Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02916063 2015-12-18
SYSTEMS AND METHODS FOR DEPLOYING TUBULAR CONDUITS
AND TUBING
CROSS-REFERENCE TO RELATED APPLICATIONS
100011 This application claims benefit of U.S. provisional patent application
Serial No. 62/094,742
filed December 19, 2014, and entitled "Systems and Methods for Deploying
Tubular Conduits and
Tubing," which is hereby incorporated herein by reference in its entirety for
all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED
RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND
[0003] This disclosure generally relates to tubular conduits. More particular,
this disclosure
generally relates to apparatus and methods for deploying tubular conduits from
a spool.
[0004] Tubular conduits (e.g., tubing and coiled tubing) are employed in many
industrial
applications such as, for example, the transport of fluids, and oil and gas
drilling and production
operations. In some applications, the tubular conduits are constructed from a
continuous tube
(rather than a plurality of flanged pipe segments connected together end-to-
end) to reduce the
number of attachment or connection points along the conduit, simplify the
installation process, etc.
These continuous tubing conduits are typically wound onto a spool facilitate
ease of storage,
transportation, and deployment.
BRIEF SUMMARY OF THE DISCLOSURE
[0005] Some embodiments disclosed herein are directed to a system for
deploying tubing disposed
on a spool. In an embodiment, the system includes a tubing support trailer
including a towing
hookup assembly configured to couple the system to a vehicle, a spool support
frame coupled to
the towing hookup assembly, and a tubing spool rotatably coupled to the spool
support frame. In
addition, the system includes a tubing straightener trailer pivotally coupled
to the tubing support
trailer. The tubing straightening trailer includes a cart having a
longitudinal cart axis and including
a plurality of wheels. In addition, the tubing straightener trailer includes a
tubing straightening
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assembly coupled to the cart. The tubing straightening assembly is configured
to move laterally
relative to the cart and the cart axis. The tubing straightening assembly
includes a plurality of
rollers configured to engage and reduce the curvature of the tubing paid out
from the spool.
[0006] Other embodiments disclosed herein are directed to a tubing
straightener trailer for
straightening tubing paid out from a spool. In an embodiment, the tubing
straightener trailer
includes a cart having a longitudinal cart axis and including a plurality of
wheels. In addition,
tubing straightener trailer includes a tubing straightening assembly coupled
to the cart. The tubing
straightening assembly is configured to move laterally relative to the cart
and the cart axis. The
tubing straightening assembly includes a plurality of rollers configured to
engage and reduce the
curvature of the tubing paid out from the spool.
[0007] Still other embodiments disclosed herein are directed to a method for
deploying tubing
disposed on a spool. In an embodiment, the method includes (a) feeding the
tubing through a
tubing straightening assembly, wherein the tubing straightening assembly is
moveably coupled to a
cart having a longitudinal cart axis. In addition, the method includes (b)
engaging the tubing with
a plurality of rollers mounted within the tubing straightening assembly during
(a). Further, the
method includes (c) reducing a curvature of the tubing with the tubing
straightening assembly
during (b) as the tubing is paid out from the spool and fed through the tubing
straightening
assembly. Still further, the method includes (d) moving the tubing
straightening assembly laterally
with respect to the cart axis relative to the cart during (b) and (c).
100081 Embodiments described herein comprise a combination of features and
characteristics
intended to address various shortcomings associated with certain prior
devices, systems, and
methods. The foregoing has outlined rather broadly the features and technical
characteristics of the
disclosed embodiments in order that the detailed description that follows may
be better understood.
The various characteristics and features described above, as well as others,
will be readily apparent
to those skilled in the art upon reading the following detailed description,
and by referring to the
accompanying drawings. It should be appreciated that the conception and the
specific
embodiments disclosed may be readily utilized as a basis for modifying or
designing other
structures for carrying out the same purposes as the disclosed embodiments. It
should also be
realized that such equivalent constructions do not depart from the spirit and
scope of the principles
disclosed herein.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a detailed description of exemplary embodiments, reference will now
be made to the
accompanying drawings in which:
[0010] Figure 1 is a perspective view of an embodiment of a tubing
transportation and
deployment system in accordance with the principles disclosed herein;
[0011] Figure 2 is a perspective view of the tubing straightener trailer of
the system of Figure 1;
[0012] Figure 3 is a top view of the tubing straightener trailer of Figure 2;
[0013] Figure 4 is a perspective view of the cart of the tubing straightener
trailer of Figure 2;
[0014] Figure 5 is a top view of a tubing roller mounted to the cart of Figure
4;
[0015] Figure 6 is a side view of the tubing straightener trailer of Figure 2;
[0016] Figure 7 is an enlarged partial perspective view of one side of the
tubing straightener
trailer of Figure 2;
[0017] Figure 8 is an enlarged partial perspective view of the opposite side
of the tubing
straightener trailer of Figure 2;
[0018] Figure 9 is an enlarged partial perspective view of the rear roller
assembly of the tubing
straightener trailer of Figure 2;
[0019] Figure 10 is an enlarged perspective view of one of the straightener
rollers of the tubing
straightener trailer of Figure 2;
[0020] Figure 11 is an enlarged partial perspective view of the tubing
straightener trailer of
Figure 2;
[0021] Figure 12 is a side view of the tubing straightener trailer of Figure 2
schematically
illustrating the path of the tubing paid out from the tubing spool through the
tubing straightening
assembly;
[0022] Figures 13A and 138 are sequential top views of the system of Figure 1
illustrating the
tubing being paid out from the tubing spool;
[0023] Figure 14 is an enlarged partial perspective view of one of the
universal joints coupling
the tubing support trailer and the tubing straightener trailer of Figure 1;
[0024] Figure 15 is a schematic side view of an alternative arrangement for
the tubing roller of
Figure 5;
[0025] Figure 16 is a side view of an embodiment of a tubing straightener
trailer for use in the
system of Figure 1;
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,
[0026] Figure 17 is a perspective view of the tubing straightening assembly of
the tubing
straightener trailer of Figure 16;
[0027] Figure 18 is a schematic side view of one of the traversing cars
engaging with one of the
traversing bars of the tubing straightening assembly of Figure 17;
[0028] Figure 19 is an enlarged side view of the tubing straightening assembly
of Figure 17;
[0029] Figure 20 is a top view of one of the roller assembly of the tubing
straightening assembly
of Figure 17;
[0030] Figure 21 is a side view of the roller assembly of Figure 20;
[0031] Figure 22 is a top view of the outfeed alignment assembly of the tubing
straightening
assembly of Figure 17; and
[0032] Figure 23 is a side view of the tubing straightening assembly of Figure
17 schematically
illustrating the path of the tubing paid out from the tubing spool through the
tubing straightening
assembly.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0033] The following discussion is directed to various exemplary embodiments.
However, one
skilled in the art will understand that the examples disclosed herein have
broad application, and
that the discussion of any embodiment is meant only to be exemplary of that
embodiment, and not
intended to suggest that the scope of the disclosure, including the claims, is
limited to that
embodiment.
[0034] Certain terms are used throughout the following description and claims
to refer to particular
features or components. As one skilled in the art will appreciate, different
persons may refer to the
same feature or component by different names. This document does not intend to
distinguish
between components or features that differ in name but not function. The
drawing figures are not
necessarily to scale. Certain features and components herein may be shown
exaggerated in scale
or in somewhat schematic form and some details of conventional elements may
not be shown in
interest of clarity and conciseness.
[0035] In the following discussion and in the claims, the terms "including"
and "comprising" are
used in an open-ended fashion, and thus should be interpreted to mean
"including, but not limited
to... ." Also, the term "couple" or "couples" is intended to mean either an
indirect or direct
connection. Thus, if a first device couples to a second device, that
connection may be through a
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direct connection, or through an indirect connection via other devices,
components, and
connections. In addition, as used herein, the terms "axial" and "axially"
generally mean along or
parallel to a central axis (e.g., central axis of a body or a port), while the
terms "radial" and
"radially" generally mean perpendicular to the central axis. For instance, an
axial distance refers to
a distance measured along or parallel to the central axis, and a radial
distance means a distance
measured perpendicular to the central axis.
[0036] As previously described, continuous tubular conduits, also referred to
herein as "tubing,"
are typically wound onto a spool to facilitate ease of storage,
transportation, and deployment. In
many cases, especially in the case of larger diameter and/or more rigid
tubing, the winding of the
tubing onto the spool imparts a continuous bend or curve into the tubing,
which generally follows
and conforms with the curvature of the spool onto which the tubing is wound.
However, in many
applications, it is preferred that the tubing be deployed and installed in a
straight or linear fashion
(i.e., without bends or curves). Consequently, in such applications it is
necessary to reduce or
eliminate any bends and curves in the tubing. Typically, straightening devices
and operations for
tubing requires the use of multiple pieces of relatively large equipment,
which undesirably
increases the footprint and number of processing steps to deploy and install
the tubing. However,
embodiments disclosed herein include systems and methods for simultaneously
deploying and
straightening continuous tubular conduits paid out from spools while
minimizing the size and
footprint of the associated equipment and operation.
[0037] Referring now to Figure 1, an embodiment of a tubing transportation and
deployment
system 10 is shown. In this embodiment, system 10 includes a tubing support
trailer 20 and a
tubing straightener trailer 100 pivotably coupled to support trailer 20 with a
pair of universal
joints 50 (which will be described in more detail below).
[0038] Referring still to Figure 1, in this embodiment, tubing support trailer
20 is similar to those
available from Big Reel Services, Inc. located in Calgary, Alberta, Canada. In
particular, in this
embodiment, trailer 20 includes a first or front end 20a, a second or rear end
20b opposite front
end 20a, a base frame or chassis 22, a pair of wheels 24 pivotably coupled to
chassis 22 (note:
only one wheel 24 is visible in Figure 1), and a pair tubing spool support
frames 26 mounted to
chassis 22. Chassis 22 is generally U-shaped with a towing attachment or
hookup assembly 30
disposed at front end 20a and a pair of frame members 23 extending from
assembly 30 to rear
end 20b. As a result, an opening or space 29 is formed between members 23. As
will be
CA 02916063 2015-12-18
described in more detail below, opening 29 is sized to receive a spool 21 of
tubing (e.g., tubing
18 shown in Figures 13A and 13B). Hookup assembly 30 includes a towing adapter
32
configured to engage with a corresponding towing hitch (not shown) on a
vehicle (e.g., truck,
tractor, etc.) such that trailer 20 (and/or system 10) can be towed or pulled
to a desired location.
[0039] Spool support frames 26 are positioned between rear end 20b and hookup
assembly 30,
each frame 26 being coupled to one of the frame members 23 (note: while only
one of the frames
26 is visible in Figure 1, it is to be understood that both frames 26 are
configured the same).
Each spool support frame 26 includes a vertical post member 27 extending
upward from the
corresponding frame member 23 and a spool shaft support saddle 25 supported by
the upper end
of the vertical framing member 27. Saddles 25 are generally aligned with one
another across
opening 29 such that a central shaft (not visible) extending through tubing
spool 21 along a
central axis of rotation 17 can be seated therein. Thus, during both
transportation and
deployment operations, tubing spool 21 is rotatably supported on support
frames 26 through the
engagement of the tubing spool shaft and saddles 25 such that spool 21 may
rotate about axis 17.
[0040] Referring now to Figures 2 and 3, tubing straightener trailer 100 is
configured to
straighten tubing deployed or paid out from tubing spool 21 mounted to support
trailer 20. In
this embodiment, tubing straightener trailer 100 includes a base cart 110 and
a tubing
straightening assembly 150 moveably mounted to cart 110.
[0041] Referring now to Figures 2-4, cart 110 provides a platform for
supporting and
transporting tubing straightening assembly 150 during deployment operations.
Cart 110 has a
central or longitudinal axis 105, a first or front end 110a, and a second or
rear end 110b opposite
front end 110a. In addition, cart 110 includes a base frame or chassis 112, a
first pair of wheels
111 rotatably mounted to chassis 112 at front end 110a, and a second pair of
wheels 113
rotatably mounted to chassis 112 at rear end 110b. Chassis 112 is generally
rectangular in shape
and includes a pair of parallel frame members 114 extending axially between
ends 110a, 110b.
Each frame member 114 includes an angled or bent portion 116 proximate front
end 110a such
that each member 114 includes a first or front second 115 extending axially
from front end 110a
to bent portion 116 and a second or rear section 117 extending axially from
bent portion 116 to
rear end 110b. As best shown in Figure 4, due to the shape and orientation of
bent portion 116,
front portion 115 is vertically elevated relative to rear portion 117. A
plurality of generally
radially (or laterally) extending support members 118A, 118B, 118C span
between frame
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members 114 to provide rigidity and support to cart 110. In particular, a
first or front support
member 118A extends between front sections 115, a second or mid support member
118B
extends between members 114 at or proximate to the junction of rear sections
117 and bent
portions 116, and a third or rear support member 118C extends between rear
sections 117 at rear
end 110b. In addition, a pair of support plates 119 extend between rear
sections 117 of members
114. Still further, a plurality of traversing bars 120A, 120B, 120C extend
between rear sections
117 of frame members 114 to provide a track for mounting pipe straightening
assembly 150 to
cart 110. A first or front traversing bar 120A extends between rear sections
117 proximate bent
portion 116, a second or rear traversing bar 120B extends between members 114
at rear end
110b, and a third or mid traversing bar 120C extends between sections 117
axially between front
and rear traversing bars 120A, 120B, respectively.
100421 Referring now to Figures 2-5, a roller support bar 124 having a central
axis 115 extends
between front sections 115 of frame members 114, proximate front end 110a. A
chassis roller
126 is slidably mounted to bar 124 such that roller 126 is free to rotate
about axis 125 and
traverse axially along bar 124 relative to axis 125. As is best shown in
Figure 5, roller 126 is a
hollow tubular member having a first end 126a, a second end 126b opposite
first end 126a, a
throughbore 128 extending axially (relative to axis 125) between ends 126a,
126b, and a radially
outer surface 123 extending between ends 126a, 126b. Outer surface 123
includes a first
frustoconical section 127 extending axially from first end 126a and a second
frustoconical
section 129 extending axially from second end 126b to first frustoconical
section 127. Outer
surface 123 tapers radially inward toward axis 125 moving from each end 126a,
126b along each
section 127, 129, respectively. Thus, outer surface 123 is oriented at an
acute angle 0 along each
section 127, 129. In this embodiment the angle 0 preferably ranges between 0
and 90 . As will
be described in more detail below, frustoconical sections 127, 128 of outer
surface 123 allow
tubing paid out from spool 21 (see Figure 1) to be guided onto and retained on
roller 126.
100431 As previously described, trailers 20, 100 are pivotably coupled to one
another at a pair of
universal joints 50. Referring now to Figures 1 and 14, one universal joint 50
is shown, it being
understood that the other joint 50 is the same. In this embodiment, universal
joint 50 includes a
plurality of rigid coupling members 52, 54, 56 pivotably coupled to each other
and to trailers 20,
100 to allow tubing straightener trailer 100 to pivot along multiple
directions relative to tubing
support trailer 20 during transportation and deployment operations. In
particular, joint 50
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includes a first coupling member 52 pivotably coupled to tubing straightening
trailer 100, a
second coupling member 56 pivotably coupled to tubing support trailer 20, and
a third coupling
member 54 pivotably coupled to each of the first and second coupling members
52, 56. First
coupling member 52 includes a first end 52a and a second end 52b opposite
first end 52a. First
end 52a is pivotably coupled to front section 115 of one frame member 114 with
a pair of
connection flanges 51 such that member 52 may pivot relative to tubing
straightening trailer 100
about a vertical axis 47. Second coupling member 56 includes a first end 56a
and a second end
56b opposite first end 56a. Second end 56b is pivotably coupled one frame
member 23 at rear
end 20b of tubing support trailer 20 with a pair of connection flanges 27 such
that member 56
may pivot relative to support trailer 20 about a vertical axis 59 (i.e.,
parallel to and radially offset
from first axis 47). Third coupling member 54 includes a first end 54a, a
second end 54b
opposite first end 54a, a first pair of connection flanges 53 extending from
first end 54a, and a
second pair of connection flanges 58 extending from second end 54b. Second end
52b of first
coupling member 52 is pivotably coupled between flanges 53 on first end 54a of
third coupling
member 54 about a horizontal axis 55 (i.e., oriented at 90 relative to
vertical axes 47, 59
previously described). First end 56a of second coupling member 56 is pivotably
coupled
between flanges 27 on second end 54b of third coupling member 56 about a
horizontal axis 57
(i.e., axis 57 is parallel to and radially offset from axis 55). Thus, third
coupling member 56 may
pivot about axes 55, 57 relative to first and second coupling members 54, 56,
respectively. As a
result, all movement (e.g., rotation) of tubing support trailer 20 relative to
tubing straightening
trailer 100 is accommodated by universal joint 50. Specifically, any rotation
of trailer 20 relative
to trailer 100 along a vertically oriented axis is accommodated by rotation of
member 52 relative
to trailer 100 about axis 47 and rotation of member 56 relative to trailer 20
about axis 59.
Additionally, any rotation of trailer 20 relative to trailer 100 along a
horizontally oriented axis,
and any vertical movement of trailer 20 relative to trailer 100 is
accommodated by rotation of
member 54 relative to members 52, 56 about axes 55, 57, respectively.
[0044] Referring now to Figures 3 and 6-8, tubing straightening assembly 150
receives tubing
paid out from spool 21 (see Figure 1) and straightens the tubing to a desired
curvature depending
on the specific application. In this embodiment, straightening assembly 150
includes a base or
deck 152 coupled to cart 110, a mounting plate 180 extending vertically upward
from deck 152,
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and a plurality of straightening roller assemblies 190, 200, 220 having
rollers configured to
engage with and straighten the tubing paid out from spool 21 during deployment
operations.
[0045] Deck 152 has a longitudinal axis 155, a first or front end 152a, a
second or rear end 152b
opposite front end 152a, a top side 151, a bottom side 153 radially opposite
top side 151, a first
lateral side 157, and a second lateral side 159 radially opposite first
lateral side 157 with respect
to axis 155. Deck 152 is mounted to cart 110 such that axis 155 of deck 152 is
generally parallel
to axis 105 (but axes 152, 105 may be radially offset from one another
depending on the precise
position of deck 152 along cart 110), front end 152a is proximate front end
110a of cart 110 and
rear end 152b is proximate rear end 110b of cart 110. In addition, deck 152 is
mounted to cart
110 such that it may freely traverse laterally relative to cart 110. In
particular, a first or front
roller assembly 154 is mounted to bottom side 153 at front end 152a and a
second or rear roller
assembly 156 is mounted to bottom side 153 at rear end 152b. Front roller
assembly 154
engages front traversing bar 120A with a plurality of rollers and rear roller
assembly 156
engages rear traversing bar 120B with a plurality of rollers. Each roller
assembly 154, 156 is
configured the same; and thus, only the details of rear roller assembly 156
will be described
below, it being understood that front roller assembly 154 is the same.
[0046] Referring now to Figures 3 and 7-9, rear roller assembly 156 includes
one or more
coupling flanges 160 extending from bottom side 153 of deck 152 at rear end
152b. Coupling
flanges 160 rotatably support a first plurality of traversing rollers 162 on
first lateral side 157 of
deck 152 and a second plurality of traversing rollers 164 on second lateral
side 159. A plurality
of covers or shields 166 are coupled to coupling flanges 160 such that each
shield 166 covers one
of the rollers 162 or one of the rollers 164.
[0047] As is best shown in Figures 8 and 9, in this embodiment, the first
plurality of traversing
rollers 162 includes a total of three (3) rollers 162 ¨ with one of the
rollers 162 engaging the top
of rear traversing bar 120B, a second of the rollers 162 engaging the bottom
of bar 120B, and a
third of the rollers 162 engaging a side of bar 120B. While not specifically
shown, it should be
appreciated that second plurality of traversing rollers 164 similarly includes
a total of three (3)
rollers 164 ¨ with one of the rollers 164 engaging the top of rear traversing
bar 120B, a second of
the rollers 164 engaging the bottom of bar 120B, and a third of the rollers
164 engaging the side
of bar 120B. Thus, the engagement of rollers (e.g., rollers 162, 164) of front
roller assembly 154
with front traversing bar 120A and the engagement of rollers (e.g., rollers
162, 164) of rear roller
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assembly 156 with rear traversing bar 120B allows deck 152 (and thus tubing
straightening
assembly 150) to traverse in a lateral direction represented by arrow A in
Figure 3 that is
oriented 90 relative to axes 105, 155 in top view. As will be described in
more detail below,
movement of straightening assembly 150 along direction A (Figure 3) allows
assembly 150 to
receive and straighten tubing (e.g., tubing 18 shown in Figures 13A and 13B)
paid out from
tubing spool 21 (see Figure 1) while reducing the risk of bending or kinking
the same during
deployment operations.
[0048] Referring now to Figures 6 and 7, a leading roller 192 is disposed on
top side 151 of deck
152 at front end 152a. As will be described in more detail below, leading
roller 192 guides
tubing from chassis roller 126 toward the roller assemblies of tubing
straightening assembly 150.
In this embodiment, leading roller 192 is rotatably mounted to a shaft 191
that extends between a
support plate 193 mounted to top side 151 of deck 152 and mounting plate 180.
As shown, shaft
191 extends between plates 193, 180 along a direction that is parallel to and
radially offset from
axis 125. In addition, roller 192 is shaped in a substantially similar manner
to roller 126
previously described. Thus, roller 192 has an outer surface that includes a
pair of frustoconical
surfaces that taper inward toward each other (e.g., at angle 0) from the outer
ends in order to
guide and retain tubing paid out from spool 21 during operations in the same
manner as
described above for roller 126.
[0049] Referring still to Figures 6 and 7, a winch assembly 170 is mounted to
deck 152 at front
end 152a. As will be described in more detail below, winch assembly 170
provides a powered
mechanism for pulling the leading end of tubing paid out from spool 21 (Figure
1) through
tubing straightening assembly 150. In this embodiment, winch assembly 170
includes a winch
172 that is mounted to a winch support plate 174 extending axially from front
end 152a of deck
152 with respect to axis 155. A winch cable guide 167 is mounted at rear end
152b of deck 152
and includes a pair of guide wheels 169A, 169B rotatably mounted between a
pair of support
plates 168. In particular, winch cable guide 167 includes a first or upper
guide wheel 169A
proximate top side 151 and a second or lower guide wheel 169B proximate bottom
side 153. As
will be described in more detail below, during deployment operations, to
initiate the feed of
tubing from spool 21 (Figure 1) through straightening assembly 150, a winch
cable (not shown)
is fed between deck 152 and cart 110 from winch 172 and is guided over guide
wheels 169A,
169B. Thereafter, the winch cable is routed through straightening assembly 150
toward spool 21
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where is it coupled to a leading end of the tubing disposed thereon. As a
result, subsequent
actuation of winch 172 to retract the winch cable allows the tubing to be
initially fed through the
tubing straightening assembly 150.
[0050] Referring now to Figures 6-8, mounting plate 180 is coupled to first
lateral side 157 of
deck 152, and extends vertically upward from top side 151. In addition,
mounting plate 180
includes a first or front end 180a that is proximate front end 152a on deck
152 and a second or
rear end 180b that is proximate rear end 152b. As previously described above,
mounting plate
180 and deck 152 support a plurality straightening roller assemblies for
engaging with and
straightening tubing paid out from spool 21 (Figure 1) during deployment
operations. In
particular, in this embodiment, a total of three (3) roller assemblies are
mounted on or proximate
mounting plate 180 ¨ a first or front roller assembly 190 proximate front end
180a, a second or
rear roller assembly 220 that is proximate rear end 180b, and a third or mid
roller assembly 200
that is axially disposed between rollers assemblies 190, 220, with respect to
axes 155, 105.
[0051] Referring still to Figures 6-8, front roller assembly 190 includes a
first straightening
roller 250A rotatably disposed on a shaft 195 mounted to a bracket 196 that is
fixably mounted
to plate 180 proximate front end 180a. Referring briefly to Figure 10, roller
250A will be
described it being understood that rollers 2508, 250C, 250D, 250E are the
same. Roller 250A
includes a central or longitudinal axis 255, a first end 252, a second end 254
opposite front end
252, a radially outer surface 256 extending axially between ends 252, 254, and
a throughbore
258 also extending axially between ends 252, 254. Radially outer surface 256
includes a first
cylindrical surface 257 extending axially from first end 252, a second
cylindrical surface 259
extending axially from second end 254, and an annular recess 253 extending
axially between
surfaces 257, 259 and radially inward (e.g., toroidally) from surfaces 257,
259. During
deployment and straightening operations, tubing paid out from spool 21 (see
Figure 1) engages
with radially outer surface 256 of roller 250A such that the tubing is
substantially seated within
recess 253. As a result, in at least some embodiments, recess 253 may be
formed to correspond
with the outer curvature of the tubing being straightened; however, such
correspondence is not
required. Referring again now to Figures 6-8, roller 250A is mounted to shaft
195 on bracket
196 such that shaft 195 is aligned with axis 255 (see Figure 9) and axis 255
extending parallel to
and radially offset from axis 125 of bar 124.
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100521 Front roller assembly 190 also includes a second straightening roller
250B rotatably
mounted to a shaft 199 that is coupled to a pivot arm 198. As previously
described, roller 250B
is the same as roller 250A. It should also be appreciated that when roller
250B is installed on
shaft 199, axis 255 of roller 250B is substantially aligned with shaft 199 and
is oriented parallel
to and radially offset from axis 255 of roller 250A.
[0053] As is best shown in Figure 6, pivot arm 198 is an elongate member that
includes a first
end 198a and a second end 198b opposite first end 198a. Shaft 199 is mounted
to first end 198a
while second end 198b is pivotably mounted to deck 152 such that arm 198 and
roller 250B may
rotate about end 198b during operations. As will be appreciated by one of
ordinary skill in the
art, such rotation of arm 198 about end 198b results in a vertical height
adjustment for roller
250B relative to deck 152. A linear actuator 194, which in this embodiment is
a hydraulic
cylinder, is coupled to pivot arm 198 between ends 198a, 198b. Actuator 194
includes a central
longitudinal axis 197, a first end 194a, and a second end 194b opposite first
end 194a. First end
197a is pivotably coupled to pivot arm 198 while second end 194b is pivotably
mounted to deck
152. During operations, actuator 194 is actuated to extend and/or retract ends
194a, 194b apart
and/or away from each other, respectively, in order to induce rotation of
pivot arm 198 about
second end 198b and thereby adjust the vertical height of roller 250B relative
to deck 152 as
previously described.
[0054] Referring still to Figures 6-8, mid roller assembly 200 includes a
third straightening roller
250C and a fourth straightening roller 250D arranged axially adjacent one
another with respect to
the axes 105, 155. As previously described, each of the third and fourth
straightening rollers
250C, 250D, respectively, are the same as roller 250A. As is best shown in
Figure 7, each roller
250C, 250D is rotatably mounted to a respective shaft 202 depending from one
of a pair of
support blocks 204, each support block 204 being disposed on a pair of
respective tie rods 206
that extend vertically between a pair of vertically opposing mounting brackets
208 mounted to
plate 180. In this embodiment, one of the pair of rods 206 extending through
each block 204 is
threaded along its entire length (e.g., with Acme threads) while the other one
of the pair of rods
206 extending through each block 204 is smooth (note: the threaded rod 206 for
each block 204
is designated in the Figures and herein as 206' and the smooth rod 206 for
each block 204 is
designated in the Figures and herein as 206"). In addition, each threaded rod
206' is threadably
received through the corresponding block 204 and each smooth rod 206" is
slidably received
12
CA 02916063 2015-12-18
through the corresponding block 204. Thus, the vertical positions of rollers
250C, 250D relative
to deck 152 may be adjusted through rotation of the threaded rods 206',
thereby causing threaded
engagement between rods 206' and the corresponding block 204, and sliding
engagement
between rods 206" and the corresponding block 204. In addition, when each of
the rollers 250C,
250D are installed on the respective shafts 202, axes 255 of rollers 250C,
250D are substantially
aligned with shafts 202 and are each oriented parallel to and radially offset
from axes 255 of
roller 250A, 250B, and axis 125 of bar 124.
100551 Referring now to Figures 6-8 and 11, rear roller assembly 220 includes
a fifth
straightening roller 250E arranged proximate rear end 180b of plate 180. As
previously
described, fifth roller 250E is the same as roller 250A previously described.
As is best shown in
Figures 6 and 7, roller 250E is rotatably mounted to a shaft 222 depending
from a support block
224, which is slidably disposed on a pair of tie rods 226 that extend
vertically between a pair of
vertically opposing mounting brackets 228 mounted to plate 180. In addition, a
vertically
extending transfer member 223 is coupled to block 224 and extends vertically
through a
corresponding aperture 219 in the uppermost mounting bracket 228. During
operations, roller
250E may traverse along tie rods 226 through sliding engagement between rods
226 and block
224 in a manner similar to that described above for blocks 204 supporting
rollers 250C, 250D. It
should be appreciated from Figures 6 and 7, when roller 250E is installed on
shafts 222, axis 255
of rollers 250E is substantially aligned with shaft 222 and is oriented
parallel to and radially
offset from axes 255 of roller 250A, 250B, 250C, 250D and axis 125 of bar 124.
100561 Referring now to Figures 6-8 and 11, transfer member 223 includes a
first or upper end
223a, and a second of lower end 223b opposite upper end 223a. Upper end 223a
includes a
connection flange 221 that extends through a slot 227 in plate 180, while
lower end 223b is
coupled (e.g., mounted) to support block 224. A linear actuator 229 (e.g., a
hydraulic cylinder)
is disposed on an opposing side of plate 180 from roller 250E and includes a
central or
longitudinal axis 225 that is generally vertically oriented and is parallel to
and radially offset
from tie rods 226, a first or upper end 229a, and a second or lower end 229
opposite upper end
229a along axis 225. Upper end 229a is pivotably coupled to connection flange
221 of transfer
member 223 and lower end 229b is pivotably coupled to plate 180. During
operations, actuator
229 is actuated to extend and/or retract ends 229a, 229b apart and/or away
from each other along
13
CA 02916063 2015-12-18
axis 225, respectively, in order to raise and/or lower roller 250E along tie
rods 226 between
brackets 228 as previously described.
[0057] Referring now to Figures 1, 6, and 12, during deployment operations,
tubing wound on
spool 21 is paid out toward chassis roller 124, is fed toward leading roller
192, and then is routed
into straightening roller assemblies 190, 200, 220 in tubing straightening
assembly 150 to
remove a desired amount of the curvature or bend in the tubing resulting from
being previously
wound on spool 21. In particular, to initiate these deployment operations, the
winch cable (not
shown) of winching assembly 170 is fed between deck 152 and cart 110 from
winch 172, guided
over guide wheels 169A, 169B, and fed through straightening assembly 150 such
that it may
then be secured to a leading end of the tubing on spool 21, in the manner
previously described.
Thereafter, winch 172 is actuated to retract the winch cable, and thus, pulls
the leading end of the
tubing through straightening assembly 150. In particular, as is best shown in
Figure 12 (where
the path of the tubing through straightening assembly 150 is generally
schematically indicated
with arrows 275), tubing is routed over leading roller 192, between first and
second straightening
rollers 250A, 250B, under third and fourth straightening rollers 250C, 250D,
and finally over
fifth straightening roller 250E. As a result, as tubing is routed between and
around rollers 250A,
250B, 250C, 250D, 250E as described above, it is effectively bent in
alternating directions (e.g.,
upward and downward), which removes (or lessens) the original bend or
curvature caused by
winding tubing on spool 21 such that the tubing may be substantially straight
after engaging with
roller 250E. Upon exiting straightening assembly 150 (i.e., at rear end 110b
of cart), the now
substantially straightened tubing is connected to another component (e.g.,
pipeline, well, etc.),
such that additional tubing may be paid out from spool 21 and fed through
straightening
assembly 150 by simply moving (e.g., towing) tubing transportation and
deployment system 10
(e.g., tubing support trailer 20 and tubing straightening trailer 100) along
the desired path (e.g.,
with a vehicle coupled to cowing coupler 32) for tubing. Alternatively, in
some embodiments,
upon exiting straightening assembly 150 a separate machine or vehicle (e.g.,
an excavator) is
used to pull the leading end of the tubing from spool 21 and through
straightening assembly 150.
[0058] To facilitate appropriate contact between the tubing and rollers 250A,
250B, 250C, 250D,
250E during the above described straightening operations, the height of second
roller 250B is
adjusted through actuation of actuator 194, the vertical heights of rollers
250C, 250D are
adjusted along tie rods 206 through rotation of threaded rods 206' extending
through blocks 204,
14
CA 02916063 2015-12-18
and the vertical height of roller 250E is adjusted through actuation of
actuator 229, all in the
manner described above. Specifically, actuator 194 is extended/retracted along
axis 197 to
ensure that tubing fed from spool 21 is engaged between rollers 250A, 250B. In
addition, the
vertical position of rollers 250C, 250D is set along tie rods 206 in the
manner previously
described prior to the initiation of deployment operations to ensure adequate
contact between the
tubing and rollers 250C, 250D. The pre-set vertical positions of rollers 250C,
250D is influenced
by a variety of factors such as, for example, the desired final bend in the
tubing (if any), the size
(e.g., outer diameter) of the tubing, the rigidity of the tubing, etc..
Further, actuator 229 is
extended/retracted along axis 225 to achieve a desired level of
contact/bending of the tubing as it
moves over top of roller 250E. The vertical height of roller 250E and the
level of
contact/bending of tubing over roller 250E has a notable influence in the
resulting straightness of
the tubing upon exiting straightening assembly 150. Specifically, in this
embodiment, as the
vertical separation between the positions of rollers 250C, 250D and roller
250E increases, the
amount of bend/curve in the deployed tubing also increases and as the vertical
separation
between the positions of rollers 250C, 250D and roller 250E decreases, the
amount of bend/curve
in the deployed tubing also decreases.
[0059] Referring now to Figures 13A and 13B, as tubing 18 is paid out from
spool 21 and spool
21 is rotated about axis 17 in the manner described above, a payout point 19,
where the tubing 18
leaves spool 21, traverses axially back and forth with respect to axis 17.
Specifically, the
progression from Figure 13A to 13B shows payout point 19 for tubing 18
shifting axially along
spool 21 with respect to axis 17. For larger and more rigid tubing, there is
an increased risk of
kinking or unwanted lateral bending when the position of straightening
assembly 150 is greatly
separated from point 19 along the axial or lateral direction (e.g., along
direction A, axis 17, etc.).
As a result, as is shown in Figures 13A and 13B, in this embodiment, during
deployment
operations, straightening assembly 150 is allowed to traverse laterally along
direction A relative
to cart 110 such that payout point 19 is always generally aligned with tubing
straightening
assembly 150. It should be appreciated that in at least some embodiments,
straightening
assembly 150 slightly lags behind payout point 19 along axis 17 due to the
balance of forces
within system 10; however, this slight difference in position during
deployment operations is
small enough so as not to cause kinking or bending of tubing 18 in the lateral
direction (e.g., axis
17, direction A, etc.). As previously described above, the lateral movement of
straightening
CA 02916063 2015-12-18
,
assembly 150 along direction A relative to cart 110 is facilitated through
engagement of rollers
(e.g., rollers 162, 164) of roller assemblies 154, 156 along front and rear
transfer bars 120A,
120B, respectively (Figures 8 and 9). Moreover, in this embodiment, since
chassis roller 126 is
slidably engaged with bar 124, during the above described movement of point 19
and assembly
150, roller 126 also traverses laterally (e.g., along direction A) with
respect to cart 110 to further
facilitate guiding of tubing 18 from spool 21 to straightening assembly 150.
[0060] In this embodiment, traversal or movement of assembly 150 along
direction A is driven
or caused by the movement of payout point 19, such that assembly 150 passively
follows (or is
pulled) along direction A by tubing. However, it should be appreciated that in
other
embodiments, assembly 150 is independently driven along direction A
independent of the
influence by tubing 18 (e.g., with a motor or other actuator). Specifically,
in some embodiments,
assembly 150 is driven along direction A with one of more hydraulic cylinders
mounted between
cart 110 and assembly 150.
[0061] Referring now to Figure 16, an embodiment of a tubing straightener
trailer 300 is shown.
Trailer 300 can be used in place of trailer 100 within the tubing
transportation and deployment
system 10. Tubing straightener trailer 300 is configured to straighten tubing
deployed or paid
out from the tubing spool 21 mounted to support trailer 20 as previously
described and shown in
Figure 1. In this embodiment, tubing straightener trailer 300 includes a base
cart 310, a base
frame 352 mounted to cart 310, and a tubing straightening assembly 350
moveably coupled to
cart 310 via the base frame 352. In other words, the base frame 352 attaches
the tubing
straightening assembly 350 to cart 310.
[0062] Cart 310 provides a platform for supporting and transporting tubing
straightening
assembly 350 during deployment operations. Cart 310 has a central or
longitudinal axis 315, a
first or front end 310a, and a second or rear end 310b opposite front end
310a. In addition, cart
310 includes a bed or base 312, a first or front axle assembly 314 mounted to
base 312 at front
end 310a, a second or rear axle assembly 316 mounted to base 312 at rear end
310b, a first pair
of wheels 311 rotatably mounted to front axle assembly 314, and a second pair
of wheels 313
rotatably mounted to rear axle assembly 316. In this embodiment, base 312 is
generally
rectangular in shape and includes an upper support surface 318 extending
axially between ends
110a, 110b. While not specifically shown, in this embodiment, front end 310a
includes
connection members and/or structure to facilitate coupling of tubing
straightening trailer 300 to
16
CA 02916063 2015-12-18
tubing support trailer 120 in the same manner as described above for tubing
straightening trailer
100 (see Figure 1). In other embodiments, front end 310a of tubing
straightening trailer 300 may
include any suitable structure or assembly for coupling cart 310 to another
component, such as,
for example, a vehicle (e.g., truck, tractor, etc.) or another trailer (e.g.,
tubing support trailer
120).
[0063] Referring now to Figures 16 and 17, tubing straightening assembly 350
receives tubing
paid out from spool 21 (see Figure 1) and straightens the tubing to a desired
curvature depending
on the specific application. In this embodiment, straightening assembly 350
includes a roller
support frame 380 moveably coupled to base frame 352, and a plurality of
straightening roller
assemblies 420, 430, 440 having rollers that engage and straighten the tubing
paid out from spool
21 during deployment operations.
[0064] Referring still to Figures 16 and 17, base frame 352 includes a pair of
laterally extending
traversing bars 354A, 354B that are axially spaced from one another with
respect to axis 315,
and a pair of connecting members 359 coupled to and extending axially between
traversing bars
354A, 354B with respect to axis 315. Thus, traversing bars 354A, 354B extend
parallel to one
another in the lateral or radial direction with respect to axis 315.
Traversing bars include a first
or front traversing bar 354A and a second or rear traversing bar 354B. As
shown in Figure 16,
when base frame 352 is mounted to support surface 318, front traversing bar
354A is proximate
front end 310a of cart 310 and rear traversing bar 354B is proximate rear end
310b of cart 310.
In this embodiment, front and rear traversing bars 354A, 3548 are I-beams that
each include an
upper flange 356 and a lower flange 358 vertically spaced from one another by
a connecting
member 357. Lower flanges 358 of traversing bars 354A, 354B engage with and
are mounted to
support surface 318 on cart 310 such that base frame 352 is secured to cart
310 during
operations. As will be described in more detail below, upper flanges 356 of
traversing bars
354A, 354B support roller support frame 380.
[0065] Roller support frame 380 is movably coupled to base frame 352 and is
configured to
support a plurality of roller assemblies 400, 420, 430, 440 for engaging with
and straightening
tubing as it is fed from spool 21 (see Figure 1). Roller support frame 380
includes a central axis
385 that is parallel to and radially offset from axis 315 of cart 310, a first
or front end 380a, and a
second or rear end 380b opposite front end 380a. As shown in Figure 16, when
tubing
17
CA 02916063 2015-12-18
straightening assembly 350 is mounted to cart 310, front end 380a is proximate
front end 310a of
cart 310, and rear end 380b is proximate rear end 310b of cart 310.
[0066] In addition, roller support frame 380 includes a pair of axially
extending frame members
382 and a housing 381 mounted to and supported by frame members 382. Frame
members 382
each extend axially between ends 380a, 380b and are spaced from one another in
the lateral or
radial direction with respect to axis 385. Housing 381 includes a plurality of
vertical support
members 384 coupled to and extending from frame members 382, and a pair of
axially or
horizontally extending support members 386 coupled to the frame members 382.
Together,
members 384, 386 of housing 381 define (at least partially) a space 383 that
receives at least
some of the roller assemblies 420, 430, 440 during deployment operations.
[0067] Referring now to Figures 17 and 18, roller support frame 380 is movably
supported on
base frame 352 with a pair of traversing carts 390A, 390B. In particular,
roller support frame
380 is mounted on a first or front traversing cart 390a that is movably
disposed on front
traversing bar 354A, and roller frame 380 is mounted on a second or rear
traversing cart 390B
that is movably disposed on a rear traversing bar 354B.
[00681 Referring particularly now to Figure 18, traversing carts 390A is
shown. Although only
one traversing cart 390A and associated traversing bar 354A is shown in Figure
18, it should be
appreciated that the other cart 390B and corresponding bar 354B, respectively,
are the same.
[0069] As shown in Figure 18, traversing cart 390A includes an upper support
plate 392, a pair
of frame members 394 extending from plate 392, and a roller support plate 396
extending
between frame members 394 in a direction that is parallel to plate 392.
Traversing cart 390A
supports a plurality of roller assemblies 398 that engage with flange 356 of
the corresponding
traversing bar 354A to facilitate relative movement of cart 390A relative to
traversing bar 354A.
Specifically, roller support plate 396 supports a pair of roller assemblies
398, and one of the
frame members 394 supports another pair of roller assemblies 398. Each roller
assembly 398
includes a roller 399 rotatably mounted on a shaft 397. The shaft 397 and
roller 399 of each
assembly 398 are secured to the plate 396 or member 394 with a coupling member
393 which in
this embodiment comprises a threaded nut that engages with threads on one end
of shaft 397. In
this embodiment, the rollers 399 of the roller assemblies 398 on roller
support plate 396 engage
with a pair of laterally extending side surfaces 356a on flange 356 and the
rollers 399 of the
roller assemblies 398 on the frame member 394 engage with a pair of laterally
extending upper
18
CA 02916063 2015-12-18
and lower surfaces 356b on flange 356. Thus, cart 390A may freely traverse in
the lateral or
radial directions with respect to axes 315, 385 (see Figures 16 and 17)
through rolling
engagement of the rollers 399 in assemblies 380 and the laterally extending
surfaces 356a, 356b
making up upper flange 356.
[0070] Referring again to Figure 17, frame members 382 of roller support frame
380 are
mounted and secured to upper support plates 392 of traversing carts 390A,
390B. Therefore,
during operations, roller support frame 380 can freely traverse laterally or
radially with respect to
axes 315, 385 along traversing bars 354A, 354B to facilitate removal of tubing
(e.g., tubing 18)
from spool 21 (see e.g., Figures 13A and 13B), during operations.
[0071] Referring now to Figure 17 and 19, a pre-bend assembly 400 is coupled
to front end 380a
of roller support frame 380. Pre-bend assembly 400 is configured to receive
tubing (e.g., tubing
18) from spool 21 (see Figure 1) during operations and place an initial bend
thereon to counteract
any curvature of the tubing caused by its storage on spool 21. Pre-bend
assembly 400 includes
upper linkage assembly 410 and a lower linkage assembly 411, each assembly
410, 411 being
coupled to both roller support frame 380 and to a linear actuator 418.
[0072] Upper linkage assembly 410 includes a first upper link 412 and a second
upper link 414.
First upper link 412 is pivotably coupled to roller support frame 380 via a
sub-frame assembly
413 and second upper link 414 is pivotably coupled to first link 412.
Specifically, first upper
link 412 includes a first end 412a and a second end 412b opposite first end
412a. First upper link
412 is pivotably coupled to support assembly 413 at second end 412b, and a
roller 450A is
pivotably coupled to first upper link 412 at first end 412a. Roller 450 is the
same as rollers
250A-250E, previously described above.
[0073] Second upper link 414 includes a first end 414a and a second end
opposite first end 414b.
First end 414a is pivotably coupled to first upper link 412 at a point along
first upper link 412
between the first end 412a and the second end 412b. Second end 414b of second
upper link 414
is pivotably coupled to linear actuator 418. Linear actuator 418, which in
this embodiment is a
hydraulic cylinder, includes a first end 418a and a second end 418b opposite
first end 418a. First
end 418a is pivotably coupled to second end 414a of second upper link 414 and
second end 418b
is pivotably coupled to a pair of the vertical support members 384 of housing
381 on frame 380.
During operations, actuator 418 is actuated to extend or retract ends 418a,
418b apart or away
from each other, respectively. Because of the pivotal connection of second
upper link 414 to
19
CA 02916063 2015-12-18
first upper link 412, when actuator 418 is actuated to extend ends 418a, 418b
apart from one
another, first upper link 412 is rotated about second end 412b in a first
direction 401 shown in
Figure 19. Conversely when actuator 418 is actuated to retract ends 418a, 418b
toward one
another, first upper link 412 is rotated about second end 412b in a second
direction 403 shown in
Figure 19 that is opposite first direction 401.
[0074] Lower linkage assembly 411 includes a lower link 416 comprising a first
end 416a and a
second end 416b opposite first end 416a. First end 416a is rotatable coupled
to first end 418a of
actuator 418 and second end 416b is pivotably coupled to frame members 382 of
roller support
frame 380. A roller 450B is also pivotably coupled to second end 416b of lower
link 416. As
previously described above for roller 450A, roller 450B is the same as rollers
250A-250E,
previously described above. Because of the pivotable coupling between first
end 416a of lower
link 416 and second end 418b of actuator 418, when actuator 418 is actuated to
extend ends
418a, 418b apart from one another, lower link 416 is rotated about second end
416b in a first
direction 407 shown in Figure 19. Conversely, when actuator 418 is actuated to
retract ends
418a, 418b toward one another, lower link 416 is rotated about second end 416b
is a second
direction 409 shown in Figure 19 that is opposite first direction 407.
[0075] As can be appreciated from Figure 19, when actuator 418 is actuated to
extend ends 418a,
418b apart from one another, rollers 450A, 450B on links 412, 416,
respectively, are rotated
away from one another (with roller 450A rotating about second end 412b of
first upper link 412
in the first direction 401 and with roller 450B rotating about second end 416b
of lower link 416
in the first direction 407). Conversely, as can also be appreciated from
Figure 19, when actuator
418 is actuated to retract ends 418a, 418b toward one another, rollers 450A,
450B on links 412,
416, respectively, are rotated toward one another (with roller 450A rotating
about second end
412b of first upper link 412 in the second direction 403 and with roller 450B
rotating about
second end 416b of lower link 416 in the second direction 409).
[0076] Referring again to Figures 17 and 19, as previously described above,
roller support frame
380 supports a plurality of roller assemblies 400, 420, 430, 440 for engaging
with and
straightening a tubing conduit as it is fed from spool 21 (see Figure 1).
Specifically, in this
embodiment, roller support frame 380 supports a first or front roller assembly
420, a second or
rear roller assembly 430, and a third or mid roller assembly 440. Front roller
assembly 420 is
coupled between frame members 382 and is axially adjacent front end 380a and
pre-bend roller
CA 02916063 2015-12-18
assembly 400. Rear roller assembly 430 is coupled between frame members 382
and is axially
adjacent rear end 380b of frame 380. Mid roller assembly 440 is disposed
within space 383
defined by housing 381 and is axially disposed between front and rear roller
assemblies 420,
430, respectively.
[0077] Referring now to Figures 20 and 21, front roller assembly 420 is shown.
While only a
single roller assembly 420 is shown in Figures 20 and 21, it should be
appreciated that the other
roller assembly 430 is the same.
[0078] Roller assembly 420 includes a support frame 422 comprising a central
axis 425 and a
pair of support plates 421 that radially oppose one another across axis 425.
Plates 421 are
coupled to one another with a pair of connecting members 429. Axis 425 is
parallel to and
radially offset from axes 315, 385 when roller assemblies 420, 430 are mounted
to frame 380 and
frame 380 is coupled to cart 310 (see Figures 16 and 17). Each support plate
421 includes an
axially extending slot 424 that includes a plurality of axially spaced
recesses or notches 426
formed therein. Plates 421 are arranged within frame 422 such that slot 424
and notches 426 are
radially and axially aligned with one another with respect to axis 425. Each
roller assembly 420,
430 includes a roller 450C, 450F that is rotatably disposed on a corresponding
shaft 428 that
extends radially through each of the slots 424. As previously described above
for rollers 450A,
450B, rollers 450C, 450F are the same as rollers 250A-250E, previously
described above. As
can be appreciated from Figures 20 and 21, the position of rollers 450C, 450F
within the
corresponding frames 422 is axially adjustable by seating shaft 426 within
different axially
aligned pairs of notches 426 along slots 424.
[0079] Referring now to Figures 19-21, frames 422 of roller assemblies 420,
430 are coupled to
frame members 382 by inserting bolts 427 through radially aligned holes in
plates 421 and frame
members 382, and securing bolts 427 to frame members 382 and plates 421 with
threaded nuts
427. However, it should be appreciated that frames 422 of roller assemblies
420, 430 may be
coupled to frame members 382 in any other suitable fashion, such as, for
example, by welding
plates 421 to frame members 382.
100801 Referring again to Figure 19, mid roller assembly 440 includes a pair
of rollers 450D,
450E, a rocker arm assembly 442, a pivoting arm 444, and a linear actuator
446. As previously
described above for rollers 450A, 450B, 450C, 450F, rollers 450D, 450E are the
same as rollers
250A-250E, previously described above, and thus, a detailed description of
rollers 450D, 450E is
21
CA 02916063 2015-12-18
omitted herein in the interests of brevity. Rocker arm assembly 442 includes a
first end 442a,
and a second end 442b opposite first end 442a. Roller 450D is pivotably
mounted to rocker arm
assembly 442 at first end 442a, and roller 450E is pivotably mounted to rocker
arm assembly 442
at second end 442b. Pivoting arm 444 is an elongate member that includes a
first end 444a, and
a second end 444b opposite first end 444a. Second end 444b is pivotally
coupled to support
members 386 of housing 381, and first end 444a is pivotably coupled to rocket
arm assembly
442 at a point between ends 442a, 442b. Linear actuator 446, which in this
embodiment is a
hydraulic cylinder, includes a first end 446a and a second end 446b opposite
first end 446a.
Second end 446b is pivotably coupled to support members 386 of housing 381,
and first end
446a is pivotably coupled to rocker arm assembly 442 at the same point as the
first end 444a of
pivoting arm 444 (i.e., at a point on rocker arm assembly 442 between ends
442a, 442b).
[0081] During operations, actuator 446 is actuated to extend or retract ends
446a, 446h apart or
away from each other, respectively. Specifically, when actuator 446 is
actuated to extend ends
446a, 446b away from one another, both pivoting arm 444 and rocker arm
assembly 422 are
rotated about second end 444b of pivoting arm 444 in a first direction 443
shown in Figure 19.
Conversely, when actuator 446 is actuated to retract ends 446a, 446b toward
one another, both
pivoting arm 444 and rocker arm assembly 442 are rotated about second end 444b
of pivoting
arm 444 in a second direction 441 shown in Figure 19 that is opposite first
direction 443. Thus,
as can be appreciated in Figure 19, extension of the ends 446a, 446b of
actuator 446 causes
rocker arm assembly 422 and rollers 450D, 450E to traverse vertically downward
and axially
rearward with respect to axis 385 along an arcuate path defined by pivoting
arm 444 (particular
end 444a), and a retraction of ends 446a, 446b of actuator 446 causes rocker
arm assembly 442
and rollers 450D, 450E to traverse both vertically upward and axially
frontward with respect to
axis 385 along an arcuate path defined by pivoting arm 444 (particularly end
444a).
100821 Referring again to Figures 16 and 17, a winch assembly 460 is mounted
to roller support
frame 380 at rear end 380b. As will be described in more detail below, winch
assembly 460
provides a powered mechanism for pulling the leading end of tubing from spool
(Figure 1)
through tubing straightening assembly 350. In this embodiment, winch assembly
460 includes a
winch 462 mounted to roller support frame 380 and guide boom 464 extending
axially from
roller support frame 380. Guide boom 464 is an elongate member that includes a
first end 464a
and a second end opposite first end 464a. First end 464a is coupled to roller
support frame 380
22
CA 02916063 2015-12-18
and second end 464b is distal to roller support frame 380. Thus, first end
464a may be referred
to herein as a proximate end 464a, and second end 464b may be referred to
herein as a distal end
464b. Proximate end 464a (see Figure 16) is povotably coupled to roller
support frame 380 such
that boom 464 may be rotated about proximate end 464a relative to roller
support frame 380
during operations. As a result, when winch assembly 460 is not needed (e.g.,
after the leading
end of the tubing has been fed through tubing straightening assembly 350) boom
464 may be
pivoted about proximate end 464a from the position shown in Figures 16 and 17
(which may be
referred to herein as an operating position) to a stowed position (i.e., boom
464 may be pivoted
about end 464a such that distal end 464b is rotated clockwise toward roller
support frame 380 in
the view shown in Figure 16). Boom 464 may be secured in both the operating
position and the
stowed position by a pinned connection (e.g., by engaging a pin through
appropriate apertures in
frame 380). A guide wheel 466 is rotatably coupled to distal end 464b of guide
boom 464 that is
configured to guide a winch cable (not shown) during winching operations. More
particularly, as
will be described in more detail below, during deployment operations, to
initiate the feed of
tubing from spool 21 (Figure 1) through straightening assembly 350, a winch
cable (not shown)
is fed from winch 462 and is guided over guide wheel 466 (in this embodiment,
the winch cable
may be fed through boom 464 as it is routed to wheel 466). Thereafter, the
winch cable is routed
through straightening assembly 350 toward spool 21 where is it coupled to a
leading end of the
tubing disposed thereon. As a result, subsequent actuation of winch 462 to
retract the winch
cable allows the tubing to be initially fed through the tubing straightening
assembly 350.
[0083j Referring now to Figures 16, 17, and 22, an outfeed alignment assembly
480 is coupled
to rear end 380b of roller support assembly 380 and aligns the tubing in the
desired deployment
direction relative to straightening assembly 350 during deployment operations.
As is best shown
in Figures 17 and 22, outfeed alignment assembly 480 includes a mounting plate
481 attached to
rear end 380b of roller support frame 380 and a pair of vertically spaced
housing plates 482
rotatably coupled to mounting plate 481 with a pin member 486 having a
vertically oriented
central axis 485. Plate 481 includes a recess 483 sized to allow tubing fed
from spool 21 to
extend therethrough during operations. In this embodiment, plates 482 each
extend parallel to
axis 385, and axis 485 is disposed within a plane (not shown) that extends
perpendicularly to
each of the axes 315, 385. A pair of guide rollers 484 are rotatably mounted
vertically between
23
CA 02916063 2015-12-18
plates 482 such that each guide roller 484 is parallel to and radially offset
from axis 485 of pin
486.
[0084] As will be described in more detail below, during tubing straightening
operations, tubing
that has exited tubing straightening assembly 350 is directed through recess
483 in plate 381 and
between plates 482 and finally between rollers 484. Thus, the rotational
position of plates 482
about axis 485 can determine the final bend or orientation of the tubing as it
exits tubing
straightening assembly 350. Accordingly, outfeed alignment assembly 480 also
includes a linear
actuator 488 to control and maintain the exiting orientation of outfeed
alignment assembly 480,
and thus, also the tubing as it is fed from tubing straightening assembly 350
during operations.
In particular, linear actuator 488, which comprises a hydraulic cylinder in
this embodiment, has a
first end 488a and a second end 488b opposite first end 488a. Second end 488b
is pivotably
coupled to mounting plate 481, and first end 488a is pivotably coupled to
housing plates 482 at a
point that is distal pin 486. During operations, actuator 488 is actuated to
extend or retract ends
488a, 488b apart or away from each other, respectively. In particular, when
actuator 488 is
actuated to extend ends 488a, 488b away from one another, plates 482 are
rotated about axis 485
of pin 486 in a first direction 487 shown in Figure 22. Conversely, when
actuator 488 is actuated
to retract ends 488a, 488b toward one another, plates 482 are rotated about
axis 485 of pin 486 in
a second direction 489 shown in Figure 22 that is opposite the first direction
487. Thus,
actuation of linear actuator 488 to extend or retract ends 488a, 488b controls
the final lateral
bend or orientation of the tubing as it exits tubing straightening assembly
350.
100851 Referring now to Figures 16, 17, and 23, during deployment operations,
tubing wound on
spool 21 (Figure 1) is paid out and then is routed toward pre-bend roller
assembly 400 and then
into straightening roller assemblies 420, 430, 440 in tubing straightening
assembly 350 to
remove a desired amount of the curvature or bend in the tubing resulting from
being previously
wound on spool 21. In particular, to initiate these deployment operations, the
winch cable (not
shown) of winching assembly 460 is fed over guide wheel 466 and through
straightening
assembly 350 such that it may then be secured to a leading end of the tubing
on spool 21 in the
manner previously described. Thereafter, winch 462 is actuated to retract the
winch cable, and
thus, pull the leading end of the tubing through straightening assembly 350.
As is best shown in
Figure 23 (where the path of the tubing through straightening assembly 350 is
generally
schematically indicated with arrows 490), tubing is routed between rollers
450A, 450B of pre-
24
CA 02916063 2015-12-18
bend roller assembly 400, over roller 450C of front straightening roller
assembly 420, under
rollers 450D, 450E of mid straightening roller assembly 440, and finally over
roller 450F of rear
straightening roller assembly 430. As a result, as tubing is routed between
and around rollers
450A, 450B, 450C, 450D, 450E, 450F as described above, it is effectively bent
in alternating
directions (e.g., upward and downward), which removes (or lessens) the
original bend or
curvature caused by winding tubing on spool 21 such that the tubing is
straight or substantially
straight after engaging with roller 450F. Upon exiting straightening assembly
350, the tubing is
finally routed through outfeed alignment assembly 480, where a final, desired
lateral bend (if
any) is imparted on the tubing by the rollers 484 and linear actuator 488.
Thereafter, the now
substantially straightened tubing is connected to another component (e.g.,
pipeline, well, etc.),
such that additional tubing may be paid out from spool 21 and fed through
straightening
assembly 350 by simply moving (e.g., towing) tubing transportation and
deployment system 10
(e.g., tubing support trailer 20 and tubing straightening trailer 300) along
the desired path (e.g.,
with a vehicle) for tubing. Alternatively, in some embodiments, upon exiting
straightening
assembly 350 a separate machine or vehicle (e.g., an excavator) is used to
pull the leading end of
the tubing from spool 21 and through straightening assembly 350.
[0086] To facilitate appropriate contact between the tubing and rollers 450A,
450B, 450C, 450D,
450E, 450F during the above described straightening operations, the positions
of rollers 450A,
450B, 450C, 450D, 450E, 450F may be adjusted relative to frame 380. In
particular, linear
actuator 418 may be extended or retracted to move rollers 450A, 450B apart or
together,
respectively, as described above. In addition, the positions of rollers 450C,
450F of front and
rear roller assemblies 420, 430, respectively, are axially adjusted by
traversing the rollers 450C,
450F through the corresponding slots 424 in frames 422 and seating the shafts
428 carrying
rollers 450C, 450F within aligned pairs of notches 426 formed in slots 424 as
previously
described. Further, linear actuator 446 is extended/retracted to adjust the
positions of rollers
450D, 450E in mid-roller assembly 440 as previously described.
[0087] Referring particularly to Figure 17, during these above described
tubing deployment
operations, as tubing 18 is paid out from spool 21 and spool 21 is rotated
about axis 17 (see
Figure 1), roller support frame 380 of tubing straightening assembly 350 is
free to traverse
laterally along traversing bars 354A, 354B via the traversing carts 390A,
390B, respectively, as
described above. Thus, roller assemblies 400, 420, 430, 440 and outfeed
alignment assembly
CA 02916063 2015-12-18
480 of tubing straightening assembly 350 traverse freely in the lateral
direction (e.g., direction A
shown in Figures 13A, 13B) to maintain alignment between the roller assemblies
400, 420, 430,
440, and outfeed alignment assembly 480 with the payout point (e.g., payout
point 19 shown in
Figure 13A, 13B) of tubing 18 as it reciprocates laterally across spool 21
(see Figure 1) during
tubing payout and deployment operations in the manner previously described
above.
[0088] In the manner described herein, through use of a tubing transportation
and deployment
system in accordance with the principles disclosed herein (e.g., system 10),
tubing (e.g., tubing
18) may be paid out from a spool (e.g., spool 21) and simultaneously
straightened within a single
deployment operation, thus greatly reducing the complexity and time required
for such
operations. In addition, through use of a tubing transportation and deployment
system in
accordance with the principles disclosed herein (e.g., system 10), undesired
lateral kinking or
bending of the tubing (e.g., tubing 18) as it is paid out from a spool (e.g.,
spool 21) is avoided
through the lateral movement of the tubing straightening assembly (e.g.,
assemblies 150, 350).
[0089] While embodiments disclosed herein have shown the deck 152 to be
mounted to front
and rear transfer bars 120A, 120B with front and rear roller coupling
assemblies 154, 156,
respectively, it should be appreciated that in other embodiments, deck 152 may
additionally or
alternatively be coupled to mid transfer bar 120C with a roller assembly
(e.g., assemblies 154,
156) in a similar manner while still complying with the principles disclosed
herein. In addition,
while the specific path (e.g., arrows 275) of tubing that is routed through
tubing straightening
assembly 150 is shown and described as extending under rollers 250C, 250D, and
over roller
250E, it should be appreciated that the specific path taken by tubing through
rollers 250A, 250B,
250C, 250D, 250E can be widely varied while still complying with the
principles disclosed
herein. For example, in some embodiments, tubing extends above and over
rollers 250C, 250D
and then under roller 250E. Further, it should be appreciated that the
specific designs of rollers
126, 192, 250A-250E, 450A-450F can be varied while still complying with the
principles
disclosed herein. For example, while chassis roller 126 has been described as
including a
radially outer surface 123 having first and second frustoconical sections 127,
129, it should be
appreciated that in other embodiments, as is shown in Figure 15, outer surface
123 of roller 126
may include a pair of radial extensions 327, 329 defining a central guide
region 330 for receiving
tubing paid out from spool 21 during operations.
26
CA 02916063 2015-12-18
[0090] While preferred embodiments have been shown and described,
modifications thereof can
be made by one skilled in the art without departing from the scope or
teachings herein. The
embodiments described herein are exemplary only and are not limiting. Many
variations and
modifications of the systems, apparatus, and processes described herein are
possible and are
within the scope of this disclosure. Accordingly, the scope of protection is
not limited to the
embodiments described herein, but is only limited by the claims that follow,
the scope of which
shall include all equivalents of the subject matter of the claims. Unless
expressly stated
otherwise, the steps in a method claim may be performed in any order. The
recitation of
identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method
claim are not intended to
and do not specify a particular order to the steps, but rather are used to
simplify subsequent
reference to such steps.
27
