WO2015031672A1

WO2015031672A1 - Combination pipe spinner and rotary tong device

Info

Publication number: WO2015031672A1
Application number: PCT/US2014/053255
Authority: WO
Inventors: Thomas D. Hauk
Original assignee: Hauk Thomas D
Priority date: 2013-08-28
Filing date: 2014-08-28
Publication date: 2015-03-05

Abstract

A device that is configured to be a multi modal drilling device. The device is multi modal because in one mode, it is a drill pipe spinner and in another mode, it is a pipe rotary power tong. A user inserts a module to change from the spinning mode to the tong mode. The spinner mode (i.e., the spinning mode) facilitates low torque spinning of drill pipe. The tong mode facilitates high torque rotation of drill tubing and casing. Heretofore, there has never existed a machine capable of both modes. In some implementations, the device includes a floating rotor with cam ramps that increase a hoop pressure on a pipe element within the rotor as torque is increased. Accordingly, a self-energized gripping system is provided.

Description

COMBINATION PIPE SPINNER AND ROTARY TONG

DEVICE

BACKGROUND

Field

[0001] Various features relate to devices configured for handling cylindrical type pipe elements, such as, for example, but not limited to, drill pipe, casing, and/or tubing.

Background

[0002] A special machine, called a spinner machine, is used to spin drill pipe up to or away from the shoulder seal. The drill pipe requires very little force and typically, the spinner machine just wraps a chain around the drill pipe and uses friction to spin the drill pipe. Other pipe elements are employed in drilling operations such as pipe casing and tubing. The casing and tubing require more force than a chain spinner can provide. The casing and tubing are threaded and interconnect in a tapered interference threaded connection requiring torqueing to make the connection. In addition, a second specialized machine (a rotary power tong machine) is employed to torque the casing and tubing. The rotary power tong machine grips the casing and tubing more aggressively than just a chain frictionally rubbing against the pipe elements. Having two separate devices for handling pipe elements is inefficient and costly.

[0003] Therefore, there is a need for a device that will allow users (e.g., oil rig workers) to use a single machine that has both a spinner mode and a tong mode (i.e., a torque mode).

DRAWINGS

[0004] Various features, nature and advantages may become apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify correspondingly throughout.

[0005] FIG. 1 conceptually illustrates a multi modal drilling device in a rotary power tong mode.

[0006] FIG. 2 conceptually and translucently illustrates a multi modal drilling device in the rotary power tong mode. [0007] FIG. 3 conceptually illustrates a top view of the device in a spinner mode wherein a clamshell rotor is not present.

[0008] FIG. 4 conceptually illustrates a perspective view of the device in spinner mode.

[0009] FIG. 5 conceptually illustrates a top view of the device in a tong mode.

[0010] FIG. 6 conceptually illustrates a rotor cracking pin protruding from a cracking pin cylinder.

[0011] FIG. 7 conceptually illustrates a top view of the device to show the cracked condition of the rotor.

[0012] FIG. 8 conceptually illustrates a top view of the device in tong mode.

[0013] FIG. 9 conceptually illustrates the device and rotor open.

[0014] FIG. 10 conceptually illustrates the device and rotor open.

[0015] FIG. 11 conceptually illustrates a perspective view of the device in tong mode.

[0016] FIG. 12 conceptually illustrates a top view of the device in tong mode.

[0017] FIG. 13 conceptually illustrates a top view of the device in tong mode and open.

[0018] FIG. 14 conceptually illustrates an implementation of a self-energizing grip system.

[0019] FIG. 15 conceptually illustrates an implementation of a self-energizing grip system.

[0020] FIG. 16 conceptually illustrates an implementation of a self-energizing grip system in use and under a mechanical resistive torque.

[0021] FIG. 17 conceptually illustrates an isometric view of the full rotor control system with the rotor closed.

[0022] FIG. 18 conceptually illustrates an isolated closed rotor.

[0023] FIG. 19 conceptually illustrates air control logic for the device.

[0024] FIG. 20 conceptually illustrates the self-energizing principle that allows for increased grip pressure on the pipe as torque is increased.

[0025] FIG. 21 conceptually illustrates an isometric view of the open rotor chain path.

[0026] FIG. 22 conceptually illustrates a top view of the chain path.

[0027] FIG. 23 conceptually illustrates the isolated rotor with its various components.

[0028] FIG. 24 conceptually illustrates the self-energizing principle that allows for increases grip pressure on the pipe as torque is increased. [0029] FIG. 25 conceptually illustrates the dies and die holder extending substantially inward to effectuate a different inner diameter to enable torqueing a different sized casing or tubing.

DETAILED DESCRIPTION

[0030] In the following description, specific details are given to provide a thorough understanding of the various aspects of the disclosure. However, it will be understood by one of ordinary skill in the art that the aspects may be practiced without these specific details.

Overview

[0031] Some implementations provide a device that is configured to be a multi modal drilling device. The device is multi modal because in one mode, it is a drill pipe spinner and in another mode, it is a pipe rotary power tong. A user inserts a module to change from the spinning mode to the tong mode. The spinner mode (i.e., the spinning mode) facilitates low torque spinning of drill pipe. The tong mode facilitates high torque rotation of drill tubing and casing. Heretofore, there has never existed a machine capable of both modes. In some implementations, the device includes a floating rotor with cam ramps that increase a hoop pressure on a pipe element within the rotor as torque is increased. Accordingly, a self-energized gripping system is provided.

[0032] In some implementations, the rotor includes gripping dies to grip the pipe element. A chain turns or rotates the clamshell rotor and, as torque is increased, the chain rollers move from a trough up onto the cam ramps increasing the radially inward force of the gripping dies on the pipe. Thus, the pipe is held tighter under heavy torque loads and looser under lighter torque loads achieving self-energization. However, even under the "looser" grip, the pipe element is still gripped relatively forceful enough such that slippage does not occur.

Exemplary Device Configured for Providing Tong operation in a Tong Mode [0033] FIG. 1 conceptually illustrates a multi modal drilling device 100, wherein the device 100 has a spinning mode and a rotary power tong mode as described in detail below. Specifically, FIG. 1 illustrates the device 100 configured in the rotary power tong mode. The device 100 includes a motor 102 with a plurality of hydraulic ports 104a and 104b. A hydraulic fluid passes in one of the ports 104a and 104b and spins the motor 102 before exiting the other port 104a and 104b. In particular, the motor 102 is bidirectional. When the hydraulic fluid enters port 104a and leaves port 104b, the direction of the motor 102 is counterclockwise. Likewise, when the hydraulic fluid enters port 104b and leaves port 104a, the direction of the motor 102 is clockwise.

[0034] Additionally the speed of the hydraulic fluid controls the rotational speed of the motor. Below the motor 102 is a transmission 106 for transferring the rotation of the motor 102 to a drive sprocket (not shown in FIG. 1) mounted on a transmission shaft. In addition to achieving a transfer of rotation between the motor 102 and the drive sprocket, the transmission (i.e. gearbox), 106, in at least one implementation, is capable of changing the rotational speed being transferred. As used herein the term rotor broadly refers to any rotating object, and although illustrated in the drawings as cylindrical rotors, the term rotor is not to be limited to only cylindrical objects.

[0035] A chain 108 extends from the drive sprocket to a pair of roller assemblies 110a and 110b. As seen in FIG. 2 each roller assembly includes bearing caps 112, roller portions 113, and chain handling portions 144. Although illustrated as guide sprockets, the chain handling portions 144 (i.e., guides) can be smooth rollers or can have recessed channels to limit vertical travel of the chains 108.

[0036] Referring back to FIG. 1, the device 100 includes a tong 114 having a fixed portion 118 and a rotating portion 120. As is better illustrated below, the tong 114 can open and close by way of a hydraulic piston or cylinder 122 pushing or pulling the rotating portion 120 away from or towards the fixed portion 118. The hydraulic piston 122 can be normally open or normally closed. A second hydraulic piston or cylinder 124 is mounted to an underside of the device 100. Together, fixed portion 118 and rotating portion 120 form a spinning clamshell. The device 100 also includes a clamshell rotor 126 having mounted on an inner diameter one or more gripping dies 128 or gripping die holders 128. In implementations utilizing gripping die holders 128, different sized dies can be changed to hold different size casing and tubing. The clamshell rotor 126 is hinged at a back side and includes an elastomeric biasing member 130, which applies an opening or an outwardly biasing force. As shown in a later figure, the elastomeric biasing member 130 can include a metal spring within elastomeric material that biases the rotor clamshell 126 open and against the chain element 108. Although illustrated using a metal closed loop roller chain 108, it is contemplated that the benefits of the invention accrue to any type of chain like element, metal, or non-metal, which can be used to transfer rotation to the clamshell rotor 126 when present in tong mode.

[0037] The device 100 is also herein called a Floating Rotor Spinner Tong and in FIG. 1, the device 100 is illustrated in a rotary power tong mode because device 100 includes the clamshell rotor 126 that can open and close allowing insertion or removal of pipe. More specifically, the device 100 closes the clamshell rotor 126 in order to clamp down on tubing or casing. The rotor 126 floats in that it is capable of being user inserted and user removed in the field during drilling operations whether oil drilling or water well drilling. The gripping dies 128 (best seen in FIGS. 14-16) typically have teeth like structures that engage on outer diameter of the pipe such that rotation of the clamshell rotor 126 effectuates a rotation of the pipe within the clamshell rotor 126. The clam shell rotor 126 can be installed in minutes to convert from the spinner mode (as illustrated in other figures, e.g., FIG. 3).

[0038] As stated above, installed on the I.D. of the rotor 126 are steel tipped gripping dies 128 that grip a pipe positioned within the rotor 126 when the rotor 126 is closed by the top and bottom hydraulic cylinders 122 and 124 when the spinner clamshell (portions 118 and 120 together) is closed. In one implement, the dies are not steel. Rather the dies can be aluminum or rubber and other materials (lead) that grip pipe like structures without making deformations on the pipe element. Alternatively, the die holder can be rubber and other material (especially resilient materials). The rubber dies are self energizing in that they compressibly grip the pipe element. Also the dies and die holders can have different surfaces such as being knurled. Both dies and dies holders (retainers) can also be covered in martial that aids in gripping. A compression spring 132 is located inside each cylinder 122 and 124. These springs 132 will crack (slightly open) the rotor 126 when hydraulic pressure is removed from the rod side of the cylinders. To insure that the cracking aperture (the gap 198 Fig. 7) is in the front of the rotor 126 is consistent, a cracking pin air cylinder 136 is located just rear of the closing hydraulic cylinders 122 and 124 on the moving side 120 of the case (yellow) that lowers a pin into a slot in the stationary side of the case (blue) 118. This is described in more detail below with respect to other figures. In addition, there are two sensor cam rollers 140 on the stationary side 118 of the case 114 at the top front. These sensor rollers 140 are for control of the rotor 126 as explained in more detail below. Another part of a rotor control system for device 100 is two retaining pins located on the front of the tong on the bearing caps as also explained below.

[0039] FIG. 2 conceptually illustrates a transparent view of the device in FIG. 1 where, for clarity reasons, identical elements shown in FIG. 1 are not redundantly numbered in FIG. 2. Device 100 includes a sprocket with multiple sprocket rows 144 on the roller assemblies 110a and 110b for use with multiple strand chain. Note that roller assemblies 110a and 110b do not need to have sprockets, they could include smooth rollers or channeled rollers (i.e., rollers with valleys or channels). FIG. 2 further illustrates that device 100 includes a peripheral retaining pin or member 146 engaged in a peripheral rotor retaining channel 148 which prevents rotor 126 from being released from the clam shell 126 when open. In other words, the opening cogs or rotor retaining channels 148 constrain the retaining pins 146 within the opening cogs 148 preventing the rotor clamshell 126 from being released when in an open configuration. Using alternative terminology, the nesting pins 146 are nested within the nesting cogs 148 limiting movement of the rotor clam shell 126.

[0040] Although FIG. 2 illustrates two nesting pins 146 at the upper portion of the roller assemblies 110a and 110b in the bearing caps 112, there can also be two additional nesting pins 146 at a lower portion of the roller assemblies 110a and 110b in bottom bearing caps 112. An adjustment pin 150 can be selectively inserted in any of a plurality of adjustment pin holes 152. Although only one pin 150 and four holes 152 are shown, another pin 150 and another four holes 152 are behind the gearbox 106. The length of the chain element 108, which is available to the rotor assemblies 110a and 110b, can be adjusted through selection of a particular hole 152. In other words, the motor 102, the transmission 106 and the driving sprocket, all forming a column, can be moved to four or more different positions with respect to the roller assemblies 110a and 110b to accommodate pipe elements of different diameters in the spin mode.

Exemplary Device Configured for Spinner Mode

[0041] FIG. 3 conceptually illustrates a top view of the device 100 in a spinner mode wherein clamshell rotor 126 is not present. In other words, the clamshell rotor 126 has been removed and the drive chain 108 is gripping directly on a pipe 160. This mode is for spinning a drill pipe up to or away from a shoulder of another drill pipe. This operation typically does not require very high torque, and thus, only the chain 108 grips directly on the pipe 150. This conversion from rotary power tong mode to spinner mode just takes a few minutes. To change modes, a user merely pushes a button on the device 100, configuring the device 100 for its different modes, and removes or inserts rotor 126. This device 100 has been designed for oil and gas work over drilling rigs and water well drilling rigs with tight working space, reducing the associated cost of operation. Because the rotor 126 is removable, rotor 126 can be deemed a floating rotor 126, or a floating rotor insert, or a clamshell floating rotor, and those terms are used herein interchangeably. The rotor 126 is designed to grip tubing and casing and torque them.

[0042] While the device 100 is in the spinner mode, with rotor 126 removed, the device 100 is designed to spin drill pipe. In other words, in spin mode, device 100 spins pipe elements under little to no torque. However, when device 100 is in the rotary power tong mode with the floating clamshell insert 126 in place, the device 100 is capable of torqueing a pipe element under substantial torque. Put yet a different way, in spinner mode, the device 100 is used to spin out drill pipe after the drill pipe has been disconnected from its shouldered connection with another drill pipe. The spinning out of the drill pipe is done with the chain 108 resting directly against the pipe element 160 (drill pipe). While the device 100 is in the rotary power tong mode, the device 100 is capable of torqueing tubing and casing, which are different from drill pipe.

[0043] Moreover, in the rotary power tong mode, the chain 108 does not rest up against or contact the drill element (e.g., drill pipe, casing, and/or tubing). Rather, the chain 108 contacts the floating clamshell rotor 126, which in turn contacts the pipe element via the gripping, dies 128. Additionally, as explained in greater detail below, because of the configuration of the float rotor 126, compression of the rotor 126 against a pipe element increases as the torque increases. In addition, although illustrated with the pins 146 extruding somewhat in FIG. 3, actually, in spinner mode, the pins are fully retracted. However, full retraction is not necessary, only that the pins 146 do not contact any moving part. As stated above, installed on the I.D. of the rotor 126 are steel tipped gripping dies 128 that grip a pipe positioned within the rotor 126 when the rotor 126 is closed by the top and bottom hydraulic cylinders 122 and 124 when the spinner clamshell (portions 118 and 120 together) is closed.

[0044] To insure that the cracking aperture in the front of the rotor 126 is consistent, a cracking pin air cylinder 136 is located just rear of the closing hydraulic cylinders 122 and 124 on the moving side 120 of the case (yellow) that lowers a pin into a slot in the stationary side of the case (blue) 118. This is described in more detail below with respect to other figures.

[0045] FIG. 4 conceptually illustrates a perspective view of the device 100 in spinner mode wherein clamshell rotor 126 is not present. The pins 146 do not contact any moving part in this configuration. The chain 108 is frictionally grips directly on the pipe 160 and the clamshell rotor 126 has been removed taking merely a couple of minutes. The on-board control systems configuring only takes activation of one button located on the device. In other words, to convert from rotary power tong mode to spinner mode, a user merely has to remove the floating rotor 126 and push a button on the device 100.

[0046] FIG. 5 conceptually illustrates a top view of the device 100 in a rotary power tong mode wherein clamshell rotor 126 is present. The sensor 140 includes a roller portion 170 and an air logic controller valve 172. When a roller cam 174 on the rotating portion 120 contacts and moves the roller portion 170, the air logic controller valve 172 sends a signal and rotor 126 is only allowed to be rotated when the rotating portion 120 is closed against the fixed portion 118 as shown in FIG. 5. In other words, the closed sensor 140 has been activated by the cam 174 on the moving case side (yellow) 120. This senses that the device is closed and gripped on the pipe so rotation can start. If the sensor 140 is not fully actuated, then rotation of the rotor 126 is disabled. In addition, a rotor index sensor finger 176 has been pulled back away from the rotor by an air cylinder incorporated into the sensor 140 body. It can be seen in FIG. 5 that the capture pins (retainer pins 146) located on the bearing caps (yellow and translucent) are retracted to allow rotation of the rotor. Also, the elastomeric rotor spring (dark gray) 130 is fully flexed and ready to open the rotor 126, when necessary. In addition, it can be seen that a rotor index cam surface 180 is rotating freely and will be rotated back to an opening index location 182 when the pipe rotation is complete as shown better below. The rotor index sensor (lowermost of the two 140s in FIG. 5) and capture pins 146 are positioned radially. This enables the retraction of these systems (to keep them out of the way) while the tong is rotating pipe.

[0047] FIG. 6 conceptually illustrates a cracking pin 190 protruding from a cracking cylinder pin cylinder housing 192 wherein when the cracking pin 190 is moved toward a ramp 194 the pin 190 will retract partially before inserting itself into a locking slot 196. Once the cracking pin 190 is trapped inside channel 196, rotation of rotating portion 120 relative to fixed portion 118 is limited by the length of the slot 196. In other words, using different terminology, FIG. 6 illustrates a cracking pin air cylinder 192 (gray with a gold colored cracking pin 190) that is mounted on the moving side 120 of the case. The cracking pin 190 drops into the slot 196 located on the stationary (blue) case 118 to limit the opening of the clamshell rotor 126 so that the rotor 126 can be cracked (opened slightly) for breaking the dies 128 off of the casing or tubing. Then the floating rotor 126 can be rotated without rotating the tubing. The cracking enables the rotor 126 to be indexed without rotating the tubing or casing, which was being torqued. When a casing is being torqued, there is no telling at what position the rotor 126 will end up at when the torqueing is finished.

[0048] FIG. 7 conceptually illustrates a top view of the device 100 to show the cracked condition of the rotor 126. Notice that the closed sensor is not actuated because the round roller cam (purple) is not in full contact with the sensor cam roller. This disables rotation in the torqueing or clockwise direction but allows rotation in the opposite direction. The indexing sensor is rolling on the major diameter of the rotor and when it rotates to the cam bump on the rotor it will automatically stop and a user then opens the rotor for extraction of the pipe as shown in the following figure. Also notice the cracking pin 190 is in the slot and the rotor is cracked open slightly to break off the grip and allow indexing for opening. Notice a gap 198 between ends of the rotor 126 where in the gap 198 is larger in FIG. 7 than in earlier figures. That gap 198 causes the dies 128 to break their grip on a pipe and allows rotor 126 to be rotated independently of the pipe. The device 100 can operate with or without pipe and without damaging itself either way. Also the capture pins are retracted because the rotor is not indexed for opening yet.

[0049] FIG. 8 conceptually illustrates a top view of the device 100 in rotary power tong mode and indexed for opening. In other words, the rotor 126 is in a cracked condition and clocked correctly for opening. Notice that an index sensor roller 200 has climbed a cam surface 202 on the periphery of the rotor 126 which sends a signal to the logic to stop rotation of the rotor 126 automatically. Also notice that the close and grip sensor has a standoff 204 between its cam and the cam roller on the sensor system. This sends a signal to the logic that the rotor is cracked and ready to open. The sensor also disables rotation in the torqueing direction and only allows reverse rotation for open rotor clocking index positioning. Also notice that the capture pins are extended to retain the rotor in the open position. The capture pin is energized automatically by the logic only when two criteria are met, namely the standoff of the close and grip sensor and the energizing of the clocking sensor. Also notice that the cracking pin 190 is down in the slot of the stationary case (blue) 118. This limits the cracking aperture of the rotor 126 so that rotor 126 can be rotated to an opening position. When the rotor 126 is ready to be opened, the cracking pin is raised automatically to allow that opening.

Exemplary Device Configured for Rotary Power Tong Mode and Open

[0050] FIG. 9 conceptually illustrates a top view of the device 100 in rotary power tong mode and showing the device 100 and rotor 126 open. Please note that the closed loop chain 108 (gray) wraps around the rear of the rotor 126 although not drawn in FIG. 9. In fact, there is no single figure that shows the entire chain 108 path with the chain 108 in place, however, in all configurations shown, the chain 108 makes a complete closed loop from the drive sprocket around the two roller assemblies and then returning to the drive sprocket. This is regardless of the presence or absence of the floating clamshell rotor. Additionally, as explained above, the drive chain 108 path is adjustable for different size pipe elements in spinner mode through selection of which adjustment hole 152 to position the adjustment pin 150. However, in rotary power tong mode, the pin is always in the hole closest to rotor 126 and adjustments due to different sized pipe elements is made by having rotors 126 with different sized die retainers and/or dies. One way to implement different sized interior diameters is shown in FIG. 25 using large gripping dies 128. Referring still to FIG. 9, the two capture pins 146 are located in the translucent bearing caps on the front of the device. These pins 146 are actuated by air before the rotor 126 is opened to insure retention of the rotor 126 while open. The pins 146 retract when the rotor 126 is closed and rotating the pipe.

[0051] FIG. 10 conceptually illustrates a top view of the device 100 in rotary power tong mode and showing the device 100 and the rotor 126 open. Pipe can now be inserted or extracted from the rotor. Notice that the crack pin has been raised to allow opening of the rotor. Both sensors have been deactivated signaling that the device is open. The logic also plays an important role in insuring that the operator can not cause bodily injury or malfunction of the device.

Exemplary Device Configured for Tong Mode and Closed

[0052] FIG. 11 conceptually illustrates a perspective view of the device 100 in tong mode and showing the device 100 closed and the rotor 126 gripping a pipe.

[0053] FIG. 12 conceptually illustrates a top view of the device 100 in tong mode and showing the device 100 closed and the rotor 126 gripping a pipe. Here, the rotor 126 is indexed for either opening the rotor 126 or for torqueing the rotor 126 (i.e., applying a torqueing force to a pipe within rotor 126). This view shows the device 100 gripped on the pipe with the radial rotor index cam roller riding on top of the index cam on the rotor 126 on its major diameter. The rotor 126 is timed to this position before the rotor 126 will open or before a torque operation (a rotating) is initiated.

Exemplary Device Configured for Tong Mode and Open for Insertion or Removal of a Pipe Element [0054] FIG. 13 conceptually illustrates a top view of the device 100 in tong mode and open large enough that a pipe element 250 is insertable or removable from the rotor 126. Pipe element 250 is not part of device 100. This view shows device 100 in the open rotor condition that will allow the pipe entry and exit from the rotor. Also notice that the capture pins are retaining the rotor 126 while the rotor 126 is open. They are extended by air and are commanded by the logic via the rotor index sensor. Also notice the clamshell rotor spring at the hinged rear of the rotor 126. It assures that the rotor 126 always spring loads against the yellow spacer rollers located on the centerline of the roller assemblies 110a and 110b on the front of the device. Also see the crack pin is rotated away from the slot on the stationary (blue) case. This raising of the crack pin is accomplished by the air logic shown later.

[0055] FIG. 14 conceptually illustrates an implementation of a self-energizing grip system 300. Notice that the chain 108 rollers 302, of the roller chain 108, are contacting the rotor 126 on cam surface ramps 304 instead of on the periphery of the roller chain 108. The clamshell rotor 126 is closed and the chain 108 rollers 302 nest on the bottom of the cam ramps of the rotor 126. This closing action creates an initial grip that slightly embeds the dies 128 (yellow) into the pipe surface 310 (gray) as the chain 108 wraps around the rotor 126 and contains it. The orange rollers 312 seat tangentially on the clamshell rotor 126 and create tunnels 320 through which the chain 108 travels so that no interference between the chain 108 and the roller sprockets occurs at the tangency points. Additionally, because the rollers 302 nest in troughs of the cam ramps as resistance to rotation grows the rollers 302 roll up the cam ramps increasing the radially inward pressure of the dies 128 into the pipe 310. Accordingly, as the torque increases so does the gripping action. This is what is meant by "self-energizing". Not shown is a torque measuring device that measures the torque applied to the chain 108 and when a certain torque is achieved, the pipe is considered fitted, and torqueing is stopped. Additionally, as shown in FIG. 14, the rollers 302 make contact with the teeth of the driven cogs and with the cam ramps. Opposed to this, in FIG. 23 the peripheral of the chain 108 makes contact with the ramps. The roller configuration as shown in FIG. 14 preferable because the self-energization is quicker because the rollers 302 roll with less friction along the cam ramps than the chain 108 peripheral slides along the cam ramps. However, either implementation is sufficiently efficient. Additionally, chain 108 can be a single row of chain like a bicycle chain or it can have multiple rows as is illustrated in FIG. 2 with three rows. Other numbers are likewise implementable.

[0056] FIG. 15 conceptually illustrates an implementation of the self-energizing grip system 300 detailing the location of the cam ramps portions relative to the retainer channels and sprockets 350 on the roller assemblies 110a and 110b. FIG. 15 shows the roller ramped drive cams on the clamshell rotor 126. These ramp cams nest the chain 108 rollers 302 for driving the rotor 126 to turn the pipe (not shown so that the grip dies 128 (yellow) can be seen). Notice the rotor opening springs (black) located on the top and bottom of the clamshell rotor 126 at the hinge point of the rotor 126. These elastomeric/metal springs keep an opening force on the rotor 126. The opening springs are of course loaded because the rotor 126 is closed.

[0057] FIG. 16 conceptually illustrates an implementation of the self-energizing grip system in action. Here the chain 108 rollers 302, of the roller chain 108 (light gray), are contacting the rotor 126 on cam surface ramps (red) instead of on the periphery of the roller chain 108. The grip cylinders close the clamshell rotor 126 and the chain 108 rollers 302 nest on the bottom of the cam ramps of the clamshell rotor 126 (red). As shown in FIG. 14, the closing action creates an initial grip that slightly embeds the dies 128 (yellow) into the pipe surface (gray) as the chain 108 wraps around the rotor 126 and contains it. The orange rollers, pivoting on the sprockets (purple), seat tangentially on the clamshell rotor 126 and create a tunnel through which the chain 108 travels so that no interference between the chain 108 and the roller sprockets occurs at the tangency point. As the chain 108 pull is increased causing clockwise rotation of the pipe (gray), the roller chain 108 rollers 302 (light gray) climb the cam ramps (note that the chain 108 roller has moved off the bottom of the cam trough and is now rolled up upon the cam surface). This increases the chain 108 hoop pressure against the clamshell rotor 126 thus increasing the die 128 (yellow) penetration into the pipe surface causing a self-energizing grip on the pipe so that no slipping occurs. This self-energizing grip works in counterclockwise rotation as well as clockwise because of the symmetrical shape of the ramp cams. Moreover, because the rotor 126 includes the cam ramps it can be called a cam sprocket, because the rotor 126 acts as a sprocket and is cammed. [0058] Additionally, the rotor 126 includes an opening 340, which is always present to some degree while using gripping dies. The opening 340 also allows the rotor 126 to be repeatedly made smaller by further compression. In other words, the opening 340 allows the dies 128 to fully seat into the pipe 310 if needed. Alternatively, using resilient dies, the gap can be closed totally to limit compressive forces on the held pipe. In other words, device 100 can use gripping dies and resilient dies. The resilient dies are especially useful for turning pvc pipes and other pipes that are more fragile than steel pipe.

[0059] FIG. 17 conceptually illustrates an isometric view of the full rotor control system with the rotor 126 closed. Please notice the air actuated capture pins, set for retention of the rotor 126. Also see the two sensors, the closed rotor sensor located to the rear of the rotor 126, and the radially located rotor opening index sensor for correctly clocking the rotor 126 for opening. The two crack pin air cylinders that drop into slots in the stationary case to limit spring loaded cracking of the hydraulic closing cylinders located on the top and bottom of the device (seen and explained on other diagrams). The closed loop drive chain 108 path that traverses around the drive sprocket 360, around the two roller assemblies 110a and 110b on the front of the device and around the back side of the rotor 126 periphery.

[0060] FIG. 18 conceptually illustrates an isolated closed rotor 126. As discussed above, notice that there is a small gap in the front of the rotor 126. This gap assures that all closing and gripping torque is carried to the pipe gripping dies 128. Although this exemplary implementation utilizes only the back of the gripping dies 128 for providing cam ramps, other implementations utilize the entire peripheral of the rotor 126 for locating cam ramps thereupon.

[0061] FIG. 19 conceptually illustrates air control logic for the device 100. Although air logic is illustrated, hydraulic logic and electronic logic, wired, wireless, and combinations are possible. Any logic can be used, both fluid logic and non-fluid logic.

[0062] FIG. 20 conceptually illustrates the self-energizing principle that allows increase grip pressure on the pipe as torque is increased. The chain 108 links climb up on the drive cogs and increase chain 108 tension or hoop tension in the chain 108, thus increasing grip pressure on the pipe. This assures that the grip dies 128 will not slip. Here the periphery of the chain 108 contacts the cam ramps. [0063] FIG. 21 conceptually illustrates an isometric view of the open rotor chain 108 path.

[0064] FIG. 22 conceptually illustrates a top view of the chain 108 path. Note that for brevity not all the chain 108 links are shown. The chain 108 path is a closed loop that projects from each end of the shown chain 108. Notice that the front two sprockets that nest the rotor 126 in the open condition can be driven and the drive sprocket is the single sprocket behind the rotor 126. However, the roller assemblies 110a and 110b do not need to be driven. One can also see the drive shaft concentric to the drive sprocket. Two radial capture pins are shown in capture (extended position) and they nest in a pocket on the major outside diameter (O.D.) of the rotor 126. These pins assures that the rotor 126 is captured in the device while open.

[0065] FIG. 23 conceptually illustrates the isolated rotor 126 with its various components. Please notice that the rotor 126 is a two piece clamshell that hinges in the rear. However, the rotor 126 can have more than two pieces. The rotor 126 can be a three- piece or a four-piece clamshell, or a more piece. Notice the serpentine corrugated metal spring impregnated within a elastomeric material that forces the rotor 126 open. This assures that the rotor 126 always stays nested on the chain 108 while opening. Gripping dies 128 (gold) are located on the inside diameter of the rotor 126. The dies 128 dig into the pipe and rotate the pipe. Notice the rotor control cam (bump) on the periphery of the rotor 126 top. This cam surface allows correct indexing for opening the rotor 126. A radial sensor is activated when the correct opening clocking has been achieved.

[0066] Also, capture pin pockets are located at the opening aperture on both halves of the clamshell. These pockets nest two air actuated radial capture pins on the bearing caps of the case halves shown in other diagrams. Notice the gray combination die retainer cog cams located around the periphery of the clamshell halves. They are for driving the clamshell rotor 126 during rotor 126 cracking (rotor 126 indexing) and torqueing pipe. One can see the closed loop drive chain 108 that encircles the rotor 126 periphery and nests in the drive cogs described above. Also important is the cam angle of the drive cogs. They help achieve a self-energizing grip when the chain 108 slides up the cogs. This action effectively increases the hoop load on the chain 108 which thus increases the gripping pressure on the pipe. The combination die retainer cog cams can be replaced with separate die holders and separate cog cams. The cog cams can extend all around the periphery of the rotor while the die holders can extend only partially around an inner diameter. The cog cams can be molded into the rotor 128 similar to the rotor cams in FIG. 15. In FIGS. 18, 20, 21, 23, and 24 the chain periphery contacts and slides up on the cams of the cogs to increase inward pressure. While in other figures (e.g., FIG. 15), the rollers roll up the cams to increase inward pressure.

[0067] FIG. 24 conceptually illustrates the self-energizing principle that allows increase grip pressure on the pipe as torque is increased. The chain 108 links climb up on the drive cogs and increase chain 108 tension or hoop tension in the chain 108, thus increasing grip pressure on the pipe. This assures that the grip dies 128 will not slip.

[0068] Some implementations provide a device that is configured to be a multi modal drilling device. The device is multi modal because in one mode, it is a pipe spinner and in another mode, it is a power rotary tong. A user inserts a module to change from the spinning mode to a tong mode. The spinner mode facilitates low torque spinning of drill pipe, while the tong mode facilitates high torque rotation of drill casing and tubing with interference fit tapered threads. Heretofore, there has never existed a machine capable of both modes. In some implementations, the device includes a floating rotor 126 with cam ramps that increase a hoop pressure on a pipe element within the rotor 126 as torque is increased. Accordingly, a self-energized gripping system is realized.

[0069] In some implementations, the rotor 126 includes gripping dies 128 to grip the pipe element. A roller chain 108 rotates the rotor 126 and as torque is increased the chain 108 rollers 302 move from a trough up onto cam ramps increasing the radially inward force of the gripping dies 128 on the pipe. Alternatively, the chain 108 periphery moves from the troughs onto cam ramps to increase the radially inward pressure exerted on the pipe from the rotor 126. In some implementations, the device 100 provides a novel combination tong mode and spinner mode device. Additionally, the clamshell floating rotor 126 provides a novel module that can be inserted to obtain the tong mode. Furthermore, the novel cam ramps provide a self-energizing automatically self-adjusting variable grip force. Moreover, device 100 handles pipe element and is therefore a pipe element handling device.

[0070] FIG. 25 conceptually illustrates the dies and die holder extending substantially inward to enable torqueing a different sized casing or tubing. The use of different die holder and/or dies configuration can be field changeable or not. If not, different rotors 126 can be available with different dies and/or holders for different sized pipes. Alternatively, both, and the customer can decide if field technicians swap out entire rotors 126 or change dies and/or die holders.

[0071] It should be apparent to one skilled in the art that various features of the present disclosure may be applicable to grab, turn, and/or torque various other types of pipes. For example, sucker rod (used in the oil industry for the extraction of oil) may also be grabbed, turned, and/or torqued using the combination pipe spinner and tong device described herein. Such sucker rods may have a threaded male end and a threaded female end. The female end of the sucker rod may have a square or hexagonal outer shape with flat surfaces that may be used for torqueing the sucker rod. The dies of the combination pipe spinner and tong device may be adapted to accommodate various shapes (e.g., square, hexagonal, etc.) of pipes, rods, and/or objects to be grabbed, turned, and/or torqued.

[0072] One or more of the elements, steps, features, and/or functions illustrated in FIGS. 1-24 (alone or in any combination thereof) may be rearranged and/or combined into a single component, step, feature, or function or embodied in several components, steps, or functions. Additional elements, components, steps, and/or functions may also be added without departing from the invention.

[0073] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation or aspect described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other aspects of the disclosure. Likewise, the term "aspects" does not require that all aspects of the disclosure include the discussed feature, advantage or mode of operation. The term "coupled" is used herein to refer to the direct or indirect coupling between two objects. For example, if object A physically touches object B, and object B touches object C, then objects A and C may still be considered coupled to one another— even if they do not directly physically touch each other.

[0074] In the present disclosure, numerous materials are listed as possible materials that can be used to manufacture the device and its components (e.g., elastomeric material). However, it should be noted that these materials are merely examples and that other materials may be used as well. [0075] The various features of the invention described herein can be implemented in different systems without departing from the invention. It should be noted that the foregoing aspects of the disclosure are merely examples and are not to be construed as limiting the invention. The description of the aspects of the present disclosure is intended to be illustrative, and not to limit the scope of the claims. As such, the present teachings can be readily applied to other types of apparatuses and many alternatives, modifications, and variations will be apparent to those skilled in the art.

Claims

CLAIMS WHAT IS CLAIMED IS:

1. A combination pipe spinner and tong device comprising:

a fixed portion;

a rotating portion coupled to the fixed portion;

a pair of roller assemblies, one coupled to the fixed portion, and one coupled to the rotating portion;

a chain element coupling the pair of roller assemblies together, wherein the chain element is capable of rotating a pipe element in a spinning mode; and

a tong rotor element removably positioned against the chain element, wherein the tong rotor is capable of rotating a pipe element in a tong mode.

2. The device of claim 1, wherein the tong rotor element comprises a clamshell rotor.

3. The device of claim 1, wherein the tong rotor element comprises a clamshell rotor including a biasing member biasing the clamshell rotor toward on open configuration.

4. The device of claim 1, wherein the tong rotor element comprises a clamshell rotor including at least one indexing portion.

5. The device of claim 4, wherein the clamshell rotor comprises a biasing member biasing the clamshell rotor toward on open configuration.

6. The device of claim 5, wherein the clamshell rotor comprises at least one retaining channel.

7. The device of claim 1, wherein the tong rotor element comprises a clamshell rotor comprising at least one retaining channel.

8. The device of claim 7, wherein the clamshell rotor comprises two retaining channels positioned distally from a hinge and separated from each other by an opening.

9. The device of claim 1 further comprising a hydraulic cylinder operationally coupled to the fixed portion and the rotating portion to affect a separation of the rotating portion from the fixed portion.

10. The device of claim 9 further comprising a sensor positioned on the fixed portion to determine if the rotating portion is apart from the fixed portion or if the rotating portion is adjacent the fixed portion.

11. The device of claim 10, wherein the fixed portion comprises a channel receiving a pin extending from the rotating portion such that travel of the rotating portion is limited by the pin traveling in the channel.

12. The device of claim 10, wherein the fixed portion comprises a ramp adjacent to the channel for the pin to slide upon prior to being engaged with the channel.

13. Apparatus comprising :

means for performing drill pipe spinning; and

means for performing pipe casing or tubing torqueing, wherein the means for performing pipe casing or tubing torqueing is operationally coupled to the means for performing drill pipe spinning.

14. The apparatus of claim 13 further comprising means for determining if the apparatus is in a cracked position or an un-cracked position.

15. The apparatus of claim 13 further comprising means for determining if the means for performing pipe casing or tubing torqueing is in an indexed position or an un-indexed position. .

16. The apparatus of claim 13, wherein the means for performing pipe element tonging includes a biasing member biasing the means for performing pipe element tonging to be in an open position.

17. The apparatus of claim 16, wherein the means for performing pipe element tonging includes a retaining channel.

18. The apparatus of claim 17 wherein the means for performing pipe spinning comprises at least one retaining pin sized to engage the retaining channel.

19. The device of claim 18, wherein the means for performing pipe spinning comprises an index sensor configured to detect when the means for performing pipe element tonging is in a particular position.

20. A kit comprising:

a device having a spinning mode; and

a module user insertable into the spinning mode device enabling the spinning device to have a tong mode.

21. A method comprising manufacturing a pipe element handling device with both a spinning mode and a tong mode.

22. Drilling apparatus comprising:

a floating clamshell rotor comprising a plurality of cam ramps on an outer periphery of the rotor; and

at least one gripping die or resilient die coupled to an inner diameter of the rotor to provide a deforming grip or a non-deforming grip.