when casing towards WC 203 when nears vertical. pin
end is above stick- up. 5.4. Pipe Move THA/CTO to WC CTO open. CTO
will move to WC THA/CTO in Handler 203: WC 203 selected. 203. WC
203. Verify casing is in WC LSA 228 in WC 203. Elevate to stick-up.
203 and LSA 228 is ZMS will prevent above CTO working CTO start if
TD 116 or area. LSA 228 is too low. Start CTO sequence to move THT
to WC 203. 5.5. Pipe Close CTO BUT: Visual/ CTO in WC 203. Close
CTO BUT. CTO to closed Handler Adjust/verify correct CCTV Close
stabbing guide. state. CTO elevation. Continue CTO sequence. 5.6.
Pipe Optional: Close make- Visual/ CTO in WC 203. Close MUST. MUST
to Handler up spinning tong CCTV MUST will take some Closed state.
(MUST) for soft load if closed prior to stabbing: stabbing casing.
Adjust CTO elevation and TD 116 elevation if required. Continue CTO
sequence. 6. Driller Stab casing: Visual/ TD 116 link tilt float.
Weight transferred to CTO to open Lower TD 116 to stab CCTV CTO in
WC 203 with MUST per casing data state. casing (soft stab).
stabbing guide closed. input. Open CTO stabbing guide. 6.1. Pipe
Open and retract LSA Visual/ CTO stabbing guide LSA 228 Open
Handler 228: CCTV closed. status. Open and retract LSA 228 when
casing has entered stabbing guide. 6.2. Pipe CTO spin-in and make-
Visual/ Single casing stabbed CTO will Casing Handler up: CCTV in
stick-up. automatically spin-in connected state. Verify casing is
TD 116 unloaded, and make-up per stabbed. elevator 129 below TJ
casing data settings. Continue CTO to permit spinning. If Accept:
Open sequence. spinner, guide, and Accept or reject clamps.
make-up. Return to park position. 7. Driller Open slips 161: Visual
Elevator 129 must be Slips 161 to Open slips 161 closed. Open
state. (command). CTO has completed DW 119 load. Hoist to open
slips MU sequence with 161. accepted connection. 8. Driller Lower
casing string: Visual Slips 161 open. Optional: Selected MP MP 144
Verify slips 161 are Optional: MP 144 144 will pump a set strokes.
open before lowering ready. number of strokes at MP 144 drill
string 120. set rate with selected pressure. Optional: Fill casing
MP 144 and stop. IBOP to Open volume if selected. state. Extend
fill-up tool, if mounted. Open IBOP. Start MP 144. Close IBOP. 9.
Driller Set slips: Visual Stick-up at correct Slips 161 to Set
slips 161 at height. Closed state. correct stick-up height. DW 119
load Set-off weight. indicator. 10. Driller Check gain/loss: Visual
Trip tank or active Volume control. Check trip tank gain/ tank gain
is loss or active gain/loss determined and depending on selected
displayed. operation. 11. Repeat sequence for next casing
single.
[0192] When a tripping-out "wet" (while the drill string 120 is
full of mud) operation is to be performed, an operator 195 on the
rig floor 114 may verify that various pieces of equipment are
properly shut down and locked out, and then perhaps perform other
preparations such as the examples set forth below in Table 9A.
TABLE-US-00022 TABLE 9A Tripping-In Wet Preparations Equipment
Responsible Verifications FIB 166 Operator 195 on rig floor 114.
Tubulars 111 exist per HMI/tally. Setback 164 Fingers are closed.
Travel path is unobstructed. TBR 254 Operator 195 on rig floor 114.
Travel path is unobstructed. SGA 262 Gripper inserts/dies are
clean, not worn. LTC 244 Operator 195 on rig floor 114. Travel path
is unobstructed. ITC 236 Gripper inserts/dies are clean, not worn.
UTC 242 ITC 236 is open and retracted. THP Operator 195 on rig
floor 114. Travel path is unobstructed. Doper 209 Water, correct
dope available for doper 209. LSA 228 Operator 195 on rig floor
114. Travel path is unobstructed. TDA 202 Operator 195 on rig floor
114. Travel path is unobstructed. Correct dope available for doper
209. Correct inserts/dies in gripper/elevator. Inserts/dies are
clean, not worn. RN 151 Operator 195 on rig floor 114. Drill pipe
tong (DPT) is connected. (THT + DPT) Gripper dies are clean, not
worn. Travel path is unobstructed. THA + MB Operator 195 on rig
floor 114; and/or MB is connected. "Driller" 195 at workstation
452. Inserts correct size, not worn or damaged. Travel path is
unobstructed. Slips 161, Operator 195 on rig floor 114; and/or
Correct inserts/dies. Rotary "Driller" 195 at workstation 452.
Inserts/dies are clean, not worn. Table Pipe viper mounted inside
or on top of slips 161. TD 116 Operator 195 on rig floor; and/or
Correct inserts/dies in elevator 129. "Driller" 195 at workstation
452. Correct saver sub status. Travel path is unobstructed. DW 119
Operator 195 on rig floor; and/or Checked. "Driller" 195 at
workstation 452.
[0193] The well construction system 100, 200 can then be set-up for
the trip-out wet sequence. Examples of such set-up may be as set
forth below in Table 9B.
TABLE-US-00023 TABLE 9B Tripping-Out Wet Set-Up Equipment
Responsible Set-Up HMI Pipe Driller/ Verify operator 195 on rig
floor 114 completed Verify Setback handling: Pipe pre-checks and
deactivated emergency stop for screen. TBR 254, Handler all pipe
handling equipment. Construction SGA 262, Open Construction Program
screen on Program UTC 242, touchscreen 522, 524. setup wizard. LTC
244, Select Trip Out Wet mode. After startup: THP 207, Select setup
wizard to open pop-up on front Check for TDA 202, screen 532, 534,
536. Verify settings: green light in LSA 228, Select slot,
direction for storing tubulars 111. Construction RN 151 Select pipe
type. Program Select RN 151 (THT) to use, check MU status header
torque. on front Select MB (THA). screen 532, Select pin/box
doping. 534, 536. Stick-up target. Select "activate all machines"
to startup and prepare all machines. TD 116, Driller Verify
operator 195 on rig floor 114 completed Verify Setback DW 119,
pre-checks and deactivated emergency stop for screen. MP 144, all
pipe handling equipment. Construction Trip tank Open Construction
Program screen on Program touchscreen 522, 524. setup wizard.
Select Trip Out Wet mode. After startup: Select setup wizard to
open pop-up on front Check for screen 532, 534, 536. Verify
settings: green light in Stick-up target. Construction Set DW 119
upper/lower stops. Program Set maximum lowering speed. status
header Set over pull. on front Trip tank 1/2/auto. screen 532, Trip
tank low/high levels. 534, 536. Select "activate all machines" to
startup and prepare all machines. TD 116 Driller Verify operator
195 on rig floor 114 completed Verify operator pre-checks. screen,
system Activate TD 116 from touchscreen 522, 524. status/alarms.
Select Operation screen on touchscreen 522, 524. DW 119 Driller
Activate DW 119 from touchscreen 522, 524. Verify operator screen,
system status/alarms. All Driller Verify all relevant machines are
enabled in zone Verify operator machines management system and
tubular interlock screen, system system. status/alarms.
[0194] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example trip-out wet sequence may start with the TD 116 in lower
position over WC 203 with closed slips 161 and elevator 129, with a
stick-up of about one meter. The TDA 202 and LSA 228 are open in
THP 207 position (tubular 111 delivered from WC 203 to THP 207).
The UTC 242 and LTC 244 are closed on the tubular 111 in the THP
207, and the ITC 236 is open and retracted. The TBR 254 and SGA 262
are empty, on the way from the FIB 166 to get a new tubular 111 in
the THP 207. Example steps of the trip-out wet sequence may be as
set forth below in Table 9C.
TABLE-US-00024 TABLE 9C Tripping-Out Wet Operation Operator Line of
Equipment Equipment 195 Operation Sight precondition Functionality
HMI 1. Driller Open slips 161 and Visual/ Elevator 129 must be
Slips 161 Open is Slips 161 to hoist to upper stop: CCTV closed
before opening not selectable if Open state. Verify elevator 129 is
slips 161. elevator 129 is not Settings: closed. closed. DW 119
Open slips 161 Slips 161 Open hoisting (command). command is reset
speed and Hoist to take weight after a set time if the maximum and
verify slips 161 slips 161 are not overpull. opening. opened. 1.1.
Pipe TBR 254 and SGA 262 Visual/ TBR 254 and SGA 262 TBR 254 and
Handler pick up next tubular 111 CCTV open. SGA 262 grips/ from THP
207: guides to Closed TBR 254 and SGA 262 state. move to tubular
111 in THP 207. Close TBR 254 and SGA 262 guides/clamps on tubular
111. 1.2. Pipe UTC 242 and LTC 244 Visual/ TBR 254 and SGA 262 UTC
242 and LTC 244 UTC 242 and Handler open and retract: CCTV closed
on tubular 111 open and retract. LTC 244 to Open UTC 242 and LTC in
THP 207. state - retracted. 244 open. UTC 242 and LTC 244 retract
from THP 207. 1.3. Pipe TBR 254 and SGA 262 Visual/ Valid FIB 166
position TBR 254 and SGA THP load. Handler move toward FIB 166 CCTV
selected. 262 will follow with tubular 111: predefined path. Lift
tubular 111 from FIB 166 latches will THP 207. open when tubular
111 Move to selected is outside selected FIB position in FIB 166.
166 row. FIB 166 latches will close prior to setting down tubular
111. Set down tubular 111 on selected position. 1.4. Pipe TDA 202
and LSA 228 Visual/ TDA 202 retracts to TDA 202 load Handler move
to WC 203: CCTV vertical, hoists, and indication. TDA 202 moves to
rotates, extending to WC 203. WC 203 at about two LSA 228 moves to
meters below stick-up. WC 203. TDA 202 and LSA 228 will stop/wait
outside WC 203 area if TD 116 is moving. 1.5. Pipe Move RN 151 to
WC RN 151 tongs open. RN 151 will move to TJ (Stick-up) Handler
203: WC 203 selected. WC 203. assist indication. Verify TD 116 is
Elevate RN 151 to hoisted above RN 151 stick-up. working area. RN
151 will stop/ Start 151 RN break- wait outside WC 203 out sequence
to move area if TD 116 is RN 151 to WC 203. moving. 2. Driller Set
slips 161: Visual/ DW 119 upper Verify required stick-up CCTV stop
setting. height. Set slips 161 (command). Set off weight. 2.1. Pipe
TDA 202 close and LSA Visual/ Slips 161 closed. TDA 202 and LSA 228
TDA 202 to Handler 228 guide close: CCTV will not close in WC
Closed state. Verify TDA 202 and 203 if slips 161 are not TDA 202
and LSA 228 at WC 203. closed. LSA 228 in WC Close TDA 202. 203.
Close LSA 228 guide LSA 228 guide funnel. funnel to Closed state.
2.2. Pipe RN 151 break-out and CCTV Slips 161 closed. Break-out and
spin- RN 151 Handler spin-out: out. Double break-out indication.
Verify slips 161 closed available if required. and weight set off.
Open RN 151 Adjust RN 151 spinner, guide, and elevation if
required. clamps. Continue RN 151 Return RN 151 to sequence. park
position. RN 151 may wait in WC 203 until TDA 202 has lifted
tubular 111. 3. Driller Open TD elevator 129, Visual/ TDA 202
closed. TD elevator retract, and lower: CCTV Slips 161 closed. 129
to Closed Verify TDA 202 is state. closed. TD 116 Open TD elevator
129 retracted and retract. position. Lower TD 116 (e.g., to rig
floor 114. 3.1. Pipe MB (THA) extend to WC Visual/ RN 151/THT MB
will extend to MB in WC Handler 203: CCTV retracted. WC 203 and
close. 203. Verify THT is out of the MB open. MB to Closed area.
state. Continue MB sequence. 3.2. Pipe TDA 202 lift tubular 111
Visual/ RN 151 in parked TDA 202 will hoist TDA 202 load Handler
out of stick-up: CCTV position. about two meters indication. Hoist
TDA 202 to pick MB in WC 203. before lifting tubular TDA 202 up
weight. TD 116 retracted. 111. position LSA 228 centralizer Tubular
111 is lifted indicator. will close on tubular 111 carefully.
Lifting is LSA 228 above stick-up. stopped if tubular centralizer.
Hold stand above 111 is catching on stick-up until drained. threads
in TJ. LSA 228 centralizer closes after lifted above the box. 3.3.
Pipe MB open and retract: Visual/ MB will open and MB to Closed
Handler Verify tubular 111 is CCTV retract. state. drained. MB
parked. Continue MB sequence. 3.4. Pipe TDA 202 and LSA 228 Visual/
TDA 202 closed. TDA 202 will retract TDA 202 load Handler move
tubular 111 to CCTV to vertical position indication. THP 207: above
MOH 204 (or TDA 202 TDA 202 and LSA 228 rig floor 114), then
position move toward THP 207. rotate, lower, and indicator. LTC 244
extends to extend to THP 207. LSA 228 THP 207 and closes TDA 202
will slow extend. guide when tubular 111 down above THP LTC 244 to
is close to THP 207. 207. Closed state. Set down tubular 111 LTC
244 is extended at THP 207. and closed. Wash and dope pin if LSA
228 is open. preselected. 3.5. Pipe UTC 242 extend to THP Visual/
TDA 202 and LSA 228 UTC 242 extend and UTC 242 and Handler 207 and
close. CCTV in THP 207 with tubular close. LTC 244 to UTC 242
extends to 111. LTC 244 continue Closed state. THP 207. close. UTC
242 and LTC 244 close. 4. Driller Extend TD 116 and Visual RN 151
parked. Elevator 129 latch elevator 129: to Closed state. Extend TD
116 to WC Indicate TD 203. 116 in WC 203. Latch elevator 129
(automatic close on impact). 5. Driller Check trip tank volume,
Visual Trip tank gain/loss is Trip sheet/ gain/loss: determined and
volume control. Determine trip tank displayed. gain/loss. Repeat
all steps for next tubular 111. Continue on step 1. 5.1. Pipe TDA
202 open and Visual/ UTC 242 closed. TDA 202 to Handler retract
from THP 207: CCTV Open state. Verify UTC 242 and LSA 228 open. LTC
244 are closed. Open TDA 202. Open LSA 228 guide funnel. Continue
on step 1.4. 5.2. Pipe TBR 254 and SGA 262 UTC 242 and LTC 244
Handler move to FIB 166: closed on tubular 111. Open TBR 254 and
SGA 262. Move TBR 254 and SGA 262 toward THP 207/ next tubular 111.
Continue step 1.1.
[0195] When a back-reaming operation is to be performed, an
operator 195 on the rig floor 114 may verify that various pieces of
equipment are properly shut down and locked out, and then perhaps
perform other preparations such as the examples set forth above in
Table 9A. The well construction system 100, 200 can then be set-up
for the back-reaming sequence. Examples of such set-up may be as
set forth below in Table 10A.
TABLE-US-00025 TABLE 10A Back-Reaming Set-Up Equipment Responsible
Set-Up HMI Pipe Driller/ Verify operator 195 on rig floor 114
Verify Setback handling: Pipe completed pre-checks and deactivated
screen. TBR 254, Handler emergency stop for all pipe handling
Construction SGA 262, equipment. Program setup UTC 242, Open
Construction Program screen on wizard. LTC 244, touchscreen 522,
524. After startup: Check ITC 236, Select Back-Reaming mode. for
green light in THP 207, Select setup wizard to open pop-up on front
Construction TDA 202, screen 532, 534, 536. Verify settings:
Program status LSA 228, Select slot, direction for setting back
header on front RN 151 pipe. screen 532, 534, Select pipe type.
536. Select RN 151 (THT) and MB (THA). Check RN 151 MU torque.
Select pin/box doping. Stick-up target. Select "activate all
machines" to startup and prepare all machines. TD 116, Driller
Verify operator 195 on rig floor 114 Verify Setback DW 119,
completed pre-checks and deactivated screen. MP 144 emergency stop
for all pipe handling Construction equipment. Program setup Open
Construction Program screen on wizard. touchscreen 522, 524. After
startup: Check Select Drilling mode. for green light in Select
setup wizard to open pop-up on front Construction screen 532, 534,
536. Verify settings: Program status Stick-up target. header on
front Set DW 119 upper/lower stops. screen 532, 534, Set relevant
Autodriller parameters 536. (ROP, WOB, delta-P, torque, etc.) Set
maximum pull. Verify correct TD 116 MU torque setting. Verify
correct drilling torque setting. Verify spin-in speed and torque
setting. Verify spin-out time. Verify MP 144 liner size setting and
efficiency. Verify MP 144 pressure limit setting. Assign pumps to
MP 144 master slider. Verify/set MP 144 ramp-up parameters. Verify
active tanks are selected and lined up. Select "activate all
machines" to startup and prepare all machines. All Driller Verify
all relevant machines are enabled in Verify operator machines zone
management system and tubular screen, system interlock system.
settings.
[0196] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example back-reaming sequence may start with the top drive 116
in lower position and retracted (with elevator links vertical), the
slips 161 closed, and the TDA 202 and LSA 228 open in the THP 207.
The UTC 242 and LTC 244 may be closed on a tubular 111 in the THP
207, with the ITC 236 being open and retracted, and the TBR 254 and
SGA 262 empty (on the way from the FIB 166 to get the next tubular
111 in the THP 207). Example steps of the back-reaming sequence may
be as set forth below in Table 10B.
TABLE-US-00026 TABLE 10B Back-Reaming Operation Operator Line of
Equipment Equipment 195 Operation Sight precondition Functionality
HMI 1. Driller Extend TD 116, tilt up Visual TD 116 to WC links:
203. Verify tubular 111 is Links to out of WC 203. parked position.
Extend TD 116 to WC 203. Tilt elevator 129 to parked position. 2.
Driller TD 116 spin-in: Visual Slips 161 closed. Spin-in will
activate TD 116 to WC Apply dope on saver TD 116 thread 203. sub
(manual). compensator system. Links to Start spin-in. Spin-in with
spin-in parked position. Lower TD 116 and settings (e.g., RPM/
Thread spin to stick-up. torque). compensator. Spin-in will stop at
set torque and release the spin-in torque. 3. Driller TD 116
make-up: Visual TD 116 spin-in TD 116 MU will TD 116 BUC Activate
TD 116 MU finished. automatically close close. (joystick button and
BUC and increase TD TD 116 MU joystick) (may be 116 torque to set
MU torque. operated manually on torque. TD 116 torque touchscreen
522, 524). Release torque and log updated. Release button when open
BUC when TD 116 MU torque is reached. button is released. connected
state DW 119 is when MU interlocked from torque is moving when BUC
is reached. closed. TD thread TD 116 thread compensator compensator
system deactivated. is deactivated. 3.1. Pipe TDA 202 and LSA 228
Visual/ UTC 242 closed. TDA 202 will retract, TDA 202 to Handler
move from THP 207 to CCTV TDA 202 open. hoist, and rotate when Open
state. rig floor 114: LSA 228 open. moving from THP 207 LSA 228 to
Verify UTC 242 and ITC 236 open and to rig floor 114 Open state.
LTC 244 are closed. retracted. standby. TDA 202 and LSA 228 move to
rig floor 114 standby. 3.2. Pipe TBR 254 and SGA 262 Visual/ TBR
254 and SGA TBR 254 and Handler get tubular 111 from CCTV 262 open.
SGA 262 to THP 207: Closed states. TBR 254 and SGA 262 move to
tubular 111 in THP 207. Close TBR 254 and SGA 262 on tubular 111.
3.3. Pipe UTC 242 and LTC 244 Visual/ TBR 254 and SGA UTC 242 and
LTC UTC 242 and Handler open and retract: CCTV 262 closed on
tubular 244 open and retract. LTC 244 to UTC 242 and LTC 111 in THP
207. Open state - 244 open. retracted. UTC 242 and LTC 244 retract
from THP 207. 3.4. Pipe TBR 254 and SGA 262 Visual/ Valid FIB 166
position TBR 254 and SGA THP load. Handler move toward FIB 166 CCTV
selected. 262 will follow with tubular 111: predefined path. Lift
tubular 111 from FIB 166 latches will THP 207. open when tubular
Move to selected 111 is outside position in FIB 166. selected FIB
166 row. FIB 166 latches will close prior to setting down tubular
111. Set down tubular 111 in selected position. 4. Driller Open
slips 161 and Visual/ TD 116 connected. Slips 161 to ream out
tubular 111: CCTV TD thread Open state. Verify TD 116 is
compensator IBOP to Open connected. deactivated. state. Open slips
161. TD 116 RPM. Open IBOP. TD 116 Continue to ream out torque.
tubular 111 per drilling MP 144 SPM. program. Standpipe pressure.
5. Driller Set slips 161: Visual Slips 161 to Stop rotation and
Closed state. release torque. Stop MP 144 and close IBOP. Set slips
161 at required stick-up (e.g., about 1-2 meters). 5.1. Pipe TDA
202 and LSA 228 Visual/ TDA 202 open. TDA 202 retract to TDA 202
Load Handler move to WC 203 (from CCTV LSA 228 open. vertical,
hoist, rotate, indication. rig floor 114 standby). and extend to WC
203 about two meters below stick-up. TDA 202 and LSA 228 will
stop/wait outside WC 203 area if TD 116 is moving. 5.2. Pipe Move
RN 151 to WC RN 151 clamps open. RN 151 will move to TJ (stick-up)
Handler 203: WC 203 selected. WC 203. assist Start RN 151 break-
Elevate RN 151 to indication. out sequence to move stick-up. RN 151
to WC 203. RN 151 will stop/ wait outside WC 203 area if TD 116 is
moving. 5.3. Pipe TDA 202 and LSA 228 Visual/ Slips 161 closed. TDA
202 and LSA TDA 202 to Handler guide close. CCTV 228 will not close
in Closed state. Verify TDA 202 and WC 203 if slips 161 TDA 202 and
LSA 228 in WC 203. are not closed. LSA 228 in WC Close TDA 202.
203. Close LSA 228 guide LSA 228 guide funnel. funnel to Closed
state. 6. Driller TD 116 break-out Visual Slips 161 must be TD 116
Break-Out TD 116 thread connection: closed before TD 116 function
will activate compensator. Verify slips 161 are BUT/Break-Out clamp
and increase TD 116 not closed. function is available. torque to
break connected. Activate TD 116 connection. TD 116 BUC. break-out
function TD 116 break-out (joystick button + will activate TD 116
joystick). (Clamp on/ thread compensator break-out may be and TD
116 pipe operated manually on handler lock. touchscreen 522, 524).
When connection is Deactivate break-out broken, release button when
button. Torque will be connection is broken released and TD 116
(torque dropping and BUC opened. shaft rotating). DW 119 is
interlocked from hoisting when TD 116 BUC is closed. 7. Driller TD
116 spin-out: Visual Slips 161 must be Spin-Out will TD 116 thread
Verify break-out is closed. activate TD 116 compensator. completed.
Break-Out not active. thread compensator Spin-out. TD 116 BUC open.
system. Hoist out of stick-up. Spin-Out function will spin-out per
settings. TD 116 thread compensator is deactivated. 8. Driller
Retract and lower TD Visual/ Lowering will be Links will tilt down
TD 116 116 to stick-up: CCTV stopped if TD 116 is when TD 116 is
retracted. Verify TD 116 is retracted and links retracted. Indicate
TD above tubular 111. are tilted to parked TD 116 pipe handler 116
lower stop Retract TD 116 and position. has preset position
position. tilt links down (float). facing TDA 202. Link tilt Lower
TD 116 to position. stick-up (lower stop). 8.1. Pipe RN 151
break-out and CCTV Slips 161 closed. Break-out and spin- RN 151
Handler spin-out: out. Double break- indication. TD 116
disconnected out available if and hoisted above required. tubular
111. Open RN 151 Adjust RN 151 spinner, guide, and elevation if
required. clamps. Continue RN 151 Return RN 151 to sequence. park
position. 8.2. Pipe MB (THA) extend to Visual/ RN 151/THT MB will
extend to WC MB in WC Handler WC 203: CCTV retracted. 203 and
close. 203. Verify THT is out of MB open. MB to Closed the area.
state. Continue the MB sequence. 8.3. Pipe TDA 202 lift tubular
Visual/ RN 151 in parked TDA 202 will hoist TDA 202 load Handler
from stick-up: CCTV position. about two meters indication. Hoist
TDA 202 to pick MB in WC 203. before lifting tubular TDA 202 up
weight. TD 116 retracted. 111. position LSA 228 centralizer Tubular
111 is lifted indicator. closed on tubular 111 carefully. Lifting
is LSA 228 in WC 203. stopped if tubular 111 centralizer. Hold
tubular 111 catches on TJ above stick-up until threads. drained.
LSA 228 centralizer closes after lifted above box. 8.4. Pipe MB
open and retract: Visual/ MB will open and MB to Open Handler
Verify tubular 111 is CCTV retract. state. drained. MB parked.
Continue MB sequence. 8.5. Pipe TDA 202 and LSA 228 Visual/ TD 116
elevator 129 TDA 202 will retract TDA 202 load Handler move tubular
111 to CCTV closed. to vertical position indication. THP 207: above
MOH 204 (rig TDA 202 TDA 202 and LSA floor 114 standby), position
228 will move towards then rotate, lower, indicator. THP 207. and
extend to THP LSA 228 LTC 244 extends to 207. extend. THP 207 and
closes TDA 202 will slow LTC 244 to guide when tubular 111 down
above THP Closed state. is close to THP 207. 207. Wash and Set down
tubular 111 LTC 244 is extended dope (if on THP 207. and closed.
selected). Wash and dope pin if LSA 228 open. preselected. 8.6.
Pipe UTC 242 extend THP Visual/ TDA 202 and LSA UTC 242 extend and
UTC 242 and Handler 207 and close: CCTV 228 in THP 207 with close.
LTC 244 to UTC 242 extends to tubular 111. LTC 244 continue Closed
states. THP 207. close. UTC 242 and LTC 244 close. 8.7. Pipe TDA
202 open and Visual/ UTC 242 closed. TDA 202 to Handler retract
from THP 207: CCTV Open state. Verify UTC 242 and LSA 228 open. LTC
244 are closed. Open TDA 202. Open LSA 228 guide funnel. Continue
on step 3.1. 8.8. Pipe TBR 254 and SGA 262 FIB 166 latches FIB 166
Handler move toward THP 207: closed. latches closed. Open TBR 254
TBR 254 and clamps and guide and SGA 262 open. SGA 262 guide (in
FIB 166). Move toward THP 207/ next tubular 111. Continue step
3.2.
[0197] For tripping-in drill collar stands, an operator 195 on the
rig floor 114 may verify that various pieces of equipment are
properly shut down and locked out, and then perhaps perform other
preparations such as the examples set forth below in Table 11A.
TABLE-US-00027 TABLE 11A Preparations for Tripping-In Drill Collar
Stands Equipment Responsible Verifications FIB 166 Operator 195 on
rig floor 114. Tubulars 111 exist in FIB 166 slots per Setback 164
HMI/tally. Fingers are closed. Travel path is unobstructed. TBR 254
Operator 195 on rig floor 114. Travel path is unobstructed. SGA 262
Gripper inserts/dies are clean, not worn. LTC 244 Operator 195 on
rig floor 114. Travel path is unobstructed. ITC 236 Gripper
inserts/dies are clean, not worn. UTC 242 THP Operator 195 on rig
floor 114. Travel path is unobstructed. Doper 209 Water, correct
dope available for doper 209. LSA 228 Operator 195 on rig floor
114. Travel path is unobstructed. TDA 202 Operator 195 on rig floor
114. TDA 202 is parked outside collision area. RN 151 Operator 195
on rig floor 114. DPT is connected. THT - DPT Gripper dies are
clean, not worn. THA - DPT Travel path is unobstructed. Slips 161
Operator 195 on rig floor 114; and/or Correct inserts/dies.
"Driller" 195 at workstation 452. Inserts/dies are clean, not worn.
TD 116 Operator 195 on rig floor; and/or Correct inserts/dies in
elevator 129. "Driller" 195 at workstation 452. Correct saver sub
status. Travel path is unobstructed. DW 119 Operator 195 on rig
floor; and/or Checked. "Driller" 195 at workstation 452.
[0198] The well construction system 100, 200 can then be set-up for
the trip-in sequence. Examples of such set-up may be as set forth
below in Table 11B.
TABLE-US-00028 TABLE 11B Set-Up for Tripping-In Drill Collar Stands
Equipment Responsible Set-Up HMI Pipe Driller/ Verify operator 195
on rig floor 114 Verify Setback screen. handling: Pipe completed
pre-checks and deactivated Construction Program TBR 254, Handler
emergency stop for all pipe handling setup wizard. SGA 262,
equipment. After startup: Check for UTC 242, Open Construction
Program screen on green light in LTC 244, touchscreen 522, 524.
Construction Program THP 207, Select Trip In mode. status header on
front LSA 228, Select setup wizard to open pop-up on screen 532,
534, 536. RN 151 front screen 532, 534, 536. Verify settings:
Select slot, direction for picking pipe. Select pipe type. Select
RN 151 to use. RN 151 MU torque. Select pin/box doping. Stick-up
target. Select "activate all machines" to startup and prepare all
machines. TD 116, Driller Verify operator 195 on rig floor 114
Verify Setback screen. DW 119, completed pre-checks and deactivated
Construction Program MP 144, emergency stop for all pipe handling
setup wizard. Trip tank equipment. After startup: Check for Open
Construction Program screen on green light in touchscreen 522, 524.
Construction Program Select Trip In mode. status header on front
Select setup wizard to open pop-up on screen 532, 534, 536. front
screen 532, 534, 536. Verify settings: Stick-up target. Set DW 119
upper/lower stops. Set maximum lowering speed. Set minimum slack
off weight. Trip tank 1/2/auto. Trip tank low/high levels. Select
"activate all machines" to startup and prepare all machines. TD 116
Driller Verify operator 195 on rig floor 114 Verify operator
screen, completed pre-checks. system status/alarms. Activate TD 116
from touchscreen 522, 524. Select Operation screen on touchscreen
522, 524. DW 119 Driller Activate DW 119 from touchscreen 522,
Verify operator screen, 524. system status/alarms. All Driller
Verify all relevant machines are enabled Verify operator screen,
machines in zone management system and system status/alarms.
tubular interlock system.
[0199] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
The sequence for tripping-in drill collar stands may start with a
drill collar stand 111 stick-up at WC 203, with the top drive 116
elevator 129 closed on the stick-up and the slips 161 closed. The
UTC 242 and LTC 244 may be closed on another drill collar stand 111
in the THP 207, with washing and doping of the pin already
completed. The TDA 202, LSA 228, TBR 254, and SGA 262 may each be
empty. Example steps of the drill collar stand tripping-in sequence
may be as set forth below in Table 11C.
TABLE-US-00029 TABLE 11C Tripping-In Drill Collar Stands Operation
Operator Line of Equipment Equipment 195 Operation Sight
precondition Functionality HMI 1. Driller Open elevator 129:
Visual/ Slips 161 must be Elevator 129 Open is Elevator 129 to
Verify slips 161 are CCTV closed before opening not selectable if
slips Open state. closed. elevator 129. 161 are not closed. Open
elevator 129. 1.1. Pipe TBR 254 and SGA 262 Visual/ TBR 254 and SGA
TBR 254 will move TBR 254 and Handler pick up new stand 111: CCTV
262 grip/guide open. into FIB 166 elevated SGA 262 grip/ Move TBR
254 and Selected FIB 166 above open latches. guide to Closed SGA
262 to selected position "valid." Adjustments available. state.
finger/slot in FIB 166. TBR 254 and SGA Close guides and 262
grip/guide will clamp on stand 111. close. 2. Driller Tilt back
elevator 129 Visual/ TD 116 pipe handler Elevator 129 will be DW
119 upper and move TD 116 to CCTV positioned facing UTC tilted back
and then stop setting. latching height: 242. slide back to vertical
Verify elevator 129 is position (float). open. Tilt back (or
retract) TD 116 to clear TJ. Hoist elevator 129 to stand 111 latch
height (upper stop). 2.1. Pipe UTC 242 and LTC 244 Visual/ UTC 242
and LTC UTC 242 and Handler tilt stand 111 to drill CCTV 244 will
stop at LTC 244 closed. collar handover correct angle, DCH. UTC 242
and position (DCH): LTS 244 to DCH. UTC 242 and LTC 244 extend to
tilt stand 111 toward WC 203. 2.2. Pipe LSA 228 extend to Visual/
LSA 228 guide funnel LSA 228 funnel Handler stand 111 in THP 207:
CCTV must be open. to Closed state. Extend LSA 228 to UTC 242 and
LTC stand 111 in THP 207 244 in DCH. (tilted). Close LSA 228
funnel. 3. Driller Extend TD 116 and Visual/ UTC 242 and LTC
Elevator 129 to latch elevator 129: CCTV 244 in DCH. Closed state.
Extend TD 116 to WC TD 116 in WC 203. 203. Latch elevator 129 UTC
242 and (automatic close on LTC 244 in DCH. impact). 3.1. Pipe UTC
242 and LTC 244 Visual/ TD 116 elevator 129 UTC 242 and LTC UTC 242
and Handler open and retract. CCTV must be closed. 244 open and
retract. LTC 244 to LSA 228 funnel must Open states. be closed.
3.2. Pipe Move RN 151 to WC Only possible with RN 151 will move to
TJ (stick-up) Handler 203: THT. If THA is used, WC 203. assist
Start RN 151 MU wait for stand 111 Elevate RN 151 to indication.
sequence to move RN located above stick-up. stick-up. 151 to WC
203. RN 151 tongs open. WC 203 selected. 4. Driller TD 116 hoist
stand 111 Visual/ UTC 242 or LTC 244 Slips 161 Open will TD 116 at
WC from THP 207: CCTV open. be blocked with 203. TD 116/DW 119 lift
elevator 129 closed in stand 111 guided by WC 203 until stand LSA
228 (e.g., about 111 is connected. nine meters). Stop when above
stick-up. Note: Drill collar stand 111 to be lifted carefully to
avoid damage to equipment. Links tilt to WC 203 (float). 4.1. Pipe
LSA 228 guide stand Visual/ LSA 228 Handler 111 to WC 203: CCTV
centralizer to LSA 228 guides stand Closed state. 111 to WC 203
when LSA 228 pin is above stick-up adjustment height. available.
LSA 228 centralizer closes when stand 111 is close to vertical
above stick-up. 4.2. Pipe Guide stand 111 with CCTV Stand 111
positioned Close RN 151 BUT. Stabbing guide Handler RN 151 in WC
203: by TD 116/LSA 228 Close stabbing guide. to Closed state.
Verify stand 111 is above stick-up in WC RN 151 BUT to located in
WC 203. 203. Closed state. Adjust RN 151 elevation if required.
Continue RN 151 sequence. 5. Driller TD 116 lower to stab Visual/
RN 151 in WC 203 stand 111 in stick-up. CCTV with stabbing guide
closed. 5.1. Pipe LSA 228 open and Visual/ RN 151 stabbing LSA 228
guide Handler retract: CCTV guide closed on stand to Open state.
LSA 228 opens and 111. retracts when RN 151 stabbing guide closed
on stand 111. 5.2. Pipe RN 151 spin-in and Visual/ Stand 111
stabbed in Spin-in and MU Torque log Handler MU: CCTV stick-up.
connection. updated. Continue RN 151 TDA 202 unloaded. Open RN 151
spinner MU torque sequence to spin-in and tongs. presented to and
MU. Return RN 151 to Driller. park position. 5.3. Pipe TBR 254 and
SGA 262 Visual/ THP 207 empty. TBR 254 cannot open Indicate FIB
Handler move stand 111 to CCTV UTC 242 and LTC with weight. 166
open THP 207: 244 open. TBR 254 grip open latches. Open FIB 166
latches Correct pipe detected when unloaded. TBR 254 load for
selected row. in TBR 254 and SGA FIB 166 latches will indication.
Verify latches open. 262. not open with TBR 254 TBR 254 lifts and
head in low position. moves stand 111 out of FIB 166 to THP 207.
FIB 166 latches will close as stand 111 moves out of FIB 166. Set
stand 111 on THP 207. Wash and dope pin if preselected. 5.4. Pipe
UTC 242 and LTC 244 Visual/ TBR 254 and SGA UTC 242 and LTC UTC 242
and Handler extend to THP 207 and CCTV 262 with stand 111 in 244
extend and close. LTC 244 to close. THP 207. Closed states. 5.5.
Pipe TBR 254 and SGA 262 UTC242 and LTC 244 Handler open and move
toward closed on stand 111. FIB 166: Open TBR 254 clamps and guide
and SGA 262 guide. Move toward FIB 166/ next stand 111. Continue
step 1. 6. Driller Opening slips: Visual TD 116 elevator 129 Slips
161 to Open slips 161 closed. Open state. (command). RN 151 MU DW
119 load. Hoist to open slips sequence finished. 161. Stand 111
connected state. 7. Driller Lower drill string 120: Visual Slips
161 open. Settings: DW Verify slips 161 are 119 lowering open
before lowering speed and drill string 120. minimum slack- off
weight. 8. Driller Set slips 161: Visual Stick-up at correct Slips
161 to Set slips 161 at height. Closed state. correct stick-up
height. DW 119 load Set off weight. indicator. 9. Driller Check
trip tank Visual Slips 161 closed. Trip tank gain/loss is Trip
sheet/ volume, gain/loss: determined and volume control. Trip tank
gain/loss. displayed. Repeat all steps for next stand 111.
[0200] Different combinations of the aspects described above may
also be utilized for running casing from the CW 131 with the TDA
202 and a casing running tool (CRT). Preparations for such
operation may include the examples set forth below in Table
12A.
TABLE-US-00030 TABLE 12A Preparations for Running Casing from CW
with TDA and CRT Equipment Responsible Verifications CW 131
Operator 195 on Travel path is unobstructed. rig floor 114. Casings
are laid out correct with aft end in line with skate 133 for
correct loading. Prepare to pick up casing. CTO: Operator 195 on
CTO is rigged up in THA (or THT). THA + CTO rig floor 114. CTO
adjusted for casing size. as primary, Dies are correct, clean, and
not worn. THT + CTO Travel path is unobstructed. as backup LSA 228
Operator 195 on Travel path is unobstructed. rig floor 114. Slips
161 Operator 195 on Correct inserts in slips 161. Rotary rig floor
114. Dies are clean and not worn. Table Rotary table rotation lock
activated. TD 116, Operator 195 on Correct inserts in elevator 129
CRT rig floor 114. (or elevator 129 removed, if required). Operator
screen, system status. Travel path is unobstructed. CRT installed
and tested. DW 119 Operator 195 on Checked. rig floor 114. Tubulars
Operator 195 on Tubulars 111 to be laid out on CW 131. 111 rig
floor 114. Tubulars 111 to be cleaned and doped, protectors removed
(other implementations may be used for casing with protectors).
Casings measured, marked, and tally updated.
[0201] The well construction system 100, 200 can then be set-up for
the operation. Examples of such set-up may be as set forth below in
Table 12B.
TABLE-US-00031 TABLE 12B Set-Up for Running Casing from CW with TDA
and CRT Equipment Responsible Set-Up HMI Pipe Pipe Verify operator
195 on rig floor 114 Verify Setback handling: Handler completed
pre-checks and deactivated screen. LSA 228, emergency stop for all
pipe handling Construction CTO, equipment. Program setup CW 131
Open Construction Program screen on wizard. touchscreen 522, 524.
After startup: Check Select Running Casing from CW with TDA for
green light in and CRT mode. Construction Select setup wizard to
open pop-up on front Program status screen 532, 534, 536. Verify
settings: header on front Select casing type and verify casing
screen 532, 534, data (size, weight, MU loss, torque 536. settings,
weight, etc.). Select CTO to use in the operations. Stick-up
target. Select "activate all machines" to startup and prepare all
machines. TD 116, Driller Verify operator 195 on rig floor 114
Verify Setback DW 119, completed pre-checks and deactivated screen.
MP 144 emergency stop for all pipe handling Construction equipment.
Program setup Open Construction Program screen on wizard.
touchscreen 522, 524. After startup: Check Select Running Casing
from CW with TDA for green light in and CRT mode. Construction
Select setup wizard to open pop-up on front Program status screen
532, 534, 536. Verify settings: header on front Stick-up target.
screen 532, 534, Set DW 119 upper/lower stops. 536. Set maximum
lowering speed. Set minimum slack off weight. Trip tank 1/2/auto.
Trip tank low/high levels. Verify active tanks are selected and
lined up. Select MP 144 (to fill casing, optional). Verify MP 144
pressure limit setting. Assign pumps to master slider. Set number
of strokes and SPM to fill casing (optional). Set ramp-up
parameters. Select "activate all machines" to startup and prepare
all machines. TD 116 Driller Verify operator 195 on rig floor 114
Verify operator completed pre-checks. screen, system Activate TD
116 from touchscreen 522, status/alarms. 524. Verify correct
elevator 129 setting (manual/remote). Select Operation screen on
touchscreen 522, 524. DW 119 Driller Activate DW 119 from
touchscreen 522, Verify operator 524. screen, system Set maximum
lowering speed. status/alarms. Set minimum slack off weight. Slips
161, Driller Verify correct setting for slips 161 Verify operator
Rotary (manual/remote). screen, system table status/alarms. All
Driller Verify all relevant machines are enabled in machines zone
management system and tubular interlock system. Tubulars Pipe All
types of tubulars 111 are registered. 111 Handler
[0202] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example of this sequence may start with a casing stick-up at WC
203, with the slips 161 closed and the CRT engaged. Casing may be
laid out on the CW 131 casing side (e.g., Driller's side), having
been cleaned, doped, and tallied, and with protectors removed. The
TDA 202 and LSA 228 may hold a casing 111 in the rig floor 114
standby position. Example steps of the sequence may be as set forth
below in Table 12C.
TABLE-US-00032 TABLE 12C Sequence for Running Casing from CW with
CTO Operator Line of Equipment Equipment 195 Operation Sight
precondition Functionality HMI 1. Driller Release CRT from Visual/
Slips 161 must be CRT to stick-up: CCTV closed before releasing
Disconnect Verify slips 161 are CRT. state. closed, MP 144 stopped,
and IBOP closed. Release CRT from stick-up. Hoist CRT above
stick-up. Retract and hoist to casing stabbing position. 1.1. Pipe
Move THT/CTO to WC CTO open. CTO will move to WC THT in WC 203.
Handler 203 (optional): WC 203 selected. 203. Verify TD 116 hoisted
Elevate to stick-up. above CTO working ZMS will prevent area. CTO
start if TD 116 is Start CTO sequence too low. to move THT/CTO to
WC 203. 1.2. Pipe TDA 202 and LSA 228 CTO open. TDA 202 and Handler
extend casing to WC LSA 228 in WC 203: 203. Verify TD 116 is
retracted. TDA 202 and LSA 228 will extend casing to WC 203 above
stick- up. 1.3. Pipe Guide single casing Visual/ CTO in WC 203.
Close CTO BUT. Handler with CTO in WC 203: CCTV LSA 228 in WC 203.
Close stabbing guide. Verify casing at WC 203. Continue CTO
sequence. 1.4. Pipe Close MUST for soft Visual/ CTO in WC 203.
Close MUST. MUST to Handler stabbing (optional): CCTV Must will
take some Closed state. Adjust CTO elevation load if closed prior
to and TD 116 elevation if stabbing casing. required. Continue CTO
sequence. 1.5. Pipe Stab casing: Visual/ TDA 202 in WC 203. TDA 202
will lower to TDA 202 Handler Lower TDA 202 to CCTV CTO in WC 203
with stab casing and unloaded. stab casing in stick-up. stabbing
guide closed. continue lowering (e.g., about one meter). 1.6. Pipe
Open and retract LSA Visual/ CTO stabbing guide LSA 228 Open
Handler 228: CCTV closed. status. Open and retract LSA 228 when
casing has entered stabbing guide. 1.7. Pipe CTO spin-in and MU:
Visual/ Single casing stabbed CTO will spin-in and Casing Handler
Verify casing is CCTV in stick-up. MU automatically per Connected
state. stabbed in box. TD 116 unloaded, casing data settings.
Continue CTO elevator 129 below TJ If Accept: Open sequence. to
permit spinning. spinner, guide, and Accept or reject MU. clamps.
Return to park position. 1.8. Pipe Load casing into ramp Visual/
Casing ready in Handler 149: CCTV loading position. Use CW 131
loading CW 131 in loading fingers to load casing position. single
into ramp 149. 1.9. Pipe Run ramp 149 to rig Visual/ Casing loaded
onto Ramp 149 will tilt to CW 131 Handler floor 114: CCTV ramp 149.
rig floor 114 tubular animated. Verify casing is position. loaded
in ramp 149. Skate 133 will move Move ramp toward toward rig floor
114. pipe pick-up position. Skate 133 will stop with casing box
inside ramp 149. 2. Driller Stab and engage CRT: Visual/ Single
casing CRT Connected Verify casing is CCTV stabbed in stick-up.
state. stabbed and MU TDA 202 unloaded, accepted. elevator (or
gripper Stab and engage 169) below TJ to CRT. permit spinning. CTO
open. 2.1. Pipe Open TDA 202 and Casing connected. Open CTO BUT and
TDA 202 Open. Handler move to pick up next CRT connected. move THT
to parked casing single: position. Open TDA 202 and move to CW 131
pick- up position. 3. Driller Open slips 161: Visual CRT connected.
Slips 161 to Open slips 161 Casing connected. Open state.
(command). DW 119 load. Hoist to open slips 161. 4. Driller Lower
drill string 120: Visual Slips 161 open. Optional: The selected MP
144 SPM Verify slips 161 are Optional: MP 144 MP 144 will pump a
and pressure. open before lowering ready. set number of strokes
drill string 120. at set rate with Optional: Fill casing selected
MP 144 and volume, if selected. stop. Open IBOP. Start MP 144.
Close IBOP. 4.1. Pipe Push casing to pick-up Visual Ramp 149 in rig
floor Skate 133 will push CW 131 in pick- Handler position: 114
position. casing a defined up position. Verify TDA 116 TDA 202 in
CW 131 distance forward. TDA 202 in CW elevator 129 is pick-up
position. 131 pick-up positioned in CW 131 TDA 202 open. position.
pick-up position. Run skate 133 until casing is positioned above
elevator 129. 4.2. Pipe Close TDA 202: Visual Casing in CW 131
Tubular interlock will TD 202 to Handler Hoist/tilt TDA 202 and
pick-up position, above prevent hoisting Closed state. close. TDA
202 elevator. without closed elevator (above certain height). 5.
Pipe Lift casing to rig floor Visual TDA 202 closed. Hoisting will
stop LSA 228 guide Handler 114 DF standby Verify LSA 228 is prior
to lifting casing to Closed state. position: positioned to receive
out of CW 131 without LSA 228 Verify TDA 202 is casing bottom
before guiding. centralizer to closed. hoisting. LSA 228
centralizer Closed state. Hoist TDA 202 to pick TDA 202 above LSA
close when casing is Indicate TDA up single from CW 228 operating
area. close to vertical. 202/LSA 228 in 131. TDA 202 and LSA MOH
204 Move LSA 228 to 228 will position position. preset position to
casing above MOH prepare for guiding. 204/ITC 236 with TDA Before
casing lower 202 elevator facing end leaves CW 131, TD 116. close
LSA 228 funnel. Continue hoisting and rotate TDA 202 until casing
is above MOH 204 (rig floor 114 standby position). Continue step.
1.1. 6. Pipe CW 131 retract to Visual/ Skate 133 will move Handler
loading position: CCTV to loading position. Verify casing pin end
Ramp 149 will tilt to is clear of ramp 149. loading position. Move
CW 131 toward FT loading position. Continue step 1.6. 7. Driller
Set slips 161: Visual Stick-up at correct Slips 161 to Set slips
161 at height. Closed state. correct stick-up height. DW 119 load
Set off weight. indicator. 8. Driller Check gain/loss: Visual Trip
tank or active Volume control. Check trip tank gain/ tank gain/loss
is loss or active gain/loss determined and depending on selected
displayed. operation. 9. Repeat sequence for next casing.
[0203] Different combinations of the aspects described above may
also be utilized for building stands of two or more casing singles.
Such casing stand building may be performed during drilling and
other operations performed at WC 203. Such simultaneous operations,
however, are coordinated to avoid conflicts and obstructions
between the different machines and systems. For example, the
elevator of the TDA 202 may have two different sizes of inserts to
permit building casing stands while drilling. The change of head
size may be done remote from the Pipe Handler's workstation 450 (or
452 or 454). When a casing stand building operation is to be
performed, an operator 195 on the rig floor 114 may verify that
various pieces of equipment are properly shut down and locked out,
and then perhaps perform other preparations such as the examples
set forth below in Table 13A.
TABLE-US-00033 TABLE 13A Casing Stand Building Preparations
Equipment Responsible Verifications CW 131 Operator 195 on Travel
path is unobstructed. rig floor 114. Prepare for casing pick-up.
Casings are laid out correctly with aft end in line with skate 133
for correct loading. FIB 166 Pipe Handler Stands in FIB 166 slots
per HMI. Fingers closed. Travel path is unobstructed. TBR 254 Pipe
Handler Travel path is unobstructed. SGA 262 Pipe Handler Travel
path is unobstructed. LTC 244 Operator 195 on Travel path is
unobstructed. ITC 236 rig floor 114. Dies are clean and not worn.
UTC 242 THP Operator 195 on Travel path is unobstructed. Doper 209
rig floor 114. Water and correct dope available for doper 209. LSA
228 Operator 195 on Travel path is unobstructed. rig floor 114. TDA
202 Operator 195 on Travel path is unobstructed. rig floor 114.
Correct dope is available for associated doper 209. Correct inserts
installed. CTO: Operator 195 on CTO is rigged up in THA. THA - CTO
rig floor 114. Correct adaptors and stabbing guide funnel are
installed. Dies are correct, clean, and not worn. Travel path is
unobstructed. Tubulars Operator 195 on Tubular 111 to be loaded on
FT. 111 rig floor 114. Tubulars 111 to be cleaned and doped,
protectors removed.
[0204] The well construction system 100, 200 can then be set-up for
the casing stand building operation. Examples of such set-up may be
as set forth below in Table 13B.
TABLE-US-00034 TABLE 13B Casing Stand Building Set-Up Equipment
Responsible Set-Up HMI Pipe Pipe Verify operator 195 on rig floor
114 Verify Setback handling: Handler completed pre-checks and
deactivated screen. TBR 254, emergency stop for all pipe handling
Construction SGA 262, equipment. Program setup UTC 242, Open
Construction Program screen on wizard. LTC 244, touchscreen 522,
524. After startup: Check ITC 236, Select Casing Stand Building
mode. for green light in THP 207, Select setup wizard to open
pop-up on front Construction TDA 202, screen 532, 534, 536. Verify
settings: Program status LSA 228, Select slot, direction for
racking stands. header on front RN 151, Select casing size/type.
screen 532, 534, CW 131 Select CTO (with THA) to use. 536. CTO MU
torque. Perform pin/box doping. Stick-up target. Select "activate
all machines" to startup and prepare all machines. All Pipe Verify
all relevant machines are enabled in machines Handler zone
management system and tubular interlock system. Tubulars Pipe All
tubulars 111 to be registered in 111 Handler electronic tally
system.
[0205] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example casing stand building sequence may start with the MOH
204 and THP 207 empty, the ITC 236 retracted, and the CW 131
feeding table pre-loaded with casing singles (perhaps already
cleaned and doped). Example steps of the casing stand building
sequence may be as set forth below in Table 13C. In such example,
among others within the scope of the present disclosure, the pipe
handling equipment may be operated automatically via the
Construction Program, and the step execution of the pipe handling
equipment may be controlled automatically by one or two operators
195 at the associated workstation(s) 450, 452, 454. The
Construction Program may also feature configurable step
confirmations. The casing stand building sequence controlled by the
Construction Program may be stopped or interrupted at any time, and
some or all functions may be operated manually by the one or two
operators 195 at the associated workstation(s) 450, 452, 454.
TABLE-US-00035 TABLE 13C Casing Stand Building Operation Operator
Line of Equipment Equipment 195 Operation Sight precondition
Functionality HMI 1. Pipe Load casing single into Visual/ Casing
ready in Handler ramp 149: CCTV loading position. Verify ramp 149
is CW 131 in loading empty and in position. position. Use loading
fingers to load casing single into ramp 149. 2. Pipe Run ramp 149
to pick- Visual/ Casing loaded on Ramp 149 will tilt Handler up
position: CCTV ramp 149. to rig floor 114 Verify casing is tubular
position. loaded in ramp 149. Skate 133 will Move ramp 149 move
toward rig toward pipe pick-up floor 114. position. Skate 133 will
stop with casing box on ramp 149. 3. Pipe Move TDA 202 to pick-
Visual TDA 202 open. Handler up position: Tilt TDA 202. Lower and
extend TDA 202 to CW 131 pick-up position (above THP 207). 4. Pipe
Present casing above Visual Ramp 149 in pick-up Skate 133 will move
CW 131 Handler TDA 202: position. forward a defined position. Run
skate 133 until 202 TDA in receive distance depending casing
positioned position. on casing size. above the TDA 202 elevator
(e.g., gripper 169). 5. Pipe Latch TDA 202: Visual Casing is
positioned Tubular interlock TDA 202 to Handler Hoist TDA 202 to
correctly above TDA will prevent hoisting Closed state. latch onto
casing. 202 elevator. without closed Close TDA 202. elevator (above
certain height). 6. Pipe Lift casing to vertical Visual TDA 202
closed. Hoisting will stop LSA 228 guide Handler position above MOH
Verify LSA 228 is prior to lifting casing to Closed state. 204:
positioned to receive out of CW 131 without LSA 228 Verify TDA 202
is casing bottom before guiding. centralizer to closed. hoisting.
LSA 228 centralizer Closed state. Hoist TDA 202 to TDA 202 above
LSA close when casing is Show TDA 202/ pick-up casing single 228
operating area. close to vertical. LSA 228 in MOH from CW 131. TDA
202 and LSA 204 position. Move LSA 228 to 228 will position preset
position to casing above MOH prepare for guiding. 204/ITC 236.
Before casing lower end leaves CW 131, close LSA 228 funnel.
Continue hoisting TDA 202 until the casing is above MOH 204. 6.1.
Pipe CW 131 retract to Visual/ Skate 133 will move Animate Handler
loading position: CCTV to loading position. position. Verify casing
pin end Ramp 149 will tilt to is clear of ramp149. loading
position. Move CW 131 toward FT loading position. 6.2. Pipe CW 131
load and Visual/ See steps 1 and 2. Handler present next casing
CCTV single: Pick up next casing single per steps 1 and 2. 7. Pipe
Stab/position first Visual Casing bottom clear TDA 202 is rotated
Indicate LSA Handler casing in MOH 204/ of CW 131. when casing
single 228, ITC 236, ITC 236: LSA 228 close when is lowered into
MOH and LTC 244 Verify TDA 202/LSA casing close to vertical. 204
with elevator guide/grip 228 are above MOH LTC 244 open above
opening facing Pipe states. 204. MOH 204. Handler Operator Indicate
LSA Lower casing single 195 (permits open 228, ITC 236, into ITC
236/LSA 228. and retract outside and LTC 244 Extend ITC 236 when WC
203 area). positions. pin end below guide. Close ITC 236 guide.
Open and retract LSA 228. Close LTC 244 guide when pin end above
MOH 204. Continue lowering casing inside MOH 204. Stop with
stick-up of about one meter. 8. Pipe Close ITC 236 clamp Visual/
ITC 236 and Handler on casing: CCTV LTC 244 to Verify correct
stick- Closed state. up. Close ITC 236 guide and clamps. Open and
retract LTC 244. 9. Pipe Transfer weight to ITC Visual/ ITC 236
closed. Verify weight TDA 202 load Handler 236 and open TDA CCTV
Weight transferred. transferred prior to indicator. 202: opening
TDA 202. TDA to Open Lower TDA 202 to state. transfer casing weight
to ITC 236. Open TDA 202 and retract from stick-up. Move TDA 202 to
CW 131 pick-up position. 10. Pipe Present second casing Visual Ramp
149 in tubular Skate 133 will move Handler single above TDA 202
pick-up position. forward a defined elevator: TDA 202 in tubular
distance depending Verify TDA 202 pick-up position. on casing size
(see elevator open and step 4). below tubular pick-up position. Run
skate 133 until casing is positioned above TDA 202 elevator. 11.
Pipe Latch TDA 202 on Visual Second casing single Tubular interlock
TDA 202 to Handler second casing single: is positioned correctly
will prevent hoisting Closed state. Hoist TDA 202 to above TDA 202
without TDA 202 latch onto second elevator. elevator closed casing
single. (above certain Close TDA 202. height). 12. Pipe Lift casing
to vertical Visual TDA 202 closed. Hoisting will stop Indicate LSA
Handler position above MOH Verify LSA 228 is prior to lifting
casing 228 guide 204: positioned to receive single out of CW 131
position. Verify TDA 202 is casing bottom before without guiding.
Indicate TDA closed. hoisting. LSA 228 centralizer 202/LSA 228 in
Hoist TDA 202 to pick TDA 202 above LSA close when casing MOH 204
up casing single from 228 operating area. single is close to
position. CW 131. vertical. Move LSA 228 to TDA 202 and LSA preset
position to 228 will position prepare for guiding. casing single
tubular Before casing single above MOH 204/ITC lower end leaves CW
236. 131, close LSA 228 funnel. Continue hoisting TDA 202 until
casing single is above MOH 204. 13. Pipe CW 131 retract to Visual/
CWM 131 pipe Indicate Handler loading position: CCTV feeder will
move to positions. Verify casing pin end loading position. is clear
of ramp 149. Ramp 149 will tilt to Move CW 131 toward loading
position. FT loading position. 14. Pipe CW 131 load and Visual/ See
steps 1 and 2. Handler present third casing CCTV single (if
applicable): Pick up next casing single per steps 1 and 2. 15. Pipe
Move THA/CTO to CTO open. CTO will move to THA/CTO in Handler MOH
204: WC 203 selected. MOH 204. MOH 204. Verify that casing is LSA
228 in WC 203. Elevate to stick-up. located above MOH ZMS will stop
CTO if 204 and LSA 228 TD 116 or LSA 228 is above CTO working too
low. area. Start CTO sequence to move THT to MOH 204. 16. Pipe
Close CTO BUT: Visual/ CTO in MOH 204. CTO BUT will close. CTO BUT
to Handler Adjust/verify correct CCTV CTO stabbing guide Closed
state. CTO elevation. will close. CTO SG to Continue CTO Closed
state. sequence. 17. Pipe Close MUST for soft Visual/ CTO in WC
203. MUST will close. MUST to Handler stabbing (optional): CCTV
MUST will take some Closed state. Adjust CTO elevation load if
closed prior to and TDA 202 elevation stabbing casing (soft if
required. stab). Continue CTO sequence. 18. Driller Stab casing:
Visual/ CTO in WC 203 with Weight transferred CTO SG to Lower TDA
202 to CCTV stabbing guide to MUST per casing Open state. stab
casing (soft stab). closed. data input. TDA 202 weight Open CTO
stabbing indicator. guide (e.g., for better view). 19. Pipe Open
and retract LSA Visual/ CTO stabbing guide LSA 228 to Handler 228:
CCTV closed. Open status. Open and retract LSA 228 when casing has
entered stabbing guide. 20. Pipe CTO spin-in and MU: Visual/ Casing
stabbed in CTO will spin-in and Casing Handler Verify casing is
CCTV stick-up. MU automatically per connected state. stabbed in
box. TDA 202 unloaded, casing data settings. Continue CTO elevator
below TJ to If Accept: Open sequence. permit spinning. spinner,
guide, and Accept or reject MU. clamps. Return to park position. If
not accepted: Evaluate break-out, spin-out, and new attempt. 21.
Pipe Lower casing double Visual/ CTO has completed TDA 202/LSA
Handler into MOH 204 (if CCTV MU sequence with 228 close/open
applicable): accepted MU. status. Verify connection is TDA 202
load. made-up. LTC 244/ITC 236 Hoist TDA 202 to pick status. up
weight. Open ITC 236 guide and clamps. Lower casing double to
correct stick-up. Stop at selected stick- up (e.g., about one
meter). Close ITC 236 guide and clamps. Lower TDA 202 to transfer
weight to ITC 236. Open TDA 202 and retract from stick-up. 22. Pipe
Repeat steps 10-20 for Handler third single (if applicable). 23.
Pipe Move casing stand to Visual/ RN 151 has Weight transfer.
Handler THP 207: CCTV completed MU
LTC 244 extends to sequence with correct casing stand in MOH
torque. 204 position and close Complete casing guide. stand in MOH
204. Hoist TDA 202 to pick up weight. Open ITC 236 guide and
clamps. Retract ITC 236 head. TDA 202 will lift casing stand from
MOH 204 and stop with pin end above THP doper 209. TDA 202 and LTC
244 move casing stand to above THP 207. UTC 242 extends to casing
stand and closes. TDA 202 opens and retracts from casing stand. 24.
Pipe Set back casing stand: Visual/ UTC 242 and LTC TBR 254/SGA
Handler TBR 254 and SGA CCTV 244 closed on casing 262 status. 262
move to THP 207 stand in THP 207. TBR 254 load. and close guide and
TDA 202 retracted clamps on casing from casing stand in stand. THP
207. UTC 242 and LTC 244 open and retract. TBR 254 and SGA 262 set
back casing stand to selected position in FIB 166. 25. Pipe TBR 254
and SGA 262 UTC 242/LTC 244 TBR 254 clamp and TBR 254 clamp Handier
move to THP 207: closed on casing guide and SGA 262 and guide and
Open TBR 254 and stand. guide will open. SGA 262 guide SGA 262 in
FIB 166. TBR 254 will hoist to Open state. Move toward THP before
it retracts out of 207/next casing stand. FIB 166. Continue step
1.
[0206] For tripping-in casing stands without the CRT, an operator
195 on the rig floor 114 may verify that various pieces of
equipment are properly shut down and locked out, and then perhaps
perform other preparations such as the examples set forth below in
Table 14A.
TABLE-US-00036 TABLE 13A Casing Stand Building Preparations
Equipment Responsible Verifications FIB 166 Operator 195 on rig
floor 114. Casing stands (111) exist in FIB 166 Setback 164 slots
per HMI/tally. Fingers are closed. Travel path is unobstructed. TBR
254 Operator 195 on rig floor 114. Travel path is unobstructed. SGA
262 Gripper inserts/dies are clean, not worn. LTC 244 Operator 195
on rig floor 114. Travel path is unobstructed. ITC 236 Gripper
inserts/dies are clean, not worn. UTC 242 LSA 228 Operator 195 on
rig floor 114. Travel path is unobstructed. TDA 202 Operator 195 on
rig floor 114. Travel path is unobstructed. Correct inserts in TDA
202 elevator/grippers. CTO Operator 195 on rig floor 114. CTO is
rigged up in THA (or THT). THA - CTO Correct adaptors and stabbing
guide (primary) funnel is installed. THT - CTO Dies are correct,
clean, and not worn. (backup) Travel path is unobstructed. Slips
161 Operator 195 on rig floor 114; and/or Correct inserts/dies.
"Driller" 195 at workstation 452. Inserts/dies are clean, not worn.
TD 116 Operator 195 on rig floor; and/or Correct inserts/dies in
elevator 129. "Driller" 195 at workstation 452. Correct saver sub
status. Travel path is unobstructed. DW 119 Operator 195 on rig
floor; and/or Checked. "Driller" 195 at workstation 452.
[0207] The well construction system 100, 200 can then be set-up for
the non-CRT casing stand trip-in sequence. Examples of such set-up
may be as set forth below in Table 14B.
TABLE-US-00037 TABLE 14B Set-Up for Tripping-In Casing Stands
Without CRT Equipment Responsible Set-Up HMI Pipe Pipe Verify
operator 195 on rig floor 114 Verify Setback screen. handling:
Handler completed pre-checks and deactivated Construction Program
TBR 254, emergency stop for all pipe handling setup wizard. SGA
262, equipment. After startup: Check for UTC 242, Open Construction
Program screen on green light in LTC 244, touchscreen 522, 524.
Construction Program THP 207, Select Trip In Casing mode. status
header on front TDA 202, Select setup wizard to open pop-up on
screen 532, 534, 536. LSA 228, front screen 532, 534, 536. Verify
THA - settings: CTO Select casing type and verify casing data
(size, weight, MU loss, torque settings, etc.). Select CTO to use.
Stick-up target. Select "activate all machines" to startup and
prepare all machines. TD 116, Driller Verify operator 195 on rig
floor 114 Verify Setback screen. DW 119, completed pre-checks and
deactivated Construction Program MP 144, emergency stop for all
pipe handling setup wizard. Trip tank equipment. After startup:
Check for Open Construction Program screen on green light in
touchscreen 522, 524. Construction Program Select Trip In Casing
mode. status header on front Select setup wizard to open pop-up on
screen 532, 534, 536. front screen 532, 534, 536. Verify settings:
Stick-up target. Set DW 119 upper/lower stops. Set maximum lowering
speed. Set minimum slack off weight. Trip tank 1/2/auto. Trip tank
low/high levels. Active tanks selected and lined up. Set alarm
limits for gain/loss. Select MP 144 for filling casing. MP 144
liner size setting and pump efficiency. Set number of strokes for
filling casing stand (selected MP 144 will stop after set number of
strokes). Select "activate all machines" to startup and prepare all
machines. TD 116 Driller Verify operator 195 on rig floor 114
Verify operator screen, completed pre-checks. system status/alarms.
Activate TD 116 from touchscreen 522, 524. Select Operation screen
on touchscreen 522, 524. DW 119 Driller Activate DW 119 from
touchscreen 522, Verify operator screen, 524. system status/alarms.
All Driller Verify all relevant machines are enabled Verify
operator screen, machines in zone management system and system
status/alarms. tubular interlock system.
[0208] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
The sequence for non-CRT tripping-in casing stands may start with
the top drive 116 in lower position at WC 203, with the slips 161
closed around a casing stick-up of about one meter. Another casing
stand 111 may be in the TDA 202/LSA 228, lifted from THP 207 to
stick-up level above the MOH 204, with the TDA 202 elevator facing
the top drive 116. The THP 207, UTC 242, and LTC 244 may be open
and retracted. The TBR 254 and SGA 262 may be empty (e.g., on the
way to pick up a new casing stand from the FIB 166). Example steps
of the non-CRT tripping-in casing stand sequence may be as set
forth below in Table 14C.
TABLE-US-00038 TABLE 14C Tripping-In Casing Stands Without CRT
Operation Operator Line of Equipment Equipment 195 Operation Sight
precondition Functionality HMI 1. Driller Open TD 116 elevator
Visual/ Slips 161 must be Elevator 129 Open is TD 116 elevator 129:
CCTV closed before opening not selectable if slips 129 to Open
Verify slips 161 are elevator 129. 161 are not closed. state.
closed. Open elevator 129. 1.1. Pipe TBR 254 and SGA 262 Visual/
TBR 254 and SGA TBR 254 will move TBR 254 and Handler pick up new
casing CCTV 262 grip/guide open. into FIB 166 elevated SGA 262
grip/ stand: Selected FIB 166 above open latches. guide to Closed
Move TBR 254 and position "valid." Adjustments available. state.
SGA 262 to selected TBR 254 and SGA finger/slot in FIB 166. 262
grip/guide will Close TBR 254 and Close. SGA 262 guides and clamp
on stand. 2. Driller Retract and move TD Visual/ TD 116 pipe
handler DW 119 Upper 116 to latching height: CCTV position facing
TDA Stop setting. Verify elevator 129 is 202. open. Retract TD 116
to clear TJ. Hoist TD 116 elevator 129 to stand latch height (upper
stop or calculated stop point). 2.1. Pipe TDA 202 move stand
Visual/ TD 116 retracted. Tilt towards WC 203. TDA 202 Load Handler
to WC 203: CCTV TDA 202 dope top indication. Continue lifting TDA
box if preselected 202 and extend to WC (automatic). 203 (above
stick-up). LSA 228 guide to WC 203 when pin end above rig floor.
2.2. Pipe Move THA/CTO to WC CTO open. CTO will move to WC THA/CTO
in Handler 203: WC 203 selected. 203. WC 203. Verify stand is
located LSA 228 in WC 203. Elevate to stick-up. in WC 203 and LSA
ZMS will prevent 228 is above CTO CTO start if TD 116 or working
area. LSA 228 is too low. Start CTO sequence to move THT to WC 203.
Optional: Move THT/ CTO to WC 203 when TD 116 is above THA, if
selected. 2.3. Pipe Close CTO BUT: Visual/ CTO in WC 203. Close CTO
BUT. CTO BUT to Handler Adjust/verify correct CCTV Close stabbing
guide. Closed state. CTO elevation. CTO SG to Continue CTO Closed
state. sequence. 2.4. Pipe Close MUST for soft Visual/ CTO in WC
203. Close MUST. MUST to Handler stabbing (optional): CCTV MUST
will take some Closed state. Adjust CTO elevation load if closed
prior to and TD 116 elevation if stabbing the casing. required.
Continue CTO sequence. 2.5. Driller Stab casing: Visual/ TD 116
link tilt float. Weight transferred to CTO SG to Lower TD 116 to
stab CCTV CTO in WC 203 with MUST per casing Open state. casing
(soft stab). stabbing guide closed. data input. Open CTO stabbing
guide. 2.6. Pipe Open and retract LSA Visual/ CTO stabbing guide
LSA 228 Open Handler 228: CCTV closed. status. Open and retract LSA
228 when casing has entered stabbing guide. 2.7. Pipe CTO spin-in
and MU: Visual/ Stand stabbed in CTO will spin-in and Casing
Handler Verify casing is CCTV stick-up (TD 116 MU automatically per
Connected state. stabbed the box. unloaded, elevator casing data
settings. Continue CTO 129 below TJ to If Accept: Open sequence.
permit spinning). spinner, guide, and Accept or reject MU. clamps,
then return to park position. 2.8. Pipe TBR 254 and SGA 262 Visual/
THP 207 empty. TBR 254 cannot Indicate open Handler move stand to
THP CCTV UTC 242/LTC 244 open with weight. latches. 207: open. TBR
254 grip open TBR 254 load Open FIB 166 latches Correct pipe
detected when unloaded. indication, for selected row. in TBR 254
and SGA FIB 166 latches will unload. Verify latches open 262. not
open with TBR (visual/CCTV). 254 head in low TBR 254 lift stand
position. and move out of FIB 166 to THP 207. FIB 166 latches will
close as stand moves out of FIB 166. Set down stand on THP 207.
2.9. Pipe UTC 242 and LTC 244 Visual/ TBR 254 and SGA UTC 242 and
LTC UTC 242 and Handler extend to THP 207 and CCTV 262 with stand
in THP 244 extend and close. LTC 244 to close: 207. Closed state.
UTC 242 and LTC 244 extend to THP 207. UTC 242 and LTC 244 close.
2.10. Pipe TBR 254 and SGA 262 UTC 242/LTC 244 TBR 254 and Handler
open and move toward closed on stand. SGA 262 to FIB 166: Open
state. Open TBR 254 clamps and guide and SGA 262 guide. Move toward
FIB 166/ next stand. Continue step 1.1 3. Driller Extend TD 116 and
Visual/ TDA 202 below TJ. Elevator 129 latch elevator 129: CCTV
Closed state. ExtendTD 116 to WC Indicate TD 116 203. in WC 203.
Latch elevator 129 (automatic close on impact). 3.1. Pipe TDA 202
open and Visual/ Elevator 129 closed. TDA 202 will retract TDA 202
Handler move to THP 207: CCTV from WC 203, rotate, elevator Open
Verify TD 116 and lower until state. elevator 129 is closed.
elevator (e.g., gripper TDA 202 Open elevator 129. 169) faces
toward position Retract to vertical THP 207. animation. link.
Rotate and lower to stand in THP 207. 4. Driller Open slips 161:
Visual TD 116 elevator 129 Slips 161 to Open slips 161 must be
closed. Open state. (command). CTO has completed DW 119 load. Hoist
to take weight MU sequence and open slips 161. with accepted
connection. 5. Driller Lower casing string in Visual Slips 161
open. MP 144 will stop after Settings: DW wellbore 102: set number
of 119 lowering Verify slips 161 are strokes, if selected. speed
and open before lowering minimum slack- casing string. off weight.
Open IBOP and start IBOP open. MP 144 to fill casing, if MP 144
selected. (Extend running. filling tool, if installed). 5.1. Pipe
TDA 202 and LSA 228 Visual/ TDA 202 elevator TDA 202 tilt out/
Handler extend to stand in THP CCTV must be open. extend elevator
until 207: LSA 228 guide funnel contact with stand in Tilt
out/extend TDA must be open. THP 207. 202 elevator until contact
with stand in THP 207 below TJ. 5.2. Pipe TDA 202 and LSA 228
Visual/ TDA 202 elevator TDA 202 Handler latch onto stand in THP
CCTV must be in THP 207 elevator to 207: position. Closed state.
Close TDA 202 LSA 228 guide elevator. to Closed state. Close LSA
228 guide funnel. 5.3. Pipe UTC 242 and LTC 244 Visual/ TDA 202
elevator UTC 242 and LTC UTC 242 and Handler open and retract. CCTV
must be closed. 244 open and retract. LTC 244 to Open state. UTC
242 and LTC 244 position animation. 5.4. Pipe TDA 202 move stand
Visual/ UTC 242 or LTC 244 TDA 202 hoist, tilt to TDA 202 Load
Handler to rig floor: CCTV open. vertical, rotate 180 indication.
TDA 202 lift stand degrees to face TD TDA 202 guided by the LSA 228
116. position (e.g., about nine TDA 202 dope top animation. meters)
to rig floor 114 box if preselected standby position. (automatic).
Continue step 2.2 6. Driller Set slips 161: Visual Stick-up at
correct Slips 116 to Set slips 161 at height. Closed state. correct
stick-up height. DW 119 load Set off weight. indicator. Tally
update. 7. Driller Check trip tank or Visual Slips 161 closed. Trip
tank gain/loss is Trip Sheet/ active volume, determined and Volume
control. gain/loss: displayed. Trip tank or active gain/loss.
Repeat all steps for next stand.
[0209] Different combinations of the aspects described above may
also be utilized for running large-diameter casing (LDC) from the
CW 131 with the top drive 116 and CRT. For example, LDC may have an
outer diameter of about 13.375 inches (about 34 centimeters) or
larger. Preparations for such operation may include the examples
set forth below in Table 15A.
TABLE-US-00039 TABLE 15A Preparations for Running LDC from CW with
TD and CRT Equipment Responsible Verifications CW 131 Operator 195
on Travel path is unobstructed. rig floor 114. Casings are laid out
correct with aft end in line with skate 133 for correct loading.
Prepare to pick up casing. CTO: Operator 195 on Casing backup tong
(CBU) is rigged up in THT. THT + CBU rig floor 114. CBU adjusted
for casing size. Dies are correct, clean, and not worn. Travel path
is unobstructed. LSA 228 Operator 195 on Travel path is
unobstructed. rig floor 114. Slips 161 Operator 195 on Correct
inserts in slips 161. Rotary rig floor 114. Dies are clean and not
worn. Table Rotary table rotation lock activated. TD 116 Operator
195 on Correct pick-up elevator 129. rig floor 114. Check elevator
link extension chains. Operator screen, system status. Travel path
is unobstructed. CRT installed and tested. DW 119 Operator 195 on
Checked. rig floor 114. Tubulars Operator 195 on Tubulars 111 to be
laid out on CW 131. 111 rig floor 114. Tubulars 111 to be cleaned
and doped, protectors removed (other implementations may be used
for casing with protectors). Casings measured, marked, and tally
updated.
[0210] The well construction system 100, 200 can then be set-up for
the operation. Examples of such set-up may be as set forth below in
Table 8B.
TABLE-US-00040 TABLE 15B Set-Up for Running LDC from CW with TD and
CRT Equipment Responsible Set-Up HMI Pipe Pipe Verify operator 195
on rig floor 114 Verify Setback handling: Handler completed
pre-checks and deactivated screen. LSA 228, emergency stop for all
pipe handling Construction CBU, equipment. Program setup CW 131
Open Construction Program screen on wizard. touchscreen 522, 524.
After startup: Check Select Running 13 3/8'' Casing from CW for
green light in with TD and CRT mode. Construction Select setup
wizard to open pop-up on front Program status screen 532, 534, 536.
Verify settings: header on front Select casing size. screen 532,
534, Select CBU to use. 536. Stick-up target. Select "activate all
machines" to startup and prepare all machines. TD 116, Driller
Verify operator 195 on rig floor 114 Verify Setback DW 119,
completed pre-checks and deactivated screen. MP 144 emergency stop
for all pipe handling Construction equipment. Program setup Open
Construction Program screen on wizard. touchscreen 522, 524. After
startup: Check Select Running 13 3/8'' Casing from CW for green
light in with TD and CRT mode. Construction Select setup wizard to
open pop-up on front Program status screen 532, 534, 536. Verify
settings: header on front Stick-up target. screen 532, 534, Set TD
elevator link length. 536. Set DW 119 upper/lower stops. Set
maximum lowering speed. Set minimum slack off weight. Trip tank
1/2/auto. Trip tank low/high levels. Verify active tanks are
selected and lined up. Select MP 144 (to fill casing, optional).
Verify MP 144 pressure limit setting. Assign pumps to master
slider. Set number of strokes and SPM to fill casing (optional).
Set ramp-up parameters. Verify correct elevator setting
(manual/remote). Select "activate all machines" to startup and
prepare all machines. TD 116 Driller Verify operator 195 on rig
floor 114 Verify operator completed pre-checks. screen, system
Activate TD 116 from touchscreen 522, status/alarms. 524. Verify
correct elevator 129 setting (manual/remote). Select Operation
screen on touchscreen 522, 524. DW 119 Driller Activate DW 119 from
touchscreen 522, Verify operator 524. screen, system Set maximum
lowering speed. status/alarms. Set minimum slack off weight. Slips
161, Driller Verify correct setting for slips 161 Verify operator
Rotary (manual/remote). screen, system table status/alarms. All
Driller Verify all relevant machines are enabled in machines zone
management system and tubular interlock system. Tubulars Pipe All
tubulars 111 are registered. 111 Handler
[0211] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
An example of this sequence may start with a casing stick-up (e.g.,
about 1.5 meters) at WC 203, with the slips 161 closed and the CRT
engaged. Casing may be laid out on the CW 131 casing side (e.g.,
Driller's side), having been cleaned, doped, and tallied, and with
protectors removed. The catwalk ramp 149 may be loaded with casing.
The TDA 202 may be parked outside the collision area (e.g., top of
the mast), and the LSA 228 may be ready. Example steps of the
sequence may be as set forth below in Table 15C.
TABLE-US-00041 TABLE 15C Sequence for Running LDC from CW with TD
and CRT Operator Line of Equipment Equipment 195 Operation Sight
precondition Functionality HMI 1. Driller Release CRT from Visual/
Slips 161 must be CRT to stick-up: CCTV closed before Disconnect
Verify slips 161 are releasing CRT. state. closed and links/
elevator tilted towards CW 131. Release CRT from stick-up. Hoist TD
116 to CW 131 pick-up position (above casing). 1.1. Pipe Push
casing to rig floor Visual/ Skate 133 will move CW 131 to CW
Handler 114 pick-up position: CCTV forward a set 131 pick-up Verify
TD elevator distance. position. 129 is above CW 131 pick-up
position. Activate CW 131 sequence to move casing to CW 131 pick-
up position. 2. Driller Latch pick-up elevator Visual CW 131 in
pick-up 129: position. Extend links above casing. Lower TD 116 to
latch elevator 129. Engage safety pin (manual). 3. Driller TD 116
hoist casing Visual TD elevator 129 Hoisting will stop prior from
CW 131: closed. to lifting casing out of Hoist TD 116 to pick Link
tilt float: Elevator CW 131 without up casing from CW 129 in WC 203
above guiding. 131. RN 151 working area. Activate link tilt float
or move elevator 129 to vertical position. 3.1. Pipe LSA 228 extend
to Visual/ TD 116 above LSA 228 LSA 228 funnel Handler guide casing
above CCTV operating area. to Closed state. CW 131: Move LSA 228 to
preset position to receive casing above CW 131. Before casing lower
end leaves CW 131, close LSA 228 funnel. 3.2. Pipe Move THT/CBU to
WC CBU open. CBU will move to WC CBU in WC Handler 203: 203. 203.
Verify TD 116 hoisted Elevate to stick up. above CBU working ZMS
will prevent area. CBU start if TD 116 is Start CBU sequence too
low. to move THT/CBU to WC 203. 3.3. Pipe LSA 228 tail in casing
Visual Casing bottom clear LSA 228 Handler to WC 203: of CW 131 and
centralizer to TD continues elevated above stick- Closed state.
hoisting. up. LSA 228 tail in casing LSA 228 funnel close. towards
WC 203 when pin end is above stick- up. LSA 228 centralizer will
close when casing is close to WC 203. 3.4. Pipe Guide casing single
Visual/ CBU in WC 203. Close CBU BUT. CBU BUT to Handler with CBU
in WC 203: CCTV LSA 228 in WC 203. Close stabbing guide. Closed
state. Verify casing single CBU guide to located in WC 203. Closed
state. Continue CBU sequence. 3.5. Pipe Stab casing: Visual/ TD 116
in WC 203. Handler Lower TD 116 to stab CCTV CBU in WC 203 with
casing in stick-up. stabbing guide closed. Continue lowering to
stab CRT. 3.6. Pipe Open and retract LSA Visual/ CTO stabbing guide
LSA 228 Open Handler 228: CCTV closed. status. Open and retract LSA
228 when casing has entered stabbing guide. 3.7. Pipe CW 131
retract to Visual/ Skate 133 will move CW 131 Handler loading
position: CCTV to loading position. animation. Verify casing pin
end Ramp 149 will tilt to is clear of ramp 149. loading position.
Move CW 131 toward FT loading position. 4. Driller Stab CRT,
spin-in, and Visual/ Casing single TD 116/CRT will CBU closed for
MU: CCTV stabbed in stick-up automatically spin-in backup. Verify
casing is (TD elevator 129 and MU. Casing stabbed and elevator is
below TJ to permit Connected state. unloaded (elevator spinning).
CRT Engaged sliding down). CBU slips back up. state. Verify CBU
closed for backup. (Optional: or slips 161 closed for backup). Stab
and engage (lock) CRT. Spin-in and MU casing connection. 4.1. Pipe
Open CBU and move Casing connected. Open CBU BUT and CBU open.
Handler to parked position: CRT connected. move THT to parked CBU
parked. Verify casing has position. been made-up. Continue CBU
backup sequence. 5. Driller Open slips 161: Visual TD 116/CRT has
Slips 161 to Open slips 161 completed MU Open state. (command).
sequence with correct DW 119 load. Hoist to take up torque (CRT
weight and open slips connected). 161. 6. Driller Run-in-Hole:
Visual Slips 161 open. Optional: The selected MP 144 SPM, Verify
slips 161 are Optional: MP 144 MP 144 will pump a total strokes,
open before lowering ready. set number of strokes and pressure.
casing string into at set rate with wellbore 102. selected MP 144
and Optional: Fill casing, if stop. selected. Open IBOP. Start MP
144 (casing fill mode). Close IBOP. 6.1. Pipe Load next casing onto
Visual/ Casing ready in Handler ramp 149: CCTV loading position.
Use loading fingers to CW 131 in loading load another casing
position. into ramp 149. 7. Driller Open pick-up elevator Visual
and tilt out: When elevator is close to rig floor 114, an operator
195 removes safety pin and opens elevator. When the operator is out
of the area, tilt links out and continue lowering. 7.1. Pipe Run
ramp 149 to rig Visual/ Casing loaded onto Ramp 149 will tilt to CW
131 Handler floor: CCTV ramp 149. rig floor 114 tubular animated.
Verify casing is position. loaded in ramp 149. Skate 133 will move
Move ramp 149 toward rig floor 114. toward pipe pick-up Skate 133
will stop position. with casing box inside ramp 149. 8. Driller Set
slips161: Visual Stick-up at correct Slips 161 to Set slips 161 at
height. Closed state. correct stick-up height. DW 119 load Set off
weight. indicator. 9. Driller Check gain/loss: Visual Trip tank or
active Volume control. Check trip tank gain/ tank gain/loss is loss
or active gain/loss determined and depending on selected displayed.
operation. 10. Repeat sequence for next casing.
[0212] For tripping-out drill collar stands, an operator 195 on the
rig floor 114 may verify that various pieces of equipment are
properly shut down and locked out, and then perhaps perform other
preparations such as the examples set forth above in Table 11A. The
well construction system 100, 200 can then be set-up for the drill
collar stand trip-out sequence. Examples of such set-up may be as
set forth below in Table 16A.
TABLE-US-00042 TABLE 16A Set-Up for Tripping-Out Drill Collar
Stands Equipment Responsible Set-Up HMI Pipe Driller/ Verify
operator 195 on rig floor 114 Verify Setback screen. handling: Pipe
completed pre-checks and deactivated Construction Program TBR 254,
Handler emergency stop for all pipe handling setup wizard. SGA 262,
equipment. After startup: Check for UTC 242, Open Construction
Program screen on green light in LTC 244, touchscreen 522, 524.
Construction Program THP 207, Select Tripping mode. status header
on front LSA 228, Select setup wizard to open pop-up on screen 532,
534, 536. RN 151 front screen 532, 534, 536. Verify settings:
Select slot, direction for setting back drill collar stands. Select
pipe type. Select RN 151 to use. RN 151 MU torque. Select pin/box
doping. Stick-up target. Select "activate all machines" to startup
and prepare all machines. TD 116, Driller Verify operator 195 on
rig floor 114 Verify Setback screen. DW 119, completed pre-checks
and deactivated Construction Program MP 144, emergency stop for all
pipe handling setup wizard. Trip tank equipment. After startup:
Check for Open Construction Program screen on green light in
touchscreen 522, 524. Construction Program Select Tripping DC mode.
status header on front Select setup wizard to open pop-up on screen
532, 534, 536. front screen 532, 534, 536. Verify settings:
Stick-up target. Set DW 119 upper/lower stops. Set maximum lowering
speed. Set minimum slack off weight. Trip tank 1/2/auto. Trip tank
low/high levels. Select "activate all machines" to startup and
prepare all machines. TD 116 Driller Verify operator 195 on rig
floor 114 Verify operator screen, completed pre-checks. system
status/alarms. Activate TD 116 from touchscreen 522, 524. Select
Operation screen on touchscreen 522, 524. DW 119 Driller Activate
DW 119 from touchscreen 522, Verify operator screen, 524. system
status/alarms. All Driller Verify all relevant machines are enabled
Verify operator screen, machines in zone management system and
system status/alarms. tubular interlock system.
[0213] After such preparations and set-up, the operator 195 may
vacate the rig floor 114, and the equipment may be configured to be
ready for remote control (e.g., by deactivating emergency stops).
The sequence for tripping-out drill collar stands may start with a
drill collar stand 111 stick-up at WC 203, with the top drive 116
elevator 129 closed on the stick-up and the slips 161 closed. The
UTC 242 and LTC 244 may be closed on another drill collar stand 111
in the THP 207, with washing and doping of the pin already
completed. The TDA 202 may be parked outside the collision area,
and the LSA 228, TBR 254, and SGA 262 may each be empty. Example
steps of the drill collar stand tripping-out sequence may be as set
forth below in Table 16B.
TABLE-US-00043 TABLE 16B Tripping-Out Drill Collar Stands Operation
Operator Line of Equipment Equipment 195 Operation Sight
precondition Functionality HMI 1. Driller Open slips 161 and
Visual/ Elevator 129 must be Slips 161 Open is Slips 161 to hoist
drill string 120: CCTV closed before opening not selectable if Open
state. Verify TD elevator slips 161. elevator 129 is not Settings:
DW 129 is closed under TJ. closed. 119 hoisting Open slips 161.
Slips 161 Open speed and Hoist to take weight command is reset
maximum and verify slips 161 after a set time if slips overpull.
open. 161 are not opened. 1.1. Pipe TBR 254 and SGA 262 Visual/ TBR
254 and SGA TBR 254 and SGA TBR 254 and Handler will pick up stand
from CCTV 262 grip/guide open. 262 grip/guide will SGA 262 grip/
THP 207: close automatically. guide to Closed Move TBR 254 and
states. SGA 262 to THP 207. Close guides and clamp on stand. 1.2.
Pipe UTC 242 and LTC 244 Visual/ TBR 254 and SGA UTC 242 and LTC
UTC 242 and Handler open and retract: CCTV 262 closed on stand 244
open and retract. LTC 244 to UTC 242 and LTC in THP 207. Open state
244 open guides. retracted. UTC 242 and LTC 244 retract from THP
207. 1.3. Pipe TBR 254 and SGA 262 Visual/ Valid FIB 166 position
TBR 254 and SGA TBR 254 load. Handler move toward FIB 166 CCTV
selected. 262 will follow FIB 166 latches with stand: predefined
path. to Open state. Lift stand from THP FIB 166 latches will FIB
166 latches 207. open when stand is to Closed state. Move to
selected outside selected FIB position in FIB 166. 166 row. FIB 166
latches will close prior to setting down the stand. Set down stand
on selected position. 1.4. Pipe Move RN 151 to WC Visual/ RN tongs
open. RN 151 will move to TJ (stick-up) Handler 203: CCTV WC 203
selected. WC 203. assist Verify TD 116 is Elevate RN 151 to
indication. hoisted above RN 151 stick-up. working area. RN 151
will stop/wait Start RN 151 break- outside WC 203 area if out
sequence to move TD 116 is moving. RN 151 to WC 203. 1.5. Pipe LSA
228 move to WC Visual/ LSA 228 will stop/ Handler 203: CCTV wait
outside WC 203 LSA 228 move to WC area if TD 116 is 203. moving. 2.
Driller Set slips 161: Visual/ DW 119 Upper Verify required stick-
CCTV stop setting. up height. Set slips 161 (command). Set off
weight. 2.1. Pipe RN 151 break-out and CCTV Slips 161 closed.
Break-out and spin- RN 151 Handler spin-out: out. Double breakout
indication. Verify slips 161 available if required. Stand not
closed and weight set Open RN 151 connected. off. spinner, guide,
and Adjust RN 151 clamps. elevation if required. Return RN 151 to
Continue RN 151 park position. sequence. Note: Spin-out carefully.
Manual mode available. 2.2. Pipe LSA 228 guide close: Visual/ Slips
161 closed. LSA 228 will not close LSA 228 in WC Handler Verify LSA
228 in WC CCTV in WC 203 if slips 161 203. 203 and slips 161 are
not closed. LSA 228 guide closed. funnel to Closed Close LSA 228
guide state. funnel. 3. Driller Hoist stand from stick- Visual/ RN
finished spin-out, The stand is lifted up: CCTV BUT open.
carefully. Lifting is Verify RN 151 is LSA 228 funnel stopped if
stand finished and open and closed. catches on threads in LSA 228
is closed. TJ. Option: If second RN 151 is used, first RN 151
should be retracted. Hoist stand above stick-up. 3.1. Pipe LSA 228
guides stand Visual/ RN 151 open. Animated Handler to THP 207: CCTV
Optional: Second RN positions. Verify pin above stick- 151 open and
up. retracted. LSA 228 guides stand toward THP 207. UTC 242 and LTC
244 extend to DCH. 4. Driller Lower stand to THP Visual/ TD 116
will stop with 207: CCTV elevator 129 above Verify stand (pin end)
UTC 242. is outside rig floor 114. Lower stand to THP 207 guided by
LSA 228. Tilt links out toward UTC 242. 4.1. Pipe TD and LSA 228
move Visual/ UTC 242 open. DW 119 will slow UTC 242 Handler stand
to DCH: CCTV LSA 228 guide funnel down above DCH. animated in TD
116 and LSA 228 closed. UTC 242 closes DCH. move toward DCH. UTC
242 open in when stand is inside LSA 228 LTC 244 closes when DCH.
UTC 242. extend. stand is close to DCH. LTC 244 closes when LTC 244
is extended LTC 244 to Set down stand on stand is below LTC and
closed. Closed state. DCH. 244. UTC 242 to TD links tilted out
Closed state. toward UTC 242. LSA 228 open. UTC 242 closes when
stand is inside guide. LSA 228 opens and retracts. 5. Driller Open
TD elevator 129, Visual/ UTC 242 closed. Elevator 129 to lower to
stick-up: CCTV Open state. Verify UTC 242 and LTC 244 are closed.
Open elevator 129. Tilt links vertical (float). Lower TD 116 to
stick-up. 5.1. Pipe UTC 242 and LTC 244 Visual/ TD elevator 129 UTC
242 and LTC UTC 242 and Handler tilt stand to vertical CCTV open.
244 will stop in LTC 244 Closed. position: vertical position. UTC
242 and UTC 242 and LTC LCS to DCH. 244 extend to tilt stand Doper
toward WC 203. animated. Wash and dope pin, if preselected. 6.
Driller Extend TD 116 and Visual RN 151 retracted. Elevator 129
latch elevator 129: Closed state. Extend TD 116 to WC Indicate TD
116 203. in WC 203. Latch elevator 129 (automatic close on impact).
7. Driller Check trip tank Visual Trip tank gain/loss is Trip
Sheet/ volume, gain/loss: determined and Volume control. Trip tank
gain/loss. displayed. Repeat all steps for next tubular. Continue
on step 1. 7.1. Pipe TBR 254 and SGA 262 Visual/ UTC 242 and LTC
TBR 254 clamp and TBR 254 clamp Handler move to THP 207: CCTV 244
closed on stand. guide and SGA 262 and guide and Open TBR 254 and
guide will open. SGA 262 guide SGA 262 in FIB 166. TBR 254 will
hoist to Open states. Move toward THP before it retracts out of
207/next stand. FIB 166. Continue step 1.1.
[0214] The zone management system (ZMS) mentioned in the sequences
above define a zone for each physical component of the IWCS for
which collisions are to be avoided. The zone is a three-dimensional
space defined according to a coordinate system common of the IWCS.
Each zone pertains to one or more different pieces of equipment,
including those structures or components that are stationary as
part of the IWCS. The zone is attached to the equipment and travels
with the equipment. The size of the zone may change (expand or
shrink) depending on the transport speed of the related equipment,
or the transport speed of surrounding equipment. Some machinery and
equipment is complex enough to warrant using multiple zones within
the machinery, and the ZMS maintains information pertaining to the
zones of the different subcomponents. The ZMS monitors the zones to
prevent collisions.
[0215] FIG. 24 depicts a component 1140 that is a subject of the
ZMS. The component 1140 can be any component of the IWCS. The
component 1140 has a zone 1141 that at least partially envelops the
component 1140. The zone 1141 may be larger than the component 1140
such that a buffer zone is created between the extremities of the
component 1140 and the zone 1141 to further help avoid collisions
between components. A database 1142 stores characteristics of the
components tracked by the ZMS. The database 1142 may store
information related to position, size, shape, weight, motion path,
tolerance, impact sensitivity, reference point, center of mass
1143, and attachment points. A processing system 1144 of the ZMS
may execute the logic and calculations. The processing system 1144
may be an instance of the processing system 1000 shown in FIG.
23.
[0216] The position of the component 1140 can be expressed in terms
of coordinates relative to one or more coordinate systems. Each
coordinate system can be an x-y-z system, a polar coordinate
system, or another type of coordinate system. The coordinate system
can be centered on any arbitrary point, such as a north-west
extreme of the rig floor 114 (FIG. 1) or the intersection of the
well center and the rig floor 114, among other examples. The
position of the component 1140 is monitored and continuously
compared against the position of other relevant components of the
IWCS. The position information of a component, in conjunction with
the size, and/or shape information of the component, may be used to
describe the equipment and its associated zone in the
three-dimensional space of the coordinate system in relation to
other components of the IWCS. The ZMS system can detect when a
collision between two or more components is imminent and,
consequently, issue a warning or take action to prevent the
collision.
[0217] The component sizes are stored by the database 1142 to help
calculate the zones 1141. The database 1142 may be at least a
portion of an instance of the processing system 1000 shown in FIG.
23. The database 1142 can store the sizes of the components 1140 in
terms of coordinates at various extremities of the component 1140.
If the component 1140 has a generally cubic shape, the size can be
described by the edges and the orientation of the cube or other
coordinate system. If the shape of the component 1140 is more
complex, more coordinates can be used to define size and shape. The
size and/or shape information of each component 1140 is used to
define the corresponding size and/or shape of the associated zones
1141. The zone 1141 may fully envelop the physical component 1140,
or may encompass just a part of the physical component 1140 that
may collide with other components 1140. The size of the zone 1141
may also expand in a direction aligned with movement of that
component 1140, and/or in a direction of another approaching
component 1140. The extent of this expansion may depend on the
speed of the moving component(s) 1140.
[0218] The database 1142 also tracks the weight of the components
1140, which the ZMS may use to determine how much force is required
to move or stop motion of a component 1140. The weight of a
component 1140 may be known, such as when entered during sequence
set-up, while in other cases the IWCS may comprise sensors
configured to determine the weight of the component 140. For
example, if the component 1140 is the top drive 116 connected to
the drill string 120, the weight of the component 1140 varies
depending on the length and other parameters of the drill string
120. The sensors may perform weight measurements to determine
weight as needed.
[0219] The positions of the various components 1140 of the IWCS
varies from time to time. The motion path of each component 1140
can also be stored by the database 1142. The motion path of a
component 1140 could be a complete path, such as when a component
1140 could travel from one position to another position.
Alternatively, the motion path of the component 1140 could be just
the direction in which the component 1140 may travel, with no
defined end point. The database 1142 can store a routine path of
motion for the components 1140. For example, an iron roughneck 151
has a movement path between retracted and expanded positions. The
trajectory of the path can be known ahead of time. The ZMS
processing system 1144 can be informed of a proposed motion path
for a given component 1140, and can calculate whether the component
1140 can make the proposed movement at the proposed time without
intersecting with a zone of another component of the IWCS. If so,
the ZMS processing system 1144 approves the movement.
Alternatively, when the component 1140 is commanded to move in a
particular direction, the zone 1141 associated with the component
1140 may be expanded in the direction of the intended movement. The
extent of the zone 1141 expansion may depend on the speed of the
associated component 1140. With the expanded zone 1141 for a
component 1140, the ZMS processing system 1144, may calculate
whether the expanded zone 1141 could intersect with a zone 1141 of
another component 1140 of the IWCS. If not, the ZMS processing
system 1144 approves the movement. In addition, when a component
1140 is commanded to move in a particular direction, the zones 1141
associated with surrounding components 1140 that may come in
contact with the moving component 1140 may be expanded in the
direction of the incoming component 1140. The extent of the zone
1141 expansion may depend on the speed of the incoming component
1140. The ZMS processing system 1144 may perform similar
calculations to evaluate whether a zone 1141 intersection may occur
and react accordingly. The movement of the components 1140 can be
under the direction and control of the Construction Program, so
actions controlled by the Construction Program may be subject to
the approval of the ZMS processing system 1144 to prevent
collisions between components 1140.
[0220] The movement of one or more portable components may be
unscheduled. A portable component is an object that is not part of
the IWCS equipment, but may be present during the operation. For
example, a human operator 195 on the rig floor 114 may be a
portable object. The ZMS processing system 1144 is equipped to
detect and monitor unscheduled movement of the portable components.
For example, the various cameras, sensors, and other measuring
equipment described above can be used to identify the portable
component and detect its movement. The ZMS processing system 1144
can establish a zone associated with the portable component,
evaluate its risk for colliding with surrounding equipment, and
issue a warning and/or take action to prevent a collision. The ZMS
processing system 1144 may move other components 1140 out of the
way, or may stop the movement of other components 1140, to avoid a
collision. The ZMS processing system 1144 may also calculate an
expected damage for a given collision, and may include logic to
permit the ZMS processing system 1144 to determine a course of
action under a given set of circumstances. For example, if the top
drive 116 is moving down toward the rig floor 114 when the ZMS
processing system 1144 detects an operator 195 walking toward well
center, the ZMS processing system 1144 may immediately establish a
zone 1141 around the operator 195 and evaluate whether this zone
1141 would intersect with the zone 1141 associated with the top
drive 116. Depending on safety policy established for the
operation, the ZMS processing system 1144 may take a number of
measures to avoid collision between the top drive 116 and the
operator 195, such as triggering an alarm, slowing movement of the
top drive 116, and/or emergency stop of top drive 116, among other
examples.
[0221] The database 1142 can store information relating to a
tolerance for a given component 1140. The tolerance can be defined
as a distance from the edge of the physical structure of the
component 1140 and the corresponding edge of the defined zone 1141.
The nature of the component 1140 and the environment in which it is
being used can factor into determining the tolerance. Generally,
the faster the speed of the component 1140, the larger the
tolerance in the direction of the movement. Alternatively, the
faster the speed of the incoming component 1140, the larger the
tolerance in the direction of the incoming component 1140. It is
also possible that the more sensitive the component 1140, the
larger the tolerance can be. The constraints of the environment may
also determine what the tolerance is. For example, if the component
1140 is to be installed into predefined space where it is next to
another component, then the tolerance can be adjusted accordingly
so as not to trigger an alarm or corrective action when installed
in the desired location. The tolerance may also be altered during
movement, such that when a given component 1140 is stationary, the
tolerance can be smaller, and when the component 1140 is moving,
the tolerance (and, thus, the zone 1141) can be temporarily
enlarged.
[0222] Various components are made of different materials and some
are more delicate than others. The nature of the component's
resistance to collision can be factored into the calculation of the
zone 1141. The notion of impact sensitivity may be more than
physical impact, and can include chemical, thermal, vibrational,
and electromagnetic contact. Thus, the zone 1141 of a component
1140 can be enlarged or reduced according to the collision,
checmical, thermal, vibrational, electromagnetic, and other
sensitivity of the component 1140.
[0223] The components 1140 each generally have a physical body, and
to properly address the location of the component 1140 and its
proximity to other components, the component 1140 can be given a
reference point and the dimensions of the component 1140 can be
defined with reference to the reference point. The reference point
can be arbitrarily chosen, or it can have some importance. For
example, the reference point can coincide with the center of mass
1143, an important corner, an edge, or another significant point on
the component 1140. If a component 1140 is routinely rotated, the
reference point and geometry of the component 1140 can be updated
as it is rotated during service. The zone 1141 pertaining to the
component can also be updated accordingly. Some components 1140
have are attachment points, such as hooks, rails, skids, eyelets,
bolt patterns, or other physical connection points. This
information can also be stored in the database 1142 to permit
handling of the components. In the event of an impending collision,
information on where an attachment point is located may prove
useful and can determine what course of action is taken to prevent
or mitigate a collision. Another type of attachment point are
ports, such as valves, electrical outlets/ports, etc. Knowing the
location and existence of these attachment points and ports can
also prove useful and can determine the actions taken by the
systems and methods of the present disclosure.
[0224] Different priorities may be associated with different
components 1140. Each component 1140 can be given a priority
relative to other components, and if there are two competing
movement proposals, the higher priority can be given the green
light and the lesser priority components will have to wait or find
another movement path. The higher priority component can be
referred to as the commanding component and the lesser component
can be referred to as the lesser component or the subservient
component.
[0225] A rig control system according to the present disclosure
(which may be similar or identical to system 800 shown in FIG. 22)
may comprise a communication network (e.g., ring network 900 from
FIG. 22), a control workstation connected directly to the
communication network (e.g., control workstation(s) 850 and/or 852
from FIG. 22), a plurality of control devices that are each
connected directly to the communication network, at least some
(maybe each) of which control devices may comprise or be a computer
(PC or IPC) and/or a programmable logic controller (PLC) (e.g.,
PLCs 901, 911, 921, 931, 941, 951, 961, 971, 981, 991 from FIG.
22), a plurality of local control networks (e.g., subsystem network
rings 909, 919, 929, 939, 949, 959, 969, 979, 989, 999 from FIG.
22) that are each connected to the communication network via a
corresponding one of the plurality of control devices, and a
plurality of local control devices, at least some (and maybe each)
of which may comprise or be a computer (PC or IPC) and/or a
programmable logic controller (PLC) (e.g., devices 902-905,
912-915, 922-925, 932-935, 942-945, 952-955, 962-965, 972-975,
982-984, 992-995 from FIG. 22) and each of which is connected
(e.g., directly) to a corresponding one of the plurality of local
control networks (in which case each is connected indirectly to the
larger communication network). The communication network may
comprise or be a single ring, star, or daisy-chain network, and/or
may be fiberoptic. Each of the plurality of control devices may
perform, be caused to perform, sense, measure, monitor, log, and/or
the like an action (e.g., a mechanical, software, or other action)
of a surface or downhole component (or group thereof), subsystem
(or group thereof), and/or system (or group thereof). By virtue of
their connection through the communication network, each of the
plurality of control devices may directly or indirectly communicate
with each other of the plurality of control devices. In an
advantageous embodiment, the communication network is configured
such that the plurality of control devices (and/or the plurality of
local control devices) may (and, in some embodiments, do) perform
substantially all control logic involved in direct operation of an
array of individual tools/equipment and/or individual subsystems
controlled by the rig control system, whereas the control
workstations, e.g., via user-input data comprising, consisting
essentially of, or being operating parameters and/or
multi-tool/multi-subsystem tasks, substantially exchange data
comprising, being, and/or derived from the user-input data with the
plurality of control devices (and/or, through the plurality of
local control networks, with the plurality of local control
devices, and thus ultimately with various
tools/equipment/subsystems controlled by the rig control
system.
[0226] In this or another embodiment, or as a stand-alone
embodiment, an analysis-while-drilling (AWD) control system
according to the present disclosure (which may be similar or
identical to system 800 shown in FIG. 22) may be operable to
display and/or utilize a plurality of drilling-related parameters
that can be and/or have been input by a user and/or that can be
and/or have been calculated by one or more algorithms (e.g., based
on parameters that can be or have been input by a user). The AWD
control system may utilize as input data drilling-related
parameters involving well configuration, drill string (including
BHA) configuration, drilling-related sensor data/parameters (e.g.,
mud pit level sensors, standpipe pressure sensors, mud flow
sensors, and the like), and drilling equipment data/parameters
(e.g., directly from the corresponding equipment, such as drill
string revolutions per minute (RPM), make-up torque, mud pump SPM,
and the like). The AWD control system may provide output data that
can be delivered to and/or used by workstation(s) display(s) (e.g.,
including the AWD display), a historical logging system (e.g.,
which may be comprised within and/or accessible via a remote
computing resource environment such as environment 206 from FIGS. 3
and 4), a mud logging system (e.g., which may be comprised within
and/or accessible via a remote computing resource environment such
as environment 206 from FIGS. 3 and 4), etc. The AWD control system
output data may comprise: drilling operation warnings and alarms, a
kick calculator and kill sheet; sensor data and sensor data
calculations for storage in a historical trending/logging system,
dynamic tracking of data/parameters related to/indicative of a
predetermined set of operating parameters, parameters and/or other
information indicative of well configuration, and/or parameters
and/or other information indicative of drill string (e.g.,
including BHA) configuration. The predetermined set of operating
parameters may include, but may not necessarily be limited to: well
depth/shape; bit depth; stands in hole; sectioned mud volumes;
drill string volume, displacement, and weight; mud tank volumes,
including active tank selection and loss/gain calculation
information; trip tank difference volume; trip tank accumulated
volume; mud pump total stroke counters (individual stroke count is
tracked by/on behalf of each mud pump); mud pump SPM total; setting
of mud pump liner capacities and efficiencies; mud flow into hole,
individual and total; annular mud velocity per section; mud volume
per section; total strokes per section; strokes to go per section;
total minutes per section; minutes to go per section; mud return
flow; bit runtime and revolutions; WOB; ROP; hook load; and
standpipe pressure; inter alia.
[0227] The AWD system is operable for delivering high-quality
calculations for real-time monitoring and alarming of complex
drilling and tripping parameters. Input from following sources may
the basis for AWD calculations: well and drill string
configuration; and drilling parameter sensors, as mud pit level
sensors, standpipe pressure sensors, and mud flow sensors; directly
from the drilling equipment, such as drill string RPM, make-up
torque, and mud pump SPM. The AWD system may output results to
workstation displays (e.g., an AWD display screen viewable by the
operator on a control workstation display), a historical logging
system, and a mud logger system. The AWD system may have direct
access to all necessary sensor signals, and may permit further
understanding and comprehension by the operator.
[0228] The AWD system may provide determination and/or confirmation
of: well and drill string configuration; dynamic tracking of well
and bit depth; stands in well; dynamic calculation of sectioned mud
volumes, drill string volume, displacements, and weight; mud tank
volumes, including active tank selection and loss/gain calculation;
trip tank difference volume; trip tank accumulated volume; mud pump
total stroke counters (individual count may be performed by the
individual mud pumps); total mud pump strokes per minute; settings
of mud pump liner capacities and efficiencies; mud flow into hole,
individual and total; dynamic calculation of annular mud velocity
per section; dynamic calculation of mud volume per section; dynamic
calculation of total strokes per section; dynamic calculation of
strokes to go per section; dynamic calculation of total minutes per
section; dynamic calculation of minutes to go per section; mud
return flow; bit runtime and revolutions; WOB; ROP; hookload;
standpipe pressure; casing pressure; cement pressure; kick
calculator and kill sheet (e.g., following the "Drillers Method")'
sensors and calculations for storage in historical trending system;
and operation warnings and alarms.
[0229] The AWD system may contain specific WITS (Well Site
Information Transfer Standard) computations and triggers used to
populate serial communication utilizing the WITS0 protocol. The AWD
system may calculate data for the WITS records "RECORD1--General
Time-based" and "RECORD11--Mud Tank Volumes--Time-based." The WITS
record "RECORD19--Hole and Drill String" may be used for
configuration.
[0230] The AWD system may calculate mud active volume from the
levels measured by the mud pit level instrumentation. The level
sensors may be wired to the AWD system, or the AWD system may
receive the level sensor data from the drilling fluid control
system. Active tanks may be selected by the operator to be included
as a part of the active volume. Any tank combination is possible
for active volume. Once selected, the tank is automatically added
to the active volume. All calculations involving active volume will
be updated with the new value. The AWD screen may indicate the
status of which tanks contribute into the mud active volume
determination, which may always be visible to the operator.
[0231] The AWD system calculates data for the mud balance volume
indicator showing loss/gain volume with an arrow for
increasing/decreasing trend. System loss/gain is calculated as
variation in active volume from a reset value.
[0232] The AWD system calculates bit and well depth automatically
by use of hoist position, hook load, and slips status. Each time
the bit moves in the well, or the well is being lengthened, the
well and bit depths are automatically calculated by the AWD system.
The update is dependent on a certain weight of the drill string,
i.e., the ability to measure hook load. In cases when the weight of
the drill string is too low to obtain a reliable signal, it is
possible to manually decide when the bit depth should be updated.
The bit and well depth calculator also includes an automatic Stands
In Hole counter based on an input average stand length.
[0233] The AWD system may have two options for depth calculations:
"slips" for depth calculation active when the slips are not set;
and "hookload" for depth calculation when load is in the
elevator.
[0234] The AWD system may include individual SPM and stroke
counters for each mud pump. In addition, there may be multiple
(e.g., four) independent total strokes counters and total SPM for
the active mud pumps. The operator may select which pumps to count
into the active mud pumps for total counters.
[0235] The AWD system may include monitoring of the mud flow pumped
into the drill string, as well as mud return flow. Calculation of
flow in depends on configuration of liner capacity and efficiency
factor set for the individual mud pumps. By use of these data and
SPM, the AWD system may calculate the mud flow in per pump, in
addition to total flow pumped into the well.
[0236] The mud return flow may be read directly from a mud return
sensor, which an operator may choese via a sensor-select pop-up
menu.
[0237] The ROP may be calculated as a result of well or bit depth
increase over time. The operator may select whether the ROP
calculation will be done from bit depth or well depth.
[0238] The WOB may be calculated as variation in hook load from a
reset value.
[0239] The AWD system may include counters for bit revolutions and
runtime. These counters may depend on top drive RPM and calculated
mud flow in. Updating the counters may be done when the bit is on
bottom.
[0240] The AWD system may display a well configuration used to
configure well and drill string parameters, as well as to give a
summarized view of the current configurations being used.
[0241] The well design entered in the AWD system includes number of
well sections, as well as well diameter and planned length for each
section. The choke and kill line design entered in the AWD system
may include choke line ID, choke line joint ID, choke line joint
fraction, choke line length, kill line ID, kill line joint ID, kill
line joint fraction, and kill line length. The drill string design
entered in the AWD system may include dimensions and length of each
drill string section, including number of drill string sections,
planned length, drill string capacity, drill string steel
displacement, drill string closed displacement, average length of
tubular tool joint, average length of stand, and number of tool
joints per stand, among other examples.
[0242] The kick calculator may be used if the well kicks and the
well must be shut in and circulated out to regain control over the
well. The kick calculator does not start any equipment, sequences,
or processes, and may be used at any time or point of the well.
Inputs for the kick calculator may include measured depth, true
vertical depth, measured shoe depth (e.g., second-lowest well
section), vertical shoe depth, original mud weight, leak off test
mud weight, leak off test pressure, shut in casing pressure, shut
in drill pipe pressure, kick gain volume, kill pump selection, kill
pump capacity (e.g., calculated from mud pumps configuration), kill
pump speed, slow circulation rate pressure, safety margin, and
selected choke/kill line to use, among other examples. The kick
calculator may also use previously entered and/or measured
parameters as string and well properties, riser dimensions, and
kill and choke line properties. The volumes, shoe, and pump data
may be gathered from the mud pumps and well configuration settings.
The kick calculator may output initial circulation pressure,
interim circulation pressure, final circulation pressure, kill mud
weight, maximum mud weight, pressure drop per 100 strokes, gradient
of influx, height of influx, surface to bit strokes and minutes,
bit to shoe strokes and minutes, shoe to bop strokes and minutes,
bop to choke strokes and minutes, and total circulation strokes and
minutes, among other examples.
[0243] The AWD system may determine the trip tank difference via a
comparison between expected drill string displacement tripped into
the well and actual volume measured in the trip tank. Drill string
displacement may depend on the drill string configuration and bit
depth.
[0244] The AWD system may determine the trip tank accumulated
volume as the total volume of mud during tripping in or out. The
accumulator may be frozen when filling or draining to make it
possible to fill or empty the trip tank without reflecting the
accumulated value.
[0245] The AWD display screen may dynamically show the configured
and drilled well and drill string graphically. The AWD display
screen may also dynamically show mud volumes, strokes, and velocity
for the different well sections. The AWD system may also track the
mud front depth, which may be displayed textually (e.g.,
numerically) and graphically on the well animation. The AWD display
screen may contain a graphical display of the well configuration
and well section depths, a graphical display of the shoe, an
animation of drilled well relative to well configuration, an
animation of the drill string in the well, the mud front tracking
(e.g., mud front depth value and graphical display), annular
velocity per well section, open hole volume, and dynamic
determination of total strokes and minutes, strokes and minutes to
go, and volume for surface to bit, bit to shoe, bit to BOP, and bit
to surface, well circulation, and full circulation, among other
examples. The AWS display screen may also display other AWD
parameters already determined by the AWD System, such as drill
string displacement--open end, drill string displacement--closed
end, drill string weight, stands in the well, active volume, mud
flow in, bit revolutions, and bit runtime, among other examples.
The AWD display screen may also summarize the configured well
section lengths, and may display the depth of each section in
addition to graphically indicating the shoe depth. If the actual
well depth exceeds the configured well depth, the length of the
deepest well section may automatically be updated so that volume,
time, and stroke calculations are correct. Well and drill string
animation may also be updated to reflect exceeded well depth.
[0246] When a well configuration is input to the AWD system, the
well may be filled with a first color, and as drilling progresses,
the well animation may correspondingly be filled with a second
color according to the calculated well depth. The drill string may
be graphically displayed with the second color or a third color in
the configured well. Depth of the drill string will indicate the
bit depth.
[0247] The mud front tracking position may be calculated in
relation to the mud pump total strokes counter and the drill string
and well configurations. It may be possible to track the mud front
from the surface or the bit. When the operator selects to start
tracking the mud front from the surface, and a selected total
strokes counter is set to zero, a graphical symbol may indicate the
mud front position moving from the surface towards the bit inside
the drill string while mud is pumped into the well. When the stroke
counter exceeds the number of strokes for surface to bit, another
graphical symbol may indicate the mud front position in the annular
volume going from bottom to surface. When the mud front indication
reaches the surface, it may stay on the surface until the selected
total stroke counter is reset. When the operator selects to start
tracking the mud front from the bit (or bottom), and the selected
total strokes counter is set to zero, a graphical symbol may
indicate the mud front position in the annular volume starting from
the bit and moving towards the surface. When the mud front
indication reaches the surface, it may stay on the surface until
the selected total stroke counter is reset. In addition to the
graphical display of the mud front depth, there may also be a
numerical display showing the depth. For example, the value may be
a positive value if the mud front is moving towards the bit inside
the drill string or towards surface in the annular volume.
[0248] The AWD system may calculate and display annular velocity
with a numerical display for each of the well sections. If the
drill string has several outer diameters inside the same well
sections, the velocity calculated may be the average in the
specific well section.
[0249] The AWD system may calculate the open hole volume according
to the well configuration at current well depth.
[0250] The AWD system may dynamically calculate volume, total
strokes, total minutes and strokes, and minutes to go for one or
more of: surface to bit (drill string volume); bit to shoe (annular
volume from bit to shoe); bit to surface (total annular volume);
well circulation (drill string+annular volume); and full
circulation (drill string+annular volume+active volume). The
strokes and minutes to go may be calculated from the last reset of
the selected total strokes counter. If the operator selected to
start tracking from surface, strokes and minutes to go may be
calculated starting from counting strokes from surface. If the
operator selected to start tracking from bottom, strokes and
minutes to go may be calculated starting from bit position. The
surface to bit strokes and time to go may be be set to zero when
the operator selects to start tracking from bottom.
[0251] Volume calculations may be related to the well and drill
string configurations and the calculated bit depth. Strokes
calculations may depend on calculated volumes and active mud pump
capacity settings. Minutes to go calculations may depend on
calculated volumes, active mud pump capacity settings, and mud pump
total SPM.
[0252] A control system according to one or more aspects of the
present disclosure (which may be similar or identical to system 800
shown in FIG. 22) may be operable to monitor and at least partially
(e.g., completely) control drilling operations of a drilling rig
and one or more of the following modules: drill pipe tripping in
(with and/or without drill collar stand); drill pipe tripping out
(with and/or without drill collar stand); drill pipe connecting;
drill pipe stand-building (offline); drill pipe laydown standing
(offline); casing stand-building; casing tripping in; stand
breakdown; running casing from catwalk; picking up singles from
catwalk; laying down singles from well center to catwalk;
back-reaming; wet tripping; normal drilling shut-down; and
emergency drilling shut-down (based on alarm conditions). One such
example module involves running 13-3/8'' casing from catwalk using
top drive and casing running tool. This module sequence may start
with top drive in lower position, casing running tool engaged,
closed slips (e.g., approximately 1.5 meters stick up), catwalk
machine feeding table loaded with (cleaned) tubulars, catwalk
machine ramp loaded with casing (e.g., on its way up), tubular
delivery arm parked in/near top of mast, and lower stabilizing arm
ready. The module sequence may then include: (i) releasing casing
running tool from stick up and hoisting top drive to pick up
position; (ii) latching elevator; (iii) top drive/lower stabilizing
arm hoisting the casing to well center and catwalk machine being
moved to loading position; (iv) stabbing the casing; (v) loading
another (e.g., the next) casing on catwalk machine ramp; (vi)
running catwalk to drill floor; (vii) engaging casing running tool
and making-up casing connection; (viii) opening backup tong and
retracting tong handling trolley; (ix) lowering casing string and
opening elevator; (x) tilting out elevator link(s) and setting
slips; and (xi) optionally repeating some or all of these steps for
additional (e.g., the next) casing(s), as desired.
[0253] A drilling system according to one or more aspects of the
present disclosure (which may be similar or identical to system 800
shown in FIG. 22) may comprise at least partially (e.g.,
completely) automated control of equipment comprising, consisting
essentially of, or consisting of each of: drawworks; top drive;
iron roughneck; mud bucket; cathead(s); mousehole; mud system
comprising mud pumps; catwalk; fingerboard; vertical pipe handler;
CCTV system; riser tension system; top-mounted compensator; and
optionally bottom hole assembly (BHA).
[0254] A control system according to one or more aspects of the
present disclosure (which may be similar or identical to system 800
shown in FIG. 22) may be operable for controlling drilling
operations in which automated tripping in and/or automated tripping
out modules may be advantageously more efficient than manual
tripping in and/or tripping out modules for an average human
working crew. The control system may effectuate one, some, or all
of the following: an automated average tripping in and/or tripping
out speed [in stands/hour] that is at least 5% (e.g., at least 6%,
at least 7%, at least 8%, at least 9%, or at least 10%) better/more
than an average tripping in and/or tripping out speed of an average
human working crew; an automated standard deviation from average
tripping in and/or tripping out speed that is at least 50% (e.g.,
at least 55%, at least 60%, at least 65%, at least 70%, at least
75%, or at least 80%) better/lower than a standard deviation from
an average tripping in and/or tripping out speed of an average
human working crew; an automated average tripping in and/or
tripping out slip-to-slip connection time [in seconds] that is at
least 4% (e.g., at least 5%, at least 6%, or at least 7%)
better/lower than an average tripping in and/or tripping out
slip-to-slip connection time of an average human working crew; and
an automated standard deviation from average tripping in and/or
tripping out slip-to-slip connection time that is at least 50%
(e.g., at least 55%, at least 60%, at least 65%, at least 70%, at
least 75%, or at least 80%) better/lower than a standard deviation
from an average tripping in and/or tripping out slip-to-slip
connection time of an average human working crew.
[0255] A control system according to one or more aspects of the
present disclosure (which may be similar or identical to system 800
shown in FIG. 22) may be operable for controlling drilling
operations in which collisions are prevented between: (a) drawworks
and one or more of iron roughneck, tong-handling trolley,
tong-handling arm, catwalk, tubular delivery arm, lower stabilizing
arm, and upper tubular constraint; (b) top drive and one or more of
iron roughneck, tong-handling trolley, tong-handling arm, catwalk,
tubular delivery arm, lower stabilizing arm, and upper tubular
constraint; (c) iron roughneck and one or more of drawworks, top
drive, catwalk, tubular delivery arm, lower stabilizing arm,
intermediate tubular constraint, rotary table, power slips, well
center connection, and mousehole connection; (d) tong-handling
trolley and one or more of drawworks, top drive, catwalk, tubular
delivery arm, lower stabilizing arm, rotary table, power slips, and
well center connection; (e) tong-handling arm and one or more of
drawworks, top drive, catwalk, tubular delivery arm, lower
stabilizing arm, intermediate tubular constraint, rotary table,
power slips, well center connection, and mousehole connection; (f)
catwalk and one or more of drawworks, top drive, iron roughneck,
tong-handling trolley, tong-handling arm, tubular delivery arm,
lower stabilizing arm, pipes around stand hand-off position, and
pipes by mousehole; (g) tubular delivery arm and one or more of
drawworks, top drive, iron roughneck, tong-handling trolley,
tong-handling arm, catwalk, lower stabilizing arm, transfer bridge
rackers, upper tubular constraint, intermediate tubular constraint,
lower tubular constraint, setback guide arm(s), stand hand-off
position, rotary table, and power slips; (h) lower stabilizing arm
and one or more of drawworks, top drive, iron roughneck,
tong-handling trolley, tong-handling arm, catwalk, tubular delivery
arm, and intermediate tubular constraint; (i) transfer bridge
rackers and one or more of tubular delivery arm, upper tubular
constraint, lower tubular constraint, setback guide arm(s), stand
hand-off position, and fingerboard; (j) upper tubular constraint
and one or more of drawworks, top drive, tubular delivery arm,
transfer bridge rackers, lower tubular constraint, and setback
guide arm(s); (k) intermediate tubular constraint and one or more
of iron roughneck, tong-handling arm, tubular delivery arm, lower
stabilizing arm, and mousehole connection; (l) setback guide arm(s)
and one or more of tubular delivery arm, lower stabilizing arm,
transfer bridge rackers, upper tubular constraint, and lower
tubular constraint; (m) setback guide arms; (n) fingerboard and
transfer bridge rackers; (o) lower tubular constraint and one or
more of tubular delivery arm, lower stabilizing arm, transfer
bridge rackers, upper stabilizing arm, and setback guide arm(s);
(p) stand hand-off position and one or both of tubular delivery arm
and transfer bridge rackers; and/or (q) rotary table/power slips
and one or more of drawworks, top drive, iron roughneck,
tong-handling trolley, tong-handling arm, tubular delivery alarm,
lower stabilizing arm, and well center connection.
[0256] A control system according to one or more aspects of the
present disclosure (which may be similar or identical to system 800
shown in FIG. 22) may be operable for controlling drilling
operations in which a level of automation for various drilling
operations can be selected by: generating a control screen
facilitating selection of automation level; and facilitating
selection of full (i.e., substantially complete) automation,
semi-automation (e.g., confirmation by driller/operator to start a
specific operational sequence, automating a first portion of a
larger operational sequence such as waiting for a driller/operator
to authorize completion and/or a second portion of the larger
operational sequence, or the like), or manual control (e.g., via a
joystick).
[0257] A control system according to one or more aspects of the
present disclosure (which may be similar or identical to system 800
shown in FIG. 22) may be operable for controlling drilling
operations and may comprise a customizable display screen on which
a control screen is generated and which control screen may be
operable to facilitate selection of scale and/or limits for
indicator graphs (e.g., pie chart(s), linear bar graph(s), spider
graph(s), and/or the like, as well as combinations thereof) that
may graphically represent one or more aspects of the drilling
operations. The selection of scale and/or limits may include, but
are not necessarily limited to, minimum and maximum graph values;
warning value limits; and graph scale.
[0258] A control system according to one or more aspects of the
present disclosure (which may be similar or identical to system 800
shown in FIG. 22) may be operable for controlling drilling
operations and may comprise a display of software objects (e.g.,
symbols, icons, buttons, and/or the like) that: may be displayed on
a monitor or touchscreen; may be indicative of
equipment/tool/device status via changing color, localized
background color, adjacent or localized background symbol (e.g.,
check or X), flashing color, filled/unfilled object, and/or the
like; may show operational status (e.g., high value, open, closed,
running, idle, error, and/or the like); may show communication
status (e.g., feedback error, communication error, and/or the
like); may show control status (e.g., auto, manual, local, and/or
the like); and may be displayed in association with displayed
numerical values; inter alia.
[0259] A control system according to one or more aspects of the
present disclosure (which may be similar or identical to system 800
shown in FIG. 22) may comprise an AWD display screen showing one,
some, or all of the following information: (a) graphic display of
well configuration and hole section depths; (b) graphic display of
shoe; (c) animation of planned vs. actual well; (d) animation of
drill string in well; (e) value and graphic display of mud front
tracking/depth; (f) annular velocity per section; (g) open hole
volume; (h) dynamic calculation of total strokes and minutes,
strokes and minutes to go, and volume for at least the following:
(i) Surface To Bit; (ii) Bit To Shoe; (iii) Bit To BOP; (iv) Bit To
Surface; (v) Well Circulation; (vi) Full Circulation; (j) drill
string displacement, open end and closed end; (k) drill string
weight; (1) stands in hole; (m) active volume; (n) mud flow in; (o)
bit revolutions; and (p) bit runtime.
[0260] A control system according to one or more aspects of the
present disclosure (which may be similar or identical to system 800
shown in FIG. 22) may comprise an alarm system that can assist
equipment operators/resource producers to operate equipment (e.g.,
drilling equipment) in an efficient and safe manner The alarm
system may be operable to: draw operator attention to alarms by use
of colors, symbols, flashing, sounds, and other notations with
distinct meaning; present descriptive and easy to understand alarm
texts; use alarm priority with distinct meaning; logically group
alarms; and keep an alarm rate as low as possible. The alarm system
may additionally or alternatively utilize screen objects/symbols
that are indicative of equipment or device and that may show status
via changing color, localized background color, adjacent or
localized background symbol, flashing color, filled or unfilled
object, and/or the like. The alarm system may additionally or
alternatively be configured: such that the driller/operator
responds to all alarms; for intuitive navigation and alarm
acknowledgment; to automatically log each alarm and alarm state
change; and for high system availability and robustness.
[0261] A method of at least partially automating drilling
operations according to one or more aspects of the present
disclosure, which may be employed using one, some, or all of the
(control) systems described herein, can comprise utilizing data
indicative of operation or capability of a first piece of drilling
equipment as an input parameter for controlling operation of a
second piece of drilling equipment, wherein impact of the data
indicative of the operation/capability of the first piece of
drilling equipment is either not intuitively linked to or is
counterintuitive to operation/capability of the second piece of
drilling equipment. For example, an output parameter involving a
piece of drilling equipment A may be used as an input parameter for
operation of a piece of drilling equipment B, and an output
parameter (e.g., similar to or different from the input parameter)
involving the piece of drilling equipment B may be used as an input
parameter for operation of a piece of drilling equipment C. In this
example, one or more effects of operation/capability of a parameter
involving the piece of equipment A is either not intuitively linked
to or is counterintuitive in its applicability to the
operation/capability of the piece of equipment C. In this example,
the "piece of drilling equipment B" may represent a single piece of
drilling equipment or a series of pieces of drilling equipment, an
output parameter of each of which serves as an input parameter for
the next piece of drilling equipment throughout the series
(notably, it may be, although it need not be, the same output
and/or input parameter throughout the series of drilling
equipment).
[0262] In view of the entirety of the present disclosure, including
the figures and the claims, a person having ordinary skill in the
art will readily recognize that the present disclosure introduces
an apparatus comprising an integrated well construction system
(IWCS) operable for constructing a well via integrated control of a
plurality of integrated control devices that collectively control a
plurality of integrated subsystems of the IWCS, wherein the IWCS
comprises: an IWCS communication network; the integrated control
devices, each directly connected with the IWCS communication
network; the integrated subsystems; and a control workstation
directly connected with the IWCS communication network and operable
to control each of the integrated control devices to thereby
control the integrated subsystems.
[0263] Each integrated control device may control a corresponding
one of the integrated subsystems.
[0264] The IWCS communication network may be a single, fiberoptic,
ring-topology network.
[0265] The integrated subsystems may include at least: a rig
control subsystem comprising a drawworks, a top drive, an iron
roughneck, automated slips, and automated pipe handling equipment;
a fluid circulation subsystem comprising a drilling fluid pump and
drilling fluid reconditioning equipment; a managed pressure
drilling control subsystem; a choke pressure control subsystem; a
well pressure control subsystem; and a closed-circuit television
subsystem.
[0266] Each subsystem may comprise: a subsystem network directly
connected with the integrated control device of that subsystem; and
a plurality of subsystem components each directly connected with
the subsystem network. The subsystem components may each control,
perform, sense, measure, and/or monitor an aspect of well
construction performed in association with the subsystem comprising
that subsystem component.
[0267] The control workstation may comprise a processor and a
memory storing a construction program that, when executed by the
processor, controls each integrated control device at least
partially in response to data received from at least one other one
of the integrated control devices.
[0268] The control workstation may comprise a processor and a
memory storing a construction program that, when executed by the
processor, controls each integrated control device during each of a
plurality of predetermined operational sequences. The plurality of
predetermined operational sequences may comprise: picking up single
tubulars; making drilling connections; building tubular stands;
tripping-in drill collar stands; tripping-out drill collar stands;
tripping-out wet; backreaming; moving single tubulars from a well
center to a catwalk using a top drive; moving tubular stands from
the well center to the catwalk; moving casing from the catwalk to
the well center using a casing tong; moving casing from the catwalk
to the well center using a tubular delivery arm and a casing
running tool; moving large diameter casing from the catwalk to the
well center using the top drive and the casing running tool;
building casing stands; and tripping-in casing stands without using
the casing running tool. The construction program, when executed by
the processor, may control the top drive, a drawworks, automated
slips, a top drive elevator, an iron roughneck, a drilling fluid
pumping system, the catwalk, an automated racker, an automated
fingerboard, and the tubular delivery arm, via control of the
integrated control devices, during performance of the predetermined
operational sequences. The construction program may be configurable
by a human operator to permit the operator to select human
interaction levels during performance of the predetermined
operational sequences. The construction program may be configurable
by a human operator to permit the operator to select levels of
automation of the IWCS during performance of the predetermined
operational sequences. The construction program may be configurable
by a human operator to permit the operator to select which machines
of the IWCS will be controlled by the construction program during
performance of each predetermined operational sequence. The
construction program may be configurable by human operators to
permit the operators to select which machines of the IWCS will be
controlled by the construction program, and to select which
machines of the IWCS will be supervised by which operator, during
performance of each predetermined operational sequence. The
construction program may be configurable by human operators to
permit the operators to select which steps of each predetermined
operational sequence will be performed and/or confirmed manually,
and by which operator.
[0269] The IWCS may be operable for constructing a well without
operation of other components not controlled by, monitored by, or
otherwise in communication with any of the integrated control
devices.
[0270] The IWCS may be operable for constructing a well without
operation of other components not controlled by any of the
integrated control devices.
[0271] The present disclosure also introduces an apparatus
comprising a control workstation directly connected with a
communication network and operable to control each of a plurality
of integrated control devices each directly connected with the
communication network, wherein each integrated control device
controls a corresponding component of an integrated well
construction system, whereby control of the integrated control
devices, via operations of the control workstation, controls the
integrated well construction system.
[0272] The integrated well construction system may be operable, via
operations of the control workstation, for constructing a well
exclusive of any component not controlled by any of the integrated
control devices.
[0273] The present disclosure also introduces a computer program
product comprising a tangible, computer-readable, non-transitory
medium having instructions stored thereon for: automatically
controlling a plurality of integrated control devices that control
integrated subsystems of an integrated well construction system
(IWCS) to perform combinations of a plurality of predetermined
operational sequences for constructing a well; receiving, via
operation of a control workstation by a human operator, a selection
of one of the operational sequences to be performed by the IWCS;
receiving, via operation of the control workstation by the human
operator, settings for first machines of the IWCS to be operated
during the selected operational sequence; and in response to
receiving a single commencement input via operation of the control
workstation by the human operator, automatically starting and
controlling the first machines and second machines of the IWCS to
perform the selected operational sequence using the received
settings.
[0274] The automatic start and control of the first and second
machines may perform the selected operational sequence without
further human action.
[0275] The present disclosure also introduces a method comprising
operating an integrated well construction system (IWCS) comprising
a fiberoptic ring network, wherein the fiberoptic ring network
comprises a plurality of nodes comprising: programmable logic
controllers (PLCs) of individual pieces of machinery forming the
IWCS; video feed; drilling operator control; high-level supervisory
control; and combinations thereof.
[0276] The IWCS machinery PLCs may comprise: a drilling fluid
pumping system PLC; a top drive PLC; a drawworks PLC; an automated
slips PLC; an iron roughneck PLC; a catwalk PLC; an automated
racker PLC; an automated fingerboard PLC; and a tubular delivery
arm PLC.
[0277] The fiberoptic ring network may exchange data between the
PLCs for coordinated control of the machinery.
[0278] The fiberoptic ring network may exchange data between one or
more of the PLCs and the drilling operator for manual or
semi-automatic control of the IWCS.
[0279] The fiberoptic ring network may exchange data between one or
more of the PLCs and a supervisory controller for automatic and
optimized control of the IWCS.
[0280] The present disclosure also introduces an apparatus
comprising: a communication network; a plurality of integrated
control devices each directly connected with the communication
network, wherein each integrated control device controls a
corresponding component of an integrated well construction system,
and wherein the integrated well construction system is operable for
constructing a well without other components not controlled by any
of the integrated control devices; and a control workstation
directly connected with the communication network and operable to
control each of the integrated control devices to thereby control
the integrated well construction system.
[0281] The present disclosure also introduces an apparatus
comprising: a communication network; a plurality of integrated
control devices each directly connected with the communication
network, wherein each integrated control device controls a
corresponding one of a plurality of integrated well construction
components, and wherein the integrated well construction components
are collectively operable for constructing a well exclusive of any
component not controlled by any of the integrated control devices;
and a control workstation directly connected with the communication
network and operable to control each of the integrated control
devices to thereby control the integrated well construction
system.
[0282] The present disclosure also introduces an apparatus
comprising: a communication network; a plurality of integrated
control devices each directly connected with the communication
network, wherein each integrated control device controls a
corresponding one of a plurality of integrated well construction
components, and wherein the integrated well construction components
form an integrated well construction system operable for
constructing a well without any other components; and a control
workstation directly connected with the communication network and
operable to control each of the integrated control devices to
thereby control the integrated well construction system.
[0283] The present disclosure also introduces a method comprising
causing a well construction system to perform a well construction
operation, whereby data associated with the well construction
operation is automatically collected and analyzed in real-time to
determine a plurality of parameters based on the data, and wherein
at least some of the determined parameters are used for controlling
the well construction operation.
[0284] The data may be selected from: human operator inputs;
equipment control, feedback, and interlock signals; surface sensor
signals; and downhole sensor signals.
[0285] The well construction system may comprise a processing
system comprising a processor and a memory having instructions
recorded thereon for, when executed by the processor: automatically
determining the parameters; and automatically controlling at least
a portion of the well construction operation based at least
partially on the determined parameters.
[0286] The well construction system may comprise a processing
system comprising a processor and a memory having instructions
recorded thereon for, when executed by the processor: automatically
determining the parameters; and automatically displaying at least
some of the determined parameters to a human operator in
substantially real-time. The method may further comprise at least
partially controlling, by the human operator, at least a portion of
the well construction operation based at least partially on the
displayed parameters. The displaying may comprise numbers,
pictures, animations, or combinations thereof.
[0287] The determined parameters may comprise one or more of
drilling fluid active volume, drilling fluid loss and/or gain, bit
depth, wellbore depth, hook load weight and friction, drilling
fluid pump strokes, drilling fluid stroke rate, rate of
penetration, weight on bit, bit revolutions, bit runtime, well
configuration, drill string configuration, choke configuration,
kill line configuration, kick calculator, trip tank volume, trip
tank difference determinations, and trip tank accumulated
volume.
[0288] One of the determined parameters may be a kick determination
based on: measured depth; true vertical depth; measured shoe depth;
vertical shoe depth; original drilling fluid weight; leak off test
drilling fluid weight; leak off test pressure; shut in casing
pressure; shut in drill pipe pressure; kick gain volume; kill pump
selection; kill pump capacity; kill pump speed; slow circulation
rate pressure; safety margin; and selected choke/kill line.
[0289] The present disclosure also introduces a method comprising
causing a well construction system to perform a well construction
operation, whereby data associated with the well construction
operation is automatically collected and analyzed in real-time to
determine a plurality of parameters based on the data, and wherein
at least some of the determined parameters each provide a basis for
triggering at least one real-time well construction operation
alarm.
[0290] The data may be selected from: human operator inputs;
equipment control, feedback, and interlock signals; surface sensor
signals; and downhole sensor signals.
[0291] The at least one real-time alarm may be a plurality of
alarms comprising: high trip tank volume; low trip tank volume;
high active drilling fluid volume; low active drilling fluid
volume; high drilling fluid loss; low drilling fluid loss; high
drilling fluid gain; low drilling fluid gain; high drilling fluid
flow return; low drilling fluid flow return; high standpipe
pressure; low standpipe pressure; drilling fluid pumping system
total stroke rate; and drilling fluid pumping system total
strokes.
[0292] The well construction system may comprise a processing
system comprising a processor and a memory having instructions
recorded thereon for, when executed by the processor: automatically
determining the parameters; and automatically triggering the at
least one real-time alarm based on at least one of the determined
parameters.
[0293] The determined parameters may comprise one or more of
drilling fluid active volume, drilling fluid loss and/or gain, bit
depth, wellbore depth, hook load weight and friction, drilling
fluid pump strokes, drilling fluid stroke rate, rate of
penetration, weight on bit, bit revolutions, bit runtime, well
configuration, drill string configuration, choke configuration,
kill line configuration, kick calculator, trip tank volume, trip
tank difference determinations, and trip tank accumulated
volume.
[0294] The present disclosure also introduces an apparatus
comprising an analysis-while-drilling (AWD) control system utilized
in conjunction with a well construction system during a well
construction operation, wherein inputs for the AWD control system
comprise: intended configuration of a well being constructed by the
well construction system during the well construction operation;
configuration of a drill string being used by the well construction
system during the well construction operation; signals from
drilling parameter sensors; and drilling equipment parameters.
Outputs from the AWD control system comprise real-time
determination of: depth and trajectory of the well; bit depth;
number of drill string tubulars and/or stands in the well; drill
string volume, displacements, and weight; drilling fluid tank
volumes and tank selections; drilling fluid loss and/or gain; trip
tank difference volume; trip tank accumulated volume; total and/or
per-section strokes and/or strokes-to-go of drilling fluid pumping
system; total stroke rate of drilling fluid pumping system;
drilling fluid pumping system liner capacities and efficiencies;
individual and total drilling fluid flow into the well; annular
drilling fluid velocity; total and/or per-section drilling fluid
volumes; total minutes and/or minutes-to-go per section; drilling
fluid return flow; bit runtime and revolutions; weight-on-bit; rate
of penetration; hook load; and standpipe pressure. The outputs from
the AWD control system may further comprise a kick calculator and a
kill sheet. The outputs from the AWD control system may further
comprise sensors and calculations for storage in a historian
associated with the well construction system. The outputs from the
AWD control system may further comprise well construction operation
warnings and alarms. The drilling parameter sensors may comprise
drilling fluid tank level sensors, standpipe pressure sensors,
cement manifold pressure sensors, and drilling fluid flow
sensors.
[0295] The drilling equipment parameters may comprise drill string
revolutions per minute, make-up torque, hoist position, hook load,
slips status, average stand length, average tubular length, liner
capacities and efficiencies of individual drilling fluid system
pumps, top drive revolutions per minute, choke like parameters,
kill line parameters, number of drill string sections, drill string
capacity, drill string steel displacement, and drill string closed
displacement.
[0296] The present disclosure also introduces an apparatus
comprising a control workstation directly connected with a
communication network and operable to control each of a plurality
of control devices each directly connected with the communication
network, wherein each control device controls a corresponding
component of an integrated well construction system, whereby
control of the control devices, via operations of the control
workstation, controls the integrated well construction system,
wherein the control workstation comprises a display, a processor,
and a memory storing: a construction program that, when executed by
the processor, controls each control device; and an
analysis-while-drilling (AWD) program. Inputs for the AWD system
comprise: intended configuration of a well being constructed by the
well construction system during the well construction operation;
configuration of a drill string being used by the well construction
system during the well construction operation; signals from
drilling parameter sensors; and drilling equipment parameters. When
executed by the processor, the AWD program generates in real-time,
and displays in real-time in an AWD screen on the display, one or
more of: a graphic display of the intended configuration and/or an
actual configuration of the well, including depths; a graphic
display of a shoe in the well; an animation of the intended and
actual configurations of the well; an animation of the drill string
in the well; value textual and/or graphic display of drilling fluid
front tracking and/or depth; annular velocity per section; open
hole volume; total strokes and minutes, strokes and minutes-to-go,
and volume for one or more of: surface to bit; bit to shoe; bit to
blow-out preventer; bit to surface; well circulation; full
circulation; drill string displacement, open end and closed end;
drill string weight; number of tubulars in the well; active volume;
drilling fluid flow into the well; bit revolutions; and bit
runtime.
[0297] The present disclosure also introduces an apparatus
comprising a control workstation for use with an integrated well
construction system (IWCS), wherein the IWCS is operable for
constructing a well via integrated control of a plurality of
integrated control devices that collectively control a plurality of
integrated subsystems of the IWCS, and wherein the control
workstation comprises a human-machine interface (HMI) comprising a
display, a touchscreen, a joystick, and a processing system
comprising a processor and a memory having a construction program
thereon that, when executed by the processor: presents a human
operator of the control workstation with a setup wizard guiding the
operator through entering operating parameters for one or more well
construction machines of the integrated subsystems to perform a
well construction sequence; and controls the integrated control
devices, and thus the integrated subsystems, to perform the well
construction sequence based on the entered operating
parameters.
[0298] The well construction sequence may be selected from: picking
up single tubulars; making drilling connections; building tubular
stands; tripping-in drill collar stands; tripping-out drill collar
stands; tripping-out wet; backreaming; moving single tubulars from
a well center to a catwalk using a top drive; moving tubular stands
from the well center to the catwalk; moving casing from the catwalk
to the well center using a casing tong; moving casing from the
catwalk to the well center using a tubular delivery arm and a
casing running tool; moving large diameter casing from the catwalk
to the well center using the top drive and the casing running tool;
building casing stands; and tripping-in casing stands without using
the casing running tool.
[0299] The entered operating parameters may be for one or more of a
top drive, a drawworks, automated slips, a top drive elevator, an
iron roughneck, a drilling fluid pumping system, a catwalk, an
automated racker, an automated fingerboard, and a tubular delivery
arm.
[0300] The entered operating parameters may comprise speed
limitations of at least one of the well construction machines.
[0301] The entered operating parameters may comprise travel stops
of at least one of the well construction machines.
[0302] The entered operating parameters may comprise maximum
limitations of at least one of the well construction machines.
[0303] The entered operating parameters may comprise target
settings of at least one of the well construction machines.
[0304] The entered operating parameters may comprise target
settings of the well construction sequence.
[0305] The entered operating parameters may comprise automation
levels. The automation levels may be selected from: automated
control by the construction program; automated control by the
construction program after confirmation by the human operator; and
manual operation by the human operator.
[0306] The human operator may cause commencement of the well
construction sequence by actuating a button on the touchscreen.
[0307] The human operator may cause commencement of the well
construction sequence by actuating the joystick to ramp up the
speed of the well construction machines.
[0308] The construction program may permit the human operator to
take manual control of one or more of the well construction
machines during the well construction sequence.
[0309] The construction program may permit the human operator to
change an operating parameter of one or more of the well
construction machines during the well construction sequence.
[0310] The well construction sequence may be a tripping-in or
tripping-out sequence, which may be performed with an average
stands-per-hour tripping-in or tripping-out speed that is at least
five percent faster than attainable by an average human working
crew not using the IWCS.
[0311] The well construction sequence may be a tripping-in or
tripping-out sequence, which may be performed with a standard
deviation from average tripping-in or tripping-out speed that is at
least fifty percent lower than attainable by an average human
working crew not using the IWCS.
[0312] The well construction sequence may be a tripping-in
sequence, which may be performed with an average slips-to-slips
connection time that is at least four percent faster than
attainable by an average human working crew not using the IWCS.
[0313] The well construction sequence may be a tripping-in
sequence, which may be performed with a standard deviation from
average slips-to-slips connection time that is at least fifty
percent lower than attainable by an average human working crew not
using the IWCS.
[0314] The present disclosure also introduces an apparatus
comprising an integrated well construction system (IWCS) operable
for constructing a well via integrated control of a plurality of
integrated control devices that collectively control a plurality of
integrated subsystems of the IWCS, wherein the IWCS comprises a
processing system comprising a processor and a memory having a
construction program thereon that, when executed by the processor:
controls each integrated control device, and thus each integrated
subsystem, during each of a plurality of predetermined operational
sequences; and prevents collisions between machines of the
IWCS.
[0315] The IWCS machines prevented from colliding by the
construction program may comprise: a drawworks; an iron roughneck;
a tong-handling trolley; a tong-handling arm; a catwalk; a tubular
delivery arm; a lower stabilizing arm; an upper tubular restraint;
an intermediate tubular restraint; a lower tubular restraint; a top
drive; a top drive elevator; a fingerboard; a transfer bridge
racker; and a setback guide arm. The construction program may
further prevent collisions between: the IWCS machines; tubulars
being transported by any of the IWCS machines; tubulars sticking up
out of the well; tubulars in a mousehole of the IWCS; and tubulars
in a hand-off position of the IWCS. The construction program may
prevent collisions between: a drawworks and one or more of a
catwalk, an iron roughneck, a lower stabilizing arm, a
tong-handling arm, a tong-handling trolley, a tubular delivery arm,
and an upper tubular constraint; and/or a top drive and one or more
of the iron roughneck, the tong-handling trolley, the tong-handling
arm, the catwalk, the tubular delivery arm, the lower stabilizing
arm, and the upper tubular constraint; and/or the iron roughneck
and one or more of the drawworks, the top drive, the catwalk, the
tubular delivery arm, the lower stabilizing arm, an intermediate
tubular constraint, a rotary table, automated slips, a tubular
sticking up out of the well, and a tubular sticking up out of a
mousehole of the IWCS; and/or the tong-handling trolley and one or
more of the drawworks, the top drive, the catwalk, the tubular
delivery arm, the lower stabilizing arm, the rotary table, the
automated slips, and a tubular sticking up out of the well; and/or
the tong-handling arm and one or more of the drawworks, the top
drive, the catwalk, the tubular delivery arm, the lower stabilizing
arm, the intermediate tubular constraint, the rotary table, the
automated slips, a tubular sticking up out of the well, and a
tubular sticking up out of a mousehole; and/or the catwalk and one
or more of the drawworks, the top drive, the iron roughneck, the
tong-handling trolley, the tong-handling arm, the tubular delivery
arm, the lower stabilizing arm, a tubular in a hand-off position of
the IWCS, and a tubular sticking up out of a mousehole; and/or the
tubular delivery arm and one or more of the drawworks, the top
drive, the iron roughneck, the tong-handling trolley, the
tong-handling arm, the catwalk, the lower stabilizing arm, a
transfer bridge racker, the upper tubular constraint, the
intermediate tubular constraint, a lower tubular constraint, a
setback guide arm, a tubular in the hand-off position, the rotary
table, and the automated slips; and/or the lower stabilizing arm
and one or more of the drawworks, the top drive, the iron
roughneck, the tong-handling trolley, the tong-handling arm, the
catwalk, the tubular delivery arm, and the intermediate tubular
constraint; and/or the transfer bridge racker and one or more of
the tubular delivery arm, the upper tubular constraint, the lower
tubular constraint, the setback guide arm, a tubular in the
hand-off position, and a fingerboard; and/or the upper tubular
constraint and one or more of the drawworks, the top drive, the
tubular delivery arm, the transfer bridge rackes, the lower tubular
constraint, and the setback guide arm; and/or the intermediate
tubular constraint and one or more of the iron roughneck, the
tong-handling arm, the tubular delivery arm, the lower stabilizing
arm, and a tubular in the mousehole; and/or the setback guide arm
and one or more of the tubular delivery arm, the lower stabilizing
arm, the transfer bridge racker, the upper tubular constraint, and
the lower tubular constraint; and/or the fingerboard and the
transfer bridge racker; and/or the lower tubular constraint and one
or more of the tubular delivery arm, the lower stabilizing arm, the
transfer bridge racker, the upper stabilizing arm, and the setback
guide arm; and/or a tubular in the hand-off position and one or
both of the tubular delivery arm and the transfer bridge racker;
and/or the automated slips and one or more of the drawworks, the
top drive, the iron roughneck, the tong-handling trolley, the
tong-handling arm, the tubular delivery arm, and the lower
stabilizing arm.
[0316] The present disclosure also introduces a method comprising
constructing a well utilizing each of a plurality of automatically
controlled well construction machines, including: a drawworks; an
iron roughneck; a tong-handling trolley; a tong-handling arm; a
catwalk; a tubular delivery arm; a lower stabilizing arm; an upper
tubular restraint; an intermediate tubular restraint; a lower
tubular restraint; a top drive; a top drive elevator; a
fingerboard; a transfer bridge racker; a setback guide arm; a
mousehole; a mousehole; a drilling fluid pumping system; and a
drilling fluid recondition system.
[0317] The present disclosure also introduces a system operable to
completely control each of a plurality of predetermined operational
sequences of a well construction operation, wherein the sequences
include: picking up single tubulars; making drilling connections;
building tubular stands; tripping-in drill collar stands;
tripping-out drill collar stands; tripping-out wet; backreaming;
moving single tubulars from a well center to a catwalk using a top
drive; moving tubular stands from the well center to the catwalk;
moving casing from the catwalk to the well center using a casing
tong; moving casing from the catwalk to the well center using a
tubular delivery arm and a casing running tool; moving large
diameter casing from the catwalk to the well center using the top
drive and the casing running tool; building casing stands; and
tripping-in casing stands without using the casing running
tool.
[0318] The present disclosure also introduces a control system for
controlling drilling operations in which a level of automation for
various operations can be selected. It may generate a control
screen facilitating selection of level of automation. It may
facilitate selection of full automation, semi-automation (e.g.,
confirmation by driller to start a specific sequence), or manual
control (e.g., via a joystick).
[0319] The present disclosure also introduces a control system for
controlling drilling operations comprising: a customizable display;
a control screen facilitating selection of scale and limits for
indicator graphs (e.g., circular bar graph, linear bar graph);
customizable selections including minimum and maximum graph values,
warning value limits, and scale.
[0320] The present disclosure also introduces a control system for
controlling drilling operations, including a display of software
objects (symbols, icons, buttons, etc.) that: are displayed on a
monitor or touchscreen; are indicative of equipment or device
status via changing color, localized background color, adjacent or
localized background symbol (e.g., check or X), flashing color,
filled or unfilled object, etc.; show operational status (e.g.,
high value, open, closed, running, idle, error, etc.); show
communication status (e.g., feedback error, communication error,
etc.); show control status (e.g., auto, manual, local, etc.);
and/or can be displayed in association with displayed numerical
values.
[0321] The present disclosure also introduces a rig control system
comprising a communication network. The communication network may
be a single ring, star, or daisy-chain network. The communication
network may be fiberoptic. The rig control system also comprises a
control workstation connected directly to the network. The rig
control system also comprises multiple different control devices.
Each control device may perform, cause the performance of, sense,
measure, monitor, and/or log a mechanical, software, or other
action of a mechanical, software, or other surface or downhole
component (or group thereof), subsystem (or group thereof), or
system (or group thereof). Each control device may be connected
directly to the communication network. Each control device may
communicate (directly or indirectly) with each other control
device. Each control device may act at least partially in response
to, or act at least partially based on, or otherwise use data from
at least one other control device. For example, each control device
may have an input from (the control device(s) of) another rig
component (or group thereof), rig subsystem (or group thereof), or
rig system (or group thereof). Each control device may be a
computer (PC or IPC) or a PLC. The rig control system may also
comprise multiple local control networks. Each local control
network may be connected with the communication network, such as
via a corresponding one of the control devices. The rig control
system may also comprise multiple local control devices. Each local
control device may be connected directly with a corresponding local
control network. Each local control device may be a computer (PC or
IPC) or a PLC. The control devices connected directly to the
communication network may perform all control logic, and the
control workstation may be (at least mostly) a data exchange.
[0322] The present disclosure also introduces an alarm system that
helps operators to operate equipment and processes in an efficient
and safe manner The alarm system may utilize screen objects/symbols
that: are indicative of equipment or device; show status via
changing color, localized background color, adjacent or localized
background symbol, flashing color, filled or unfilled object, etc.;
are designed to draw operator attention to alarms by use of colors,
symbols, flashing, sounds, and other notations with distinct
meaning, present descriptive and easy to understand alarm texts,
use alarm priority with distinct meaning, logically group alarms,
keep the alarm rate as low as possible, ensure operators responds
to all alarms, permit intuitive navigation and alarm
acknowledgement, permit logging all alarms and alarm state changes,
and provide high system availability and robustness.
[0323] The present disclosure also introduces an
analysis-while-drilling (AWD) control system that is operable to
show a large number of drilling related parameters determined by
sophisticated algorithms The AWD inputs may include: well
configuration; drill string (including BHA) configuration; drilling
parameter sensors (e.g., mud pit level sensors, standpipe pressure
sensors, mud flow sensors); and drilling equipment parameters
(e.g., directly from the equipment, such as drill string RPM,
make-up torque, mud pump SPM). The AWD outputs may be delivered to
and/or used by: workstation(s) display(s), including an AWD
display; a historical logging system; and/or a mud logger system.
The AWD outputs may include well configuration, drill string
(including BHA) configuration, and dynamic tracking of: the well;
bit depth; stands in hole; sectioned mud volumes; drill string
volume, displacements, and weight; mud tank volumes, including
active tank selection and loss/gain calculation; trip tank
difference volume; trip tank accumulated volume; mud pump total
stroke counters (individual count may be done in mud pumps); mud
pump SPM total; mud pump liner capacities and efficiencies; mud
flow into hole, individual and total; annular mud velocity per
section; mud volume per section; total strokes per section; strokes
to go per section; total minutes per section; minutes to go per
section; mud return flow; bit runtime and revolutions; WOB; ROP;
hook load; and standpipe pressure. The AWD outputs may also
include: kick calculator and kill sheet; sensors and calculations
for storage in historical trending system; drilling operation
warnings and alarms.
[0324] The present disclosure also introduces an AWD display screen
showing: graphic display of well configuration and hole section
depths; graphic display of shoe; animation of planned vs. actual
well; animation of drill string in well; value and graphic display
of mud front tracking/depth; annular velocity per section; open
hole volume; dynamic calculation of total strokes and minutes,
strokes and minutes to go, and volume for Surface To Bit, Bit To
Shoe, Bit To BOP, Bit To Surface, Well Circulation, Full
Circulation, drill string displacement (open end and closed end),
drill string weight, stands in hole, active volume, mud flow in,
bit revolutions, and bit runtime.
[0325] The present disclosure also introduces automated tripping-in
(or tripping-out) resulting in: an automated average tripping-in
speed (e.g., in stands/hour) that is at least 5% faster than an
average human working crew; and/or an automated standard deviation
from average tripping-in speed that is at least 50% lower than for
an average human working crew; and/or an automated average
tripping-in slip-to-slip connection time that is at least 4% faster
than an average human working crew; and/or an automated standard
deviation from average tripping-in slip-to-slip connection time
that is at least 50% lower than for an average human working
crew.
[0326] The present disclosure also introduces a method of
automating drilling operations that requires entry of at least a
given group of input parameters and requires ability to exercise
automated control over at least a given group of equipment related
to drilling operations.
[0327] The present disclosure also introduces a control system for
controlling drilling operations in which a level of automation for
various operations can be selected. It may generate a control
screen facilitating selection of level of automation. It may
facilitate selection of full automation, semi-automation (e.g.,
confirmation by driller to start a specific sequence), or manual
control (e.g., via a joystick).
[0328] The present disclosure also introduces a control system for
controlling drilling operations comprising: a customizable display;
a control screen facilitating selection of scale and limits for
indicator graphs (e.g., circular bar graph, linear bar graph); and
customizable selections, including: minimum and maximum graph
values, warning value limits, and scale.
[0329] The present disclosure also introduces a control system for
controlling drilling operations, including a display of software
objects (symbols, icons, buttons, etc.) that: are displayed on a
monitor or touchscreen; are indicative of equipment or device
status via changing color, localized background color, adjacent or
localized background symbol (e.g., check or X), flashing color,
filled or unfilled object, etc.; show operational status (e.g.,
high value, open, closed, running, idle, error, etc.); show
communication status (e.g., feedback error, communication error,
etc.); show control status (e.g., auto, manual, local, etc.);
and/or can be displayed in association with displayed numerical
values.
[0330] The foregoing outlines features of several embodiments so
that a person having ordinary skill in the art may better
understand the aspects of the present disclosure. A person having
ordinary skill in the art should appreciate that they may readily
use the present disclosure as a basis for designing or modifying
other processes and structures for carrying out the same purposes
and/or achieving the same advantages of the embodiments introduced
herein. A person having ordinary skill in the art should also
realize that such equivalent constructions do not depart from the
scope of the present disclosure, and that they may make various
changes, substitutions and alterations herein without departing
from the spirit and scope of the present disclosure.
[0331] The Abstract at the end of this disclosure is provided to
permit the reader to quickly ascertain the nature of the technical
disclosure. It is submitted with the understanding that it will not
be used to interpret or limit the scope or meaning of the
claims.
* * * * *