Deconstructable coiled tubing spool and method of shipping same

A deconstructable coiled tubing spool is disclosed and includes one or more flange segments, and a core comprising a flange portion that is adapted to couple and decouple from each of the one or more flange segments, wherein the core remains intact when the one or more flange segments are decoupled from the flange portion. One or more of the deconstructable coiled tubing spools can be deconstructed and stored in a standard shipping container for shipment.

BACKGROUND

Field

Embodiments of the disclosure generally relate to a spool for coiled tubing, more specifically, to a spool that may be deconstructed for shipping after the coiled tubing is removed.

Description of the Related Art

In the oil and gas industry, coned tubing, which is generally a very long metal pipe, is supplied and shipped around the world on a large spool consisting of a core surrounded by a flange on both sides of the core. The coned tubing, normally about 1 inch in diameter to about 3.25 inch in diameter, may be used for interventions in oil and gas wells, pipelines, and sometimes as production tubing.

When the coiled tubing is removed from the spool, the empty spool is usually scrapped because shipping the empty spool back to the supplier for reuse is cost prohibitive. Most conventional spools are heavy and large, having a height between about 100 inches and about 204 inches based on the flange diameter. When supplied overseas, the size of the empty spools requires shipment on a deck of a ship, in which individual spools are loaded and unloaded using a crane, and the spools take up a large footprint on the deck of the ship, all of which increases the shipping cost of the empty spools.

Therefore, there exists a need for a spool that can be reused and shipped more efficiently.

SUMMARY

In one embodiment, a deconstructable coiled tubing spool is disclosed and includes a core having a curved outer surface; and a plurality of flange segments each having a first structural member coupled to the curved outer surface of the core, wherein the core remains intact when the flange segments are decoupled from the core.

In one embodiment, a deconstructable coiled tubing spool is disclosed and includes one or more flange segments, and a core comprising a flange portion that is adapted to couple and decouple from each of the one or more flange segments, wherein the core remains intact when the one or more flange segments are decoupled from the flange portion.

In one embodiment, a standard intermodal shipping container is disclosed and includes an interior volume containing one, two, three, four, five, six, seven, or more deconstructable coiled tubing spools, each of the spools comprising an intact core and at least four flange segments.

In one embodiment, a method for deconstructing a coiled tubing spool is disclosed and includes (a) detaching four flange segments from each side of a core by removing a plurality of fasteners disposed in a bolt interface at an intersection between a flange portion of the core and an end of each of the flange segments.

DETAILED DESCRIPTION

FIGS. 1A and 1Bare schematic views of a deconstructable spool100according to one embodiment.FIG. 1Ais a side elevation view of the deconstructable spool100andFIG. 1Bis a front elevation view of the deconstructable spool100. InFIGS. 1A and 1B, the deconstructable spool100is shown intact but without any coiled tubing spooled onto the deconstructable spool100.

The deconstructable spool100includes two flanges105that are coupled to opposite ends of a core110. The core110may be a hollow tubular member having an opening into an interior volume on at least one side of the core110. As shown inFIG. 1B, a space115between an outer surface of the core110and interior surfaces of the flanges105would generally be occupied with coiled tubing (not shown) that is spooled around the core110, and subsequently reeled-off and used leaving the deconstructable spool100intact as shown.

The deconstructable spool100may include a major dimension120(a height or width, depending on the perspective, or a diameter of the flanges105) of about 100 inches to about 204 inches. A diameter125of the core110may be between about 50 inches and about 80 inches. In some embodiments, the diameter125of the core110is constant while the diameter of the flanges105(the major dimension120) may vary to accommodate different capacities of the deconstructable spool100.

For example, the major dimension120may be changed to accommodate coiled tubing having a larger diameter and/or coiled tubing of different lengths without modifying the core110. Other dimensions of the deconstructable spool100include a flange width130and a flange-to-flange outside dimension135as well as a flange-to-flange inside dimension140. In one embodiment, the flange-to-flange inside dimension140is about 78 inches and the flange width130is about 5 inches which makes the flange-to-flange outside dimension135about 88 inches.

In one embodiment, the deconstructable spool100may be dismantled along the dashed lines shown inFIG. 1Ato fit within a standard intermodal shipping container (shown inFIGS. 5A-5C). The deconstructable spool100, once dismantled according to the embodiments described herein, may fit easily within the shipping container with the core110intact. Upon delivery of the dismantled deconstructable spool100, the deconstructable spool100may be reconstructed for another use.

Referring toFIG. 1A, each of the flanges105(only one is shown inFIG. 1Abut the other may be configured similarly) include four flange segments145A-145D that are detachable and separable from a flange portion150of the core110using fasteners. Although four flange segments145A-145D are shown, one or both of the flanges105may be formed out of two or more flange segments. The flange portions150of the core110may be coupled, such as by welding or fasteners, to the opposite ends of the hollow tubular member forming the core110. In one embodiment, the flange portions150of the core110may be rectangular plates. The core110may remain intact when the flange segments145A-145D are coupled to and decoupled from the flange portions150of the core110.

Each of the flange segments145A-145D, as well as the flange portion150, include dimensions that easily fit within the volume of a shipping container when dismantled. For example, when the major dimension120is about 170 inches, the flange segments145A-145D include a depth dimension155of about 43 inches, and a first length dimension160or a second length dimension165. The first length dimension160may be about 140 inches and the second length dimension165may be about 84 inches, which is less than the first length dimension160. The second length dimension165may be equal to the dimensions of sides170of the flange portion150. In some embodiments, intersections of the dashed lines in the flange segments145A-145D may form corner sections175that may not be included in some embodiments, thus making the second length dimension165substantially equal for all flange segments145A-145D.

FIG. 2is a schematic side view of one embodiment of a deconstructable spool200. In this embodiment, the flange segments145A-145D do not include corner sections as shown inFIG. 1A. A first dimension205(e.g. a length dimension) of each of the flange segments145A-145D may be substantially the same. Likewise, a second dimension210(e.g. a width dimension) of each of the flange segments145A-145D may be substantially the same. The first dimension205may also be the same on each side of the flange portion150. The second dimension210and the first dimension205are sized to allow the deconstructable spool200to fit within a standard intermodal shipping container.

The deconstructable spool200may also include support members215that extend across the flange portion150and to a periphery of the flange segments145A-145D. The support members215may be tubing, channel iron, or other supports that provide structural rigidity to the deconstructable spool200. A bolt interface220may be used to remove or attach the flange segments145A-145D from or to the flange portion150. The bolt interface220may be fixed to the flange portion150, the flange segments145A-145D, and/or the support members215, such as by welding or fasteners.

FIG. 3is an enlarged side view of the bolt interface220ofFIG. 2.FIG. 4is a sectional view of a portion of the bolt interface220ofFIG. 3. Referring toFIGS. 3 and 4, the bolt interface220may include a first structural member300coupled to the flange portion150, such as by welding or fasteners, and a second structural member305coupled to the flange segment145D, such as by welding or fasteners. The first structural member300and the second structural member305may be flat bar, legs of angle iron, or other structural supporting shapes.

When the deconstructable spool200is intact, the first structural member300abuts the second structural member305. Fasteners310, such as nuts and bolts, may be utilized to fix the first structural member300to the second structural member305, and thereby attach the flange segment145D to the flange portion145D. Likewise, the fasteners310may be removed to detach the flange segment145D from the flange portion150. The remaining flange segments145A-145C may be attached and detached from the flange portion150in a similar manner such that the deconstructable spool200can be repeatedly constructed for reuse, and repeatedly deconstructed for ease of shipping.

FIGS. 5A-5Care schematic cutaway top views of an exemplary standard intermodal shipping container400showing various methods for shipping the deconstructable spool100or the deconstructable spool200. A “standard intermodal shipping container” as described herein includes a container with an inside width of about 92 inches, and an outside length of between about 20 feet and about 53 feet with a maximum cargo capacity of between about 30,000 pounds and about 60,000 pounds, or greater. While the length and the height dimension may vary between containers, the inside width may be common with all containers.

The shipping container400includes a body405having major sides410A adjacent to minor sides410B, and at least one of the minor sides410B includes a door for access to an internal volume415. The internal volume415may include a length dimension420of between about 19.5 feet and about 52.5 feet, a width dimension425of about 7 feet, 8 inches (92 inches), and a height dimension (not shown) of between about 7 feet, 9 inches (93 inches) and about 9 feet, 1.5 inches (109.5 inches). The width dimension425and the height dimension are greater than the dimensions of the flange portion150(84 inches×88 inches, which relate to dimensions165and135, respectively, ofFIGS. 1A and 1B). The width dimension425and the height dimension are also greater than the dimensions of the flange segments145A-145D (84 inches×5 inches×43 inches, which relate to dimensions165,130, and155, respectively, ofFIGS. 1A and 1B).

In the shipping method shown inFIG. 5A, the internal volume415may be divided into one, two, three, four, five, six, seven, or more large volumes, although five large volumes430A-430E and four smaller volumes435in between the large volumes430A-430E are shown. According to the length dimension420, each of the large volumes430A-430D may contain one core110, with the flange portions150, of the deconstructable spools100or200. Each of the large volumes430A-430E may include a length dimension426of about 88 inches while a length dimension428of each of the smaller volumes435may be about 12 inches.

The large volumes430A-430E provide enough space to store the core110, and the smaller volumes provide enough space to store the corresponding flange segments145A-145D. Thus, the shipping container400according to the embodiment shown inFIG. 5Amay provide shipping of four deconstructable spools100or200(i.e., four cores and thirty-two flange segments) with a large volume430E having a length440of about 82 inches that is not occupied. The large volume430E may also be utilized to ship cargo other than spools, or left empty. The weight of each of the deconstructable spools100or200within the internal volume415of the shipping container400according to the embodiment ofFIG. 5Amay be about 10,000 pounds that is multiplied by four to about 40,000 pounds, which is well within the capacity of the shipping container400.

In the shipping method shown inFIG. 5B, the internal volume415may be divided into one, two, three, four, five, six, seven, or more large volumes, although five large volumes430A-430E and a single smaller volume435is shown. The single smaller volume435may be at one end of the shipping container400as shown, or in between two of the large volumes430A-430E. According to the length dimension420, each of the large volumes430A-430E may contain one core110, including the flange portions150, of the deconstructable spools100or200while the single smaller volume435may contain flange segments145A-145D corresponding to the core110in the large volumes430A-430E.

The single smaller volume435may include a length dimension440of about 32 inches which has space for 5 sets of flange segments145A-145D that are stacked according to this embodiment. Thus, the shipping container400according to the embodiment shown inFIG. 5Bmay provide shipping of five deconstructable spools100or200(i.e., five cores and forty flange segments). The weight of the five deconstructable spools100or200within the internal volume415of the shipping container400according to the embodiment ofFIG. 5Bmay be about 50,000 pounds, which is well within the capacity of the shipping container400.

In the shipping method shown inFIG. 5C, the internal volume415may be divided into one, two, three, four, five, six, seven, or more large volumes, although five large volumes430A-430E and a single smaller volume435similar to the embodiment shown inFIG. 5Bis shown. According to the length dimension420, each of the large volumes430A-430E may contain one core110, including the flange portions150, of the deconstructable spools100or200. However, the flange segments145A-145D may be placed within the internal volume of the core110(i.e., inside the hollow tubular member) which leaves the single smaller volume435empty or free for shipment of other products. Thus, the shipping container400according to the embodiment shown inFIG. 5Cmay provide shipping of five deconstructable spools100or200(i.e., five cores and forty flange segments). The weight of the five deconstructable spools100or200within the internal volume415of the shipping container400according to the embodiment ofFIG. 5Cmay be about 50,000 pounds, which is well within the capacity of the shipping container400.

While the exemplary shipping container400is described having a length of about 40 feet, the shipping container400may have a shorter length, such as a length of about 20 feet, with a capacity to ship one of the deconstructable spools100or200. Additionally, a shipping container with a length of about 45 feet, or a shipping container with a length of about 53 feet, may have the capacity to store and ship up to two, three, four, five, six, seven, or more of the deconstructable spools100or200, respectively.

FIG. 6Ais a side elevation view of a deconstructable spool600according to one embodiment. The front elevation view of the deconstructable spool may be similar to the deconstructable spool100as shown inFIG. 1B.FIG. 6BandFIG. 6Care isometric views of flange segments605of the deconstructable spool600shown inFIG. 6A.FIG. 6Dis an isometric view of a core110of the deconstructable spool600ofFIG. 6A.

Referring toFIGS. 6A-6D, the deconstructable spool600includes a plurality of flange segments605that are removably coupled to the core110. Each flange segment605may be coupled to the core110by fasteners310, which may be nuts and bolts as described above. The fasteners310may be disposed through openings625formed in the flange segments605that align with opening formed in the core110. The openings625in the flange segments605are disposed through a first structural member615of the flange segments605. The openings625in the core100are disposed through a plurality of structural members610that are attached to the ends of the core110and/or an outer surface660of the core110that is coupled to the structural members610.

Similarly, the flange segments605may be coupled to each other to form the two flanges105of the deconstructable spool600, only one of which is shown inFIG. 6A. In particular, the flange segments605include a pair of second structural members620coupled to the ends of the first structural member615to form the sides of the flange segments605. The fasteners310may be disposed through openings625formed in the second structural members620to couple adjacent flange segments605together.

The flange segments605include a third structural member675coupled to the ends of the second structural members620opposite from the first structural member615to form the top of the flange segments605. The flange segments605may further include one or more fourth structural members640coupled between and/or to the first, second, and/or third structural members615,620,675as shown inFIG. 6BandFIG. 6C. The first, second, third, and fourth structural members may be flat bar, rectangular tubing, angle iron, and/or other structural supporting members of different shapes.

The first structural member615of each the flange segment605includes an arcuate surface655that corresponds to the curvature of the outer surface660of the core110. Each flange segment605includes an arc length665that is about 45 degrees. However, the arc length665is not limited to 45 degrees and may be 22.5 degrees, 90 degrees, and/or 120 degrees depending on the major dimension120as shown inFIG. 1Bor other factors.

The flange segment605shown inFIG. 6Cmay be a load bearing flange segment630. The deconstructable spool600may include one or more load bearing flange segments630although only one is shown inFIG. 6AandFIG. 6C. Each load bearing flange segment630may include at least three fourth structural members640coupled to each of the other structural members, as well as a lifting lug635coupled to the fourth structural members640. The load bearing flange segments630may be used to suspend the deconstructable spool600by a crane when assembled.

The deconstructable spool600may include one or more support plates645coupled on each end of the core110. Two support plates645are shown inFIG. 6D. The support plate645includes a flat portion650configured to stabilize and prevent the core110from rolling when the flange segments605are removed and the core110is placed on a flat surface. Also shown inFIG. 6D, is an opening670formed in the outer surface660of the core110where a tubing may be inserted to begin coiling of the tubing onto the core110of the deconstructable spool600.

Embodiments of the deconstructable spools100,200, or600as described herein provide a coiled tubing spool that may be re-used. The deconstructable spools100,200, or600may be easily dismantled and shipped after use, and the spool may be re-constructed and re-spooled with another coiled tubing string.

While the foregoing is directed to embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.