Patent Grant
10233704
Tubular handling equipment is used on an oil rig to make up and lower casing and other tubulars into the wellbore (“trip-in”). During trip-in, an elevator picks up a length of one or more joints of tubular from a rack and brings the tubular into position above a “stump” or open connection of a previously-run tubular. The stump is typically supported at the rig floor by a spider, which supports the weight of the deployed tubular string at the rig floor. An operator may then guide the new length of tubular (an “add-on” tubular) into position over the stump (i.e., at well center). The operator may then assist in stabbing the add-on tubular into the open connection of the stump.
Once this occurs, the operator may engage a power tong onto the new tubular to make-up the add-on tubular to the string via the power tong. The torque applied by the power tong causes the new tubular to rotate into connection with the stump. The stump is generally held rotationally stationary by a backup tong. The elevator may then engage the new tubular, after the new tubular is made up to the remainder of the string, and the spider may disengage from the tubular string, leaving the weight of the tubular string to be supported by the elevator. The elevator may then lower the tubular string into the well, until nearing the rig floor, at which point the spider may be re-engaged, and the process starts again.
This is typically a labor-intensive process and generally includes one or more workers exposed at the rig floor and manually handling extremely heavy machinery.
Embodiments of the disclosure may provide a tubular handling system that includes a power tong configured to engage and rotate an add-on tubular by applying a torque thereto, the power tong defining a central opening configured to receive the add-on tubular therethrough, a spider disposed at a rig floor, the spider being configured to support a tubular string, a lifting assembly coupled with the power tong and configured to move the power tong vertically with respect to the tubular string and the spider, and a torque-measuring device configured to measure a reactionary torque transmitted from the power tong to the lifting assembly.
Embodiments of the disclosure may also provide a method for handling tubulars, the method including supporting a tubular string using a spider of a tubular handling assembly. A power tong of the tubular handling system is disposed around the tubular string, the tubular handling system further including a lifting assembly in a collapsed configuration. The method also includes moving the power tong upwards along the tubular string, past an upper connection thereof, and around an add-on tubular to be connected to the tubular string, by expanding the lifting assembly and without laterally moving the power tong from around the tubular string. The method further includes rotating the add-on tubular using the power tong, to connect a lower connection of the add-on tubular to the upper connection of the tubular string, such that the add-on tubular becomes part of the tubular string, disengaging the power tong from the add-on tubular, lowering the power tong past the lower connection of the add-on tubular and the upper connection of the tubular string by collapsing the lifting assembly, without laterally moving the power tong from around the tubular string, such that the power tong is positioned proximal to the spider, disengaging the spider from the tubular string, and lowering the tubular string, including the add-on tubular, through the spider and the power tong.
The foregoing summary is intended merely to introduce a subset of the features more fully described of the following detailed description. Accordingly, this summary should not be considered limiting.
The accompanying drawing, which is incorporated in and constitutes a part of this specification, illustrates an embodiment of the present teachings and together with the description, serves to explain the principles of the present teachings. In the figures:
It should be noted that some details of the figure have been simplified and are drawn to facilitate understanding of the embodiments rather than to maintain strict structural accuracy, detail, and scale.
Reference will now be made in detail to embodiments of the present teachings, examples of which are illustrated in the accompanying drawings. In the drawings, like reference numerals have been used throughout to designate identical elements, where convenient. In the following description, reference is made to the accompanying drawing that forms a part thereof, and in which is shown by way of illustration a specific exemplary embodiment in which the present teachings may be practiced. The following description is, therefore, merely exemplary.
In general, the present disclosure provides a tubular handling system that includes a spider, a power tong, a lifting assembly for the power tong, and a boxing device. These components are configured to operate in concert to reduce manual manipulation of the various pieces of equipment used to handle, make-up, and support the tubular string being run. The assembly provides for reliable acceptance and positioning of a new or “add-on” tubular, using the boxing device, while the spider holds the “stump” (i.e., previously-run tubular string) at the rig floor.
The power tong has retractable jaws, allowing it to be lifted above the stump, past the tubular connections, centralizers, and other tools that may be attached to the tubulars, and into engagement with the add-on tubular. In at least some embodiments, the power tong of the assembly is movable vertically past the connections of the tubular string, and thus may not need to be moved laterally onto and off of the tubular string when new tubulars are added. The power tong is then employed to rotate the new tubular, such that the new tubular is threaded into the stump. Reactionary torque of the power tong is supported either by a spider with torque-holding capacity or by a backup tong incorporated into the system. The assembly then collapses to allow the elevator to lower the tubular string through the power tong and the spider into the well, and then the spider re-engages the tubular string once the elevator and string have been lowered.
Turning now to the illustrated embodiments,
In an embodiment, the lifting assembly 106 includes a base plate 112, which may be secured to the rotary 110. The lifting assembly 106 may also include one or more structures configured to raise the power tong 104 with respect to the base plate 112 (and/or with respect to the rotary 110). In the illustrated embodiment, the lifting assembly 106 may include a linear actuator 114, such as, for example, a hydraulic actuator, for this purpose. The linear actuator 114 may be linked with lifting arms 116, 118. The lifting arms 116, 118 may be pivotally connected to guide arms 122, 124, respectively, and pivotally connected to the base plate 112. Further, the lifting arms 116, 118 may be connected together via a cross-member 121, such as a cylindrical bar or tube (as shown), which may prevent twisting of the lifting arms 116, 118.
The guide arms 122, 124 may include slidable feet 126, which may be disposed in a channel 128, 130, thereby controlling the lifting of the lifting assembly 106. At the top side, the lifting assembly 106 may include a lifting frame 132, which may be coupled with the lifting arms 116, 118, the guide arms 122, 124, the power tong 104, and the boxing device 102. Slidable feet may also be provided at the pivoting connection between the guide arms 122, 124 and the lifting frame 132. Accordingly, actuation (i.e., extension or retraction) of the linear actuator 114 may be translated into vertical movement of the lifting frame 132, and thus vertical movement of the boxing device 102 and the power tong 104. In an embodiment, the lifting assembly 106 may be movable from a collapsed configuration, in which the lifting arms 116, 118 are pivoted together and positioned at or near the base plate 112, to an expanded configuration, in which the lifting arms 116, 118 extend upwards, e.g. such that the lower portion of the lifting arms 118 forms an angle of between about 45 degrees and about 80 degrees with respect to the base plate 112. Further, the lifting assembly 106 may be configured to hold the power tong 104 at a range of elevations above the spider 108, between the expanded and collapsed configurations.
Although described and illustrated as a type of scissor-jack arrangement, it will be appreciated that the lifting assembly 106 may, in some embodiments, take on other forms of kinematic linkage lifting mechanisms. Moreover, it will be appreciated that the linear actuator 114 may be substituted or augmented with any suitable type of actuator, and one or more additional actuators 114 (e.g., an actuator attached directly to the lifting arm 118) may be employed.
Turning now to the boxing device 102 positioned above the power tong 104, the boxing device 102 may include two or more arms 134A, 134B, an upper frame (e.g., a plate) 136, and a base 137. The base 137 may be coupled with the lifting frame 132 and/or the power tong 104. The arms 134A, 134B may be pivotally coupled with the base 137 and the upper frame 136.
Further, the boxing device 102 may include one or more actuators (two are shown: 138A, 138B, one along each arm 134A, 134B, respectively), which may be pivotally coupled with the upper frame 136 and the base 137. The actuators 138A, 138B may either or both be hydraulic, pneumatic, electric, etc. In an embodiment, each actuator 138A, 138B may include a primary actuator 142 and a secondary actuator 144. The upper frame 136 may form a recess 139, which may be configured to laterally receive a tubular (e.g., casing), as will be described in greater detail below.
In operation, the boxing device 102 may move between a collapsed configuration and an expanded configuration by operation of the linear actuator 138A, 138B. For example, in the collapsed configuration, the boxing device 102 may have a minimal vertical height, e.g., the arms 134A, 134B may be pivoted toward the lifting frame 132, e.g., by retraction of the linear actuator 138A, 138B, and the upper frame 136 may accordingly rest at or near the lifting frame 132. The boxing device 102 may also have a neutral or “well centered” position, in which the boxing device 102 is configured to center a tubular received into the recess 139 on the well, as will be described in greater detail below.
The boxing device 102 may also include grippers 146A, 146B, which may be movable along the upper frame 136, e.g., under force applied by a linear actuator (e.g., a hydraulic, pneumatic, or electric actuator). For example, the grippers 146A, 146B may be configured to be brought together to grip part of the tubular received into the recess 139. The grippers 146A, 146B may also include rollers 150, or other friction-reducing members, to facilitate movement of the tubular therethrough, while providing lateral stability.
Considering the power tong 104 in greater detail,
The rotatable section 200 may include a top guard 206, which may be generally disk-shaped and may serve to protect other power tong 104 components from damage, e.g., if an elevator or another object lands on the power tong 104. Further, the rotatable section 200 may include a guide 210, which may be coupled with or disposed within the top guard 206. The guide 210 may be annular and beveled or tapered, so as to receive and direct an end of a tubular therethrough. The guide 210 may be positioned in alignment with the receiving hole 204, and thus may serve to guide the tubular into the receiving hole 204. Further, the guide 210 may be provided in at least two pieces (e.g., segments 210A, 210B), which may be separately removable.
The stationary section 202 may include a device configured to measure a torque on the power tong 104. In an embodiment, such torque-measuring device may be provided in the form of a load cell 216 configured to measure a torque applied thereto. The measured torque may provide information about the torque load applied by the power tong 104 onto a tubular connection, thereby indicating when the connection is fully made up. In an embodiment, the motor 214 may be a hydraulic or electric motor, but in other embodiments, other types of drive systems may be employed.
The jaws 500A-C are illustrated in the retracted position. In particular, in this embodiment, the rotary ring 215 includes an inner diameter 502 in which one or more pockets (three are shown: 504A, 504B, 504C) are defined, for example, one for each of the jaws 500A-C. The pockets 504A-C may extend radially outward from the inner diameter 502, providing a location into which the jaws 500A-C may be retracted and held away from the tubular received through the receiving hole 204. Thus, the pockets 504A-C may allow the jaws 500A-C to retract, which may allow the power tong 104 to slide over tubular connections, etc. The inner diameter 502 may also include one or more camming surfaces (three shown: 506A, 506B, 506C), which may be arcuate segments that extend radially inwards as proceeding in a circumferential direction around the inner diameter 502 of the rotary ring 215.
In operation, the rotary ring 215 may be driven to rotate relative to the body 212 by the motor 214, which may be hydraulic, electric, etc. The jaws 500A-C may be coupled with the cage plate 211 such that they are non-rotational but radially slidable relative to the cage plate 211. The cage plate 211 may be initially secured against rotation by friction forces applied by the brake band 213. Thus, as the rotary ring 215 begins to rotate relative to the body 212, the rotary ring 215 may also rotate relative to the jaws 500A-C. By such rotation, the jaws 500A-C may be forced out of the pockets 504A-C and radially inward onto the camming surfaces 506A-C. Continued rotation may cause the jaws 500A-C to move farther radially inward until reaching an engaging position, where the jaws 500A-C are designed to engage a tubular received in the receiving hole 204.
When the jaws 500A-C engage a tubular, a force between the jaws 500A-C and the camming surfaces 506A-C may increase, as the camming surfaces 506A-C wedge the jaws 500A-C tighter against the tubular. This may eventually overcome the holding force applied on the cage plate 211 by the brake band 213. Thus, as the rotary ring 215 continues to rotate, the jaws 500A-C and the cage plate 211 may also rotate. Further, this may also cause the tubular engaged by the jaws 500A-C to rotate with respect to the body 212.
When release of the tubular is desired, the rotation of the rotary ring 215 may reverse. Upon reverse rotation of the rotary ring 215, the return springs 510 may hold the jaws 500A-C radially outwards against the camming surface 506A-C and eventually force the jaws 500A-C back into the pockets 504A-C. The pockets 504A-C may thus allow the jaws 500A-C to retract, which may allow the power tong 104 to remain received around a tubular while providing an opening hole 204 sized and configured to allow for passage of a tubular collar. Power tongs of other designs that allow for vertical passage of the tubular and collar through the opening may also be employed with the system 100.
Turning now to the illustrated embodiment of the spider 108, which may fit into the central opening of a rig rotary table or rotary, as mentioned above with respect to
Further, the can 700 includes an open door 806, which may extend along the height of the can 700. The open door 806 may allow for removal of the can 700 (e.g., along with the rest of the system 100), for example, upon completion of run-in, or at any other suitable time. The open door 806, along with the segmented structure of the power tong 104 described above, and the segmented structure of the spider 108, as will be described below, may cooperate to allow system 100 to be removed while the tubular string is supported by an elevator.
The spider 108 may further include a body 900, which may be separated into two or more segments 903, 904. The segments 903, 904 may be held together by one or more keyed doors 906, which may, for example, include legs 908 received into grooves 910 formed in the segments 903, 904. The keyed doors 906 may be located 180 degrees apart, for example, around the body 900. As noted above, this segmented structure of the spider 108 may allow for separation and lateral removal of the spider 108 from a tubular received therein (or vice versa). Further, the body 900 may define a conical or tapered bore therein, along which the slips 804 may slide, such that, as the segments 903, 904 move downward relative to the body 900, the slips 804 are pushed radially inwards, e.g., to grip the tubular string.
Further, the body 900 may be coupled with one or more extendable cylinders 912. The extendable cylinders 912 may also be coupled with the timing ring 802 and may be operable to adjust the distance between the body 900 and the timing ring 802. The slips 804, as noted, above, may follow the timing ring 802, and may thus be raised or lowered with respect to the body 900 via the cylinders 912. The cylinders 912 may be hydraulically, pneumatically, mechanically, electro-mechanically, or otherwise actuated. As the slips 804 are lowered into the body 900 (e.g., from
The spider 108 may also include one or more control-line guards (e.g., made from an appropriate nonabrasive material). Further, a top guard 914, which may allow for passage of a control line therethrough, may also include a protective layer of a non-abrasive material, e.g., to avoid damaging such a control line.
The body 900 may also include two or more lugs (four shown: 950A, 950B, 950C, 950D). The lugs 950A-D may be received into corresponding pockets of the can 700, and may thus transmit torque between the body 900 and the can 700. Furthermore, the lugs 950A-D may be sized smaller than the pockets of the can 700, which may provide a range of motion for the spider 108 within the can 700 and thus with respect to the rotary 110 and the rig floor. In addition, the bottom of the body 900 may be provided with a machined annular space 952 for hydraulic or pneumatic lines used to transfer hydraulic fluid or compressed air (or another gas) to cylinders 912 to extend and retract the cylinders 912.
In the embodiment shown, the system 1100 may include a lifting assembly 1102, extending between the can 700 (or the rotary 110, not shown here) and the power tong 104, for lifting the power tong 104. Rather than (or in addition to) a scissor lift, the lifting assembly 1102 may include a “four-bar linkage” type of lifting device. In particular, the lifting assembly 1102 may include a first pair of lifting arms 1106A, 1106B, and a second pair of lifting arms 1108A, 1108B. The arms 1106A,B, 1108A,B, may be pivotably connected to one another, such that an angle formed therebetween may move between, for example, about 0 degrees and about 150 degrees (or more). As the angle increases, the distance between the power tong 104 and the base plate 112 may increase, thereby raising the power tong 104. The lower arms 1106B, 1108B may be pivotably connected to the base plate 112, and the upper arms 1106A, 1108A may be pivotally connected to the power tong 104 and/or to the lifting frame 132.
It will be appreciated that the precise details of the four-bar linkage may be implemented in a variety of ways. For example, a driver 1109 (
The lifting assembly 1102 may also include one or more cross-members 1120, which may extend between the pairs of arms 1106A,B, 1108A,B and may be provided to increase a stiffness of the lifting assembly 1102.
In this configuration, the boxing device 102, power tong 104, and lifting assembly 1102 are immediately adjacent to one another, providing a reduced vertical profile as compared to the extended position previously discussed. The collapsed configuration may be employed after tubulars are made up together, so as to reduce the obstruction that the system 1100 presents to the vertical range of motion of the tubular handling equipment (e.g., elevators, top drives, etc.), allowing such equipment to be lowered as close as possible to the spider 108 at the rig floor.
In a specific embodiment, the backup tong 1402 may include gripping members 1404, 1406, which may be movable toward and away from each other via one or more actuators 1408, 1410. The actuators 1408, 1410 may be hydraulic actuators. Further, the gripping members 1404, 1406 may have teeth, wickers, buttons, grit, high-friction material, etc. on an inner radial surface thereof, which may be configured to bite into or otherwise engage a tubular received through the power tong 104 and the spider 108. The backup tong 1402 may thus be configured to transmit torque applied to the lifting assembly 1102 by the action of the power tong 104 and safely transmit the torque to the rig floor.
Generally, the backup tong 1602 may be positioned sufficiently vertically below the power tong 104 that the power tong 104 may be positionable to engage one tubular, while the backup tong 1602 may be configured to engage another tubular. For example, the backup tong 1602 may engage the stump held in the spider 108, while the power tong 104 engages a new, add-on tubular to be made up to the stump.
In a specific embodiment, the backup tong 1602 may include a torque-reaction frame 1604, which may be connected to the power tong 104, the lifting frame 132, or both. Further, the backup tong 1602 may be suspended from the power tong 104, the lifting frame 132, or both by any number of supporting members, such as cables 1608, 1610. The cables 1608, 1610 may permit the lifting assembly to collapse until the power tong 104 approaches the top of the backup tong 1602.
The system 1600 may also include a torque-reaction post 1606 and a torque-reaction mechanism 1620, which cooperate with the torque-reaction frame 1604 to receive and measure torque applied to the tubular connection being made up. Accordingly, in this embodiment, the torque-measuring device may be provided in the form of the torque-reaction mechanism 1620.
An example of the operation of one or more embodiments of the tubular handling systems 100, 1100, 1400, 1600, and 1800 will now be described. In particular,
The method 1900 may begin by supporting a tubular string 2002 using a spider 108 near the rig floor 2000, as at 1902. This is illustrated in
When it becomes desirable to add a new tubular to an upper connection 2004 of the tubular string 2002, the method 1900 may proceed to extending the tubular handling system 1100 to an intermediate position, as at 1904. This is shown in
Referring now to
Next, as at 1912 and shown in
Further, as at 1914, the lifting assembly 1102 may be extended upward (e.g., away from the rig floor 2000) to an extended position, which may or may not be the full extent of the range of motion of the lifting assembly 1102, depending on the configuration. As the lifting assembly 1102 is moved, the power tong 104 may slide axially past the upper connection 2004, without the power tong 104 being laterally removed from the tubular string 2002. Eventually, as shown, the power tong 104 becomes positioned around the tubular 2100, e.g. above the threaded region of the lower connection 2200.
The power tong 104 may then engage the add-on tubular 2100, as described above, as at 1916, and apply torque thereto, to rotate the add-on tubular 2100, as at 1918. The reactionary torque in the power tong 104 may be transmitted to the tubular string 2002 via the lifting assembly 1102 and the spider 108, in one embodiment. In some embodiments, a backup tong (as described above) may engage the tubular string 2002, as indicated at 1917, and may be employed in addition to or instead of a spider 108 to transmit such torque to the tubular string 2002.
Rotation of the add-on tubular 2100 may proceed by rotating the rotatable section 200 of the power tong 104 until the jaws 500A-C (
As the power tong 104 applies torque to the add-on tubular 2100, the add-on tubular 2100 rotates relative to the tubular string 2002, resulting in engagement therebetween, as noted above. Further, such rotation and engagement results in the add-on tubular 2100 moving downwards as the threads of the upper connection 2200 are progressively received into the lower connection 2004. The lifting assembly 1102 may thus collapse slightly, moving the power tong 104 downwards, during the connection process, as at 1920. This is referred to as “thread compensation.”
Referring to
As shown in
While the present teachings have been illustrated with respect to one or more implementations, alterations and/or modifications may be made to the illustrated examples without departing from the spirit and scope of the appended claims. In addition, while a particular feature of the present teachings may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular function. Furthermore, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof are used in the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” Further, in the discussion and claims herein, the term “about” indicates that the value listed may be somewhat altered, as long as the alteration does not result in nonconformance of the process or structure to the illustrated embodiment. Finally, “exemplary” indicates the description is used as an example, rather than implying that it is an ideal.
Other embodiments of the present teachings will be apparent to those skilled in the art from consideration of the specification and practice of the present teachings disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the present teachings being indicated by the following claims.
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