The Next Major Step in Total Hands-Free Pipe Handling—No Derrickman in the Derrick Racking and Unracking Pipe

Abstract

Abstract The paper identifies the challenges that were overcome to realize hands free tripping, racking and un-racking of drill pipe and collars in medium and large land based drilling rigs through the development of a new technology racking board pipe handling system. The steps of development and design involving Mechanical, Electrical and Robotic Motion Control Engineering Technologies combined with drilling operations knowledge and experience are laid out to show how adapting these new ideas to existing double and triple drilling rig masts without any structural mast modifications was achieved. A comparison to offshore racking board pipe handling systems highlights the technical and economic difficulties experienced in applying the land based systems successfully with frequent moves, weight/size restrictions and reliability concerns. Field gathered tripping and connection test times in comparison to a human Derrickman working the racking board are put forward. Field tests further describe how drilling hands on the drill floor typically needed to set pipe back and lead pipe into well center during tripping in-hole and out-hole are eliminated. The paper looks at how conventional robotic motion control technology has resulted in reliable "Nintendo-style" control operation with smooth solid control of moving pipe. Further discussions in the paper examine the current obstacles that remain to completely remove drilling personnel from the harms way on the drill floor. Finally, the paper will show how this direction of design development and implementation in safe drilling rig equipment is necessary to keep employees healthy, productive, profitable and working in the drilling industry.