ACTUATION SYSTEMS AND RELATED WRENCH TOOLS AND METHODS FOR MAKING UP AND BREAKING OUT TUBULAR CONNECTIONS

Abstract

Implementations described herein relate to actuation systems, wrench tools, and methods for making up and breaking out tubular connections. An actuation system for iron roughnecks includes an actuation assembly. The actuation assembly includes a carriage including a set of carriage rails, and a support frame. The support frame includes a set of support rails. The actuation system includes one or more actuators configured to extend and retract the carriage along a first direction. At least one of the one or more actuators is coupled between a carriage flange of the carriage and a support flange of the support frame.

Description

BACKGROUND

Field

Implementations described herein relate to actuation systems, wrench tools, and methods for making up and breaking out tubular connections.

Description of the Related Art

Positioning wrench tools in relation to rig floors can be difficult and can involve interference of equipment. For example, positioning systems can have large footprints that take up large amounts of space on a rig floor. Large footprints can also increase chances of equipment interference. Modularity can also be limited because some large positioning systems may not fit on certain rig floors, which can involve foregoing use or modifying the rigs. Motion paths of positioning systems can also be limited. For example, horizontal movement of wrench tools can also involve vertical movement, which can increase chances of interference of equipment.

Therefore, there is a need for actuation systems that facilitate reduced size, rig modularity, and reduced or eliminated chances of interference of equipment.

SUMMARY

Implementations described herein relate to actuation systems, wrench tools, and methods for making up and breaking out tubular connections.

In one or more embodiments, an actuation system for iron roughnecks includes an actuation assembly. The actuation assembly includes a carriage including a set of carriage rails, and a support frame. The support frame includes a set of support rails. The actuation system includes one or more actuators configured to extend and retract the carriage along a first direction. At least one of the one or more actuators is coupled between a carriage flange of the carriage and a support flange of the support frame.

In one or more embodiments, a wrench tool for making up and breaking out tubular connections on an oil and gas rig includes an actuation assembly and a second actuation assembly. The actuation assembly includes a carriage, a support frame, and one or more actuators configured to extend and retract the carriage along a first direction relative to the support frame. The second actuation assembly includes a second carriage, a second support frame coupled to the carriage, and one or more second actuators configured to extend and retract the second carriage along a second direction that is oriented at an angle relative to the first direction. The wrench tool includes a spinner section including a plurality of spinner rollers. The spinner section is coupled to the second carriage. The wrench tool includes a power tong section coupled to and suspended from the spinner section. The power tong section includes a plurality of grippers and a plurality of tong actuators configured to pivot at least part of the power tong section.

In one or more embodiments, a method of making up or breaking out a tubular connection includes extending a carriage linearly along a horizontal direction to linearly move a spinner section and a power tong section of a wrench tool. The extending of the carriage includes actuating one or more actuators coupled to the carriage to move the carriage relative to a support frame positioned at least partially around the carriage. The method includes extending a second carriage linearly along a vertical direction to linearly move the spinner section and the power tong section of the wrench tool. The extending of the second carriage includes actuating one or more second actuators coupled between the second carriage and the carriage. The method includes positioning a first tubular and a second tubular in a first opening of the power tong section and a second opening of the spinner section. The method includes spinning the second tubular relative to the first tubular using a plurality of spinner rollers of the spinner section, and pivoting at least part of the power tong section to torque the second tubular relative to the first tubular.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above-recited features of the disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

FIG. 1A is a schematic perspective front view of a wrench tool for making up and breaking out tubular connections on an oil and gas rig, according to one or more embodiments.

FIG. 1B is a schematic enlarged perspective view of the wrench tool shown in FIG. 1A, according to one or more embodiments.

FIG. 2 is a schematic enlarged front view of the actuation assembly shown in FIG. 1A, according to one or more embodiments.

FIG. 3 is a schematic enlarged perspective front view of the actuation assembly shown in FIGS. 1 and 2, according to one or more embodiments.

FIG. 4 is a schematic back view of the wrench tool shown in FIG. 1A, according to one or more embodiments.

FIG. 5 is a schematic enlarged back view of the actuation assembly shown in FIG. 4, according to one or more embodiments.

FIG. 6 is a schematic perspective back view of the wrench tool shown in FIGS. 1 and 4, according to one or more embodiments.

FIG. 7 is a schematic enlarged perspective back view of the second actuation assembly shown in FIGS. 1, 4, and 6, according to one or more embodiments.

FIG. 8 is a schematic flow diagram view of a method of making up or breaking out a tubular connection, according to one or more embodiments.

FIG. 9 is a schematic perspective side view of the wrench tool shown in FIG. 1A after the actuation assembly linearly moves the carriage relative to the support frame along the first direction using the one or more actuators, according to one or more embodiments.

FIG. 10 is a schematic perspective back view of the wrench tool shown in FIG. 9 after the second actuation assembly linearly moves the second carriage relative to the first carriage and the second support frame along the second direction using the one or more second actuators, according to one or more embodiments.

FIG. 11 is a schematic enlarged front perspective view of an actuation assembly, according to one or more embodiments.

FIG. 12 is a schematic enlarged back perspective view of the actuation assembly shown in FIG. 11, according to one or more embodiments.

FIG. 13 is a schematic partial side perspective view of the linkage system shown in FIG. 12, according to one or more embodiments.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one implementation may be beneficially utilized on other implementations without specific recitation.

DETAILED DESCRIPTION

Implementations described herein relate to actuation systems, wrench tools, and methods for making up and breaking out tubular connections. In one or more embodiments, a first actuation assembly is configured to actuate a first carriage to linearly move a wrench tool along a first direction (e.g., a horizontal direction), and a second actuation assembly is configured to actuation a second carriage to independently and linearly move the wrench tool alone a second direction (e.g., a vertical direction). The wrench tool can linearly move the wrench tool along the first direction and the second direction simultaneously and/or sequentially.

The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to bonding, embedding, welding, fusing, melting together, interference fitting, threading, and/or fastening such as by using bolts, threaded connections, pins, and/or screws. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to integrally forming. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to direct coupling and/or indirect coupling, such as indirect coupling through components such as links, blocks, and/or frames.

FIG. 1A is a schematic perspective front view of a wrench tool 100 for making up and breaking out tubular connections on an oil and gas rig, according to one or more embodiments. The wrench tool 100 can be, for example, an iron roughneck.

The wrench tool 100 includes an actuation system 110 that includes an actuation assembly 120 and a second actuation assembly 150. The actuation assembly 120 includes a carriage 121 and a support frame 125. The second actuation assembly 150 includes a second carriage 151 and a second support frame 155 coupled to the carriage 121. The actuation assembly 120 is operable to move the carriage 121 along a first direction D1, and the second actuation assembly 150 is operable to move the second carriage 151 along a second direction D2 that is oriented at an angle (such as about 90 degrees) relative to the first direction D1. In one or more embodiments, the first direction D1 is a horizontal direction and the second direction D2 is a vertical direction.

The wrench tool 100 includes a spinner section 101 including a plurality of spinner rollers 102. The spinner section 101 is coupled to the second carriage 151. The wrench tool 100 includes a power tong section 103 coupled to and suspended from the spinner section 101. The power tong section 103 includes a plurality of grippers 104 and a plurality of tong actuators 105 configured to pivot at least part of the power tong section 103. For example, the tong actuators 105 can pivot upper grippers 104 relative to lower grippers 104. The carriage 121 is aligned under the spinner section 101 and the power tong section 103.

The carriage 121 includes a set of carriage rails 122 and a carriage frame 123 movable relative to the set of carriage rails 122. The support frame 125 includes a set of support rails 126. One of the carriage 121 or the support frame 125 is nested within the other of the carriage 121 or the support frame 125. In the implementation shown in FIG. 1A, the carriage 121 is nested within the support frame 125. The set of support rails 126 are aligned with the set of carriage rails 122, and the set of carriage rails 122 are spaced from each other and comprise carriage channels 127. The actuation system 110 includes a slew bearing 128 coupled to the actuation assembly 120 and operable to rotate the actuation assembly 120. The second support frame 155 includes a pair of second support rails 157 including second support channels 158.

The actuation system 110 includes a rotatable platform 129 coupled to the slew bearing 128. The support frame 125 is coupled to the rotatable platform 129. The support frame 125 includes a plurality of side flanges 130 coupled to the support rails 126. One of two side flanges 130 are shown in FIG. 1A, and the two side flanges 130 are shown in FIG. 2. The support frame 125 is coupled to the rotatable platform 129 using a plurality of retention pins 131 extending through some of a plurality of retention openings 132 formed in each of the plurality of side flanges 130.

The actuation system 110 includes a rotational sensor 196 operable to measure an angle of the slew bearing 128, one or more first position sensors 197 operable to measure a horizontal position of the carriage 121 along the first direction D1. The one or more first position sensors 197 can be mounted to the support rails 126 to track the horizontal position of the carriage rails 122, and/or can be mounted to the carriage rails 122 to track the horizontal position of the carriage frame 123. As an example, the one or more first position sensors 197 can use imaging and/or laser light to track the positions of the carriage rollers 136 and/or the support rollers 139 described below, and correlate the positions to the horizontal positions of the carriage frame 123 and/or the carriage rails 122. The actuation system 110 includes one or more second position sensors 198 operable to measure a vertical position of the second carriage 151 along the second direction D2. The one or more second position sensors 198 can be mounted to the second support rails 157 of the second support frame 155. As an example, the one or more second position sensors 198 can use imaging and/or laser light to track the positions of the second rollers 161 described below, and correlate the positions to the vertical position of the second carriage 151.

The actuation system 110 can be used manually, automatically, or partially manually and partially automatically. Use that is at least partially automatic can include the use of sensors 196-198 and the controller 190 that automatically controls operations described herein. Manual use may omit the use of sensors 196-198 and/or the use of the controller 190.

The controller 190 is in communication with the sensors 196-198 and is used to control processes and methods, such as the operations of the methods described herein. The controller 190 is configured to receive data or input as sensor readings from the sensors 196-198. The controller 190 includes a central processing unit (CPU) 193 (e.g., a processor), a memory 191 containing instructions, and support circuits 192 for the CPU 193. The controller 190 controls various items directly, or via other computers and/or controllers. In one or more embodiments, the controller 190 is communicatively coupled to dedicated controllers, and the controller 190 functions as a central controller.

The controller 190 is of any form of a general-purpose computer processor that is used in an industrial setting for controlling iron roughnecks, and sub-processors thereon or therein. The memory 191, or non-transitory computer readable medium, is one or more of a readily available memory such as random access memory (RAM), dynamic random access memory (DRAM), static RAM (SRAM), and synchronous dynamic RAM (SDRAM (e.g., DDR1, DDR2, DDR3, DDR3L, LPDDR3, DDR4, LPDDR4, and the like)), read only memory (ROM), floppy disk, hard disk, flash drive, or any other form of digital storage, local or remote. The support circuits 192 of the controller 190 are coupled to the CPU 193 for supporting the CPU 193. The support circuits 192 include cache, power supplies, clock circuits, input/output circuitry and subsystems, and the like. Operational parameters and operations are stored in the memory 191 as a software routine that is executed or invoked to turn the controller 190 into a specific purpose controller to control the operations of the various components described herein. The controller 190 is configured to conduct any of the operations described herein. The instructions stored on the memory, when executed, cause one or more of the operations (such as the operations of the method 800) described herein.

As an example, the controller 190 can control power to the one or more actuators 135A, 135B and/or the one or more second actuators 159.

FIG. 1B is a schematic enlarged perspective view of the wrench tool 100 shown in FIG. 1A, according to one or more embodiments.

In FIG. 1B, the side flanges 130 and the support rail 126 are not shown for visual clarity purposes. The retention pins 131 extend through a plurality of second retention openings 133 formed in each of a plurality of platform flanges 134 coupled to the rotatable platform 129.

In relation to FIGS. 1A and 1B, an extension range of the carriage 121 relative to the slew bearing 128 is adjustable. In one or more embodiments, the extension range is adjustable by removing the retention pins 131 from the some of the plurality of retention openings 132, moving the support frame 125 relative to the rotatable platform 129, inserting the retention pins 131 through other of the plurality of retention openings 132, and inserting the retention pins 131 back through the plurality of second retention openings 133. When the retention pins 131 are extended through the retention openings 132 and the second retention openings 133, the support rails 126 are fixedly coupled to the rotatable platform 129 such that the support frame 125 is fixed in place relative to the rotatable platform 129.

FIG. 2 is a schematic enlarged front view of the actuation assembly 120 shown in FIG. 1A, according to one or more embodiments.

The actuation assembly 120 includes one or more actuators 135A, 135B configured to extend and retract the carriage 121 along the first direction D1. In one or more embodiments, one actuator 135A coupled to a crossbar 185 coupled between the carriage rails 122 extends and retracts to move the carriage rails 122 relative to the support frame 125. Actuator 135A is coupled to the crossbar 185 through a first carriage flange 181. In one or more embodiments, another actuator 135B coupled to the carriage frame 123 extends and retracts to move the carriage frame 123 relative to the carriage rails 122. Actuator 135B is coupled to the carriage frame 123 through a second carriage flange 182.

The actuation assembly 120 includes a plurality of rollers 136, 139 coupling the set of carriage rails 122 to the set of support rails 126. The plurality of rollers 136, 139 include one or more carriage rollers 136 (a plurality is shown) and one or more support rollers 139 (a plurality is shown).

FIG. 3 is a schematic enlarged perspective front view of the actuation assembly 120 shown in FIGS. 1 and 2, according to one or more embodiments.

The set of support rails 126 include support channels 143, and the set of support rails 126 are positioned inwardly or outwardly of the set of carriage rails 122 (FIGS. 1-3 show the support rails 126 as outwardly of the carriage rails 122). The one or more carriage rollers 136 respectively include a shaft section 137 extending into an ear 124 of the carriage frame 123 and a head section 138 configured to roll within one of the carriage channels 127. The one or more support rollers 139 respectively include a shaft section 141 extending into one of the carriage rails 122 and a head section 142 configured to roll within one of the support channels 143. As actuator 135A moves the carriage rails 122 relative to the support frame 125, the support rollers 139 roll along the support rails 126. As actuator 135B moves the carriage frame 123 relative to the carriage rails 122, the carriage rollers 136 roll along the carriage rails 122.

The present disclosure contemplates that one or more of the rollers described herein can be omitted. For example, the one or more carriage rollers 136 can be omitted and the carriage frame 123 can slide relative to the carriage rails 122, and/or the one or more support rollers 139 can be omitted and the carriage rails 122 can slide relative to the support rails 126.

The present disclosure contemplates that the rails and channels described herein (such as the carriage rails 122, the carriage channels 127, the support rails 126, and/or the support channels 143) can be a variety of structural members and/or shapes. For example, the rails can be bars, beams, tubulars, pipes, and/or other structural members. As another example, the channels can be rectangular, circular, or semi-circular.

FIG. 4 is a schematic back view of the wrench tool 100 shown in FIG. 1A, according to one or more embodiments.

The second carriage 151 includes a set of second carriage rails 156 spaced from each other, and a set of second support rails 157 positioned inwardly or outwardly of the set of second carriage rails 156. FIG. 4 shows the second support rails 157 positioned outwardly of the second carriage rails 156. The second actuation assembly 150 includes one or more second actuators 159 (one is shown in FIG. 4) configured to extend and retract the second carriage 151 along the second direction D2. At least one of the one or more second actuators 159 is coupled between a carriage flange 160 of the second carriage 151 and a carriage platform 106 of the carriage frame 123. In one or more embodiments, the one or more first actuators 135A, 135B and the one or more second actuators 159 respectively are linear actuators that include one or more of: a hydraulic actuator, a pneumatic actuator, a worm gear actuator, and/or a rack-and-pinion actuator.

The second actuation assembly 150 includes a plurality of second rollers 161 coupling the set of second carriage rails 156 to the set of second support rails 157. The plurality of second rollers 161 respectively comprise a shaft section 162 (FIGS. 6 and 7) extending into one of the second carriage rails 156 and a head section 163 (FIG. 7) configured to roll within one of the second support channels 158 of the set of second carriage rails 156.

Actuator 135A that moves the carriage rails 122 is coupled to a support connector bar 145 through a support flange 144. The support connector bar 145 is connected between the support rails 126. Actuator 135B that moves the carriage frame 123 is coupled to a connector bar 147 through a third carriage flange 183. The connector bar 147 is connected between the carriage rails 122. The support connector bar 145 and the connector bar 147 are disposed on a rear side of the second actuation assembly 150 relative to the crossbar 185. The support frame 125 is positioned at least partially around the carriage 121, and the second support frame 155 is positioned at least partially around the second carriage 151.

FIG. 5 is a schematic enlarged back view of the actuation assembly 120 shown in FIG. 4, according to one or more embodiments.

The second support frame 155 is fixedly coupled to the carriage platform 106 of the carriage frame 123 of the carriage 121 such that the second support frame 155 and the second carriage 151 are movable with the carriage 121 along the first direction D1, and the second carriage 151 is movable relative to the carriage 121 along the second direction D2.

FIG. 6 is a schematic perspective back view of the wrench tool 100 shown in FIGS. 1 and 4, according to one or more embodiments.

FIG. 7 is a schematic enlarged perspective back view of the second actuation assembly 150 shown in FIGS. 1, 4, and 6, according to one or more embodiments.

FIG. 8 is a schematic flow diagram view of a method 800 of making up or breaking out a tubular connection, according to one or more embodiments. The method 800 is described in relation to the wrench tool 100 for exemplary purposes. The method 800 can be used in relation to other apparatus and/or components.

Optional operation 802 includes measuring one or more parameters of the wrench tool 100. In one or more embodiments, the one or more parameters include the angle of the slew bearing 128 measured using the rotational sensor 196. In one or more embodiments, the one or more parameters include the horizontal position of the carriage 121 measured using the one or more first position sensors 197. In one or more embodiments, the one or more parameters include the vertical position of the second carriage 151 measured using the one or more second position sensors 198.

Optional operation 804 includes comparing the one or more parameters of operation 802 to a target position. In one or more embodiments, the angle, the horizontal position, and the vertical position of operation 802 are compared to the target position. In one or more embodiments, the target position corresponds to a rig floor position, such as a wellbore center or a mousehole. The target position can be disposed at other equipment or other locations, for example other locations at a rigsite. The comparing can include calculating an adjusted angle, an adjusted horizontal position, and/or an adjusted vertical position to align a first opening 108 of the power tong section 103 and a second opening 109 of the spinner section 101 with the target position.

Optional operation 805 includes pivoting the carriage 121 and the second carriage 151. In one or more embodiments, the pivoting includes powering the slew bearing 128 to position the carriage 121 and the second carriage 151 at the adjusted angle;

Operation 806 includes extending the carriage 121 linearly along the first direction D1 (e.g., the horizontal direction) to linearly move the spinner section 101 and the power tong section 103 of the wrench tool 100. The extending of the carriage 121 includes actuating the one or more actuators 135A, 135B coupled to the carriage 121 to move the carriage 121 relative to the support frame 125 positioned at least partially around the carriage 121. In one or more embodiments, the extending of the carriage 121 includes powering the one or more actuators 135A, 135B to position the carriage 121 at the adjusted horizontal position.

Operation 808 includes extending the second carriage 151 linearly along the second direction D2 (e.g., the vertical direction) to linearly move the spinner section 101 and the power tong section 103 of the wrench tool 100. The extending of the second carriage 151 includes actuating the one or more second actuators 159 coupled between the second carriage 151 and the carriage 121. In one or more embodiments, the extending of the second carriage 151 includes powering the one or more second actuators 159 to position the second carriage 151 at the adjusted vertical position.

Operation 810 includes positioning a first tubular and a second tubular in the first opening 108 of the power tong section 103 and the second opening 109 of the spinner section 101. The positioning of operation 810 can result from the extending of operation 806 and/or the extending of operation 808.

Operation 812 includes spinning the second tubular relative to the first tubular using the plurality of spinner rollers 102 of the spinner section 101.

Operation 814 includes pivoting at least part of the power tong section 103 to torque the second tubular relative to the first tubular using the grippers 104.

The present disclosure contemplates that the operations of the method 800 can be performed in a variety of orders and/or simultaneously. As an example, in one or more embodiments, the vertical extending of operation 808 is conducted prior to the horizontal extending of operation 806. The vertical extending of the second carriage 151 can vertically clears the spinner section 101 and the power tong section 103 above a piece of equipment disposed along a rig floor, and the horizontal extending of the carriage 121 can extend the spinner section 101 and the power tong section 103 horizontally past the piece of equipment and toward a well center opening formed in the rig floor. As another example, the pivoting of operation 814 can be conducted before (e.g., to break out a connection) or after (e.g., to make up a connection) the spinning of operation 812.

FIG. 9 is a schematic perspective side view of the wrench tool 100 shown in FIG. 1A after the actuation assembly 120 linearly moves the carriage 121 relative to the support frame 125 along the first direction D1 using the one or more actuators 135A, 135B, according to one or more embodiments.

FIG. 10 is a schematic perspective back view of the wrench tool 100 shown in FIG. 9 after the second actuation assembly 150 linearly moves the second carriage 151 relative to the first carriage 121 and the second support frame 155 along the second direction D2 using the one or more second actuators 159, according to one or more embodiments.

FIG. 11 is a schematic enlarged front perspective view of an actuation assembly 1120, according to one or more embodiments. The actuation assembly 1120 is similar to the actuation assembly 120 shown in FIGS. 1-7 and 9-10, and includes one or more aspects, features, components, operations, and/or properties thereof. The actuation assembly 1120 can be used in place of the actuation assembly 120 shown in FIGS. 1-7 and 9-10. FIG. 11 shows the actuation assembly 1120 in an extended position.

The actuation assembly 1120 includes a single actuator 135A coupled to a crossbar 1136 of the carriage 121 through a carriage flange 1145. A carriage platform 1106 of the carriage frame 123 is between a pair of ears 1124.

FIG. 12 is a schematic enlarged back perspective view of the actuation assembly 1120 shown in FIG. 11, according to one or more embodiments.

The support frame 125 of the actuation assembly 1120 includes a support platform 1129 coupled (e.g., welded) to the support rails 126. The support platform 1129 is coupled (e.g., fastened) to the slew bearing 128 such that the slew bearing 128 rotates the support platform 1129. The actuation assembly 1120 omits the side flanges 130, the retention pins 131, and the platform flanges 134 such that the support rails 126 are fixed in place relative to the slew bearing 128 and the support platform 1129. The actuator 135A is coupled between the carriage flange 1145 and a support flange 1146 of the support frame 125. The support flange 1146 is coupled to the support platform 1129.

The actuation system 110 includes a linkage system 1170 coupled between the carriage 121 and the support frame 125. The linkage system 1170 includes a first chain 1171 wound about a first gear 1172 coupled to the crossbar 1136 between the set of carriage rails 122 and a second gear 1173 coupled to connector bar 147 between the carriage rails 122. The linkage system 1170 includes a second chain 1174 wound about a third gear 1175 coupled to the crossbar 1136 between the set of carriage rails 122 and a fourth gear 1176 coupled to the connector bar 147 between the carriage rails 122.

FIG. 13 is a schematic partial side perspective view of the linkage system 1170 shown in FIG. 12, according to one or more embodiments.

The first chain 1171 includes a first travel block 1177 coupled to the support frame 125, and the second chain 1174 includes a second travel block 1178 coupled to the support frame 125. The first travel block 1177 and the second travel block 1178 are coupled to a crossbar 1149 coupled between the support rails 126 of the support frame 125. As shown in FIG. 12, the first chain 1171 includes a third travel block 1181 and the second chain 1174 includes a fourth travel block 1182. The third travel block 1181 and the fourth travel block 1182 are coupled to the carriage platform 1106 of the carriage frame 123.

As the actuator 135A extends and retracts the carriage rails 122 using the crossbar 1136, the travel blocks 1177, 1178, 1181, 1182 tension the chains 1171, 1174 to extend and retract the carriage frame 123 using the carriage platform 1106. Using the chains 1171, 1174, the carriage frame 123 can move at a speed ratio relative to the carriage rails 122. In one or more embodiments, the speed ratio is 2:1. As an example, an extension range of 36 inches for the actuator 135A can achieve an overall extension range of 72 inches for the carriage frame 123 relative to the support platform 1129 and the slew bearing 128. The single actuator 135A and the linkage system 1170 facilitate a more compact wrench tool 100 for larger extensions ranges, reliability of movement, and simpler actuation. The present disclosure contemplates that linkages other than chains can be used in place of the chains 1171, 1174. For example, one or more ropes, one or more belts, one or more cables, and/or one or more other linkages can be used in place of the first chain 1171 and/or the second chain 1174.

Benefits of the present disclosure include reduced sizes of positioning systems that position wrench tools, modularity of positioning systems and wrench tools across various rigs having various derricks and various rig floors, and reduced or eliminated chances of interference of equipment (such as interference of positioning systems with other equipment along the rig floor. Benefits also include larger extension ranges for positioning systems, reliability of movement, and simple and reliable actuation.

The present disclosure contemplates that one or more aspects of the embodiments described herein may be substituted in for and/or combined with one or more of the other aspects described. Moreover, it is contemplated that one or more of these aspects may include some or all of the aforementioned benefits. For example, the present disclosure contemplates that one or more aspects, features, components, operations, and/or properties of the wrench tool 100, the actuation assembly 120, the second actuation assembly 150, the method 800, the actuation assembly 1120, and/or the linkage system 1170 may be combined.

While the foregoing is directed to embodiments of the disclosure, other and further embodiments may be devised without departing from the basic scope thereof. As is apparent from the foregoing general description and the specific embodiments, while forms of the present disclosure have been illustrated and described, various modifications can be made without departing from the spirit and scope of the present disclosure. Accordingly, it is not intended that the present disclosure be limited thereby. It is intended that all modifications, permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the scope of the disclosure. It is therefore intended that the following appended claims may include all such modifications, permutations, enhancements, equivalents, and improvements.

Claims

1. An actuation system for iron roughnecks, comprising: an actuation assembly comprising: a carriage comprising a set of carriage rails,a support frame, the support frame comprising a set of support rails, andone or more actuators configured to extend and retract the carriage along a first direction, at least one of the one or more actuators coupled between a carriage flange of the carriage and a support flange of the support frame.

2. The actuation system of claim 1, wherein one of the carriage or the support frame is nested within the other of the carriage or the support frame.

3. The actuation system of claim 1, wherein the set of support rails are aligned with the set of carriage rails, the set of carriage rails are spaced from each other and comprise carriage channels.

4. The actuation system of claim 3, wherein the set of support rails comprise support channels, and the set of support rails are positioned inwardly or outwardly of the set of carriage rails.

5. The actuation system of claim 4, wherein the carriage further comprises a carriage frame movable relative to the set of carriage rails, and the actuation assembly further comprises a plurality of rollers coupling the set of carriage rails to the set of support rails, and the plurality of rollers comprise: one or more carriage rollers respectively comprising a shaft section extending into an ear of the carriage frame and a head section configured to roll within one of the carriage channels; andone or more support rollers respectively comprising a shaft section extending into one of the carriage rails and a head section configured to roll within one of the support channels.

6. The actuation system of claim 1, and the actuation system further comprises: a second actuation assembly comprising: a second carriage comprising a set of second carriage rails, the set of second carriage rails spaced from each other,a second support frame coupled to the carriage, the second support frame comprising a set of second support rails positioned inwardly or outwardly of the set of second carriage rails,one or more second actuators configured to extend and retract the second carriage along a second direction that is oriented at an angle relative to the first direction, at least one of the one or more second actuators coupled between a carriage flange of the second carriage and a carriage platform of the carriage frame.

7. The actuation system of claim 6, wherein the actuation assembly further comprises a plurality of rollers coupling the set of carriage rails to the set of support rails, the second actuation assembly further comprises a plurality of second rollers coupling the set of second carriage rails to the set of second support rails, and the plurality of second rollers respectively comprise a shaft section extending into one of the second carriage rails and a head section configured to roll within one of second support channels of the set of second carriage rails.

8. The actuation system of claim 6, wherein the support frame is positioned at least partially around the carriage, and the second support frame is positioned at least partially around the second carriage.

9. The actuation system of claim 6, wherein the direction is a horizontal direction and the second direction is a vertical direction.

10. The actuation system of claim 6, wherein the second support frame is fixedly coupled to the carriage such that the second support frame and the second carriage are movable with the carriage along the first direction, and the second carriage is movable relative to the carriage along the second direction.

11. The actuation system of claim 1, further comprising a slew bearing coupled to the actuation assembly and operable to rotate the actuation assembly.

12. The actuation system of claim 11, wherein an extension range of the carriage relative to the slew bearing is adjustable.

13. The actuation system of claim 11, further comprising: a rotational sensor operable to measure an angle of the slew bearing; andone or more first position sensors operable to measure a horizontal position of the carriage along the first direction.

14. The actuation system of claim 13, further comprising: a controller comprising instructions stored in a memory that, when executed by a processor, cause a plurality of operations to be conducted, the plurality of operations comprising: measuring the angle of the slew bearing using the rotational sensor;measuring the horizontal position using the one or more first position sensors; andcomparing the angle and the horizontal position to a target position that corresponds to a rig floor position.

15. The actuation system of claim 14, wherein the plurality of operations further comprise: powering the slew bearing to position the carriage at the angle; andpowering the one or more actuators to position the carriage at the horizontal position.

16. The actuation system of claim 1, wherein the carriage further comprises a set of carriage rails and a carriage frame movable relative to the set of carriage rails, and the actuation system further comprises a linkage system coupled between the carriage and the support frame.

17. The actuation system of claim 16, wherein the linkage system comprises: a first chain wound about a first gear coupled to a crossbar between the set of carriage rails and a second gear coupled to a connector bar between the carriage rails, the first chain comprising a first travel block coupled to the support frame; anda second chain wound about a third gear coupled to the crossbar between the set of carriage rails and a fourth gear coupled to the connector bar between the carriage rails, the second chain comprising a second travel block coupled to the support frame.

18. A wrench tool for making up and breaking out tubular connections on an oil and gas rig, the wrench tool comprising: an actuation assembly comprising: a carriage,a support frame, andone or more actuators configured to extend and retract the carriage along a first direction relative to the support frame;a second actuation assembly comprising: a second carriage,a second support frame coupled to the carriage,one or more second actuators configured to extend and retract the second carriage along a second direction that is oriented at an angle relative to the first direction;a spinner section comprising a plurality of spinner rollers, the spinner section coupled to the second carriage; anda power tong section coupled to and suspended from the spinner section, the power tong section comprising a plurality of grippers and a plurality of tong actuators configured to pivot at least part of the power tong section.

19. The wrench tool of claim 18, wherein the carriage is aligned under the spinner section and the power tong section.

20. A method of making up or breaking out a tubular connection, the method comprising: extending a carriage linearly along a horizontal direction to linearly move a spinner section and a power tong section of a wrench tool, the extending of the carriage comprising: actuating one or more actuators coupled to the carriage to move the carriage relative to a support frame positioned at least partially around the carriage;extending a second carriage linearly along a vertical direction to linearly move the spinner section and the power tong section of the wrench tool, the extending of the second carriage comprising: actuating one or more second actuators coupled between the second carriage and the carriage;positioning a first tubular and a second tubular in a first opening of the power tong section and a second opening of the spinner section;spinning the second tubular relative to the first tubular using a plurality of spinner rollers of the spinner section; andpivoting at least part of the power tong section to torque the second tubular relative to the first tubular.

21. The method of claim 20, wherein: the extending of the second carriage occurs prior to the extending of the carriage;the extending of the second carriage vertically clears the spinner section and the power tong section above a piece of equipment disposed along a rig floor; andthe extending of the carriage extends the spinner section and the power tong section horizontally past the piece of equipment and toward a well center opening formed in the rig floor.