Hoist spooling assembly and methods of using same

A hoist spooling assembly for spooling a cable about a drum while preventing relative movement between the cable and the drum. The hoist spooling assembly evenly delivers force from a roller to the cable while reducing the incidence of spooling problems, including mechanical wear of the cable and formation of loops and kinks in the cable.

FIELD

This application relates generally to apparatus and methods for spooling a cable about a drum and, more particularly, to a hoist spooling assembly for spooling a cable about a drum.

BACKGROUND

Poor hoist spooling can be characterized by the presence of gaps between cable wraps, multiple cable layers on a drum designed for single-layer cable wrapping, mechanical cable damage, reduced productivity, reduced cable life, and/or operator injury. Mechanical damage to a cable can be caused by “bird-caging” and formation of loops and/or kinks.

These problems often arise when a hoist spooling assembly is used to lift or lower a drill string. As a drill string is lowered into a drill hole, its velocity will sometimes decelerate relative to the constant velocity of the cable line of the main line hoist. This deceleration can be attributed to an obstruction or to the viscous effects of drilling mud or water in the drill hole. This change in relative velocities can result in an excess amount of cable, which, in turn, can lead to formation of a loop. If such a loop is pulled through the hoist spooling assembly, a kink can form, thereby damaging the cable such that the cable is unfit for service. Kinks of this kind often form when the hoist operator stops activating the winch and the drill string breaks free of the obstruction, thereby allowing the full weight of the drill string to be applied to the cable with loops present. If the loops are large enough, then they can also get caught on—and irreparably damage—any tensioning mechanisms or encoders of the assembly. Slack in the cable can also arise when there are gaps between cable wraps. When these gaps occur, the length of the cable in a single wrap is longer than the length of the cable in a properly spooled wrap. Thus, when the cable shifts laterally on the drum, the extra length creates slack that can cause damage as described herein.

When a hoist is used to lift the drill string, a hoist plug must typically be threaded on the drill rods. Often, the hoist plug is lowered into the drill string with an excessive amount of unwound cable having little or no tension. Subsequent activation of the hoist can cause a sudden application of tension force to the cable, which is typically at a fleet angle of 1 to 2 degrees relative to a center of the drum. This sudden application of force can result in a side load that forces the cable to “jump” towards the center of the drum, thereby creating a gap. Over time, these spooling errors can perpetuate until the rope is damaged or until the operators are required to re-spool the rope, which can result in severe operator injury.

Accordingly, there is a need in the pertinent art for apparatus and methods for preventing relative motion between a cable and a drum, optimizing the interface between a roller and the cable, and improving the overall functionality and robustness of a hoist spooling assembly in drilling applications.

SUMMARY

Described herein is a hoist spooling assembly for spooling a cable about a drum. The hoist spooling assembly can include a frame having a base portion and first and second spaced support portions. The base portion of the frame has a top surface. The first and second support portions of the frame can extend upwardly from the top surface of the base portion and define respective openings.

The hoist spooling assembly also includes a rod having a longitudinal axis and opposed first and second ends. The first end of the rod can be configured for secure coupling to the base portion of the frame.

Additionally, the hoist spooling assembly includes first and second bushings configured for receipt within the respective openings of the first and second support portions of the frame. The first and second bushings can define respective openings.

The hoist spooling assembly further includes first and second arms having respective proximal and distal portions. The proximal portions of the first and second arms can define respective openings.

The hoist spooling assembly also includes an elongate suspension unit defining a central bore and a retainer defining at least one opening configured to receive at least a portion of the elongate suspension unit. The retainer can be configured for adjustable coupling to the second end of the rod.

Further, the hoist spooling assembly includes an elongate shaft having a longitudinal axis and opposed first and second end portions. The elongate shaft can be configured for receipt within the central bore of the elongate suspension unit such that the first and second end portions of the elongate shaft extend from the central bore of the elongate suspension unit and the longitudinal axis of the elongate shaft is substantially perpendicular to the longitudinal axis of the rod.

The hoist spooling assembly can additionally include first and second spacer tubes. The first spacer tube can be configured to receive the first end portion of the elongate shaft, while the second spacer tube can be configured to receive the second end portion of the elongate shaft.

The hoist spooling assembly still further includes a roller coupled to and positioned between the distal portions of the first and second arms. The roller can be configured for engagement with the cable.

In an operative position of the hoist spooling assembly, the first end portion of the elongate shaft can extend through the first spacer tube and the opening of the first bushing such that at least a portion of the first end portion is positioned within the opening of the proximal portion of the first arm and the second end portion of the elongate shaft extends through the second spacer tube and the opening of the second bushing such that at least a portion of the second end portion is positioned within the opening of the proximal portion of the second arm. In the operative position, the proximal portion of the first arm can be configured for secure coupling to the first end portion of the elongate shaft, and the proximal portion of the second arm can be configured for secure coupling to the second end portion of the elongate shaft.

At least one of the described hoist spooling assemblies can be incorporated into a hoist spooling system including a cable and a drum. Methods of using the described hoist spooling assemblies and systems are also disclosed.

DETAILED DESCRIPTION

As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a rod” can include two or more such rods unless the context indicates otherwise.

As used herein, the terms “securely coupled” and “secure coupling” can optionally refer to elements that are rigidly coupled to one another or configured for rigid coupling to one another such that there is no relative movement between the elements.

Described herein with reference toFIGS. 1-6is a hoist spooling assembly10for spooling a cable200about a drum300. In exemplary aspects, the cable200can be a hoist cable, such as those used in conventional drilling operations. However, it is contemplated that the disclosed spooling assembly and spooling system can be used to spool any conventional cable and/or rope. In additional aspects, the drum300can be substantially cylindrical and can define an outer surface310. Optionally, it is contemplated that the outer surface310can be a grooved surface. For example, as shown inFIG. 6, the outer surface310can define a groove312that is configured to receive and retain the cable200, thereby reducing the occurrence of loops and kinks in the cable. In exemplary aspects, the groove312can be defined in a helical pattern on the outer surface310of the drum300such that the groove is a continuous groove extending from a first end of the hoist drum to a second, opposed end of the hoist drum. In yet another aspect, the groove312can have a groove diameter sized to correspond to a diameter of the cable200. For example, the groove diameter can be substantially equal to or slightly larger than the diameter of the cable200so that the cable can be positioned in the groove312. It is contemplated that the groove312can comprise at least one groove sidewall configured to separate one course of the groove from an adjacent course of the groove.

In one aspect, the groove312and/or the groove sidewall can position the cable200around the drum300in an orderly and/or repeatable manner. For example, the groove312and/or the groove sidewall can position a portion of the cable200around the drum300in a single layer of cable that is positioned in the groove. It is contemplated that the groove312can be further configured to prevent undesired movement of the cable200toward a center portion of the outer surface310of the drum300(as often occurs in known spooling systems). In exemplary aspects, it is contemplated that one or more of the disclosed hoist spooling assemblies10can be provided in the form of a hoist spooling system150, including the cable200as well as the drum300.

In one aspect, and with reference toFIGS. 1-4, the hoist spooling assembly10can comprise a frame20having a base portion22and first and second spaced support portions26a,26b. In this aspect, the base portion22can have a top surface23. In another aspect, the first and second support portions26a,26bcan extend upwardly from the top surface23of the base portion22. In this aspect, it is contemplated that the first and second support portions26a,26bcan define respective openings28a,28b. In exemplary aspects, the base portion22of the frame20can comprise first and second spaced braces24a,24bextending upwardly from the top surface23of the base portion. In these aspects, the first and second spaced braces24a,24bcan define respective openings25a,25b. It is contemplated that the frame20can provide structural rigidity for the mounting of the various components of the assembly10described herein. It is further contemplated that the frame20can be configured to support roller reaction forces. It is still further contemplated that the frame20can be configured to provide a mounting interface with a crown block installation, such as those crown block installations conventionally known in the art.

In an additional aspect, and with reference toFIGS. 1-4, the hoist spooling assembly10can comprise a rod30having a longitudinal axis32and opposed first and second ends34,36. In this aspect, it is contemplated that the first end34of the rod30can be configured for secure coupling to the base portion22of the frame20. In exemplary aspects, the first end34of the rod30can define a transverse opening35extending substantially perpendicular to the longitudinal axis32of the rod. In these aspects, the transverse opening35of the rod30can be configured for alignment with the openings25a,25bof the first and second braces24a,24bof the base portion22of the frame20. Optionally, as shown inFIGS. 1-4, the first end34of the rod30can have a substantially rounded shape.

In a further aspect, and with reference toFIGS. 2 and 4, the hoist spooling assembly10can further comprise first and second bushings40a,40b. In this aspect, the first and second bushings40a,40bcan be configured for receipt within the respective openings28a,28bof the first and second support portions26a,26bof the frame20. In exemplary aspects, the first and second bushings40a,40bcan define respective openings42a,42b. In these aspects, it is contemplated that the openings42a,42bof the bushings40a,40bcan optionally have a substantially rectangular shape. It is further contemplated that the openings42a,42bof the bushings40a,40bcan optionally have a substantially square shape.

As shown inFIGS. 1-4, in another aspect, the hoist spooling assembly10can further comprise first and second arms50a,50bhaving respective proximal portions52a,52band distal portions56a,56b. In this aspect, the proximal portions52a,52bof the first and second arms50a,50bcan define respective openings54a,54b. Optionally, the openings54a,54bof the proximal portions52a,52bcan have a shape substantially corresponding to the shapes of the openings42a,42bof the first and second bushings40a,40b. In another aspect, the distal portions56a,56bof the first and second arms50a,50bcan define respective openings58a,58b. Optionally, in exemplary aspects, the first and second arms50a,50bcan comprise respective lip portions59a,59bextending at least partially about the openings58a,58bof the first and second arms50a,50b. In these aspects, as shown inFIGS. 1-2, the lip portions59a,59bcan extend outwardly relative to an outer surface of the arms50a,50b.

In still another aspect, and as shown inFIGS. 1-4, the hoist spooling assembly10can further comprise an elongate suspension unit60defining a central bore62. In this aspect, it is contemplated that the bore62can have a substantially rectangular shape. It is further contemplated that the bore62can have a substantially square shape. In an exemplary aspect, the elongate suspension unit60can comprise an outer element64defining a central chamber65. In this aspect, the elongate suspension unit60can further comprise a at least one support element66positioned within the central chamber65. It is contemplated that the elongate suspension unit60can still further comprise an inner element68supported by the at least one support element66within the central chamber65. It is further contemplated that the inner element68can define the central bore62of the elongate suspension unit60. Optionally, it is contemplated that the at least one support element66can comprise a plurality of support elements spaced about the periphery of the inner element68. In exemplary aspects, the plurality of support elements66can comprise four spaced support elements, as shown inFIGS. 2 and 4. In other exemplary aspects, each support element66of the at least one support element can comprise a flexible and/or resilient material such that the support elements function as a spring. In other exemplary aspects, it is contemplated that the elongate suspension unit60can be a ROSTA rubber suspension unit system (ROSTA AG). However, it is contemplated that any known elongate suspension unit can be employed within the disclosed hoist spooling assembly10.

In an additional aspect, and with reference toFIGS. 1-4, the hoist spooling assembly10can further comprise a retainer70defining at least one opening72configured to receive at least a portion of the elongate suspension unit60. In exemplary aspects, the retainer70can be configured for adjustable coupling to the second end36of the rod30. In another aspect, the retainer70can comprise a platform74defining a slot76configured to receive the second end36of the rod30. In one exemplary aspect, as shown inFIG. 2, the retainer can comprise a pair of spaced retention arms78defining two respective openings72. In this aspect, the platform74can be secured to and span between the respective retention arms78. However, it is contemplated that the retainer70can have any configuration permitting receipt of the second end36of the rod30by the slot76of the platform74.

In a further aspect, and with reference toFIGS. 2 and 4, the hoist spooling assembly10can further comprise an elongate shaft80having a longitudinal axis82and opposed first and second end portions84,86. In this aspect, the elongate shaft80can be configured for receipt within the central bore62of the elongate suspension unit60such that the first and second end portions84,86of the elongate shaft extend from the central bore of the elongate suspension unit and the longitudinal axis82of the elongate shaft is substantially perpendicular to the longitudinal axis32of the rod30. Thus, it is contemplated that the elongate shaft80can have a substantially rectangular or substantially square cross-section. In exemplary aspects, the elongate shaft80can define a bore88extending substantially parallel to the longitudinal axis82of the elongate shaft.

As shown inFIGS. 1-4, and in still a further aspect, the hoist spooling assembly10can further comprise first and second spacer tubes90a,90b. In this aspect, it is contemplated that an opening92aof the first spacer tube90acan be configured to receive the first end portion84of the elongate shaft80, and an opening92bof the second spacer tube90bcan be configured to receive the second end portion86of the elongate shaft.

In another aspect, and with reference toFIGS. 1-6, the hoist spooling assembly10can further comprise a roller100securely coupled to and positioned between the distal portions56a,56bof the first and second arms50a,50b. In this aspect, it is contemplated that the roller100can be configured for engagement with the cable200. Optionally, in exemplary aspects, the roller100can be a one-piece roller. In these aspects, it is contemplated that the one-piece roller can eliminate the problem of the cable200getting caught in gaps defined by the roller, as commonly occurred within two- or three-piece rollers known in the art. In exemplary aspects, the roller100can comprise a material having a relatively high stiffness, such as, for example and without limitation, Nylatron® GSM nylon (Professional Plastics, Inc.). In an additional aspect, the roller100can define a bore101configured to receive a roller shaft102. In this aspect, the roller shaft102can have first and second end portions104a,104b. It is contemplated that, upon positioning of the roller shaft102within the bore101, the first and second end portions104a,104bof the shaft can be configured to extend from the roller100, as shown inFIG. 4. It is further contemplated that the first and second end portions104a,104bcan have a reduced outer diameter relative to the remaining portions of the shaft102.

It is contemplated that various known fasteners and coupling mechanisms can be used to adjustably secure the components of the hoist spooling assembly10in an operative position. For example, a known fastener and/or coupling mechanism can be used to operatively couple: (a) the elongate shaft80to the first and second arms50a,50b; (b) the shaft102of the roller100to the first and second arms50a,50b; (c) the base portion22of the frame20to the rod30; and (d) the rod30to the retainer70.

In one exemplary aspect, as shown inFIGS. 2 and 4, the hoist spooling assembly10can comprise a torque nut120configured to adjustably couple the second end36of the rod30to the retainer70. In exemplary aspects, after the second end36of the rod30is passed through the slot76defined by the platform74of the retainer70, the torque nut120can be configured for threaded engagement with the second end of the rod and further configured for advancement toward the platform of the retainer. In additional exemplary aspects, the torque nut120can be a ⅝″-11 UNC 3B nyloc lock nut. Optionally, the hoist spooling assembly10can further comprise a washer122configured for positioning on the rod30such that the washer is positioned between the torque nut120and the platform74of the retainer. It is contemplated that the washer122can have an outer diameter that is greater than a width of the slot76of the platform74. In exemplary aspects, the washer122can be a ⅝ GR 8 flat washer. It is further contemplated that washer122can be configured to cover the slot76of the retainer70and provide a flat mating surface for the torque nut120. In use, it is contemplated that the torque nut120can be configured to adjustably apply a torsional force to the suspension unit60and/or the elongate shaft80through the retainer70. More specifically, it is contemplated that the torque nut120can be configured to selectively apply torque to the support elements66of the suspension unit60, thereby adjusting the flexion of the support elements of the suspension unit.

In another exemplary aspect, the hoist spooling assembly10can further comprise a pin110configured to securely couple the first end34of the rod30to the frame20. In this aspect, it is contemplated that, in the operative position, the first end34of the rod30can be positioned between the first and second braces24a,24b, and the transverse opening35of the rod and the openings25a,25bof the first and second braces can be configured to receive the pin110. In exemplary aspects, the pin110can be a shoulder bolt, such as, for example and without limitation, a ⅝-13 UNC shoulder bolt having a length of about 0.5 inches. Optionally, the hoist spooling assembly10can further comprise a washer112and a nut114positioned thereon a portion of the pin110extending from the opening25bof the second brace24b. It is contemplated that the washer112can be positioned on the pin110in between the nut114and the second brace24b, with the nut being configured for threaded engagement with the exposed end portion of the pin. In exemplary aspects, the washer112can be a ½″ GR 8 flat washer, and the nut114can be a ½″-13 UNC 3B hex nut.

In a further exemplary aspect, the hoist spooling assembly10can further comprise first and second bolts130a,130bconfigured for insertion within the bore88of the elongate shaft80. In this aspect, the first bolt130acan be configured for insertion within the first end portion84of the shaft80, and the second bolt130bcan be configured for insertion within the second end portion86of the shaft. In exemplary aspects, the first and second bolts130a,130bcan be hex head cap screws, such as, for example and without limitation, ¾-10 UNC GR8 hex head cap screws with a length of about 1.5 inches. Optionally, it is contemplated that the hoist spooling assembly10can further comprise first and second washers132a,132bthat are configured for positioning between the first and second bolts130a,130band the proximal portions52a,52bof the first and second arms50a,50b. In exemplary aspects, the first and second washers132a,132bcan be ¾″ fender washers.

In still another exemplary aspect, the hoist spooling assembly10can further comprise first and second nuts140a,140bconfigured for engagement with the first and second end portions104a,104bof the shaft102of the roller100. In this aspect, as shown inFIG. 2, it is contemplated that the first and second end portions104a,104bof the shaft102can be configured to extend through the openings58a,58bof the distal portions56a,56bof the first and second arms50a,50b. In exemplary aspects, the first and second nuts140a,140bcan be nyloc nuts. Optionally, it is further contemplated that the hoist spooling assembly10can further comprise first and second washers142a,142bthat are configured for positioning between the first and second nuts140a,140band the distal portions56a,56bof the first and second arms50a,50b.

In the operative position of the hoist spooling assembly10, it is contemplated that the first end portion84of the elongate shaft80can extend through the opening92aof the first spacer tube90aand the opening42aof the first bushing40asuch that at least a portion of the first end portion is positioned within the opening54aof the proximal portion52aof the first arm50a, and the second end portion86of the elongate shaft can extend through the opening92bof the second spacer tube90band the opening42bof the second bushing40bsuch that at least a portion of the second end portion is positioned within the opening54bof the proximal portion52bof the second arm50b. In the operative position, it is further contemplated that the proximal portion52aof the first arm50acan be configured for secure coupling to the first end portion84of the elongate shaft, and the proximal portion52bof the second arm50bcan be configured for secure coupling to the second end portion86of the elongate shaft80. In the operative position, it is still further contemplated that the proximal portion52aof the first arm50acan be rigidly secured to the first end portion84of the elongate shaft80, and the proximal portion52bof the second arm50bcan be rigidly secured to the second end portion86of the elongate shaft. It is contemplated that the rigid engagement between the first and second arms50a,50band the elongate shaft80can overcome the inherent compliance of the suspension unit60to provide for improved delivery of force throughout the assembly (and to a cable). In the operative position, it is still further contemplated that the first and second bushings40a,40bcan be positioned within the first and second openings28a,28bof the first and second support portions26a,26bof the frame20.

In operation, it is contemplated that the retainer70can be configured to transform axial clamping forces of the torque nut120into a moment that is applied to the suspension unit60. It is contemplated that the suspension unit60can undergo an angular deflection in response to the torque transferred by the retainer70. It is further contemplated that the retainer70can be configured to retain a desired torsion force on the suspension unit60by preventing movement of the suspension unit such that the suspension unit maintains a deflected position. It is still further contemplated that the reaction forces within the suspension unit60can be configured to transmit torque to the elongate shaft80. The elongate shaft80, in turn, can be configured to transmit the torque from the suspension unit80to the first and second arms50a,50band, ultimately, to the cable200.

In operation, the first and second spacer tubes90a,90bcan be configured to restrict lateral movement of the suspension unit60while also retaining the first and second bushings40a,40bin engagement with (or proximate thereto) the first and second support portions26a,26bof the frame20. It is contemplated that the first and second bushings40a,40bcan provide support for the elongate shaft80while also permitting adjustable articulation of the first and second arms50a,50b. It is further contemplated that the first and second arms50a,50bcan be configured to transmit the torque from the elongate shaft80to the shaft102of the roller100, and the shaft102can be configured to transmit the torque to the roller itself. It is still further contemplated that the washers132a,132bcan be configured to ensure that the first and second arms50a,50bremain in substantially constant contact with the elongate shaft80at all times by preventing the elongate shaft from shifting out of position. It is still further contemplated that the washers132a,132bcan be configured to cover at least a portion of openings54a,54b, thereby providing a flat surface for fastening first and second bolts130a,130b. The first and second bolts130a,130bcan be configured to provide a clamping force sufficient to retain the first and second arms50a,50bin engagement with the frame20while locking the elongate shaft80in a desired position.

In operation, the first end34of the rod30can be configured for pivotal rotation about the pin110as the suspension unit60is deflected. It is contemplated that the pin110can be configured to act such that the longitudinal axis32of the rod30remains substantially perpendicular to the top and bottom surfaces of the platform74of the retainer70throughout its range of pivotal motion. It is further contemplated that the nut114can be configured to retain the pin110in engagement with a portion of the frame20, such as, for example and without limitation, braces24a,24b.

In operation, the torque nut120can be configured to permit an operator to adjustably apply a selected level of torsion force to the suspension unit60while also ensuring that the energy stored in the suspension unit is not released. It is further contemplated that the torque nut120can permit ergonomic adjustment of the level of torque applied to the suspension unit60.

In operation, the roller100can be configured to transmit the radial force to the cable200that is spooled on the drum300. It is contemplated that the roller can be configured to reduce the wear and frictional forces applied to the cable200, thereby allowing the cable to be unwound from the drum with minimal kink and/or loop formation. It is further contemplated that the shaft102of the roller100can act as an axle upon which the roller rotates. It is still further contemplated that the shaft102can effectively join the first and second arms50a,50btogether such that the force is evenly applied to the cable200.

In exemplary aspects, the hoist spooling system150can comprise conventional processing means400for effecting selective positioning of the at least one hoist spooling assembly10relative to the outer surface310of the drum300. In these aspects, it is contemplated that the processing means400can comprise, for example and without limitation, a processor in communication with a memory and a user interface. It is further contemplated that the processing means400can be in operative communication with each hoist spooling assembly10of the hoist spooling system150.

In exemplary aspects, as shown inFIG. 5, the at least one hoist spooling assembly10of the hoist spooling system150can comprise a plurality of hoist spooling assemblies. In these aspects, it is contemplated that the plurality of hoist spooling assemblies can comprise three hoist spooling assemblies. It is further contemplated that the plurality of hoist spooling assemblies can be substantially equally spaced about the outer surface310of the drum300. In various aspects, it is contemplated that a first spooling assembly of the plurality of spooling assemblies10can be positioned proximate a location where the cable200makes initial contact with the outer surface310of the drum300. In these aspects, it is contemplated that the placement of the first spooling assembly in this location can ensure that slack within the cable200is present in the relatively straight portion of the cable (before the cable contacts the drum) rather than in the curved portion of the cable (around the drum). In additional aspects, the roller100of each hoist spooling assembly10of the system150can be configured to press the cable200against the outer surface310of the drum300, thereby increasing frictional engagement between the cable and the outer surface of the drum and limiting undesired movement of the cable.

In exemplary aspects, it is contemplated that the hoist spooling assembly10and/or the hoist spooling system150can be configured for operation with a hoist limiting system, such as the hoist limiting system described in co-pending U.S. patent application Ser. No. 13/718,026, filed on Dec. 18, 2012 and entitled “Hoist Limiting Systems and Methods,” which is incorporated by reference herein in its entirety.

In use, and with reference toFIGS. 1-6, the disclosed assemblies10and systems150can be employed in a method of spooling the cable about the drum. In one aspect, the method can comprise positioning the cable in engagement with the outer surface of the drum. In another aspect, the method can comprise operatively positioning at least one spooling assembly relative to the cable and the drum.