Note: Descriptions are shown in the official language in which they were submitted.
CA 02773295 2012-04-03
TITLE: POWER TONG APPARATUS -
INVENTOR: Mark Charles Taggart
TECHNICAL FIELD:
The present disclosure is related to the field of tools for use on a well, in
particular, automated and hydraulic-powered power tongs for making and
breaking joints between sections of pipe.
BACKGROUND:
In drilling a well, a drill string is used. The drill string can comprise a
drill
bit attached to sections of drill pipe. As the well is drilled, additional
sections of
drill pipe are added to the drill string to extend its length until the well
is drilled
deep enough to reach a formation where substances, such as water, oil or gas,
can be produced from the well. Sections of pipe are joined together using
threaded connections on the pipe, often referred to as "pin" and "box", where
the
pin of one section of pipe is threaded into the box into an adjoining section
of
pipe. The drill string is rotated to turn the drill bit in order to drill the
well. When
the drill string is removed from the wellbore, the sections of pipe can be
removed
from the drill string one or more sections at a time.
To make or break the threaded connection between sections of pipe, a
power tong device can be used to do so. Known designs use a motor with a
transmission to operate the power tong mechanism to grip and turn one section
of pipe relative to another section of pipe to thread them together or to
separate
them. When breaking a joint, the power tong uses a lower gear to increase the
torque applied to the pipe to a level required to break the joint, then the
power
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tong is shifted to a higher gear to increase the rotation speed of the pipe to
unthread the connection. When a making a joint, the higher gear can be used to
start the threaded connection, and then the lower gear is used to torque the
connection together. This process of shifting gears to make or break joints is
time consuming, and can make the time required to replace a worn out drill
bit,
thus requiring the complete removal of the entire drill string and then
reinstalling
the drill string, quite lengthy.
It is, therefore, desirable to provide a power tong overcomes the
shortcomings of the prior art and decrease the time required to make and break
joints between sections of pipe on a drilling rig.
SUMMARY:
Broadly stated, in some embodiments, a power tong apparatus is provided
for making and breaking connection joints between sections of pipe on a
drilling
rig, the apparatus comprising: a support assembly, further comprising a
vertical
riser assembly configured for attachment to the drilling rig, and a swing arm
assembly operatively attached to the vertical riser assembly wherein the
vertical
riser and swing arm assemblies are configured such that the swing arm
assembly can move up and down relative to the vertical riser assembly, the
swing arm assembly further configured to pivot in a substantially horizontal
plane
relative to the vertical riser assembly; a power tong assembly operatively
attached to the swing arm assembly, the power tong assembly further
comprising: a back-up tong configured to grasp a first section of pipe, a
power
tong configured to grasp and rotate a second section of pipe relative to the
first
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section of pipe to make or break a connection joint between the first and
second
sections of pipe, and power tong support means for supporting the power tong
above the back-up tong; and control means for controlling the operation of the
support assembly and of the power tong assembly.
Broadly stated, in some embodiments, the vertical riser assembly can
further comprise: a substantially vertical outer tube member further
comprising at
least one mounting bracket configured for attaching the outer tube member to
the
drilling rig; a substantially vertical slot disposed along the outer tube
member; an
inner tube member having upper and lower ends, the inner tube member slidably
disposed in the outer tube member and configured for upward and downward
movement within the outer tube member; means for moving the inner tube
member upwards and downwards relative to the outer tube member; and
attachment means for pivotally attaching the swing arm assembly, the
attachment means disposed on the inner tube member and further configured to
extend through the slot wherein the power tong assembly can be raised or
lowered relative to the vertical riser member when the swing arm assembly is
pivotally attached to the attachment means and when the inner tube member
moves upwards or downwards within the outer tube member.
Broadly stated, in some embodiments, the means for moving the inner
tube member can further comprise a first telescoping member operatively
coupled between the inner tube member and the outer tube member wherein the
inner tube member can move upwards or downwards as the first telescoping
member extends or retracts.
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Broadly stated, in some embodiments, the attachment means can further
comprise an upper pivot bracket disposed near the upper end of the inner tube
member and a lower pivot bracket disposed near the lower end of the inner tube
member. In further embodiments, the lower pivot bracket can further comprise
an offset arm.
Broadly stated, in some embodiments, the apparatus can further comprise
a second telescoping member operatively coupled between the offset arm and
the swing arm assembly wherein the swing arm assembly can pivot in the
substantially horizontal plane when the second telescoping member extends or
retracts.
Broadly stated, in some embodiments, the swing arm assembly can
further comprise: a fixed horizontal member configured to operatively couple
with
the attachment means; a telescoping horizontal member operatively coupled to
the fixed horizontal member, wherein the telescoping horizontal member is
configured to extend from and retract towards the fixed horizontal member; and
a
third telescoping member operatively coupled to the fixed and telescoping
horizontal members wherein the telescoping horizontal member can extend from
and retract towards the fixed horizontal member when the third telescoping
member extends and retracts.
Broadly stated, in some embodiments, the back-up tong can further
comprise: a first frame comprising a first opening configured to receive the
first
section of pipe; and a back-up jaw assembly configured for receiving and
grasping the first section of pipe.
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Broadly stated, in some embodiments, the back-up jaw assembly can
further comprise: a pair of back-up jaw carriers operatively coupled together
via a
hinge, the back-up jaw carriers operatively attached to the first frame, the
back-
up jaw carriers disposed about the first opening, each back-up jaw carrier
5 comprising a first jaw block configured for gripping the first section of
pipe; a
back-stop jaw block disposed near the hinge; and means for closing the pair of
back-up jaw carriers wherein the first section of pipe is grasped by the first
jaw
blocks and the back-stop jaw block.
Broadly stated, in some embodiments, the means for closing the pair of
back-up jaws can further comprise: a pincer assembly operatively coupled to
the
first frame and to the pair of back-up jaws; and a third telescoping member
disposed on the pincer assembly wherein the pair of back-up jaws closes or
opens when the third telescoping member extends or retracts.
Broadly stated, in some embodiments, one or more of the first, second
and third telescoping members can further comprise a hydraulic cylinder.
Broadly stated, in some embodiments, the back-up assembly can further
comprise three telescoping back-up jaw blocks disposed about the first
opening.
In further embodiments, one or more of the telescoping back-up jaw blocks can
further comprise a hydraulic ram mechanism.
Broadly stated, in some embodiments, the power tong further comprises:
a second frame comprising a second opening configured to receive the second
section of pipe; a jaw drive assembly rotatably disposed in the second frame,
the
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jaw drive assembly configured for receiving, grasping and rotating the second
section of pipe; and drive means for rotating the jaw drive assembly.
Broadly stated, in some embodiments, the drive means can further
comprise: a drive motor; a gear reducer operatively coupled to the drive
motor; a
drive shaft operatively coupled to the gear reducer; a drive sprocket or
pulley
disposed on the drive shaft; and a drive chain or belt operatively coupling
the
drive sprocket or pulley to the jaw drive assembly. In some embodiments, the
drive motor can further comprise a hydraulic motor.
Broadly stated, in some embodiments, the jaw drive assembly can further
comprise: an upper jaw ring configured to receive the second section of pipe;
a
lower jaw ring configured to receive the second section of pipe, the lower jaw
ring
operatively coupled to the upper jaw ring in a spaced-apart configuration; a
jaw
cam rotatably disposed between the upper and lower jaw rings, the jaw cam
configured to be rotated by the drive means, the jaw cam comprising a cam
opening further comprising a cam profile disposed thereon; a pair of jaws
pivotally disposed between the upper and lower jaw rings within the cam
opening, the pair of jaws disposed against the cam profile, each jaw further
comprising a second jaw block configured for gripping the second section of
pipe;
and a rear jaw block disposed in the cam opening wherein the rear jaw block
and
the second jaw blocks are in are in a spaced-apart configuration about the cam
opening, the rear jaw block disposed against the cam opening whereupon the
jaw cam is rotated relative to the upper and lower jaw rings, the cam profile
urges
the rear jaw block and the pair of jaws inwardly to grasp and rotate the
second
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section of pipe. In further embodiments, the jaw cam can further comprise
means for being driven by the drive means.
Broadly stated, in some embodiments, the means for being driven can
further comprise teeth disposed on an outer circumferential edge of the jaw
cam,
the teeth configured for engaging with the drive chain. In other embodiments,
the
means for being driven can further comprise a pulley disposed on an outer
circumferential edge of the jaw cam, the pulley configured for engaging with
the
drive belt.
Broadly stated, in some embodiments, the power tong support means can
further comprise: a plurality of guide rod receivers disposed on a top surface
of
the back-up tong; a plurality of guide rods extending downwardly from the
second
frame, wherein the guide rods are slidably disposed in the guide rod
receivers;
and a plurality of support springs, one support spring disposed on each guide
rod, the support springs further disposed between the power tong and the back-
up tong, and further configured to suspend the power tong above the back-up
tong.
Broadly stated, in some embodiments, the control means can further
comprise:
means for supplying a source of motive power for the support assembly and the
power tong assembly, wherein the source of motive power is selected from a
group consisting of a pneumatic supply system and a hydraulic fluid supply
system; and means for controlling the source of motive power, the controlling
means operatively coupling the source of motive power to the support assembly
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and the power tong assembly. In further embodiments, the controlling means
can further comprise a plurality of manually operated valves. In yet further
embodiments, the controlling means can further comprise a plurality of
controllable valves.
Broadly stated, in some embodiments, the controlling means can further
comprise a programmable logic controller configured to operatively control the
controllable valves. In further embodiments, the controlling means can further
comprise an operator's console operatively coupled to the programmable logic
controller, wherein the console can further comprise a joystick mechanism
configured for operatively controlling the programmable logic controller.
BRIEF DESCRIPTION OF THE DRAWINGS:
Figure 1 is a perspective view depicting one embodiment of a power tong
assembly.
Figure 2 is a perspective view depicting the power tong assembly of
Figure 1 installed on a drilling rig.
Figure 3 is a top plan view depicting the swing arm assembly of the power
tong assembly of Figure 1.
Figure 4 is a side elevation view depicting the swing arm assembly of
Figure 3.
Figure 5 is a perspective view depicting the swing arm assembly of Figure
3.
Figure 6 is an exploded perspective view depicting the vertical riser
assembly of the swing arm assembly of Figure 3.
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Figure 7 is a perspective view depicting the swing arm assembly of Figure
3.
Figure 8 is a side elevation view depicting the swing arm assembly of
Figure 7.
Figure 9 is a perspective view depicting one embodiment of a backup tong
of the power tong assembly of Figure 1.
Figure 10 is a close-up perspective view depicting the jaw assembly of the
backup tong of Figure 9.
Figure 11 is a top plan view depicting the backup tong of Figure 9 with the
top plate removed to reveal the jaw mechanism disposed therein.
Figure 12 is a perspective view depicting an alternate embodiment of a
backup tong of the power tong assembly of Figure 1.
Figure 13 is an exploded perspective view depicting the backup tong of
Figure 12.
Figure 14 is a top plan cross-section view depicting a hydraulically-
actuated jaw of the backup tong of Figure 13.
Figure 15 is a perspective view depicting the power tong of the power tong
assembly of Figure 1.
Figure 16 is a side elevation view depicting the power tong of Figure 15.
Figure 17 is a perspective view depicting the power tong of Figure 15 with
a lifting arm attached, and a portion of the covers removed to reveal the
drive
mechanism disposed therein.
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Figure 18 is a perspective exploded view depicting the hydraulic motor
assembly of the power tong of Figure 15.
Figure 19A is a perspective view depicting the jaw assembly of the power
tong of Figure 15, wherein the jaw cam is centered with the upper and lower
jaw
5 rings.
Figure 19B is a perspective view depicting the jaw assembly of Figure 19A
with the upper jaw ring removed to reveal the mechanism disposed therein,
wherein the jaw cam is rotated counter-clockwise relative to the lower jaw
ring.
Figure 20 is a perspective exploded view depicting the jaw carrier of
10 Figures 19A and 19B.
Figure 21A is a top plan view depicting the jaw assembly of Figure 19A.
Figure 21B is a top plan view depicting the jaw assembly of Figure 19B.
Figure 22 is a close-up perspective view depicting the make/break
selector mechanism of the jaw assembly of Figure 19A.
Figure 23 is a perspective view depicting a jaw with a jaw block insert.
Figure 24 is a perspective view depicting a first embodiment of a jaw.
Figure 25 is a perspective view depicting a second embodiment of a jaw.
Figure 26 is perspective view depicting a second embodiment of a power
= tong assembly.
Figure 27 is a top plan view depicting the power tong assembly of Figure
26 in a fully retracted horizontal position, and in a fully extended
horizontal
position.
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Figure 28 is a block diagram depicting one embodiment of a control
system for controlling the power tong assembly of Figure 1.
Figures 29A and 29B comprise a flowchart depicting a Manual Operation
Make Mode of the control system of Figure 28.
Figures 30A and 30B comprise a flowchart depicting a Manual Operation
Break Mode of the control system of Figure 28.
Figures 31A and 31B comprise a flowchart depicting an Auto Operation
Make Mode of the control system of Figure 28.
Figures 32A and 32B comprise a flowchart depicting an Auto Operation
Break Mode of the control system of Figure 28.
Figure 33 is a perspective view depicting an operator console for use with
the power tong assembly of Figure 1 or Figure 26.
Figure 34 is a depiction of a Menu Screen displayed on the operator
console of Figure 33.
Figure 35 is a depiction of a Main Screen displayed on the operator
console of Figure 33.
Figure 36 is a depiction of a Manual Screen displayed on the operator
console of Figure 33.
Figure 37 is a depiction of a Pipe Table screen displayed on the operator
console of Figure 33.
Figure 38 is a depiction of a Datalog screen displayed on the operator
console of Figure 33.
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Figure 39 is a depiction of a first set of Error Messages screen displayed
on the operator console of Figure 33.
Figure 40 is a depiction of a second set of Error Messages screen
displayed on the operator console of Figure 33.
Figure 41 is a depiction of a third set of Error Messages screen displayed
on the operator console of Figure 33.
DETAILED DESCRIPTION OF EMBODIMENTS:
A power tong apparatus is provided. Referring to Figure 1, one
embodiment of power tong apparatus 10 is shown. In some embodiments,
apparatus 10 can comprise of support assembly 15 and power tong assembly 11
operatively attached thereto. In some embodiments, support assembly 15 can
further comprise of vertical riser assembly 16 and swing arm assembly 18
pivotally attached thereto. Vertical riser assembly 16 can further comprise
brackets 20 disposed thereon for mounting apparatus 10 to drilling rig 28, as
shown in Figure 2. In some embodiments, power tong assembly 11 can further
comprise power tong 12, back-up tong 14, drive assembly 24 and hydraulic valve
bank 22 for manually controlling the operation of apparatus 10. Power tong
assembly 11 can further comprise lifting frame 26 disposed on power tong 12
for
lifting power tong assembly 11. Referring to Figure 2, apparatus 10 can
further
driller's console 30, which is operatively coupled to apparatus 10 to operate
apparatus 10 from a remote locate on drilling rig 28.
Referring to Figures 3 to 8, some embodiments of support assembly 15
and its sub-components are shown in more detail. Referring to Figure 6,
vertical
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riser assembly 16 is shown. In some embodiments, vertical riser assembly 16
can comprise of outer tube 42 and inner tube 44 slidably disposed therein. In
the
illustrated embodiments, outer tube 42 and inner tube 44 are shown having a
rectangular cross-sectional shape although any suitable shape can be
substitutes as obvious to those skilled in the art. In some embodiments, inner
tube 44 can comprise upper arm 35 and lower offset arm 36 that can extend
through slot 43 disposed along the vertical length of outer tube 42 when inner
tube 44 is slidably disposed in outer tube 42. Vertical riser assembly 16 can
further comprise telescoping member 56 operatively coupled between inner box
44 and outer box 42 by pin 66 inserted into tube 64 through holes 68, and
secured therein, and by pin 66 inserted into tube 58 through holes 62, and
secured therein. Therefore, when telescoping member 56 is extended, inner
tube 44 can move upwards within outer tube 42 thereby raising swing arm
assembly 18, and when telescoping member 56 retracts, inner tube 44 can move
downwards within outer tube 42 thereby lowering swing arm assembly 18, as
shown in Figure 4.
In some embodiments, swing arm assembly 18 can comprise swing arm
46, diagonal member 70 disposed on swing arm 46 and inner arm 48 slidably
disposed within swing arm 46. Swing arm assembly 18 can further comprise
telescoping member 47 operatively coupled between swing arm 46 and inner
arm 48 and secured with pins 49, as shown in Figure 8. Therefore, when
telescoping member 47 is extended, inner arm 48 can extend outwardly from
swing arm 46 a distance "X", as shown in Figure 8. When telescoping member
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47 retracts, inner arm 48 can retract into swing arm 46. In some embodiments,
"X" can represent a distance of approximately 8 to 12 inches. Swing arm 46 can
further comprise lower bracket 76 having holes 78 for pivotal attachment to
offset
arm 36, which can be secured by pin 34 set through and secured in holes 78
disposed on bracket 76 and hole 37 disposed on offset arm 36. Diagonal
member 70 can further comprise upper bracket 72 having holes 74 for pivotal
attachment to upper arm 35, which can be secured by pin 34 set through and
secured in holes 74 disposed on bracket 72 and hole 39 disposed on upper arm
35. In some embodiments, junction box 54 can be disposed on swing arm
assembly 18 to house power cable connections, and electrical control and
instrumentation cable connections to and from a programmable logic controller
configured to control the operation of power tong apparatus 10, to and from
valve
bank 22, and to and from operator console 30.
Referring to Figure 5, swing arm assembly 18 is shown pivotally attached
to vertical riser assembly 16. In some embodiments, telescoping member 32 can
be coupled to bracket 41 disposed on swing arm 46 with pin 40, and can further
be coupled to offset arm 36 with pin 38. Therefore, when telescoping member 32
is extended, swing arm assembly 18 can rotate or swing clockwise (when viewed
from above), and when telescoping member 32 retracts, swing arm assembly 18
can rotate or swing counter-clockwise, as shown in Figures 3 and 27.
In some embodiments, telescoping members 32, 47 and 56 can comprise
hydraulic ram cylinders, as well known to those skilled in the art, although
in
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other embodiments, these telescoping members can comprise pneumatic ram
cylinders, as well known to those skilled in the art.
Referring to Figures 9 to 11, one embodiment of back-up tong 14 is
shown. In some embodiments, back-up tong 14 can comprise back-up tong
5 assembly 80 that can further comprise frame 81, pincer assembly 82 pivotally
attached to frame 81 via pivot pin 86 and back-up jaw assembly 84. In some
embodiments, back-up jaw assembly 84 can further comprise hinged back-up
jaw carriers 94 attached to frame 81 via jaw pins 100 and bolts 101, wherein
each jaw carrier 94 can comprise slot 91 configured for receiving jaw block
90,
10 which can be configured with a removable die 95. In some embodiments,
back-
up jaw assembly 84 can further comprise backstop 92, which can further
comprise removable die 95. In some embodiments, backstop 92 can be
removably attached to back-up jaw assembly 84 via quick release pin 98. This
can enable easy replacement of backstop 92 with different sizes of backstops
92
15 to accommodate different diameters of pipe. In addition, different sizes
or
configurations of jaw carriers 94 can be installed to accommodate different
diameters of pipe.
In some embodiments, pincer assembly 82 can comprise telescoping
member 88 disposed between arms 83. When telescoping member 88 is
extended, arms 83 can pivot about pivot pin 86 to contact jaw carriers 94 at
contact point 97 that, in turn, can close about a section of pipe disposed
therebetween. Centering linkage 96 coupled between arms 83 can help jaw
carriers 94 to grip the pipe such that it is centered between jaw carriers 94
and
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backstop 92. In some embodiments, telescoping member 88 can comprise a
hydraulic or pneumatic ram cylinder, as well known to those skilled in the
art.
Referring to Figures 12 to 14, a second embodiment of back-up tong 14 is
shown. In some embodiments, back-up tong 14 can comprise back-up tong
assembly 102 that can further comprise of frame 104 having throat 106
configured for receiving a section of pipe. Frame 102 can further comprise
valve
bank 110 for manually controlling the operation of apparatus 10. Back-up tong
assembly 102 can further comprise a plurality of ram jaws 108 disposed about
opening 106. In the illustrated embodiment, there can be three ram jaws 108
positioned in a substantially equal spaced-apart configuration about opening
106.
In some embodiments, each ram jaw 108 can be slidably disposed in frame 104
by guide track 114, guide rails 116 and end block 112 operatively attached to
frame 104. Referring to Figure 14, each ram jaw 108 can comprise housing 124
and piston 126 slidably disposed therein to form annular chamber 128. Piston
126 can extend through opening 125 disposed in end 127, and can further be
fasted to end block 112 with fastener 113. Each ram jaw 108 can further
comprise die face 120 having die slot 122 disposed thereon to receive
removable
die 118, which is configured with grooves or teeth to grip pipe. As die 118
wears
out, it can be replaced with a new die 118. Fittings 130 and 131 can be
coupled
to a source of pressurized hydraulic fluid or air. In operation, pressurized
fluid or
air introduced into chamber 128 through fitting 130 can force piston 126 to
extend out from opening 125 and contact end block 112. This can force housing
124 to travel along guide track 114 and guide rails 116 towards throat opening
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106 to grip a section of pipe. When pressurized fluid or air introduced into
chamber 128 through fitting 131, piston 126 can be retracted into housing 124
thereby drawing ram jaw 108 back along guide track 114 and guide rails 116
away from throat opening 106 to release the pipe.
In some embodiments, back-up tong 14 can comprise centering pin 132
having v-shaped profile 134 disposed thereon, profile 134 can be configured to
match the profile of detent 52 of pivot tube 50 disposed on inner arm 48 of
swing
arm assembly 18. Therefore, when back-up tong 14 is pivotally attached to
pivot
tube 50, profile 134 can fit in detent 52 and can further act as means to
center
power tong assembly 11 in a desired orientation with respect to swing arm
assembly 18.
Referring to Figures 15 to 17, an embodiment of power tong assembly 11
is shown. In some embodiments, power tong 12 can comprise of frame 136
further comprising of top plate 138 and bottom plate 140 joined together by
support posts 142 disposed around the perimeter of frame 136. In some
embodiments, jaw assembly 150 can be rotatably disposed in frame 136
between top plate 138 and bottom plate 140 and can further form jaw opening
151 to receive a section of pipe. In some embodiments, drive assembly 24 can
provide the motive power to rotate jaw assembly 150 via drive chain 160 driven
by drive sprocket 164, wherein drive chain 160 can be guided by idler posts
156
and 159, and by tensioner posts 158, to engage and rotate jaw assembly 150. In
some embodiments, drive chain 160 can comprise a 6-row, #80 roller chain. In
some embodiments, drive chain 160 can pass between idler posts 159 and
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tensioner posts 158, wherein tensioner posts 158 can comprise an eccentric
mechanism to move tensioner posts 158 against drive chain 160 to remove any
slack in the chain.
In some embodiments, power tong 12 can further comprise upper brake
band 152 disposed around upper brake hub 184 disposed on jaw assembly 150.
In some embodiments, power tong 12 can further comprise lower brake band
153 disposed around lower brake hub 186. Brake band posts 154 can be
disposed on top plate 138 and bottom plate 140 to control the movement of
upper brake band 152 and lower brake band 153 when jaw assembly 150 is
rotated. In some embodiments, frame 136 can further comprise torque reactor
144 disposed thereon, and load cell 146, operatively coupled to a programmable
logic controller or other monitoring electronics (not shown) as well known to
those skilled in the art to measure the torque applied to pipe when disposed
in
jaw opening 151 by power tong 12. In some embodiments, power tong 12 can
further comprise guards 162 disposed on frame 136 near jaw opening 151 that
can be configured to open to receive a section of pipe, and to close when the
pipe is within jaw assembly 150 as safety means to protect personnel from the
rotating components of power tong 12 when in operation.
Referring to Figure 18, one embodiment of drive assembly 24 is shown.
In some embodiments, drive assembly 24 can comprise motor 166 operatively
coupled to gear reducer 170. In some embodiments, motor 166 can comprise a
variable speed hydraulic motor. In using such a motor, power tong apparatus 10
can avoid the necessity of changing gears using a conventional 2-speed
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transmission, which can avoid over-torqueing a joint between sections of pipe
when the transmission is shifted from high gear to low gear to apply the final
torque. In this situation, starting in low gear can require overcome the
static
friction in the connection to reach the desired torque for the connection. In
a
representative embodiment, a Series 51, 80 cc bent-axis hydraulic motor as
manufactured by Sauer-Danfoss Gmbh & Co. OHG of Neumunster, Germany
can be used as motor 166, although functionally equivalent motors can be used,
as well known to those skilled in the art. In some embodiments, gear reducer
170 can comprise a Model 25D planetary gear reducer as manufactured by Heco
Gear of West Sacramento, California, U.S.A. In some embodiments, encoder
ring 168 can be disposed between motor 166 and gear reducer 170 as a means
for monitoring the rotational speed of output shaft 167, in combination with
sensors disposed in gear reducer 170 (not shown) as well known to those
skilled
in the art. In some embodiments, drive assembly 24 can further comprise drive
shaft 172 operatively coupled to gear reducer 170, which can be further
operatively coupled to drive sprockets 164 via keys 174 disposed between slot
176 disposed on driveshaft 172 and slots 165 disposed in drive sprockets 164.
In some embodiments, drive sprockets 164 can be retained on driveshaft 172 by
snap ring 180, and supported by idler bearing 182 when disposed in frame 136.
Referring to Figures 19A, 1913 and 20, an embodiment of jaw assembly
150 is shown. In some embodiments, jaw assembly 150 can comprise of upper
jaw ring 188 and lower jaw ring 190 operatively coupled together with rod
spacers 203 and eye bolts 208. In further embodiments, jaw assembly 150 can
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further comprise jaw cam 192 rotatably disposed between upper jaw ring 188
and lower jaw ring 190. Each of upper jaw ring 188, lower jaw ring 190 and jaw
cam 192 can each further comprise an opening that can align together to form
jaw opening 151. In some embodiments, upper jaw ring 188 can comprise upper
5 brake hub 184 disposed on an upper surface of upper jaw ring 188 and
attached
with fasteners 210, and lower jaw ring 190 can comprise lower brake hub 186
disposed on a lower surface of lower jaw ring 190 and attached with fasteners
210. Upper jaw ring 188 can further comprise grease fittings 212, wherein jaw
assembly 150 can be lubricated with grease injected through fittings 212. In
10 some embodiments, jaw cam 192 can comprise one or more sprockets 196
disposed on a circumferential edge thereof for engagement with drive chain
160.
In some embodiments, drive chain 160 can be substituted with a functionally
equivalent drive belt, wherein drive sprocket 164, sprockets 196, tensioner
posts
158 and idler posts 159 can also be suitably modified for operation therewith,
and
15 further comprise pulleys configured for operation with a drive belt.
In some embodiments, jaw cam 192 can further comprise circumferential
.
grooves 198 disposed on upper and lower surfaces thereof configured to receive
rollers 194 that can travel therein. In some embodiments, rollers 194 can be
disposed on a lower surface of upper jaw ring 188, and on an upper surface of
20 lower jaw ring 190 to travel within grooves 198, wherein jaw cam 192 can
rotate
between upper and lower jaw rings 188 and 190.
In some embodiments, jaws 202 can be disposed within jaw opening 151
between upper jaw ring 188 and lower jaw ring 190, wherein jaws 202 can be
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pivotally attached to eye bolts 208. Each jaw 202 can further comprise a jaw
block 204 configured to have a replaceable die 205 disposed thereon. Dies 205
can be configured with grooves or teeth so as to grip a pipe. Dies 205 can
wear
out over time, whereupon worn out dies 205 can then be replaced with new dies
205. In some embodiments, jaw assembly 150 can further comprise rear jaw
block 206 disposed between upper and lower jaw rings 188 and 190 near the
back of jaw opening 151. Rear jaw block 206 can further comprise rear jaw
carrier 207 slidably disposed therein, wherein rear jaw carrier 207 can
further
comprise a replaceable die 205 disposed thereon. In some embodiments, jaw
assembly 150 can further comprise centering mechanism or switch 200 disposed
on upper jaw ring 188 near rear jaw block 206. Centering mechanism or switch
200 can be used to switch the operation of power tong 12 between "make-up
mode" (to join sections of pipe together) and "break-out mode" (to separate
sections of pipe). In some embodiments, centering mechanism or switch 200
can further comprise proximity sensors 218 (see Figure 22) operatively coupled
to a programmable logic controller to detect what mode of operation power tong
12 is in, as well as when jaw cam 192 is centered with upper and lower jaw
rings
188 and 190.
Referring to Figures 21A and 21B, one embodiment of jaw assembly 150
is shown with upper jaw ring 188 removed to illustrate the operation of jaw
assembly 150. In Figures 21A, jaw cam 192 is shown centered with lower jaw
ring 190, wherein jaw opening 151 is open to receive a section of pipe. In
this
position, biasing means 219 keep jaws 202 biased towards cam profile 214
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22
disposed on an inner circumferential edge of jaw cam 192 to keep jaw opening
151 clear for the pipe. In some embodiments, biasing means 219 can comprise
a spring. In some embodiments, jaws 202 can comprise rollers 216, wherein
jaws 202 can roll against cam profile 214 when jaw cam 192 is rotated. When,
for example, power tong 12 is in "break-out mode", drive assembly 24 can
rotate
jaw cam 192 counter-clockwise, as shown in Figure 21B, by rotating chain 160
(as shown in Figure 17) to engage sprockets 196. Brake bands 152 and 153 (as
shown in Figures 15 and 16) can hold upper and lower jaw rings 188 and 190 in
place so that jaw cam 192 can rotate relative to upper and lower jaw rings 188
and 190, and urge jaws 202, as they pivot about eye bolts 208, towards jaw
opening 151 to grip a pipe disposed therein as rollers 216 follow cam profile
214.
Brake band posts 154, as shown in Figures 15 and 16, can act to keep brake
bands 152 and 153 in place while jaw assembly is rotating. In some
embodiments, cam profile 214 can be configured to urge rear jaw carrier 207
towards jaw opening 151 to grip the pipe as well. Once jaws 202 and rear jaw
carrier 207 grip the pipe, jaw cam 192 can be continued to be rotated by drive
assembly 24 and chain 160 until a joint between a section of pipe and the
drill
string has been completely separated. At this point, drive assembly 24 can be
reversed to center jaw cam 192 with upper and lower jaw rings 188 and 190,
wherein jaws 202 and rear jaw carrier release the pipe so it can be removed
from
power tong 12. In "make-up mode", the procedure is reversed such that a
section of pipe to be joined to the drill string is placed in the jaw opening
151 and
jaw cam 192 can be rotated clockwise by drive assembly 24 to first engage and
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23
grip the pipe and then thread the pipe to the drill string to a desired
torque,
whereupon drive assembly 24 is reversed to center jaw cam 192 with upper and
lower jaw rings 188 and 190 so that power tong 12 can move away from the drill
string.
Referring to Figures 23 to 25, some embodiments of jaw 202 are shown.
Referring to Figure 23, in some embodiments, jaw 202 can comprise slot 201
configured for receiving jaw block 204, which can be secured to jaw 202 with a
fastener 199 secured to jaw 202. Jaw block 204 can further be configured to
receive replaceable die 205, which can be secured to jaw block 204 with
another
fastener 199. Referring to Figures 24 and 25, in some embodiments, jaw 202
can further comprise roller recess 217 configured to receive jaw roller 216
rotatably disposed therein. In some embodiments, roller pin 220 can pass
through holes 224 disposed in jaw 202 and jaw roller 216 and be secured to jaw
202, wherein jaw roller 216 can rotate within roller recess 217. In further
embodiments, roller pin 220 can comprise grease fitting 222 to permit
lubrication
of jaw roller 216 so that it can freely rotate about roller pin 220. In Figure
24, the
embodiment of jaw 202 shown is configured to grip pipe having diameters
ranging from 2-3/8 inches to 4-1/2 inches. In Figure 25, the embodiment of jaw
202 shown is configured to grip pipe having diameters ranging from 5 inches to
5-1/2 inches. In some embodiments, jaws 202 can be interchanged in jaw
assembly 150 by removing eye bolts 208, placing the desired size of jaws 202
within jaw assembly 150 and reinstalling eye bolts 208.
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24
Referring to Figure 26, an embodiment of power tong apparatus 10 is
shown. In some embodiments, power tong 12 can be supported above back-up
tong 14 by a plurality of guide rods 226 extending downwardly from power tong
12 (as shown in Figure 17) slidably disposed in guide rod receivers 228
disposed
in back-up tong 14, and coil springs 230 disposed about guide rods 226 between
power tong 12 and back-up 14. In a representative embodiment, power tong
apparatus 10 can comprise three sets of guide rod 226, guide rod receiver 228
and spring 230 to support power tong 12 above back-up tong 14. With this
configuration, power tong 12 can move upwards or downwards relative to back-
up tong 14, depending on whether power tong apparatus 10 is being operated in
a "bread-out mode" or "make-up mode".
Referring to Figure 28, one embodiment of control system 238 for
controlling the operation of power tong assembly 10 is shown. In some
embodiments, control system 238 can comprise hydraulic power unit ("HPU")
240, which can further comprise of hydraulic pump 242 and hydraulic fluid tank
244. In further embodiments, HPU 240 can further comprise hydraulic fluid
filtering system 246. In yet further embodiments, filtering system 246 can
further
comprise a hydraulic cooling system, which can comprise of a radiator or heat
exchanger, to cool hydraulic fluid pumped by HPU 240. In some embodiments,
HPU 240 can be configured to pump hydraulic fluid at a pressure of up to 3600
psi at a rate of up to 22 gallons per minute. In some embodiments, pump 242
can provide a hydraulic power rating of up to 29 horsepower. In some
embodiments, control system 238 can comprise hydraulic send and return lines
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operatively coupled between HPU 240 and controllable valve bank 250, which
can be operatively controlled by programmable logic controller ("PLC") 254 via
control cable 252 disposed therebetween. Valve bank 250 can be controlled by
PLC 254 to provide pressurized hydraulic fluid from HPU 240 to telescoping
5
member 56, disposed in vertical riser assembly 16, via send and return
hydraulic
lines 258; to telescoping member 47, disposed in swing arm 46, via send and
return hydraulic lines 260; to telescoping member 32, disposed on swing arm
assembly 18, via send and return hydraulic lines 262; to telescoping member 88
disposed in back-up tong assembly 80, or to ram jaws 108 disposed in back-up
10 tong assembly 102, depending on which embodiment of back-up tong 14 is
disposed in power tong apparatus 10, via send and return hydraulic lines 264;
and to drive assembly 24, via send and return hydraulic lines 266. In some
embodiments, valve bank 250 can comprise model no. PVG32 hydraulic valves
as manufactured by Sauer-Danfoss Gmbh & Co. OHG of Neumiinster, Germany,
15 although any functionally equivalent hydraulic valves as well known by
those
skilled in the art can be used. In some embodiments, PLC 254 can comprise a
model CP1H PLC as manufactured by Omron Corporation of Kyoto, Japan,
although any functionally equivalent PLC as well known by those skilled in the
art
can be used.
20 In
some embodiments, control system 238 can comprise console
assembly 30 operatively coupled to PLC 254 via control cable 256. In some
embodiments, control system 238 can operate power tong assembly apparatus
10 in a number of modes. Referring to Figures 29A and 2913, a flowchart is set
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out for manually operating power tong apparatus 10 to perform a "make-up
mode" operation, as can be carried out by control system 238. In some
embodiments, manual make-up mode process 2900 can comprise of the
following steps. At step 2902, an operator can select what size and type of
pipe
to be made-up from a menu displayed on console 30. At step 2904, a query can
be made whether power tong apparatus 10 is centered. If not, then power tong
apparatus 10 can be centered at step 2906, and the query at step 2904
repeated. If it is, then a query can be made at step 2908 whether centering
mechanism or switch 200 is set correctly for the operation. If not, then
centering
switch 200 can be correctly set at steps 2910 and 2912, and the query at step
2908 repeated. If yes, then confirmation of centering switch being correctly
set
can be made at step 2914. At step 2916, the operator can move power tong
apparatus 10 into position and vertical align it with the pipe joint. At step
2918,
the operative can press Torque Mode on console 30 wherein back-up tong 14
can close and grip the drill string. At step 2920, a query can be made whether
centering switch 200 is set correctly. If not, switch 200 can be set correctly
for
make-up mode at steps 2922 and 2924, and the query at step 2920 repeated. If
yes, the setting of switch 200 can be confirmed at step 2926, and the operator
can operate joystick 232 disposed on console 30 (as shown in Figure 33) to
start
the make-up of the joint connection at step 2928. At step 2930, jaw assembly
150 of power tong 12 can be rotated clockwise to grip and rotate the section
of
pipe to be connected to the drill string. At step 2932, a query can be made if
the
rotation speed of jaw assembly 150 is below a desired speed or setpoint for
the
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type and size of pipe being joined. If not, the speed can be lowered at step
2934,
and the query at step 2932 repeated. If yes, the process at step 2930 can be
continued. At step 2936, a query can be made to determine if the torque
applied
to the pipe is within the setpoints set for the type and size of pipe being
joined. If
not, a further query at step 2938 can be made if the number of turns required
for
joining the pipe is within the setpoints set for the type and size of pipe
being
joined. If not, then the process can at step 2930 can be continued. If yes,
then a
message stating that the make-up operation failed can be displayed on console
30 at step 2940, and the information logged in a datafile. If the answer to
the
query at step 2936 is yes, then a further query at step 2942 can be made if
the
number of turns for joining the pipe is within the setpoints set for the pipe.
If not,
then a message stating that the make-up operation failed can be displayed on
console 30 at step 2940, and the information logged in a datafile. If yes,
then a
message stating that the make-up operation is complete can be displayed on
console 30 at step 2944. Continuing through connector 2946 from Figure 29A to
Figure 29B, process 2900 can continue at step 2948, where a query can be
made whether power tong apparatus 10 is centered. If not, power tong
apparatus 10 can be centered at step 2950, and the query at step 2948
repeated. If yes, the operator can press Position Mode on console 30 at step
2952, wherein back-up tong 14 can release the drill string, and then move
power
tong apparatus 10 away from the hole center and completed pipe joint at step
2954.
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Referring to Figures 30A and 308, a flowchart is set out for manually
operating power tong apparatus 10 to perform a "break-out mode" operation, as
can be carried out by control system 238. In some embodiments, manual break-
out mode process 3000 can comprise of the following steps. At step 3002, an
operator can select what size and type of pipe to be broken out from a menu
displayed on console 30. At step 3004, a query can be made whether power
tong apparatus 10 is centered. If not, then power tong apparatus 10 can be
centered at step 3006, and the query at step 3004 repeated. If it is, then a
query
can be made at step 3008 whether centering switch 200 is set correctly for the
operation. If not, then centering switch 200 can be correctly set at steps
3010
and 3012, and the query at step 3008 repeated. If yes, then confirmation of
centering switch being correctly set can be made at step 3014. At step 3016,
the
operator can move power tong apparatus 10 into position and vertical align it
with
the pipe joint. At step 3018, the operative can press Torque Mode on console
30
wherein back-up tong 14 can close and grip the drill string. At step 3020, a
query
can be made whether centering switch 200 is set correctly. If not, switch 200
can
be set correctly for break-out mode at steps 3022 and 3024, and the query at
step 3020 repeated. If yes, the setting of switch 200 can be confirmed at step
3026, and the operator can operate joystick 232 disposed on console 30 (as
shown in Figure 33) to start the break-out of the joint connection at step
3028. At
step 3030, jaw assembly 150 of power tong 12 can be rotated counter-clockwise
to grip and rotate the section of pipe to be disconnected from the drill
string. At
step 3032, a query can be made if the rotation speed of jaw assembly 150 is
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below a desired speed or setpoint for the type and size of pipe being broken
out.
If not, the speed can be lowered at step 3034, and the query at step 3032
repeated. If yes, the process at step 3030 can be continued. At step 3036, a
query can be made to determine if the number of turns required for breaking
the
pipe joint is within the setpoints set for the type and size of pipe being
broken out.
If not, then a query can be made at step 3038 if jaw assembly 150 is turning.
If
not, then a message stating that the break-out operation failed can be
displayed
on console 30 at step 3040, and the information logged in a datafile. If the
answer to the query at step 3038 is yes, then the query at step 3036 can be
repeated. If the answer to the query at step 3036 is yes, then a message
stating
that the break-out operation is complete can be displayed on console 30 at
step
3042. Continuing through connector 3044 from Figure 30A to Figure 30B,
process 3000 can continue at step 3046, where a query can be made whether
power tong apparatus 10 is centered. If not, power tong apparatus 10 can be
centered at step 3048, and the query at step 3046 repeated. If yes, the
operator
can press Position Mode on console 30 at step 3050, wherein back-up tong 14
can release the drill string, and them move power tong apparatus 10 from the
hole center and broken out pipe joint at step 3052.
Referring to Figures 31A and 31B, a flowchart is set out for automatically
operating power tong apparatus 10 to perform a "make-up mode" operation, as
can be carried out by control system 238. In some embodiments, manual make-
up mode process 3100 can comprise of the following steps. At step 3102, an
operator can select what size and type of pipe to be made-up from a menu
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displayed on console 30. At step 3104, a query can be made whether power
tong apparatus 10 is centered. If not, then power tong apparatus 10 can be
centered at step 3106, and the query at step 3104 repeated. If it is, then a
query
can be made at step 3108 whether centering switch 200 is set correctly for the
5 operation. If not, then centering switch 200 can be correctly set at steps
3110
and 3112, and the query at step 3108 repeated. If yes, then confirmation of
centering switch being correctly set can be made at step 3114. At step 3116,
the
operator can move power tong apparatus 10 into position and vertical align it
with
the pipe joint. At step 3118, the operative can press Torque Mode on console
30
10 wherein back-up tong 14 can close and grip the drill string. At step
3120, a query
can be made whether centering switch 200 is set correctly. If not, switch 200
can
be set correctly for make-up mode at steps 3122 and 3124, and the query at
step
3120 repeated. If yes, the setting of switch 200 can be confirmed at step
3126,
and the operator can press Start on console 30 to start the make-up of the
joint
15 connection at step 3128. At step 3130, jaw assembly 150 of power tong 12
can
be rotated clockwise to grip and rotate the section of pipe to be connected to
the
drill string. At step 3132, a query can be made if the rotation speed of jaw
assembly 150 is below a desired speed or setpoint for the type and size of
pipe
being joined. If not, the speed can be lowered at step 3134, and the query at
20 step 3132 repeated. If yes, the process at step 3130 can be continued.
At step
3136, a query can be made to determine if the torque applied to the pipe is
within
the setpoints set for the type and size of pipe being joined. If not, a
further query
at step 3138 can be made if the number of turns required for joining the pipe
is
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within the setpoints set for the type and size of pipe being joined. If not,
then the
process can at step 3130 can be continued. If yes, then a message stating that
the make-up operation failed can be displayed on console 30 at step 3140, and
the information logged in a datafile. If the answer to the query at step 3136
is
yes, then a further query at step 3142 can be made if the number of turns for
joining the pipe is within the setpoints set for the pipe. If not, then a
message
stating that the make-up operation failed can be displayed on console 30 at
step
3140, and the information logged in a datafile. If yes, then a message stating
that the make-up operation is complete can be displayed on console 30 at step
3144. Continuing through connector 3146 from Figure 31A to Figure 31B,
process 3100 can continue at step 3148, where a query can be made whether
power tong apparatus 10 is centered. If not, power tong apparatus 10 can be
centered at step 3150, and the query at step 3148 repeated. If yes, the
operator
can press Position Mode on console 30 at step 3152, wherein back-up tong 14
can release the drill string, and then move power tong apparatus 10 from the
hole center and completed pipe joint to one of two operator-defined positions
at
either of steps 3154 and 3156.
Referring to Figures 32A and 32B, a flowchart is set out for automatically
operating power tong apparatus 10 to perform a "break-out mode" operation, as
can be carried out by control system 238. In some embodiments, manual break-
out mode process 3200 can comprise of the following steps. At step 3202, an
operator can select what size and type of pipe to be broken out from a menu
displayed on console 30. At step 3204, a query can be made whether power
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tong apparatus 10 is centered. If not, then power tong apparatus 10 can be
centered at step 3206, and the query at step 3204 repeated. If it is, then a
query
can be made at step 3208 whether centering switch 200 is set correctly for the
operation. If not, then centering switch 200 can be correctly set at steps
3210
and 3212, and the query at step 3208 repeated. If yes, then confirmation of
centering switch being correctly set can be made at step 3214. At step 3216,
the
operator can move power tong apparatus 10 into position and vertical align it
with
the pipe joint. At step 3218, the operative can press Torque Mode on console
30
wherein back-up tong 14 can close and grip the drill string. At step 3220, a
query
can be made whether centering switch 200 is set correctly. If not, switch 200
can
be set correctly for break-out mode at steps 3222 and 3224, and the query at
step 3220 repeated. If yes, the setting of switch 200 can be confirmed at step
3226, and the operator can press Start on console 30 to start the break-out of
the
joint connection at step 3228. At step 3230, jaw assembly 150 of power tong 12
can be rotated counter-clockwise to grip and rotate the section of pipe to be
disconnected from the drill string. At step 3232, a query can be made if the
rotation speed of jaw assembly 150 is below a desired speed or setpoint for
the
type and size of pipe being broken out. If not, the speed can be lowered at
step
3234, and the query at step 3232 repeated. If yes, the process at step 3230
can
be continued. At step 3236, a query can be made to determine if the number of
turns required for breaking the pipe joint is within the setpoints set for the
type
and size of pipe being broken out. If not, then a query can be made at step
3238
if jaw assembly 150 is turning. If not, then a message stating that the break-
out
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operation failed can be displayed on console 30 at step 3240, and the
information logged in a datafile. If the answer to the query at step 3238 is
yes,
then the query at step 3236 can be repeated. If the answer to the query at
step
3236 is yes, then a message stating that the break-out operation is complete
can
be displayed on console 30 at step 3242. Continuing through connector 3244
from Figure 32A to Figure 32B, process 3200 can continue at step 3246, where a
query can be made whether power tong apparatus 10 is centered. If not, power
tong apparatus 10 can be centered at step 3248, and the query at step 3246
repeated. If yes, the operator can press Position Mode on console 30 at step
3250, wherein back-up tong 14 can release the drill string, and then power
tong
apparatus 10 from the hole center and broken out pipe joint to one of two
operator-defined positions at either of steps 3252 and 3254.
Referring to Figure 33, an embodiment of console 30 for use with power
tong apparatus 10 is shown. In some embodiments, console 30 can comprise
housing 231 that can further comprise joystick 232, push-button controls 234,
touchscreen 236, and push-button controls 233 disposed on joystick 232 for
controlling power tong assembly 10. In some embodiments, an operator can use
the automatic controls on console 30 or use the manual hydraulic levers 22 on
the side of power tong assembly 10 itself, as shown in Figures 1 or 26. In
some
embodiments, Auto Control can be used to control power tong assembly 10. In
some embodiments, controls 234 can comprise of 3 buttons: "Start", "Reset" and
an "ESD" (Emergency Shut Down) button. Console 30 can further comprise a 2
way switch (VALVE CNTR), a 4-axis joystick 232 (Up, Down, In, Out) and touch
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screen 236. Joystick 232 can further comprise 4 thumb buttons 233: "TORQ",
"POSI", "MAKE BREAK" and "CNTR". Joystick 232 can further comprise a dead
man trigger switch (not shown).
In some embodiments, joystick 232 can be used to control movement of
power tong apparatus 10 (position mode) and to makeup/breakout joints (torque
mode). In some embodiments, the movement controls of joystick 232 can be
configured to work only if the dead man switch is squeezed and held. To adjust
the position of power tong apparatus 10 in some embodiments, console 30 can
be set in "POSITION MODE" by pressing the POSI button. The "POSMON
MODE" indicator light on touchscreen 236 will be highlighted green if position
mode is selected. Moving joystick 232 to the left or right can rotate power
tong
apparatus 10 in and out of hole center, whereas moving joystick 232 up and
down can raise or lower power tong apparatus 10 to the desired height. To
makeup or breakout a joint, "TORQUE MODE" can be selected by pressing the
TORQ button to switch to torque mode upon which, the "TORQUE MODE"
indicator light will be highlighted green on touchscreen 236.
In some
embodiments, when "TORQUE MODE" is selected, back-up tong 14 can
automatically close upon a pipe, and when "POSITION MODE" is selected, back-
up tong 14 can automatically open. In some embodiments, pressing the MAKE
BREAK button can switch between make up and break out modes upon which,
the appropriate indicator on touchscreen 236 can turn green to show the
current
mode. In some embodiments, pressing the CNTR button can automatically
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center the jaw assembly 150. Jaw assembly 150 will rotate to center in the
clockwise direction if in break-out mode, and in the counter-clockwise
direction if
in make-up mode. In some embodiments, pressing the Start button can begin
the make-up or break-out auto sequence. Pressing the Reset button can stop
5 the auto sequence, and can be used to clear error messages. Pressing the ESD
button can stop the operation of power tong apparatus 10 immediately and
disable all controls on console 30. In some embodiments, the VALVE CNTRL/PLC
CNTRL selector switch can be used to set the method of control of power tong
apparatus 10. If the switch is set to PLC CNTRL, console 30 can be used. If
the
10 switch is set to VALVE CNTRL, then hydraulic valve bank 22 can to be
used, and
controls on console 30 can be disabled.
Referring to Figure 34, touchscreen 236 can be used to navigate through
a number of different screens and functions displayed thereon. As shown in
Figure 34, in some embodiments, the MENU screen can display seven modes of
15 functionality: MAIN, MANUAL, SETUP, PIPE SET, DATALOG, AUTO MONITOR and
HELP, in addition to EXIT mode.
Referring to Figure 35, an embodiment of the MAIN screen is shown. In
some embodiments, the MAIN screen can list information such as: torque
setpoint, last torque achieved, number of turns of the tong during the last
20 make/break and instantaneous torque reading. This screen can be the most
used screen as an operator will want to see the torque readings when making up
a joint. An operator can switch between metric and imperial units by pressing
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the button on the lower right corner of the screen. When this button reads
"IMPERIAL", the units displayed can be in imperial. If the button reads
"METRIC", the units being displayed can be metric. "FINAL TORQUE" can be the
torque that has been reached while making up a joint, "INSTANT TORQUE" can
be the torque being applied to the joint at that exact moment. "FINAL TURNS"
can be how may turns of the tong it took to make up the joint. "TONG RPM" can
be the RPM of the tong at a given moment. "MOTOR RPM" can be the RPM of
the motor at a given moment. "TORQUE SETTING" can be the set point for
makeup that has been input into the current pipe profile. The "BREAK OUT
TURNS" box will only be displayed if console 30 is in break-out mode. If
console
30 is in make-up mode, then the label can be replaced by 2 labels: "TURN MIN"
and "TURN MAX". These settings can be displayed from the pipe profile that the
operator has chosen. To change a pipe setting, the "PIPE SET" box at the top
middle of touchscreen 236 can be pressed. This can bring up a popup window
where the operator user can select a specific predetermined pipe profile. If
the
operator wants to quickly change the torque setting to a custom torque, he can
simply choose "0" on the pipe setting popup. This will allow the operator to
input different settings directly into the boxes on the main screen.
Referring to Figure 36, an embodiment of the MANUAL screen is shown.
In some embodiments, the MANUAL screen can be used to control power tong
apparatus 10 via touchscreen 236. The MANUAL screen can comprise of many
buttons for the various functions of power tong apparatus 10. In some
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embodiments, the Invert Joystick button can invert the vertical controls of
the
joystick. The other buttons are self evident to those skilled in the art. This
MANUAL screen control can be used as a back-up control option. The joystick or
the auto control mode of operation can be used as the standard method of
operating power tong apparatus 10.
Referring to Figure 37, an embodiment of the PIPE TABLE screen is
shown. In some embodiments, the PIPE TABLE screen can be used by an
operator to set up all the different types of pipe that the rig will be
running. In
some embodiments, the operator can input up to 10 different pipe profiles,
where each profile requires an input for the "PIPE TYPE DESCRIPTION", "TURN
MIN", "TURN MAX", "BO TURNS", "RPM MAX" and "TORQUE VALUE".
PIPE TYPE DESCRIPTION ¨ This can be the description of the pipe given
by the operator. TURN MAX and TURN MIN -These can represent the min and
max number of turns jaw assembly 150 should rotate for the joint to be made
up. If the joint is made up before the min number of turns, then a message can
be displayed stating that the pipe might be incorrectly torqued and it should
be
checked. This might happen if the joint was cross threaded. The turn max
setting is the maximum turns allowed. Jaw assembly 150 can stop rotating if
the
max turn limit has been reached. This is to prevent over torque due to a
failure
in the torque sensor. It can state the size and type of pipe.
BO TURNS - This box can be used to set the total number turns that the
auto breakout will complete per sequence.
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RPM MAX ¨ can set the max speed of the tong for makeup or breakout.
TORQUE VALUE ¨The torque set point for every joint made up under the
given profile.
DRILL PIPE ¨ This check box can be checked off if the type of pipe is drill
pipe. This can be used when making up so that the tong will shoulder the
connection softly to avoid over torquing the joint.
Referring to Figure 38, an embodiment of the DATALOG screen is shown.
In some embodiments, the DATALOG screen can list information for every joint
made up. In some embodiments, up to 500 logs can be recorded. Each record
can comprise 5 components: "ORDER", "PIPE DESCRIPTION", "TORQUE
SETPOINT", "ACHIEVED TORQUE" and "M.U. TURNS" (make-up turns).
ORDER ¨ This can describe the order of the joints made up, 1 through
500, "1" being the first joint made up for the well.
PIPE DESCRIPTION ¨ This can be the description of the pipe used
including pipe size and type.
TORQUE SETPOINT ¨ This can be the desired torque set point for the
joint.
ACHIEVED TORQUE ¨ This can be the torque that was actually achieved
during make up.
M.U. TURNS ¨ This can show how many turns of the tong it took to
completely torque the joint.
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39
In some embodiments, pressing the next or prey buttons can skip to the
next or previous page of logs. The reset data button can erase all the data in
the datalog. In some embodiments, the reset button is only displayed on the
first datalog screen.
Referring to Figures 39 to 41, embodiments of ERROR MESSAGES screens
are shown. In some embodiments, a number of different error messages can be
displayed during use of console 30 in the operation of power tong apparatus
10.
Figures 39 to 41 illustrate the different error messages that can be
displayed,
and describe the meaning or nature of these error messages.
In some embodiments, power tong apparatus 10 can be operated by the
following steps. While in position mode, joystick 232 can be used to move
power
tong apparatus 10 to hole-center, and to center the apparatus on the joint
with
power tong 12 over the pipe coupling and back-up tong 14 under the pipe
coupling. Once the apparatus has been positioned correctly on the joint, the
"Torque Mode" button can be pressed on joystick 232. Back-up tong 14 will
close automatically, and a joint can now be made up or broken out. The
MAKEUP BREAKOUT button can be used to switch between these two modes of
operation. The make/break selector (centering switch 200) must match the
mode of operation to be used. For example, in Make Up mode on touchscreen
236, centering switch 200 must be up so jaw assembly 150 will close on the
pipe
while rotating clockwise to make up the joint. If the joint is to be broken
out,
centering switch 200 must be in break-out mode. In some embodiments,
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CA 02773295 2012-04-03
centering switch 200 can only be switched between make-up and break-out if
jaw assembly 150 has already been centered. If centering switch 200 is
operated when jaw assembly 150 is not at center, the apparatus will not
operate
correctly and there can be risk ins damaging the apparatus and/or the pipe.
5 Once centering switch 200 and the mode button are properly selected, an
operator can make up or break out the joint with the operators controls using
one of three different methods: Joystick Control, Auto Control and Screen
Control.
JOYSTICK CONTROL: - the dead-man switch on joystick 232 can be
10 squeezed, and joystick 232 can be pulled back for break out or pushed
forward
for make-up. Jaw assembly 150 can then start spinning. If making up the joint,
once the joint has reached the desired torque the apparatus will stop, and the
CNTR button can be pressed to center jaw assembly 150.
SCREEN CONTROL ¨ In some embodiments, the apparatus' functions can
15 be controlled using the MANUAL screen as well. To do this, an operator must
make sure the apparatus is in the correct mode, and that centering switch 200
is
set correctly. The Torque mode can be used to make-up or break-out a joint.
The Break Out or Make Up buttons can be pressed and held to break or make a
joint. If in makeup mode, the apparatus will stop and jaw assembly 150 can
20 center automatically once the joint reaches its torque set point.
AUTO CONTROL- In some embodiments, this can be the simplest way to
control the apparatus. As in other modes, an operator can make sure the
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CA 027732 95 2014-06-25
41
apparatus is centered over the joint, and that the apparatus is in "Torque
Mode",
and that centering switch 200 is in the correct position. The "Start" button
can
then be pressed, and the apparatus can either break or make the joint. If in
Make-up mode, a torque can be read on the main screen, and when the torque
setting has been reached, the apparatus can automatically stop making the
joint
up and rotate the other direction until jaw assembly 150 is centered. If in
break
out mode, the apparatus can break the joint and spin out the pipe for a set
amount of rotations (this is set in the "Pipe Set" screen and determined by
what
pipe setting you have selected). Once jaw assembly 150 has rotated the set
amount of turns, jaw assembly 150 can stop and rotate the other direction
until it
has reached the center position.
Although a few embodiments have been shown and described, it will be
appreciated by those skilled in the art that various changes and modifications
can
be made to these embodiments without changing or departing from their scope,
intent or functionality. The terms and expressions used in the preceding
specification have been used herein as terms of description and not of
limitation,
and there is no intention in the use of such terms and expressions of
excluding
equivalents of the features shown and described or portions thereof, it being
recognized that the invention is defined and limited only by the claims that
follow.
8754409_11NATDOCS
