Modular well tubular handling system and method of use

Abstract

The invention provides a modular rig system for wellbore operations. The system comprises two or more modules, each module comprising at least one rig system component. The two or more modules are configured to be connected or interconnected together so as to form an integrated structure.

1 . A modular tubular lifting and handling system, the system comprising:
 two or more modules wherein each module comprises at least one system component;   wherein the two or more modules are configured to be connected or interconnected together so as to form an integrated structure;
 wherein the two or more modules are configured to be assembled and/or arranged into a first configuration to perform one or more tubular member lifting and handling tasks in a first wellbore operation; and 
 wherein the two or more modules are configured to be assembled and/or arranged into a second configuration to perform one or more tubular member lifting and handling tasks in a second wellbore operation. 
   
     
     
         2 . The modular system according to  claim 1  configured to be assembled, positioned and/or installed substantially above and/or adjacent to a wellbore. 
     
     
         3 . The modular system according to  claim 1  wherein the two or more modules comprise a frame wherein the frames of the two or more modules are assembled together to form the integrated structure. 
     
     
         4 . (canceled) 
     
     
         5 . (canceled) 
     
     
         6 . The modular system according to  claim 1  wherein the two or more modules are configured to be arranged in a different configurations by adding to or removing at least one module from the integrated structure depending on the wellbore operation. 
     
     
         7 . The modular system according to  claim 1  wherein the two or more modules are arranged in a vertical and/or horizontal stacked arrangement. 
     
     
         8 . The modular system according to  claim 1  wherein the arrangement of the two or more modules in the integrated structure are configured to transfer loads acting on each of the two or more modules directly to a base support structure. 
     
     
         9 . The modular system according to  claim 1  wherein the modular system is selected from the group comprising a tubular handling system, a tubular lifting system, a pipe removal system, a conductor pipe handling system, a drill system and/or a wireline system. 
     
     
         10 . The modular system according to  claim 1  wherein the wellbore operation is selected from the group comprising running in, pulling out, drilling, milling, workover, completion and/or decommissioning operation. 
     
     
         11 . The modular system according to  claim 1  wherein the two or more modules is selected from the group comprising lifting module, crane module, iron roughneck, platforms, slip assembly, top drive assembly, elevator assembly, lubricator system, mast; support mast; catwalk module, monkey arm, racker, radial racker, BOP module, base support module, lift support module, crane module, jib crane module, diamond cutter, skidding system, driller cabin, motor control centre, sub-structure, bell nipple frame, pipe handling module and/or tubular storage module. 
     
     
         12 . The modular system according to  claim 11  wherein at least one module comprises at least one lifting module. 
     
     
         13 . The modular system according to  claim 12  wherein the at least one lifting module comprises at least one lifting mechanism 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. 
     
     
         14 . The modular system according to  claim 1  comprising two or more lifting mechanisms where a first lifting mechanism is configured to lift or lower a tubular a first distance and a second mechanism is configured to lift and/or lower a tubular a second distance. 
     
     
         15 . The modular system according to  claim 14  wherein the two or more lifting mechanisms are hydraulically connected and configured to transfer hydraulic fluids between the two or more lifting mechanisms. 
     
     
         16 . The modular system according to  claim 1  wherein the two or more modules are configured for continuously and/or automatic tripping. 
     
     
         17 . A method of configuring a modular tubular lifting and handling system comprising:
 providing a modular tubular lifting and handling system comprising two or more modules wherein each module comprises at least one system component, wherein the two or more modules are configured to be connected or interconnected together to form an integrated structure, wherein the two or more modules are configured to be assembled and/or arranged into a first configuration to perform one or more tubular member lifting and handling tasks in a first wellbore operation, and wherein the two or more modules are configured to be assembled and/or arranged into a second configuration to perform one or more tubular member lifting and handling tasks in a second wellbore operation; and   assembling the two or more modules in a first configuration to form an integrated structure to perform a first well operation.   
     
     
         18 . The method according to  claim 17  comprising assembling the two more modules into at least a second configuration to perform at least a second well operation. 
     
     
         19 . The method according to  claim 17  wherein the first well operation and/or second well operation is selected from the group comprising a wellbore tubular lifting operation, a drilling operation, a pipe removal operation, a conductor jacking operation, completion operation and/or a wireline operation. 
     
     
         20 . The method according to  claim 17  comprising arranging the two or more modules in a stacked or connected arrangement to form an integrated structure. 
     
     
         21 . The method according to  claim 17  comprising removing, adding and/or repositioning at least one module in the integrated structure to form the second configuration. 
     
     
         22 . A method of operating a modular tubular lifting and handling system comprising:
 providing a modular tubular lifting and handling system comprising two or more modules, each module comprising at least one system component, wherein the two or more modules are configured to be connected or interconnected together so as to form an integrated structure, wherein the two or more modules are configured to be assembled and/or arranged into a first configuration to perform one or more tubular member lifting and handling tasks in a first wellbore operation, and wherein the two or more modules are configured to be assembled and/or arranged into a second configuration to perform one or more tubular member lifting and handling tasks in a second wellbore operation;   assembling the two or more modules in a first configuration to form an integrated structure;   performing a first well operation;   reconfiguring the two or more module to form a second configuration; and   performing a second well operation.   
     
     
         23 . The method according to  claim 22  wherein the first or second well operation is a tubular handling operation, wherein system comprises at least one lifting module comprising a lifting mechanism configured to lift and/or lower a tubular; and
 actuating the lifting mechanism to lift or lower a tubular section out from or into the wellbore. 
 
     
     
         24 . The method according to  claim 22  wherein the first or second well operation is a drilling operation, wherein system comprises at least one lifting module and a top drive module, and wherein the at least one lifting module comprises two or more lifting mechanisms configured to support the load of the top drive module, the method further comprising:
 moving a top drive module connected to a drill pipe member a first vertical distance using a first lifting mechanism; 
 transferring the load of the top drive module to a second lifting mechanism; and 
 moving the top drive module a second vertical distance using the second lifting mechanism. 
 
     
     
         25 . The method according to  claim 22  wherein the first or second well operation is
 a wireline operation, and wherein the system comprises at least a wireline assembly and a crane module, the method further comprising:
 lifting the wireline assembly into position above the wellbore; 
 passing a wireline into the well; and 
 conducting the wireline operation.