Abstract:
An apparatus and method for an integrated flush-mount spider and power-tong apparatus comprising a flush-mount spider integrated with an attached power-tong and electronic load cell torque monitor. The power-tong applies rotation in opposite directions to make-up and breakout the pipe string. The flush mount spider holds the lower pipe string in place and serves as a backup tong to prevent rotation of the lower pipe string. The addition of a pipe spinner allows the integrated flush-mount spider and power-tong apparatus to replace a top drive for advancing a wellbore.

Description:
PRIORITY 
       [0001]    This application claims priority to U.S. Provisional Application Ser. No. 62/335,131 filed May 12, 2016 for Integrated Flush-Mount Spider And Power-Tong Apparatus And Method Of Use, the entire content of which is incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to a tool to make-up and breakout pipe segments in a pipe string for use on oil and gas drilling rigs. More particularly, the invention relates to an integrated spider and tong combination that may be utilized in place of separate equipment more expensive equipment. 
       BACKGROUND 
       [0003]    During the drilling of an oil and gas well, long strings of pipe are created by threadedly connecting shorter pipe segments. The series of connected pipe segments is called a pipe string. The pipe string is usually supported by spider slips placed in an opening on the floor of a drilling rig. When a pipe segment is to be added to the pipe string using a top drive, the spider slips are set to hold and support the weight of the pipe string. A pick up elevator is used to grab and lift a new segment of pipe which is then stabbed into the threaded connection in the pipe string. Separate power tongs are then used to tighten the connection of a desired torque. 
         [0004]    The primary advantage of a top drive unit is that, it combines the virtues of a travelling block, with a vertical guide system and a power tong. Its use saves rig time by allowing a more efficient make-up and breakout of the pipe segments that comprise the pipe string than that of a conventional rotary drilling rig. Consequently, using a top drive is typically safer because fewer drill crew workers on the rig floor are required. However, a top drive system is bulky, very expensive, and still requires back-up tongs, pick-up elevators, and a sizeable crew of workers on the rig floor. 
         [0005]    Consequently, there is a present need for a compact and less expensive tool that may be utilized on a rig floor in place of a top drive to make-up and breakout pipe segments on a drilling rig floor. 
       SUMMARY OF THE INVENTION 
       [0006]    The disclosed invention is an integrated flush-mount spider and power-tong apparatus to make-up and breakout pipe on a pipe string of an oil and gas chilling rig. The apparatus may be mounted in an opening on the rig floor over the wellbore and is readily removable when it is not needed. The apparatus provides the features of a rotary spider, a backup tong, a power tong, and a torque monitor in compact, single, piece of equipment. The apparatus can be configured so that its power-tong component may be vertically adjusted and positioned as desired so that the power-tong is placed at a convenient working height with respect to the rig floor. The adjustable height of the power-tong component is particularly useful on land rigs. 
         [0007]    The torque monitor provided in the disclosed invention utilizes electronic load cells in the head of the power tong for accurate torque measuring and monitoring as torque is applied during make-up of the pipe string. The torque monitor may include a processor to generate and transmit torque readings to a digital display and the monitor may store the torque readings generated during the make-up of the pipe segments. The torque monitor may also utilize other torque measuring devices such as hydraulic load gages for measuring, monitoring, recording applied torque when appropriate. 
         [0008]    The disclosed invention will replace a conventional power tong, a torque monitor, and torque reaction cables and is less expensive than individual pieces of equipment. When the disclosed integrated flush-mount spider and power-tong apparatus is provided, only a pipe spinner, which is typically provided on every rig, is needed to advance the pipe string. 
         [0009]    The disclosed invention eliminates the need for a top drive and a separate backup tong, Use of the disclosed integrated flush-mount spider and power-tong apparatus will reduce the number of personnel required on the rig floor, safe time, enhance safety, reduce cost, and allow rotary table drilling rigs to be competitive with top-drive rigs by providing most of the advantages associated with the use of a top-drive at a fraction of the cost. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a schematic perspective view showing selected features of the integrated flush-mount spider and power-tong apparatus positioned in a rotary table opening on a rig floor. 
           [0011]      FIG. 2  is a schematic side view of the integrated flush-mount spider and power-tong apparatus shown in  FIG. 1 . 
           [0012]      FIG. 3  is a schematic partial top view of the gripping jaws and gripping dies of the power tong component of the integrated flush-mount spider and power-tong apparatus shown in  FIG. 1 . 
           [0013]      FIGS. 4-7  are schematic top views showing the opening, closing, and rotation of the power-tong during the make-up of a pipe joint. 
           [0014]      FIGS. 8 and 9  illustrate the use of the integrated flush-mount spider and power-tong apparatus of  FIG. 1  for pipe make-up, breakout, and advancement of the wellbore. 
       
    
    
       [0015]    These drawings may omit features that are well established in the art and that do not bear upon points of novelty in the interest of descriptive clarity. Such features include wiring, hoses, hydraulic couplings, pumps, motors, fluid reservoirs, controls, gauges, threaded junctures, weld lines, sealing elements, screws, bolts, pins, and brazed junctures. 
       DESCRIPTION OF THE INVENTION 
       [0016]    The spider with integrated power-tong apparatus ( 10 ) is shown in  FIGS. 1 and 2 . The apparatus ( 10 ) is comprised of a spider ( 20 ) having an integral power tong ( 30 ). Preferably spider ( 20 ) will be a flush-mount spider configured to fit and rest within, and be readily removable from, an opening ( 15 ) in a rig floor ( 16 ) with only the upper portion of the spider, preferably no more than 12 inches, extending above the rig floor ( 16 ). 
         [0017]    For clarity and orientation purposes, only portions of the flush-mount spider ( 20 ) are shown in  FIG. 1 . The flush-mount spider ( 20 ) will have a body shown as a slip frame ( 22 ) and slips, dies, and a slip manipulation mechanism utilizing linear actuators such as hydraulic rams. Details of a suitable flush-mount spider ( 20 ) with slips and dies and slip manipulation mechanisms are shown and described in Applicant&#39;s U.S. Pat. No. 7,775,270 for “Spider with Distributed Dies”, U.S. Pat. No. 7,267,168 for “Spider with Discrete Die Supports” or in Applicant&#39;s U.S. Pat. No. 7,891,469 for “Discrete Element Spider”. 
         [0018]      FIG. 2  shows a schematic side view of the flush-mount spider with integrated power-tong apparatus ( 10 ). The slip frame ( 22 ) of the flush-mount spider ( 20 ) component of apparatus ( 10 ) is comprised of a plurality of slip rails ( 23 ), each having an inwardly tapered surface ( 23   a ), arrayed around a central axis (CA) to create a central opening ( 25 ). Slip rail support plates ( 21 ) provide lateral support and torque resistance, for the slip frame ( 22 ). The slip manipulation mechanism is comprised of timing ring ( 24 ) positioned above the central opening ( 25 ) by means of a plurality of extendable and retractable hydraulic timing ring rams ( 27 ). The timing ring ( 24 ) is pivotally attached to a plurality of tapered spider slips ( 26 ) by slip links ( 24   a ). The spider slips ( 26 ) are slideably mounted on the slip rails ( 23 ) and move vertically upward and downward along the tapered slip rail surfaces ( 23   a ) and radially inward and outward within opening ( 25 ) in response to upward and downward movement of the timing ring ( 24 ) by hydraulic rams ( 27 ) to grip and release the pipe string (PS). The spider slips ( 26 ) are provided with gripping dies ( 26   a ) to enhance gripping engagement with the pipe string (PS). 
         [0019]    Power tong ( 30 ) has support blocks ( 41 ) where it is adjustably attached to a vertically extending support shown as post ( 31 ) that is fixed to brackets ( 32 ) mounted on the slip frame ( 22 ) of the flush-mount spider ( 20 ). Removable fasteners such as bolts or mounting pins ( 28 ) inserted into fastener holes ( 29 ) along the length of support post ( 31 ) may be used to adjustably attach power tong ( 30 ) in a desired vertical position on support post ( 31 ). The, adjustably mounted power tong ( 30 ) allows the height of the power tong ( 30 ) to be adjusted with respect to the rig floor ( 16 ) to facilitate its use. 
         [0020]    The power tong ( 30 ) has a first jaw ( 33   a ) and a second jaw ( 33   b ), each having a first end and a second end, positioned about central axis (CA) to create a central tong opening ( 35 ) that is positioned in vertical alignment with the central opening ( 25 ) of the flush-mount spider ( 20 ). The first jaw ( 33   a ) and the second jaw ( 33   b ) of power tong ( 30 ) are pivotally attached to each other at their respective first ends by pivot pin ( 34 ). A hydraulic jaw ram ( 36 ) is pivotally attached by ram pins ( 37 ) to extend between the respective second ends of first jaw ( 33   a ) and second jaw ( 33   b ). A first gripping die ( 38   a ) is pivotally attached to the first jaw ( 33   a ) and a second gripping die ( 38   b ) is pivotally attached to the second jaw ( 33   b ) on pivot pins ( 39 ) so that gripping dies ( 38   a ) and ( 38   b ) oppose each other across the central tong opening ( 35 ) of the tong ( 30 ). 
         [0021]    As shown in  FIG. 3 , gripping dies ( 38   a ) and ( 38   b ) are V-shaped and are pivotally attached to jaws ( 33   a ) and ( 33   b ), respectively, by pin ( 39 ). The V-shaped configuration and pivotal attachment of gripping dies ( 38   a ) and ( 38   b ) enhance the positioning of gripping dies ( 38   a ) and ( 38   b ) against a new pipe segment (P) extending through the central tong opening ( 35 ) of the tong ( 30 ). Extension and retraction of hydraulic ram ( 36 ) will cause the first jaw ( 33   a ) and the second jaw ( 33   b ) to pivot on pin ( 34 ) to move the first jaw ( 33   a ) and the second jaw ( 33   b ) away from and toward each other and thereby closing and opening central tong opening ( 35 ) to engage and disengage gripping dies ( 38   a ) and ($ 8   b ) with new pipe segment (P). 
         [0022]    Power tong ( 30 ) is provided with a torqueing mechanism ( 40 ) comprised of a first torque arm ( 42 ) mounted to and extending outwardly from the support block ( 41 ), a second torque arm ( 43 ) mounted to and extending outwardly from the second end of the second jaw ( 33   b ), and a hydraulic torque ram ( 44 ) pivotally attached to the outward ends of the first torque arm ( 42 ) and the second torque arm ( 43 ) by pivot pins ( 45 ). Extension and retraction of hydraulic ram ( 44 ) of the torqueing mechanism ( 40 ) will cause the power tong ( 30 ) slide on the support blocks ( 41 ) along guide slot ( 42 ) on jaw ( 33   a ) to rotate the power tong ( 30 ) about central axis (CA). When the jaws ( 33   a ) and ( 33   b ) are moved to a closed position to engage gripping dies ( 38   a ) and ( 38   b ) with new pipe segment (P), new pipe segment (P) will be rotated as the power tong ( 30 ) is rotated. 
         [0023]    Torqueing mechanism ( 40 ) may be provided with a torque monitor ( 47 ). Torque monitor ( 47 ) may include at least one electronic load cell, preferably a compression load cell, positioned on torque rant ( 44 ). Torque monitor ( 47 ) may also have an analog, or digital display to advise a user of the torque applied during connection of a new pipe segment (P). Torque monitor ( 47 ) may also include an audible alarm to advise the user when the applied torque is over or under a desired torque setting. Torque monitor ( 47 ) may also include a memory to store readings of the torque applied to each successive pipe segment. Torque monitor ( 47 ) may be mounted on the power tong ( 30 ) or it may be located remote from the power tong 
         [0024]      FIGS. 4-7  show the torqueing sequence for make-up of a new pipe segment (P) to a pipe string (PS) with the apparatus ( 10 ). In  FIG. 4 , hydraulic ram ( 36 ) of power tong ( 30 ) is extended to open gripping dies ( 38   a ) and ( 38   b ) allowing the new pipe segment (P) to be placed through the central tong opening ( 35 ) of the tong ( 30 ) for engagement with pipe collar (PC) of pipe string (PS) held in place by spider slips ( 26 ) of spider ( 20 ). Hydraulic ram ( 36 ) is then retracted to close gripping dies ( 38   a ) and ( 38   b ) to engage new pipe segment (P) as shown in  FIG. 5 . With the pipe string (PS) held by slips ( 26 ) of spider ( 20 ), and the new pipe segment (P) engaged with gripping dies ( 38   a ) and ( 38   b ), hydraulic ram ( 44 ) of the torqueing mechanism ( 40 ) of power tong ( 30 ) is extended as shown in  FIG. 6  to rotate the pipe segment (P) onto threaded engagement with pipe string (PS) to a desired torque to make-up new pipe segment (P) with pipe string (PS). Hydraulic ram ( 36 ) of power tong ( 30 ) is then extended to open gripping dies ( 38   a ) and ( 38   b ) as shown in  FIG. 7  to allow the process to be repeated. The spider ( 20 ) serves to hold pipe string (PS) in place in the wellbore and as well as a backup tong to prevent rotation when the pipe spinner and the power-tong ( 30 ) rotate new pipe segment (P). The torque applied to rotate new pipe segment (P) onto pipe string (PS) is measured and monitored by a torque monitor ( 47 ) at the ram end of torque ram ( 44 ). The process may then be repeated to farther threadedly engage new pipe segment (P) with pipe string (PS) until a desired torque is reached. The process is reversed to breakout the pipe string (PS) when removing the pipe string from the wellbore. 
         [0025]      FIGS. 8 and 9  show the process of making up the pipe string (PS) with a conventional rig ( 50 ). The spider component ( 20 ) of the apparatus ( 10 ) is fitted into rotary table opening ( 15 ) of the rig floor ( 16 ) and the power-tong ( 30 ) is adjusted vertically on support ( 31 ) to a desired position with respect to the rig floor ( 16 ). The rig drawworks ( 55 ) is then attached to elevator ( 60 ). Elevator ( 60 ) is then placed to rotatably support a new pipe segment (P) to be added to pipe string (PS). With hydraulic rant ( 36 ) of power tong ( 30 ) extended to open gripping dies ( 38   a ) and ( 38   b ) in central tong opening ( 35 ) of tong ( 30 ), and with the while the pipe string (PS) is being held by the spider ( 20 ), elevator ( 60 ) is used to move new pipe segment (P) into the central tong opening ( 35 ) to stab the pipe collar (PC) of the pipe string (PS). 
         [0026]    Power-tong ( 30 ) of apparatus ( 10 ) is then used to make-up pipe segment (P) with pipe string (PS) as shown and described in  FIGS. 4-7 . The slips ( 26 ) of the spider ( 20 ) of apparatus ( 10 ) are closed to hold pipe string (PS) in place in the wellbore (WB) to prevent its rotation during make-up of new pipe segment (P). The slips ( 26 ) of spider ( 20 ) are then opened to release the pipe string (PS) and the pipe string (PS) is further lowered into the wellbore (WB) by elevator ( 60 ) to a position. New pipe segment (P) is then gripped by closing slips ( 26 ) of spider ( 20 ) allowing elevator ( 60 ) to be disengaged to connect another new pipe segment (P). The process may be reversed to breakout a pipe (P) from pipe string (PS) to remove the pipe stung (PS) from the well bore. 
         [0027]    Apparatus ( 10 ) may also be used with a pipe spinner ( 70 ) as shown in  FIG. 9  to rotate the pipe string (PS) and the drill bit ( 75 ) to advance pipe string (PS) in wellbore (WB). This will eliminate the need for a top drive mechanism for rotating the pipe string (PS). 
         [0028]    It is thought that the integrated flush-mount spider and power-tong apparatus ( 10 ) presented herein as well as its attendant advantages will be understood from the foregoing description. It is also thought that it will be apparent that various changes may be made in the form, construction, and arrangement of the parts thereof without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form herein being merely in example embodiment of the invention.