Robotic apparatus for performing drill floor operations

Abstract

A robotic apparatus (1) for performing drill floor operations comprises a support arrangement (2) and at least one manipulator arm (6). The at least one manipulator arm (6) is configured to carry an end effector (11) configured to manipulate one or more of tubing, tools and/or equipment on a drill floor (d) or pipe deck of an oil and gas rig in order to perform a given drill floor operation.

Claims

1. A self-propelled robotic apparatus for performing offshore drill floor operations, comprising: a support arrangement having an onboard electric power supply including a battery; at least one manipulator arm configured for coupling to the support arrangement, the at least one manipulator arm is configured to carry an end effector configured to manipulate tubing, tools or equipment in order to perform a predetermined drill floor operation; wherein the support arrangement is configured to move across an offshore drill floor, and the movement is powered by the onboard power supply; and wherein the support arrangement comprises an omni-directional drive unit disposed on an undercarriage and having one or more omni-directional rollers.

2. The robotic apparatus according to claim 1, wherein the onboard power supply provides power for moving on the drill floor.

3. The robotic apparatus according to claim 1, wherein the onboard power supply provides power for the apparatus to move between a storage position and a deployed position.

4. The robotic apparatus according to claim 3, wherein the apparatus may be configured to move between the storage position and the deployed position via one or more intermediate locations disposed on the drill floor.

5. The robotic apparatus according to claim 1, and comprising an onboard hydraulic power system receiving from external hydraulic lines hydraulic power required by the least one manipulator arm for performing a predetermined work task.

6. The robotic apparatus according to claim 1, wherein the battery is a rechargeable battery.

7. A robotic apparatus for performing drill floor operations, comprising: a support arrangement having an onboard electric power supply including a battery; at least one manipulator arm configured for coupling to the support arrangement, the at least one manipulator arm is configured to carry an end effector configured to manipulate tubing, tools or equipment in order to perform a predetermined drill floor operation; wherein the support arrangement is configured to move across an offshore drill floor, and the movement is powered by the onboard power supply; wherein the onboard power supply provides power for moving on the drill floor; and wherein the support arrangement includes a continuous track system, and is configured to utilize the onboard power supply to power the continuous track system and maneuver the apparatus from a docking station which forms a storage location for the apparatus to a work location around a well center on the drill floor.

8. The robotic apparatus according to claim 7, wherein the continuous track system comprises a multi-directional caterpillar drive.

9. The robotic apparatus according to claim 7, wherein the continuous track system comprises a track driven by a number of wheels, wherein the track comprises a plurality of interconnected chain links, and wherein the wheels are formed as sprocket wheels.

10. A robotic apparatus for performing drill floor operations, comprising: a support arrangement having an onboard electric power supply including a battery; at least one manipulator arm configured for coupling to the support arrangement, the at least one manipulator arm is configured to carry an end effector configured to manipulate tubing, tools or equipment in order to perform a predetermined drill floor operation; wherein the support arrangement is configured to move across the offshore drill floor, the movement is powered by the onboard power supply; wherein the support arrangement comprises a continuous track system and the apparatus is configured to move along a path determined by the type of operations to be carried out, and by equipment present on the drill floor.

11. A self-propelled robotic apparatus for performing offshore drill floor operations, comprising: a support arrangement configured to move the apparatus across an offshore drill floor; at least one manipulator arm configured for coupling to the support arrangement, the least one manipulator arm is configured to carry an end effector configured to manipulate tubing, tools or equipment in order to perform a predetermined drill floor operation; a visual sensor arrangement formed as a camera system operatively associated with a machine vision system; wherein the machine vision system being operatively associated with a machine learning system configured to control apparatus motions to perform given tasks; and wherein the apparatus through compliant motion control by the control system is configured to perform collaborative operations with other machinery on drill floor.

12. The robotic apparatus according to claim 11, comprising: a control system configured for using compliant motion control; wherein the control system is configured to apply supervised learning through which the apparatus is guided through a number of predefined sequences and thereby learn to perform Previously Presented tasks and operations.

13. The robotic apparatus according to claim 12, wherein the control system receives input from a sensor arrangement and is configured to perform inspection of tools.

14. The robotic apparatus according to claim 12, wherein the control system receives input from a sensor arrangement and is configured to perform identification operation, including reading of ID codes, or recognition of objects.

15. The robotic apparatus according to claim 14, wherein the control system is configured for personnel detection.

16. The robotic apparatus according to claim 11, wherein the visual sensor arrangement is operatively associated with a personnel detection and protection system for detecting the presence of human operators, wherein personnel detection and protection system is configured to issue a detection signal to be sent to a controller, wherein controller is adapted to issue a stop command or movement command to move away from the detected personnel.

17. The robotic apparatus according to claim 11, wherein the visual sensor arrangement includes proximity sensors, movement sensors, or thermals sensors for detecting personnel.

18. A self-propelled robotic apparatus for performing offshore drill floor operations, comprising: a support arrangement configured to move the apparatus across an offshore drill floor; at least one manipulator arm for coupling to the support arrangement, the least one manipulator arm is configured to carry an end effector configured to manipulate tubing, tools or equipment in order to perform a predetermined drill floor operation; a visual sensor arrangement formed as a camera system operatively associated with a machine vision system; a control system configured for using compliant motion control; wherein the machine vision system being operatively associated with a machine learning system configured to control apparatus motions to perform given tasks; wherein the control system is configured to apply supervised learning through which the apparatus is guided through a number of predefined sequences and thereby learn to perform tasks and operations; and wherein the control system receives input from the machine vision system and is configured to reliable sensing and object detection, and to control both the motion of the apparatus across the drill floor and motion of the at least one manipulator arm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform;

(2) FIG. 2 shows an enlarged perspective view of an end effector of the apparatus shown in FIG. 1;

(3) FIG. 3 shows an enlarged plan view of the end effector of the apparatus shown in FIG. 1;

(4) FIG. 4 shows an alternative robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform;

(5) FIG. 5 shows an enlarged perspective view of an end effector of the apparatus shown in FIG. 4;

(6) FIG. 6 shows an enlarged plan view of the end effector of the apparatus shown in FIG. 4;

(7) FIG. 7 shows an alternative robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform;

(8) FIG. 8 shows an enlarged perspective view of a first end effector of the apparatus shown in FIG. 7;

(9) FIG. 9 shows an enlarged plan view of the first end effector of the apparatus shown in FIG. 7;

(10) FIG. 10 shows an enlarged perspective view of a second end effector of the apparatus shown in FIG. 7;

(11) FIG. 11 shows an enlarged plan view of the second end effector of the apparatus shown in FIG. 7;

(12) FIG. 12 shows an alternative robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform;

(13) FIG. 13 shows an enlarged perspective view of a first end effector of the apparatus shown in FIG. 12;

(14) FIG. 14 shows an enlarged plan view of the first end effector of the apparatus shown in FIG. 12;

(15) FIGS. 15 to 18 a second end effector of the apparatus shown in FIG. 12;

(16) FIG. 19 shows an alternative application of the apparatus shown in FIG. 12;

(17) FIG. 20 shows an alternative robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform;

(18) FIG. 21 shows an enlarged perspective view of a first end effector of the apparatus shown in FIG. 20;

(19) FIG. 22 shows an enlarged plan view of the first end effector of the apparatus shown in FIG. 20;

(20) FIG. 23 shows an enlarged perspective view of a second end effector of the apparatus shown in FIG. 20;

(21) FIG. 24 shows an enlarged plan view of the second end effector of the apparatus shown in FIG. 20;

(22) FIGS. 25, 26 and 27 show side, front and bottom views respectively of a robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform, performing a drill floor operation;

(23) FIG. 28 shows an enlarged view of part of the apparatus shown in FIGS. 25 to 27;

(24) FIGS. 29 and 30 show side and front views respectively of a robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform, performing another drill floor operation;

(25) FIG. 31 shows a side view of a robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform, performing another drill floor operation;

(26) FIG. 32 shows a side view of a robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform, performing another drill floor operation;

(27) FIG. 33 shows a side view of a robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform, performing another drill floor operation;

(28) FIG. 34 shows a side view of a robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform, performing another drill floor operation;

(29) FIG. 35 shows a side view of a robotic apparatus for the manipulation of tubing, tools and/or equipment on a drill floor or pipe deck of an oil and gas platform, performing another drill floor operation;

(30) FIG. 36 is a flow chart of a method of performing a drill floor operation using the robotic apparatus; and

(31) FIG. 37 is a flow chart of a method of performing another drill floor operation using the robotic apparatus.

DETAILED DESCRIPTION OF THE DRAWINGS

(32) FIG. 1 of the accompanying drawings shows a robotic apparatus 1 for the manipulation of tubing, tools and/or equipment on a drill floor D of an oil and gas rig R.

(33) In use, the apparatus 1 is utilised to replace the manual operation of safety clamps and slips, e.g. when handling drill collars and bottom hole assemblies through the rotary.

(34) As shown in FIG. 1, the apparatus 1 comprises a support arrangement in the form of an undercarriage 2. In the illustrated apparatus 1, the undercarriage 2 is movable relative to the drill floor D and takes the form of a continuous track system having a track 3 which in use is driven by a number of wheels 4. In the illustrated apparatus 1, the track 3 is formed using interconnected chain links (not shown) and the wheels 4 take the form of sprocket wheels. However, it will be recognised that other drive arrangements may be provided.

(35) A manipulator arm 5 is coupled to the undercarriage 2. The manipulator arm 5 comprises a body 6 for coupling the manipulator arm 5 to the undercarriage 2, a first linkage element 7 and a second linkage element 8. The first linkage element 7 is coupled to the body 6 by an actuator 9. The actuator 9 provides a first degree of freedom of the manipulator arm 5. In the illustrated apparatus 1, the actuator 10 takes the form of a rotary actuator. The second linkage element 8 is coupled to the first linkage element 7 by an actuator 10. The actuator 10 provides a second degree of freedom of the manipulator arm 5. In the illustrated apparatus 1, the actuator 10 takes the form of a rotary actuator.

(36) As shown in FIG. 1, and referring also to FIGS. 2 and 3 of the accompanying drawings, an end effector—which in the illustrated apparatus 1 takes the form of a clamping tool 11—is connected at a distal end of the manipulator arm 5.

(37) As shown in FIGS. 2 and 3, the clamping tool 11 comprises a first jaw portion 12 and a second jaw portion 13. The first jaw portion 12 and the second jaw portion 13 are pivotably coupled together at hinge 14.

(38) In use, the clamping tool 11 is reconfigurable between an open configuration which facilitates location of the clamping tool 11 about a tubing section T and a closed configuration (as shown in FIGS. 2 and 3) permitting the clamping tool 11 to be secured about the tubing section T. The clamping tool 11 further comprises or is coupled to slips 15 for gripping the tubing section 19. In the illustrated apparatus 1, the slips 15 form part of the clamping tool 11. A lower section of the clamping tool 11 is tapered, providing a guide for location of another tubing section onto the tubing section T (as will be described further below).

(39) In use, the undercarriage 2 is moveable across the drill floor D from a first, storage, position to a second, deployed, position (as shown in FIG. 1). In the second, deployed, position the manipulator arm 5 and clamping tool 11 are operable to engage and hold down the slips 15 until there is sufficient weight on the tubing section T to force the tubing section T down into the slips 15.

(40) FIG. 4 of the accompanying drawings shows a robotic apparatus 101 for the manipulation of tubing, tools and/or equipment on the drill floor D.

(41) As shown in FIG. 4, the apparatus 101 comprises a support arrangement which in the illustrated apparatus 101 takes the form of a catwalk 102. The catwalk 102 comprises a platform 103 and is supported on the drill floor D by a number of wheels 104.

(42) In use, the apparatus 101 is utilised to replace the manual handling and installation of drill pipe, casing, pup joints, crossovers or the use of lifting-subs where these are being installed inside the tubulars while on the drill floor 2.

(43) As shown in FIG. 4, a manipulator arm 105 is coupled to the catwalk 102. The manipulator arm 105 comprises a body 106 for coupling the manipulator arm 105 to the catwalk 102, a first linkage element 107 and a second linkage element 108. The first linkage element 107 is coupled to the body 106 by an actuator 109. The actuator 109 provides a first degree of freedom of the manipulator arm 105. In the illustrated apparatus 101, the actuator 109 takes the form of a rotary actuator. The second linkage element 108 is coupled to the first linkage element 107 by an actuator 110. The actuator 110 provides a second degree of freedom of the manipulator arm 105. In the illustrated apparatus 101, the actuator 110 takes the form of a rotary actuator.

(44) As shown in FIG. 4, and referring also to FIGS. 5 and 6 of the accompanying drawings, an end effector—which in the illustrated apparatus 101 takes the form of a tubing handling tool 111—is connected at a distal end of the manipulator arm 105.

(45) As shown in FIGS. 5 and 6, the tubing handling tool 111 comprises a first jaw portion 112 and a second jaw portion 113. The first jaw portion 112 and the second jaw portion 113 are pivotably coupled together at hinge 114.

(46) In use, the catwalk 102 is moveable across the drill floor D from a first, storage, position to a second, deployed, position (as shown in FIG. 4). In the second, deployed, position the manipulator arm 105 and tubing handling tool 111 are operable to engage and manipulate a tubing section, in the illustrated apparatus 101 a pup joint T2, so as to locate the pup joint T2 on a tubing section T.

(47) In order to engage and manipulate the pup joint T2 the tubing handling tool 111 is reconfigurable between an open configuration and a closed configuration (as shown in FIGS. 5 and 6) permitting the tubing handling tool 111 to securely grasp pup joint T2.

(48) FIG. 7 of the accompanying drawings shows an alternative robotic apparatus 201 for the manipulation of tubing, tools and/or equipment on the drill floor D.

(49) In use, the apparatus 201 is utilised to replace the manual operation of safety clamps and slips when handling drill collars and bottom hole assemblies through the rotary and to replace the manual handling and installation of drill pipe, casing, pup joints, crossovers or the use of lifting-subs where these are being installed inside the tubulars while on the drill floor D.

(50) As shown in FIG. 7, the apparatus 201 comprises a support arrangement in the form of an undercarriage 202. In the illustrated apparatus 201, the undercarriage 202 is movable relative to the drill floor D and takes the form of a continuous track system having a track 203 which in use is driven by a number of wheels 204. In the illustrated apparatus 201, the track 203 is formed using interconnected chain links (not shown) and the wheels 204 take the form of sprocket wheels. However, it will be recognised that other drive arrangements may be provided.

(51) As shown in FIG. 7, the apparatus 201 comprises two manipulator arms in the form of a first manipulator arm 205a and a second manipulator arm 205b coupled to the undercarriage 202.

(52) The first manipulator arm 205a is coupled to the undercarriage 202. The first manipulator arm 205a comprises a body 206a for coupling the manipulator arm 205a to the undercarriage 202, a first linkage element 207a and a second linkage element 208a. The first linkage element 207a is coupled to the body 206a by an actuator 209a. The actuator 209a provides a first degree of freedom of the manipulator arm 205a. In the illustrated apparatus 201, the actuator 209a takes the form of a rotary actuator. The second linkage element 208a is coupled to the first linkage element 207a by an actuator 210a. The actuator 210a provides a second degree of freedom of the manipulator arm 205a. In the illustrated apparatus 201, the actuator 210a takes the form of a rotary actuator.

(53) As shown in FIG. 7, and referring also to FIGS. 8 and 9 of the accompanying drawings, an end effector—which in the illustrated apparatus 201 takes the form of a clamping tool 211a—is connected at a distal end of the manipulator arm 205a.

(54) As shown in FIGS. 8 and 9, the clamping tool 211a comprises a first jaw portion 212a and a second jaw portion 213a. The first jaw portion 212a and the second jaw portion 213a are pivotably coupled together at hinge 214a.

(55) In use, the damping tool 211a is reconfigurable between an open configuration which facilitates location of the clamping tool 211a about a tubing section T and a closed configuration (as shown in FIGS. 8 and 9) permitting the clamping tool 211a to be secured about the tubing section T. The clamping tool 211a further comprises or is coupled to slips 215a for gripping the tubing section T. In the illustrated apparatus 201, the slips 215a form part of the clamping tool 211a. A lower section of the clamping tool 211a is tapered, providing a guide for location of another tubing section onto the tubing section T (as will be described further below).

(56) The manipulator arm 205b comprises a body 206b for coupling the manipulator arm 205b to the undercarriage 202, a first linkage element 207b and a second linkage element 208b. The first linkage element 207b is coupled to the body 206b by an actuator 209b. The actuator 209b provides a first degree of freedom of the manipulator arm 105. In the illustrated apparatus 201, the actuator 209b takes the form of a rotary actuator. The second linkage element 208b is coupled to the first linkage element 207b by an actuator 210b. The actuator 210b provides a second degree of freedom of the manipulator arm 205b. In the illustrated apparatus 201, the actuator 210b takes the form of a rotary actuator.

(57) As shown in FIG. 7, and referring also to FIGS. 10 and 11 of the accompanying drawings, an end effector—which in the illustrated apparatus 201 takes the form of a tubing handling tool 211b—is connected at a distal end of the manipulator arm 205b.

(58) As shown in FIGS. 10 and 11, the tubing handling tool 211b comprises a first jaw portion 212b and a second jaw portion 213b. The first jaw portion 212b and the second jaw portion 213b are pivotably coupled together at hinge 214b.

(59) In use, the undercarriage 202 is moveable across the drill floor D from a first, storage, position to a second, deployed, position (as shown in FIG. 7). In the second, deployed, position the manipulator arm 205a and clamping tool 211a are operable to engage and hold down the slips 215a until there is sufficient weight on the tubing section T to force the tubing section T down into the slips 215a.

(60) The manipulator arm 205b and the tubing handling tool 211b are operable to engage and manipulate a tubing section, in the illustrated apparatus 201 a crossover T2, so as to locate the crossover T2 on the tubing section T.

(61) In order to engage and manipulate the crossover T2 the tubing handling tool 211b is reconfigurable between an open configuration and a closed configuration (as shown in FIGS. 10 and 11) permitting the tubing handling tool 211b to securely grasp crossover T2.

(62) Beneficially, the apparatus 201 facilitates rapid and accurate location of the crossover T2 onto the tubing section T, since when the first manipulator arm 205a is engaged, the position of the apparatus 201 on the drill floor D is known and can be used to facilitate the accurate positioning and manipulation of the second manipulator arm 205b and crossover T2.

(63) FIG. 12 of the accompanying drawings shows an alternative robotic apparatus 301 for the manipulation of tubing, tools and/or equipment on the drill floor D.

(64) In use, the apparatus 301 is utilised to replace the manual operation of safety clamps and slips and to replace the manual alignment/guidance and thread alignment (doping”) of connections of drill pipe, casing, pup joints, and crossovers.

(65) As shown in FIG. 12, the apparatus 301 comprises a support arrangement in the form of an undercarriage 302. In the illustrated apparatus 301, the undercarriage 302 is movable relative to the drill floor D and takes the form of a continuous track system having a track 303 which in use is driven by a number of wheels 304. In the illustrated apparatus 301, the track 303 is formed using interconnected chain links (not shown) and the wheels 304 take the form of sprocket wheels. However, it will be recognised that other drive arrangements may be provided.

(66) As shown in FIG. 12, the apparatus 301 comprises two manipulator arms in the form of a first manipulator arm 305a and a second manipulator arm 305b coupled to the undercarriage 302.

(67) The first manipulator arm 305a is coupled to the undercarriage 302. The first manipulator arm 305a comprises a body 306a for coupling the manipulator arm 305a to the undercarriage 302, a first linkage element 307a and a second linkage element 308a. The first linkage element 307a is coupled to the body 306a by an actuator 309a. The actuator 309a provides a first degree of freedom of the manipulator arm 305a. In the illustrated apparatus 301, the actuator 309a takes the form of a rotary actuator. The second linkage element 308a is coupled to the first linkage element 307a by an actuator 310a. The actuator 310a provides a second degree of freedom of the manipulator arm 305a. In the illustrated apparatus 301, the actuator 310a takes the form of a rotary actuator.

(68) As shown in FIG. 12, an end effector—which in the illustrated apparatus 301 takes the form of a clamping tool 311a—is connected at a distal end of the manipulator arm 205a.

(69) As shown in FIGS. 13 and 14, the clamping tool 311a comprises a first jaw portion 312a and a second jaw portion 313a. The first jaw portion 312a and the second jaw portion 313a are pivotably coupled together at hinge 314a. The clamping tool 311a further comprises or is coupled to slips 315a for gripping the tubing section, which in the illustrated apparatus 301 takes the form of a pup joint T2. In the illustrated apparatus 301, the slips 215a form part of the clamping tool 311a.

(70) The second manipulator arm 305b comprises a body 306b for coupling the manipulator arm 305b to the undercarriage 302, a first linkage element 307b and a second linkage element 308b. The first linkage element 307b is coupled to the body 306b by an actuator 309b. The actuator 309b provides a first degree of freedom of the manipulator arm 305b. In the illustrated apparatus 301, the actuator 309b takes the form of a rotary actuator. The second linkage element 308b is coupled to the first linkage element 307b by an actuator 310b. The actuator 310b provides a second degree of freedom of the manipulator arm 305b. In the illustrated apparatus 301, the actuator 310b takes the form of a rotary actuator.

(71) As shown in FIG. 12, and referring also to FIGS. 15 to 18, an end effector—which in the illustrated apparatus 301 takes the form of a guidance tool 311b—is connected at a distal end of the manipulator arm 305b.

(72) As shown in FIGS. 15 to 18, the guidance tool 311b comprises a first jaw portion 312b and a second jaw portion 313b. The first jaw portion 312b and the second jaw portion 313b are pivotably coupled together at hinge 314b. As shown, the guidance tool 311b defines a funnel and beneficially, the apparatus 301 facilitates rapid and accurate location of a tubing section T3 onto tubing section T, since when the first manipulator arm 305a is engaged, the position of the apparatus 301 on the drill floor D is known and can be used to facilitate the accurate guidance of the second manipulator arm 305b and tubing section T3.

(73) FIG. 19 of the accompanying drawings shows an alternative application of the apparatus 301. As shown in FIG. 19, the apparatus 301 is configured to facilitate the guidance of tubing section T3 onto tubing section T2. To facilitate this, the clamping tool 311a also defines a guidance member 316 to assist in alignment of the tubing section T3 with the tubing section T2.

(74) FIG. 20 of the accompanying drawings shows an alternative robotic apparatus 401 for the manipulation of tubing, tools and/or equipment on the drill floor D.

(75) In use, the apparatus 401 is utilised to replace the manual operation of safety clamps and slips when handling drill collars and bottom hole assemblies through the rotary and to replace the manual operation of removal of thread protectors on the drill floor D.

(76) As shown in FIG. 20, the apparatus 401 comprises a support arrangement in the form of an undercarriage 402. In the illustrated apparatus 401, the undercarriage 402 is movable relative to the drill floor D and takes the form of a continuous track system having a track 403 which in use is driven by a number of wheels 404. In the illustrated apparatus 401, the track 403 is formed using interconnected chain links (not shown) and the wheels 404 take the form of sprocket wheels. However, it will be recognised that other drive arrangements may be provided.

(77) As shown in FIG. 20, the apparatus 401 comprises two manipulator arms in the form of a first manipulator arm 405a and a second manipulator arm 405b coupled to the undercarriage 402.

(78) The first manipulator arm 405a is coupled to the undercarriage 402. The first manipulator arm 405a comprises a body 406a for coupling the manipulator arm 405a to the undercarriage 402, a first linkage element 407a and a second linkage element 408a. The first linkage element 407a is coupled to the body 406a by an actuator 409a. The actuator 409a provides a first degree of freedom of the manipulator arm 405a. In the illustrated apparatus 401, the actuator 409a takes the form of a rotary actuator. The second linkage element 408a is coupled to the first linkage element 407a by an actuator 410a. The actuator 410a provides a second degree of freedom of the manipulator arm 405a. In the illustrated apparatus 401, the actuator 410a takes the form of a rotary actuator.

(79) As shown in FIG. 20, and referring also to FIGS. 21 and 22 of the accompanying drawings, an end effector—which in the illustrated apparatus 401 takes the form of a clamping tool 411a—is connected at a distal end of the manipulator arm 405a.

(80) As shown in FIGS. 21 and 22, the clamping tool 411a comprises a first jaw portion 412a and a second jaw portion 413a. The first jaw portion 412a and the second jaw portion 413a are pivotably coupled together at hinge 414a.

(81) In use, the clamping tool 411a is reconfigurable between an open configuration which facilitates location of the clamping tool 411a about a tubing section T and a closed configuration (as shown in FIGS. 21 and 22) permitting the clamping tool 411a to be secured about the tubing section T. The clamping tool 411a further comprises or is coupled to slips 415a for gripping the tubing section T. In the illustrated apparatus 401, the slips 415a form part of the clamping tool 411a.

(82) The manipulator arm 205b comprises an impact wrench tool 411b configured to remove the thread protector from the tubing section T2.

(83) Beneficially, the apparatus 401 facilitates rapid and accurate location of the crossover T2 onto the tubing section T, since when the first manipulator arm 205a is engaged, the position of the apparatus 201 on the drill floor D is known and can be used to facilitate the accurate positioning and manipulation of the second manipulator arm 205b and crossover T2.

(84) Referring now to FIGS. 25 to 28 of the accompanying drawings, there is shown another robotic apparatus 501 for the manipulation of tubing, tools and/or equipment on the drill floor D. FIGS. 25, 26 and 27 show side, front and bottom views respectively of the robotic apparatus 501 and FIG. 28 shows an enlarged view of part of the apparatus 501 shown in FIG. 26.

(85) As shown, the apparatus 501 comprises a support arrangement in the form of an undercarriage 502. In the illustrated apparatus 501, the undercarriage 502 is movable relative to the drill floor D and takes the form of a continuous track system having tracks 503 which are driven by wheels 504. In the illustrated apparatus 501, the tracks 503 are formed from interconnected chain links 504 while the wheels 504 take the form of sprocket wheels. It will be recognised, however, that other drive arrangements may be utilised.

(86) In the illustrated apparatus 501, the apparatus 501 further additionally or alternatively comprises a number of omni-directional rollers 506 disposed in the undercarriage 502 (shown in FIGS. 25 and 27). Beneficially, the omni-directional rollers 506 facilitate movement of the apparatus 501 in any required direction, including forwards and/or backwards movements, lateral or sideways movements, diagonal movements and/or rotational movements. As such, the apparatus 501 is highly manoeuvrable around the drill floor D.

(87) As shown in FIG. 25, the illustrated apparatus 501 utilises a hybrid power supply, having an onboard electrical power supply in the form of battery 507 and a hydraulic power supply view hydraulic lines 508. However, it will be recognised that other means of providing electrical and/or hydraulic power may be provided. For example, the apparatus 501 may alternatively or additionally be provided with a cabled electrical power supply, such as a drag chain power supply or the like.

(88) Beneficially, the apparatus 501 is configured to utilise the onboard power supply in the form of battery 507 to manoeuvre from a charging/docking station which forms a storage location (not shown) to a work location around the well centre WC on the drill floor D (shown in FIGS. 25 and 26), the apparatus 501 configured to use electrical power and/or hydraulic power (from hydraulic lines 508) for the given work task itself.

(89) As shown in FIGS. 25 and 26, the illustrated apparatus 501 comprises two manipulator arms in the form of a first manipulator arm 509a and a second manipulator arm 509b.

(90) The first manipulator arm 509a is pivotably coupled to the undercarriage 502 by a base 510a while the second manipulator 509b is similarly coupled to the undercarriage 502 by base 510b (shown in FIG. 26).

(91) As shown most clearly in FIG. 25, the first manipulator arm 509a comprises linkage elements 511a, 512a, 513a, 514a. Linkage element 511a is rotationally coupled to the base 510a by rotary actuator 515a. Linkage element 512a is rotationally coupled to linkage element 511a by rotary actuator 516a. Linkage element 513a is rotationally coupled to linkage element 512a by rotary actuator 517a. Linkage element 514a is rotationally coupled to linkage element 513a by rotary actuator 518a.

(92) It will be recognised that manipulator arm 509a may alternatively comprise more or less linkage elements and actuators as required.

(93) An end effector 519a is connected at a distal end of the manipulator arm 509a. In the illustrated apparatus 501, end effector 519a takes the form of a handling tool suitable for manipulating and connecting sections of drill pipe P.

(94) As shown most clearly in FIG. 25, the second manipulator arm 509b comprises linkage elements 511b, 512b, 513b, 514b. Linkage element 511b is rotationally coupled to the base 510b by rotary actuator 515b. Linkage element 512b is rotationally coupled to linkage element 511b by rotary actuator 516b. Linkage element 513b is rotationally coupled to linkage element 512b by rotary actuator 517b. Linkage element 514b is rotationally coupled to linkage element 513b by rotary actuator 518b.

(95) It will be recognised that manipulator arm 509b may alternatively comprise more or less linkage elements and actuators as required.

(96) An end effector 519b is connected at a distal end of the manipulator arm 509b. In the illustrated apparatus 501, end effector 519b also takes the form of a handling tool suitable for manipulating and connecting sections of drill pipe DP.

(97) In use, the apparatus 501 is configured to move between a storage position, e.g. a charging/docking station (not shown), and a deployed position located adjacent to the well centre WC (as shown in FIGS. 25 and 26).

(98) A sensor arrangement includes sensors 520 to facilitate accurate location of the apparatus 501 at the well centre WC.

(99) In the illustrated apparatus 501, the sensors 520 form part of a machine vision system which, using machine learning, facilitates reliable sensing and object detection and which controls both motion of the apparatus 501 around the drill floor D to/from the well centre WC and motion of the manipulator arms 509a, 509b.

(100) However, as outlined above the sensors arrangement may be configured to perform other functions, such as facilitate inspection of tools, equipment or the apparatus 501 or its components; facilitate an identification operation, for example but not exclusively permitting the reading of ID codes, recognition/distinction of objects, shapes e.g. for ACS, personnel detection.

(101) Referring now in particular to FIGS. 27 and 28, once located at the well centre WC, an anchor arrangement—which in the illustrated apparatus 501 takes the form of locking pins 521 disposed in the undercarriage 502—is configured to be activated. As shown in FIG. 28, when activated the locking pins 521 extend into the drill floor D and are secured by a wedge lock arrangement 522.

(102) When the locking pins 521 are engaged with the drill floor D, the apparatus 501 has a fixed point of reference relative to the well centre WC. This means that the position of the apparatus 501 and the manipulator arms 509a, 509b is known with respect to the stick up and/or the well centre WC. Accordingly, the apparatus 501 can precisely move the effectors 519b and 519b and e.g. the drill pipe sections P. This means that the efficiency of assembly of the drill pipe sections is increased.

(103) The manipulator arms 509a, 509b and end effectors 519a, 519b are then operated to manipulate the drill pipe sections DP in order to stab in and make up the necessary connection.

(104) The illustrated apparatus 501 may further comprise an onboard rack 523 for tools—in the illustrated apparatus 501 another end effector 524, obviating the requirement for the apparatus 501 to return to the docking station (not shown) to be reconfigured for another operation.

(105) Beneficially, the apparatus 501 may be adapted to perform a variety of drill floor operations, obviating the requirement for bespoke tools for each operation and reducing the space occupied on the drill floor.

(106) For example, FIGS. 29 to 35 of the accompanying drawings show the apparatus 501 configured to perform a number of different drill floor operations.

(107) FIGS. 29 and 30 show the apparatus 501 performing the drill floor operation of manipulating drilling pup-joints P, drilling-subs S or cross-overs X.

(108) The apparatus 501 is arranged and operated substantially as described above with reference to FIG. 25, the apparatus 501 configured to utilise the onboard power supply in the form of battery 507 to power the continuous track system and manoeuvre the apparatus 501 from the charging/docking station which forms the storage location (not shown) for the apparatus 501 to the work location around the well centre WC on the drill floor D, the apparatus 501 configured to use electrical power (in this embodiment from battery 507) and/or hydraulic power (from hydraulic lines 508) for the given work task itself.

(109) Once located at the well centre WC, the locking pins 521 disposed in the undercarriage 502 are activated to extend into the drill floor D and are secured by the wedge lock arrangement 522.

(110) The manipulator arms 509a, 509b and end effectors 519a, 519b are then operated to manipulate a pup-joint P (or a crossover X) in order to stab in and make up the necessary connection with the pipe stick-up in the well centre.

(111) The end-effector 519a in this example is used for providing a reference position and possible offset/inclination of the pipe in the well centre WC in order to accurately align the pup-joint P with the pipe, while the optical sensors 520 will provide input of the vertical height of the pipe stick-up.

(112) The end effectors 519a, 519b described above with reference to FIG. 25 are also used for this operation, although it will be recognised that alternative end effectors may be utilised where appropriate.

(113) FIG. 31 shows the apparatus 501 in an alternative configuration in order to perform the drill floor operation of thread protector removal.

(114) As shown, the apparatus 501 is arranged and operated substantially as described above with reference to FIG. 25. However, in this embodiment the end effectors 519a has been replaced with a casing handling tool 519c and the end effector 519b has been replaced with a thread protector removal tool 519d.

(115) In use, the apparatus 501 is configured to utilise the onboard power supply in the form of battery 507 to power the continuous track system and manoeuvre the apparatus 501 from the charging/docking station which forms the storage location (not shown) for the apparatus 501 to the work location around the well centre WC on the drill floor D, the apparatus 501 configured to use electrical power (in this embodiment from battery 507) and/or hydraulic power (from hydraulic lines 508) for the given work task itself.

(116) Once located at the well centre WC, the locking pins 521 disposed in the undercarriage 502 are activated to extend into the drill floor D and are secured by the wedge lock arrangement 522.

(117) The manipulator arms 509a, 509b and end effectors 519c, 519d are then operated to hold the casing (using end effector 519c) and rotate the thread protector removal tool 519d to remove the thread protector.

(118) FIG. 32 shows the apparatus 501 configured to perform the drill floor operation of casing stabbing.

(119) As shown, the apparatus 501 is arranged and operated substantially as described above with reference to FIG. 25. However, in this embodiment the end effectors 519a has been replaced with casing handling tool 519c and the end effector 519b has been replaced with casing stabbing tool 519e.

(120) In use, the apparatus 501 is configured to utilise the onboard power supply in the form of battery 507 to power the continuous track system and manoeuvre the apparatus 501 from the charging/docking station which forms the storage location (not shown) for the apparatus 501 to the work location around the well centre WC on the drill floor D, the apparatus 501 configured to use electrical power (in this embodiment from battery 507) and/or hydraulic power (from hydraulic lines 508) for the given work task itself.

(121) Once located at the well centre WC, the locking pins 521 disposed in the undercarriage 502 are activated to extend into the drill floor D and are secured by the wedge lock arrangement 522.

(122) The manipulator arms 509a, 509b and end effectors 519c, 519e are then operated to hold the casing (using end effector 519c) and stab in the casing C using tool 519e.

(123) FIG. 33 shows the apparatus 501 configured to perform the drill floor operation of installing a lift sub into a bottom hole assembly (BHA) element disposed on a catwalk machine CW.

(124) As shown, the apparatus 501 is arranged and operated substantially as described above with reference to FIG. 25. However, in this embodiment the end effectors 519b has been parked in the onboard tool rack 523.

(125) In use, the apparatus 501 is configured to utilise the onboard power supply in the form of battery 507 to power the continuous track system and manoeuvre the apparatus 501 from the charging/docking station which forms the storage location (not shown) for the apparatus 501 to the work location around the well centre WC on the drill floor D, the apparatus 501 configured to use electrical power (in this embodiment from battery 507) and/or hydraulic power (from hydraulic lines 508) for the given work task itself.

(126) Once located at the well centre WC, the locking pins 521 disposed in the undercarriage 502 are activated to extend into the drill floor D and are secured by the wedge lock arrangement 522.

(127) The manipulator arms 509a and end effector 519a is then manipulated to insert a lifting sub L into the BHA element disposed on the catwalk machine CM.

(128) FIG. 34 shows the apparatus 501 configured to perform the drill floor operation of setting manual slips and safety clamps.

(129) As shown, the apparatus 501 is arranged and operated substantially as described above with reference to FIG. 25. However, in this embodiment the end effectors 519a has been replaced with a spinner/impact wrench 519f and the end effector 519b has been replaced with a safety clamp manipulator 519g.

(130) The apparatus 501 has also been fitted with a slip lifter 525 at its front end. As the name suggests, the slip lifter 525 is configured to lift or insert a set of slips 526 into the rotary table bushings 527 around the tubular TUB. The tubular TUB is slowly lowered into the rotary table 528 and the set of slips 526 are further lowered until they wedge into the gap provided between the rotary bushings 527 and the tubular TUB. Once the set of slips 526 are set and the vertical movement of the tubular TUB has been arrested, the safety clamp is manipulated to close around the tubular TUB at a short distance above the set of slips 526. Once the safety clamp has been closed around the tubular TUB, the spinner/impact wrench 519f will engage to spin-in the locking nut on the safety clamp. The spinner/impact wrench 519f will further torque up the nut until a set torque value has been achieved. After this the spinner/impact wrench 519f will disengage and the lower manipulator 519g will release its grip on the safety clamp and both of the manipulator arms 509a, 509b will clear away from the tubular TUB, making ready to accurately stab in and spin in the next BHA element on top of the previous one sitting inside the slips 526 (i.e. this is done after sequentially repeating the steps of first removing the lifting sub on top of the BHA sitting in the slips 526, inserting a lifting sub horizontally into the next BHA element, removing the pin-end thread protector from the BHA before stabbing-and spinning it in to the one sitting in the slips 526. Once the new BHA element has been made up by an “iron roughneck” hydraulic tong HT (approaching from the opposing side of the apparatus 501) the top drive will pick-up weight on the new BHA. The apparatus 501 will now engage to grip and hold onto the safety clamp while the spinner/impact wrench 519f opens and releases the safety clamp. The slip lifter 525 will start pulling up on the set of slips 526 which will release and lift when the top drive slowly lifts the BHA a short vertical distance before lowering the BHA through the rotary table 528.

(131) Hereafter, the process described above will repeat itself until the BHA has been fully assembled and set in the slips 526 and a drill pipe crossover is connected to the BHA. After this final step, the conventional set of slips 526 is no longer employed as from hereon in the BHA will be run from a drillstring through a hydraulic power slip in a standard automated drill pipe tripping sequence which will then not will require the apparatus 501 to be involved.

(132) FIG. 35 shows the apparatus 501 configured to guide a tugger line TL.

(133) As described above, it is envisaged that the SWL-rating of the apparatus 501 will be such that as is necessary for the machine to be able to replace manual work processes normally performed by one or more personnel working around the work-centre—e.g. typically in the range of a few hundred kilos, but significantly less than a thousand kilos. For non-routine lifting of heavier items near or beyond the SWL-rating of the robot, the load of such items may be partly or entirely taken by a drill floor winch/tugger-line TL or by other means of hoisting or load carrying, while being guided into the work center WC position by the robot arm(s).

(134) As shown, the apparatus 501 is arranged and operated substantially as described above with reference to FIG. 25. However, in this embodiment the end effectors 519a, 519b has been replaced with appropriate wire- and handle grabbers 519h, 519i for guidance of heavier items.

(135) It will be recognised that the apparatus 501 may be configured to perform a number of operations. Beneficially, the provision of a modular apparatus permits a single apparatus to be adapted to perform a variety of drill floor operations, obviating the requirement for bespoke tools for each operation and reducing the space occupied on the drill floor.

(136) By way of example of drill floor operations utilising the robotic apparatus 501 described above, reference is now made to FIGS. 36 and 37 of the accompanying drawings.

(137) FIG. 36 shows a method of building a Bottom Hole Assembly (BHA) in a Mouse Hole utilizing the robotic apparatus 501.

(138) (A mousehole is an offline work centre in the drill floor wherein single joints/elements of tubulars are being assembled into longer stands (STD) of pipes, typically consisting of 3 or 4 joints, whereupon the stands are then transferred by a piperacker/Hydraracker (HR) to be held in the derrick vertical setback until needed).

(139) FIG. 37 shows a method of handling and running the BHA on main well centre utilizing the robotic apparatus 501.