Power tong apparatus

A power tong apparatus is provided. The power can include a vertical riser assembly for attaching to a drilling rig, and a swing arm assembly pivotally attached to the vertical riser assembly. The apparatus can include a power tong assembly pivotally attached to the swing arm assembly. The power tong assembly can include a back-up tong to grip a first pipe, and a power tong to grip and rotate a second pipe to make or break a joint between the pipes. The power tong can include a jaw assembly that, when rotated, grips the second pipe. The power tong can include a hydraulic motor to operate a drive chain or belt to rotate the jaw assembly.

TECHNICAL FIELD

The present disclosure is related to the field of tools for use on a well, in particular, automated and hydraulic-powered power tongs for making and breaking joints between sections of pipe.

BACKGROUND

In drilling a well, a drill string is used. The drill string can comprise a drill bit attached to sections of drill pipe. As the well is drilled, additional sections of drill pipe are added to the drill string to extend its length until the well is drilled deep enough to reach a formation where substances, such as water, oil or gas, can be produced from the well. Sections of pipe are joined together using threaded connections on the pipe, often referred to as “pin” and “box”, where the pin of one section of pipe is threaded into the box into an adjoining section of pipe. The drill string is rotated to turn the drill bit in order to drill the well. When the drill string is removed from the wellbore, the sections of pipe can be removed from the drill string one or more sections at a time.

To make or break the threaded connection between sections of pipe, a power tong device can be used to do so. Known designs use a motor with a transmission to operate the power tong mechanism to grip and turn one section of pipe relative to another section of pipe to thread them together or to separate them. When breaking a joint, the power tong uses a lower gear to increase the torque applied to the pipe to a level required to break the joint, then the power tong is shifted to a higher gear to increase the rotation speed of the pipe to unthread the connection. When a making a joint, the higher gear can be used to start the threaded connection, and then the lower gear is used to torque the connection together. This process of shifting gears to make or break joints is time consuming, and can make the time required to replace a worn out drill bit, thus requiring the complete removal of the entire drill string and then reinstalling the drill string, quite lengthy.

It is, therefore, desirable to provide a power tong overcomes the shortcomings of the prior art and decrease the time required to make and break joints between sections of pipe on a drilling rig.

SUMMARY

Broadly stated, in some embodiments, a power tong apparatus is provided for making and breaking connection joints between sections of pipe on a drilling rig, the apparatus comprising: a support assembly, further comprising a vertical riser assembly configured for attachment to the drilling rig, and a swing arm assembly operatively attached to the vertical riser assembly wherein the vertical riser and swing arm assemblies are configured such that the swing arm assembly can move up and down relative to the vertical riser assembly, the swing arm assembly further configured to pivot in a substantially horizontal plane relative to the vertical riser assembly; a power tong assembly operatively attached to the swing arm assembly, the power tong assembly further comprising: a back-up tong configured to grasp a first section of pipe, a power tong configured to grasp and rotate a second section of pipe relative to the first section of pipe to make or break a connection joint between the first and second sections of pipe, and power tong support means for supporting the power tong above the back-up tong; and control means for controlling the operation of the support assembly and of the power tong assembly.

Broadly stated, in some embodiments, the vertical riser assembly can further comprise: a substantially vertical outer tube member further comprising at least one mounting bracket configured for attaching the outer tube member to the drilling rig; a substantially vertical slot disposed along the outer tube member; an inner tube member having upper and lower ends, the inner tube member slidably disposed in the outer tube member and configured for upward and downward movement within the outer tube member; means for moving the inner tube member upwards and downwards relative to the outer tube member; and attachment means for pivotally attaching the swing arm assembly, the attachment means disposed on the inner tube member and further configured to extend through the slot wherein the power tong assembly can be raised or lowered relative to the vertical riser member when the swing arm assembly is pivotally attached to the attachment means and when the inner tube member moves upwards or downwards within the outer tube member.

Broadly stated, in some embodiments, the means for moving the inner tube member can further comprise a first telescoping member operatively coupled between the inner tube member and the outer tube member wherein the inner tube member can move upwards or downwards as the first telescoping member extends or retracts.

Broadly stated, in some embodiments, the attachment means can further comprise an upper pivot bracket disposed near the upper end of the inner tube member and a lower pivot bracket disposed near the lower end of the inner tube member. In further embodiments, the lower pivot bracket can further comprise an offset arm.

Broadly stated, in some embodiments, the apparatus can further comprise a second telescoping member operatively coupled between the offset arm and the swing arm assembly wherein the swing arm assembly can pivot in the substantially horizontal plane when the second telescoping member extends or retracts.

Broadly stated, in some embodiments, the swing arm assembly can further comprise: a fixed horizontal member configured to operatively couple with the attachment means; a telescoping horizontal member operatively coupled to the fixed horizontal member, wherein the telescoping horizontal member is configured to extend from and retract towards the fixed horizontal member; and a third telescoping member operatively coupled to the fixed and telescoping horizontal members wherein the telescoping horizontal member can extend from and retract towards the fixed horizontal member when the third telescoping member extends and retracts

Broadly stated, in some embodiments, the back-up tong can further comprise: a first frame comprising a first opening configured to receive the first section of pipe; and a back-up jaw assembly configured for receiving and grasping the first section of pipe.

Broadly stated, in some embodiments, the back-up jaw assembly can further comprise: a pair of back-up jaw carriers operatively coupled together via a hinge, the back-up jaw carriers operatively attached to the first frame, the back-up jaw carriers disposed about the first opening, each back-up jaw carrier comprising a first jaw block configured for gripping the first section of pipe; a back-stop jaw block disposed near the hinge; and means for closing the pair of back-up jaw carriers wherein the first section of pipe is grasped by the first jaw blocks and the back-stop jaw block.

Broadly stated, in some embodiments, the means for closing the pair of back-up jaws can further comprise: a pincer assembly operatively coupled to the first frame and to the pair of back-up jaws; and a third telescoping member disposed on the pincer assembly wherein the pair of back-up jaws closes or opens when the third telescoping member extends or retracts.

Broadly stated, in some embodiments, one or more of the first, second and third telescoping members can further comprise a hydraulic cylinder.

Broadly stated, in some embodiments, the back-up assembly can further comprise three telescoping back-up jaw blocks disposed about the first opening. In further embodiments, one or more of the telescoping back-up jaw blocks can further comprise a hydraulic ram mechanism.

Broadly stated, in some embodiments, the power tong further comprises: a second frame comprising a second opening configured to receive the second section of pipe; a jaw drive assembly rotatably disposed in the second frame, the jaw drive assembly configured for receiving, grasping and rotating the second section of pipe; and drive means for rotating the jaw drive assembly.

Broadly stated, in some embodiments, the drive means can further comprise: a drive motor; a gear reducer operatively coupled to the drive motor; a drive shaft operatively coupled to the gear reducer; a drive sprocket or pulley disposed on the drive shaft; and a drive chain or belt operatively coupling the drive sprocket or pulley to the jaw drive assembly. In some embodiments, the drive motor can further comprise a hydraulic motor.

Broadly stated, in some embodiments, the jaw drive assembly can further comprise: an upper jaw ring configured to receive the second section of pipe; a lower jaw ring configured to receive the second section of pipe, the lower jaw ring operatively coupled to the upper jaw ring in a spaced-apart configuration; a jaw cam rotatably disposed between the upper and lower jaw rings, the jaw cam configured to be rotated by the drive means, the jaw cam comprising a cam opening further comprising a cam profile disposed thereon; a pair of jaws pivotally disposed between the upper and lower jaw rings within the cam opening, the pair of jaws disposed against the cam profile, each jaw further comprising a second jaw block configured for gripping the second section of pipe; and a rear jaw block disposed in the cam opening wherein the rear jaw block and the second jaw blocks are in are in a spaced-apart configuration about the cam opening, the rear jaw block disposed against the cam opening whereupon the jaw cam is rotated relative to the upper and lower jaw rings, the cam profile urges the rear jaw block and the pair of jaws inwardly to grasp and rotate the second section of pipe. In further embodiments, the jaw cam can further comprise means for being driven by the drive means.

Broadly stated, in some embodiments, the means for being driven can further comprise teeth disposed on an outer circumferential edge of the jaw cam, the teeth configured for engaging with the drive chain. In other embodiments, the means for being driven can further comprise a pulley disposed on an outer circumferential edge of the jaw cam, the pulley configured for engaging with the drive belt.

Broadly stated, in some embodiments, the power tong support means can further comprise: a plurality of guide rod receivers disposed on a top surface of the back-up tong; a plurality of guide rods extending downwardly from the second frame, wherein the guide rods are slidably disposed in the guide rod receivers; and a plurality of support springs, one support spring disposed on each guide rod, the support springs further disposed between the power tong and the back-up tong, and further configured to suspend the power tong above the back-up tong.

Broadly stated, in some embodiments, the control means can further comprise:

means for supplying a source of motive power for the support assembly and the power tong assembly, wherein the source of motive power is selected from a group consisting of a pneumatic supply system and a hydraulic fluid supply system; and means for controlling the source of motive power, the controlling means operatively coupling the source of motive power to the support assembly and the power tong assembly. In further embodiments, the controlling means can further comprise a plurality of manually operated valves. In yet further embodiments, the controlling means can further comprise a plurality of controllable valves.

Broadly stated, in some embodiments, the controlling means can further comprise a programmable logic controller configured to operatively control the controllable valves. In further embodiments, the controlling means can further comprise an operator's console operatively coupled to the programmable logic controller, wherein the console can further comprise a joystick mechanism configured for operatively controlling the programmable logic controller.

DETAILED DESCRIPTION OF EMBODIMENTS

A power tong apparatus is provided. Referring toFIG. 1, one embodiment of power tong apparatus10is shown. In some embodiments, apparatus10can comprise of support assembly15and power tong assembly11operatively attached thereto. In some embodiments, support assembly15can further comprise of vertical riser assembly16and swing arm assembly18pivotally attached thereto. Vertical riser assembly16can further comprise brackets20disposed thereon for mounting apparatus10to drilling rig28, as shown inFIG. 2. In some embodiments, power tong assembly11can further comprise power tong12, back-up tong14, drive assembly24and hydraulic valve bank22for manually controlling the operation of apparatus10. Power tong assembly11can further comprise lifting frame26disposed on power tong12for lifting power tong assembly11. Referring toFIG. 2, apparatus10can further comprise driller's console30, which is operatively coupled to apparatus10to operate apparatus10from a remote locate on drilling rig28.

Referring toFIGS. 3 to 8, some embodiments of support assembly15and its sub-components are shown in more detail. Referring toFIG. 6, vertical riser assembly16is shown. In some embodiments, vertical riser assembly16can comprise of outer tube42and inner tube44slidably disposed therein. In the illustrated embodiments, outer tube42and inner tube44are shown having a rectangular cross-sectional shape although any suitable shape can be substitutes as obvious to those skilled in the art. In some embodiments, inner tube44can comprise upper arm35and lower offset arm36that can extend through slot43disposed along the vertical length of outer tube42when inner tube44is slidably disposed in outer tube42. Vertical riser assembly16can further comprise telescoping member56operatively coupled between inner box44and outer box42by pin66inserted into tube64through holes68, and secured therein, and by pin66inserted into tube58through holes62, and secured therein. Therefore, when telescoping member56is extended, inner tube44can move upwards within outer tube42thereby raising swing arm assembly18, and when telescoping member56retracts, inner tube44can move downwards within outer tube42thereby lowering swing arm assembly18, as shown inFIG. 4.

In some embodiments, swing arm assembly18can comprise swing arm46, diagonal member70disposed on swing arm46and inner arm48slidably disposed within swing arm46. Swing arm assembly18can further comprise telescoping member47operatively coupled between swing arm46and inner arm48and secured with pins49, as shown inFIG. 8. Therefore, when telescoping member47is extended, inner arm48can extend outwardly from swing arm46a distance “X”, as shown inFIG. 8. When telescoping member47retracts, inner arm48can retract into swing arm46. In some embodiments, “X” can represent a distance of approximately 8 to 12 inches. Swing arm46can further comprise lower bracket76having holes78for pivotal attachment to offset arm36, which can be secured by pin34set through and secured in holes78disposed on bracket76and hole37disposed on offset arm36. Diagonal member70can further comprise upper bracket72having holes74for pivotal attachment to upper arm35, which can be secured by pin34set through and secured in holes74disposed on bracket72and hole39disposed on upper arm35. In some embodiments, junction box54can be disposed on swing arm assembly18to house power cable connections, and electrical control and instrumentation cable connections to and from a programmable logic controller configured to control the operation of power tong apparatus10, to and from valve bank22, and to and from operator console30.

Referring toFIG. 5, swing arm assembly18is shown pivotally attached to vertical riser assembly16. In some embodiments, telescoping member32can be coupled to bracket41disposed on swing arm46with pin40, and can further be coupled to offset arm36with pin38. Therefore, when telescoping member32is extended, swing arm assembly18can rotate or swing clockwise (when viewed from above), and when telescoping member32retracts, swing arm assembly18can rotate or swing counter-clockwise, as shown inFIGS. 3 and 27.

In some embodiments, telescoping members32,47and56can comprise hydraulic ram cylinders, as well known to those skilled in the art, although in other embodiments, these telescoping members can comprise pneumatic ram cylinders, as well known to those skilled in the art.

Referring toFIGS. 9 to 11, one embodiment of back-up tong14is shown. In some embodiments, back-up tong14can comprise back-up tong assembly80that can further comprise frame81, pincer assembly82pivotally attached to frame81via pivot pin86and back-up jaw assembly84. In some embodiments, back-up jaw assembly84can further comprise hinged back-up jaw carriers94attached to frame81via jaw pins100and bolts101, wherein each jaw carrier94can comprise slot91configured for receiving jaw block90, which can be configured with a removable die95. In some embodiments, back-up jaw assembly84can further comprise backstop92, which can further comprise removable die95. In some embodiments, backstop92can be removably attached to back-up jaw assembly84via quick release pin98. This can enable easy replacement of backstop92with different sizes of backstops92to accommodate different diameters of pipe. In addition, different sizes or configurations of jaw carriers94can be installed to accommodate different diameters of pipe.

In some embodiments, pincer assembly82can comprise telescoping member88disposed between arms83. When telescoping member88is extended, arms83can pivot about pivot pin86to contact jaw carriers94at contact point97that, in turn, can close about a section of pipe disposed there between. Centering linkage96coupled between arms83can help jaw carriers94to grip the pipe such that it is centered between jaw carriers94and backstop92. In some embodiments, telescoping member88can comprise a hydraulic or pneumatic ram cylinder, as well known to those skilled in the art.

Referring toFIGS. 12 to 14, a second embodiment of back-up tong14is shown. In some embodiments, back-up tong14can comprise back-up tong assembly102that can further comprise of frame104having throat106configured for receiving a section of pipe. Frame102can further comprise valve bank110for manually controlling the operation of apparatus10. Back-up tong assembly102can further comprise a plurality of ram jaws108disposed about opening106. In the illustrated embodiment, there can be three ram jaws108positioned in a substantially equal spaced-apart configuration about opening106. In some embodiments, each ram jaw108can be slidably disposed in frame104by guide track114, guide rails116and end block112operatively attached to frame104. Referring toFIG. 14, each ram jaw108can comprise housing124and piston126slidably disposed therein to form annular chamber128. Piston126can extend through opening125disposed in end127, and can further be fasted to end block112with fastener113. Each ram jaw108can further comprise die face120having die slot122disposed thereon to receive removable die118, which is configured with grooves or teeth to grip pipe. As die118wears out, it can be replaced with a new die118. Fittings130and131can be coupled to a source of pressurized hydraulic fluid or air. In operation, pressurized fluid or air introduced into chamber128through fitting130can force piston126to extend out from opening125and contact end block112. This can force housing124to travel along guide track114and guide rails116towards throat opening106to grip a section of pipe. When pressurized fluid or air introduced into chamber128through fitting131, piston126can be retracted into housing124thereby drawing ram jaw108back along guide track114and guide rails116away from throat opening106to release the pipe.

In some embodiments, back-up tong14can comprise centering pin132having v-shaped profile134disposed thereon, profile134can be configured to match the profile of detent52of pivot tube50disposed on inner arm48of swing arm assembly18. Therefore, when back-up tong14is pivotally attached to pivot tube50, profile134can fit in detent52and can further act as means to center power tong assembly11in a desired orientation with respect to swing arm assembly18.

Referring toFIGS. 15 to 17, an embodiment of power tong assembly11is shown. In some embodiments, power tong12can comprise of frame136further comprising of top plate138and bottom plate140joined together by support posts142disposed around the perimeter of frame136. In some embodiments, jaw assembly150can be rotatably disposed in frame136between top plate138and bottom plate140and can further form jaw opening151to receive a section of pipe. In some embodiments, drive assembly24can provide the motive power to rotate jaw assembly150via drive chain160driven by drive sprocket164, wherein drive chain160can be guided by idler posts156and159, and by tensioner posts158, to engage and rotate jaw assembly150. In some embodiments, drive chain160can comprise a 6-row, #80 roller chain. In some embodiments, drive chain160can pass between idler posts159and tensioner posts158, wherein tensioner posts158can comprise an eccentric mechanism to move tensioner posts158against drive chain160to remove any slack in the chain.

In some embodiments, power tong12can further comprise upper brake band152disposed around upper brake hub184disposed on jaw assembly150. In some embodiments, power tong12can further comprise lower brake band153disposed around lower brake hub186. Brake band posts154can be disposed on top plate138and bottom plate140to control the movement of upper brake band152and lower brake band153when jaw assembly150is rotated. In some embodiments, frame136can further comprise torque reactor144disposed thereon, and load cell146, operatively coupled to a programmable logic controller or other monitoring electronics (not shown) as well known to those skilled in the art to measure the torque applied to pipe when disposed in jaw opening151by power tong12. In some embodiments, power tong12can further comprise guards162disposed on frame136near jaw opening151that can be configured to open to receive a section of pipe, and to close when the pipe is within jaw assembly150as safety means to protect personnel from the rotating components of power tong12when in operation.

Referring toFIG. 18, one embodiment of drive assembly24is shown. In some embodiments, drive assembly24can comprise motor166operatively coupled to gear reducer170. In some embodiments, motor166can comprise a variable speed hydraulic motor. In using such a motor, power tong apparatus10can avoid the necessity of changing gears using a conventional 2-speed transmission, which can avoid over-torquing a joint between sections of pipe when the transmission is shifted from high gear to low gear to apply the final torque. In this situation, starting in low gear can require overcome the static friction in the connection to reach the desired torque for the connection. In a representative embodiment, a Series 51, 80 cc bent-axis hydraulic motor as manufactured by Sauer-Danfoss Gmbh & Co. OHG of Neumünster, Germany can be used as motor166, although functionally equivalent motors can be used, as well known to those skilled in the art. In some embodiments, gear reducer170can comprise a Model 25D planetary gear reducer as manufactured by Heco Gear of West Sacramento, Calif., U.S.A. In some embodiments, encoder ring168can be disposed between motor166and gear reducer170as a means for monitoring the rotational speed of output shaft167, in combination with sensors disposed in gear reducer170(not shown) as well known to those skilled in the art. In some embodiments, drive assembly24can further comprise drive shaft172operatively coupled to gear reducer170, which can be further operatively coupled to drive sprockets164via keys174disposed between slot176disposed on driveshaft172and slots165disposed in drive sprockets164. In some embodiments, drive sprockets164can be retained on driveshaft172by snap ring180, and supported by idler bearing182when disposed in frame136.

Referring toFIGS. 19A,19B and20, an embodiment of jaw assembly150is shown. In some embodiments, jaw assembly150can comprise of upper jaw ring188and lower jaw ring190operatively coupled together with rod spacers203and eye bolts208. In further embodiments, jaw assembly150can further comprise jaw cam192rotatably disposed between upper jaw ring188and lower jaw ring190. Each of upper jaw ring188, lower jaw ring190and jaw cam192can each further comprise an opening that can align together to form jaw opening151. In some embodiments, upper jaw ring188can comprise upper brake hub184disposed on an upper surface of upper jaw ring188and attached with fasteners210, and lower jaw ring190can comprise lower brake hub186disposed on a lower surface of lower jaw ring190and attached with fasteners210. Upper jaw ring188can further comprise grease fittings212, wherein jaw assembly150can be lubricated with grease injected through fittings212. In some embodiments, jaw cam192can comprise one or more sprockets196disposed on a circumferential edge thereof for engagement with drive chain160. In some embodiments, drive chain160can be substituted with a functionally equivalent drive belt, wherein drive sprocket164, sprockets196, tensioner posts158and idler posts159can also be suitably modified for operation therewith, and further comprise pulleys configured for operation with a drive belt.

In some embodiments, jaw cam192can further comprise circumferential grooves198disposed on upper and lower surfaces thereof configured to receive rollers194that can travel therein. In some embodiments, rollers194can be disposed on a lower surface of upper jaw ring188, and on an upper surface of lower jaw ring190to travel within grooves198, wherein jaw cam192can rotate between upper and lower jaw rings188and190.

In some embodiments, jaws202can be disposed within jaw opening151between upper jaw ring188and lower jaw ring190, wherein jaws202can be pivotally attached to eye bolts208. Each jaw202can further comprise a jaw block204configured to have a replaceable die205disposed thereon. Dies205can be configured with grooves or teeth so as to grip a pipe. Dies205can wear out over time, whereupon worn out dies205can then be replaced with new dies205. In some embodiments, jaw assembly150can further comprise rear jaw block206disposed between upper and lower jaw rings188and190near the back of jaw opening151. Rear jaw block206can further comprise rear jaw carrier207slidably disposed therein, wherein rear jaw carrier207can further comprise a replaceable die205disposed thereon. In some embodiments, jaw assembly150can further comprise centering mechanism or switch200disposed on upper jaw ring188near rear jaw block206. Centering mechanism or switch200can be used to switch the operation of power tong12between “make-up mode” (to join sections of pipe together) and “break-out mode” (to separate sections of pipe). In some embodiments, centering mechanism or switch200can further comprise proximity sensors218(seeFIG. 22) operatively coupled to a programmable logic controller to detect what mode of operation power tong12is in, as well as when jaw cam192is centered with upper and lower jaw rings188and190.

Referring toFIGS. 21A and 21B, one embodiment of jaw assembly150is shown with upper jaw ring188removed to illustrate the operation of jaw assembly150. InFIG. 21A, jaw cam192is shown centered with lower jaw ring190, wherein jaw opening151is open to receive a section of pipe. In this position, biasing means219keep jaws202biased towards cam profile214disposed on an inner circumferential edge of jaw cam192to keep jaw opening151clear for the pipe. In some embodiments, biasing means219can comprise a spring. In some embodiments, jaws202can comprise rollers216, wherein jaws202can roll against cam profile214when jaw cam192is rotated. When, for example, power tong12is in “break-out mode”, drive assembly24can rotate jaw cam192counter-clockwise, as shown inFIG. 21B, by rotating chain160(as shown inFIG. 17) to engage sprockets196. Brake bands152and153(as shown inFIGS. 15 and 16) can hold upper and lower jaw rings188and190in place so that jaw cam192can rotate relative to upper and lower jaw rings188and190, and urge jaws202, as they pivot about eye bolts208, towards jaw opening151to grip a pipe disposed therein as rollers216follow cam profile214. Brake band posts154, as shown inFIGS. 15 and 16, can act to keep brake bands152and153in place while jaw assembly is rotating. In some embodiments, cam profile214can be configured to urge rear jaw carrier207towards jaw opening151to grip the pipe as well. Once jaws202and rear jaw carrier207grip the pipe, jaw cam192can be continued to be rotated by drive assembly24and chain160until a joint between a section of pipe and the drill string has been completely separated. At this point, drive assembly24can be reversed to center jaw cam192with upper and lower jaw rings188and190, wherein jaws202and rear jaw carrier release the pipe so it can be removed from power tong12. In “make-up mode”, the procedure is reversed such that a section of pipe to be joined to the drill string is placed in the jaw opening151and jaw cam192can be rotated clockwise by drive assembly24to first engage and grip the pipe and then thread the pipe to the drill string to a desired torque, whereupon drive assembly24is reversed to center jaw cam192with upper and lower jaw rings188and190so that power tong12can move away from the drill string.

Referring toFIGS. 23 to 25, some embodiments of jaw202are shown. Referring toFIG. 23, in some embodiments, jaw202can comprise slot201configured for receiving jaw block204, which can be secured to jaw202with a fastener199secured to jaw202. Jaw block204can further be configured to receive replaceable die205, which can be secured to jaw block204with another fastener199. Referring toFIGS. 24 and 25, in some embodiments, jaw202can further comprise roller recess217configured to receive jaw roller216rotatably disposed therein. In some embodiments, roller pin220can pass through holes224disposed in jaw202and jaw roller216and be secured to jaw202, wherein jaw roller216can rotate within roller recess217. In further embodiments, roller pin220can comprise grease fitting222to permit lubrication of jaw roller216so that it can freely rotate about roller pin220. InFIG. 24, the embodiment of jaw202shown is configured to grip pipe having diameters ranging from 2⅜ inches to 4½ inches. InFIG. 25, the embodiment of jaw202shown is configured to grip pipe having diameters ranging from 5 inches to 5½ inches. In some embodiments, jaws202can be interchanged in jaw assembly150by removing eye bolts208, placing the desired size of jaws202within jaw assembly150and reinstalling eye bolts208.

Referring toFIG. 26, an embodiment of power tong apparatus10is shown. In some embodiments, power tong12can be supported above back-up tong14by a plurality of guide rods226extending downwardly from power tong12(as shown inFIG. 17) slidably disposed in guide rod receivers228disposed in back-up tong14, and coil springs230disposed about guide rods226between power tong12and back-up14. In a representative embodiment, power tong apparatus10can comprise three sets of guide rod226, guide rod receiver228and spring230to support power tong12above back-up tong14. With this configuration, power tong12can move upwards or downwards relative to back-up tong14, depending on whether power tong apparatus10is being operated in a “bread-out mode” or “make-up mode.”

Referring toFIG. 28, one embodiment of control system238for controlling the operation of power tong assembly10is shown. In some embodiments, control system238can comprise hydraulic power unit (“HPU”)240, which can further comprise of hydraulic pump242and hydraulic fluid tank244. In further embodiments, HPU240can further comprise hydraulic fluid filtering system246. In yet further embodiments, filtering system246can further comprise a hydraulic cooling system, which can comprise of a radiator or heat exchanger, to cool hydraulic fluid pumped by HPU240. In some embodiments, HPU240can be configured to pump hydraulic fluid at a pressure of up to 3600 psi at a rate of up to 22 gallons per minute. In some embodiments, pump242can provide a hydraulic power rating of up to 29 horsepower. In some embodiments, control system238can comprise hydraulic send and return lines operatively coupled between HPU240and controllable valve bank250, which can be operatively controlled by programmable logic controller (“PLC”)254via control cable252disposed there between. Valve bank250can be controlled by PLC254to provide pressurized hydraulic fluid from HPU240to telescoping member56, disposed in vertical riser assembly16, via send and return hydraulic lines258; to telescoping member47, disposed in swing arm46, via send and return hydraulic lines260; to telescoping member32, disposed on swing arm assembly18, via send and return hydraulic lines262; to telescoping member88disposed in back-up tong assembly80, or to ram jaws108disposed in back-up tong assembly102, depending on which embodiment of back-up tong14is disposed in power tong apparatus10, via send and return hydraulic lines264; and to drive assembly24, via send and return hydraulic lines266. In some embodiments, valve bank250can comprise model No. PVG32 hydraulic valves as manufactured by Sauer-Danfoss Gmbh & Co. OHG of Neumünster, Germany, although any functionally equivalent hydraulic valves as well known by those skilled in the art can be used. In some embodiments, PLC254can comprise a model CP1H PLC as manufactured by Omron Corporation of Kyoto, Japan, although any functionally equivalent PLC as well known by those skilled in the art can be used.

In some embodiments, control system238can comprise console assembly30operatively coupled to PLC254via control cable256. In some embodiments, control system238can operate power tong assembly apparatus10in a number of modes. Referring toFIGS. 29A and 29B, a flowchart is set out for manually operating power tong apparatus10to perform a “make-up mode” operation, as can be carried out by control system238. In some embodiments, manual make-up mode process2900can comprise of the following steps. At step2902, an operator can select what size and type of pipe to be made-up from a menu displayed on console30. At step2904, a query can be made whether power tong apparatus10is centered. If not, then power tong apparatus10can be centered at step2906, and the query at step2904repeated. If it is, then a query can be made at step2908whether centering mechanism or switch200is set correctly for the operation. If not, then centering switch200can be correctly set at steps2910and2912, and the query at step2908repeated. If yes, then confirmation of centering switch being correctly set can be made at step2914. At step2916, the operator can move power tong apparatus10into position and vertical align it with the pipe joint. At step2918, the operative can press Torque Mode on console30wherein back-up tong14can close and grip the drill string. At step2920, a query can be made whether centering switch200is set correctly. If not, switch200can be set correctly for make-up mode at steps2922and2924, and the query at step2920repeated. If yes, the setting of switch200can be confirmed at step2926, and the operator can operate joystick232disposed on console30(as shown inFIG. 33) to start the make-up of the joint connection at step2928. At step2930, jaw assembly150of power tong12can be rotated clockwise to grip and rotate the section of pipe to be connected to the drill string. At step2932, a query can be made if the rotation speed of jaw assembly150is below a desired speed or setpoint for the type and size of pipe being joined. If not, the speed can be lowered at step2934, and the query at step2932repeated. If yes, the process at step2930can be continued. At step2936, a query can be made to determine if the torque applied to the pipe is within the setpoints set for the type and size of pipe being joined. If not, a further query at step2938can be made if the number of turns required for joining the pipe is within the setpoints set for the type and size of pipe being joined. If not, then the process can at step2930can be continued. If yes, then a message stating that the make-up operation failed can be displayed on console30at step2940, and the information logged in a datafile. If the answer to the query at step2936is yes, then a further query at step2942can be made if the number of turns for joining the pipe is within the setpoints set for the pipe. If not, then a message stating that the make-up operation failed can be displayed on console30at step2940, and the information logged in a datafile. If yes, then a message stating that the make-up operation is complete can be displayed on console30at step2944. Continuing through connector2946fromFIG. 29AtoFIG. 29B, process2900can continue at step2948, where a query can be made whether power tong apparatus10is centered. If not, power tong apparatus10can be centered at step2950, and the query at step2948repeated. If yes, the operator can press Position Mode on console30at step2952, wherein back-up tong14can release the drill string, and then move power tong apparatus10away from the hole center and completed pipe joint at step2954.

Referring toFIGS. 30A and 30B, a flowchart is set out for manually operating power tong apparatus10to perform a “break-out mode” operation, as can be carried out by control system238. In some embodiments, manual break-out mode process3000can comprise of the following steps. At step3002, an operator can select what size and type of pipe to be broken out from a menu displayed on console30. At step3004, a query can be made whether power tong apparatus10is centered. If not, then power tong apparatus10can be centered at step3006, and the query at step3004repeated. If it is, then a query can be made at step3008whether centering switch200is set correctly for the operation. If not, then centering switch200can be correctly set at steps3010and3012, and the query at step3008repeated. If yes, then confirmation of centering switch being correctly set can be made at step3014. At step3016, the operator can move power tong apparatus10into position and vertical align it with the pipe joint. At step3018, the operative can press Torque Mode on console30wherein back-up tong14can close and grip the drill string. At step3020, a query can be made whether centering switch200is set correctly. If not, switch200can be set correctly for break-out mode at steps3022and3024, and the query at step3020repeated. If yes, the setting of switch200can be confirmed at step3026, and the operator can operate joystick232disposed on console30(as shown inFIG. 33) to start the break-out of the joint connection at step3028. At step3030, jaw assembly150of power tong12can be rotated counter-clockwise to grip and rotate the section of pipe to be disconnected from the drill string. At step3032, a query can be made if the rotation speed of jaw assembly150is below a desired speed or set point for the type and size of pipe being broken out. If not, the speed can be lowered at step3034, and the query at step3032repeated. If yes, the process at step3030can be continued. At step3036, a query can be made to determine if the number of turns required for breaking the pipe joint is within the set points set for the type and size of pipe being broken out. If not, then a query can be made at step3038if jaw assembly150is turning. If not, then a message stating that the break-out operation failed can be displayed on console30at step3040, and the information logged in a data file. If the answer to the query at step3038is yes, then the query at step3036can be repeated. If the answer to the query at step3036is yes, then a message stating that the break-out operation is complete can be displayed on console30at step3042. Continuing through connector3044fromFIG. 30AtoFIG. 30B, process3000can continue at step3046, where a query can be made whether power tong apparatus10is centered. If not, power tong apparatus10can be centered at step3048, and the query at step3046repeated. If yes, the operator can press Position Mode on console30at step3050, wherein back-up tong14can release the drill string, and them move power tong apparatus10from the hole center and broken out pipe joint at step3052.

Referring toFIGS. 31A and 31B, a flowchart is set out for automatically operating power tong apparatus10to perform a “make-up mode” operation, as can be carried out by control system238. In some embodiments, manual make-up mode process3100can comprise of the following steps. At step3102, an operator can select what size and type of pipe to be made-up from a menu displayed on console30. At step3104, a query can be made whether power tong apparatus10is centered. If not, then power tong apparatus10can be centered at step3106, and the query at step3104repeated. If it is, then a query can be made at step3108whether centering switch200is set correctly for the operation. If not, then centering switch200can be correctly set at steps3110and3112, and the query at step3108repeated. If yes, then confirmation of centering switch being correctly set can be made at step3114. At step3116, the operator can move power tong apparatus10into position and vertical align it with the pipe joint. At step3118, the operative can press Torque Mode on console30wherein back-up tong14can close and grip the drill string. At step3120, a query can be made whether centering switch200is set correctly. If not, switch200can be set correctly for make-up mode at steps3122and3124, and the query at step3120repeated. If yes, the setting of switch200can be confirmed at step3126, and the operator can press Start on console30to start the make-up of the joint connection at step3128. At step3130, jaw assembly150of power tong12can be rotated clockwise to grip and rotate the section of pipe to be connected to the drill string. At step3132, a query can be made if the rotation speed of jaw assembly150is below a desired speed or setpoint for the type and size of pipe being joined. If not, the speed can be lowered at step3134, and the query at step3132repeated. If yes, the process at step3130can be continued. At step3136, a query can be made to determine if the torque applied to the pipe is within the setpoints set for the type and size of pipe being joined. If not, a further query at step3138can be made if the number of turns required for joining the pipe is within the setpoints set for the type and size of pipe being joined. If not, then the process can at step3130can be continued. If yes, then a message stating that the make-up operation failed can be displayed on console30at step3140, and the information logged in a datafile. If the answer to the query at step3136is yes, then a further query at step3142can be made if the number of turns for joining the pipe is within the setpoints set for the pipe. If not, then a message stating that the make-up operation failed can be displayed on console30at step3140, and the information logged in a datafile. If yes, then a message stating that the make-up operation is complete can be displayed on console30at step3144. Continuing through connector3146fromFIG. 31AtoFIG. 31B, process3100can continue at step3148, where a query can be made whether power tong apparatus10is centered. If not, power tong apparatus10can be centered at step3150, and the query at step3148repeated. If yes, the operator can press Position Mode on console30at step3152, wherein back-up tong14can release the drill string, and then move power tong apparatus10from the hole center and completed pipe joint to one of two operator-defined positions at either of steps3154and3156.

Referring toFIGS. 32A and 32B, a flowchart is set out for automatically operating power tong apparatus10to perform a “break-out mode” operation, as can be carried out by control system238. In some embodiments, manual break-out mode process3200can comprise of the following steps. At step3202, an operator can select what size and type of pipe to be broken out from a menu displayed on console30. At step3204, a query can be made whether power tong apparatus10is centered. If not, then power tong apparatus10can be centered at step3206, and the query at step3204repeated. If it is, then a query can be made at step3208whether centering switch200is set correctly for the operation. If not, then centering switch200can be correctly set at steps3210and3212, and the query at step3208repeated. If yes, then confirmation of centering switch being correctly set can be made at step3214. At step3216, the operator can move power tong apparatus10into position and vertical align it with the pipe joint. At step3218, the operative can press Torque Mode on console30wherein back-up tong14can close and grip the drill string. At step3220, a query can be made whether centering switch200is set correctly. If not, switch200can be set correctly for break-out mode at steps3222and3224, and the query at step3220repeated. If yes, the setting of switch200can be confirmed at step3226, and the operator can press Start on console30to start the break-out of the joint connection at step3228. At step3230, jaw assembly150of power tong12can be rotated counter-clockwise to grip and rotate the section of pipe to be disconnected from the drill string. At step3232, a query can be made if the rotation speed of jaw assembly150is below a desired speed or setpoint for the type and size of pipe being broken out. If not, the speed can be lowered at step3234, and the query at step3232repeated. If yes, the process at step3230can be continued. At step3236, a query can be made to determine if the number of turns required for breaking the pipe joint is within the setpoints set for the type and size of pipe being broken out. If not, then a query can be made at step3238if jaw assembly150is turning. If not, then a message stating that the break-out operation failed can be displayed on console30at step3240, and the information logged in a datafile. If the answer to the query at step3238is yes, then the query at step3236can be repeated. If the answer to the query at step3236is yes, then a message stating that the break-out operation is complete can be displayed on console30at step3242. Continuing through connector3244fromFIG. 32AtoFIG. 32B, process3200can continue at step3246, where a query can be made whether power tong apparatus10is centered. If not, power tong apparatus10can be centered at step3248, and the query at step3246repeated. If yes, the operator can press Position Mode on console30at step3250, wherein back-up tong14can release the drill string, and then power tong apparatus10from the hole center and broken out pipe joint to one of two operator-defined positions at either of steps3252and3254.

Referring toFIG. 33, an embodiment of console30for use with power tong apparatus10is shown. In some embodiments, console30can comprise housing231that can further comprise joystick232, push-button controls234, touchscreen236, and push-button controls233disposed on joystick232for controlling power tong assembly10. In some embodiments, an operator can use the automatic controls on console30or use the manual hydraulic levers22on the side of power tong assembly10itself, as shown inFIG. 1or26. In some embodiments, Auto Control can be used to control power tong assembly10. In some embodiments, controls234can comprise of 3 buttons: “Start”, “Reset” and an “ESD” (Emergency Shut Down) button. Console30can further comprise a 2 way switch (VALVE CNTR), a 4-axis joystick232(Up, Down, In, Out) and touch screen236. Joystick232can further comprise 4 thumb buttons233: “TORQ”, “POSI”, “MAKE BREAK” and “CNTR”. Joystick232can further comprise a dead man trigger switch (not shown).

In some embodiments, joystick232can be used to control movement of power tong apparatus10(position mode) and to makeup/breakout joints (torque mode). In some embodiments, the movement controls of joystick232can be configured to work only if the dead man switch is squeezed and held. To adjust the position of power tong apparatus10in some embodiments, console30can be set in “POSITION MODE” by pressing the POSI button. The “POSITION MODE” indicator light on touchscreen236will be highlighted green if position mode is selected. Moving joystick232to the left or right can rotate power tong apparatus10in and out of hole center, whereas moving joystick232up and down can raise or lower power tong apparatus10to the desired height. To makeup or breakout a joint, “TORQUE MODE” can be selected by pressing the TORQ button to switch to torque mode upon which, the “TORQUE MODE” indicator light will be highlighted green on touchscreen236. In some embodiments, when “TORQUE MODE” is selected, back-up tong14can automatically close upon a pipe, and when “POSITION MODE” is selected, back-up tong14can automatically open. In some embodiments, pressing the MAKE BREAK button can switch between make up and break out modes upon which, the appropriate indicator on touchscreen236can turn green to show the current mode. In some embodiments, pressing the CNTR button can automatically center the jaw assembly150. Jaw assembly150will rotate to center in the clockwise direction if in break-out mode, and in the counter-clockwise direction if in make-up mode. In some embodiments, pressing the Start button can begin the make-up or break-out auto sequence. Pressing the Reset button can stop the auto sequence, and can be used to clear error messages. Pressing the ESD button can stop the operation of power tong apparatus10immediately and disable all controls on console30. In some embodiments, the VALVE CNTRL/PLC CNTRL selector switch can be used to set the method of control of power tong apparatus10. If the switch is set to PLC CNTRL, console30can be used. If the switch is set to VALVE CNTRL, then hydraulic valve bank22can to be used, and controls on console30can be disabled.

Referring toFIG. 34, touchscreen236can be used to navigate through a number of different screens and functions displayed thereon. As shown inFIG. 34, in some embodiments, the MENU screen can display seven modes of functionality: MAIN, MANUAL, SETUP, PIPE SET, DATALOG, AUTO MONITOR and HELP, in addition to EXIT mode.

Referring toFIG. 35, an embodiment of the MAIN screen is shown. In some embodiments, the MAIN screen can list information such as: torque setpoint, last torque achieved, number of turns of the tong during the last make/break and instantaneous torque reading. This screen can be the most used screen as an operator will want to see the torque readings when making up a joint. An operator can switch between metric and imperial units by pressing the button on the lower right corner of the screen. When this button reads “IMPERIAL”, the units displayed can be in imperial. If the button reads “METRIC”, the units being displayed can be metric. “FINAL TORQUE” can be the torque that has been reached while making up a joint, “INSTANT TORQUE” can be the torque being applied to the joint at that exact moment. “FINAL TURNS” can be how may turns of the tong it took to make up the joint. “TONG RPM” can be the RPM of the tong at a given moment. “MOTOR RPM” can be the RPM of the motor at a given moment. “TORQUE SETTING” can be the set point for makeup that has been input into the current pipe profile. The “BREAK OUT TURNS” box will only be displayed if console30is in break-out mode. If console30is in make-up mode, then the label can be replaced by 2 labels: “TURN MIN” and “TURN MAX”. These settings can be displayed from the pipe profile that the operator has chosen. To change a pipe setting, the “PIPE SET” box at the top middle of touchscreen236can be pressed. This can bring up a popup window where the operator user can select a specific predetermined pipe profile. If the operator wants to quickly change the torque setting to a custom torque, he can simply choose “0” on the pipe setting popup. This will allow the operator to input different settings directly into the boxes on the main screen.

Referring toFIG. 36, an embodiment of the MANUAL screen is shown. In some embodiments, the MANUAL screen can be used to control power tong apparatus10via touchscreen236. The MANUAL screen can comprise of many buttons for the various functions of power tong apparatus10. In some embodiments, the Invert Joystick button can invert the vertical controls of the joystick. The other buttons are self evident to those skilled in the art. This MANUAL screen control can be used as a back-up control option. The joystick or the auto control mode of operation can be used as the standard method of operating power tong apparatus10.

Referring toFIG. 37, an embodiment of the PIPE TABLE screen is shown. In some embodiments, the PIPE TABLE screen can be used by an operator to set up all the different types of pipe that the rig will be running. In some embodiments, the operator can input up to 10 different pipe profiles, where each profile requires an input for the “PIPE TYPE DESCRIPTION”, “TURN MIN”, “TURN MAX”, “BO TURNS”, “RPM MAX” and “TORQUE VALUE”.

PIPE TYPE DESCRIPTION—This can be the description of the pipe given by the operator. TURN MAX and TURN MIN—These can represent the min and max number of turns jaw assembly150should rotate for the joint to be made up. If the joint is made up before the min number of turns, then a message can be displayed stating that the pipe might be incorrectly torqued and it should be checked. This might happen if the joint was cross threaded. The turn max setting is the maximum turns allowed. Jaw assembly150can stop rotating if the max turn limit has been reached. This is to prevent over torque due to a failure in the torque sensor. It can state the size and type of pipe.

BO TURNS—This box can be used to set the total number turns that the auto breakout will complete per sequence.

RPM MAX—This can set the max speed of the tong for makeup or breakout.

TORQUE VALUE—The torque set point for every joint made up under the given profile.

DRILL PIPE—This check box can be checked off if the type of pipe is drill pipe. This can be used when making up so that the tong will shoulder the connection softly to avoid over torquing the joint.

Referring toFIG. 38, an embodiment of the DATALOG screen is shown. In some embodiments, the DATALOG screen can list information for every joint made up. In some embodiments, up to 500 logs can be recorded. Each record can comprise five components: “ORDER”, “PIPE DESCRIPTION”, “TORQUE SETPOINT”, “ACHIEVED TORQUE” and “M.U. TURNS” (make-up turns).

ORDER—This can describe the order of the joints made up, 1 through 500, “1” being the first joint made up for the well.

PIPE DESCRIPTION—This can be the description of the pipe used including pipe size and type.

TORQUE SETPOINT—This can be the desired torque set point for the joint.

ACHIEVED TORQUE—This can be the torque that was actually achieved during make up.

M.U. TURNS—This can show how many turns of the tong it took to completely torque the joint.

In some embodiments, pressing the next or prev buttons can skip to the next or previous page of logs. The reset data button can erase all the data in the datalog. In some embodiments, the reset button is only displayed on the first datalog screen.

Referring toFIGS. 39 to 41, embodiments of ERROR MESSAGES screens are shown. In some embodiments, a number of different error messages can be displayed during use of console30in the operation of power tong apparatus10.FIGS. 39 to 41illustrate the different error messages that can be displayed, and describe the meaning or nature of these error messages.

In some embodiments, power tong apparatus10can be operated by the following steps. While in position mode, joystick232can be used to move power tong apparatus10to hole-center, and to center the apparatus on the joint with power tong12over the pipe coupling and back-up tong14under the pipe coupling. Once the apparatus has been positioned correctly on the joint, the “Torque Mode” button can be pressed on joystick232. Back-up tong14will close automatically, and a joint can now be made up or broken out. The MAKEUP BREAKOUT button can be used to switch between these two modes of operation. The make/break selector (centering switch200) must match the mode of operation to be used. For example, in Make Up mode on touchscreen236, centering switch200must be up so jaw assembly150will close on the pipe while rotating clockwise to make up the joint. If the joint is to be broken out, centering switch200must be in break-out mode. In some embodiments, centering switch200can only be switched between make-up and break-out if jaw assembly150has already been centered. If centering switch200is operated when jaw assembly150is not at center, the apparatus will not operate correctly and there can be risk ins damaging the apparatus and/or the pipe. Once centering switch200and the mode button are properly selected, an operator can make up or break out the joint with the operators controls using one of three different methods: Joystick Control, Auto Control and Screen Control.

JOYSTICK CONTROL—The dead-man switch on joystick232can be squeezed, and joystick232can be pulled back for break out or pushed forward for make-up. Jaw assembly150can then start spinning. If making up the joint, once the joint has reached the desired torque the apparatus will stop, and the CNTR button can be pressed to center jaw assembly150.

SCREEN CONTROL—In some embodiments, the apparatus' functions can be controlled using the MANUAL screen as well. To do this, an operator must make sure the apparatus is in the correct mode, and that centering switch200is set correctly. The Torque mode can be used to make-up or break-out a joint. The Break Out or Make Up buttons can be pressed and held to break or make a joint. If in makeup mode, the apparatus will stop and jaw assembly150can center automatically once the joint reaches its torque set point.

AUTO CONTROL—In some embodiments, this can be the simplest way to control the apparatus. As in other modes, an operator can make sure the apparatus is centered over the joint, and that the apparatus is in “Torque Mode”, and that centering switch200is in the correct position. The “Start” button can then be pressed, and the apparatus can either break or make the joint. If in Make-up mode, a torque can be read on the main screen, and when the torque setting has been reached, the apparatus can automatically stop making the joint up and rotate the other direction until jaw assembly150is centered. If in break out mode, the apparatus can break the joint and spin out the pipe for a set amount of rotations (this is set in the “Pipe Set” screen and determined by what pipe setting you have selected). Once jaw assembly150has rotated the set amount of turns, jaw assembly150can stop and rotate the other direction until it has reached the center position.