Advanced rig design for automated tubular installation and removal operations

Abstract

A tubular handling system includes at least one first storage tub configured to hold one or more tubular singles, at least one second storage tub configured to hold one or more stands of tubulars having two or more tubular singles, and a catwalk operable between the at least one second storage tub and a rig floor, wherein the catwalk is configured to allow the stands of tubulars to be transferred from the catwalk to the rig floor.

1 . A tubular handling system comprising:
 at least one first storage tub configured to hold one or more tubular singles;   at least one second storage tub configured to hold one or more stands of tubulars comprising two or more tubular singles; and   a catwalk operable between the at least one second storage tub and a rig floor, wherein the catwalk is configured to allow the stands of tubulars to be transferred from the catwalk to the rig floor.   
     
     
         2 . The system of  claim 1 , further comprising a bucking machine configured to assemble tubular singles into stands of tubulars. 
     
     
         3 . The system of  claim 2 , further comprising one or more pipe handler arms configured to transfer stands of tubulars from the bucking machine to the at least one storage tub. 
     
     
         4 . The system of  claim 2 , further comprising one or more pipe handler arms configured to transfer tubular singles from the at least one first storage tub to the bucking machine. 
     
     
         5 . The system of  claim 1 , further comprising one or more pipe handler arms configured to transfer stands of tubulars from the at least one storage tub to the catwalk. 
     
     
         6 . The system of  claim 1 , further comprising a top drive unit, wherein the top drive unit configured to retract and pick up stands of tubulars from the catwalk. 
     
     
         7 . The system of  claim 1 , wherein at least one of the first and second storage tubs is sloped. 
     
     
         8 . The system of  claim 1 , further comprising one or more horizontal dividers positioned between rows of stands of tubulars. 
     
     
         9 . A method of handling tubulars, comprising:
 making up two or more tubular singles into one or more stands of tubulars;   transferring the one or more stands of tubulars into one or more storage tubs;   transferring the one or more stands of tubulars from at least one storage tub to an automated catwalk; and   transferring the one or more stands of tubulars from the automated catwalk directly to a drilling rig floor.   
     
     
         10 . The method of  claim 9 , further comprising making up the two or more tubular singles into one or more stands of tubulars with a bucking machine. 
     
     
         11 . The method of  claim 9 , further comprising transferring the one or more stands of tubulars from the automated catwalk with a top drive unit. 
     
     
         12 . The method of  claim 9 , further comprising storing the one or more tubular singles in a storage tub. 
     
     
         13 . The method of  claim 9 , further comprising transferring the one or more stands of tubulars with pipe handler arms.