AU2008202799A1 - A Tubular Load Handler - Google Patents

Description

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AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name of Applicant: Address for Service: Invention Title: Easternwell Group Holdings Pty Ltd CULLEN CO Patent Trade Mark Attorneys 239 George Street Brisbane Qld 4000 A Tubular Load Handler The following statement is a full description of this invention, including the best method of performing it, known to us: 00 FIELD OF THE INVENTION This invention relates to a tubular load handler. In particular, the invention concerns a Shandler for handling tubular loads such as pipes, tubes, drill collars and pumping rods that are predominantly used in drilling operations and in servicing drilled wells.

BACKGROUND

Tubes, drill collars and pumping rods that are used in drilling operations are usually stored in a vertical position. As they are pulled out of a bore of a well, operators Sdisconnect the tube (rod) from the rest of the tubes (stem) in the bore and the 00 10 disconnected tube is lifted with a derrick and pushed aside in finger-boards for Sstorage. Generally, three people are required for this operation. Two are on a work floor handling a lower end of the tube and they disconnect the tube from the stem.

One person is located on a high platform and handles an upper end of the tube. When drilling a new bore or returning the stem to bore, the described operation is carried out in reverse.

Problems with the above described operation include that: it is very hard labour; there is a danger of tools or other objects falling from the high platform and injuring the operators on the work floor; work on the high platform is dangerous because the platform must have an open space in the floor for allowing side shifting of the tubes, to get them in or out of the finger-board storage, and the operator could easy fall through the open space and sustain a serious injury; and handling of heavy tubes on either the high platform of work floor could cause an injury by crushing an operator's limbs or other body parts.

An alternative tube-handling operation involves storing the tubes horizontally at ground level. In this case, a static low platform "catwalk" is positioned adjacent to the derrick. Attached to one or both sides of the catwalk are horizontally extending racking rails, serving as a temporary storage for tubes.

0After a tube is disconnected from a drill string, an upper end of the tube is lifted by a Sderrick and operators on a work platform push a lower end of the tube over the railing Sand drop the lower end through a door. Operators on the catwalk control the Smotion of the lower end of the tube. The tube is then lowered by the derrick and the C 5 upper end is released from the derrick. The tube then slides to the catwalk and the operator rolls it off onto the horizontally extending racking rails for temporary storage. The whole process is carried out in reversed when running the tube back into the bore of the well.

00 Because the horizontal tube-storage operation does not store tubes vertically, it Seliminates some of the safety hazards associated with finger-boards. However, there are still problems with the operation in that there is hard and hazardous labour involved, particularly when pushing the tube over the railing and controlling the motion of the heavy tube.

There are some mechanical tube-handling machines used in the field today with varying levels of sophistication. The most basic machine still utilises a door but uses a mechanical pusher instead of a winch to get the tube from the catwalk to the work floor. This only reduces one of the above major risks as it is less likely that a tube will become lodged and store potential energy, as the door is usually purpose built with smooth edges and guided track.

More sophisticated mechanical catwalks incorporate racking rails with mechanical powered jacks to roll the tubes to or away from a centre of the catwalk. A mechanism is then required to ensure only one tube at a time is allowed on the catwalk and must be able to load and unload the tube from the catwalk.

Some of the most sophisticated machines use the above mentioned racking rail system with a moving trough that lifts out of the centre of the catwalk and rises up to work floor height, thus eliminating the need for a door. This ameliorates some of the major safety hazards, but their use is limited for one size of tube only. T'hey cannot be use for drill collars or pumping rods.

00 A major disadvantage of all known tubular load handling machines is that they cannot 0 Shandle tubes, rods and drill collars of differing length and diameter. They are set for Sone diameter and length of tube, and none of them can handle pumping rods. These cnmust be handled manually, and this, of course, again raises the problems of heavy S 5 labour and safety.

A typical well service scenario requires that all types of tubular loads be handled but, Sto date, there does not exist a machine capable of doing so.

00 C 10 The present inventors have now developed a tubular load handler that can minimise or ri overcome one or more of the problems referred to above.

The present inventors have also developed a range of mechanisms for handling tubular loads, and those mechanisms may be used together in a single handler or may be used independently of one another.

DETAILED DESCRIPTION OF THE INVENTION According to the present invention, there is provided a tubular load handler.

The handler may comprise a main body and the body may be of any suitable size, shape and construction. The main body preferably comprises a frame. The main body may have a front end and a rear end.

The handler may be transportable from one location to another and this may be achieved in any suitable way. Preferably, the handler has a wheeled undercarriage and the undercarriage is mounted to the main body. The undercarriage may be like a trailer undercarriage of a semi-trailer, for coupling to a prime mover.

The main body may comprise a catwalk extending parallel with a longitudinal axis of the main body. The catwalk may be of any suitable size, shape and construction.

Preferably, the handler has a catwalk extending along each longitudinal side of the main body. The main body may comprise a deck. The deck may be of any suitable size, shape and construction. The deck may be located at the front end of the main body.

00 The handler may have a cabin for an operator. Any suitable type of cabin may be 0 Sused. The cabin may be connected to the main body, such as to the deck of the main Sbody. Preferably, the cabin is pivotally connected to the main body such that it may n, be pivoted to different positions relative to the main body, such that the operator may Vt) N 5 optimise his or her vantage point of either catwalk. Also, the cabin may be pivoted between a working position/mode whereby it extends laterally of the deck, and a C* transport position/mode whereby it is located immediately above the deck.

The handler may have a cabin actuator, such as a hydraulic or pneumatic cylinder, for 00 10 pivoting the cabin. Preferably, the actuator is a hydraulic cylinder having a housing Spivotally connected to the deck and a piston operatively connected to the cabin.

The handler may comprise a racking rail assembly for supporting or storing tubular loads. The racking rail assembly may be of any suitable size, shape and construction.

Preferably, the racking rail assembly comprises at least two spaced racking rails extending parallel with one another and extending laterally of the main body. The racking rail may comprise, for example, a bar or beam. The beam may be of tubular construction. Preferably, a racking rail assembly extends from each longitudinal side of the main body.

The racking rails may be movable relative to the main body and this may be achieved in any suitable way. The racking rails may be movable between a transport position/mode, whereby the racking rails are folded substantially parallel with and against the main body, and a working position/mode, whereby the racking rails are unfolded and extend laterally of the main body. Preferably, an end of each racking rail is pivotally connected to the main body, such as to a catwalk, such that the racking rail may be pivoted between the working and transport positions.

The racking rails may also be connected to the main body such that they may be moved vertically relative to the main body. This may be achieved in any suitable way. Preferably, each racking rail is pivotally connected to the main body, such as to a catwalk, such that it may be raised and lowered relative to the main body. The racking rails may be angled such that tubular loads may be either gravity fed towards the catwalk or way from the catwalk.

0 The racking rail assembly may include a locking mechanism for locking the racking rails in the transport position. Any suitable type of locking mechanism may be used.

Preferably, the locking mechanism comprises a latch which locks the racking rails together adjacent the main body.

The racking rail assembly may include a height-adjustable ground support actuator connected to each racking rail, for adjusting the height of the racking rail relative to the ground. The ground support actuator may be pivotally connected to one end of the racking rail and the other end of the racking rail may be pivotally connected to the

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10 main body.

The height-adjustable ground support actuator may be of any suitable size, shape and construction. The ground support actuator may comprise a hydraulic or pneumatic cylinder. Preferably, the ground support actuator is a hydraulic cylinder having a housing pivotally connected to the racking rail, a piston extending from the housing and a ground-bearing pad connected to an end of the piston. The ground support actuator may further comprise an adjustment mechanism for finely adjusting the height of the racking rail relative to the cylinder housing. Any suitable type of adjustment mechanism may be used.

The handler may comprise one or more structural members, such as cross beams or auxiliary rails, for providing stability to the racking rail assemblies and/or for providing additional support for the tubular loads. Any suitable type of structural member may be used. The structural member may be, for example, a bar or beam.

The beam may be of tubular construction.

The structural member may be a cross beam extending between the racking rails of the racking rail assembly, so as to provide additional structural stability. Preferably, each end of the cross beam is adapted to detachably couple to a racking rail. The cross beam may comprise a tubular beam extending between adjacent racking rails, rigging guides extending from the beam and tensionable rigging extending over the guides between opposing ends of the beam. The cross beam may comprise a carry handle at each end of the beam.

00 The structural member may be an auxiliary rail for providing additional support for 0 tubular loads. The auxiliary rail may extend parallel with and between the racking (Ni Srails. The auxiliary rail may be movable between the transport position/mode and the Sworking position/mode, as described previously for the racking rails. Preferably, an C 5 end of the auxiliary rail is pivotally connected to the main body, such as to a catwalk, such that the auxiliary rail may be pivoted between the working and transport C, positions and/or vertically. The auxiliary rail may extend transversely of the cross t"beam and locate within a seat of the cross beam. The auxiliary rail may be, for N, example, a bar or beam. The beam may be of tubular construction.

00 C- The handler may comprise stabilisers for stabilising and adjusting the height of the main body, and any suitable type of stabiliser may be used. Preferably, the handler has a plurality of stabilising jacks. Each stabilising jack may comprise a hydraulic or pneumatic cylinder connected to the main body. Preferably, each stabilising jack comprises a hydraulic cylinder having a cylinder housing extending from the main body, a piston extending from the housing and a ground-bearing pad connected to an end of the piston. The ground-bearing pad and cylinder may be pivoted upwardly from the ground when the loader is being transported to another location. This may be achieved in any suitable way.

The handler may comprise a trough assembly for conveying tubular loads parallel with the longitudinal axis of the main body, from one end of the main body to the other. Any suitable type of trough assembly may be used.

The trough assembly may comprise a trough body having a channel extending parallel with the longitudinal axis of the main body and a tubular load may be conveyed within the channel. The trough body may be of any suitable size, shape and construction. It may be of any suitable cross section. The trough body may have a pair of spaced side walls and a top wall may extend between those side walls. The channel may be a V-shaped groove in the top wall of the trough body. Regions of the top wall that flank the chamnnel may both slope downwardly towards an adjacent racking rail assembly. The trough body may have an upper end and a lower end. The trough body preferably extends along the longitudinal axis of the main body between 00 the catwalks. The trough body may include transition ramps extending from the side 0 Swalls that allow tubular loads to roll from the channel to the racking rails.

(Ni SThe trough assembly may comprise a roller arrangement mounted to the upper end of N 5 the trough body, for assisting in the loading and unloading of tubular loads from the channel. The roller arrangement may be of any suitable size, shape and construction.

Preferably, the roller arrangement includes a bracket-mounted roller and the roller is adjustable in position relative to the trough body.

(Ni 00 C 10 The trough assembly may comprise an ejector system for ejecting tubular loads from the channel of the trough body to the racking rail assembly. The ejector system may be of any suitable size, shape and construction. The ejector system may comprise at least one ejector having an ejector arm mounted to the trough body and an actuator for moving the ejector arm between parked and ejecting positions. The ejector arm may have a mounting end pivotally mounted to a side wall of the trough body and a working end that pushes the tubular load from the channel towards the racking rails.

The top wall of the trough body may have an opening through which the ejector arm may extend when moving to the ejecting position. Preferably, the working end has a lower region in the form of a ramp or nose for improving the ejection of tubular loads of small diameter.

Any suitable type of actuator may be used. Preferably, the actuator is a hydraulic cylinder having a housing pivotally mounted to a side wall of the trough body, within the trough body, and a piston having an end pivotally connected to the ejector arm.

Preferably, the ejector system comprises a plurality of ejectors positioned along an upper region of the trough body. Preferably, the ejectors are mounted to each side wall of the trough body such that tubular loads may be ejected from either side of the channel.

The trough assembly may comprise a trough lift system for raising and lowering the trough body relative to the main body. Any suitable type of trough lift system may be used. The trough lift system may comprise a lift arm having an upper end pivotally connected to the upper end of the trough body and a lower end pivotally connected to the main body. The trough lift system may comprise an actuator connected to the main body and the lift arm, and the lift arm may be moveable between a raised position and lowered position by the actuator. Any suitable type of actuator may be used, such as a hydraulic or pneumatic cylinder. Preferably, the actuator is a N 5 hydraulic cylinder having a housing pivotally mounted to the main body by way of a main pivot pin and a piston pivotally mounted to the lift arm. Preferably, the main pivot pin extends between the catwalks at the rear end of the main body.

SThe trough lift system may comprise one or more rollers mounted to the lower end of 00 S 10 the trough body and a runner (track or channel) for each said roller that is connected to the main body and which extends parallel with the longitudinal axis of the main body. The runner may be of any suitable size, shape and construction. Preferably, a runner extends parallel with the longitudinal axis of the main body adjacent each catwalk. In order to raise the trough body, the actuator may exert a force on the lift arm so as to generate a rotational motion around the main pivot pin, such that the rollers travel within the runners towards the main pivot pin.

The trough lift system may comprise a control mechanism for determining to what height the trough body may be raised. Any suitable type of control mnechanism may be used. Preferably, the control mechanism comprises one or more limit switches operatively connected to the actuator of the trough lift system. The limit switch may include a control valve that, when moved from an open to a closed position, restricts the flow of hydraulic fluid to the actuator.

The control mechanism preferably comprises a limit switch connected to a side wall of the trough body, a roller stiker arm pivotally mounted to the side wall adjacent the limit switch, and a limit for pivoting a striker of the roller striker arm into engagement with the limit switch so as to activate the limit switch. The striker of the roller striker arm may be biased, e.g. by way of a spring, in a non-activating position and a roller of the roller striker arm may run along a runner extending parallel with the trough side wall. The limit may be positionable along the runner, and its position relative to the roller striker arm may determine the height to which the trough body may be raised.

The limit may be in the form of a ramp, and the striker made pivot into engagement with the limit switch once the roller rolls onto the ramp.

0 The trough assembly may comprise a tube pusher assembly, the main function of which is to convey tubular loads within the channel of the trough body. Other functions of the tube pusher assembly may be to catch a tubular load sliding down the channel and to adjust the position of the tubular load such that it may be ejected onto N 5 the racking rails. The pusher assembly may comprise different types of pusher components that may be readily coupled to one another.

N The pusher assembly may comprise a trolley that travels within the channel along a N lower region of the trough body. The pusher assembly may include an actuator for 00 S 10 moving the trolley within the channel. Any suitable type of actuator may be used, but N preferably the actuator is a hydraulic cylinder having a housing and a piston. The housing may be connected to the trough body and extend within the trough body, and the piston may be connected to the trolley. When the piston is extended relative to the housing, then the trolley may be located adjacent the rollers of the trough lift system at the lower end of the trough body. When the piston is retracted relative to housing, then the pusher trolley may be located approximately halfway up the trough body.

The trolley may be of any suitable size, shape and construction. The trolley may have a body and three pairs of rollers mounted to the body with axes parallel with the channel so as to transfer the reaction forces of the trolley onto the trough body, whilst reducing the friction between the trough body and pusher components. Two of the roller pairs may travel along a top surface of the channel whereas the third pair of rollers may travel along a lower surface of the channel and hold the upward reaction force of the trolley.

The trolley body may have a coupling end that may be readily coupled to another component of the pusher assembly. The coupling end may be coupled in any suitable way, but is preferably a quick-hitch type coupling. The coupling end may be cushioned so as to protect the trolley from shock generated by tubular loads sliding down the channel. The coupling end may be cushioned in any suitable way. For instance, the trolley body may have one or more pads of foam rubber or plastics material at the coupling end.

00 The pusher assembly may comprise at least one type pusher extension to compensate for different lengths of tubular loads. The pusher extension may be of any suitable size, shape and construction. The pusher assembly may comprise a plurality of pusher extensions and these may be of varying length.

(N Each pusher extension may comprise a tubular body and a carry handle extending from the body. Opposing ends of each pusher extension may be readily coupled to other components of the pusher assembly, such as to other pusher extensions or to the trolley. The ends of adjacent pusher extensions may be coupled in any suitable way,

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but are preferably coupled by way of a quick-hitch type coupling. One or more of the ends may be cushioned so as to protect the trolley from shock generated by tubular loads sliding down the channel. The ends may be cushioned in any suitable way, e.g.

cushion pads of foam rubber or plastics material.

The pusher assembly may comprise a buffer extension for cushioning shocks from high inertia tubular loads, such as drill collars or heavier tubes, sliding down the channel from a high-set work floor. The buffer extension may be of any suitable size, shape and construction. The buffer extension may comprise a tubular body and a carry handle extending from the body. Opposing ends of the buffer extension may be readily coupled to other components of the pusher assembly, preferably by way of a quick-hitch type coupling. One or more of the ends may be cushioned so as to protect the trolley from shock generated by tubular loads sliding down the channel. The ends may be cushioned as described above.

The buffer extension may comprise a gas spring, a slide bearing located within the body, and a push rod extending through the slide bearing and out of the body. The push rod may be guided by the slide bearing. The impact of a moving tubular load may be transferred to the gas spring via the push rod.

The pusher assembly may comprise a guide extension for preventing the jumping of a tubular load out of the channel. The guide extension may be of any suitable size, shape and construction. The guide extension may comprise a roller carriage, a clamp arrangement connected to the roller carriage and extending transversely of a clamped pusher extension, and vertical force reaction retainers each side of the roller carriage 0that engage an underside of the top wall of the trough body. The carriage may include a U-shaped collar within which is locatable the tubular body of a pusher extension and Sthe clamp arrangement may allow for the ready interchange of different pusher Sextensions.

The pusher assembly may comprise a tube retaining extension for retaining an end of a tubular load. The tube retaining extension may be of any suitable size, shape and construction. The tube retaining extension may prevent a lower end of the tubular load from jumping out of the channel by accident. The tube retaining extension may 00 comprise a shroud extendable over the lower end of the tubular load, for retaining the Ni lower end of the tubular load. The tube retaining extension may have an end that may be readily coupled to an adjacent component of the pusher assembly, such as to a pusher extension, preferably by way of a quick-hitch type coupling.

The trough assembly may comprise a pusher control mechanism for controlling the actuator connected to the pusher trolley. Any suitable type of pusher control mechanism may be used. Preferably, the pusher control mechanism comprises one or more limit switches operatively connected to the actuator that are activated by a striker of the trolley. The limit switch may include a control valve that, when struck by the striker, moves from an open to a closed position and restricts the flow of hydraulic fluid to the actuator.

The handler may comprise a tube loader system for moving a tubular load from the racking rails to the chalnnel of the trough body. The tube loader system may be of any suitable size, shape and construction.

The tube loader system may comprise a tube loader assembly. The tube loader assembly may comprising at least one tube loader comprising a loading arm having a cradle for a tubular load, and an actuator for moving the loading arm and cradle between a tube loading position and a tube unloading position. Preferably, the loading arm is pivotally mounted to the main body and the cradle is pivotable between the tube loading position and the tube unloading position.

0 The loading arm may have a mounting end and a working end. The mounting end of the loading arm may be pivotally mounted to the main body. The working end of the loading arm may have a lift finger extendable beneath a tubular load and an upstanding finger that cooperates with the lift finger to provide the cradle and to c 5 cradle the tubular load whilst the tubular load is being moved to the tube unloading position. The upstanding finger may be shaped such that the tubular load will roll off the upstanding finger when the cradle is in the unloading position. An end of the lift finger may be upturned so as to better engage behind a tubular load. An end of the upstanding finger may be wedge-shaped such that the tubular load may readily roll off

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00 C 10 the upstanding finger when in the unloading position.

The loading arm may comprise a pair of spaced parallel plates wherein each plate provides part of the lift finger and one of the plates provides the upstanding finger.

The loading arm may comprise a striker extending transversely of the lift finger at the working end of the loading arm, and a bush at the mounting end of the loading arm.

The tube loader may comprise a setting mechanism for adjusting the position of the lift finger in the tube loading position relative to a tubular load. Any suitable type of setting mechanism may be used. The setting mechanism may comprise a torsion bar extending through the bush of the loading arm wherein the bush may rotate relative to the torsion bar, an action arm fixedly connected to the torsion bar and adjustably connected to the loading arm such that the lift finger may be selectively raised or lowered relative to the action arm. The action arm may be adjustably connected to the loading arm in any suitable way. Preferably, a rack and pinion arrangement on both of the arms allows for the adjustment.

The tube loader assembly preferably comprises two or three tube loaders interconnected by way of the torsion bar. The tube loader assembly may comprise at least one mount for mounting the torsion bar to the main frame. Any suitable type of mount may be used.

Preferably, the tube loader assembly comprises tube loaders extending adjacent each catwalk, and the torsion bars extend parallel with the longitudinal axis of the main 00 body. A tube loader may be located adjacent to an end of each racking rail and 0 auxiliary rail.

Any suitable type of actuator may be used. Preferably, the actuator is a hydraulic cylinder having a housing pivotally connected to the main body and a piston having an end pivotally connected to the loading arm. When the piston extends relative to the housing, the cradle may be pivoted to the tube unloading position.

The tube loader system may comprise at least one tube stopper for positioning a 0 10 tubular load for lifting by a tube loader. The tube stopper may be of any suitable size, N shape and construction. A tube stopper may be connected to an end of each racking rail above each catwalk. The tube stopper may have a body extending substantially parallel with the racking rail and a tube stopping member connected to the body that is attachable to different positions along a length of the stopper body, such that the stopping member is positionable relative to the tube loader. Preferably, teeth extend along an upper edge of the stopper body and along a lower edge of the stopping member, and these teeth may mesh with one another. The tube stopper may rest on a catwalk and may be height adjustable. The tube stopper may movable between a working position and a stowed position, and this may be achieved in any suitable way.

Preferably an end of the tube stopper body is pivotally connected to the racking rail such that the tube stopper may be pivoted to a stowed position.

When a racking rail gravity feed tubular loads toward the tube loader, then the stopping member may extend above a top surface of the racking rail. When the racking rail is angled so as to gravity feed tubular loads away from the tube loader, then the pivotal connection may allow the racking rail to pivot relative to the stopping member so that the stopping member is located below the top surface of the racking rail.

The tube loader system may comprise at least one tube separator for enabling only one tubular load at a time to be lifted by the tube loader. The separator may comprise a separator finger that is movable between a tube separating position between adjacent tubular loads above the top surface of the racking rail, and a resting position below the top surface whereby adjacent tubular loads above the separator finger may be in direct 00contact with one another. The separator finger may be moved in any suitable way.

SThe separator finger is preferably pivotally connected to an end of the racking rail Sabove a catwalk. Preferably, the tube separator includes a biasing member that biases Sthe separator finger in the tube separating position and is moved to the resting position N 5 by the load arm at the tube loader when in the tube loading position. More preferably, the tube separator comprises a catch extending laterally of the separator finger and a striker of the loading arm engages the catch when moving to the tube unloading N, position, and moves the catch such that the separator finger is in the resting position N, in which case a tubular load may roll into contact with the tube stopper.

00 The tube stopper may comprise a pistol-shaped lever that is pivotally connected to the racking rail. The separator finger and catch may be connected to a barrel of the pistolshaped lever and the biasing member may be connected to a handle of the pistolshaped lever. The biasing member is preferably a coil spring.

The tube loader system preferably comprises a tube loader assembly having six tube loaders, six tube stoppers and six tube separators, wherein a single tube loader, tube stopper and tube separator is associated with each racking rail and auxiliary rail.

The handler may comprise at least one tube agitator for assisting tubular load rolling towards the tube stopper and to ensure that the tubular loads are the same distance from the tube loaders of the tube loader assembly. Preferably, a tube agitator extends transversely of each catwalk adjacent each racking rail.

The tube agitator may be of any suitable size, shape and construction. The tube agitator may comprise an agitator member comprising a substantially flat upper face and a sloping lower face, and the agitator member may be adjustably mounted to a support such that the agitator member is tiltable relative to the support. The agitator assembly may further comprise a roller runner engaging the sloping lower face of the agitator member, and an actuator for moving the roller runner relative to the agitator member such that the agitator member vibrates when moved relative to the roller runner.

0The agitator member may be mounted to the support in any suitable way. Preferably, a first end of the agitator member has a slot through which a slide pin of the support Sextends and a second end of the agitator member is connected to a spring of the cnsupport. In this way, the agitator member may tilt forwards or backwards relative to K 5 the direction of travel of the roller runner.

Any suitable type of support may be used. Preferably, the support is in the form of an Sangle bracket wherein the agitator member extends parallel to and is pinned to a Svertically extending part of the angle bracket. The angle bracket may comprise a 00 C 10 horizontally extending part on which the roller runner travels.

(Ni Any suitable type of roller runner may be used. Preferably, the roller runner has an upper roller which engages the sloping lower face of the agitator member and at least one other roller for travelling along the horizontal part of the angle bracket.

Any suitable type of actuator may be used. The actuator may be a hydraulic or pneumatic cylinder. Preferably, the actuator is a hydraulic cylinder having a housing connected to the support and a piston connected to the roller runner.

The tube agitator may be connected to the main body in any suitable way. Preferably, the tube agitator is connectable to a catwalk by way of a locking pin that extends through an opening in the catwalk.

Preferably, the agitator member tilts downwardly towards the loading arm of the tube loader when the piston is retracted relative to the cylinder housing. To increase vibration, the sloping lower face of the agitator member is preferably undulated.

Preferred embodiments of the invention will now be described by way of example with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a perspective view of a tubular load handler having racking rails of racking rail assemblies in a working position and a trough body in a raised position, according to an embodiment of the present invention; 00 0 Figure 2 is substantially the same as Figure 1 but tubular loads are shown on the Sracking rails; Figure 3 is substantially the same as Figure 2 but the trough body has been lowered; C, Figure 4 shows the handler of Figure 1 but configured for transport;

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SFigure 5 is a perspective view chiefly of part of a racking rail assembly mounted to a 00 10 catwalk; Figures 6-8 are side elevation views of the racking rail assembly shown in Figure showing how the tilt angle of a racking rail may be adjusted; Figure 9 is a perspective view of the racking rails of a racking rail assembly when locked together in a transport position; Figure 10 shows end elevation views corresponding to that shown in Figure 9, and the sequence of events when locking the racking rails together; Figure 11 shows a perspective view and an end elevation view of a cross beam of the handler shown in Figure 1; Figures 12-14 are perspective views of a stabiliser jack of the handler of Figure 1 in both extended and parked conformations; Figures 15-17 are perspective views of a pivotal coupling connecting a cabin of the handler to a deck of the handler of Figure 1, and the sequence of events when pivoting the cabin relative to the deck; Figures 18-20 show perspective views of the cabin, deck and pivotal coupling, and how the cabin may be pivoted relative to the deck; 18 Figure 21 is a perspective view of part of a tube loader assembly, main frame and trough body of the handler shown in Figure 1; Figure 22 is a perspective view of a tube loader of the tube loader assembly shown in Figure 21 Figure 23 is a top plan view of the tube loader shown in Figure 22; Figure 24 is a side elevation view of the tube loader shown in Figure 22; Figure 25 is a perspective view of a tube separator of the tube loader assembly shown in Figure 21 as well as part of a racking rail; Figure 26 is a side elevation view of a tube stopper of the tube loader assembly shown in Figure 21; Figure 27 is a perspective view corresponding to Figure 26; Figure 28 is another perspective view of the tube stopper shown in Figure 26; Figure 29 corresponds to Figure 21 and shows the sequence of events when loading a tubular load into a channel of the trough body; Figure 30 corresponds to Figure 29, but is shown in end elevation; Figures 3 1-33 are perspective views of a tube agitator of the handler shown in Figure 1; Figure 34 is the same as Figure 32 except that some details have been omitted; Figures 35-37 are detailed side elevation views of the tube agitator shown in Figure 31, showing the sequence of events of how tubular loads may be agitated and fed to the tube stopper; Figure 38 is a perspective view of part of a trough assembly of the handler shown in Figure 1, when being used to convey a tubular load; Figures 39 and 40 are perspective views of the trough body and roller arrangement of the trough assembly; Figures 41 and 42 are end elevation views showing an ejector system of the trough assembly when ejecting tubular loads from the channel to the racking rails; Figures 43 and 44 are perspective views of part of the trough body and components of a pusher assembly; Figure 45 is a perspective view of a buffer extension of the pusher assembly; Figure 46 is a partial view of the buffer extension shown in Figure Figure 47 is a side elevation view of the buffer extension shown in Figure Figure 48 is a detailed top plan view of the buffer extension shown in Figure Figure 49 is a longitudinal sectional view taken through plane A-A of Figure 48; Figure 50 is a perspective view of various components of the pusher assembly when coupled to one another; Figure 51 is a perspective view of a guide extension of the pusher assembly; Figure 52 is a perspective view of a tube retaining extension of the pusher assembly; Figure 53 is a perspective view of part of the pusher assembly; and Figure 54 is a perspective view of a pusher control mechanism of the trough assembly and a control mechanism of the trough lift system.

00 In the figures, like reference numerals refer to like features.

SPREFERRED EMBODIMENTS OF THE INVENTION Figures 1-4 show a tubular load handler 1 for handling long tubular loads 2 such as pipes, tubes, drill collars and pumping rods that are predominately used in drilling operations and in servicing drilled wells. The handler 1 can handle rods having an C* outer diameter from about 5/8 inch to 1 inch, and having a length up to 25 feet. The handler 1 can handle pipes and drill collars having an outer diameter from about Sinch to 6 inch, and having a length from about 15 feet to 45 feet.

00 SThe handler 1 includes a main frame 3 and a wheeled undercarriage 4 connected to the main frame 3 such that the handler 1 is transportable from one location to another.

The main frame 3 includes a deck 100 at a front end of the handler 1, catwalks 6, 7 extending parallel with a longitudinal axis of the main firame 3, along each longitudinal side of the main frame 3.

The handler 1 includes an operator's cabin 5 pivotally connected to the deck 100. The cabin 5 is pivotable such that the operator may optimise his or her vantage point of either catwalk 6, 7.

Racks containing hydraulic accumulators 26 (shown in Figure hydraulic pumps, manifolds and hydraulic fluid reservoirs 27 are located on the deck 100 adjacent the cabin The handler 1 comprises a pair of racking rail assemblies 8, 9 for supporting or storing tubular loads 2. Each racking rail assembly 8, 9 comprises two spaced racking rails 40 extending parallel with one another and extending laterally of each longitudinal side of the main frame 3. Each racking rail assembly 8, 9 also includes a height-adjustable ground support actuator 41 connected to each racking rail The handler 1 comprises six cross beams 14 and two auxiliary rails 12, for providing stability to the racking rail assemblies 8, 9 and/or for providing additional support for the tubular loads 2.

00 The handler 1 includes a trough assembly for conveying tubular loads 2 parallel with the longitudinal axis of the main frame 3.

SThe trough assembly includes a trough body 34 and a channel 522 extending parallel Ni 5 with the longitudinal axis of the main frame 3 in which a tubular load 2 may be conveyed. The trough body 34 extends between the catwalks 6, 7.

N The trough assembly includes a roller arrangement 523 mounted to an upper end of N the trough body 34, for assisting in the loading and unloading of tubular loads 2 from 00 the channel 522.

The trough assembly includes an ejector system having ejectors 231 (see Figure 41) for ejecting tubular loads 2 from the channel 522 of the trough body 34 to either racking rail assembly 8, 9.

The handler 1 includes a trough lift system 35 for raising and lowering the trough body 34 relative to the main frame 3.

The trough assembly includes a tube pusher assembly 600 for pushing tubular loads 2 along the channel 522 of the trough body 34.

The trough assembly includes a pusher control mechanism 36 for controlling the tube pusher assembly 600.

The handler 1 includes a tube loader system for loading tubes 2 into the channel 522 of the body 34. This system includes a tube loader assembly having six tube loaders 340, six tube stoppers 380 and six tube separators 400 (see Figure 21). One tube loader 340, tube stopper 380 and tube separator 400 is associated with each racking rail 40 and auxiliary rail 12 (depicted by numeral 28 in Figures 1-3).

The handler 1 includes four tube agitators 420 for assisting tubular load 2 rolling towards the tube stoppers 380 and to ensure that the tubular loads 2 are the same distance from the tube loaders 340 of the tube loader assembly.

00 0 The racking rail assemblies 8, 9 are used to store tubular loads 2 either side of the Strough body 34 and are best seen in Figures 1-10, particularly Figures 5-9. Each Sracking rail 40 extends laterally of a catwalk 6, 7 and the height-adjustable ground support actuator 41 is connected to an end of each racking rail 40. A travel stop (not C 5 shown) for stopping tubular loads 2 extends vertically through each racking rail adjacent the ground support actuator 41. The other end of each racking rail 40 is located adjacent the trough body 34 and is lined with a cushion pad of foam rubber N 1020 (see Figure 3).

00 Each racking rail assembly 8, 9 has a racking rail 40 folding mechanism that enables r easy and fast change from a working position/mode (as shown in Figures 1-3) to a transport position/mode (as shown in Figure 4) and back to the working position. The racking rails 40 can be tilted so as to enable tubular loads 2 to either gravity feed towards the trough body 34 (see racking rail assembly 8 of Figure 3) or away from the trough body 34 (see racking rail assembly 9 of Figure 3).

Referring now to Figures 5-8, each racking rail 40 includes a box section tubular beam 43 and a wall 44 extending downwardly from the beam 43. Tubular loads 2 roll along a top surface of the beam 43. A rest bracket 51 extends from each wall 44.

Each rest bracket 51 includes a bush having a central opening 54, as seen in Figures and 9. Each beam 43 also has three cross beam locator pins 45 as seen in Figure The racking rails 40a at the front end of the handler 1 further have a locking pin 42 that extends from beam 43, as seen in Figure 9.

As seen in Figure 5, each racking rail assembly 8, 9 includes a swivel bracket 46 having a horizontal rail pivot pin 47, a vertical rail pivot pin 48, a rest seat 49 and a locking pin 50. The bracket 46 is mounted to a catwalk 6, 7. The vertical rail pivot pin 48 enables the beams 43 to be rotated in a horizontal plane for transport against the main frame 3 and the horizontal rail pivot pin 48 allows a change in beam 43 angle relative to the horizontal plane. In order to rotate the beams 43 for transport, first the ground support actuator 41 is fully extended. As a result, the opening 54 in the rest bracket 51 aligns with an opening 57 in the rest seat 49. Insertion of the locking pin 50 through those aligned openings 54, 57 prevents the beams 43 from returning back after the support actuator 41 has been retracted and enables the beams 00 43 to be rotated to the transport position. The locking pin 50 may then be removed for transport. In order to extend the beams 43 such that they are in the working Sposition, the process is carried out in reverse. The locking pin 50 is removed and n placed in a storage sleeve (not shown).

Racking rail assemblies 8 and 9 each include a latching mechanism for locking the racking rails 40 for transport, as seen in Figures 9 and 10. The latching mechanism includes a rail cradle 60, a cradle pivot pin 61, a racking rail bracket 62, a sprung (Ni latching hook 63, the latching pin 42, and a latching hook pivot pin 64. The racking 00 0 10 rail bracket 62 is connected to wall 44 and has a rail cradle travel stop 65. The rail Scradle 60 has a lower end pinned to the bracket 62 by way of the cradle pivot pin 61 and has an upper end having a rail cradle seat 66. A pair of cradle fingers 67, 68 define the rail cradle seat 66. The sprung latching hook 63 is pivotally connected to the rail cradle 60 by way of the latching hook pivot pin 64. A coil spring 69 has an end connected to the latching hook 63 and an end connected to the rail cradle 60. The sprung latching hook 63 is shaped to hook around the top and side of the beam 43 of the rear racking rail 40b, as shown in Figure In order to fold the firont 40a and rear 40b racking rail beams 43 for transport, first each rear beam 43, 40b is rotated forward and parallel with the longitudinal axis of the main body 3 and secured into position, then each front beam 43, 40a is rotated back adjacent each rear rail 43, 40b. As the front beam 43, 40a is pushed towards the rear beam 43, 40b, the latching pin 42 of the front beam 43, 40a hits the cradle finger 67 and causes the rail cradle 60 to pivot about the cradle pin 64. As the rail cradle rotates, the cradle seat 66 pivots upwardly and supports the front beam 43, 40a. As the pivoting motion continues towards the rear beam 43, 40b, the latching hook 63 extends over the top and catches behind a side wall of the rear beam 43, 40b. The position of the latching pin 42 generates increased latching force as the force on the latching hook 63 increases. The spring 69 of the latching hook 63 provides additional security from accidental release by the latching hook 63. This automatic latching mechanism latches each front beam 43, 40a with each rear one 43. 40b so that both sets of racking rails 40 are secured for transport.

00 As seen in Figure 9, the latching mechanism also includes a latch arrangement 900 0 secured to rail cradle 60 that is used to set the cradle ready to lock the racking rail.

SThe latch arrangement 900 allows for rail cradle 60 to be folded down out of the road Swhen the tubular loads 2 are rolled down the racking rail. The latch arrangement 900 includes a bolt having a T-shaped end 901. Figure 10 shows that when the arrangement is set, it sits higher than the top of the racking rail.

SReferring now to Figure 5, each extendable ground support actuator 41 provides angle adjustment to the beams 43 relative to the horizontal plane, to compensate for uneven 00 ground conditions and to maintain the same angle for both racking rails 40 of an Sassembly 8, 9. The height of the ground support actuators 41 determines whether the tubular loads 2 will be gravity fed towards the trough body 34 or away from the trough body 34.

Figure 5 shows that the ground support actuator 41 includes a hydraulic cylinder having a housing 81 pivotally connected to the racking rail 40, a piston 80 extending from the housing 81 and a ground-bearing pad 82 connected to an end of the piston The ground support actuator 41 further includes a bracket 83 connected to beam 43 and an adjustment mechanism for finely adjusting the height of the beam 43 relative to the housing 81. The adjustment mechanism includes a crank 84 operatively connected to the housing 81 by way of an L-shaped intermediate pivotable lever 85. The lever 85 is pinned with pin 86 to the bracket 83. The crank 84 has a handle and a threaded shaft 87. A lower end of the lever 85 is screwed to the threaded shaft 87 of the crank 84 and an upper end of the lever 85 is pinned with pin 88 to an upper end of the housing 81. Depending on in which direction the crank 84 is turned, the lower end of the lever 85 either moves towards or away from the handle of the crank 84 and the upper end of the lever 85 either raises or lowers the housing 81.

Referring now to Figures 1-4, the auxiliary rails 12 provide additional support to tubular loads 2, particularly flexible tubular loads. The auxiliary rails 12 extend parallel with and between the racking rails 40 and the weight of the auxiliary rails 12 is transferred to the racking rails 40 through the cross beams 14. Each auxiliary rail 12 is a box section tubular beam. The auxiliary rails 12 have a substantially identical swivel bracket 46a pin arrangement for angle change and transport fold as the racking 00 rail assemblies 8, 9. Because the auxiliary rails 12 are of light construction, they do 0 Snot require the latching mechanism of the racking rail assemblies 8, 9. An end of Seach auxiliary rail 12 adjacent the trough body 34 has a foam rubber cushion pad cn1020a.

kn t(,i Referring now to Figure 11, each cross beam 14 is of a light rigging construction and Nincludes a box section tubular beam 70, a rail coupling 71, 72 at each end of the beam 70, a pair of rigging guides 73, 74 extending downwardly from the beam 70, and C, tensionable rigging 75 extending over the guides 73, 74 between the couplings 71, 72.

00 Each rail coupling 71, 72 has a seat pocket 76, 77 for receiving a locator pin 45 of a beam 43. Seats 78, 79 for auxiliary rails 12 comprising two pairs of lugs, are located on the beam 70 and an auxiliary rail 12 is locatable between either lug pair. A carry handle 905 extends between each coupling 71, 72 and the beam 70. In transport mode, the cross beams 40 are detached from beams 43 and placed on the catwalks 6, 1 5 7, as shown in Figure 4.

As shown in Figures 1-4, the handler 1 includes six stabilising jacks 20 connected to the main frame 3. The stabiliser jacks 20 give the handler 1 additional stability in work mode. In addition, they can compensate for uneven ground to maintain the catwalks 6, 7 level. Referring now to Figures 12-14, each stabiliser jack 20 includes an upper sleeve 1000, a lower sleeve 1001 slideable within the upper sleeve 1000, and a ground bearing foot 90. Each stabiliser jack 20 also includes a hydraulic cylinder, wherein a housing of the cylinder is pinned within the upper sleeve 1000 and to the main frame 3 by way of a pin 1002, and a piston of the cylinder is pinned to the lower sleeve 1001 and foot 90 by way of a pin 1003.

To achieve greater ground clearance in transport mode, the lower sleeve 1001 is retractable within upper sleeve 1000 and the foot 90 can fold to the position shown in Figure 13. When the lower sleeve 1001 is retracted within the upper sleeve 1000, tab 1005 bears against projection 1004 of the foot 90 and causes the foot 90 to rotate to a folded position, as seen in Figure 13. The middle jacks 20 can also be rotated from vertical to horizontal by way of a rotating mechanism 1010, to gain additional clearance for transport, as shown in Figure 14.

0The cabin 5 is movable between a folded position for transport and unfolded position Sfor work. The cabin 5 may also be rotated during operation to improve the operator's g view of either catwalk 6, 7 and associated racking rail assemblies 8, 9. As seen in SFigures 15-20, the cabin 5 is pivotally connected to a deck 100 of the main frame 3 by way of a pivot arrangement. The arrangement includes a flanged tubular pivot member 101, a hydraulic cylinder 104, an intermediate arcuate arm 109 and a slotted guide 107.

SThe hydraulic cylinder 104 has a housing 105 connected to the deck 100 and a piston 00 106 that is pinned to an end of the arcuate arm 109. The other end of the arcuate arm 109 is pinned to a flange 102 of the flanged pivot member 101. The slotted guide 107 is connected to the deck 100 and guides movement of the piston 106. When the piston 106 extends or retracts relative to the housing 105, then the pivot member 101 together with the cabin 5 rotate relative to the platform 100, as seen in Figures 18-20.

Figures 21-30 show the tube loader assembly for loading tubes 2 into the channel 522 of the trough body 34. As seen in Figures 21-24, each tube loader 340 includes a loading arm 341, 342 having a cradle 365 for a tubular load 2, and a hydraulic cylinder 347 (see Figure 29) for moving the cradle 365 between a tube loading position and a tube unloading position. Each tube loader 340 also includes a setting mechanism 345 and part of a torsion bar 346.

The loading arm 341, 342 includes a finger plate 341 and auxiliary arm 342 that extend in spaced parallel planes and each has a working end 348, 349 and a mounting end 350, 351. The finger plate 341 and auxiliary arm 342 each have an aperture 352, 353 at the mounting end (see Figure 22). A bush 344 extends between the finger plate 341 and auxiliary arm 342 at the mounting end 350, 351 such that the torsion bar 346 may extend through those apertures 352, 353 and bush 344. A striker bar 343 extends through the finger plate 341 and auxiliary arm 342 and beyond the auxiliary arm 342 at the working end 348, 349.

A torsion bar mount 354 extends from the main frame 3 and the torsion bar 346 extends through that mount 354. The finger plate 341 and auxiliary arm 342 can pivot relative to the torsion bar 346.

00 The finger plate 341 and auxiliary arm 342 each provide part of a lift finger 355, 357 0 Sextendable beneath a tubular load 2 and the finger plate 341 has an upstanding finger S356 that cooperates with the lift finger parts 355, 357 to provide the cradle 365 and to Scradle the tubular load 2 whilst the tubular load 2 is being moved to the tube S 5 unloading position. The upstanding finger 356 is wedge-shaped such that the tubular load 2 will roll off the upstanding finger 356 when the cradle 365 is in the unloading position. An end of each lift finger 355, 357 is upturned so as to better engage behind a tubular load 2. The finger plate 341 has a slot 358 intermediate the upstanding Sfinger 356 and the aperture 352 (see Figures 22 and 24).

00 As seen in Figures 22-24, the setting mechanism 345 includes an action arm 360, a pinion 361, a pinion locking bolt and nut 362, and an action arm locking bolt and nut 363. The action arm 360 has a front end 364 and a rear end 368. The rear end 368 has an aperture 366 through which the torsion bar 346 extends. The rear end 368 is fixed to the torsion bar 346 such that the action arm 360 rotates with the torsion bar 346. The front end 364 of the action arm 360 has a rack 367 having teeth. The pinion 361 is mounted to the finger plate 341 by way of the pinion locking bolt and nut 362.

Teeth of the pinion 361 mesh with the teeth of the rack 367. A slot 369 extends within the action arm 360 intermediate the rack 367 and the aperture 366 (see Figure 24). The slots 369, 358 of the action arm 360 and finger plate 341 coincide and the action arm locking bolt 363 extends through those slots 358, 369. The action arm locking bolt 363 can be tightened to lock the action arm 360 and finger plate 341 together and can be loosened such that the finger plate 341 can be adjusted in position relative to the action arm 360. In order to adjust the position of thile finger plate 341 relative to the action arm 360, the action arm locking bolt 363 and pinion locking bolt 362 are loosened, the action arm locking bolt 363 moves within the slots 358, 369 and the pinion 361 rotates relative to the rack 367. After the required adjustment has been made, the action arm locking bolt 362 and pinion locking bolt 363 are tightened.

As seen in Figures 29 and 30, the hydraulic cylinder 347 comprises a housing 370 and a piston 372. A trunnion 371 at an end of the piston 372 is pinned to a lower region of the finger plate 341. The housing 370 is connected to the main frame 3 by way of a bracket. When the piston 372 of the hydraulic cylinder is extended, the finger plate 341 is raised such that a tubular load 2 in the cradle 365 may roll off the upstanding 0finger 356 into the channel 522. When the piston 372 is retracted, the finger plate 341 Sis lowered such that a tubular load 2 may roll onto the lift finger 355, 357 and be Scradled. This sequence of events is shown in Figures 29 and

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N 5 Referring now to Figures 26-28, the tube stopper 380 positions each tubular load 2 adjacent the finger plate 341 of the tube loader 340. The tube stopper 380 includes a swing arm 381 and a stopper 382. The swing arm 381 includes a plate 383 and teeth 384 extend along an upper edge of the plate 383. A fulcrum pin 385 extends from one Send of the plate 383 through an aperture (not shown) in beam 43. The fulcrum pin 00 385 enables the swing arm 381 to be rotated to a stowed position below the top (N surface of the beam 43 when the tube stopper 380 is not being used. In the stowed position, a pin 1030 of the racking rail 40 rests within a recess 1031 of the plate 381.

An adjustable support 386 extends from a lower end of the plate 383. The adjustable support 386 comprises a bolt housing 387 extending from the plate 383 and a height adjustment bolt 388 extending from within the housing 387. The adjustable support 386 also includes a pair of adjustment nuts 389, 390 threaded onto the bolt 388. The adjustment bolt 388 rests on a catwalk 6, 7 and enables the swing arm plate 383 to be raised or lowered relative to the catwalk 6, 7, according to the diameter of the tubular load 2.

The stopper 382 includes a pair of spaced parallel plates 392, 393 that extend either side of the swing arm plate 383. Each plate 392, 393 has an upper end and a lower end. A stopper block 394 is pinned between the upper end of each plate 392, 393. A bottom surface of the stopper block 394 has teeth that can mesh with the teeth 384 of the swing arm plate 383. A guide pin 396 extends between the lower end of each plate 392, 393. The stopper 382 can be positioned at different positions along the swing arm plate 383 by way of rotating the stopper block 394 relative to the guide pin 396 until the teeth of the stopper block 394 and teeth 384 of the swing arm plate 383 disengage (as seen in Figure 28), and the stopper block 394 can lock to the swing arm plate 383 by way of re-engaging the teeth of the stopper block 394 with the teeth 384 of the swing arm plate 383 (as seen in Figure 27).

0Referring now to Figure 25, the separator 400 enables only one tubular load 2 at a time to be lifted by the tube loader 340. The separator 400 includes a separator bar 402, a spring arm 403 and a pistol-shaped lever 404 extending between the separator bar 402 and spring arm 403. The separator bar 402 is arcuate and has an upstanding separating finger 405 that can be inserted between adjacent tubular loads 2 on the racking rails 40 as well as a catch 414. The lever 404 is pivotally connected to the beam 43 such that the separator bar 402 may be raised and lowered relative to the Sbeam 43. The lever 404 has an aperture through which a pivot pin 407 extends into the beam 43. The spring arm 403 is a pin extending laterally of the lever 404 beneath 00 the beam 43.

The separator 400 includes a coil spring 410, a spring lug 411 and a tensioning nut and bolt 412. A first end of the coil spring 410 is attached to the spring arm 403 and the other end is attached to the spring lug 411. The nuts and bolt 412 are used to fasten the spring lug 411 to a bracket 413 of the beam 43. The spring 410 urges the separator bar 402 into a raised position whereby the separating finger 405 is positioned between adjacent tubular loads 2 on the racking rails 40. A limiter tab 415 of the separator 400 extends laterally of the tubular rail 43 and determines the maximum height of the separator bar 402. When the loading arm 342 moves to the tube loading position, the striker bar 343 of the tube loader 380 engages the catch 414 and moves the separating finger 405 out of engagement with those tubular loads 2 and below the top surface of the beam 43 such that a tubular load 2 may roll to the stopper block 394 of the tube stopper 380.

In use, each beam 43 of a racking rail assembly 8, 9 is inclined by way of the ground support actuator 41 such that tubular loads 2 placed on the beams 43 will roll into abutment with the separating finger 405 of the separator bar 402. The tubular load 2 in contact with the separator bar 402 will roll into abutment with the stopper block 394 once the striker bar 343 has moved the separating finger 405 below the top surface of the beam 43. The tubular load 2 in contact with the stopper block 394 is positioned so that tips of the lift finger 355, 357 capture the tubular load 2 just over the centre of the tube balance point, such that the tubular load 2 rolls along the lift finger 355, 357 into abutment with the upstanding finger 356. The hydraulic cylinder 347 then raises the finger plate 341 until the tubular load 2 is able to roll of the second 00 finger portion 356 and into the channel 522. This sequence of events is shown in SFigures 29 and Figures 31-37 show a tube agitator 420 for assisting tubular load 2 rolling towards the C 5 tube stopper 380 and to ensure that the tubular loads 2 are the same distance from all finger plates 341 of the tube loaders 340. As seen in Figure 1, a pair of tube agitators 420 extends transversely of each catwalk 6, 7 adjacent the racking rails The agitator 420 includes an agitator bar 421, a spring assembly 422, a roller runner 00 423, a hydraulic cylinder 424, a rail bar 425, a bracket 426, an adjustable support 427, N and a catwalk locking pin 428.

The bracket 426 is in the form of an angle bracket having a vertically extending plate 430 and a horizontal extending plate 431. The catwalk locking pin 428 extends from the horizontal plate 431 and through an opening in a catwalk 6, 7, and is used for transport fold rotation. A slide pin 435 extends laterally of the horizontally extending plate 430 at one end of the plate 430 and a spring support pin 436 extends from the other end of the plate 430. A retainer 437 (see Figures 32 and 33) is located at a free end of the slide pin 435. The rail bar 425 extends laterally and perpendicularly of the vertically extending plate 430 beneath the agitator bar 421 and the roller runner 423.

The spring assembly 422 includes a pair of interconnected coil springs 440, 441 and a loop 442. The loop 442 extends between the agitator bar 421 and coil spring 440.

The other coil spring 441 is connected to the spring support pin 436.

The agitator bar 421 has an upper face on which tubular loads 2 may roll and a lower wedge-shaped face having teeth 445. One end of the agitator bar 421 has a slot 446 through which the slide pin 435 extends. This slot 446 and slide pin 435 arrangement, together with the spring assembly 422, enable the agitator bar 421 to vibrate and to tilt. The other end of the agitator bar 421 is wider than the first mentioned end and has an opening 448 through which the loop 442 of the spring assembly 422 extends.

0The roller runner 423 includes three rollers 450, 451, 452 pinned between a pair of Splates 454, 455. An upper roller 450 is able to engage the teeth 445 of the agitator bar S421. Two lower rollers 451, 452 travel along the rail bar 425.

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The adjustable support 427 extends from a lower end of the rail bar 425. The adjustable support 427 comprises an adjustment bolt 458 extending through the rail bar 425 and an adjustment nut 459 threaded onto the bolt 458. The adjustment bolt 458 rests on a catwalk 6, 7 and enables the rail bar 425 to be raised or lowered relative to the catwalk 6, 7.

00 The hydraulic cylinder 424 has a housing 460 pinned to the vertically extending plate 430 and a piston 461 of the cylinder is pinned between the plates 454, 455 of the roller runner 423. The agitator bar 421 vibrates and tilts when the roller runner 423 is moved by the cylinder. The agitator bar 421 tilts downwardly towards the stopper block 394 when the piston 461 has been retracted and moves to a horizontal disposition when the piston 461 has been extended. When in the retracted position, the agitator bar 421 tilts downwardly towards the stopper block 394. such that several tubular loads 2 will separate from one another and roll under gravity to the stopper block 394. This sequence of events is shown in Figures 35-37.

The trough lift system 35 is shown in Figure 38 and includes a lift arm 181, a bracket 184 and a hydraulic cylinder 185. The lift arm 181 has an upper end 183 pivotally connected to the trough body 34 and a lower end 182 pivotally connected to the bracket 184. The bracket 184 includes a base plate 200, a cylinder bracket 215 and a pair of walls 201, 202. The walls 201, 202 are connected to the main frame 3 The lift arm 181 has a pair of sidewalls 188, 189 and a reinforcing plate 190 extending along each side wall 188, 189. The lower end 182 of the lift arm 181 has a bush 206 that extends between walls 201 and 202. A pair of gussets 207 extend between the side walls 188, 189 and the bush 206. A main pivot pin 210 extends through those walls 201 and 202 and the bush 206. The trough body 34 has a pair of brackets 211 that straddle the upper end 183 of the lift arm 181, and a lift arm pivot pin 205 extends through those brackets 211 and lift arm side walls 188, 189.

00 The hydraulic cylinder 185 has a housing 186 pivotally connected to the bracket 215 by way of housing pivot pin 217. A piston 187 of the hydraulic cylinder 185 is Spivotally connected to the lift arm side walls 188, 189 intermediate the upper 183 and cnlower 182 ends by way of a cylinder pivot pin 216. The trough body 34 may be Vt') N, 5 pivoted between.a raised and lowered position by the lift arm 181. As the piston 187 extends, it exerts a force on the lift arm 181 so as to generate a rotational motion C* around the main pivot pin 210.

N

The trough lift system 35 further includes a pair of rollers 532 mounted to a lower end 00 10 of the trough body 34 and each roller 532 travels within a runner 533 of the system 35, as seen in Figure 38. Each runner 533 extends parallel with the longitudinal axis of the main frame 3 and adjacent the catwalks 6, 7. Each runner 533 has a U-shaped cross-section, as seen in Figure 38. As the lift arm 181 rotates, an upper region of the body 521 follows an uplifting curve whilst the lower region of the body 521 follows the direction of the runners 533.

The trough body 34 includes a pair of spaced side walls 521 and the top wall 536 extending there between. The top wall 536 provides the V-shaped channel 522. The channel 522 extends the length of the trough body 34. A slit 520 extends within the top wall 536 along a longitudinal axis of a lower half of the trough body 34 (see Figure 54). The trough body 34 also has a series of transition ramps 1080 extending from the side walls 521, enabling tubular loads 2 to roll smoothly onto the racking rails 40 (see Figures 21, 29 and The trough assembly includes an adjustable roller assembly 523 mounted to the upper end of the trough body 34. As seen in Figures 39 and 40, the roller assembly 523 includes a roller 525, a pair of pivotable plates 524 and a pair of sprung pivotable locking members 527. Each plate 524 is pivotally connected to the body 521 by way of a pivot pin 526. Each plate 524 has teeth 529. Each locking member 527 is pivotally connected to the body 521 by way of a pivot pin 528. Each locking member 527 has teeth 530. The position of each plate 524 may be adjusted relative to the body 521 by way of disengaging the teeth 530 of the locking member 527 from the teeth 529 of the plate 524 against the force of the spring 531, as shown in Figure 00 The roller 525 has a centrally located neck that helps align the tubular load 2 with the channel 522.

SThe trough assembly includes an ejector system for ejecting tubular loads 2 from the C 5 channel 522 to the racking rails 40. The ejector system includes a series of ejectors 231 that are movable by way of hydraulic cylinders 232 between parked and tube C* ejecting positions. The ejectors 231 are situated such that tubular loads 2 may be ejected from the channel 522 to racking rails 40 on either side of the trough body 34.

00 10 As seen in Figures 41 and 42, each ejector 231 includes an ejector bar 233, a swing arm 235, a swing arm pin 236 and a cylinder pin 237. An upper end of the swing arm 235 is connected to a lower end of the ejector bar 233. A lower end of the swing arm 235 is pivotally mounted to a bracket 238 of the trough side wall 521 by way of the swing arm pin 236.

The hydraulic cylinder 232 has a housing 240 and a piston (not shown) extendable relative to the housing 240. The piston is connected to the swing arm 235 by way of the pin 237. The housing 240 is mounted to a bracket 246 of the side wall 521.

The ejector bar 233 is movable between a tube ejector position and a parked position.

In the ejector position, the ejector bar 233 extends through an opening in the top wall 536 of the trough body 34 and ejects a tubular load 2 located within the channel 522 such that it rolls or slides down ramp 1080 onto the racking rails 40. In the parked position, the ejector bar 233 rests flush with the top wall 536 of the trough body 34.

A working surface of the ejector bar 233 has a ramp/nose 245 which improves the ejection of tubular loads of small diameter.

The trough assembly 34 includes a tube pusher assembly 600, the main function of which is to move tubular loads along the channel 522 and over the roller 525 of the roller assembly 523. Another function of the tube pusher assembly 600 is to catch a tubular load 2 sliding down the channel 522 and to adjust the position of the tubular load 2 such that it can be ejected onto the racking rails 00 Components of the pusher assembly 600 are shown chiefly in Figures 43-54. The 0 Spusher assembly 600 includes a pusher trolley 601 that travels within the channel 522 Salong the lower half of the trough body 34. The pusher trolley 601 is best seen in SFigures 43, 44, 53 and 54. The pusher trolley 601 has a body 602 and three pairs of rollers 603, 604, 605 mounted to the body 602 with axes parallel with the channel 522 so as to transfer the reaction forces of the push trolley 601 onto the trough body 34, whilst reducing the friction between the trough body 34 and pusher components. Two of the roller pairs 603, 604 travel along a top surface of the channel 522 whereas the (Ni Sthird pair of rollers 605 (see Figure 53) travels along a lower surface of the channel 00 10 522 and holds the upward reaction force of the pusher trolley 601. A working end of Sthe body 602 includes a mount plate 606, a cross pin 607 located at the end of a central plate 608 and plastic and rubber cushion pads 609 connected to the mount plate 606. The cushion pads 609 protect the pusher trolley 601 from shock generated by tubular loads 2 sliding down the channel 522.

Referring now to Figure 53, the pusher assembly 600 includes a hydraulic cylinder 1100 located within the trough body 34. A housing 1101 of the cylinder 1100 is mounted to the upper half of the trough body 34 by way of a bracket 1103 and Ushaped supports 1109. A piston 1105 of the cylinder 1100 has an end 1106 pinned to the pusher trolley 601. When the piston 1105 is extended relative to the housing 1101, then the pusher trolley 601 is located adjacent the rollers 532. When the piston 1105 is retracted relative to housing 1101, then the pusher trolley 601 is located just short of halfway up the channel 522, adjacent an upper end of the slit 520.

Referring now to Figure 50, the pusher assembly 600 includes pusher extensions 620, 640, 660 to compensate for different lengths of tubular loads 2. The other function of the pusher extensions 620, 640, 660 is to bypass the slit 520 in the channel 522.

Figure 50 shows pusher extensions 620, 640, 660 of varying lengths.

Each pusher extension 620, 640, 660 includes a tubular body 621, 641, 661 having a mount plate 622, 623, 642, 643, 662, 663 each end of the body 621, 641, 661. At least one carry handle 624, 644, 664 extends from the body 621, 641, 661. A pair of coupling hooks 625, 645, 665 extends from one of the mounting plates 622, 642, 662 and a cross pin 626, 646, 666 is supported by a plate extending perpendicularly of 00 mounting plate 623, 643, 663. The coupling hooks 625, 645, 665 and cross pin 626, 646, 666 provide a quick coupling between adjacent pusher extensions 620, 640, 660.

Each pusher extension 620, 640, 660 includes plastic and foam rubber cushion pads S627, 647, 667 connected to the mount plate 623, 643, 663. A first pusher extension N 5 may be engaged with or disengaged from an adjacent second pusher extension by rotating the first pusher extension upwards to a certain angle such that there is clearance between the mount plate 623, 643, 663 of the first extension and the cushion Spad 627, 647, 667 of the second extension. With the hooks 625, 645, 665 fully engaged over the cross pin 626, 646, 666, force can be transferred in both directions, 00 tension and compression as well.

As seen in Figures 45-49, the pusher assembly 600 includes a buffer extension 670 for cushioning shocks from high inertia tubular loads 2, such as drill collars or heavier tubes sliding down the channel 522 from a high-set work floor.

The buffer extension 670 includes a cylindrical body 671 having a mount plate 672, 673 at each end of the body 671. A carry handle 674 extends from the body 671. A pair of coupling hooks 675 extends from mounting plate 672. The buffer extension 670 also includes a gas spring 677 and a slide bearing 678 located within the body 671, and a push rod 679 extending through the slide bearing 678 and out of the body 671. The push rod 679 is guided by the slide bearing 678. The impact of a moving tubular load 2 is transferred to the gas spring 677 via the push rod 679. Mounting plate 673 is connected to an end of the push rod 679. Plastic and foam rubber cushion pads 680 are connected to the mounting plate 673 (by way of screws) and a cross pin 681 is supported by a plate 682 that extends perpendicularly of the mounting plate 673. The hooks 675 and cross pin 681 allow for quick coupling to other pusher extensions.

As seen in Figures 43, 44 and 51, the pusher assembly 600 includes a guide extension 800 for preventing the jumping of a tubular load 2 out of the channel 522. The guide extension 800 includes a roller carriage 801, a clamp arrangement 802 and two vertical force reaction retainers 803, 804. The clamp arrangement 802 allows for the ready interchange of different pusher extensions 620, 640, 660.

00 As seen in Figure 51, the carriage 801 includes a U-shaped collar 805 within which is locatable the tubular body 621 of a pusher extension 620. An extension 806, 807 Sextends laterally of each side of the U. A pair of rollers 808, 809 is located each side n of the collar 805. Each pair of rollers 808, 809 is pinned to a roller frame 810, 811.

The rollers 808, 809 are each pinned between respective pairs of plates 812-815 of tilhe roller frame 808, 809. Each extension 806, 807 is connected to a plate 812-815. A retainer support arm 820, 821 extends from each lateral extension 806, 807 and between the plates 812-815 to the reaction retainers 803, 804.

00 10 Each reaction retainer 803, 804 is L-shaped. A horizontal part of the L extends N beneath an edge of the top wall 536. A vertically extending part of the L is connected to a retainer support arm 820, 821.

The clamping arrangement 802 includes a clamping arm 830, an arm mounting bracket 831, a sprung locking bolt 832 and a locking bolt mounting bracket 833. The arm mounting bracket 831 is connected to lateral extension 806 and the locking bolt mounting bracket 833 is connected to the other extension 807. One end of tilhe clamping arm 830 is pivotally connected to the arm mounting bracket 831 and the other end of the arm 830 has an eyelet 835 for receiving an end of thile locking bolt 832 (see Figure 43). The eyelet end of the clamping arm 802 may be raised when the locking bolt 832 does not engage the eyelet 835, so as to allow the insertion of a pusher extension within the collar 805, as shown in Figure 43. When the clamping arm 830 is lowered, the bolt 832 may be extended through the eyelet 835 and retain the pusher extension within the collar 805. The clamping arm 830 has a portion having an arcuate periphery 838 that snugly fits over the top of the body of the pusher extension. The clamping arrangement 802 shown in Figure 51 differs slightly from that shown in Figures 43 and 44 in that its locking bolt 832a extends vertically and is retained by an eyelet 835a at an end of the clamping arm 830.

Figures 43, 44 and 52 show that the pusher assembly 600 includes a tube retaining extension 890 for retaining an end of a tubular load 2. The tube retaining extension 890 prevents a lower end of the tubular load 2 from jumping out of the channel 522 by accident. The extension 890 includes a curved shroud 891, a lock bracket 892 extending from the shroud 891, and a support plate 893 extending between the lock 00 bracket 892 and the shroud 891. The lock bracket 892 includes a spaced pair of hooks 0 S895 that may engage a cross pin 626 of a pusher extension 620.

SThe extension 890 also includes a mechanical lock 896 that may be pivoted between a locked position and an unlocked position. The lock 896 has a lever 897 pivotally connected between the hooks 895 by way of a pivot pin 898. A handle 899 extends laterally of an upper end of the lever 897 and a lower end of the lever 897 has a hooked end that, when in the locked position, locks the tube retaining extension 890 to the mounting plate 623 of the pusher extension 620.

00 N The trough lift system 35 has a control mechanism for determining what height the trough body 34 can be raised. As seen in Figure 54, the control mechanism comprises a limit switch 1300 operatively connected to the hydraulic cylinder 185 of the trough lift system 35 (hydraulic hoses not shown). The limit switch 1300 includes a control valve that, when moved from an open to a closed position, restricts the flow of hydraulic fluid to the hydraulic cylinder 185. The limit switch 1300 is connected to the side wall 521 of the trough body 34.

The control mechanism further includes a roller stiker arm 1305 pivotally mounted to the side wall 521 adjacent the limit switch 1300. The roller striker arm 1305 includes a roller 1306, a roller mounting arm 1307 pivotally comnnected to a bracket of the side wall 521, a striker 1308 that may engage the limit switch 1300, and a spring (not shown) that biases the striker 1308 out of engagement with the limit switch 1300. The roller 1306 runs along a runner 1320 that extends parallel with the side wall 521.

The control mechanism also includes a limit 1310 for pivoting the striker 1308 into engagement with the limit switch 1300, so as to activate the limit switch 1300. The limit 1310 is in the form of a ramp 1311 and is positionable along the runner 1320 by way of a clamp. The further the limit 1310 is from the limit switch 1300, the higher the trough body 34 can be raised.

The trough assembly has a control mechanism for determining how far the pusher trolley 601 can travel in either direction along the trough body 34. As seen in Figure 54, the control mechanism comprises a pair of limit switches 1400, 1401 operatively 00 connected to the hydraulic cylinder 1100 (hydraulic hoses not shown). The limit 0 switches 1400, 1401 each include a control valve that, when moved from an open to a Sclosed position, restricts the flow of hydraulic fluid to the hydraulic cylinder 1100.

SThe limit switches 1400, 1401 are connected to the side wall 521 of the trough body 34.

The control mechanism further includes a control bar 1410 having a limit switch activator 1411, a pair of limits 1415, 1416, guide bearings 1417, 1418, 1420 and a striker arm 1419 that extends downwardly of the trolley 601.

00 CThe control bar 1410 extends slidingly through bearings 1417, 1418 and 1420. T'he limit switch activator 1411 is a cylindrical sleeve that activates either limit switch 1400, 1401 upon collision there with.

Each limit 1415, 1416 is positionable along the control bar 1410 and includes a slider body 1480, a pair of locking plates 1421, 1422 and a compression spring 1423 extending between the plates 1421, 1422. Each limit 1415, 1416 may be slid along the control bar 1410 only after pinching the locking plates 1421, 1422 together. Once the locking plates 1421, 1422 have moved apart, the limit 1415, 1416 is fixed in position on the control bar 1410. Each limit 1415, 1416 includes a lever 1425 that is pivotally connected to the slider body 1480. The lever 1425 is movable between raised and lowered positions, and is biased in the raised position by way of a spring (not shown). Limit 1415 is shown in the raised position.

The striker arm 1419 of the pusher trolley 601 is adapted to strike a free end of the lever 1425, and the collision causes the control bar 1410 to move and for the limit switch activator 1411 to engage and activate a limit switch (1400 or 1401). Upon colliding with the free end of the lever 1425, the lever 1425 moves to the lowered position and the striker arm 1419 slightly overruns the lever 1425. When the trolley 601 begins its journey in the reverse direction over the lever 1425, the control bar 1410 is not moved by the striker arm 1419 until colliding with the free end of the lever 1425 of the other limit switch (1400 or 1401). Figure 54 shows the striker arm 1419 colliding with limit 1416 and causing the activation of limit switch 1400.

00 In use, an operator on an upper platform attaches an upper end of a tubular load to a Sderrick. A lower end of the tubular load is then disconnected from a drill string that extends within a bore of a well. The tubular load is lifted by the derrick and operators non a work platform position the lower end of the tublar load with the channel 522 of the raised trough body 34. The tubular load is then detached from the derrick and allowed to slide down the channel 522 until colliding with the pusher assembly 600.

The trough body 34 is then lowered and the tube pushed to the racking rails 40 by way of the ejector system. The tubular load then rolls away from the trough body 34 to the ends of the racking rails

OO

00 1 In order to run the tubular load back into the bore of the well, the ground support actuators 41 are raised such that the tubular load gravity feeds to the tube loader assembly. The tube loader 340 places the tubular load into the channel 520, the trough body 34 is raised, the pusher trolley 601 moves the tubular load up the channels, operators on the work floor then attach the upper end of the tubular load to a derrick, the derrick raises the tubular load, and operators on the upper platform then connect the lower end of the tubular load to the drill string and detach the upper end from the derrick.

The tubular load handler as exemplified is unique in its ability to handle rods, joints and collars and the like up to 40 feet in length, with minimum set up requirements.

The loading, unloading, rack rails and trough body have all been designed to cope with the varying range of diameters, length and width throughout the three major types of joints.

The tubular load handler is very easy to change from work mode to transport mode and back, with minimal labour input. The efficiency of the handler's use is increased with the short set up times.

The foregoing embodiments are illustrative only of the principles of the invention, and various modifications and changes will readily occur to those skilled in the art. The invention is capable of being practiced and carried out in various ways and in other embodiments. It is also to be understood that the terminology employed herein is for the purpose of description and should not be regarded as limiting.

0 0 The term "comprise" and variants of the term such as "comprises" or "comprising" are used herein to denote the inclusion of a stated integer or stated integers but not to g1 exclude any other integer or any other integers, unless in the context or usage an Sexclusive interpretation of the term is required.

In oO

Claims (3)

1. 2. The tubular load handler of claim i, wherein the trough assembly comprises a trough body and a channel extending parallel with the longitudinal axis in which a (Ni C tubular load may be conveyed. 00 S3. The tubular load handler of claim 2, wherein the trough assembly comprises an ejector system having ejectors for ejecting tubular loads from the channel of the trough body to a racking rail assembly of the handler.
2. 4. The tubular load handler of claim 2 or claim 3 further comprising a tube loader system for loading tubular loads into the channel of the trough body. The tubular load handler of any one of claims 2 to 4 further comprising a trough lift system for raising and lowering the trough body relative to the main body.
3. 6. The tubular load handler of any one of claims 2 to 5 further comprising a tube pusher assembly for pushing tubular loads along the channel of the trough body. Date: 25 June 2008