System and method for remote operation of a closed mouth power tong to make up and break out tubing on a well servicing rig

A system and method for mounting a Closed-Mouth Power Tong on a Well Servicing Rig in order is disclosed. The power tong can be operated remotely when making up or breaking out connections on oilfield tubing. The system utilizes an assembly that can lift and lower the tong to the appropriate height as required to engage the threads on the tubing. The assembly is connected to the blowout preventer or wellhead with a quick connect system that is adjustable for various angles so that the tong can be utilized in various positions to run tubing into, or out from, the well center unhindered.

TECHNICAL FIELD OF THE INVENTION

The present disclosure is related to the field of power tongs for running tubing strings into and out of a well, in particular, systems for remotely operating and positioning power tongs.

BACKGROUND OF THE INVENTION

A typical Well Servicing Rig, as defined herein, can utilize a four-man crew when running a tubing string into a well or pulling it out. The crew can comprise of one rig operator, one derrickman, and two floormen, although the exact number of personnel can vary depending on the well and type of rig used. The rig operator typically operates the controls for hoisting the entire string as well as single or double joint stands. The derrickman typically handles the top end of the stand in the derrick or works on the ground to handle single joints when picking up or laying down. Normally, one floorman handles the bottom end of the stands as they are being picked up or set back, and the second floorman operates a hydraulic power tong to connect or disconnect the threaded joints.

It is, therefore, desirable to provide a system and method that enables the remote operation of a power tong that is safer, easier and less strenuous for personnel to operate on a Well Servicing Rig.

SUMMARY OF THE INVENTION

A system and method for mounting, positioning and remotely operating a power tong is provided. For the purposes of this specification and the claims that follow, the following terms shall be defined as:

TOPS—means a tong operating and positioning system.

Well Servicing Rig—can comprise one or more of a workover rig, a completion rig, a well service rig, a drillout rig, and any other rig used to service an oil and gas well post-drilling operation as well known to those skilled in the art.

Closed-Mouth Power Tong—can comprise one or more of a closed-face tong, a closed-mouth tong, a full circle tong, any tong that is not considered to be “open-faced” by those skilled in the art, and any tong designed to stay on well-center while moving tubulars in or out of a well-hole by those skilled in the art.

Slips—can comprise one or more of hydraulically-operated slips, pneumatically-operated slips (either by air or by other gases), and hand-operated slips, as well known to those skilled in the art.

Tubing String—any tubulars used in conjunction with Well Servicing Rig operations, as well known to those skilled in the art.

The system can be mounted on the wellhead or wellhead equipment to enable the power tong to be centralized on the well when in operation. In some embodiments, the system can comprise a remote-control panel that can allow the equipment to be operated from a remote position. In some embodiments, the remote-control panel can allow the system to be operated by the rig operator. In some embodiments, the system can be operated by another person from a remote position. In some embodiments, the system can comprise controls for all functions locally so that it can be operated locally.

In some embodiments, the remote-controls can be configured to position the tong vertically, engage and disengage the tubing backup, function the tong in forward and reverse, and shift the tong between high and low gear. In addition to the remote tong controls, the remote-control panel can comprise a lockable isolation valve that can allow the equipment to be de-energized prior to working on it.

In some embodiments, the system can comprise a mounting adapter flange that can be bolted to the blowout preventer or other wellhead equipment. The system can be attached to the adapter flange quickly by fitting the base assembly onto the adapter plate and attaching turnbuckles. The system can be rotated to any desired position by rotating the floating load ring to align with the turnbuckles. The base assembly is designed in such a way that wellhead equipment, for example, a tubing stripper, can be installed above the mounting adapter flange if desired.

In some embodiments, the base assembly can comprise a housing that can accept the base of a tong hoisting mast. The hoisting mast can be rotated in the housing in order to swing the tong away from well center when operations require it, and to be swung in line with well center for tubing operations. The tong hoisting mast can raise and lower a trolley that comprises guide rollers that can interface with the mast and a tong attachment mechanism. A tubing tong that can comprise a tubing backup can be attached to the tong attachment mechanism, which can allow the tong to float as the tubing is being threaded together unthreaded, such as the case may be. The tong attachment mechanism can comprise a threaded compensation mechanism that can raise or lower the tong relative to the trolley as a means to fine-tune the vertical position of the tong relative to the trolley.

Method of Operation

In some embodiments, a method for mounting, operating, dismounting and transporting the system can be described as follows.

Installation

In some embodiments, a method of installation can comprise the following steps:

1. Install the mounting adapter flange on top of blowout preventer or wellhead component.

2. Pick up the mounting base configured for transport and set on top of mounting adaptor flange at the desired angle.

3. Rotate the floating load ring to align the connecting tabs with the turnbuckles on the mounting base.

4. Connect turnbuckles on the mounting base to the connecting tabs on the floating load ring and tighten.

5. Lower stabilizing jacks on mounting base.

6. Pick up hoisting mast and insert the base into the housing on the mounting base.

7. Insert mast retaining pin on mast base.

8. Insert pin that connects the tong attachment mechanism on the travelling trolley to the tong.

9. Connect service loop to control panel.

10. Remove retaining pin from the travelling trolley.

11. Remove tong hold down threaded handle and tie down strap.

12. Energize the hydraulic circuit and the control circuit.

13. Raise tong and swing away from hole center.

14. Remove the transport adapter.

15. Remove slips hold down threaded handle.

16. Move slips to hole center and Connect air lines to slips.

17. Swing tong back to hole center and insert retention pin.

Operation—Making Up a Tubing String

In some embodiments, a method to make up a tubing string and run it into a well can comprise the following steps:

1. Lower the tong to a point just above the slips.

2. Lower the tubing through the tong until the elevators are just above the tong.

3. Close the slips.

4. Open the elevators.

5. Raise the elevators to pick up the next joint of tubing.

6. Insert the next joint of tubing into the tubing that is in the well.

7. Vertically align the tong to straddle the tubing connection.

8. Shift the tubing backup control to remote-control.

9. Shift the tong transmission into high gear.

10. Engage the tubing backup.

11. Rotate the tong in the forward direction until it stalls.

12. Shift the tong into low gear.

13. Rotate the tong in the forward direction until proper torque is achieved.

14. Rotate the tong in the reverse direction to release the tong.

16. Raise the elevators until the slips can be opened.

17. Open the slips.

18. Repeat previous steps as necessary.

Operation—Breaking Out the Tubing String

In some embodiments, a method for breaking out the tubing string and removing it from the well can comprise the following steps:

1. Lower the tong to a point just above the slips.

2. Lower the elevators to just above the tong.

3. Close the elevators.

4. Raise the elevators.

5. Open the slips.

6. Stop the elevators when the tubing connection is above the tong.

7. Close the slips.

8. Vertically align the tong to straddle the tubing connection.

9. Shift the tubing backup control to remote-control.

10. Shift the tong transmission into low gear.

11. Engage the tubing backup.

12. Rotate the tong in the reverse direction until it rotates freely.

13. Shift the tong into high gear.

14. Rotate the tong in the reverse direction until the connection has been fully disconnected.

15. Rotate the tong in the forward direction to release the tong.

17. Raise the elevators until the joint of tubing can be removed.

18. Repeat the previous steps as necessary.

In some embodiments, a method for disassembling the system can comprise the following steps:

1. Raise tong and swing away from hole center.

2. Disconnect air lines to slips.

3. Move slips to transport position.

4. Install slips hold down threaded handle.

5. Install the transport adapter.

6. Swing tong back to hole center and insert retention pin.

7. Lower the tong until it is supported by the transport adapter.

8. De-energize the hydraulic circuit and the control circuit.

9. Install the tong hold down threaded handle and tie down strap.

10. Install the retaining pin in the travelling trolley.

11. Disconnect service loop from control panel.

12. Remove the pin that connects the tong attachment mechanism on the travelling trolley to the tong.

13. Remove the mast retaining pin on mast base.

14. Remove the hoisting mast from the housing on the mounting base.

15. Support the mounting base with a winch.

16. Raise stabilizing jacks on mounting base.

17. Loosen the turnbuckles on the mounting base and disconnect from the connecting tabs on the floating load ring.

18. Pick up the mounting base configured for transport and set on top of trailer or transport truck.

19. The mounting adapter flange on top of blowout preventer or wellhead component may be removed or left in place if the system is going to be used on the next well.

Broadly stated, in some embodiments, a system can be provided for positioning and operating a tong for inserting a tubing string into a wellbore and removing the tubing string from the wellbore, the wellbore comprising a wellhead, the system comprising: a mounting base configured for mounting on the wellhead; a hoisting mast disposed on the mounting base; a trolley disposed on the hoisting mast, the trolley configured to move up and down on the hoisting mast; a tong attachment mechanism disposed on the trolley, the tong attachment mechanism configured to attach the tong to the trolley; and a hoisting mechanism configured for raising and lowering the trolley on the hoisting mast.

Broadly stated, in some embodiments, the system can further comprise a mounting adaptor flange configured for attaching the mounting base to the wellhead.

Broadly stated, in some embodiments, the mounting adaptor flange can be configured for attaching the mounting base to a blow-out preventer disposed on the wellhead.

Broadly stated, in some embodiments, the trolley can comprise a plurality of rollers rotatably disposed within rail channels disposed along the hoisting mast.

Broadly stated, in some embodiments, the tong attachment mechanism can be configured for raising and lowering the tong relative to the trolley when the tong is attached to the tong attachment mechanism.

Broadly stated, in some embodiments, the tong attachment mechanism can comprise a spring-loaded mechanism configured for vertical movement of the tong when the tubing string is being threaded together or unthreaded, and then return the tong to a nominal fixed position.

Broadly stated, in some embodiments, the hoisting mechanism can comprise: a linear actuator comprising a first end thereof operatively attached to the hoisting mast and a second end thereof comprising a pulley; and a cable comprising one end thereof operatively attached to a base of the hoisting mast and a second end thereof operatively attached to the trolley, the cable passing over the pulley, wherein extending or retracting the linear attenuator raises or lowers the pulley therein raising or lowering the trolley.

Broadly stated, in some embodiments, the hoisting mechanism can comprise: a double-ended linear actuator comprising an inner rod comprising one end thereof operatively coupled to a base of the hoisting mast and a second end thereof operatively coupled to an apex of the hoisting mast; and the double-ended linear actuator comprising an outer cylinder disposed around the inner rod, the outer cylinder operatively coupled to the trolley, wherein raising or lower the outer cylinder on the inner rod raises or lowers the trolley.

Broadly stated, in some embodiments, the hoisting mechanism can comprise: a roller chain disposed between an apex and a base of the hoisting mast; a motor disposed on the trolley, the motor comprising a drive sprocket operatively engaged with the roller chain; and at least one idler sprocket disposed on the trolley, the roller chain operatively engaged with the at least one idler sprocket, wherein operating the motor raises or lowers the trolley on the hoisting mast.

Broadly stated, in some embodiments, the hoisting mechanism can comprise: a winch disposed on the trolley or on a base of the hoisting mast; at least one idler pulley disposed at an apex of the hoisting mast; and a cable comprising a first end thereof operatively attached to the trolley and a second end thereof operatively attached to the winch, the cable passing over the at least one idler pulley between the first end and the second end, wherein reeling in or paying out the cable with the winch raises or lowers the trolley on the hoisting mast.

Broadly stated, in some embodiments, the system can further comprise a pivot mechanism configured to move the tong towards and away from a position disposed over the wellbore.

Broadly stated, in some embodiments, the system can further comprise a remote-control panel operatively coupled to the tong, wherein the remote-control panel is configured to transmit control signals to the tong whereby the tong can be operated and positioned from a location remote from the wellbore.

Broadly stated, in some embodiments, the control signals can comprise one or more of pneumatically transmitted control signals, hydraulically transmitted control signals, electrically transmitted control signals and wirelessly transmitted radio control signals.

Broadly stated, in some embodiments, a method is provided for positioning and operating a tong for inserting a tubing string into a wellbore, the wellbore comprising a wellhead, the method comprising the steps of: providing a system as set forth above; mounting the system on the wellhead; lowering a first tubing string through the tong and closing slips to hold the first tubing string in place; inserting a second tubing string into the first tubing string; operating the tong to make up a joint between the first tubing string and the second tubing string; and raising the tubing strings and opening the slips.

Broadly stated, in some embodiments, the method can further comprise the steps of: raising the joint above the tong; closing the slips; aligning the tong with the joint; operating the tong to break the joint between the first tubing string and the second tubing string; and removing the second tubing string from wellbore.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring toFIG. 1, an isometric view of one embodiment of tong operating and positioning system (“TOPS”)100is shown with a tubing joint made up of upper tubing joint53connected to lower tubing joint55via tubing coupler54. In some embodiments, a Closed-Mouth tubing tong (as provided by third party manufacturers as well known to those skilled in the art), designated by reference numeral1, can be connected to tong attachment mechanism4that can be carried by trolley3. In some embodiments, trolley3can comprise rollers that are disposed within a track on hoisting mast2. Hoisting mast2can comprise a mechanism that can be used to raise and lower the trolley3and, thus, tong1along hoisting mast2. In some embodiments, hoisting mast2can be rotatably connected to mounting base5so that it can be in position to hold tong1directly over the center of the well, or it can be turned to move tong1away to provide direct access to the well. In some embodiments, mounting base5can be configured to attach to mounting adapter flange6that, in turn, can be bolted to the blowout preventer or wellhead equipment located on the well. In some embodiments, mounting base5can be configured to have other equipment, designated as reference numeral9, attached thereon. Such other equipment can include a tubing stripper or slips as well as other equipment as well known by those skilled in the art. In some embodiments, tong1can be controlled remotely from remote-control panel7that can communicate with, and control the functions of, tong1through service loop8. In some embodiments, service loop8can comprise one or more of pneumatic, hydraulic, electronic and wireless control connections to operate tong1, depending on the control requirements of tong1.

FIGS. 2A, 2B and 2Cshows side, top and front views, respectively, of one embodiment of TOPS system100. In the illustrated embodiment, tong1can be configured or modified by having actuator10attached thereto, wherein actuator10can shift a transmission disposed on tong1between low and high gear by moving shift lever11. In some embodiments, TOPS system100can comprise actuators12operatively coupled to hydraulic controls13. In some embodiments, the hydraulic controls of tong1can be activated manually, or remotely from remote-control panel7that can communicate with the actuators through service loop8. In some embodiments, tong1can be connected to tong attachment mechanism4with pin14. In some embodiments, tong attachment mechanism4can comprise of spring15disposed within housing16such that tong attachment mechanism4can provide a spring-loaded mechanism that can allow tong1to move vertically in relation to integrated backup17as tubing is threaded together or unthreaded, and then return tong1to a nominal fixed position. In some embodiments, tong attachment mechanism4can comprise threaded means for raising or lowering tong1relative to trolley3. In some embodiments, tong attachment mechanism4can be mounted to trolley3that can move vertically on hoisting mast2by hoisting system18. In some embodiments, trolley3can be guided by rollers19that are disposed within the rails of hoisting mast2. In some embodiments, tong can be held in line with hoisting mast2with torque guide bracket20that can be attached to tong1and can protrude past the edges of hoisting mast2. In some embodiments, TOPS system100can comprise a pivot mechanism. In some embodiments, the bottom of hoisting mast2can be cylindrical in shape (cylindrical section34shown inFIGS. 5A and 5B) and can fit within round housing21that can be part of, or integral to, mounting base5. In some embodiments, hoisting mast2can be rotated as desired and held in place at specified increments with pin22passing corresponding openings disposed through cylindrical section34. In some embodiments, mast base5can be clamped to mounting adaptor flange6and can be further held in place with turnbuckles23. In some embodiments, mounting base5can comprise stabilization jacks24to stabilize the mechanism.

FIG. 3shows a section view of one embodiment of mounting base assembly5and mounting adaptor flange6of TOPS system100. In some embodiments, mounting adaptor flange6can comprise floating load ring25that can be held in place by retainer26. In some embodiments, floating load ring25can be rotated in relation to mounting adapter flange6in order to align connecting tabs27with turnbuckles23that are attached to mounting base5.

FIGS. 4A and 4Bshow front and side views of one embodiments of tong1and mounting base5when configured for transport. In some embodiments, tong1can be supported by transport adapter28and fixed stand29that can be integral to mounting base5. In some embodiments, tong1can be clamped to transport adapter28with threaded handle30. In some embodiments, transport stands31can be lowered and held in place by pin32to make the load sit level while being transported. In some embodiments, mounting base5can be used to hold slips9to keep them from moving during transport.

FIGS. 5A and 5Bshows side and rear views of one embodiment of tong hoisting mast2when in transport mode. In some embodiments, hoisting mast2can be removed from mounting base5(not shown) by removing pin33and separating cylindrical section34of hoisting mast2from the housing on the mounting base. In some embodiments, trolley3can be immobilized by inserting pin35through an opening disposed therethrough.

FIG. 6shows a side view of one embodiment of the hoisting mechanism that utilizes linear actuator36and cable sling disposed in hoisting mast2. In some embodiments, linear actuator36can support pulley38that can be guided between the rails of hoisting mast2. In some embodiments, cable sling37can be anchored at one end to the base of hoisting mast2and, at the other end, to movable trolley3with pins39. In some embodiments, movable trolley3can move vertically along hoisting mast2as linear actuator36is extended or retracted. In some embodiments, linear actuator36can comprise a hydraulic ram wherein extending or retracting linear actuator36can be accomplished by controlling the flow of hydraulic fluid to or from linear actuator36.

FIG. 7shows a side view of a second embodiment of the hoisting mechanism that can utilize double-ended linear actuator40disposed in hoisting mast2. In some embodiments, the outer cylinder body of linear actuator40can be connected directly to movable trolley3with pin39, with the ends of an inner rod of linear actuator40attached to the base and the top or apex of hoisting mast assembly2with pins39. In some embodiments, movable trolley3can move vertically along hoisting mast2as the cylinder body of linear actuator40is moved up or down along the inner rod of linear actuator40. In some embodiments, linear actuator40can comprise a hydraulic mechanism wherein moving linear actuator40can be accomplished by controlling the flow of hydraulic fluid to and from linear actuator40.

FIG. 8shows a side view of a third embodiment of the hoisting mechanism that can utilize motor41and roller chain42disposed on hoisting mast2. In some embodiments, roller chain42can be attached to the base and the top of hoisting mast2with pins39. In some embodiments, roller chain42can be routed around idler sprockets43and around a sprocket disposed on motor41, wherein motor41and idler sprockets43are mounted on movable trolley3. As motor41rotates, it can cause movable trolley3to move vertically up or down along the rails of hoisting mast2.

FIGS. 9A and 9Bshow a side view of fourth and fifth embodiments of the hoisting mechanism that can utilize winch44and cable45disposed on hoisting mast2. In some embodiments, winch44can be mounted to movable trolley3as shown inFIG. 9Aor, alternatively, to the base of hoisting mast2, as shown inFIG. 9B. In some embodiments, cable45can be routed over idler pulleys46and attached to movable trolley3with pin39. As cable45is reeled in or paid out by winch44, movable trolley3can move vertically up or down along the rails of hoisting mast2.

FIG. 10shows a front view of one embodiment of remote-control panel7that can house a circuit and controls that can allow tong1to be operated locally or remotely. In some embodiments, control panel7can comprise energize control47that can be used to energize or de-energize the remote-control system. In some embodiments, control panel7can comprise backup select control48that can allow the remote operator to control whether the tubing backup will be operated remotely with control panel7or locally on tong1. In some embodiments, control panel7can comprise tong backup control49that can allow the remote operator to control the tubing backup function of tong1remotely from control panel7. In some embodiments, control panel7can comprise three-way range select control50that can allow the remote operator to select high range or low range on the transmission of tong1, or to allow control of the transmission to be locally selected. In some embodiments, control panel7can comprise tong spin proportional control51that can allow the remote operator to control the speed and direction of the operation of tong1. In some embodiments, control panel7can comprise tong adjust proportional control52that can allow the remote operator to control the direction and speed of the vertical movement of TOPS system100to move tong1.

Referring toFIG. 11A, a side elevation view depicting TOPS system100ofFIG. 1is shown in the lowered position to allow the addition or removal of a joint of tubing53to or from lower tubing joint55. In the illustrated embodiment, tong1is shown at a lowered position relative to tubing coupler54to allow upper tubing53to be inserted into, or removed from, tubing coupler54, as the current operation requires. Lower tubing joint55is being held in place and centralized by slips9.

Referring toFIG. 11B, a side elevation view depicting TOPS system100ofFIG. 1is shown in the process of either threading together or unthreading a connection by rotating upper tubing joint53in relation to tubing coupler54. In the illustrated embodiment, tong1is shown at a position relative to tubing coupling54to allow upper tubing joint53to be rotated with tong1while lower tubing joint55or tubing coupling54is held in place by tubing backup17. Lower tubing joint55is being held in place and centralized by slips9.