Patent Grant
10267089
This invention relates to heavy lifting, particularly to apparatus and methods for coupling together elements in overhead lifting. The invention has application in drilling, particularly on-shore or offshore drilling into the earth for recovering petrochemicals, exploration or research. Some embodiments have particular application in coupling top drives to overhead lifting equipment.
A prior art drill rig 10 of the general type used for drilling is illustrated in
Travelling block 12B is coupled to a top end of a drill string 14 made up of tubular sections 14A. Drill string 14 may be many thousands of feet long. Consequently, hoist 12 must have a very large capacity. Travelling blocks having rated capacities of 250 to 750 tons are not unusual. Components coupling the travelling block to the drill string have similar capacities.
In a traditional drill rig, the drill string is rotated by a rotary table driving a kelly coupled to the top end of the drill string. An upper end of the kelly is coupled to the traveling block by a swivel. Overhead equipment connections used for kelly/swivel/rotary table operations use a traveling block equipped with a hook. The hook can easily be connected to and disconnected from the swivel for drilling and may also support elevator links for tripping. Travelling block—hook connections are made up semi-permanently since it is not generally necessary to disconnect the hook from the traveling block for rig moves.
Most travelling blocks, especially in the larger sizes (e.g. >250 ton capacity), connect to hooks using a becket connection. A becket is a beam which is pinned at either end to the traveling block. Hooks include a member which passes over the becket. Both sides of the interface between the hook and the becket have complementary compound curvatures. There are industry standards (API 8C—Specification for Drilling and Production Hoisting Equipment (PSL 1 and PSL 2), currently in its Fifth Edition) which prescribe compound contact curvatures for becket connections in overhead equipment. These API standards ensure compatibility of components across the industry.
An alternative way to rotate a drill string is by way of a top drive. Top drives are becoming preferred over kelly/rotary table drives for many drilling operations. A top drive couples to the traveling block and directly drives a top end of the drill string. When a top drive (TD) is used, a hook is neither required nor desirable. A hook adds length, weight, cost, and maintenance. It is therefore common to connect top drives directly to the traveling block, without a hook.
A top drive must typically be disconnected from the travelling block for rig moves, rig up and sometimes also for maintenance. To achieve this it has been necessary to unpin one end of the becket on the traveling block, slide a member of the top drive over the becket and then reinstall the becket. This is difficult and potentially dangerous work that is often performed 20 feet or more above the rig floor without a proper work platform. The components are heavy and can be seized in place by corrosion. To give a sense of scale, a becket pin (removal required for rig up), from a typical 500 ton capacity traveling block, weighs approximately 70 lbs. (30 kg). The becket itself, for a typical 500 ton capacity traveling block, weighs about 750 lbs, (about 350 kg), far beyond human lifting capacity for even one end. Becket pins are typically removed using a hammer and punch bar (a 2 man operation). Once the becket pin is removed, there is no good way to lift the becket—no lifting eyes for winch attachment.
In some cases, the travelling block must be pulled to one side or another to engage the top drive. In such circumstances the becket often does not have enough room to cleanly swing under the bail of the top drive. Coupling the top drive to the traveling block in such circumstances can require moving the top drive to the side and, in coordination with that movement, lifting the becket to engage under the bail of the top drive.
There is a need for a better way to couple components of hoisting equipment used in drilling operations, particularly to couple top drives to traveling blocks. Preferably in a way that provides compatibility with legacy equipment. Preferably in a way that provides some angular flexibility.
This invention has a number of aspects. One aspect provides top drives equipped for coupling to the becket of a traveling block. One aspect provides methods for coupling top drives to traveling blocks. One aspect provides a coupling assembly for coupling a top drive to a traveling block. One aspect provides a top drive equipped with a coupling for engaging a becket of a traveling block in a drill rig. One aspect provides a coupling useful in heavy lifting or pulling. The coupling may be used to couple together various elements.
One example aspect provides a coupling useful for coupling a top drive to overhead lifting equipment such as a traveling block in a drill rig. The coupling comprises a first member spaced apart from a second member by a gap dimensioned to receive a coupling member such as a becket between them. The first and second members may, for example, comprise arms attached to a top drive or to the overhead lifting equipment. A beam is supported in an aperture proximate an end of the first member. The second member has an aperture or recess dimensioned to receive a first end of the beam. The beam is movable longitudinally between a closed configuration wherein the beam spans the gap with the first end of the beam engaged in the aperture or recess on the second member and a retracted configuration wherein the first end of the beam is spaced apart from the second member. The coupling member is insertable into the gap when the beam is in the retracted configuration. The traveling block and the overhead equipment can be coupled together by moving the beam to the closed configuration. The beam has a non-circular cross section (e.g. obround, rectangular with rounded corners, oval, elliptical or the like) wherein a depth of the beam is greater than a thickness of the beam. The beam is held against rotation, at least when in the closed configuration. For example, the aperture of the first member and/or the aperture or recess of the second member may conform at least in part to the cross section of the beam and thereby prevent rotation of the beam. The beam and coupling member cross one another (for example at a 90 degree angle) when the coupling is made up.
In some embodiments the beam comprises a depth to thickness ratio of at least 1.5 to 1. The beam comprises a contact area configured to engage a corresponding contact surface of the becket. For example, the contact area may be a saddle-shaped contact area having surface curvatures as specified by API standard 8C. The contact area lies within the cross-section of the beam in some embodiments. The coupling may comprise one or more guide surfaces configured to bear against the beam to maintain the beam in alignment with the aperture or recess of the second member.
A force amplifying mechanism may be provided to slide the beam relative to the first and second members. In some embodiments the force amplifying mechanism comprises a screw and the beam comprises an opening into which the screw is threadedly engageable. In one embodiment the force amplifying mechanism comprises first and second screws respectively extending longitudinally along first and second sides of the beam. Each of the first and second screws is coupled to rotate relative to the beam and first and second half-nuts supported relative to the first member and respectively engaging the first and second screws.
The beam may be actuated by an actuation mechanism such as a linear actuator, a rack and pinion mechanism, rack and worm mechanism, a hydraulic or pneumatic piston, and a lever. A remote control mechanism may be provided for operating the actuation mechanism.
In some embodiments the beam comprises an arcuate beam and the arcuate beam is actuated in a curved path extending between the aperture of the first member and the aperture or recess of the second member. In some embodiments insertion of the becket actuates the movement of the beam from the retracted configuration to the closed configuration.
Couplings may be provided to support loads of 250 tons or more. A yield strength of the beam may be at least 110 kpsi. The beam may have an impact toughness of at least 31 ft-lb (42 J) at −40° F. (−40° C.) average. The beam may be coated with a nitride layer.
Another aspect provides a coupling useful in overhead lifting. The coupling comprises a first member spaced apart from a second member by a gap dimensioned to receive a coupling member between them. The coupling member may be a becket, but is not so limited. A beam is supported in an aperture proximate an end of the first member and the second member has an aperture or recess dimensioned to receive a first end of the beam. The beam is movable longitudinally (for example by sliding) between a closed configuration wherein the beam spans the gap with the first end of the beam engaged in the aperture or recess on the second member and a retracted configuration wherein the first end of the beam is spaced apart from the second member. The coupling member is insertable into the gap when the beam is in the retracted configuration and the coupling member retained in the gap by the beam when the beam is in the closed configuration. The beam has a non-circular cross section wherein a depth of the beam is greater than a thickness of the beam. The beam is held against rotation relative to the first and second members. Such a coupling may be used to couple a top drive to a traveling block or other overhead lifting equipment but also has other applications.
Another aspect provides a method for coupling a top drive to a traveling block in a drill rig. The top drive is coupled to a first member spaced apart from a second member by a gap dimensioned to receive a coupling member such as a becket between them. The method comprises: providing a beam supported in an aperture proximate an end of the first member and dimensioned to contact an aperture or recess dimensioned to receive a first end of the beam; and actuating the beam to move from a retracted configuration in which the becket is insertable into the gap to a closed configuration in which the beam spans the gap with the first end of the beam engaged in the aperture or recess on the second member such that the travelling block and the top drive are coupled together. The beam has a non-circular cross section and is held against rotation. For example, at least one of the aperture of the first member and the aperture or recess of the second member may conform at least in part to the cross section of the beam and thereby restrict rotation of the beam in the apertures.
Another aspect provides a method for coupling in overhead lifting. The method comprises: providing first and second members attached to a first element and a beam supported in an aperture proximate an end of the first member. The beam is dimensioned to extend from the first member to contact an aperture or recess in the second member. The aperture or recess in the second member is dimensioned to receive a first end of the beam. The method actuates the beam to move from a retracted configuration in which a coupling member attached to a second element to be coupled to the first element is insertable into the gap to a closed configuration in which the beam spans the gap with the first end of the beam engaged in the aperture or recess on the second member such that the first and second elements are coupled together. The beam has a non-circular cross section and the method holds the beam against rotation relative to the first and second members.
Apparatus and methods as described herein have particular application in heavy lifting (e.g. for design loads of 50 tons plus an appropriate safety factor or more).
Further aspects and example embodiments are illustrated in the accompanying drawings and/or described in the following description.
The accompanying drawings illustrate non-limiting example embodiments of the invention.
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive sense.
Traveling block 32 may be a legacy-style traveling block with a main body 32A supporting a becket 32B. In the illustrated embodiment, becket 32B is held to traveling block main body 32A by a set of pins. Becket 32B has a saddle-shaped contact area 32D on its upper surface. Contact area 32D has surface curvatures as specified by API standard 8C. Traveling block 32 has a capacity of 250 tons or more in some embodiments.
API Specification 8C (fifth edition) provides that the contact surface of a travelling block becket shall have a convex radius A1 in a plane transverse to the becket and a concave radius B1 in a vertical plane extending longitudinally along the becket as shown in
Coupling 30 includes spaced-apart links 35A and 35B that project upwardly from top drive 33 on either side of becket 32B. A space 36 between links 35A and 35B is wide enough to receive becket 32B. Lower ends of links 35A and 35B are coupled to top drive 33 in any suitable manner. In one example embodiment alignment of upper ends of links 35A and 35B is maintained by a bridge 35C attached to each of links 35A and 35B (see
Link 35A supports a movable beam 38 that can be actuated as described below to move between a first, retracted, configuration wherein beam 38 is retracted so that becket 32B can pass into space 36 and a second, closed, configuration wherein beam 38 spans between links 35A and 35B. With beam 38 in its first, retracted, configuration, becket 32A can be moved into space 36. When becket 32A is below the path taken by beam 38 in moving from its retracted configuration to its closed configuration, beam 38 may be actuated to move to its closed configuration, thereby making the coupling between traveling block 32 and top drive 33.
In the illustrated embodiment, beam 38 is non-circular in cross-section and has a depth D greater than its thickness T (See
The lower edge of beam 38 has a contact area 38A. Contact area 38A has a compound curvature. When coupling 30 is coupled, beam 38 extends generally at right angles to becket 32B and contact area 38A of beam 38 interfaces to contact area 32D of becket 32B. In the illustrated embodiment beam 38 has a cross-section that is uniform along the length of beam 38 except at the location of contact area 38A. In the illustrated embodiment, the profile of contact area 38A of beam 38 lies within the cross-section (i.e. contact area 38A does not project from beam 38).
The material of beam 38 preferably satisfies the requirements of API Specification 8C. In an example embodiment, the material of beam 38 has a yield strength exceeding 110 kpsi. For example, beam 38 may be made of a steel alloy having a yield strength of 120 kpsi or more. In some embodiments beam 38 has an impact toughness of 31 ft-lb (42 J) at −40° F. (−40° C.) average using test specimen with no individual value less than 24 ft-lb (32 J). In some embodiments the material of beam 38 has all of these properties. In an example embodiment, beam 38 is made from AISI 4430 quenched and tempered steel. Beam 38 may be coated, for example with a nitride layer (indicated schematically by 45, see
Beam 38 is supported against rotation relative to links 35A and 35B. In the illustrated embodiment, beam 38 extends through an aperture 39A in link 35A. Aperture 39A has a cross-sectional shape that partially or entirely conforms to the cross-sectional profile of beam 38 such that beam 38 can slide longitudinally back and forth through aperture 39A but cannot rotate significantly about its longitudinal axis in aperture 39A. In the illustrated embodiment, link 35B has an aperture or recess 39B that is aligned with aperture 39A such that, in its second, closed configuration, a first end 38B of beam 38 projects into aperture or recess 39B. In the illustrated embodiment, aperture 39B has a cross-sectional shape that partially or entirely conforms to the cross-sectional profile of beam 38 such that end 38B of beam 38 can slide longitudinally into aperture 39B but cannot rotate about its longitudinal axis in aperture 39B.
In a simple embodiment, beam 38 is manually-actuated between its retracted and closed configurations. Beam 38 may have a coupling (e.g. a hook, eye, threaded aperture, threaded stud, etc.) on one or both of its first end 38B and its second end 38C to allow attachment of a tool for pushing beam 38 toward its closed configuration or pulling beam 38 toward its retracted configuration.
Preferably a force-amplifying drive mechanism is provided. For example, the illustrated embodiment includes a drive screw 40 that can be threaded into threaded openings 41 at either end of beam 38. To draw beam 38 toward its retracted configuration screw 40 may be inserted through a hole in a plate 42 spaced outwardly from link 35A and then threadedly engaged with second end 38C of beam 38.
In the illustrated embodiment, plate 42 forms one end of a housing 43 that is attached to link 35A and covers aperture 39A. When beam 38 is in its retracted configuration, second end 38C of beam 38 is received in housing 43. Housing 43 may comprise guide surfaces that bear against beam 38 and thereby help to maintain beam 38 in alignment with apertures 39A and 39B. Housing 43 may protect the projecting part of beam 38 from damage and may help to hold beam 38 in position during transportation. Screw 40 may be left in place to hold beam 38 in its retracted configuration during transportation. This is the configuration shown in
Housing 43 may have a wide range of configurations. Housing 43 may have openings on its sides or be closed. Housing 43 may comprise an open framework, for example. In some applications housing 43, as illustrated, may be in the way and undesirable. For such applications housing 43 may be made removable and/or foldable/collapsible.
To move beam 38 toward its closed configuration, screw 40 may be inserted through a hole in a plate 44 on link 35B and threadedly engaged with first end 38B of beam 38. Tightening screw 40 pulls beam 38 toward plate 44. Screw 40 may be tightened and left in place to hold beam 32 firmly in its closed configuration.
An advantage of the illustrated arrangement is that the pull exerted by screw 40 on beam 38 as beam 38 is moved toward its closed configuration tends to pull beam 38 into alignment with aperture 39B.
In an alternative embodiment a first end 40A of drive-screw 40 is fixed in position but free to rotate relative to link 35A. For example, drive screw 40 may be mounted in an aperture in plate 42. In this embodiment, a second end 40B of drive screw 40 is threadedly engaged with end 38C of beam 38. Beam 38 may be advanced toward its closed configuration by rotating drive screw 40 in a first direction and moved toward its retracted configuration by rotating drive screw 40 in a second direction opposite to the first direction.
In some embodiments, a motor (e.g. a hydraulic motor) is provided and connected to turn drive screw 40. In some embodiments the motor comprises an impact driver. The motor may be directly coupled to drive screw 40 or coupled by way of a suitable power transmission such as a gear train, worm drive, reducing transmission, or the like.
Other actuation mechanisms may be applied for moving beam 38 between its closed and retracted configurations. Examples of such actuation mechanisms which may be coupled to drive motion of beam 38 include:
In some embodiments which provide for powered actuation of beam 38 an actuator such as a motor/hydraulic piston of the like is built into a hollow within beam 38.
When an integrated power actuation mechanism is provided, a remote control mechanism may optionally be provided to operate the actuation mechanism to move beam 38 from its retracted configuration to its closed configuration or from its closed configuration to its retracted configuration. The remote control mechanism may comprise, for example, a remotely operable electrical, pneumatic or hydraulic circuit.
In embodiments which provide means for remotely actuating beam 38 it is preferable to provide one or more mechanisms that may be provided to verify that beam 38 has properly reached its closed position. For example, one or more of the following may be supplied:
Some advantages of the illustrated example embodiments are that:
While these advantages are beneficial, it is not mandatory that all of these advantages be provided by all embodiments.
It is not mandatory that the part of a coupling like coupling 30, 47 or 50 that includes a movable beam is on a top drive. In some embodiments a traveling block or traveling block adapter includes a movable beam in place of a conventional becket.
Beam 62 may be substantially the same as beam 38 described above except that it is oriented to provide a saddle-shaped contact area on its upper edge (i.e. the edge facing toward main body 63). As described above with respect to
In the illustrated embodiment, beam 62 is retained in its closed configuration by a keeper 67 which extends across aperture 66A to block longitudinal movement of beam 62. When it is desired to move beam 62 to its retracted position, keeper 67 may be moved out of the way (e.g. by detaching it from plate 64A, unfastening one end of keeper 67 and pivoting keeper 67 out of the way, etc.).
A removal tool 68 is shown in
In cases where removal tool 68 would not pose an inconvenient obstruction, removal tool 68 may be left installed on plate 64.
In other embodiments, any of the actuation mechanisms described above are provided to actuate beam 62 between its retracted and closed configurations.
Member 73A supports thread-engaging features 76 that engage threads on each screw 74. Thread-engaging features 76 each include at least one thread, pin or blade that engages threads on the corresponding screw 74. Advantageously the features that engage threads on screws 74 may engage the threads only on a side of the corresponding screw 74 that faces away from becket beam 72. Thread-engaging features 76 may comprise half-nuts, for example.
Rotating a screw 74 causes the screw 74 to move longitudinally relative to the corresponding thread-engaging feature 76. Screws 74 are coupled to becket beam 72 so that becket beam 72 may be moved relative to member 73A by turning screws 74.
The connections between screws 74 and becket beam 72 may be constructed to allow some longitudinal play. In some embodiments the play may be 1 cm or more. This facilitates advancing becket beam 72 by turning one of screws 74 at a time. In the illustrated embodiment, each screw 74 has a turned-down portion 74A that is slidable in a bore in a lug projecting from becket beam 72. In the illustrated embodiment, screws 74 engage bores in a push/pull support rod 77 carried on becket beam 72. A pair of spaced-apart shoulders 74C and 74D limit the travel of screw 74 relative to becket beam 72 by engaging corresponding surfaces on becket beam 72. Those of skill in the art will recognize that there are many other possible arrangements for mounting screws 74 to becket beam 72 in such a manner that permits rotation of screws 74 and optionally provides some longitudinal play between screws 74 and becket beam 72.
In some embodiments each screw 74 comprises a head or other fitting that allows the screw 74 to be turned by a suitable hand or power tool. For example, ends of screws 74 may comprise hexagonal or other-shaped heads that can be gripped by a wrench or socket or hexagonal, splined or other-shaped recesses that may be rotationally engaged by a suitable wrench or key.
Some embodiments provide for synchronized turning of both screws 74. Such synchronization may be provided by a mechanism incorporated into apparatus 70 or by a tool used to operate screws 74. For example, screws 74 may be coupled by a gear train that causes both screws 74 to rotate in a synchronized fashion. In such a case the gear train may cause both screws 74 to rotate in the same direction (and both screws 74 may be threaded the same—either left-handed or right-handed threads). In the alternative, the gear train may cause screws 74 to rotate in opposite directions and screws 74 may have opposite threads.
As another example, a power or hand tool for operating screws 74 may have separate rotational outputs for coupling to each of screws 74. The rotational outputs may be connected by a gear train, timing belt or other power transmission so that screws 74 are driven in a synchronized manner to advance becket beam 72 smoothly either into a closed position where it extends across a gap between members 73A and 73B or onto a retracted position where the gap between members 73A and 73B is sufficiently unobstructed that a becket may be moved into or out of the gap. In some embodiments becket beam 72 may be completely removed from engagement with members 73A and 73B. The rotational outputs may be spaced apart from one another with a spacing that matches a spacing of screws 74.
An advantage of the apparatus illustrated in
A retractable beam becket as described herein may be provided on a top drive, on a travelling block, or both. A retractable beam becket as described herein may also be applied on other hoisting equipment (e.g. on a swivel or heave compensator).
Various alternatives are possible. For example:
The following are non-limiting enumerated example embodiments.
Unless the context clearly requires otherwise, throughout the description and the claims:
Words that indicate directions such as “vertical”, “transverse”, “horizontal”, “upward”, “downward”, “forward”, “backward”, “inward”, “outward”, “vertical”, “transverse”, “left”, “right”, “front”, “back”, “top”, “bottom”, “below”, “above”, “under”, and the like, used in this description and any accompanying claims (where present), depend on the specific orientation of the apparatus described and illustrated. The subject matter described herein may assume various alternative orientations. Accordingly, these directional terms are not strictly defined and should not be interpreted narrowly.
Where a component (e.g. a fastener, member, screw, actuator, assembly, device, circuit, etc.) is referred to above, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.
Specific examples of systems, methods and apparatus have been described herein for purposes of illustration. These are only examples. The technology provided herein can be applied to systems other than the example systems described above. Many alterations, modifications, additions, omissions, and permutations are possible within the practice of this invention. This invention includes variations on described embodiments that would be apparent to the skilled addressee, including variations obtained by: replacing features, elements and/or acts with equivalent features, elements and/or acts; mixing and matching of features, elements and/or acts from different embodiments; combining features, elements and/or acts from embodiments as described herein with features, elements and/or acts of other technology; and/or omitting combining features, elements and/or acts from described embodiments.
It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, omissions, and sub-combinations as may reasonably be inferred. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
This application claims priority to U.S. Provisional Patent Application No. 61/935,322 entitled TOP DRIVE COUPLING FOR DRILLING, filed 3 Feb. 2014, which is incorporated herewith in its entirety.
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