Modular Well Tubular Handling System and Method of Use

The present invention relates to systems and methods of lifting, lowering and/or handling tubular members in a well, and in particular to but not limited to a system for lifting, lowering and/or handling tubulars during running in, pulling out, drilling, milling, workover, completion and/or decommissioning operations.

During well drilling and workover operations, tubular lifting, lowering and handling is required to install, raise, lower and/or remove tubulars in or from a well. During well drilling, as a drill bit extends deeper into the well, further sections of drill pipe are attached to the drill string.

During the lifespan of the well, workover operations may be required to revitalize ageing wells to bring them back online to extend production. In workover operations, tools and equipment are inserted into a well to perform downhole tasks. The workover operations include running tubular, wireline, slickline, cutting tools, cementing operations, pumping equipment, and various fishing and re-entry services. Typically tools and equipment are run in and pulled out of the well using a workover jacking unit.

Wells which are no longer used are decommissioned to be made safe. During decommissioning operations, large diameter pipes are slowly removed from the well before the well is sealed. Conventionally, this is performed by a jacking unit with grippers which attach to a pipe and slowly pull the pipe out of the well.

Conventional tubular member handling systems are specific for each individual operation or task. This may present problems as there are space limitations associated with platform rigs and may create complex planning operations.

Conventional systems also lack flexibility to deal with changing operational requirements driven by the age of the rig, well or platform. These may cause different offshore infrastructure conditions such as; downgraded crane capacity, reduced skid beam loading capacity, available rig footprint, unknown well status and/or changing well conditions and of drilling/operational requirements. This may result in significant rig down time whilst suitable individual equipment packages for each operational phase can be obtained and installed on the rig to adapt to a different operation phase or specific well or rig condition. This may also result in increased costs to mobilize large heavy units to deal with all well-related uncertainties.

It is an object of at least one aspect of the present invention to obviate or at least mitigate the foregoing disadvantages of prior art tubular lifting and handling systems.

It is another object of an aspect of the present invention to provide a modular wellbore tubular lifting system with improved productivity and/or efficiency which may be capable of reliably performing a range of tubular member lifting and handling tasks over a wide range of operations.

It is an object of an aspect of the present invention to provide a modular wellbore tubular lifting system which is compact, mobile and transfigurable to adapt to a wide range of well operations and conditions.

It is another object of an aspect of the present invention to provide a lifting system for a modular wellbore tubular lifting system which may be capable of reliably performing a range of lifting tasks over a wide range of operations.

A further object of at least one aspect of the present invention is to provide a lifting system that is capable of improving the performance of a modular rig system in which the lifting system is deployed.

It is another object of an aspect of the present invention to provide a robust, reliable, sturdy lifting system suitable for deployment in a wide range of well operations which is capable of rapid tripping speeds and continuous rotary function.

It is a further object of an aspect of the present invention to provide a system with at least two lifting systems which may provide a multi-redundant lifting or hoisting system.

It is an object of an aspect of the present invention to provide a system capable of controlling the transfer of hydraulic fluid between one module and at least another module to divert, recycle and/or reuse hydraulic fluid, pressure and/or power.

It is another object of an aspect of the present invention to provide a system capable of controlling the transfer of hydraulic fluid between one lifting system and another lifting system to divert, recycle and/or reuse hydraulic fluid, pressure and/or power and/or adjust the available hoisting load capacity.

Further aims and objects of the invention will become apparent from reading the following description.

According to a first aspect of the invention, there is provided a modular system for lifting and/or lowering a tubular in wellbore operations, the system comprising:

The at least one module may comprise a frame. The frame of the at least one module may be configured to be removably connected to the at least one other module to form an integrated structure above a wellbore. The at least one module may be at least one functional module. The at least one module may be prefabricated. The at least one module may be ready for assembly into an integrated structure on a rig, platform, floor and/or deck. The rig, platform, floor and/or deck may be offshore or onshore. The modular system may be suitable for application to a wide range of types and sizes of rig, platform, floor and/or deck. The integrated structure may be assembled on site. The well may be a hydrocarbon well, a geothermal well or a carbon capture storage well. The modular system may be a modular rig system or part of a rig system. The at least one module may be configured to be transported and/or stored separately. The at least one module may be conveniently transported to a rig, platform and/or vessel deck. The system may be removably secured to a rig, platform and/or deck of a vessel. The integrated structure may be assembled offsite and mounted above the wellbore as a single unit. The frame of the at least one module may be a load-bearing structure. The integrated structure may be a load-bearing structure. Any loads acting on the at least one module may be distributed through a base support, the frame and/or integrated structure. Any loads acting on the at least one module may be directly transferred to a base support, the frame and/or integrated structure. The at least one module may be further divided into one or more sub-modules. The one or more sub-modules may be configured to operate independently from one another.

The system may comprise two or more modules. The two or more modules may be functional modules. The system may comprise a plurality of modules. Each module may comprise a frame. The frames of the two or more modules may be assembled together to form the integrated structure. At least one modules may be assembled in a first configuration to perform one or more tasks in a first wellbore operation. At least one module may be assembled in a second configuration to perform one or more tasks in a second wellbore operation. Two or more modules may be re-configured and/or re-assembled together in a different arrangement depending on the wellbore operation. At least one module may be added and/or removed to perform a wellbore operation or part of a wellbore operation, depending on the wellbore operation. The modular system may be transfigurable or reconfigurable. The system may be transfigurable or reconfigurable between a first wellbore operation mode in which the at least one module in the system is arranged in a first configuration and a second wellbore operation mode in which the at least one module of the system is arranged in a second configuration. The position of the at least one module in the integrated structure may be interchangeable with at least one other module in the integrated structure. The modules may be interconnectable. The control and/or communication connections of each function module may be through standardized interfaces.

The two or more modules may be arranged in series. The two or more modules may be arranged in series surrounding or partially surrounding a wellbore. The integrated structure may comprise a plurality of modules arranged in a stacked arrangement. The stacked arrangement may be a horizontal stacked arrangement. The stacked arrangement may be a vertical stacked arrangement. The two or more modules may be arranged in an abutting vertically stacked relationship. At least one module may be arranged in an abutting horizontally side-by-side arrangement. The two or more modules may be arranged in a combination of a vertical stack with at least one module branching off in a horizontally side-by-side arrangement. The two or more modules may be mounted or connected in a vertical and/or horizontal offset arrangement. The tubular may be selected from the group comprising: pipe, drill pipe, drill collars, conductor; reamers, shouldered pipe, risers, production pipe, composite pipe, well casing, utility line, wireline, slickline, coiled tubing and/or work over equipment.

The system may comprise two or more modules. The two or more modules may be configured to operate independently from one another. The two or more modules to move and/or operate sequentially, synchronized, alternating, overlapping and/or staggered. The wellbore operation may be selected from the group comprising installation of: pipe, drill pipe, drill collars, reamers, shouldered pipe, risers, production pipe, composite pipe, well casing, utility line, wireline, slickline and/or work over equipment. The wellbore operation may be selected from the group comprising removal of: pipe, drill pipe, drill collars, reamers, shouldered pipe, risers, production pipe, composite pipe, well casing, utility line, wireline, slickline and/or work over equipment. The wellbore operation may be a running in, pulling out, drilling, milling, workover, completion and/or decommissioning operation.

The at least one module may be selected from the group comprising; lifting module, crane module, jib crane module, iron roughneck, platforms, platform walkway, pipe deck, stairs, stair tower, transverse substructure, trip tank, jacking frame, fingerboard, service container, catwalk, slip assembly, top drive assembly, elevator assembly, lubricator system, mast; support mast; monkey arm, racker, radial racker, BOP module, base frame, diamond cutter, skidding system, BOP substructure, driller cabin, motor control centre sub-structure, bell nipple frame, pipe handling module and/or tubular storage module. The system may comprise bridge and/or automation packages. The at least one platform may be an open or closed platform. The size and/or height of installation of the at least one platform may depend on the operation. The at least one platform may be a telescopic or extendable platform, The at least one platform may comprise a telescopic or extendable section at the front enabling access to the moving platform.

The at least one module may comprise at least one lifting module. The at least one lifting module may comprise at least one lifting mechanism. Each lifting module may comprise two or more lifting mechanisms. The at least one lifting module may comprise a movable platform. The movable platform may be configured to move in a substantially vertical direction by the at least one lifting mechanism. The movable platform may be a moving table, a moving platform and/or a load beam. The at least one lifting module may comprise a stationary member. The at least one lifting mechanism may be mounted between the movable platform and the stationary member. The stationary member may be a stationary platform. The at least one lifting mechanism may be configured to move the movable platform vertically relative to the position of the stationary member. The at least one lifting mechanism may be configured to move the movable platform up and/or down vertically towards and/or away from the stationary member. The movable platform may comprise at least one tubular gripper apparatus. The movable platform may comprise a slip assembly. The slip assembly may be configured to selectively grip at least one tubular. The slip assembly may be configured to selectively grip at least one section of a tubular string. The movable platform may comprise a top drive assembly.

The at least one lifting module may comprise at least one iron roughneck. The at least one iron roughneck may be configured to selectively and/or sequentially grip at least one connection joint of a tubular member. The at least one iron roughneck may be configured to make up or break joint between a tubular member and a tubular string. The iron roughneck may be positioned on the movable platform. The iron roughneck may be positioned on a stationary platform. The iron roughneck may be positioned above the slip assembly. The iron roughneck may be configured to move parallel to one of the lifting system. The iron roughneck may comprise at least one jaw member. The at least one jaw member may be configured to grip a tubular member. The at least one jaw member may be configured to grip at least a section of a tubular member. The at least one lifting module may be configured to sequentially grip, lift and release a tubular member. The at least one lifting module may be a lower or base module. The at least one lifting module may be mounted on or to a lower or base module. The at least one lifting module may be an upper module.

The at least one lifting mechanism may be selected from the group comprising a jack system, screw jack, hydraulic cylinder, pulley system, rack and pinion system, linear motor or any other lifting device. The at least one lifting mechanism may be configured to pull a tubular member out of the well or push a tubular member into a well. The lifting mechanism may be configured to pull a section of a tubular out of the well or push a section of a tubular into a well. The lifting mechanism may be configured to pull a tubular out of the well or push a tubular into a well. The lifting mechanism may be a dual action mechanism. The lifting mechanism may be configured to provide a lifting or pulling force in a first mode. The lifting mechanism may be configured to provide a lowering or pushing force in a second mode. The lifting mechanism may be configured to provide a lifting or pulling force in a substantially upward or uphole direction in a first mode. The lifting mechanism may be configured to provide a lowering or pushing force in a substantially downward or downhole direction in a second mode. The at least one module may comprise at least one pipe handling module. The pipe handling module may comprise an elevator or gripper. The pipe handling module may comprise a crane system. The at least one pipe handling module may comprise at least one component of pipe lifting equipment. The at least one component of pipe lifting equipment is configured to lift a pipe section accommodated on a rack of a pipe storage module.

The system may comprise two or more lifting modules. The two or more lifting modules may be configured to move and/or actuate independently. The two or more lifting modules may be configured to move and/or actuate sequentially, synchronized, alternating, overlapping and/or staggered. The two or more lifting modules may be a dual action mechanism. The two or more lifting modules may be a dual action mechanism adding the full capacity of both lifting systems regarding speed and load. The two or more lifting modules may be hydraulically connected with each other to re-use working fluids from one lifting system to the other. The two or more lifting modules may be configured to transfer lifting and/or lowering of a tubular between the two or more lifting modules. The two or more lifting modules may be configured to handover a tubular between the modules. In a tubular lifting configuration, a first lifting module may be configured to lift a tubular a first distance. A second lifting module may be configured to lift the tubular a second distance. In a tubular lowering configuration, a second lifting module may be configured to lower a tubular a first distance. A first lifting module may be configured to lower the tubular a second distance. The system may be configured for continuously and/or automatic tripping. The first lifting module and second lifting module may be configured to handover a tubular between the first lifting module and second lifting modules. The first lifting module and second lifting module may be configured to transfer a load between the first lifting module and second lifting modules. The first lifting module may be configured to transfer a load acting the first lifting module directly to a support or base structure. The second lifting module may be configured to transfer a load acting the second lifting module directly to a support or base structure. This may mitigate loads acting the on the second lifting module being transfer through the first lifting module to the base structure.

The second lifting module may comprise a top drive assembly and/or an elevator system. The first lifting module may be a lower lifting module. The second lifting module may be an upper lifting module. Each of the two or more lifting modules may be configured to sequentially grip, lift, and release a tubular member. The first lifting module may be a lower or base module. The first lifting module may be mounted on or to a lower or base module. The second lifting module may be an upper module.

The system may comprise two or more lifting mechanisms. The two or more lifting mechanisms may be configured to move and/or actuate independently. The two or more lifting mechanisms may be configured to move and/or actuate sequentially, synchronized, alternating, overlapping and/or staggered. The two or more lifting mechanisms may be a dual action mechanism. The two or more lifting mechanisms may be a dual action mechanism adding the full capacity of both lifting systems regarding speed and load. The two or more lifting mechanisms may be hydraulically connected with each other to re-use working fluids from one lifting system to the other. The two or more lifting mechanisms may be configured to transfer lifting and/or lowering of a tubular between the two or more lifting mechanisms. The two or more lifting mechanisms may be configured to handover a tubular between the mechanisms. In a tubular lifting configuration, a first lifting mechanism may be configured to lift a tubular a first distance. A second lifting mechanism may be configured to lift the tubular a second distance. In a tubular lowering configuration, a second lifting mechanism may be configured to lower a tubular a first distance. A first lifting mechanism may be configured to lower the tubular a second distance. The system may be configured for continuously and/or automatic tripping. The first lifting mechanism and second lifting mechanism may be configured to handover a tubular between the first lifting mechanism and second lifting mechanism. The first lifting mechanism and second lifting mechanism may be configured to transfer a load between the first lifting mechanism and second lifting mechanism. The first lifting mechanism may be configured to transfer a load acting the first lifting mechanism directly to a support or base structure. The second lifting mechanism may be configured to transfer a load acting the second lifting mechanism directly to a support or base structure. This may mitigate loads acting the on the second lifting mechanism being transferred through the first lifting mechanism to the base structure. The first lifting mechanism may be a lower lifting mechanism. The first lifting mechanism may be a lower or base module. The second lifting mechanism may be an upper lifting mechanism. Each of the two or more lifting mechanism may be configured to sequentially grip, lift, and release a tubular member. The first lifting mechanism may be mounted on or to a lower or base module. The second lifting mechanism may be an upper module. The first lifting mechanism and the second lifting mechanism may be located in or on the same lifting module.

The system may comprise a control system. The control system may be configured to control the positioning and/or actuation of the at least one module of the system. The control system may be configured to control the positioning and/or actuation of at least one component of the at least one module of the system. The control system may be configured to control the positioning and/or actuation of at least one a lifting mechanism, iron roughneck, slip assembly, top drive assembly, crane system, elevator assembly, lubricator handling system, monkey arm and/or pipe handling apparatus.

The control system may be configured to control the position and/or actuation of a first lifting module and/or a second lifting module. The control system may be configured to control a sequential, synchronized, alternating, overlapping and/or staggered movement or actuation of the first lifting module and second lifting module relative to one another. The two or more lifting modules may be arranged in a stacked configuration with one lifting module located above another lifting module. The stacked two or more lifting modules may facilitate continuous well bore operations. The stacked two or more lifting modules may facilitate continuous tripping, drilling and/or milling operations. The control system may be configured to control a sequential, synchronized, alternating, overlapping and/or staggered movement or actuation of the first lifting mechanism and second lifting mechanism relative to one another. The two or more lifting mechanisms may be arranged in a stacked configuration with one lifting mechanism located above another lifting mechanism. The two or more lifting mechanisms may be arranged in one lifting module. The two or more lifting mechanisms may be located in one lifting module arranged in side by side configuration. The two or more lifting mechanisms may facilitate continuous well bore operations. The two or more lifting mechanisms may facilitate continuous tripping, drilling and/or milling operations. The storage module may comprise one or more racks for accommodating a plurality of tubular member sections. Each of the modules may comprise a rig component. The at least one module may be connected or interconnected together to form a modular system with the functionality of a rig. The modular system may be an offshore or onshore modular rig.

According to a second aspect of the invention, there is provided a well comprising a modular system according to the first aspect of the invention installed around and/or above the well.

Embodiments of the second aspect of the invention may include one or more features of the first aspect of the invention or its embodiments, or vice versa.

According to a third aspect of the invention, there is provided a modular wellbore tubular lifting system, the system comprising:

The frame of the at least one functional module may be load-bearing. The integrated structure when it is assembled may be configured to distribute loads acting on a frame of the at least one the functional module.

Embodiments of the third aspect of the invention may include one or more features of any of the first or second aspects of the invention or their embodiments, or vice versa.

According to a fourth aspect of the invention, there is provided a modular system for movement of tubulars into or from a well; the system comprising:

The one or more modules may be arranged in a first stacked or ordered configuration in first well operation mode. The one or more modules may be arranged in a second stacked or ordered configuration in second well operation mode. The stack or order of the one or more modules may be different in the first and second well operation modes. At least one or more modules may be different in the first and second well operation modes. The well operation may be a hydrocarbon well operation, a geothermal well operation or a carbon capture storage well operation. The at least one module may be selected from the group comprising lifting module; crane module; BOP module; pipe handling module and/or tubular storage module.

Embodiments of the fourth aspect of the invention may include one or more features of any of the first to third aspects of the invention or their embodiments, or vice versa.

According to a fifth aspect of the invention, there is provided a method of installing modular wellbore tubular lifting system above a well, method comprising:

The system may comprise two or more modules. The method may comprise arranging the two or more modules in a stacked arrangement to form an integrated structure. The integrated structure may comprise a load-bearing frame. The method may comprise re-arranging at least one module into a second configuration. The method may comprise re-arranging the two or more modules in a form of an integrated structure in a second stacked arrangement. The method may comprise removably attaching or removably mounting the at least one modules to one another to form an integrated structure. The at least one module to may be connected to one another by pins, manually actuated pins, hydraulically actuated pins, welds, bolts, clips, latches and/or flanges pins. The at least one module may be manually and/or hydraulically operated

The system may comprise at least one lifting module. The at least one lifting module may comprise at least one lifting mechanism. The system may comprise two or more lifting modules. The method may comprise arranging a first lifting module above a second lifting module. The method may comprise stacking the first lifting module above the second lifting module. The method may comprise arranging a second lifting module above a first lifting module. The method may comprise stacking the second lifting module above the first lifting module. The method may comprise positioning, locating, coupling and/or stacking the at least one lifting modules parallel, side by side and/or next to each other. The method may comprise positioning, locating, coupling and/or stacking the at least one modules on top of one another. The method may comprise positioning, locating, coupling and/or stacking the at least one modules parallel, side by side and/or next to each other.

Embodiments of the fifth aspect of the invention may include one or more features of any of the first to fourth aspects of the invention or their embodiments, or vice versa.

According to a sixth aspect of the invention, there is provided a method of reconfiguring a modular wellbore tubular lifting system, the method comprising:

The method may comprise removably attaching and/or removably mounting the at least one modules to one another to form an integrated structure. The at least one module may be connected to one another by pins, manually actuated pins, hydraulically actuated pins, welds, clips, latches, bolts and/or flanges pins. The system may comprise two or more modules. The method may comprise removably attaching and/or removably mounting the two or more modules in a stacked arrangement to form an integrated structure. The method may comprise re-arranging a stacked arrangement of at least a first module into the second configuration. The method may comprise re-arranging two or more modules in a first stacked configuration to form a second stacked configuration. The system may comprise at least one lifting module. The at least one lifting module may comprise at least one sub-module. Each sub-module may comprise at least one lifting mechanism. The system may comprise two or more lifting modules. The method may comprise arranging a first lifting module above a second lifting module. The method may comprise stacking a first lifting module above a second lifting module. The method may comprise assembling and/or reconfiguring the arrangement of at least one module in a second arrangement for a second well operation. The method may comprise adding, removing and/or repositioning at least one module in the second arrangement. When not in use, at least one or more modules may be put into storage to optimize the use of space on the rig, floor, deck and/or platform. The method may comprise assembling and/or reconfiguring the arrangement of at least one module in a third arrangement for a third well operation. The method may comprise adding, removing and/or repositioning at least one module in the third arrangement. The method may comprise removably mounting a BOP module below at least one lifting module. The method may comprise removably mounting a crane module above at least one lifting module. The method may comprise removably mounting a pipe handling module above the at least one lifting module. The method may comprise removably mounting two or more lifting modules in series above a BOP module. The method may comprise transferring a hoisting load directly to the base structure. This may avoid transferring loads acting on the upper hoisting through the lower hoisting system down to the base structure.

Embodiments of the sixth aspect of the invention may include one or more features of any of the first to fifth aspects of the invention or their embodiments, or vice versa.

According to a seventh aspect of the invention, there is provided a method of removing a tubular member from a wellbore, the method comprising:

The lifting module may comprise at least a first lifting mechanism and a second lifting mechanism. The method may comprise lifting the tubular member a first distance out of the wellbore using the first lifting mechanism and lifting the tubular member a second distance out of the wellbore using the second lifting mechanism. The system may comprise a second lifting module comprising a lifting mechanism. The method may comprise lifting the tubular member a first distance out of the wellbore using the first lifting module and lifting the tubular member a second distance out of the wellbore using the second lifting module. The method may comprise actuating the first and second lifting modules independently. The method may comprise actuating the first and second lifting mechanisms independently. The method may comprise actuating the first and second lifting modules to sequentially, synchronized or alternatively lift the tubular member. The method may comprise actuating the first and second lifting mechanisms to sequentially, synchronized or alternatively lift the tubular member The method may comprise transferring the lifting of the tubular between the two or more lifting modules and/or between the two or more lifting mechanisms. The ability to transfer lifting between the two or more lifting modules and/or two or more lifting mechanisms may speed up the recovery of the tubular from the well. While one lifting member is lifting the tubular the other lifting member may be repositioning itself to a takeover position to allow a continuous lifting action. The method may comprise actuating a slip assembly to grip the tubular. The method may comprise actuating a first lifting mechanism to lift the movable platform of the first lifting module and gripped tubular string to a first distance or a first height. The method may comprise actuating the first lifting mechanism to lift the movable platform of the first lifting module and gripped tubular string to a tubular grip handover position. The method may comprise actuating the second lifting mechanism to lower a movable platform on the second lifting module or support module to a tubular grip handover position. The movable platform on the second lifting module or lift support module may be a load beam.

The method may comprise actuating a gripping system on a top drive assembly to grip the tubular. The method may comprise actuating the slip assembly on the movable platform on the first lifting module to release the tubular. The method may comprise actuating the second lifting mechanism to lift the movable platform on the second lifting module or lift support module to pull or lift the tubular string to a second distance or a second height. The method may comprise actuating the first lifting mechanism to reposition the movable platform of the first lifting module. The method may comprise actuating the first lifting mechanism to lower the first lifting module to a tubular break position. The method may comprise moving the at least one iron roughneck assembly into alignment with a connection on the tubular. The method may comprise breaking the connection joint with the iron roughneck assembly. The method may comprise actuating the iron roughneck to break the connection between the tubular and the tubular string. The method may comprise de-actuating the iron roughneck.

The method may comprise actuating an elevator system to tilt the disconnected tubular member. The method may comprise lowering the disconnected pipe to a laydown area. The method may comprise transporting disconnected tubulars to a buffer zone area. The method may comprise actuating a crane module to pick up and/or transport a bundle of disconnected pipes. The method may comprise moving a disconnected tubular member to a tubular storage area using the pipe handling system. The method may comprise moving a disconnected tubular member to a temporary intermediate buffer and/or storage area. Providing an intermediate buffer and/or area may optimize cycle times. The method may comprise providing a radial racking system and/or vertical storage system. The method may comprise providing a monkey arm connected to the lower hoisting frame. The method may comprise moving a position of a tubular and/or at least one module using a monkey arm. The method may be automated or semi-automated. The method may comprise connecting the top drive to a mud circulation system. The method may comprise actuating the slip assembly. The method may comprise lifting the disconnected tubular member from the tubular string.

Embodiments of the seventh aspect of the invention may include one or more features of any of the first to sixth aspects of the invention or their embodiments, or vice versa.