Patent Grant
9453377
Embodiments of the present disclosure relate, generally, to apparatus and methods for making up and breaking out wellbore tubulars and, more particularly, to an integrated, electric tong system and methods of use at a wellbore.
In the oil and gas industry, oil field tools, such as tongs or wrenches, are used to grip and rotate joints of tubulars (e.g., casing, drill pipe, other tubulars), particularly during makeup operations (e.g., threadably engaging, screwing together) or break-out operations (e.g., threadably disengage, unscrew). These oil field operations typically require a set of tongs, including an upper tong, which can be used to rotate an upper tubular for threadably connecting the upper tubular to, or removing the upper tubular from, a lower tubular, and a lower tong, which can be used to secure and hold stationary a lower tubular, to prevent its rotation in conjunction with the rotating upper tubular. The upper tong is commonly referred to in the industry as a power tong. The power tong comprises a mechanism or various components for gripping and rotating a tubular, while the body or housing of the power tong remains stationary. The lower tong is commonly referred to in the industry as a backup tong, and is used, as set forth above, for securing and holding a tubular stationary.
Typically, power tongs are hydraulically driven, which can include the use of hydraulic hoses connecting the power tongs to a hydraulic power unit or source for actuating or powering the jaws of the power tong. Valves are typically used to control the flow of hydraulic fluid or oil to the power tongs, for providing power to the power tong and gearbox, which in turn, operates the jaws of the power tongs for closing around a tubular and rotating the tubular. This type of hydraulic system, for powering the power tongs, can generally lack precision in the operation of the tongs, including the control of the speed of the rotation of the tongs and the torque applied to the tubular. In addition, this type of hydraulic system can pose environmental concerns, which can be associated with a leakage or spillage of the hydraulic oil.
In addition, the combinations of hydraulically powered power tongs and backup tongs are cumbersome and heavy tools. As such, hydraulic lift cylinders are typically required for moving and supporting the power and backup tongs, particularly when making up or breaking out a string of tubulars. Although existing units have combined a power tong with a backup tong, the lift cylinders are generally added, when rigging up in the field and operated separately.
Therefore, a need exists for an electric tong system that can be packaged and integrated into a single system, comprising a power tong, a backup tong, and a lift assembly, for minimizing rig-up time and expenses.
A need exists for an integrated electric tong system comprising a power tong, a backup tong, and a lift assembly, in which the motors for the power tong, backup tong and lift assembly can be operated and controlled by the use of a single driver. The electric tong system will enable greater precision in controlling the speed, torque, and direction of the rotation of the power tongs.
A need exists for an integrated electric tong system and methods of use comprising a power tong, backup tong and lift assembly, wherein the backup tong includes automated control for enabling greater precision in the movement of the backup tong components as well as the clamping and gripping of tubulars. In addition, a need exists for an automated electric tong system, comprising interlocking, capabilities for providing remote operation and additional safety features.
A need exists for an integrated electric tong system and methods of use comprising automation for remote operation of the electric tong system and for monitoring and analyzing the turns and torque data.
The embodiments of the electric tong system and methods of use meet these needs.
Embodiments of the present disclosure relate, generally, to an integrated, electric tong system that can be usable for threading and unthreading tubular members at a wellbore. The electric tong assembly can include a frame assembly that can comprise an upper frame and lower frame, wherein the lower frame can include a first vertical member and a second vertical member. At least one actuator can be connected to the upper frame and the lower frame for moving the upper frame with respect to lower frame, and the at least one actuator can be driven by a first electric motor. In an embodiment, the at least one actuator is a linear actuator. In an embodiment, the upper frame can comprise a U-shaped frame that can be moved telescopically in relation to the lower frame.
The electric tong system can further include a backup tong that can be connected to the lower frame, wherein the backup tong can be driven by a second electric motor and can comprise a central opening for receiving a lower tubular member, such that the backup tong can receive, clamp and grip the lower tubular member during threading or unthreading operations. The electric tong system can further include a power tong that can be connected to the backup tong, and the power tong can include a central opening for receiving an upper tubular member. The power tong can be driven by a third electric motor and can be used for gripping and rotating the upper tubular member during threading or unthreading operations. In an embodiment of the electric tong system, a single driver is used for controlling the first electric motor, the second electric motor and the third electric motor of the electric tong system.
The power tong can include a housing that comprises an opening, and a rotary mechanism located within the housing that also comprises an opening. The power tong can further include a plurality of jaws and a ring gear that can be operably connected to the third electric motor of the electric tong system. The power tong housing can include a door that can be rotatably connected to the housing and located proximate to the opening of the housing, wherein the opening of the housing and the opening of the rotary mechanism can align to comprise the central opening of the power tong. The power tong can further include a plurality of sensors that can be usable for sending a signal to actuate the plurality of jaws to secure the upper tubular member, when the openings of the housing and rotary mechanisms are aligned and the power tong door is closed. In an embodiment, the ring gear and rotary mechanism can be used to transfer torque from the third electric motor to the upper tubular member when the plurality of jaws are actuated.
The backup tong of the electric tong system can be usable for clamping and gripping a tubular member during threading and unthreading of the tubular member, for example, during make-up and break out operations. The backup tong can comprise a frame that partially defines a central opening that can receive the tubular member for threading or unthreading of the tubular. A door can be rotatably connected to the frame, and the door can rotate between an open position and a closed position, and partially define the central opening. A first linear actuator can be connected to the frame and to the door for use in rotating the door between the open position and the closed position. A latching arm can be rotatably connected to the frame, wherein the latching arm can latch the door in the closed position, and a second linear actuator can be connected to the frame and to the latching arm, wherein the second linear actuator an rotate the latching arm to latch the door in the closed position, and wherein the rotation of the latching arm progressively increases a force of contact between the door and the tubular member. The second linear actuator can be driven by an electric motor, and sensors can be operably connected to the first linear actuator and the second linear actuator for detecting the positions of the linear actuators and for activation/deactivation of the linear actuators.
The backup tong can further comprise a load cell, which can be located within the frame, and a J-shaped load transfer member that can include a first end connected to the load cell and a second end connected to the second linear actuator. In an embodiment, the load transfer member can be pivotably connected to the frame assembly and can transfer a proportion of force received from the second linear actuator to the capacity of the load cell.
In an embodiment of the backup tong, the frame can include at least one guide plate, and the second linear actuator can comprise at least one protrusion that can intersect with the at least one guide plate of the frame. In another embodiment of the backup tong, the central opening can be further defined by at least one gripping member for gripping the tubular.
Embodiments of the present invention can include a method for installing or removing a plurality of tubulars into or from a wellbore, respectively, wherein the method steps can include: positioning an electric tong system onto a joint of tubulars, wherein the electric tong system can include: a frame assembly; a backup tong comprising a first opening, a first door, and a latching arm; and a power tong comprising a second opening, a second door, and a plurality of jaws. The plurality of tubulars are generally joined into a continuous string whereby each joint of tubulars can include an upper tubular connected to a lower tubular with a connector.
The steps of the method can continue by adjusting the frame assembly for aligning the first opening of the backup tong with the second opening of the power tong. The aligned backup tong can grip the lower tubular, and the aligned power tong can grip the upper tubular. The method can further include closing the first door and second door, wherein the first door can trigger a linear actuator to compress the first door against the connector, and the second door can trigger the plurality of jaws to compress the upper tubular against a rotary mechanism and operably connect the rotary mechanism to an electric motor through a low transfer gear. The steps of the method can further include rotating the aligned power tong until the upper tubular is connected or disconnected from the lower tubular, and aligning the rotary mechanism with the second opening for opening the second door. The method can conclude by de-energizing the linear actuator to open the first door, and installing or removing the upper tubular into or from the wellbore. The method steps can be repeated, as needed, for installing or removing the plurality of tubulars into or from the wellbore, respectively.
In an embodiment, the step of closing the first door can further include actuating a second linear actuator, which can be connected to the frame assembly and to the latching arm, for rotating the latching arm to latch the first door in a closed position. The rotating of the latching arm can progressively increase a force of contact between the first door and the lower tubular.
In an embodiment, the interlock system of the electric tong system can include preventing the rotation of the aligned power tong, for disconnecting the upper tubular from the lower tubular, until after the first door has been closed. In addition, the interlock system can include locking the frame assembly in place and preventing any adjustments thereto until the first door has been opened. Further, the interlock system of the electric tong system can enable the performance of only one of the following steps at a time, including: adjusting the frame assembly, compressing the first door, or rotating the power tong.
In the detailed description of various embodiments usable within the scope of the present disclosure, presented below, reference is made to the accompanying drawings, in which:
One or more embodiments are described below with reference to the listed Figures.
Before describing selected embodiments of the present invention in detail, it is to be understood that the present invention is not limited to the particular embodiments described herein. The disclosure and description of the invention is illustrative and explanatory of one or more presently preferred embodiments of the invention and variations thereof, and it will be appreciated by those skilled in the art that various changes in the design, organization, order of operation, means of operation, equipment structures and location, methodology, and use of mechanical equivalents, as well as in the details of the illustrated construction or combinations of features of the various elements, may be made without departing from the spirit of the invention.
As well, the drawings are intended to describe the concepts of the invention so that the presently preferred embodiments of the invention will be plainly disclosed to one of skill in the art, but are not intended to be manufacturing level drawings or renditions of final products and may include simplified conceptual views as desired for easier and quicker understanding or explanation of the invention. As well, the relative size and arrangement of the components may differ from that shown and still operate within the spirit of the invention as described throughout the present application.
Moreover, it will be understood that various directions such as “upper”, “lower”, “bottom”, “top”, “left”, “right”, “inward”, “outward” and so forth are made only with respect to explanation in conjunction with the drawings, and that the components may be oriented differently, for instance, during transportation and manufacturing as well as operation. Because many varying and different embodiments may be made within the scope of the inventive concept(s) herein taught, and because many modifications may be made in the embodiments described herein, it is to be understood that the details herein are to be interpreted as illustrative and non-limiting.
Embodiments of the present disclosure relate, generally, to an apparatus and methods for making up and breaking out tubular joints and, more particularly, to an integrated, electric tong system and methods of use at a wellbore. The integrated electric tong system comprises a power tong, a backup tong, and a lift system (e.g., two actuators, a gearbox, a brake, an electric motor, interconnecting components and a telescopic frame), which are integrated into a single package and operated by electrical motors that can be controlled by a single driver.
The apparatus can include the use of switchgears and contactors for enabling the use of the single driver to control and operate the individual electric motors of the power tong, backup tong, and the lift system, as described above. The driver comprises the electronics and firmware required to control the speed and direction of the electric motor(s), and the driver can be housed in a separate aluminum box (i.e., driver box) that can be positioned in a safe area (i.e., nonhazardous area), away from the electric tong system.
The backup tong is located below the power tong of the electric tong system, and comprises a pneumatic cylinder for operation of a backup door. An electric motor can be mounted on the backup tong for operating a latch, located on the backup tong, which can be used for locking the backup door and applying a clamping force to a lower tubular during make-up or break-out operations. While the backup tong clamps and holds the lower tubular stationary, the power tong can rotate the upper tubular, which allows the power tong to apply torque to the connection joint between the upper tubular and the lower tubular.
The backup tong, which is used for the clamping of the lower tubular, can comprise a backup door(s) that can be closed pneumatically (i.e., use of a pneumatic cylinder) and tightened electrically. Specifically, an electric linear actuator can be used for applying a clamp force to the lower tubular, during make-up or break-out of the tubular joint connections. The clamp force can be sensed and measured by an electronic tension load cell that can be located in the backup tong and connected to a “J-shaped” member that can be pivotally connected to the backup case. A first end of the “J-shaped” member can be connected to the electrically-operated linear actuator, while a second end of the “J-shaped” member can be connected to the electronic tension load cell. The “J-shaped” member can be a lever that is used for proportioning the force from the electric linear actuator to the capacity of the electronic tension load cell.
The pneumatic backup door cylinder can comprise sensors, which can be used to detect when the clamping cylinder should actuate. The pneumatic backup door cylinder can further comprise a magnetic piston and two reed switches, wherein the reed switches are closed when the magnetic piston is moved near to them. When the backup door is closed, via the pneumatic cylinder, the reed switch, which is near the rod end of the pneumatic backup door cylinder, can become activated and the electric motor, which actuates a linear actuator, can become energized. The other reed switch can alert the backup control system when the backup door is open. The reed switches can also serve as position sensors on the pneumatic backup door cylinders. During an end-of-stroke condition, the electric linear actuator becomes de-energized, and a linear distance sensor, located on the piston end of the electric linear actuator, can be used for sensing rod position and, hence, an end-of-stroke condition.
In an embodiment of the electric tong system, the power tong can be located above the backup tong, and can be a conventional or hydraulic tong that is retrofitted to operate via an electric motor. The motor operating the power tong can be a servo-type motor that provides precise application of torque and speed. In an embodiment, the power tong is attached to a frame, which can be extended and retracted by an electrically operated lift system, as described above, for allowing vertical movement of the electric tong system.
Unlike conventional tongs, the automation of the electric tong system enables the operation of a selected sequence of functions through a single actuation (i.e., a push of a button can close the power tong door, latch the backup door and rotate the power tong). An operator box, which can be located at various positions on or about the electric tong system, including on the power tong, at the bottom of the tong, or on a floor stand, and remotely positioned with respect to the electric tong system, can be used to operate all of the functions on the electric tong system, including tong door open/close, backup open/close, lift up/down, high/low gear, rotate/cage plate align, manual/automatic mode, and make/break direction. In an alternative embodiment, the electric tong system can be operated remotely. A computer or computerized system can be used to monitor, receive and analyze the functions and output of the power tong, backup tong, and the lift cylinder of the electric tong system.
The automated and/or remote operation of the electric tong system provides many unique and/or safety features, including: (a) operation of the electric tong system from the rig floor or remotely (hand controller) to eliminate the need for an operator to be located on an operator stand (e.g., scaffolding) and the potential danger to the operator; (b) greater precision with regard to the control of the speed and direction of the motor(s) for the power tong and backup tong; (c) better torque control of the joint connection; (d) elimination of hydraulic power usage and related environmental issues; (e) safer operation during make-up and break-out operations by capability of an enhanced interlocking system; (f) Torque Turn system built into electric tong system for monitoring and analyzing data regarding the number of turns and the torque amount, with or without the use of a computer to record connections; (g) the transport footprint is about the same as a standard tong apparatus; (h) no side load reaction system; and (i) the ability to retrofit a conventional hydraulic tong with an electric motor and a gearbox to form the electric tong system.
Referring now to the drawings and more particularly to
In this embodiment, a backup tong (30) is mounted to horizontal support beam(s) that attach(es) to the frame members (16a, 16b) and/or base members (18a, 18b). In an alternate embodiment, the backup tong can attach to a second or lower U-shaped member, which can attach to the lower end of the vertical frame members (16a, 16b) and/or the base members (18a, 18b). The backup tong (30), as shown in this embodiment of the electric tong system, will be further described in subsequent Figures. The power tong (50) and backup tong (30) can be connected to each other by a post (52) (e.g., torsion post), extending therebetween.
Conventional power tongs can include an “open throat” tong, in which the body and ring gear of the tongs have a window or opening for permitting a pipe or other tubular to be moved into and out of the central opening of the ring gear. Other conventional power tongs include a closed throat configuration, in which a pipe or other tubular must be inserted longitudinally into a ring gear opening. Open throat tongs typically have a gear train comprising two or more idler gears, while closed throat tongs may omit the idler gear(s) and drive the ring gear directly by the pinion gear. The idler gears are rotated, generally, by a gear that is rotated by a rotary power source, typically a hydraulic motor. The different gears, taken together, form a gear chain.
Power tongs generally comprise a housing, which can have a vertical slot with a vertical axis, which can be occupied by a pair of pipe or tubulars that are to be assembled or disassembled, during oil field operations. This type of power tong will generally have cam surfaces, disposed on the rotary gear, for moving the jaws, of a pair of jaw assemblies, in contact with a tubular. For example, drill pipe tongs often use hydraulic cylinders to engage the pipe, wherein a first set of hydraulic cylinders can include a pair of jaw assemblies usable to grip the pipe. The drill pipe tongs can also include a second set of hydraulic cylinders usable to rotate the pipe. A door, which is pivotally connected to the housing, may be closed during operation of the power tong. Each jaw assembly of a drill pipe tong can be powered, during a make-up or break-out operation, by one of said hydraulic cylinders, for gripping a first pipe and, thereafter, for positioning a second pipe for rotation. The pair of jaw assemblies can be mounted within cylindrical recesses provided, respectively, in the upper and lower portions of the housing. A pair of upper, laterally extending chambers and a pair of lower, laterally extending chambers can further comprise the housing.
In another arrangement, a conventional power tong can comprise a rotary, which is rotatably mounted in the housing. Relative rotation between the rotary and the housing can be inhibited by a device, such as a bolt, which is located on the power tong.
Other conventional power tongs can comprise two “passive” jaws that are fixed in the power tong, and a third “active” jaw that is advanced towards or retracted away from a pipe as desired. The active jaw may be mounted in a jaw holder, the radial extremity of which is provided with a roller which rests on a cam surface formed on a rotary. When the rotary rotates relative to the jaw holder, the roller rides along the cam surface and urges the jaw against the pipe with a force, which is a function of the slope of the cam surface. Once the jaw is firmly applied, the pipe and rotary rotate in unison. Power tongs may further use toothed dies, which are carried by the jaws, to transmit torque to the tubular connection. In yet another typical arrangement, the power tong may comprise a plurality of rollers that grip a pipe. The power tong may further comprise a belt(s), chain, and/or sprockets that function to rotate rollers or the rotary, depending on the arrangement.
Continuing with regard to the embodiment of the electric tong system, as shown in
An electric motor (56, shown in
Referring to
In another embodiment of the electric tong system and as shown in
As further depicted in
As shown in
As set forth above, a sensor, which can detect when the clamping cylinder (84) should actuate, is located on the pneumatic backup door cylinder (74). The pneumatic backup door cylinder (74) may have a magnetic piston. Attached to the body of the pneumatic backup door cylinder (74) are two reed switches (73, 75). The reed switches are closed when the magnetic piston is located near them. When the backup door (76) is closed via the pneumatic backup door cylinder (74), the reed switch (73) that is near the rod end of the pneumatic cylinder (74) can become activated, which, in turn, enables the electric linear actuator or clamping cylinder (84) to become energized. The other reed switch (75) can be used to signal the control system that the backup door (76) is open. The reed switches can also function as position sensors.
As shown in
When the backup door (76) of the backup tong (30) is in a closed position, an electric motor and brake assembly (82), depicted in
As shown in the embodiments of
In contrast, the backup tong (30) of the present invention, as particularly shown in
Turning now to
The power tong (50) can be driven by an electric motor (56), which is not shown here for clarity but depicted in
During make-up and break-out operations, the tubular (5) can be positioned at the center of the rotating mechanism (130), provided the rotating mechanism (130) is rotated such that its throat (105) is aligned with the front opening (115) in the housing (110), as shown in
During the torqueing portion of the make-up and break-out operations, a plurality of pressure and position sensors (not shown) can continuously transmit electrical torque and rotation signals to the electronic control system (to be described later). When the desired torque is imparted to the tubular (5), or if the desired number of rotations of the tubular (5) is reached, the jaws (135) automatically release and the rotating mechanism (130) reverses until its throat (105) is aligned with the front opening (115) of the housing (110).
The electronic control of the power tong (50) can be further adapted with a reset function, whereupon receiving an electrical signal, the electronic control system can cause the electrical motor to reverse direction of rotation and orient the rotating mechanism (130) to its reset position. In an embodiment, the reset function is initiated by a button on an operator box ((392), not shown here but depicted in
In another embodiment, as shown in
In this embodiment, a backup tong (330) is mounted to a post (350) (e.g., torsion post). The backup tong (330) is similar to the backup tong disclosed in
Further,
In an embodiment, the electric tong system (300) additionally includes an operator box (392) for controlling various functions of the tong system (300). The operator box (392) may be located at various positions on or about the electric tong system (300), including at the base (308) of the electric tong system (300), such that its location can eliminate the need for the operator to use a tong stand, thus providing an important safety feature. The operator box (392) may comprise seven toggle switches, which can be used for controlling the functions of the electric tong system (300), including: open/close power tong door, open/close backup tong door, up/down of lift, high/low gear, rotate/cage plate alignment, manual/automatic mode of operation, and make-up/break-out direction.
As depicted in
Additionally, the embodiment depicted in
It can of course be appreciated that the positioning of the operator box (392) is not limited to the depicted embodiments located on the base (308) or the side of the electric power tong system (300), but may be positioned anywhere on the apparatus as is convenient to the operator and required by the one of ordinary skill in the art. In an alternate embodiment, the operator box (392) can be located on a stand on the rig floor, which is positioned away from the electric tong system (300), for enabling the operator to be located remote to the electric tong system (300). This remote placement of the operator box (392) provides an enhanced safety feature with regard to the operation of the electric tong as it eliminates the need for the operator to be positioned on an operator stand (e.g., scaffolding), located above and/or adjacent to the electric tong system (300).
In another embodiment, as shown in
In another embodiment, as shown in
Referring to
In a conventional hydraulic backup tong, all backup tong functions are operated hydraulically by hydraulic cylinders that receive pressurized hydraulic fluid from a remote hydraulic power unit. The flow of hydraulic fluid into the cylinders is typically controlled by a pressure sequencing valve, which is connected between the directional control valve and the backup cylinders. This includes the control of the hydraulic actuation of the backup tong jaw grip, door opening, door closing, and door latching. Shifting the directional control valve lever will cause the backup tong grip cylinder to retract, thus releasing the grip, which is then closely followed by an opening of the backup latch and, then, the opening of the tong doors. Pushing the control valve lever will cause the backup doors to close, which is then closely followed by the closing of the backup latch and the extension of the gripping cylinder, causing the backup tong to grip the tubular. Upon release, the directional control valve spring returns to the central neutral position.
Regarding the present invention, the controlled sequence of functions, for operation of the backup tong (30), as previously discussed in
There are two conditions that dictate when a tubular joint is backed out of a wellbore. In the first instance, while running a tubular string, if the tubular joint is made up and the connection, via torque turn graph, is rejected, then the tubular joint will have to be disconnected. Because the tong was in “make-up mode”, it will have to be switched to “break mode” to back out the joint. When the operator makes the switch to “break mode”, the control system for the electric tong system sets the speed to “low gear” (low speed) for the power tongs. The second situation, where a tubular joint is backed out of a wellbore is during a ‘pull’ job (i.e., pulling all tubulars (e.g., casing, drill pipe, other tubulars) from the well bore). In this case, the electric tong system is in “break mode” throughout the job and is not switched from “make-up mode” to “break mode”. Therefore, if the electric tong system is in “break mode” and the power tong door is opened and closed, then the power tong speed will be set to “low gear”. Operationally, during a “pull job” the sequence is as follows:
1—Assume the electric tong system is in “break mode” and the backup tong and power tong doors are open.
2—The electric tong system is moved onto the pipe, and the electric tong system lift is adjusted so that the backup tong grips onto the connector and/or lower tubular joint, and the power tong grips onto the upper tubular joint to be removed.
3—The backup and power tong doors are closed, and the power tong is automatically switched into “low gear”.
4—The power tong is rotated, and the tubular joint is backed out of the wellbore.
5—The rotary is aligned, and the power tong door is opened.
6—The backup tong is released, and the electric tong system is moved away from the well center.
7—The steps are repeated, from step 2 through step 6, as needed.
The electric tong system of the present application comprises an automated control system that enables automatic performance of the above steps, as set forth in the previous paragraph. In addition, the automation by the control system enables the electric tong system to be operated remotely, which provides an enhanced safety feature as the operator is no longer required to be located above or adjacent to the electric tong system (e.g., on scaffolding above the electric tong system). Conventional tongs typically do not have automatic sequences because they use a lever for each function (e.g., backup, lift cylinder, and tong rotary).
Referring to
Referring to
Embodiments of the electric tong system can comprise a no side load reaction system, which can provide a solution to the destructive bending moment and shear forces created by a tong during make-up. The no side load reaction system is a “couple reactionary” device that eliminates the bending moment and shear forces in the connection. These forces, created by the application of torque, are cancelled at the centerline of the pipe, effectively applying only “pure torque” to the connection. Problems, such as alignment, are handled through the unique “floating support” design of the back-up. Small angular misalignment can be accommodated without any effect on the loads applied or the accuracy of the torque measurement. Torque is applied via a “couple” (e.g., a connection having two equal but opposite forces at a fixed distance). In a standard tong configuration, the forces are transmitted through a load cell and snub line, and the opposite force is transmitted through the connection to the pipe body. The resulting “side loads” are transmitted through the connection as a shear and bending moment. The externally induced loads cause high localized contact pressure between pin and box connections, which rely on high interference in either the threads or metallic seals. This additional contact pressure during make-up can greatly increase the incidence of galling. This system solves these problems through the application of innovative technology. The purpose of the no-side-load reaction system is to minimize the chances of galling of the threads and limit the forces that may increase friction during makeup.
Referring to
Referring to
A good reaction system allows the power tong (1500) to translate a limited distance in the x, y, and z directions, and rotate about the x-axis and y-axis. In this embodiment, movement along the y-axis relates to the power tong (1500) moving forwards/backwards, movement along the x-axis relates to the power tong (1500) moving side to side, and movement along the z-axis relates to the power tong (1500) moving up/down. Further, rotation about x-axis is designated as rx as shown in
The embodiments of the electric tong system previously discussed provide several advantages. As previously discussed, the tong system or electric tong consists of a power tong, backup tong, and lift cylinder that are integrated into one package and controlled and operated electrically, using one driver. The electric tong system can be built using a conventional hydraulic tong, for example, a 7⅝″ casing tong, and replacing the hydraulic motor, gearbox, hydraulic valves and plumbing with an electric motor and gearbox, as previously discussed. The electric tong system, therefore, eliminates the need for the use of a hydraulic power unit, which prevents the environmental issues associated with leakage or spillage of hydraulic oil. In addition, the integrated electric tong system provides better torque control when making up or breaking out a tubular connection, and the system can be interlocked for safe operation. Additional advantages of the tong system include, the use of a Torque Turn system that is built into the electric tong system, (e.g., power tong), and which includes the capability for use with or without a computer for analyzing and recording torque and turn data that can be used for determining proper make-up or break-out of tubular connections. Other advantages of the tong system include: using a hand controller for remote operation to eliminate the requirement of operator stands, having remote monitoring/controlling via computer and WiFi, enabling easy rig up, eliminating separate RTS units, and providing a lower total system cost.
Additional features of the electric tong system, as previously discussed, include such features as: one driver to operate three motors (i.e., power tong motor, backup tong motor, and lift assembly motor). Typically, in conventional tong systems, each motor would require a separate driver. In addition, the electric tong system includes the use of servo-motors, which can enable better control of speed and direction of the tongs, and a single motor driver that controls the speed and direction of each servo-motor.
Further, the electric tong system utilizes an integrated design of the power tong, backup tong, and lift assembly. In conventional systems, the power tong and backup tong can be integrated; however, the lift cylinders are added when rigging up in the field. The embodiments of the present invention integrate the lift assembly with the power tong and backup tong into one package, which requires less rig-up time in the field. Additionally, torque turn is built into the control system.
Further, backing out a tubular joint in high gear (speed) presents a safety hazard, given that when the power tong is operated in the back out direction, the tong body can move towards the operator, potentially knocking the operator off of the scaffolding that he/she is standing on. Therefore, a safety feature of this tong is to automatically switch the power tong to low speed when backing out a tubular joint.
An additional feature of the electric tong system includes the use of an interlocking safety system, similar to the systems described in U.S. Pat. No. 5,791,410, and/or U.S. Pat. No. 7,891,418, incorporated herein in their entireties by reference. The interlocking system of the present invention enhances the safety of the operation of the electric tong system. For example, the lift motor is not allowed to move with the backup tong clamped on a tubular joint, the power tong is not allowed to rotate unless the backup tong is clamped on the tubular joint, and the power tong is not allowed to move unless the power tong door is closed. Although, the above pertains to interlocks between functions of the electric tong system, additional interlocking can take place between the electric tong system and other devices. For example, elevator slips may not be allowed to close unless the power tong has finished rotating.
Another feature of the electric tong system includes portability of the controls. Unlike conventional tongs, where the control valves are fixed to the tong, the electric tong system controls are portable. This portability feature allows the operator to be positioned for optimal viewing and safety during operation. For example, the tong stands (scaffolding) can be eliminated because the operator can control the tong from the floor and a safe distance.
Yet another feature of the electric tong system includes control configuration. The electric tong, unlike conventional tongs, can be configured to operate functions in a sequence. For example, with the push of a button, the tong door will close, the backup will latch, and the tong will rotate.
Yet another feature of the electric tong system includes the design of the backup. The backup uses a pneumatic cylinder to close the backup door and a linear actuator driven by an electrical motor, such as a servo motor, to apply the clamp force. In addition, the pneumatic backup door cylinder can comprise sensors, which can be used to detect when the clamping cylinder should actuate. The pneumatic backup door cylinder can further comprise a magnetic piston and two reed switches, wherein the reed switches are closed when the magnetic piston is moved near to them. When the backup door is closed, via the pneumatic cylinder, the reed switch, which is near the rod end of the pneumatic backup door cylinder, becomes activated and the electric motor, which actuates the linear actuator, becomes energized (the other reed switch alerts the backup control system when the backup door is open). The reed switches can also serve as position sensors on the pneumatic backup door cylinders. There is a position sensor, located on the rod end of the electric linear actuator, that can be used to determine an end-of-stroke condition, and the electric linear actuator can become de-energized during an end-of stroke condition.
Other features of the electric tong system include a no side load reaction system, which can have five (5) degrees of freedom, and an electrical lift system that can act like a conventional hydraulic lift cylinder or the RTS elevation function.
Another feature of the electric tong system includes a control system that allows manual or automatic operation of the electric tong system, with the flip of a switch. The electric tong system includes a built-in torque turn data acquisition system, which can be monitored by a WiFi computer. The WiFi computer allows monitoring, analysis, and control of the electric tong system on the drill floor or via satellite. An LCD screen can be included to read torque on the power tong, if torque turn is not required.
Because many varying and different embodiments may be made within the scope of the inventive concept(s) herein taught, and because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
The present application is a non-provisional application that claims priority to a U.S. Provisional Application having U.S. Patent Application Ser. No. 61/893,819, filed Oct. 21, 2013, and U.S. Provisional Application having U.S. Patent Application Ser. No. 62/001,500, filed May 21, 2014, both of which are incorporated herein in their entireties by reference.
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