Patent Publication Number: US-10309170-B2

Title: Spinner tool with control valve

Description:
BACKGROUND 
     Field 
     Embodiments disclosed herein relate to a spinner system for coupling or de-coupling tubulars in a drilling or workover operation utilized in the oil and gas industry. More specifically, embodiments disclosed herein relate to a control valve that controls the fluid flow and accordingly the torque and speed at which a spinner tool can operate if the spinner tool is not secured by a safety snub line. 
     Description of the Related Art 
     A spinner tool (also known as a “pipe spinner”) is commonly used in the oil and gas industry. The spinner tool is an air or hydraulically powered tool used to spin tubular pipe in making up or breaking out threaded connections. The spinner tool may be used to thread tubulars together in a drilling operation (make-up) or used to de-couple tubulars by rotating the tubular in an opposite direction. The spinner tool is a relatively low torque device, useful for the initial makeup of threaded tool joints in a drilling operation, and a separate power tong is subsequently used to provide proper torque to complete threaded connections. 
     During operation on a rig, the spinner tool is suspended above a rotary spider that is located in the rig floor. The spinner tool has rollers that are moved into position about a pin end of a tubular and configured to rotate the tubular relative to another tubular (held by the rotary spider) to threadedly couple the two tubulars together. The rollers are coupled to a frame of the spinner tool that needs to be fixed to prevent inadvertent rotation of the frame about the tubulars. A snub line in the form of a cable or wire rope is typically utilized to secure the frame to a winch or other fixed object to prevent the frame from rotating. However, personnel sometimes forget to attach the snub line which may allow the frame to rotate when the spinner tool is operated and potentially injury nearby personnel and/or damage surrounding equipment. This creates a safety hazard on the rig. 
     Therefore, there exists a need for a new and improved spinner tool that prevents the safety hazard described above. 
     SUMMARY 
     In one embodiment, a tubular rotating system for rotating threaded tubulars comprises a frame; a plurality of rollers coupled to the frame and configured to rotate a tubular; and a control valve coupled to the frame that controls rotational speed of the rollers based on a tension force. 
     In one embodiment, a tubular rotating system for rotating threaded tubulars comprises a frame; a plurality of rollers coupled to the frame and configured to rotate a tubular; and a control valve coupled to the frame and configured to control power supplied to the rollers, wherein the rollers are rotated at a first rotational speed greater than zero when the control valve is in an off state, and at a second rotational speed greater than the first rotational speed when the control valve is in an on state. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of one embodiment of a spinner system. 
         FIGS. 2A and 2B  are isometric views of a control valve of the spinner system shown in partial cross-section. 
         FIG. 3  is an isometric view of one embodiment of a spinner system. 
     
    
    
     To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one embodiment may be beneficially utilized with other embodiments without specific recitation. 
     DETAILED DESCRIPTION 
     Embodiments of the disclosure include a tubular rotating system for use in the oil and gas industry. The system includes a spinner tool and a control valve attached to the spinner tool. The control valve controls the power utilized by the spinner tool based on tension as further described below. The power may be fluid power (such as liquid or air) or electric power. While the embodiments of the disclosure are described with respect to a spinner system and spinner tool, the embodiments of the disclosure are not limited to only spinner systems and spinner tools, but may include other similar tubular rotating systems and tools that may be coupled to a fixed object by a snub line during operation, such as an iron roughneck system. 
       FIG. 1  is an isometric view of one embodiment of a spinner system  100 . The system  100  includes a spinner tool  105 , a control valve  110  coupled to the spinner tool  105 , and a snub line  115  coupled to the control valve  110 . The spinner tool  105  may be suspended from a crane structure  120  to position a frame  125  of the spinner tool  105  above a rotary spider located in a rig floor (not shown). In one embodiment, a vertical actuator, such as a cylinder  130 , may be coupled between the crane structure  120  and the frame  125 . 
     The control valve  110  is coupled to the frame  125  and the snub line  115  may be coupled to a fixed object  135 , such as a portion of the rig or a winch. The spinner tool  105  includes a jaw assembly  140  that is pivotably coupled to the frame  125 , and an actuator assembly  145  that controls opening and closing of the jaw assembly  140  about a tubular in the direction of the arrow A. The jaw assembly  140  includes one or more rollers  150  that are movable into contact with an outer surface of a tubular when the jaw assembly  140  is closed. Each of the rollers  150  are operably coupled to a motor  155  that rotates the rollers  150  to rotate a tubular about an axis  160 . The snub line  115 , being coupled to the fixed object  135 , prevents inadvertent rotation of the frame  125  about the axis  160  when the rollers  150  are rotating a tubular. 
     Personnel may forget to attach the snub line  115  to the spinner tool  105  and/or the fixed object  135 , which may allow the frame  125  to rotate about the axis  160  in an uncontrolled manner. Alternatively, the snub line  115  may break or loosen during operation of the spinner tool  105 , which may also permit the frame  125  to rotate about the axis  160  in an uncontrolled manner. Inadvertent rotation of the frame  125  may cause injury or death to personnel, and/or may also damage the spinner tool  105  and/or other surrounding equipment. 
     To prevent inadvertent rotation of the spinner tool  105 , the control valve  110  is configured to control operation of the spinner tool  105  based on whether the snub line  115  is taut and/or attached to the fixed object  135 . The control valve  110  controls the amount of operating fluid supplied to the spinner tool  105  based on the amount of tension in the snub line  115 . If little or no tension is applied to the snub line  115 , the control valve  110  restricts the amount of operating fluid supplied to the spinner tool  105  such that spinner tool  105  may only operate at a low speed. When sufficient tension is applied to the snub line  115 , the control valve  110  permits the maximum amount of operating fluid to be supplied to the spinner tool  105  such that the spinner tool  105  may operate at a maximum speed. 
     The motors  155  may be hydraulically or pneumatically powered by an operating fluid supplied from a power source  165 . The power source  165  is in fluid communication with the motors  155  by an outlet conduit  170  that is coupled to the control valve  110 , and an inlet conduit  175  that is coupled to the power source  165  and the control valve  110 . Operating fluid that actuates the motors  155 , and in turn rotates the rollers  150 , is pumped from the power source  165  to the control valve  110  via the inlet conduit  175 , and from the control valve  110  to the motors  155  via the outlet conduit  170 . While the outlet conduit  170  and the inlet conduit  175  are described in this embodiment as transferring fluids, in other embodiments, the outlet conduit  170  and the inlet conduit  175  may be utilized to transfer electric power as described with respect to  FIG. 3  below. 
     When the control valve  110  is in an off state, such as a first position, the control valve  110  permits only a portion of the operating fluid (i.e., a first or low pressure and/or volume of fluid) to pass through the control valve  110  and to the motors  155  via the outlet conduit  170 , which rotates the rollers  150  at a first speed, such as a minimum or low speed that is greater than zero. In one example, during a make-up operation, the rollers  150  may be rotating in a counterclockwise direction to rotate a tubular about the axis  160  in a clockwise direction. 
     The frame  125  may want to rotate in the direction of arrow B when the rollers  150  are actuated to rotate a tubular and thereby pull on the snub line  115 . When the snub line  115  becomes taut and/or is tension by being attached to the fixed object  135  (such as by rotation of the frame  125  and/or tensioning of the snub line  115  by the fixed object  135 , e.g. a winch), the control valve  110  is actuated to an on state, such as a second position, that permits additional operating fluid (i.e., a second or high pressure and/or volume of fluid) to be supplied to the motors  155 . The additional operating fluid may actuate the rollers  150  to rotate at a second speed, such as a maximum or high speed, to rotate a tubular at a greater rotational speed as compared to the rotational speed when the control valve  110  is in the first position and restricts the operating fluid such that only a portion of operating fluid is supplied to the motors  155 . 
     If the snub line  115  becomes loose and is not taut and/or tensioned, the control valve  110  remains in the first position and the rollers  150  are limited in rotational speed based on the first or low pressure and/or volume of fluid. The slower rotational speed of the rollers  150 , provided when the control valve  110  is in the first position, allows personnel to react by moving out of the rotational path of the frame  125  and/or disable the operating fluid flow from the power source  165  to cease operation of the spinner tool  105 . Thereafter, the snub line  115  may be attached (or re-attached) to the fixed object  135  and the operating fluid flow from the power source  165  may resume, which may again cause slight rotation of the frame  125  in the direction of arrow B as described above. When the snub line  115  is taut and/or tensioned, the control valve  110  is actuated back to the second position to provide the second or high pressure and/or volume of fluid, which allows the rollers  150  to operate at a higher rotational speed. 
       FIGS. 2A and 2B  are isometric views of the control valve  110  in cross-section.  FIG. 2A  shows the control valve  110  in the first position, while  FIG. 2B  shows the control valve  110  in the second position. 
     The control valve  110  includes a body  200  having a central bore  205  formed therein. The outlet conduit  170  and the inlet conduit  175  are at least partially formed in and/or coupled to the body  200  to be in fluid communication with the central bore  205 . A piston  210  is retained within the body  200  by a nut  215  that may be threadedly attached to a first end of the body  200 . The piston  210  is movable within the central bore  205  in the direction of arrow C. A proximal end of the piston  210  is extends out of a first end of the body  200  and may be coupled to the snub line  115  by a coupler  220 , such as an eyelet or shackle. A second end of the body  200  may include a coupling mechanism  225  for attachment to the frame  125  of the spinner tool  105 . 
     The piston  210  includes a valve body  225  having a valve  230  and a containment ring  235 . The valve body  225  includes an elongated first volume  240  formed between a reduced inner diameter portion of the central bore  205 , and a reduced outer diameter portion of the piston  210  between the valve  230  and the containment ring  235 . A seal  245 , such as an O-ring, may be disposed on the containment ring  235  to prevent fluid flow outside of the first volume  240 . Operating fluid may flow around the valve  230  and/or between the valve  230  and the reduced inner diameter portion of the central bore  205 . Operating fluid may be contained in the body  200  by a seal  250  disposed on the piston  210  adjacent to a second volume  255  formed by an enlarged inner diameter portion of the central bore  205  that is next to the reduced inner diameter portion of the central bore  205 . 
     In the first position as shown in  FIG. 2A , a tension provided by the snub line  115  is less than a certain threshold tension, or has no tension at all (indicative of an un-attached or broken snub line  115 ), operating fluid flows from the power source  165  to the inlet conduit  175  and to the second volume  255  at a first pressure. A portion of the operating fluid and/or fluid pressure flows pass the valve  230  into the first volume  240  and to the motors  155  through the outlet conduit  170 . In one example, the first pressure of the operating fluid provided by the power source  165  may be about 200 pounds per square inch (psi). This first pressure may remain constant. 
     In the first position, a percentage of the first pressure may pass the valve  230  (i.e., a second pressure), enter the volume  240 , and flow to the motors  155  through the outlet conduit  170 . For example, when the inlet pressure is 100%, a percentage of the inlet pressure less than the inlet pressure is flowed to the motors  155 . At 100% inlet pressure, the outlet pressure may be about 10% to about 15%, such as about 12%. The reduction of pressure may be determined based on a size of a gap or gaps between the valve  230  and the central bore  205 . 
     In the example using an inlet pressure of about 200 psi, the outlet pressure may be about 24 psi. Thus, the motors  155  are operated at a reduced pressure when the control valve  110  is in the first position, which causes the rollers  150  to rotate at a rotational speed that is less than a full rotational speed when the control valve  110  is in the second position and 100% pressure is provided thereto. In one embodiment, the full rotational speed of the rollers  150  may be about 140 revolutions per minute (rpm) to about 210 rpm. According to one example, if the full rotational speed of each of the rollers is about 150 rpm, then the reduced speed provided when the control valve  110  is in the first position would be between about 14 rpm to about 21 rpm. Therefore, any rotational movement of the spinner tool  105 , if not secured by the snub line  115 , is slowed, which allows personnel to react to the non-tensioned snub line  115  without injury or damage. 
     When the snub line  115  is secured, and a predetermined tension is applied to the control valve  110 , the control valve  110  is moved to the second position as shown in  FIG. 2B . The predetermined tension may be provided to overcome a force of a biasing member  260 , such as a spring, provided in a cavity between a plate  265  of the nut  215  and a radially extending shoulder  270  of the piston  210  that forces the control valve  110  into the first position. In one embodiment, the predetermined tension may be about 25 pounds. 
     Once the tension overcomes and compresses the biasing member  260 , the piston  210  moves relative to the body  200  in the direction of arrow D. The movement displaces the position of the valve  230  relative to the inlet conduit  175  such that the valve  230  is positioned in the second volume  255 . Thus, the inlet conduit  175  is in full fluid communication with the outlet conduit  170  via the volume  240  so that all of the operating fluid flow is allowed to flow through, and fluid pressure delivered at the inlet conduit  175  is flowed out of the outlet conduit  170  to the motors  155  at the same pressure as the inlet pressure. This provides fluids to the motors  155  at a pressure and volume for maximum rotational speeds. 
     In one embodiment, the piston  210  includes a region  275  that serves as a visual indicator confirming that the control valve  110  is tensioned. The region  275  may be a depressed annular region of the piston  210  (i.e., a reduced diameter region of the piston  210 ). Alternatively or additionally, the region  275  may include a color  280  that is different than a color of the piston  210 . The color  280  may be a high-visibility paint or coating, such as orange or red, which is easily recognizable. 
       FIG. 3  is an isometric view of one embodiment of a spinner system  300 . A control valve  305  is shown coupled between the frame  125  and the snub line  115 . The control valve  305  is similar to the control valve  110  shown and described in  FIGS. 1, 2A, and 2B  with the following exceptions. 
     The motors  155  are electrically powered motors, and the control valve  305  controls the amount of electric power supplied to the motors  155  based on tension applied to the control valve  305 . The control valve  305  may control the current (amperage) and/or the voltage of the electric power supplied to the motors  155  via the inlet and outlet conduits  175 ,  170 . The control valve  305  according to this embodiment includes an electric actuator  310 . The electric actuator  310  may be a strain gauge or a proximity sensor that utilizes a contactor  315  to control an amount of electric power supplied to the motors  155  when a specified tensioned is applied between the frame  125  and the snub line  115 . 
     For example, when a specified tension is applied to the control valve  305 , the contactor  315  provides a circuit that controls electrical power to the motors  155  in an amount for maximum rotational speeds of the rollers  150 . For another example, when little or no tension is applied to the control valve  305 , the contactor  315  provides a circuit that controls electrical power to the motors  155  in an amount for less than maximum rotational speeds of the rollers  150 . 
     When the control valve  305  is at a first position (e.g. with little or no tension), a first amount of electric power may be provided to the motors  155 . When the control valve  305  is at a second position (e.g. when tensioned), a second amount of electric power greater than the first amount of electric power may be provided to the motors  155 . 
     When the control valve  305  is in the first position, electric power from the power source  165  is restricted such that only a portion of the electric power is supplied to the motors  155 . When the snub line  115  becomes taut and/or is tensioned by being attached to the fixed object  135  (such as by rotation of the frame  125  and/or tensioning of the snub line  115  by the fixed object  135 , (e.g. a winch), the control valve  305  is actuated to an on state, such as the second position, that permits a greater portion or all of the electric power from the power source  165  to be supplied to the motors  155 . The amount of electric power supplied to the motors  155  when the control valve  305  is in the second position may actuate the rollers  150  to rotate at a second speed, such as a maximum or high speed, to rotate a tubular at a greater rotational speed as compared to the rotational speed when the control valve  305  is in the first position and where the electric power from the power source  165  is restricted such that only a portion of the electric power is supplied to the motors  155 . 
     If the snub line  115  becomes loose and is not taut and/or tensioned, the control valve  305  remains in the first position and the rollers  150  are limited in rotational speed based on the first or lower amount of electrical power supplied to the motors  155 . The slower rotational speed of the rollers  150 , provided when the control valve  305  is in the first position, allows personnel to react by moving out of the rotational path of the frame  125  and/or disable the electric power from the power source  165  to cease operation of the spinner tool  105 . Thereafter, the snub line  115  may be attached (or re-attached) to the fixed object  135  and the higher amount of electric power from the power source  165  may resume, which may again cause slight rotation of the frame  125  in the direction of arrow B as described above. When the snub line  115  is taut and/or tensioned, the control valve  305  is actuated back to the second position to provide the second or higher power from the power source  165 , which allows the rollers  150  to operate at a higher rotational speed. 
     While the foregoing is directed to embodiments of the disclosure, other and further embodiments of the disclosure thus may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.