Tool detection and alignment for tool installation

• US 10,465,457 B2
• Filed: 08/10/2016
• Issued: 11/05/2019
• Est. Priority Date: 08/11/2015
• Status: Active Grant

• Current Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Original Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Inventors: Hebebrand, Christina Karin, Thiemann, Bjoern, Liess, Martin, Wern, Frank, Zouhair, Aicam, Ownby, John Fielding
• Primary Examiner(s): Bagnell, David J
• Assistant Examiner(s): Duck, Brandon M
• Application Number:
  US15/233,333
• Publication Number:
  US 20170044854A1
• Time in Patent Office: 1,182 Days
• CPC Class Codes: E21B 19/00 Handling rods, casings, tubes or the like outside the borehole, e.g. in the derrick; Apparatus for feeding the rods or cables
• CPC Class Codes: E21B 19/165 Control or monitoring arrangements therefor
• CPC Class Codes: E21B 3/022 Top drives
• CPC Class Codes: E21B 44/00 Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
• CPC Class Codes: E21B 47/002 by visual inspection
• CPC Class Codes: G06T 2207/10012 Stereo images
• CPC Class Codes: G06T 7/0004 Industrial image inspection

Abstract

A modular top drive system for construction of a wellbore includes an alignment assembly configured to align a tool with a top drive unit to facilitate automatic tool installation during rig up.

Claims

1. A modular top drive system, comprising:

a top drive unit for selectively connecting to a tool;

a tool exchange unit movable relative to the top drive unit to move the tool relative to the top drive unit; and

an alignment assembly attached to the top drive unit and configured to detect at least one of a relative position and a relative orientation between the top drive unit and the tool;

wherein the top drive unit is movable relative to the tool exchange unit.

2. The modular top drive system of claim 1, wherein the alignment assembly comprises first, second, and third proximity sensors.

3. The modular top drive system of claim 2, further comprising fourth, fifth, and sixth proximity sensors corresponding to the first, second, third proximity sensors respectively, wherein the first, second, and third proximity sensors are disposed along x, y, z axis of a Cartesian coordinate system, and the fourth, fifth, and sixth proximity sensors are disposed along x, y, z of the Cartesian coordinate system respectively.

4. The modular top drive system of claim 1, wherein the alignment assembly comprises two or more proximity sensors disposed along a coordinate system.

5. The modular top drive system of claim 1, wherein the alignment assembly comprises one of a laser sensor, a field strength sensor, an ultrasound sensor, a three dimensional camera, a two dimensional camera, and a combination thereof.

6. The modular top drive system of claim 1, further comprises an identification reader configured to obtain tool information from identification devices on tools.

7. The modular top drive system of claim 1, wherein the alignment assembly interacts with a target assembly coupled to the tool exchange unit to detect the at least one of the relative position and the relative orientation between the top drive unit and the tool.

8. The modular top drive system of claim 1, wherein the alignment assembly is configured to detect the relative position and the relative orientation between the top drive unit and the tool.

9. The modular top drive system of claim 1, wherein the tool exchange unit is configured to retrieve the tool from a storage unit.

10. A modular top drive system, comprising:

a top drive unit for selectively connecting to a tool; and

an alignment assembly having a self-alignment structure and configured to detect at least one of a relative position and a relative orientation between the top drive unit and the tool, the self-alignment structure comprising;

a funnel attached to the top drive unit; and

an alignment pole attached to a tool exchange unit, wherein the alignment pole is configured to insert into the funnel and reach an apex of the funnel.

11. The modular top drive system of claim 10, further comprising a sensor disposed on a top of the alignment pole.

12. The modular top drive system of claim 11, further comprising one or more proximity sensors disposed on the top drive unit or the tool exchange unit to prevent collision.

13. The modular top drive system of claim 10, wherein the alignment assembly is configured to detect the relative position and the relative orientation between the top drive unit and the tool.

14. A tool exchange unit configured to install a tool to a top drive unit, comprising:

a tool holder configured to grip the tool;

an actuation assembly configured to move the tool holder and the tool relative to the top drive unit from a first position suspended below the top drive unit to a second position, wherein the tool is inserted in the top drive unit in the second position; and

an alignment assembly coupled to the tool holder and configured to detect at least one of a location and an orientation of the top drive unit relative to the tool gripped by the tool holder;

wherein the top drive unit is movable relative to the tool holder, actuation assembly, and the alignment assembly.

15. The tool exchange unit of claim 14, wherein the alignment assembly comprises one or more cameras, a self-alignment structure, a laser sensor, a field strength sensor, an ultrasound sensor, or one or more proximity sensors.

16. The tool exchange unit of claim 14, wherein the alignment assembly interacts with a target assembly attached to the top drive unit to detect the at least one of the location and the orientation of the top drive unit relative to the tool gripped by the tool holder.

17. The tool exchange unit of claim 14, wherein the tool exchange unit is movable horizontally relative to the top drive unit.

18. The tool exchange unit of claim 14, wherein the alignment assembly is configured to detect the relative location and the relative orientation of the top drive unit relative to the tool gripped by the tool holder.

19. A method for operating a top drive system, comprising:

retrieving a tool using a tool exchange unit;

moving the tool relative to a top drive unit to a first position below the top drive unit by moving the tool exchange unit relative to the top drive unit;

aligning the tool with the top drive unit using an alignment assembly configured to detect at least one of a relative position and a relative orientation between the top drive unit and the tool; and

inserting the tool into the top drive unit.

20. The method of claim 19, further comprising positioning the tool proximate the top drive unit.

21. The method of claim 19, wherein aligning the tool with the top drive unit comprises:

monitoring distances between a target assembly mounted on the top drive unit and the alignment assembly mounted on the tool exchange unit; and

moving the tool exchange unit to adjust a distance or an orientation between the top drive unit and the tool.

22. The method of claim 19, wherein the alignment assembly is a funnel attached to the top drive unit, and wherein aligning the tool with the top drive unit comprises:

moving the tool exchange unit upward to insert an aligning pole attached to the tool exchange unit into the funnel; and

monitoring a distance between the aligning pole and the funnel and correcting the upward movement of the tool exchange unit to avoid contact between the alignment pole and the funnel.

23. The method of claim 19, wherein the alignment assembly further comprises at least one camera, and wherein aligning the tool with the top drive unit comprises:

capturing a three dimensional image of the top drive unit or the tool;

analyzing the three dimensional image to determine a distance or an orientation between the top drive unit and the tool; and

moving the tool exchange unit to adjust the distance or the orientation.

24. The method of claim 19, wherein the alignment assembly interacts with a target assembly to detect the at least one of the relative position and the relative orientation between the top drive unit and the tool.

25. The method of claim 19, wherein the alignment assembly is configured to detect the relative position and the relative orientation between the top drive unit and the tool.

26. The method of claim 19, wherein the tool is retrieved from a storage unit.