Patent Description:
The present disclosure relates to coiled tubing units. More particularly, the present disclosure relates to coiled tubing injector guides for directing tubing into coiled tubing injectors. Still more particularly, the present disclosure relates to devices, systems, and methods for aligning coiled tubing injector guides and doing so remotely to avoid otherwise dangerous and cumbersome adjustments.

Coiled tubing refers to a continuous string of pipe coiled on a take-up reel for transportation and handling. Coiled tubing is provided with outer diameters ranging from <NUM> to <NUM>(<NUM> inches to <NUM> inches) and may be used in a wide range of oilfield services and operations throughout the life of a well. A coiled tubing unit may be a mobile or stationary vehicle or structure for performing coiled tubing operations at a well. A coiled tubing unit may often have a coiled tubing injector. The injector may drive or guide the tubing into a well for performing various oilfield services or operations. The coiled tubing unit may additionally have a coiled tubing guide, which may generally direct the tubing, as it is unspooled from a reel, into the injector. In general, the guide may help to mitigate bends or kinks in the continuous tubing before it is fed into the injector and may be used to control alignment of the tubing as it enters the injector.

From time to time, such as during set up or during operations, the alignment of the tubing guide may be adjusted. Current systems, as shown in <FIG>, for example, include a threaded alignment shaft and a guide mount that is movable along the shaft. The guide mount may include a collar that is moveable along the shaft and large threaded nuts may be positioned on the shaft on either side of the collar. The nuts may be turned on the shaft causing them to travel along the shaft thereby adjusting the position of the collar along the shaft and thereby controlling the position of the guide mount. A locking nut may also be provided to secure the position once the mount is adjusted.

Adjusting the above-described mechanism may be done manually to align the tubing guide with the injector. This alignment may be helpful to properly align the entering tubing with the injector chains. This manual adjustment may be done on the ground (i.e., during set up) or in a man lift basket. In the latter case, the lift basket may be <NUM>-<NUM> meter (<NUM>-<NUM> feet) above the ground and an operator may use an extremely large wrench or wrenches to turn the nuts. Due to the difficulty in making these adjustments and/or due to the time required, the adjustment is often not performed or may only be performed at initial set up. This can cause issues to the machine or the tubing because the guide may not be in proper alignment with the injector causing the tubing to enter the injector out of alignment. This can lead to incorrect injector load readings and/or excess wear on, or damage to, drive bearings, traction cylinders, bushings, chains, and/or other components of the injector. In some cases, this can lead to damage to the tubing itself directly or from continued operation of the injector with damaged or failed chain components, inserts, or other components. Damage to the tubing can shorten its life, in some cases can render the tubing inoperable, and may cause potentially unsafe operating conditions. If one or more components of a tubing injector fails, the tubing may need to be cut and/or removed from the well. In some cases, this can lead to relatively high costs in both time and money because of the costs to repair components, but also because well operations may be stalled while components are repaired or replaced. <CIT> discloses a tubing guide for directing coiled tubing through an injector apparatus and into a well. A carrier is disclosed. The carrier has a plurality of segments pivotably connected to one another. The segments can pivot and thus the carrier itself can move from a fully retracted position to a fully rotated position. <CIT> discloses apparatus for handling pipe, coiled tubing, casing and conventional tubing in well drilling and servicing operations. <CIT> discloses an apparatus for conducting earth borehole operations, the apparatus having a base, a mast mounted on the base, and an integrated top drive/CT injector unit carried by the mast for longitudinal movement therealong.

The following presents a simplified summary of one or more embodiments of the present disclosure in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments, and is intended to neither identify key or critical elements of all embodiments, nor delineate the scope of any or all embodiments.

In one or more embodiments, a coiled tubing injector system may include a coiled tubing injector guide configured for guiding coiled tubing into a coiled tubing injector and a remotely adjustable guide mechanism. The remotely adjustable guide mechanism may include a guide mount configured for adjustably securing the coiled tubing injector guide to a frame of the coiled tubing injector and a drive mechanism configured for remotely adjusting a position of the guide mount relative to the frame.

In one or more embodiments, a method of adjusting a guide mount of a coiled tubing injector guide on a coiled tubing injector may be provided. The method may include receiving a coiled tubing position from an operator. The method may also include sensing a position of at least one of the guide mount and coiled tubing passing through the injector. The method may also include adjusting the position of the guide mount to an aligned position to provide the coiled tubing position.

While multiple embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the various embodiments of the present disclosure are capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present disclosure.

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the various embodiments of the present disclosure, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying Figures, in which:.

The present disclosure relates to novel and advantageous devices, systems, and methods for remotely adjusting a coiled tubing guide extending from a coiled tubing injector. In one or more embodiments, the tubing guide may be operably connected to a drive mechanism that may remotely and controllably cause the tubing guide mount to translate across the top of a coiled tubing injector frame. The drive mechanism may be configured for precise controlled movement of the tubing guide mount so as to allow for precise alignment of the coiled tubing with the tubing injector. The system may also be configured to maintain its position once aligned to avoid inadvertent movement leading to further misalignment. The system may be advantageous particularly due to its ability to be adjusted remotely thereby avoiding the need for manual adjustment and exposure of personnel to dangerous elevated conditions. The system may be further advantageous due to is high level of precision under significant loading as well as its ability to maintain its position once aligned.

As shown in <FIG>, a coiled tubing unit <NUM> may include a tubing spool <NUM> containing a very high linear footage of coiled tubing <NUM>. The unit <NUM> may also include a coiled tubing injector <NUM> for advancing the tubing into a well and a coiled tubing guide <NUM> for guiding the tubing from the spool and into the injector <NUM>. In one or more embodiments, the injector <NUM> and the guide <NUM> may be supported by a crane and suspended above a well allowing the injector <NUM> to pull the tubing <NUM> from the spool <NUM> and through the guide <NUM> and advance the tubing <NUM> into the well.

<FIG> is a side view of a tubing guide <NUM> in position on a tubing injector <NUM>. As shown, the tubing guide <NUM> may be an arcuate structure configured for guiding the tubing <NUM> off of the spool <NUM> and into the injector <NUM>. The injector <NUM> may be arranged within a frame <NUM> and the tubing guide <NUM> may be mounted on the frame. As show in a closer view in <FIG>, the tubing guide <NUM> may be secured to the frame of the injector so as to align the incoming tubing <NUM> with the injector <NUM> allowing the injector chains or other traction device to engage and advance the tubing.

<FIG> are top and side views, respectively, of the highlighted rectangular area of <FIG>. As shown, a tubing guide mount <NUM> may be arranged on the top of injector frame <NUM> and may be configured to slidably translate from side to side as shown in <FIG>. As discussed above, a threaded rod may extend through a collar on the rear portion of the mount <NUM> and the mount <NUM> and adjustment nuts may be used to control the position of the collar along the rod thereby controlling the position of the mount <NUM>.

Turning now to <FIG>, a portion of a remotely adjustable tubing guide <NUM> is shown. While not show in <FIG>, the remotely adjustable tubing guide <NUM> may include a guide frame as depicted in <FIG>. The guide frame may be pivotally secured to a tubing guide mount <NUM> and the tubing guide mount <NUM> may be slidingly positioned on a frame <NUM> of a tubing injector <NUM>. As shown, the remotely adjustable tubing guide <NUM> may include a drive mechanism <NUM> for operably adjusting the tubing guide mount <NUM> and, thus, the position of the tubing guide frame. The remotely adjustable tubing guide may include the mentioned drive mechanism <NUM>, a drive mount <NUM>, and an interface bracket <NUM>. The drive mechanism <NUM> may remotely and operably adjust the position of the interface bracket <NUM> relative to the drive mount <NUM> to adjust the position of the tubing guide <NUM>.

As shown in <FIG>, the drive mechanism <NUM> may be mounted to the drive mount <NUM> and may be configured for engagement with and adjustment of the interface bracket <NUM>. In one or more embodiments, the drive mechanism <NUM> may include an articulating element <NUM> such as an articulating and/or telescoping shaft. The drive mechanism <NUM> may cause the articulating element to advance or retract allowing for adjustment of the position of the interface bracket <NUM> and, thus, the guide mount <NUM>. The drive mechanism <NUM> may include an electrically, pneumatically, hydraulically, or mechanically driven machine. In one or more embodiments, as shown, the drive mechanism <NUM> may include a worm gear drive allowing for high levels of precision adjustment and an inherent or integrated locking mechanism for maintaining the position of the mount <NUM> when stopped. For example, the worm gear may include a helical gear or worm wheel driven by a motor. An articulating element <NUM> in the form of a worm shaft may be arranged along a longitudinal axis generally tangential to and in plane with the worm wheel and may include a worm for engaging the helical gear. In one or more embodiments, the worm shaft may include a rotation resisting feature. For example, a key or keyway may be provided for rotationally engaging a keyway or key, respectively, on a fixed element. The key/keyway system may resist rotation of the worm shaft about the axis. As such, rotation of the helical gear may drive the worm shaft tangentially to the helical gear and along the longitudinal axis rather than causing the worm shaft to rotate. In one or more embodiments, the rotation resisting feature may be provided internally to the worm gear. In other embodiments, as shown in <FIG>, the rotation resisting feature may be provided external to the worm gear and may be in the form of a brace, guide, or arm <NUM> on the interface bracket. That is, as shown, the interface bracket may include a horizontally extending tab, shoulder, or other frame engaging element. The frame engaging element may prevent and/or inhibit rotation of the interface bracket relative to the frame, but may allow the interface bracket to articulate horizontally along the frame and along the longitudinal axis of the articulating element. In one or more embodiments, while not shown, a bottom and a top tab may be provided to engage both a top surface of a frame element and a bottom surface of a frame element. Still other approaches to providing rotational resistance may be provided.

Turning back to <FIG>, the drive mount <NUM> may be configured for securing the position of the drive mechanism <NUM> and providing a secure stationary reference position. The drive mount <NUM> may be positioned on and secured to the injector frame. In one or more embodiments, the drive mount may be secured on a front side of the injector frame as opposed to the rear side. The drive mechanism <NUM> may cause the guide mount <NUM> to translate toward and/or away from the drive mount <NUM>. In one or more embodiments, the drive mount <NUM> may include a face plate extending generally vertically from the injector frame. The plate may be welded, bolted, or otherwise securely fastened to the frame. In one or more embodiments, the drive mount <NUM> may include brace plates on either side of the face plate to manage lateral loading on the face plate. In one or more embodiments, the drive mount <NUM> and, for example, the face plate, may include an opening <NUM> for allowing the articulating element <NUM> to extend through the drive mount <NUM> and articulate back and forth through the opening <NUM>.

The interface bracket <NUM> may be configured for establishing an interface between the drive mechanism <NUM> and the guide mount <NUM>. The interface bracket <NUM> may be configured for securing to the drive mechanism <NUM> at one end and for securing to the guide mount <NUM> at an opposite end. As shown in <FIG>, the tubing guide may include a stabilization mechanism arranged at or near a pivot pin where the guide frame is secured to the guide mount. The stabilization mechanism may be the same or similar to the mechanism of <CIT> entitled Tubing Guide Stabilization Mechanism. The interface bracket <NUM> may be configured to avoid interference with the stabilization mechanism while it translates with the guide mount <NUM>. In one or more embodiments, the interface bracket <NUM> may include a laterally extending beam <NUM> and a pair of longitudinally extending struts or arms <NUM>. The laterally extending beam <NUM> may be secured to and extend laterally from the articulating element <NUM> of the drive mechanism <NUM>. The beam <NUM> may be pivotally secured to the articulating element <NUM> so as to allow the beam <NUM> to rotate about the longitudinal axis <NUM> or a key/keyway connection may be provided to resist relative rotation of the beam <NUM> and remaining portions of the interface bracket <NUM> about the longitudinal axis <NUM>. However, the beam <NUM> may receive the articulating element <NUM> in a bore having a length along the longitudinal axis <NUM> sufficient to resist out of plane bending or rotation of the interface bracket <NUM> relative to the articulating element <NUM>. The struts or arms <NUM> may extend longitudinally away from the beam <NUM> to the guide mount <NUM>. The struts or arms <NUM> may be welded to the beam forming a unitary interface bracket <NUM>. In other embodiments, the struts may be bolted or otherwise secured to the beam. The struts <NUM> may be arranged on either side of the stabilization mechanism maintaining clearance around the stabilization mechanism and engaging the guide mount <NUM>. The struts or arms may each engage the guide mount and be secured thereto with a pin, a bolt, a welded connection, or another connection suitable to carry the loads from the drive mechanism and/or from the tubing guide <NUM>. It is to be appreciated that the present remotely adjustable mechanism is configured for retrofitting known or existing tubing guides by engaging the existing guide mounts or by replacing the guide mount on the existing systems with a slightly modified guide.

In one or more embodiments, the guide mount <NUM> may be modified from a conventional guide mount by including attachment features for securing the interfacing bracket to the guide mount <NUM>. As shown in <FIG>, a conventional guide mount is shown. In comparison, <FIG> includes an attachment feature <NUM> for engaging the interfacing bracket and allowing for positional control of the guide mount. Similarly, <FIG> shows a conventional guide mount and <FIG>, shows a guide mount with an attachment feature <NUM>.

In one or more embodiments, the drive mechanism <NUM> may include wired or wireless communications systems in communication with a controller <NUM> for controlling the position of the guide mount <NUM>. These systems may allow the drive mechanism to be actuated and controlled from a remote location. In addition, sensors <NUM> may be provided for sensing the position of the tubing guide mount relative to the frame and/or for sensing the position of the tubing entering the injector <NUM>. The sensor or sensors <NUM> may be in wired or wireless communication with a display which may depict the position of the tubing <NUM>, the relative position of the guide mount <NUM> and the frame or other absolute or relative positions. The user may rely on the absolute or relative positions of the elements to drive the drive mechanism and adjust the position of the guide mount so as to cause alignment of the coiled tubing with the tubing injector.

The controller <NUM> may include a computer readable storage medium, a processor, and one or more input and output features. The controller <NUM> may include software, drivers, or other software stored on the computer readable storage medium for controlling the drive mechanism. The controller may also include control software adapted to select the position of the guide mount and/or the coiled tubing and instruct the drive mechanism to move the guide mount and the coiled tubing to a selected location. In one or more embodiments, the selected location may be an aligned location where the coiled tubing is substantially center between traction units within the injector. The controller may, for example, include an input for an absolute or relative position of the coiled tubing and may have or include a stored relative dimension relating the position of the tubing to the position of the guide mount. As such, the controller may be able to adjust the guide mount to a position in order to locate the tubing at a desired location.

The sensors <NUM> may include visual sensors, position sensors, load sensors, motor feedback devices, or other sensors. The sensors may be adapted to sense the position of the coiled tubing passing through the injector and may be adapted to sense the position of the guide mount on the frame of the injector. It is to be appreciate that the positive mechanical connection between the drive mechanism and the guide mount may allow for reliance on motor feedback sensors to adjust the positions based on the assumption that a particular travel of the motor may cause a corresponding travel of the guide mount. Accordingly, the sensors may provide feedback to the user allowing for the system to be constantly calibrated to verify and control the stored relative position of the tubing and the guide mount. Still further, the sensors may provide continual, periodic, or selected feedback of the position of the coiled tubing passing through the injector.

In operation and use, and as shown in <FIG>, a method of operation <NUM> may be provided. A user may monitor the position of the coiled tubing passing through the injector <NUM> and may select a desired position of the coiled tubing <NUM>. The system may store the desired position of the coiled tubing <NUM>. The system may also continually, periodically, and/or selectively sense the actual position of the coiled tubing <NUM>. The system may also sense the absolute position of the guide mount (e.g., relative to the frame) <NUM> and may also sense and/or calculate the relative position of the guide mount to the coiled tubing <NUM>. The system may store one or more of these positions <NUM>. With the stored actual and desired position of the coiled tubing and the stored absolute and relative positions of the guide mount, the controller may be adapted to position the guide mount to locate the coiled tubing at the desired location <NUM>. In one or more embodiments, where the guide mount is moved, the controller may be adapted to automatically or, on command, return the guide mount to the stored absolute position <NUM>. In one or more embodiments, and over time, the relative position of the guide mount to the coiled tubing may change as systems wear, for example. The system may continually, periodically, or selectively sense the positions of the coiled tubing and the guide mount <NUM> and calculate a relative position <NUM>. Where the value of the relative position changes, a new relative position may be stored <NUM> for use in properly positioning the guide mount and, thus, the coiled tubing.

Referring now to <FIG>, another remotely adjustable guide mechanism <NUM> is shown. Several similarities exist between this embodiment and the previous embodiment. However, in this embodiment, the interfacing bracket <NUM> may be secured to the guide mount <NUM> with a single securing pin <NUM> extending through each of the struts and two locations on the guide mount. Moreover, in this embodiment, the securing pin may include a single pin that secures the guide frame to the guide mount and the interfacing bracket may be secured to the guide mount with the single pin.

<FIG> include another remotely adjustable guide mechanism <NUM> for a tubing guide. As may be appreciated, this system is mounted on the front side of the guide mount <NUM> and includes an interfacing bracket <NUM> that involves extending the lateral sidewalls of the guide mount <NUM>. As shown, the drive mechanism <NUM> may include a motorized drive such as a worm gear drive or other drive system. It is to be appreciated, that the circular element within the guide mount in these figures is showing the path of travel of the stabilization mechanism and is not intended to show a particular element of the design.

<FIG> include additional options and or details relating to extending the tubing guide mount and adapting it for engagement with a drive mechanism on a front side of the guide mount. In one or more embodiments, the interfacing bracket <NUM> may include a series of plates welded onto the guide mount <NUM> and extending in a forward direction and supporting a cross beam with a collar, for example. As with the earlier embodiment, the present series of plates and beams may be arranged to avoid interfering with the stabilization handle on the guide. The collar may be adapted to receive an articulating element of a drive mechanism to cause the guide mount <NUM> to articulate and allowing for alignment of the guide mount. The options shown in <FIG> may be suitable for most any drive mechanism arranged on a front side of the guide mount <NUM>. A similar interfacing bracket <NUM> is shown in <FIG> and another similar bracket <NUM> is shown in <FIG>. Still further similar brackets <NUM>, <NUM> are shown in <FIG>.

While a motorized worm gear has been shown as a drive mechanism and while the remotely controlled drive mechanism has been shown to be arranged on a front side of the guide mount, alternative approaches may be used. For example, the drive mechanism may be arranged on a rear side of the guide mount similar to the manual system and alterative drive mechanisms may be used.

One example of an alternative drive mechanism may include a hydraulic cylinder system to control the position of the guide mount. As shown in <FIG>, the drive mechanism <NUM> may include one or more hydraulic cylinders secured to the frame and to the guide mount. The cylinders may be actuated to extend or retract and adjust the position of the guide mount.

Another example of an alternative drive mechanism <NUM> is shown in <FIG> and <FIG>. In this embodiment, a series of serrated saw blade type discs may be used in ratchet like fashion to rotate a shaft and control reverse motion.

In still another embodiment, as shown in <FIG>, a gear reducing system <NUM> may be used to allow for high-power and precise control over the position of the guide mount.

Still another embodiment is shown in <FIG>, where a worm gear type system <NUM> is shown on a rear side of the guide mount.

<FIG> shows yet another embodiment of a remotely adjustable guide mechanism <NUM>. In this embodiment, a hydraulic cylinder is used to adjust locking wedges that may be secured in place using one or more transversely positioned hydraulic cylinders.

<FIG> shows yet another embodiment of a remotely adjustable guide mechanism <NUM>. In this embodiment, a hydraulic cylinder may be used to pivot a lever about a fulcrum to drive or retract the shaft and cause the guide mount to translate.

<FIG> shows yet another embodiment of a remotely adjustable guide mechanism <NUM>. In this embodiment, a rack and pinion system is used to translate the guide mount.

Still other types of drive mechanisms may be used and may be arranged on the front or rear of the guide mount.

As used herein, the terms "substantially" or "generally" refer to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is "substantially" or "generally" enclosed would mean that the object is either completely enclosed or nearly completely enclosed. However, generally speaking, the nearness of completion will be so as to have generally the same overall result as if absolute and total completion were obtained. The use of "substantially" or "generally" is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, an element, combination, embodiment, or composition that is "substantially free of" or "generally free of" an element may still actually contain such element as long as there is generally no significant effect thereof.

Claim 1:
A coiled tubing injector system, comprising:
a coiled tubing injector guide (<NUM>) configured for guiding coiled tubing (<NUM>) into a coiled tubing injector (<NUM>) arranged within a frame (<NUM>); and
a controller (<NUM>); and
guide mechanism, comprising:
a guide mount (<NUM>) configured for adjustably securing the coiled tubing injector guide (<NUM>) to the frame (<NUM>) of the coiled tubing injector (<NUM>); and
a drive mechanism (<NUM>) in communication with the controller (<NUM>) for actuating the drive mechanism (<NUM>) from a remote location to control a side-to-side position of the guide mount (<NUM>) relative to the frame (<NUM>) to align the coiled tubing (<NUM>) with the coiled tubing injector (<NUM>).