Note: Descriptions are shown in the official language in which they were submitted.
TITLE: JOINTED PIPE INJECTOR TRIGGER MECHANISM
TECHNICAL FIELD:
[0001] The present disclosure is related to the field of injecting segmented
(jointed) pipe
or tubing into a well, in particular, systems and methods for continuously
pushing, forcing,
snubbing or stripping a tubular string into or controlling when pulling or
resisting the
movement of a tubular string out of pressurized and/or horizontal well bores.
BACKGROUND:
[0002] In recent years, new technologies have been introduced that have
increased the
industry's ability to drill oil and gas wells horizontally to great measured
lengths.
Conventional vertical or directional oil or gas completion, workover, and
service rigs
primarily use the force of gravity to move drilling, completion, workover, and
service tools
to the full measured length of the oil or gas wells to complete, work over, or
service the
wells. When horizontal wells are drilled such that the horizontal section is
longer than the
length of the vertical section, it becomes difficult to move the tools to the
end of the well
for the purpose of completing, working over, or servicing the well including
the drilling and
removing of fracturing ("fracing") plugs. The well may also contain well bore
pressures
when the tools are being introduced into or removed from the wellbore,
creating a need
to force the tools into the wellbore against that pressure until such point
that the weight
of the oil field tubular string overcomes the force of the wellbore pressure
against it, or to
resist the force exerted on the tools and pipe by the wellbore pressure
forcing the tools
from the wellbore.
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[0003] It has been found that cuttings and debris tend to collect in the lower
side of the
horizontal well sections and that pipe string rotation helps to distribute the
debris and
cuttings into the annular area to help the circulating fluid to carry it out
of the wellbore.
[0004] The industry has commonly used continuous coiled tubing injector
technology or
segmented oil field tubular snubbing jack technology to complete, work over
and service
the oil and natural gas wells under pressure.
[0005] Limitations have been realized when utilizing continuous coiled tubing
injector
technology as the horizontal sections get longer. Limiting factors of coiled
tubing are
transportability to get to the well sites and the ability to push the
continuous pipe in the
extended reach horizontal section of the oil or natural gas wells.
Transportation is a
limitation because the tubing cannot be divided into multiple loads. A
practical mechanical
limitation of pushing the coiled tubing into the well exists when the friction
in the horizontal
section of the wellbore exceeds the buckling force limit of the continuous
tubing. Due to
the inherent requirement to be stored on a storage reel, coiled tubing cannot
be rotated
in order to reduce friction while moving axially and to stir cuttings and
debris from the
lower side of the wellbore into the annular area where circulating fluid can
carry it up-hole.
[0006] A method of forcing segmented oil field tubulars into a wellbore is to
use what is
commonly known as hydraulic snubbing jack technology. Generally, a snubbing
jack
consists of stationary slips and travelling slips that are connected to
hydraulic cylinders
to push sections of the pipe repetitively into the wellbore by taking multiple
strokes of
various lengths. The force that a snubbing jack can apply is limited because
the distance
between the stationary slip and the travelling slip creates an unsupported
column length
of the oil field tubular that increases the risk of buckling the tubular. Due
to the constant
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start and stop repetitive movements of using a snubbing jack to move the pipe,
it is difficult
to circulate fluid through the pipe while moving. The repetitive movements of
the snubbing
jack are operated manually up to thousands of times per well that is being
serviced
creating the high possibility of human error resulting in an operational
safety risk.
[0007] There is a demonstrated need in the industry to rotate a tubular string
while
pushing, forcing, snubbing, or stripping into or controlling when pulling
while resisting
wellbore pressures, a tubular string out of wells that may be under pressure
to reduce the
friction of axially moving the tubular string in extended reach horizontal
wells to overcome
the limitations of continuous coil tubing injector technology.
[0008] There is a further demonstrated need in the industry to reduce or
eliminate the risk
of buckling or bending an unsupported length of a tubular string being forced
into a well
under pressure.
[0009] There is further a demonstrated need in the industry to automate the
operation of
forcing or snubbing of the tubular string into or out of wells under pressure
to overcome
the safety risks of thousands of repetitive manually controlled movements of
the snubbing
jack technology. One example of a tubing injector directed toward these
operations is
disclosed in international patent application no. PCT/CA2019/050078 filed on
22 January
2019. One issue that can arise with this type of tubing injector is that the
tubing can
comprise tapered upset ends that are larger in diameter than the nominal
diameter of the
tubing itself, wherein the tapered upset ends are adjacent to tubing coupling
components
or element that are further larger in diameter than the tapered upset ends.
The larger
diameter upset tapered ends may not be large enough to cause the jaws of the
gripper
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blocks of the above-mentioned tubing injector to open but can still be large
enough to jam
or get stuck in the jaws and, therefore, cause the tubing injector to stop
operating.
[0010] It is, therefore, desirable to provide an apparatus and method that
overcomes this
problem.
SUMMARY:
This disclosure is related to improvements to the method and system of
retracting the
gripper block elements of the rotating jointed tubing injector patent
application to
accommodate the variations that exist within segmented pipe and tube diameter
profiles
directly adjacent to interconnecting couplings or tool joints within a tubing
or pipe string,
as disclosed in international patent application no. PCT/CA2019/050078 filed
on 22
January 2019. A system and method for injecting segmented pipe or tubing into
and out
of a well is provided. In some embodiments, the system can comprise a
passively rotating
jointed tubular string continuous snubbing injector ("injector") that can
continuously apply
a linear force into the tubular string while allowing the continuous rotation
of a tubular
string into and out of extended reach horizontal wellbores for the purposes of
completing,
working over, and servicing the wells.
[0011] In some embodiments, the injector can minimize the unsupported length
of a
tubular or tubular string by maintaining minimal and constant distance between
the
grippers of the injector that are gripping the tubular and the Blow Out
Preventer
(hereinafter called the "BOP") as the injector applies axial force to the
tubular string into,
or pulls the tubular string out of, the BOP and wellbore, thereby overcoming
the limitations
of the snubbing jack technology.
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[0012] In some embodiments, the injector can comprise a mechanism that can
apply a
linear, constant force through the gripper blocks onto and over a certain
length of the
tubular and onto and over a certain length of a larger diameter coupling or
tool joint
connecting the segments of tubulars together while moving the tubulars axially
into or out
of the well and allowing simultaneous rotation of the tubular.
[0013] In some embodiments, the rotational force caused by the tubular string
rotating
can be transferred through the gripper mechanisms of the injector to the
driven chains
connected to the gripper blocks, and then to a stationary structure supporting
and
containing the injector, thereby minimizing rotational forces applied to the
well head.
[0014] In some embodiments, the stationary structure supporting and containing
the
injector can provide further support for the weight of the tubular string
suspended in the
wellbore when that tubular string is held by pipe slips supported within the
uppermost part
of the stationary structure.
[0015] In some embodiments, a trigger mechanism can be disposed on the
injector as
means to retract the gripper blocks from contacting interconnecting couplings
or tool joints
disposed along the length of the tubing or pipe string as the tubing or pipe
string is being
injected into or retracted from the well. In some embodiments, the trigger
mechanism
can comprise a coupling sensor that can sense the location of a coupling
component
joining sections of tubing together wherein the trigger mechanism can cause
the jaws of
the gripper blocks adjacent to the tapered upset ends and coupling components
to open
up prior to the tapered upset ends and coupling components passing through the
tubing
injector so that no gripper blocks contact the tapered upset sections or
coupling
components. Once the tapered upset sections and coupling components are within
the
Date Recue/Date Received 2021-07-08
chains of the tubing injector, the trigger mechanism can retract so that the
jaws of the
subsequent gripper blocks of the tubing injector can continue contacting the
tubing again.
[0016] Broadly stated, in some embodiments, a trigger mechanism can be
provided for a
tubing injector for forcibly injecting or retracting a tubular string axially
into or out of a well,
the tubing injector comprising an upper end and a lower end, the tubular
string comprising
a plurality of oil field tubulars connected together with tubular connecting
elements, the
tubing injector comprising a plurality of gripping elements attached to at
least two drive
chains wherein the tubular string is disposed between the at least two drive
chains, the
at least two drive chains substantially parallel to each other, the plurality
of gripping
elements configured to make contact and apply radial force to the tubular
string, the
tubular connecting elements having a larger diameter than the tubulars, the
tubulars
comprising a tapered upset section adjacent to the tubular connecting
elements, the
tapered upset section comprising an upset diameter that is greater in diameter
than the
tubulars but less than the diameter of the tubular connecting elements, the
trigger
mechanism comprising: at least one trigger assembly disposed between the at
least two
drive chains wherein each of the at least one trigger assembly is configured
to prevent
the plurality of gripping elements from contacting the tubular connecting
elements; and a
coupling sensor configured to sense the tapered upset section and the tubular
connecting
elements when the tubular string is being injected into or retracted out of
the well.
[0017] Broadly stated, in some embodiments, the at least one trigger assembly
can
comprise: a substantially vertical frame; a wedge disposed on the frame,
wherein the
wedge is disposed substantially equidistant from each of the at least two
drive chains, the
wedge configured to prevent the plurality of gripping elements from contacting
the tapered
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upset section of the tubulars or the tubular connecting elements; and a linear
actuator
configured to move the wedge in a substantially vertical direction relative to
the frame
wherein the wedge prevents the plurality of gripping elements from contacting
the tubular
connecting elements.
[0018] Broadly stated, in some embodiments, the trigger mechanism can further
comprise
a first pair of the at least one trigger assembly wherein the tubular string
is disposed
between the first pair of the at least one trigger assembly.
[0019] Broadly stated, in some embodiments, the first pair of the at least one
trigger
assembly can be configured to operate when the tubular string is being
injected into the
well.
[0020] Broadly stated, in some embodiments, the first pair of the at least one
trigger
assembly can be disposed by the upper end of the tubing injector.
[0021] Broadly stated, in some embodiments, the trigger mechanism can further
comprise
a second pair of the at least one trigger assembly wherein the tubular string
is disposed
between the second pair of the at least one trigger assembly.
[0022] Broadly stated, in some embodiments, the second pair of the at least
one trigger
assembly can be configured to operate when the tubular string is being
retracted out of
the well.
[0023] Broadly stated, in some embodiments, the second pair of the at least
one trigger
assembly can be disposed by the lower end of the tubing injector.
[0024] Broadly stated, in some embodiments, the trigger mechanism can further
comprise
a plurality of the wedge configured to engage pairs of the plurality of
gripping elements
thereby causing the pairs of the plurality of gripping elements to open and
not contact or
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grip the tapered upset section and the tubular connecting elements as the
tubular string
is being injected into or retracted out of the well.
[0025] Broadly stated, in some embodiments, the linear actuator can be
configured to
extend and retract the wedge relative to the frame.
[0026] Broadly stated, in some embodiments, the linear actuator can comprise
one or
more of a hydraulic linear actuator, pneumatic linear actuator and an electric
linear
actuator.
[0027] Broadly stated, in some embodiments, the coupling sensor can comprise
an
electrical switch and a sensing toggle operatively coupled thereto.
[0028] Broadly stated, in some embodiments, the sensing toggle can be
configured to
rotate when contacted by the tapered upset section of the tubulars when the
tubular string
is being injected into or retracted out of the well.
[0029] Broadly stated, in some embodiments, the coupling sensor can comprise a
first
coupling sensor configured to detect when the tapered upset section and the
tubing
connecting elements are about to enter the tubing injector when the tubing
string is being
injected into the well.
[0030] Broadly stated, in some embodiments, the first coupling sensor can be
disposed
by the upper end of the tubing injector.
[0031] Broadly stated, in some embodiments, the coupling sensor can comprise a
second
coupling sensor configured to detect when the tapered upset section and the
tubing
connecting elements are about to enter the tubing injector when the tubing
string is being
retracted from the well.
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Date Recue/Date Received 2021-07-08
[0032] Broadly stated, in some embodiments, the first coupling sensor can be
disposed
by the lower end of the tubing injector.
[0033] Broadly stated, in some embodiments, the trigger mechanism can further
comprise
a control system operatively coupled to the at least one trigger assembly and
to the
coupling sensor.
[0034] Broadly stated, in some embodiments, the control system can comprise
one or
more of a general purpose computer, a microcontroller, a microprocessor and a
programmable logic controller.
[0035] Broadly stated, in some embodiments, the trigger mechanism as described
herein
can be used for injecting a tubing string into a well, and for retracting the
tubing string
from the well.
BRIEF DESCRIPTION OF THE DRAWINGS:
[0036] Figure 1 is an isometric view depicting an injector assembly, further
depicting the
injector, chains, drives, grippers, tensioners, trigger mechanisms and
supporting structure
of the injector.
[0037] Figure 2 is an isometric view depicting an injector assembly of Figure
1 with part
of the outer housing removed to allow a view of the internal workings.
[0038] Figure 3 is a front elevation cross-section view depicting an injector
assembly of
Figure 1 mounted within an outer housing, further depicting the injector
supported by a
bearing assembly and an outer housing and a rotary seal assembly.
[0039] Figure 4 is a side elevation cross-section view depicting the injector
of Figure 2,
further depicting the injector, chain drives and supporting structure of the
injector.
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[0040] Figure 5 is a top plan section view depicting the hydraulic motor
assemblies,
squeeze cylinder assembly, trigger mechanisms and the grippers of the injector
of Figure
3.
[0041] Figure 6 is a front elevation view depicting the injector, grippers,
chain drives,
trigger mechanisms and supporting structure of the injector of Figure 2 in an
operating
mode of operation.
[0042] Figure 7 is a front elevation view depicting the injector, grippers,
chain drives,
trigger mechanisms, and supporting structure of the injector of Figure 2 in a
standby mode
of operation.
[0043] Figure 8 is a front elevation detailed section view depicting the
injector of Figure 1
gripping a section of a tubular string comprising a tubing coupler.
[0044] Figure 9 is a top plan view depicting the trigger mechanisms and
gripper block
assemblies of the injector of Figure 1 in a standby mode of operation.
[0045] Figure 10 is a top plan view depicting the gripper block assemblies of
the injector
of Figure 1 in an operating mode of operation when operating on tubing.
[0046] Figure 11 is top plan view depicting the gripper block assemblies of
the injector of
Figure 1 in an operating mode of operation when operating on a tubular
connector.
[0047] Figure 12 is a top plan partial section view depicting the gripper
block of the injector
of Figure 1 in full contact with a tubular.
[0048] Figure 13 is a top plan partial section view depicting the gripper
block of the injector
of Figure 1 when tubing is fully contacted by a gripper block assembly.
[0049] Figure 14 is a top plan partial section view depicting the gripper
block of the injector
of Figure 1 when the gripper block assembly starts to engage a tubing coupler.
Date Recue/Date Received 2021-07-08
[0050] Figure 15 is a top plan partial section view depicting the gripper
block of the injector
of Figure 14 as the gripper block further engages the tubing coupler.
[0051] Figure 16 is a top plan partial section view depicting the gripper
block of the injector
of Figure 15 wherein the gripper block assembly is closing further on the
tubing coupler.
[0052] Figure 17 is a top plan partial section view depicting the gripper
block of the injector
of Figure 16 where the gripper block assembly is closing further still on the
tubing coupler.
[0053] Figure 18 is a top plan partial section view depicting the gripper
block of the injector
of Figure 17 wherein the gripper block assembly has fully retracted around the
tubing
coupler.
[0054] Figure. 19 is an exploded perspective view depicting a gripper block of
the injector
of Figure 1.
[0055] Figure 20 is a front perspective view depicting the gripper block
assembly of Figure
12 illustrating the carrier assembly being assembled onto the gripper block
housing
halves.
[0056] Figure 21 is a rear perspective view depicting the gripper block
assembly of Figure
12 illustrating the carrier assembly being assembled onto the gripper block
housing
halves.
[0057] Figure 22 is a front perspective view depicting the gripper block
assembly of Figure
12 after being assembled.
[0058] Figure 23 is an isometric view depicting a pair of the trigger assembly
of the injector
of Figure 1.
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Date Recue/Date Received 2021-07-08
[0059] Figure 24A is an isometric view depicting the trigger assembly prior to
the sensing
toggle coming into contact with the larger diameter section of the tubing as
the tubing is
being injected.
[0060] Figure 24B is a side elevation view depicting the trigger assembly
prior to the
sensing toggle coming into contact with the larger diameter section of the
tubing as the
tubing is being injected into a well.
[0061] Figure 24C is a front elevation view depicting the trigger assembly of
Figure 24B.
[0062] Figure 24D is a top plan view depicting the trigger assembly of Figure
24C along
the section line of Figure 24C.
[0063] Figure 25A is an isometric view depicting the trigger assembly as the
sensing
toggle is in contact with the larger diameter section of the tubing as the
tubing is being
injected and moves in the direction of travel of the tubular string.
[0064] Figure 25B is a side elevation view depicting the trigger assembly as
it moves in
the direction of travel of the tubular string.
[0065] Figure 25C is a front elevation view depicting the trigger assembly of
Figure 25B.
[0066] Figure 25D is a top plan view depicting the trigger assembly of Figure
25C along
the section line of Figure 25C.
[0067] Figure 26A is an isometric view depicting the trigger assembly as it
moves in the
direction of travel of the tubular string.
[0068] Figure 26B is a side elevation view depicting the trigger assembly as
it moves in
the direction of travel of the tubular string.
[0069] Figure 26C is a front elevation view depicting the trigger assembly of
Figure 26B.
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[0070] Figure 26D is a top plan view depicting the trigger assembly of Figure
26C along
the section line of Figure 26C.
[0071] Figure 27A is an isometric view depicting the trigger assembly after
the larger
diameter section of the tubing has been fully encapsulated by open gripper
blocks.
[0072] Figure 27B is a side elevation view depicting the trigger assembly
after the larger
diameter section of the tubing has been fully encapsulated by open gripper
blocks.
[0073] Figure 27C is a front elevation view depicting the trigger assembly of
Figure 27B.
[0074] Figure 27D is a top plan view depicting the trigger assembly of Figure
27C along
the section line of Figure 27C.
[0075] Figure 28A is an isometric view depicting the sensing toggle
interacting with the
larger diameter section of the tubing as the tubing is being withdrawn from a
well.
[0076] Figure 28B is a side elevation view depicting the sensing toggle
interacting with
the larger diameter section of the tubing as the tubing is being withdrawn
from a well.
[0077] Figure 28C is a front elevation view depicting the trigger assembly of
Figure 28B.
[0078] Figure 28D is a top plan view depicting the trigger assembly of Figure
28C along
the section line of Figure 28C.
[0079] Figure 29 is a schematic block diagram depicting a control system for
controlling
the trigger assembly described herein.
DETAILED DESCRIPTION OF EMBODIMENTS:
[0080] In this description, references to "one embodiment", "an embodiment",
or
"embodiments" mean that the feature or features being referred to are included
in at least
one embodiment of the technology. Separate references to "one embodiment", "an
embodiment", or "embodiments" in this description do not necessarily refer to
the same
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embodiment and are also not mutually exclusive unless so stated and/or except
as will
be readily apparent to those skilled in the art from the description. For
example, a feature,
structure, act, etc. described in one embodiment may also be included in other
embodiments but is not necessarily included. Thus, the present technology can
include
a variety of combinations and/or integrations of the embodiments described
herein.
[0081] Referring to Figure 1, an embodiment of injector (100) is shown. In
some
embodiments, drive chain links (1) and gripper block assemblies (4) can be
interconnected to form two continuous counter-rotating chain assemblies (110).
Each
chain assembly (110) can be driven by a motor (16a) and can be held by a brake
(16b).
Gripper block assemblies (4) can be attached to drive chain links (1) that can
be acted
upon by a plurality of squeeze cylinders (3) that can apply a transverse force
to cause the
counter-rotating drive chain assemblies (110) to move towards each other
thereby forcibly
engaging gripper block assemblies (4) with the outer diameter of tubing (11)
and the larger
outer diameter of a coupling, tool joint or other connecting element
connecting segments
of tubular string (120). In some embodiments, the squeeze cylinders (3) can
act upon
pressure beam shafts (22) that pass through the ends of the squeeze cylinders
(3), slotted
holes (23) on the injector housing (19) and the pressure beams (2) as shown,
for example,
in Figure 2. In some embodiments, chain tension hydraulic cylinders (13) can
apply
vertical force to idler sprocket shaft (14) to adjust the drive chain length
as the chain
components wear or as the diameter of tubular string (120) varies in diameter.
The
tensioner shafts can be guided vertically by sliders (25) moving within slots
(26) in the
injector housing (19). In some embodiments, trigger mechanisms (50) can be
mounted
between the gripper block assemblies (4) to cause the gripper block jaws to
retract into
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Date Recue/Date Received 2021-07-08
the gripper block housings when a coupler or a section of tubular string (120)
with larger
diameter passes through. In some embodiments, slip support structure (18) can
be
installed on top of the main housing (19) to provide a method of supporting
tubular string
(120) when it is not supported by injector (100), or by another structure.
[0082] Figure 2 is an isometric view of the injector of Figure 1 with part of
the injector
housing (19), some of the squeeze cylinders (3), one motor (16a) and one brake
(16b)
removed to expose the inner workings of the injector (100). The chain
assemblies (110)
can be engaged on drive sprocket assemblies (9) at the top and idler sprocket
shafts (14)
and idler sprockets (10) that can move vertically to maintain chain tension as
the pressure
beams (2) are acted upon by the squeeze cylinders (3). In some embodiments,
gripper
block assemblies (4) can be supported by rolling elements (8b) that can be
acted upon
by pressure beams (2) to force counter-rotating chain assemblies (110) towards
each
other, and to force gripper block assemblies (4) onto tubular string (120). In
some
embodiments, trigger mechanisms (50) can be mounted between the gripper block
assemblies to cause the gripper block jaws to retract into the gripper block
housings when
a coupler or a section of tubular string (120) with a larger diameter passes
through. In
some embodiments, injector (100) can be contained within main housing (19)
that can be
mounted to a wellhead, lubricator, or BOP supplied by others. In some
embodiments
coupling sensors (52) can be deployed to sense the presence of the larger
diameter
section of the tubular string (120). In some embodiments, an encoder (53) may
be
disposed on an idler shaft (14).
[0083] In some embodiments, injector (100) can be mounted within outer support
structure (5), as shown in Figure 3. In some embodiments, injector (100) can
be contained
Date Recue/Date Received 2021-07-08
within main housing (19) that can be rotatably mounted on bearings (6) within
outer
support structure (5). Pressurized hydraulic fluid can be ported through
rotary swivel (7)
and into hydraulic squeeze cylinders (3), hydraulic drive motors (16a),
hydraulic brakes
(16b) and chain tension cylinders (13). Outer support structure (5) can be
supported on
a mounting flange (17) attached to a wellhead, lubricator, or BOP supplied by
others. In
some embodiments, slip support structure (18) can be installed within the
uppermost area
of outer support structure (5) to provide a method of supporting tubular
string (120) when
it is not supported by injector (100), or by another structure.
[0084] Figure 4 illustrates a side elevation view of the injector (100)
showing hydraulic
motor assemblies (16), comprised of hydraulic drive section (16a) and
hydraulic brake
section (16b), which can apply rotational force and speed to drive chain
assemblies (110)
and chain links (1) (as shown in Figure 1).
[0085] Figure 5 illustrates a top plan section view of injector (100) showing
gripper block
assemblies (4) and trigger assemblies (50) at a stand-by position to create a
larger
opening between the chain assemblies (110) for downhole tools or wellhead
components
to be passed through. The fitment of main housing (19) and drive motor
assemblies (16)
are shown in relation to outer support structure (5) to illustrate how the
injector (100) can
rotate within the outer support structure (5).
[0086] Figure 6 illustrates a front elevation section view that shows the
hydraulic squeeze
assembly, comprising of pressure beams (2), rolling elements (8b), and
hydraulic
squeeze cylinders (3) retracted in order to cause drive chain links (1) and
gripper block
assemblies (4) to engage the outer diameter of tubing string (11) and the
larger outer
diameter of a coupling, a tool joint or another connecting element, labelled
as (12) in the
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figure, connecting segments of tubular string (120) in an operating mode.
Chain tension
cylinders (13) can retract to maintain tension on the chain assemblies (110)
as the
squeeze cylinders (3) retract to pull the grippers (4) towards each-other, in
order to
engage the tubing string (120). Trigger mechanisms (50) are shown at the point
where
the gripper blocks come together to come in contact with the tubular string
(120). Coupling
sensors (52) are shown positioned at the top and bottom of the injector (100)
to sense
the presence of the larger outer diameter of a coupling, a tool joint or
another connecting
element (12). An encoder (53) is shown on one of the idler sprocket shafts
(14).
[0087] Figure 7 illustrates a front elevation section view that shows the
hydraulic squeeze
assembly, comprising of pressure beams (2), rolling elements (8b), and
hydraulic
squeeze cylinders (3) extended in order to cause drive chain links (1) and
gripper block
assemblies (4) and trigger assemblies (50) to dis-engage the outer diameter of
tubing
(11) and the larger outer diameter of a coupling, a tool joint or another
connecting
element, labelled as (12) in the figure, connecting segments of tubular string
(120) in a
non-operating, stand-by operating mode. Chain tension cylinders (13) can
extend to
maintain tension on the chain assemblies (110) as the squeeze cylinders (3)
extend to
push the grippers (4) away from each-other, in order to dis-engage the tubing
string (120).
Coupling Sensors (52) are shown positioned at the top and bottom of the
injector (100)
to sense the presence of the larger outer diameter of a coupling, a tool joint
or another
connecting element (12). An encoder (53) is shown on one of the idler sprocket
shafts
(14).
[0088] Referring to Figure 8, gripper block assemblies (4) are shown in an
operating mode
wherein gripper block assemblies (4) are in contact with and engaging the
outer diameter
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of a tubular string (120) that can include tubing (11), which can further
include a tapered
upset section (51), and the larger outer diameter of coupler (12) that, for
the purposes of
this description, can comprise a tubing coupler, a tool joint or other type of
tubular
connecting element as well known to those skilled in the art for connecting
segments of
tubular string (120). In some embodiments, gripper block assemblies (4) can be
supported by rolling elements (8b) that can be in rolling contact with
pressure beams (2).
In some embodiments, gripper block assemblies (4) can variably adjust to the
larger
diameter of coupler (12) connecting the segments of tubular string (120) while
the rolling
elements (8b) can remain in the same plane and have evenly distributed force
on the
pressure beam (2), in order to maintain constant force on tubular string
(120).
[0089] Referring to Figure 9, gripper block assemblies (4) and trigger
assemblies (50) are
shown positioned within main injector housing (19) to a stand-by position with
the
squeeze cylinders (3) fully extended that can create a pathway for downhole
tools or
wellhead components to be passed through.
[0090] In Figure 10, gripper block assemblies (4) are illustrated to be
positioned within
main injector housing (19) in an operating mode with the squeeze cylinders (3)
retracted,
causing the pressure beams (2) to act upon the rolling elements (8b) of the
gripper block
assemblies (4), wherein gripper block assemblies (4) can be engaged onto
tubing (11).
Trigger assemblies (50) are between the gripper block assemblies (4).
[0091] In Figure 11, gripper block assemblies (4) are illustrated to be
positioned within
main injector housing (19) in an operating mode in which gripper block
assemblies (4)
can engage coupler (12). Trigger assemblies (50) are disposed between the
gripper block
assemblies (4).
18
Date Recue/Date Received 2021-07-08
[0092] Figure 12 shows a detailed view of one embodiment of gripper block
assembly (4)
and carrier assembly (8) in a top plan section view and full top view. In some
embodiments, carrier assembly (8) can comprise carrier body (8a), roller (8b)
rotatably
disposed on shaft (8c) via bearings (8d) wherein shaft (8c) can be retained in
carrier body
(8a) with retaining rings (8e) disposed on one or both ends of shaft (8c). In
some
embodiments, gripper block assembly (4) can comprise of two grippers (4b) that
can be
connected to eccentric shaft (4c) with split bushings (4d). Eccentric shaft
(4c) can rotate
inside of each of the two housing halves (4a), which can be bolted together.
In some
embodiments, gripper (4b) can comprise a pivot pin (4g) that can contact the
housing
halves (4a) at a protruding surface (20) to act as a pivot point and force
eccentric shaft
(4c) to rotate when coupler (12) contacts outer corners (4h) of grippers (4b),
which can
move gripper (4b) out of the way of coupler (12). As the gripper (4b) moves
away from
the coupler (12), the shape of the eccentric shaft (4c) causes the pivot pin
(4g) to follow
the profile of the housing (4a) until it reaches a cavity (27), which causes
the grippers (4b)
to move away from each-other creating a space for the coupler (12) to exist
while the rest
of the gripper assembly (4) and the carrier assembly (8) stay in line. In some
embodiments, spring (4f) can act on eccentric shaft (4c) to return eccentric
shaft (4c) to
the starting position when coupler (12) is no longer in contact with gripper
(4b). In some
embodiments, carrier assembly (8) and gripper block assembly (4) can be
connected
through mechanical means. In the illustrated embodiment, a dovetail mechanism
can be
used, which can allow the gripper block assembly (4) to be removed from the
carrier
assembly (8) to change sizes or replace worn or broken parts by sliding the
gripper
assembly sideways to disengage the dovetails.
19
Date Recue/Date Received 2021-07-08
[0093] Figure 13 shows a detailed view of one embodiment of gripper block
assembly (4)
in a top plan section view and full top view and illustrates tubing (11) being
contacted by
gripper block assembly (4). In this figure, gripper block assembly (4) is
being pushed
towards tubing (11) thereby providing radial force (grip) that, in turn,
allows axial force to
be applied to tubing (11). Gripping elements (4b) can self-centralize against
tubing (11).
These gripping forces are transmitted through eccentric shaft (4c) and create
a rotation
that is resisted by a face (21) of the eccentric shaft (4c), making contact
with a cast-in
feature of the gripper housing (4a) which limits the distance the gripper
block can move
and make sure the eccentric shaft will not go too far and lock up. In the
illustrated
embodiment, the stopper can be part of eccentric shaft (4c) and can act
against housing
half (4a) on a face labelled (28), although those skilled in the art will
appreciate that
various alternative configurations exist that are substantially similar.
[0094] Figure 14 shows a detailed view of one embodiment of gripper block
assembly (4)
in a top plan section view and full top view and illustrates the gripper
assembly (4) in a
position where the edges (4h) of the grippers (4b) contact coupler (12) as the
gripper
assemblies (4) begin to come together. It can be seen that pivot pin (4g) can
act as a
pivot point for the gripper (4b) as it contacts surface (20) of the gripper
housing (4a)
causing the gripper (4b) to rotate away from the coupler (12).
[0095] Figures 15 to 18 illustrate the progression of the various engagement
modes
between gripper block assembly (4) and coupler (12) as gripper block
assemblies (4)
progressively come together, thereby allowing gripping elements (4b) to open
variably
and allow larger diameter elements such as couplers (12) to pass through
without
interference. Figure 15 illustrates gripper block assembly (4) closing further
thereby
Date Recue/Date Received 2021-07-08
causing gripping elements (4b) to rotate outwards as it pivots around pivot
pin (4g) while
engaging coupler (12). Pivot pin (4g) can impede the outward rotation of
gripping
elements (4b) by contacting surface (20) disposed on housing half (4a),
therefore acting
as a pivot point for rotation of gripping element (4b). Rotation around this
pivot point can
cause eccentric shaft (4c) to rotate and move gripping (4b) element outward,
thereby
creating clearance for coupler (12).
[0096] Figure 16 illustrates still further closing of gripper block assembly
(4) and the
corresponding movement of gripper element (4b) and eccentric shaft (4c). As
the grippers
(4b) move back, the pivot pin (4g) reaches the end of surface (20) on the main
housing
(4a).
[0097] Figure 17 illustrates further progression to a position where gripper
block assembly
(4) has closed almost completely and both leading edges (4h) of gripper
elements (4b)
have made contact with coupler (12). In this figure, pivot pin (4g) is no
longer in contact
with surface (20) on housing half (4a), thus, gripper element (4b) no longer
rotates about
pivot pin (4g) but, instead, has its movement driven by the face of coupler
(12) as the
pivot pin (4g) moves into a recess (27) in the main housing (4a). In this
embodiment,
return spring (4f) can prevent gripper elements (4b) from moving further away
from the
coupler (12) and forces gripper elements (4b) towards tubing (11).
[0098] Figure 18 shows the final position of gripping elements (4b) when
gripper block
assembly (4) has fully closed around tubing (11), demonstrating that gripping
elements
(4b) have accommodated coupler (12).
[0099] Figure 19 shows an exploded view of the embodiment detailed in Figure
12,
showing the following elements: housing half (4a), gripping element (4b) with
beveled
21
Date Recue/Date Received 2021-07-08
edge (4e), eccentric shaft (4c), bushing halves (4d), return spring (4f),
pivot pin (4g), outer
corner (4h), spring retention pin (4i), alignment dowels (4j), carrier body
(8a), roller (8b),
shaft (8c), bearings (8d), retaining rings (8e) and surface (20) and recess
(27).
[0100] Figures 20 to 22 illustrate how gripper block assembly (4) can be
assembled in
some embodiments. In some embodiments, each housing half (4a) can comprise
dovetail
groove (36) that can form dovetail slot (40) when two housing halves (4a) are
assembled.
Dovetail slot (40) can receive mating male dovetail profile (38) disposed on
carrier
assembly (8). When carrier dovetail profile (38) of assembly (8) is slid into
dovetail slot
(40) of gripper block assembly (4), a spring-loaded pin (42) protruding from
each end of
the carrier assembly (8) will retain the gripper block assembly (4) to limit
the ability of the
gripper block assembly (4) to slide off the carrier assembly (8). To remove
gripper block
assembly (4) from carrier assembly (8), either to replace a worn gripper block
assembly
(4) or to install different gripper block assemblies (4) configured to work
with different
sized tubing, spring loaded pin (42) can be depressed and gripper block
assembly (4) can
slide sideways until the dovetails are disengaged thereby freeing gripper
block assembly
(4) for removal.
[0101] Figure 23 shows a detailed view of one embodiment of trigger assembly
(50). In
some embodiments, trigger assembly (50) can comprise frame (50c) and wedge
(50a)
slidably attached to frame (50c). A linear actuator (50b) can be attached to
the outboard
end of frame (50c) and to wedge (50a) with pins (50d) disposed therethrough.
[0102] Figures 24A-D, 25A-D, 26A-D, 27A-D and 28A-D are a series of drawings
that
illustrate how the trigger assembly of Figure 1 can be energized when a
section of tubular
that is tapered or has a larger diameter than the main body of the tubular is
encountered
22
Date Recue/Date Received 2021-07-08
and how it interacts with the gripper blocks of Figure 12. Each set of figures
has four views
that correspond to a particular point of operation. In these figures, the
first view "A" is an
isometric view. View "B" is an illustration that shows an isolated view of the
tubular with
a trigger assembly on each side. View A includes arrows to indicate the
direction that the
tubing is moving with respect to the trigger assemblies. View "C" is an
isolated view of the
tubular, the trigger assembly, and the gripper blocks viewed perpendicular to
view A with
a sectioning view mark that indicates the location relative to the top plan
view of the
gripper block, which is shown in view "D".
[0103] Figure 24A is an isometric view depicting the position of trigger
assembly (50) and
coupling sensor (52) prior to sensing toggle (49) coming into contact with the
larger
diameter section of tubing (51) or coupling (12) as tubing string (120) is
being injected.
[0104] In Figure 24B, tapered upset section (51) of tubing (11) is shown
coming into
contact with sensing toggle (49) as tubing string (120) passes through the
injector of
Figure 1. It can be seen in Figure 24C that trigger assembly (50) can be
positioned in the
injector of Figure 1 at a point centred between counter-rotating gripper
chains (110) where
gripper block jaws (4b) can pass by wedge (50a) unaffected. Figure 24C
includes a
section view line that indicates the corresponding point where Figure 24D is
depicted.
Figure 24D is a top plan view that shows the position of gripper jaws (4b)
fully extended
from gripper block housing (4a) and locked on the nominal diameter of tubular
(11). As
shown in this embodiment, no part of trigger assembly (50) is in contact with
gripper block
jaws (4b).
[0105] Figure 25A is an isometric view depicting the position of trigger
assembly (50) as
sensing toggle (49) is in contact with the larger diameter section of tubing
(51) as tubing
23
Date Recue/Date Received 2021-07-08
string (120) is being injected. As shown, sensing toggle (49) can move in the
direction of
travel of tubular string (120).
[0106] In Figure 25B, coupling (12) location can be sensed by the interference
of sensing
toggle (49) and the larger diameter of tapered upset section (51) in relation
to the positions
of trigger assembly (50) as shown in Figure 24B. The interference of tapered
section (51)
with sensing toggle (49) can cause sensing toggle (49) to move rotatably,
causing switch
(48) to operate and send a signal that corresponds with the location of
coupling (12).
Figure 25C shows that sensing toggle (49) has rotatably moved indicating that
it has
sensed the location of tapered upset section (51) the coupling (12). Wedge
(50a) is not
yet in contact with gripper jaws (4b). Figure 25C includes a section view line
that indicates
the corresponding point where Figure 25D is depicted. Figure 25D is a top plan
view that
shows that gripper jaws (4b) are in contact with the outer diameter of tubular
(11).
[0107] Figure 26A is an isometric view depicting trigger assembly (50) and
coupling
sensor (52) as trigger assembly (50) moves in the direction of travel of
tubular string (120).
Figure 26B illustrates that linear actuators (50b) have extended causing
wedges (50a) to
be adjacent to the larger diameter of tapered upset section (51) and tubing
coupler (12)
causing gripper jaws (4b) to fully retract into housings (4a), as can be seen
in Figure 26C
and Figure 26D. At this stage, sensing toggle (49) has returned to it's
neutral position. In
some embodiments, gripper block jaw (4b) can comprise beveled section (4e), as
shown
in Figure 19, to ensure that gripper jaw (4b) does not bind or jam on wedge
(50a). Figure
26C illustrates that gripper jaws (4b) are in contact with wedge (50a) causing
gripper jaws
(4b) to retract into gripper block housings (4a) at all points on tubular
string (120) adjacent
to a tapered upset section (51) of tubular (11) or to a coupling (12), as
illustrated in Figure
24
Date Recue/Date Received 2021-07-08
18, and that gripper jaws (4b) are extended from housings (4a) and engaged on
the main
body of tubular (11), as illustrated in Figure 13, in areas where gripper jaws
(4b) are not
adjacent to a tapered upset section (51) of tubular (11) or to a coupling
(12). It can be
seen in Figure 26D that when wedges (50a) are in full contact with gripper
jaws (4b),
coupler (12) is not in contact with gripper jaws (4b).
[0108] Figure 27A is an isometric view depicting trigger assembly (50) after
the larger
diameter sections of tubing (51) and coupling (12) has been fully encapsulated
by open
gripper jaws (4b). Figures 27A and 27B show that as tubular string (120)
continues
through the injector of Figure 1, linear actuators (50b) can retract wedges
(50a) mounted
on frame (50c). Gripper block jaws (4b) that are not adjacent to a tapered
upset section
(51) of tubular (11) or to a coupling (12) are fully extended out of gripper
block housings
(4a). Figure 27D illustrates that gripper jaws (4b) are fully extended and in
contact with
the nominal diameter of tubing (11).
[0109] Figure 28A is an isometric view depicting sensing toggle (49)
interacting with the
larger diameter section of tubing (51) as tubing string (120) is being
withdrawn from a
well. Figure 28B illustrates a tapered upset section (51) of tubular (11) or a
coupling (12)
making contact with sensing toggle (49) while tubular string (120) is moving
the opposite
direction from that shown in Figures 24 through 27C, namely, upwards as is the
case
when tubular string (120) is being withdrawn from a well. In some embodiments,
coupling
Sensor (52) can sense a tapered upset section (51) of tubular (11) or coupling
(12) and
can then signal that coupling (12) has passed completely through the injector
of Figure 1.
As shown in Figure 28C, wedges (50a) are not in contact with gripper jaws
(4b). In order
for gripper jaws (4b) to retract when tubular string (120) is moving in either
direction,
Date Recue/Date Received 2021-07-08
trigger assemblies (50) can be situated at each end and on each side of
injector (100),
as illustrated in Figure 2, and can be situated opposing each other in order
to be effective
when the tubing is moving in either direction. Thus, in the illustrated
embodiments shown
in the figures, a first set of trigger assemblies (50) can be disposed near
the upper end of
injector (100) for operating gripper block assemblies (4) when the tubing is
being injected
into a well, and a second set of trigger assemblies (50) can disposed near the
lower end
of injector (100) for operating gripper block assemblies (4) when the tubing
is being
retracted out of a well. Figure 28C shows that as the larger diameter section
of tubing
(51) or of coupler (12) passes the point where gripper assemblies (4) are
being forced
towards each other, gripper jaws (4b) that were retracted into gripper
housings (4a) can
then fully extend to their initial position. In Figure 28D, gripper jaws (4b)
can be seen
extended to illustrate the position they would be in at the point where the
section line is
shown in Figure 28C.
[0110] Figure 29 is an illustration of the components that make up one
embodiment of the
trigger system and control system thereof. In some embodiments, the control
system can
comprise one or more of a general purpose computer, a microcontroller, a
microprocessor
and a programmable logic controller, as well known to those skilled in the
art. In a
representative embodiment, the control system can comprise of programmable
logic
controller ("PLC") (47). In some embodiments, the control system can comprise
coupling
sensor (52) that can further comprise sensing toggle (49) and switch (48). In
some
embodiments, switch (48) can comprise an electric micro-switch although in
other
embodiments, switch (48) can comprise one or more of hydraulic, pneumatic and
electric
as well known to those skilled in the art. If switch (48) comprises an
electric-type switch,
26
Date Recue/Date Received 2021-07-08
switch (48) can comprise an explosion-proof enclosure and be rated for Class
1/Division
1 (Zone 1) or Class 1/Division 2 (Zone 2) application depending on the
application and
location of the site where injector (100) is being operated. In some
embodiments, the
control system can comprise encoder (53) that can be disposed on idler
sprocket shaft
(14), as shown in Figures 2, 6 and 7. When tapered upset section (51) of
tubular (11) or
a coupling (12) passes coupling sensor (52), a signal can be sent from
coupling sensor
(52) to PLC (47). In some embodiments, PLC (47) can cause linear actuators
(50b) and
squeeze cylinders (3) to function at the appropriate time in order to cause
trigger
assemblies (50) to perform as described above to prevent gripper jaws (4b)
from
contacting tapered upset section (51) and coupling (12), as shown in Figures
24A through
28D. In some embodiments, linear actuator (50b) can comprise one or more of
hydraulic,
pneumatic and electric linear actuators as well known to those skilled in the
art.
[0111] 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. In particular, the sensing toggle could be replaced with a
proximity switch,
limit switch, Vision based system, LVDT, encoder or any combination of sensor
or
mechanical configuration that can measure distance displacement.
[0112] The various illustrative logical blocks, modules, circuits, and
algorithm steps
described in connection with the embodiments disclosed herein can be
implemented as
electronic hardware, computer software, or combinations of both. To clearly
illustrate this
interchangeability of hardware and software, various illustrative components,
blocks,
modules, circuits, and steps have been described above generally in terms of
their
27
Date Recue/Date Received 2021-07-08
functionality. Whether such functionality is implemented as hardware or
software depends
upon the particular application and design constraints imposed on the overall
system.
Skilled artisans can implement the described functionality in varying ways for
each
particular application, but such implementation decisions should not be
interpreted as
causing a departure from the scope of the embodiments described herein.
[0113] Embodiments implemented in computer software can be implemented in
software,
firmware, middleware, microcode, hardware description languages, or any
combination
thereof. A code segment or machine-executable instructions can represent a
procedure,
a function, a subprogram, a program, a routine, a subroutine, a module, a
software
package, a class, or any combination of instructions, data structures, or
program
statements. A code segment can be coupled to another code segment or a
hardware
circuit by passing and/or receiving information, data, arguments, parameters,
or memory
contents. Information, arguments, parameters, data, etc. can be passed,
forwarded, or
transmitted via any suitable means including memory sharing, message passing,
token
passing, network transmission, etc.
[0114] The actual software code or specialized control hardware used to
implement these
systems and methods is not limiting of the embodiments described herein. Thus,
the
operation and behavior of the systems and methods were described without
reference to
the specific software code being understood that software and control hardware
can be
designed to implement the systems and methods based on the description herein.
[0115] When implemented in software, the functions can be stored as one or
more
instructions or code on a non-transitory computer-readable or processor-
readable
storage medium. The steps of a method or algorithm disclosed herein can be
embodied
in a processor-executable software module, which can reside on a computer-
readable or
28
Date Recue/Date Received 2021-07-08
processor-readable storage medium. A non-transitory computer-readable or
processor-
readable media includes both computer storage media and tangible storage media
that
facilitate transfer of a computer program from one place to another. A non-
transitory
processor-readable storage media can be any available media that can be
accessed by
a computer. By way of example, and not limitation, such non-transitory
processor-
readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk
storage, magnetic disk storage or other magnetic storage devices, or any other
tangible
storage medium that can be used to store desired program code in the form of
instructions
or data structures and that can be accessed by a computer or processor. Disk
and disc,
as used herein, include compact disc (CD), laser disc, optical disc, digital
versatile disc
(DVD), floppy disk, and Blu-ray disc where disks usually reproduce data
magnetically,
while discs reproduce data optically with lasers. Combinations of the above
should also
be included within the scope of computer-readable media. Additionally, the
operations of
a method or algorithm can reside as one or any combination or set of codes
and/or
instructions on a non-transitory processor-readable medium and/or computer-
readable
medium, which can be incorporated into a computer program product.
[0116] 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.
29
Date Recue/Date Received 2021-07-08
