Top drive well casing system and method

An apparatus for coupling a joint of casing to a casing string secured in a subterranean well, comprising:

• a top drive:
• a first set of links, a first end of each link in the first set of links being coupled to the top drive;
• a first casing elevator coupled to a second end of each link in the first set of links;
• a first link tilt for pivoting each link in the first set of links about its first end;
• a gripper assembly coupled to the top drive and operable to secure and engage the joint of casing;
• and
• a drive shaft coupled between the ton drive and the gripper assembly, the drive shaft transmitting rotational force from the top drive to the gripper assembly;
• wherein the top drive is operable to rotate the gripper assembly, thereby rotating the joint of casing and coupling the joint of casing to the casing string;
• and
• wherein the drive shaft comprises,
• a telescoping module capable of compensating for movement of the drive shaft along the drive shaft's vertical axis during the coupling of the casing to the casing string by the rotation of the gripper assembly;
• and
• at least one a knuckle joint that compensates for misalignment of the gripper assembly head and the drive shaft during rotation of the drive shaft.

An apparatus for coupling a joint of casing to a casing string secured in a subterranean well, comprising:

• a top drive:
• a first set of links, a first end of each link in the first set of links being coupled to the top drive;
• a first casing elevator coupled to a second end of each link in the first set of links;
• a first link tilt for pivoting each link in the first set of links about its first end;
• a gripper assembly coupled to the top drive and operable to secure and engage the joint of casing;
• and
• a drive shaft coupled between the top drive and the gripper assembly, the drive shaft transmitting rotational force from the top drive to the gripper assembly;
• wherein the gripper assembly comprises a sealing member to form a seal to allow fluids to be pumped into the casing and a remotely actuated air vent valve to release air from the casing;
• and
• wherein the ton drive is operable to rotate the gripper assembly, thereby rotating the joint of casing and coupling the joint of casing to the casing string.

A method for hoisting a joint of casing, positioning the joint of casing above a casing string, and stabbing the joint of casing into the casing string such that the joint of casing is coupled with the casing string, comprising the steps of:

• providing a top drive system, the top drive system comprising,
• a lifting elevator able to be clamped around the casing string for the purpose of hoisting the casing string;
• a transfer elevator able to be clamped around the joint of casing for the purpose of hoisting a joint of casing;
• a drive shaft;
• a drive to rotate the drive shaft;
• a handler able to rotate the lifting elevator and the transfer elevator in a horizontal plane;
• a link tilt comprising one or more hydraulic actuators, wherein the link tilt is coupled to the transfer elevator such that the extension or retraction of the hydraulic actuators can pivot the transfer elevator about a point located on a vertical axis;
• providing a casing make-up assembly coupled to the drive shaft, the casing make-up assembly comprising,
• a gripper assembly, the gripper assembly comprising,
• a nose sized to be inserted in the joint of casing;
• a gripping member to clamp around the joint of casing;
• clamping the transfer elevator around a joint of casing;
• hoisting the joint of casing above the casing string;
• positioning the joint of casing directly above the casing string by pivoting and rotating the transfer elevator;
• lowering the joint of casing until it rests on the casing string;
• lowering the gripper head until the nose is inserted in the joint of casing;
• unclamping the transfer elevator;
• positioning the lifting elevator using the link tilt until thread alignment is achieved;
• clamping the gripping member around the joint of casing;
• and
• rotating the drive shaft, thereby rotating the gripper assembly and joint of casing such that the joint of casing is coupled to the casing string.

A method of adding a joint of casing to a casing string in a well bore comprising the following steps:

• using a first link tilt to position a first casing elevator such that the first casing elevator can be coupled to the joint of casing;
• using a gripper assembly attached to a top drive to grasp and rotate the joint of casing thereby coupling the joint of casing to the casing string;
• and
• using a second casing elevator to lower the casing string into the well bore.