Patent Abstract:
The present invention relates generally to a Top Drive Pipe Spinner (TDPS). The TDPS is a tool that allows for the setting of casing without a specialized crew or any additional power source. By employing the weight of the existing top drive to set slips on the casing collar, the TDPS allows one casing to be threaded onto the next in a timely and efficient manner. The casing tongs of the TDPS use passive release weight to release the casing collar from the casing to allow for the successive insertion of another casing section. The top drive spins the TDPS and compresses the unit onto the casing, then lifts the unit and releases the casing when desired.

Full Description:
FIELD OF INVENTION 
       [0001]    The present invention relates generally to a Top Drive Pipe Spinner (TDPS). The TDPS is a tool that allows for the setting of casing without a specialized crew or any additional power source. By employing the weight of the existing top drive to set slips on the casing collar, the TDPS allows one casing to be threaded onto the next in a timely and efficient manner. The casing tongs of the TDPS use passive release weight to release the casing collar from the casing to allow for the successive insertion of another casing section. The top drive spins the TDPS and compresses the unit onto the casing, then lifts the unit and releases the casing when desired. 
       BACKGROUND 
       [0002]    The use of a top drive technology has led to substantial improvements in efficiency and safety in drilling over the past 15 to 20 years. By contrast, methods for running casing, even with top-drive technology, have remained relatively unchanged. Traditional methods of running casing require the use of a special teams employed solely for the purposes of running casing, at significant cost to the driller. Additionally, these teams must be brought in, thus slowing the drilling process. 
         [0003]    Power tongs are an established method to run casing in coordination with the drilling rig hoisting system. The power tong method allows the pipe segments to be mated with threaded ends between sequential segments as they are added to the string being installed in the well bore (or removed and disassembled). The power tong method, however, does not support other beneficial functions such as allowing the casing to be filled while moving the pipe. Previous methods and equipment do not include a tool that can run casing while serving other beneficial and time saving functions. For example, filling the pipe with fluid and the tool doubling use as a circulating tool to replace the fill tube when desired. 
         [0004]    With top-drive technology coming into the drilling arena, drilling rigs equipped with top drives have enabled new methods of running casing and other tubulars. The top drive can be equipped with known running tools to grip and seal between the proximal pipe segment and the top drive quill (wherein quill is meant to include drive string components that may be attached, the distal end effectively acting as an extension of the quill). 
         [0005]    Various devices have been developed to accomplish top-drive running casing. These devices are used in coordination with the top drive and allow rotating, pushing, and filling of the casing string with drilling fluid while running, thus removing the limitations of the power tong method. Simultaneously, automation of the gripping mechanism combined with the inherent advantages of the top drive reduces the necessity of a specialized team of skilled personnel who are being compensated for hard labor in sometimes hazardous conditions. These devices, with their independent operation without associated personnel, allow for increased safety and efficiency. 
         [0006]    To handle and run casing with these top drive tubular running tools, the string weight is transferred from the top drive to a support device when the proximal or active pipe segments are being added or removed from the otherwise assembled string. This function is typically provided by an “annular wedge grip” axial load activated gripping device that uses “slips” or jaws placed in a hollow “slip bowl” through which the casing is run, where the slip bowl has a frusto-conical bore with downward decreasing diameter and is supported in or on the rig floor. The slips then acting as annular wedges between the pipe segment and the proximal end of the string and fusto-conical interior surface of the slip bowl, tractionally grip the pipe but slide or slip downward and thus radially inward on the interior surface of the slip bowl as string weight is transferred to the grip. The radial force between the slips and pipe body is thus axial load and self-activated or “self-energized”, i.e., considering the tractional capacity the dependent and string weight the independent variable, a positive feedback loop exists where the independent variable of string weight is positively fed back to control the radial grip force with conotonically acts to control tractional capacity or resistance to sliding, the dependent variable. 
         [0007]    Similarly, the torque applied to the active pipe segment must also be reacted out of the proximal end of the assembled string. This function is typically provided by tongs which have grips that engage the proximal pipe segment and an arm attached by a link such as a chain or cable to the rig structure to prevent rotation and thereby react torque not otherwise reacted by the slips in the slip bowl. The grip force of such tongs is similarly typically self-activated or “self-energized” by positive feedback from the applied torque load. 
         [0008]    Multiple documents describe tools that can be used to run casing with the use of a top drive. For instance, U.S. Pat. No. 8,042,626 describes such a tool for use with a top drive that allows for rapid engagement, release, hoisting, pushing and rotating. The casing is engaged within the tool through rotation that is assisted by hydraulics. 
         [0009]    However, no tool has been shown to work with the top drive, which is simple, requires no outside energy source, and maintains the integrity of the casing. Thus, there is a need for a casing tool that employs the top drive and is easily used, removing the need for personnel to run casing. A self-activated tool would be particularly advantageous; requiring no outside energy source for its proper function. 
       SUMMARY OF THE PRESENT INVENTION 
       [0010]    The present invention is a top drive pipe spinner (TDPS) that substantially obviates the needs or problems due to the limitations and disadvantages of the related art. 
         [0011]    Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structural properties particularly pointed out in the written description and claims, as well as the appended drawings. 
         [0012]    To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the TDPS includes a top drive connection, bolts, turning sub with inverted taper, inverted slips, release weight, and a fill tube with fluid release valve. 
         [0013]    The present invention grips casing from its exterior, thus preventing detrimental damage to the casing. Tools that grip from the interior can make marks on the casing and where the operator needs to swab the fluid out of the casing, the imperfections of markings on the interior of the casing can deteriorate the rubber swab cup. 
         [0014]    Moreover, the present invention requires no outside energy for proper functioning by using the existing top drive and turning sub. The present invention requires little maintenance and can be used efficiently for long periods of time. 
         [0015]    The TDPS of the present invention is a durable and resilient tool. The tool may be used for many years without substantial maintenance or repair. The TDPS of the present invention may be used for up to 9 years without repair. Thus, the TDPS of the present invention offers many advantages over the prior art. 
         [0016]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. 
         [0017]    The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a cross section of one embodiment of the TDPS, with the slips disengaged of the present invention. 
           [0019]      FIG. 2  is a cross section of one embodiment of the TDPS, with the slips engaged of the present invention. 
           [0020]      FIG. 3  is a top view of an embodiment of the TDPS of the present invention. 
           [0021]      FIG. 4  is a bottom view of the TDPS of the present invention, as in one embodiment. 
           [0022]      FIG. 5  is a view of the inverted slip of the TDPS, as in an embodiment of the present invention. 
           [0023]      FIG. 6  is a cross section view of the fill tube and fluid release valve of the TDPS, as in an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0024]    Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference characters will be used throughout the drawings to refer to the same or like parts. 
         [0025]      FIG. 1  shows a cross section view of the TDPS of the present invention with the top drive connection  100  at the top of the TDPS. This connection  100  mates with an existing top drive to secure the TDPS in place. In one preferred embodiment of the present invention, the top drive connection  100  is threaded into the top head drive. Other methods of securing the top drive connection  100  to the top head drive are contemplated. In the preferred embodiment, the top drive connection  100  is about 8 inches long and 6 inches in diameter. The top drive connection  100  extends just through the top plate  102  and can be connected to the top plate  102  by welding. In the preferred embodiment the top drive connection  100  and top drive plate  102  can be made as one piece in manufacturing, lending to the durability and integrity of the TDPS of the present invention. As is known to those skilled in the art, other methods of securing the top drive connection  100  to the top plate  102  could be used, such as welding, and the like. 
         [0026]    The top plate  102  connects the top drive connection  100  to the turning sub  103  and fill tube with fluid release valve  107 . The top plate  102  is secured to the turning sub  103  by a plurality of bolts  101  on the upper surface of the top plate  102  (as is illustrated more particularly in  FIG. 3 ). In one preferred embodiment, the top plate is approximately 1 inch in thickness. Other methods of securing the top plate  102  to the turning sub  103  are contemplated such as screws or other fasteners such as clamps that provide secure and removable fastening. and other known fastening means. Where the drive connection  100  and top plate  102  are one piece as described above, the top plate is removable from the turning sub  103 , thus allowing access to the slips  106  and release weight  104 . 
         [0027]    In the preferred embodiment, the turning sub is 12 inches OD, and 8 inches ID. Moreover, the turning sub is approximately 2 feet long. The bottom half of interior of the turning sub is an inverted bevel. In one preferred embodiment, the inverted bevel is approximately 8 inches long. The bevel is approximately 11¾ inches inside diameter at its bottom most point, and 8 inches inside diameter with the wall thickness being approximately 2 inches thick at the topmost point (at the midsection of the turning sub), and approximately ⅛ inch thick at the bottom most point (at the end of the turning sub). Thus, the angle of the inverted bevel is approximately 15°. In the preferred embodiment, the turning sub extends approximately 3 inches below the bevel. In other embodiments, the angle of the bevel may be lower or higher, such as 10°, 20°, or 25°. As is known by those in the art, changing the bevel to a steeper degree (i.e., 25°) may be accomplished by shortening of the length of the bevel. In such an instance the O.D. at the top and the bottom of the bevel would be the measurements above, and the slips would have a shorter distance to travel. The preferred embodiment described above, at a 15° degree angle, will accommodate casing collars from 4½ inches to 6 inches. However, other embodiments that accommodate 6½ to 8⅝ inches, or 10 inches to 13 inches are contemplated by the present invention. Those embodiments require the scaling up of the dimensions herein provided. 
         [0028]    As shown in  FIGS. 1 and 2  the top plate  102  connects to the turning sub/spinner body  103 . In one preferred embodiment, the spinner body  103  is approximately 8 inches ID 12 inches OD and 24 inches in length. 
         [0029]    As shown further in  FIG. 1 , a release weight  104  assists the tool in properly aligning and securing the casing to the TDPS of the present invention. The release weight  104  sits on top of the slip segments to assist in releasing slip segments from casing after completion of attaching one segment of casing to another. The release weight  104  also assists in allowing the slip segments  106  to move synchronously to one another. Moreover, the release weight  104  is capable of movement upward and downward to efficiently allow casing to be secured within the TDPS. As seen in  FIG. 1 , the release weight  104  is in a downward position when the slips are disengaged, there being space between the top plate  102  and the release weight  104 . When the release weight  104  is in the downward position, approximately 6 inches of space exist between the top of the release weight  104  and the top plate  102 . 
         [0030]    The fill tube and fluid release valve  107  shown in  FIGS. 1 and 2  and detailed in  FIG. 6 , allows the filling of casing/pipe while running each joint eliminating the need to stop and fill casing after a certain amount of pipe is ran. Having to stop and fill pipe periodically takes several hours when pipe is ran thousands of feet deep. Filling pipe with fill tube as each joint of pipe is ran saves valuable time and money since laid pipe will be full of fluid when the bottom is reached allowing operations to proceed. Filling as the pipe is run also eliminates air within the pipe, which is disadvantageous and inefficient. Details of the fill tube fluid release valve  107  are described below. 
         [0031]    As shown in  FIG. 1  the bottom of the release weight  104  secures the plurality of inverted slips  106  in the TDPS of the present invention. The release weight  104  is in the top twelve inches of pipe below the top drive connection  100 . The release weight  104  sits on the slip segments  106 , thus securing the slips  106  and preventing from hanging and moving in position. The details of the inverted slips  106  are further illustrated in  FIG. 5  and described below. When the slips are disengaged position as illustrated in  FIG. 1 , the release weight  104  is in the downward position and the slip segments  106  are not in contact with the casing collar  108 . The casing collar  108  has not yet been secured by the slip segments, and the fill tube and pressure release valve have not extended into the casing  109 . 
         [0032]    The inverted slips  106  as shown in  FIG. 1  grip the casing collar  108  from its exterior, as shown in  FIG. 2  when the slips are engaged. The casing collar  108  being connected to the casing  109  to be run. That casing  109  being placed through a rotary table at its opposite end to be threaded to a separate casing located below the ground and within the rotary table, once engaged as shown in  FIG. 2 . 
         [0033]    In practice, the top head drive connection  100  is threaded to the existing top head drive. The casing  109 , containing the casing collar  108  are moved to be received by the TDPS. The casing collar  108  is received by the inverted slips  106  of the TDPS after. As the casing  109  and collar  108  become substantially vertical, the top head drive (not shown) moves downward providing the weight to engage slip segments  106 , providing enough downward pressure to cause slip segments  106  to grip the exterior of the casing collar  108  and engage the slips  106  as illustrated in  FIG. 2 . 
         [0034]    The release weight  104  keeps slip segments  106  in a downward position when not engaged and assists in making slip segments  106  move synchronously. For instance, if the casing collar  108  is placed into the TDPS at an awkward angle, and that casing depresses only one slip segment, without a release weight, the casing can become entangled in the slip segments. The casing would then need to be removed from the tool and repositioned. The release weight  104  maintains the slip segments  106  in position relative to each other, such that if the casing  108  is moved into the TDPS at an awkward angle, any one slip segment  106  will maintain its position, thus forcing the casing collar  108  into the proper position with efficiency and ease. In one embodiment of the present invention, the dimensions of the release weight  104  are 7½ O.D. by 6½ long, weighing approximately 40 lbs. 
         [0035]    The existing rotary table contains a previously existing casing within that rotary table. The new casing  109  is set to thread to the previous casing within the rotary table. The weight of the TDPS of the present invention is sufficient for the two casing pieces to be in contact. 
         [0036]    When the existing top drive connected to the TDPS is actuated and the slips  106  of the TDPS are engaged as in  FIG. 2 , the turning sub  103  rotates, threading the casing  109  into the casing previously existing within the rotary table. Once threaded, the top drive and TDPS moves upward and the release weight pushes slip segments downward, by only the force of gravity, and away from pipe, and the casing collar  108  is released (see  FIG. 1 ), allowing the casing  109  to move down within the earth and allow the process to begin again. 
         [0037]      FIG. 2  shows a cross section view of the TDPS with the spinner engaged. This position is achieved where the top drive is connected to the TDPS and the top drive is pressing downward with its weight. In this position, note that the release weight  104  is in close proximity to the top plate  102 , the slip segments  106  are in contact with the casing collar  108  and the fill tube and fluid release valve  107  extends into the casing  109 . 
         [0038]      FIG. 3  shows a top view of the TDPS. The top drive connection  100  is a threaded pipe to be received by the user&#39;s existing top drive. As shown in  FIG. 3 , a plurality of bolts  101  are used to secure the top plate  102 . In one preferred embodiment, approximately 6 bolts are used. As is well known, any different number of bolts may be sufficient to secure the top plate  102 . Other fasteners are contemplated, as well as other means of coupling the top plate  102  to the turning sub  103 . Note the top drive connection  100  can be made as one piece with the top plate  102  as shown in this illustration. Alternatively, the top drive connection  100  can be welded to the top plate  102 . As is well known in the art, other methods of securing the top drive connection  100  to the top plate  102  are well known and are contemplated by the present invention. Moreover, it is contemplated that the top drive connection  100 , top plate  102 , can be made as one piece, as stated above. 
         [0039]      FIG. 4  shows a bottom view of the TDPS of the present invention. The outer periphery is the turning sub  103 . The slip segments  106  are secured by T-slots  400  cut into the turning sub  103  (See  FIGS. 1 and 2 ). The slip segments are cavity backed and form a T to be inserted into the T-slots  400  that have been cut into the turning sub  103 . In the preferred embodiment, the T-slots  400  are constructed as part of the turning sub  103 , thus lending to the integrity of the TDPS of the present invention. Alternatively, T-slots  400  can be welded onto the turning sub  103  using appropriate pieces such as angle irons and the like. The top plate  102  secures the top drive connection  100  to the turning sub  103 . Also shown in  FIG. 4  are the plurality of inverted slips  106 . The slips  106  engage the casing collar  108  at the interior of the TDPS, and each of the T-slots  400  house one of the plurality of slips  106 .  FIG. 4  also illustrates the bottom portion of the fill tube with fluid release valve  107 . The fill tube with fluid release valve  107  reside within the TDPS at its approximate center. 
         [0040]      FIG. 5  shows an illustrative side view of one of the plurality of slips  106  used in the TDPS. In one preferred embodiment, approximately 5 slips  106  are used to create the TDPS. As is well known by those in the art, other numbers of slips, such as 3, 6, 7, 8 and more than 8 can be used to create the present invention. Slips are commonly used in the oil industry. Slips are commonly used to grip and hold the upper part of a drill string to the drill floor of an oilrig. The present invention repurposes these slips by inverting them so that they may efficiently run casing by inverting the slip. 
         [0041]    The release weight  104  illustrated in  FIGS. 1 and 2  contacts with the release weight plate  500  at the topmost portion of the slip (see  FIG. 5 ). The release weight plate  500  contacts the engaging body  501  of the slip when in the exterior position. In the preferred embodiment, the slip body  501  is approximately 4 inches in length. Below the engaging body  501  is the engaging plate  502 , which comes into contact with the casing collar  108  to engage the slips  106  as the casing  109  is received by the TDPS. When disengaged, the engaging plate  502  has an exterior position to the center of the TDPS. The casing collar  108  pushes upward on the engaging plate  502  causing the slips  106  to move upward and inward to grip the casing collar  108 . In this engaged position, the engaging plate  502  moves toward the interior position (closer to the center of the TDPS). At all times the engaging plate  502  is substantially perpendicular to the turning sub  103 . Additionally, note the dimensions of the slip will necessarily change if scaling the TDPS to suit larger casing, the present figures are for a 4″ drill pipe, 4½″, or 5½″ casing collar. 
         [0042]    Further shown in  FIG. 5 , the engaging plate  502  is connected to the slip body  503 , which is substantially perpendicular to the turning sub  103  on the interior side, and angled outward from the interior on the opposite side, the slip body  503  resembling a shark-fin type shape. On the interior edge perpendicular to the engaging plate  502  of the slip body  503  is the slip deye  504 . The slip deye  504  has a jagged interior-facing edge to grip the exterior of the casing collar  108  when the TDPS is engaged. The length of the slip deye  504  in the preferred embodiment, is approximately 4½ inches. The length of the slip body, in its entirety, is approximately 7 to 11 inches (wherein the slip body extends approximately 2 and ½ inches from the posterior end of the slip deye). The slip deye  504  is substantially parallel with the turning sub  103 . In the preferred embodiment, the slip is constructed of a durable metal such as steel, other suitable alloys, or metallurgic materials. 
         [0043]    When the slip is in the engaged position, the slip deye  504  is in an interior position, closer to the center of the TDPS. When the slip is disengaged, the slip deye  504  is in an exterior position, closer to the exterior of the TDPS. In the preferred embodiment, where the TDPS is running casing with a 5 and ½ inch collar, there is ¼ inch around the collar  108  where the TDPS is not engaged. The slips then move to contact the collar when the TDPS is engaged. This same TDPS that can run casing with a 5½ inch casing collar, can also be used for a 4 inch drill pipe or 4½ inch casing collar. 
         [0044]    While the slip is well known, inverting the slip to be used in this manner is novel and unknown to those in the art. The slip deyes  504  of the present invention are durable, and capable of use for extended periods of time, up to 9 years of regular use. Alternatively, deyes  504  can be used to run at least approximately 300,000 ft of pipe before being replaced. When slip deyes  504  become dulled, new deyes may be replaced. 
         [0045]      FIG. 6  illustrates the fill tube and fluid release valve  107  shown in  FIGS. 1 and 2 . The fill tube and fluid release valve has an uppermost threaded region  304  that secures the fill tube and fluid release valve to the top drive connection  100  and thus the TDPS. The fill tube  300  extends from the threaded region  304  down to the fluid release valve  303 . The fluid release valve  303  is functionally comprised of a ball seat  301 , ball check  305 , and tension spring  302 . The fluid release valve  303  allows for the controlled filling of casing while eliminating errant spills on the rig floor. When a predetermined pressure is reached by an existing mud pump (for instance 150 psi), the pressure overcomes the tension spring  302 , which allows the ball check  305  to move away from the ball seat  301 , allowing fluid to be pumped into casing  109  being joined to the previously existing casing within the rotary table. Once the predetermined amount of fluid is pumped into the casing  109  (see  FIGS. 1 and 2 ) the pump is disengaged and when the pressure drops below the 150 psi, then ball check  305 , move back up to seat  201  to the locked position as the tension spring  302  engages and flow of fluid is stopped. It is contemplated that rather than the ball seat and check system, a valve could be employed that is pressure dependent or manually operated to allow the filling of the casing in a controlled manner. Any such mechanized release system capable of responding to pressure would be appropriate for use in the TDPS of the present invention, as is known by those skilled in the art. 
         [0046]    For example, where a 4½ inch casing holds 0.68 gallons per foot, to fill a 40 foot joint approximately  26  gallons of fluid would be dispensed through the fluid release valve. However, where a 5½ inch casing holds approximately 1 gallon per foot, a 40 foot joint would use approximately 40 gallons of fluid. Thus, the amount of fluid dispensed by the TDPS is dependent upon the size of the joint and the diameter of casing. 
         [0047]    The dimensions provided above are for one preferred embodiment of the TDPS. Dependent on the size of casing to be run, dimensions of the TDPS will necessarily change. In the preferred embodiment described above, the TDPS can run 4 inch drill pipe, 4½ inch and 5½ inch casing. In this embodiment, the smallest tool joint measured on the drill pipe is approximately 4¾ inch, making the interior position approximately 4½ inches in diameter (the diameter of the circle formed by the plurality of slips). For the purposes of this example, note that the casing collar on a 4½ inch casing is approximately 5 inches in diameter; and where a 5½ inch casing is used, the casing collar is approximately 6 inches. Where a 5½ inch casing is used, the exterior position of the slips would be approximately 6½ inches. Also note, as stated above, to achieve a steeper bevel, the length of the bevel may be modified without modifying other parameters. Moreover, components of the TDPS will be made of a durable material such as steel, other alloys, metallurgic materials, iron, or the like. 
         [0048]    It will be apparent to those skilled in the art that various modifications and variations can be made in the TDPS of the present invention without departing from the scope or spirit of the invention and that certain features of one embodiment may be used or interchangeably in other embodiments. Thus, it is intended that the present invention cover all possible combinations of the features shown in the different embodiments, as well as modifications and variations of this invention, provided they come within the scope of the claims and their equivalents. All measurements are approximate and the size of the insert will vary with the scale remaining close to the preferred embodiment described.

Technology Classification (CPC): 4